Part B

THDC INDIA LIMITED
(A Joint Venture of Govt. of India & Govt. of U.P.)
KHURJA SUPER THERMAL POWER PROJECT
(2 X 660 MW)
TECHNICAL SPECIFICATION
FOR
WATER SYSTEM PACKAGE
SECTION - VI
PART – B
CONSULTANT
NTPC Limited
(A Government of India Enterprise)
BIDDING DOCUMENT NO.: THDC/RKSH/CC-9915-373

THDC INDIA LIMITED
(A Joint Venture of Govt. of India & Govt. of U.P.)
(2 X 660 MW)
FOR
SECTION - VI
PART – B
CONSULTANT
NTPC Limited
(A Government of India Enterprise)
BIDDING DOCUMENT NO.: THDC/RKSH/CC-9915-373
(This document is meant for the exclusive purpose of bidding against this Package and shall not be
transferred, reproduced or otherwise used for purposes other than that for which it is specifically
issued).
PART-B (MECHANICAL)
KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

(2X660 MW) SECTION-VI, PART-B
BID DOC NO: THDC/RKSH/CC-9915-373
SUB-SECTION TITLE
PART – B (MECHANICAL)
IIIA – 01 EQUIPMENT SIZING CRITERIA
IIIA – 02 CW SYSTEM
IIIA – 03 WATER TREATMENT PLANT
IIIA – 04 COOLING TOWER
IIIA – 05 METERING PUMPS
IIIA – 06 LOW PRESSURE PIPING
IIIA – 07 FIRE DETECTION & PROTECTION SYSTEM
IIIA – 08 AIR CONDITIONING & VENTILATION SYSTEM

SUB-SECTION – IIIA-01
EQUIPMENT SIZING CRITERIA

CLAUSE NO.
TECHNICAL REQUIREMENTS
1.00.00 WATER SYSTEM

1.01.00 CW Pumps
a) Number of working CW : 2 X 50 % per unit

pumps
b) Number of Standby pump : One(1) number common for two units
c) Type of CW pumps : Vertical wet pit /Concrete volute/Metallic
volute(with concrete encasement) outdoor
duty
d) CW pump flow per unit : 72000 m3/hr
e) Total Head of the CW pump : Sum of static lift from minimum water level in
CW pump house sump upto the centerline
elevation of hot water distribution header at
Cooling Tower, 110% of friction drop in the
entire CW system and pressure drop across
terminal point of Employer’s TG island as
8.5 MWC.
NOTE: For calculation of friction drop in CW
pipe /duct the “C” value shall be considered
as 100.
f) Internal Diameter of CW : Not to exceed 2 m/sec
pipes in CW pump
discharge and inlet to
cooling tower (Excluding
non-encased portion of
piping connected to
condenser)
g) Size of Discharge Butterfly : Same as that of CW discharge pipe
Valves & Duct
interconnecting Valves
h) Size of the Pump Re- : To be sized for re-circulation of about 50%
circulation Valve and pipe. capacity of one CW pump. However, in case
of Volute type pumps, the sizing should be
adequate to carry flow of one pump to
enable Performance test at Site.
i) Expansion joint : Size to suit the discharge head of CW pump
j) Water Levels in CW sump :
i. Maximum Water level : Maximum water level in Cooling tower basin
i.e. FGL at cooling tower area.

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(2X660 MW) SECTION – VI, PART-B IIIA-01 EQUIPMENT
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WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 SIZING CRITERIA
CLAUSE NO.
ii. Minimum Water level : Minimum water level in cooling tower (i.e.
1M below FGL at CT) minus drop in the CW
channel.
iii. Submergence to be : Submergence to be provided for pump - As
provided for the pump recommended by " Pump intake design" of
Hydraulic Institute - USA plus 1 m margin
(minimum)
iv. Sump invert level : As per HIS (Hydraulic Institute Standards)
v. Operating Floor level : Minimum one meter above Local Grade
level.
1.02.00 Raw Water System
a) Raw Water System to Water PT Plant
A set of pumps in raw water pump house shall supply water upto Water PT Plant
through a carbon steel pipeline. Pumps, drives, associated valves and controls shall
be located in Raw Water Pump House. Number and Capacity of Raw water pumps
shall be as follows:
Number of Pumps – 03 x 50% (Working – 02 nos.; Standby – 01 no.)
Capacity of each Pump – 2000 m3/hr (Minimum)
b) Raw Water System to Ash Handling Plant
A set of pumps in raw water pump house shall supply water upto Ash Handling Plant
through a carbon steel pipeline. The normal makeup to ash handling when ash water
recirculation is under operation will be from CW blow down. The raw water pumps
(ash) will cater to additional water required during initial operation when there is no
water available from ash water recirculation. Pumps, drives, associated valves and
controls shall be located in Raw Water Pump House. Number and Capacity of Raw
water pumps shall be as follows:
Number of Pumps – 2 x 100 % (Working – 01 no.; Standby – 01 no.)
Capacity of each Pump – 1150 m3/hr (Minimum)
1.03.00 Auxiliary Water System (AWS)
a) Makeup (Clarified water) water system to CW system
Clarified water shall be supplied from the PT plant. From the Clarified Water
collection chambers of the Clarifiers, water shall be led upto a clarified water
storage tank. From the Clarified water storage tank, CW makeup shall be given
through a gravity or pumping system (if required) through an over ground carbon

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CLAUSE NO.
steel pipe. Number and Capacity of Clarified water makeup pumps shall be as
follows:
Number of Pumps – (2x100%) (1W+1S)
Capacity of each Pump – 3000 cum/hr (min.).
b) HVAC, FGD & AHS Cooling Makeup Pumps
From the Clarified water storage tank (in PT Plant), clarified water makeup
requirement for HVAC, FGD & Ash handling system cooling shall be met by
means of a set of pumps through over ground carbon steel pipe. Number and
Capacity of HVAC, FGD & AHS cooling makeup pumps shall be as follows:
Number of Pumps – 02 x 100% (2x100%) (1W+1S)
Capacity of each Pump –85 cum/hr (min.).
c) DM Make-up water System
DM cycle make-up water to power cycle shall be from DM storage tanks through
a set of cycle make-up transfer pumps. Number and Capacity of DM Cycle make-
up pumps shall be as follows:
No. of Pumps –One (1) pump per unit +one (1) common standby.
Capacity of each Pump – 100 % of Cycle makeup water requirement for one unit
plus other non-cycle DM water requirements of the complete plant- 100 cum/hr.
(min.).
d) Boiler Fill System
Boiler fill system shall supply DM water to fill each Boiler before for start-up or to
conduct hydraulic test. Suitable tap offs shall be provided for filling of deaerators
during initial stages or exigencies. Water for this shall be drawn from main DM
water Storage tanks in Water Treatment Plant. Number and Capacity of Boiler Fill
Pumps shall be as follows:
No. of Pumps – 02 nos. (2x100%) (1W+1S)
Capacity of each Pump - 175 cum/h (minimum)
e) Service Water System
CW blow down water from the CW system shall be used as service water. Service
water pumps shall take suction from this tank and supply water to the service
water pipe network. Number and Capacity of service water pumps shall be as
follows:
No. of Pumps – Three (3) nos. (3x50%) (2W+1S) for complete plant
Capacity of each Pump – 150 cum/hr. (min).

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CLAUSE NO.
f) Potable Water System
Potable water system shall meet the drinking water required for all the plant
facilities/ buildings included in Contractor's scope and supply water to Employer's
other facilities within the plant boundary. Number and Capacity of pumps shall be
as follows:
No of pumps -Two (2) nos. (2x100%) (1W+1S) for plant.
Capacity of potable water requirement will be 25 cum/hr (min.) for plant and 75
cum/hr (min.) for colony.
g) Air Pre Heater (APH) wash water system
The system is required for washing of Air pre heater. Air pre-heater wash water
pumps shall draw water from service water tank.
For this purpose, two (2) nos (2X100 %) of pumps (1Working+1standby)
horizontal centrifugal type shall be provided.
The capacity of each pump shall be 500 cum/hr. (for 2x100%).
h) FGD Make-up water system
Two (2x100%) FGD makeup pumps with its drives, associated Valves and Piping
up to terminal point. Capacity of each pump shall be 300 cum/hr). MOC of pump
and its components shall be same as that of service water pumps specified
elsewhere. The pumps shall be suitably installed in blow down water circuit.
i) Any other pumps required for the completeness of the system shall be designed
with a redundancy of N+1 unless stated otherwise (N=No of working pumps)
1.04.00 A. PRE-TREATMENT SYSTEM
Design criteria of Pre-Treatment Plant for Circulating Water (PT-CW) & DM system
(PT-DM):
1) “PT-CW” System with minimum three (3) reactor type clarifiers, one (1)
number aerator (1x100%) & one (1) number stilling chamber (1x100%)
(Common for all the Clarifiers), three (3) Inlet channels of RCC Construction
with flow measuring element (Parshall flume), outlet Channels, Clarified
Water Storage Tank, bypass channel to by-pass the clarifier(s). CW make-up
water shall be led by gravity or pumping (if required).
2) For PT-potable system two (2) numbers of Gravity filters (2x100%), filtered
water reservoir (twin section), pump house, Two (02) nos. potable water

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CLAUSE NO.
pumps for plant and Two (02) nos. potable water pumps for colony, Gravity
Filter blowers (2x100%) shall be provided.
3) “PT-DM” System with one (1) number reactor type clarifier (1x100%), one (1)
number aerator (1x100%) & one (1) number stilling chamber (1x100%), one
(1) number inlet channel of RCC Construction with flow measuring element
(Parshall flume) and two (2) numbers of Gravity filters (2x100%), filtered
water reservoir (twin section), pump house etc. Gravity Filter blowers
(2x100%) shall be provided.
4) Three (3) numbers (3x100%) (2W+1S) Filtered Water Transfer Pumps shall
be provided for Ion Exchange based DM plant. In case of UF+RO+MB plant
be envisaged for DM water, three (3) numbers (2W+1S) Filtered Water
Supply Pumps (UF Feed Pumps) shall be provided.
5) Interconnection provision shall be provided between the clarified water outlet

channels of PT-CW System with the PT-DM System to have flexibility in
operation.
6) Chemical House: A common two (2) storey Chemical house of RCC

construction shall be provided to install various Chemical dosing equipment,
pumps, tanks, piping etc. of PT–CW & Potable, PT–DM, PT-RO plant (As
applicable) :
a) Lime preparation & dosing system consisting of minimum two (2) nos.
of RCC lime slaking tanks, minimum three (3) nos. of lime solution
Preparation tanks of RCC construction, agitators, lime slurry transfer
pumps (2x100%), lime solution dosing pumps (2x100%) etc.
b) Alum Solution preparation & dosing system consisting of minimum

four (4) nos of Alum solution preparation tanks, agitators, alum
solution dosing pumps (4x100%) (3W+1S) for PT-CW Clarifiers,
(2x100%) (1W+1S) for PT-DM Clarifier, (2x100%) (1W+1S) for
Lamella clarifier/tube settlers etc.
c) FeCl3 (35–45 % conc.) (in case of PT-RO) preparation & dosing

system consisting of minimum two (2) nos. of dosing tanks, agitators,
coagulant unloading and transfer pumps (2x100%) (1W+1S), FeCl3
dosing pumps (2x100%) (1W+1S) etc.
d) PE dosing system consisting of minimum two (2) nos. of dosing tanks,

agitators (SS-316), dosing pumps (2x100%) (1W+1S) (in case of PT-
RO) etc.
e) PAC dosing system shall consist of minimum two (2) numbers of

storage cum dosing tanks, agitators, dosing pumps (2x100%),
unloading pumps (2x100%) etc.
f) Bulk Coagulant storage tanks (2 nos), Coagulant unloading cum

transfer pumps (2x100%) (1W+1S).

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CLAUSE NO.
g) Anti-scalant preparation tanks (2 nos), Anti-scalant dosing pumps

(2x100%) (1W+1S).
h) Anti-oxidant preparation tanks (2 nos), Anti-oxidant dosing pumps

(2x100%) (1W+1S).
i) Hydrochloric Acid (HCl) unloading cum transfer pumps (2x100%),

Bulk storage tanks (3 nos) for HCl of 30-33% concentration, Acid
(HCl) measuring tanks (2 nos), Acid (HCl) dosing pumps (2x100%)
(1W+1S) for pH control of RO system and Acid (HCl) dosing pumps
(2x100%) (1W+1S) for MB regeneration etc.
j) Alkali (NaOH) unloading pumps (2x100%) (1W+1S), Alkali transfer

cum re-circulation pumps (2x100%) (1W+1S), Bulk storage tanks (2
nos) for Alkali (NaOH in lye form), Alkali preparation tanks (2 nos),
Alkali measuring tanks (2 nos), Alkali (NaOH) dosing pumps
(2x100%) (1W+1S) for pH control of RO system, Alkali (NaOH)
dosing pumps (2x100%) (1W+1S) for MB regeneration etc.
k) Two (2) numbers of electrically operated mono-rail hoists each of 1

Ton capacity in chemical preparation area to handle chemicals from
ground floor to first floor.
l) Two (2) numbers of weighing scales at ground floor for weighing of

chemicals being handled during storage and preparation.
m) Emergency safety showers with eyewash units shall be provided in

the Chemical Storage Handling facility at strategic locations such as
Acid/Alkali Storage area, outdoor Chemical storage area, ClO2 plant
area and Chemical preparation & dosing equipment area. Filtered
water shall be used for safety showers.
n) One (1) number Overhead (OST) Storage Tank shall be provided on

the top of chemical house to provide adequate storage of filtered
water to be used for preparation of the chemicals, flushing of
equipment, back washing of gravity filters etc.
7) Chemical house and Filter house shall be RCC buildings.
B. CHLORINE DI-OXIDE (ClO2) SYSTEM
a) Chlorine di-oxide plants for Circulating Water system (CW-ClO2) and Pre-
treatment plant (PT-ClO2) shall preferably be installed at a common location.
b) CW-ClO2 system is envisaged near CW Fore-bay and shall consist of two (2)
(2W) numbers of ClO2 generators. PT ClO2 system shall comprise of two (2)
(1W+1S) numbers of ClO2 generator sets.
c) Following minimum safety features/interlocking shall be available in the

offered ClO2 plants:

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CLAUSE NO.
a. Safety features at Chemical Storage Facility
1) Chemical Storage Facility (Bulk storage tanks for NaClO2 & HCl) is
provided with dyke wall.
2) Chemical Storage Facility is provided with neutralizing pits.
3) Chemical Storage Facility shall have safety shower with arrangements

for eye wash.
b. Safety features at Equipment Room
1) ClO2 gas detector (leak sensor) shall be installed inside the Equipment
room with chemical dosing pumps tripping-interlock, thereby stopping
the system and raising an alarm.
2) ClO2 generator along with dosing skid shall be located in a well-

ventilated building.
3) Typical Safety equipment shall be provided as mentioned elsewhere.
4) The ClO2 generation system stops on no / very low dilution water flow
condition.
c. Safety features (Interlock Protection) in the Process control
1) Bulk storage tanks’ (NaClO2 & HCl) very low level stops the dosing
pumps, dry run pump protection.
2) Interlock / Protection shall be there for single chemical pump running

or dozing.
3) Dilution water low flow-rate trips the related skid.
4) Either NaClO2 or HCl low flow-rate will cause the tripping of the skid.
5) Emergency push button of local control panel trips all the dosing
skids.
C. LIQUID EFFLUENT TREATMENT PLANT (LETP)
1. PT - PLANT CLARIFIER SLUDGE DISPOSAL SYSTEM
a). One (1) number RCC sludge pit (in 2 sections) to collect sludge from all
the clarifiers of PT-CW system, PT-DM system & Lamella clarifiers/tube
settlers and any other effluent connected to this sump (in case envisaged).
b). Two (2) numbers air blowers (2x100%) (1W+1S) for the air agitation
system of the sludge pit.
c). Three (3) (3x50%) (2W+1S) numbers of sludge disposal pumps.

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CLAUSE NO.
2. FILTER BACK WASH WASTE DISPOSAL SYSTEM
a) One (1) number RCC Filter backwash waste collection pit (in 2 sections) to
collect the backwash water from all the filters including Ultra filtration
system. The filters backwash water shall be collected and recycled back to
the PT-CW clarifier.
b) Two (2) (2x100%) (1W+1S) numbers of backwash disposal pumps shall

be provided.
3. WASTE SERVICE WATER TREATMENT SYSTEM
a) One (1) number RCC waste service water sump (WSWS) in two (2)
sections shall be provided for collection of waste service water. Service
water effluents and other plant effluents from various areas of the plant
shall be routed to this waste service water sump. Facility shall be provided
to collect free oil from these sumps to MS Oil drum and oil skimmers (2
nos.), Portable oil Centrifuge (1x100%) of suitable capacity shall be
provided for reuse of oil.
b) Three (3) (3x50%) (2W+1S) numbers of Waste Service water pumps.
c) Two (2) (2x50%) numbers of Lamella Clarifier/tube settlers of RCC

construction of suitable capacity shall be provided to treat the total waste
service water & other waste water of the plant for reuse.
d) One (1) number of RCC Treated water tank for collection of treated water
from Lamella Clarifier/tube settlers. Two (2x100%) (1W+1S) Treated
service water pumps shall be provided to transfer the treated service water
to plant service water system.
D. DM PLANT (ION EXCHANGE PROCESS OR RO+MB PROCESS)
Design criteria of DM plant (Ion Exchange process or RO+MB process):
1) The capacity of DM plant (either by Ion exchange process or RO process)

shall be sized to meet the steam water cycle makeup of the boiler MCR,
makeup water for closed cycle ECW system, regeneration, DM water
requirement for Hybrid System (SCR + SNCR) and any other requirement as
envisaged. However, the minimum capacity of DM plant shall be as specified
elsewhere.
2) Minimum two (2) numbers of DM water storage tanks, each of minimum

capacity 2000 cum shall be provided.
3) ION EXCHANGE BASED DM PLANT
a) Ion Exchange Demineralising Plant (2x100%) shall be provided. Weak

acid Cation exchangers, Strong acid Cation exchangers, Weak base anion
exchangers, Strong base anion exchangers shall be designed for 12 hours
of operation cycle followed by 4 hours regeneration period. MB unit shall

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CLAUSE NO.
be regenerated after minimum 108 hours of operation followed by

regeneration period not exceeding 6 hours.
b) Two (2) (2x100%) numbers of Activated carbon filters with all accessories.
c) Two (2) (2x100%) numbers of Weak Cation exchangers units & Two (2)
(2x100%) numbers of Strong Cation exchangers units with all accessories.
d) Two (2) (2x100%) numbers of Weak Anion exchangers units & Two (2)
(2x100%) numbers of Strong Anion exchangers units with all accessories.
e) Two (2) (2x100%) numbers of Degasser system comprising of Degasser

Towers and storage tanks, Air Blowers (2X100% per Degasser unit), three
(3) (3x100%)(2W+1S) numbers Degassed water transfer pumps etc.
f) Two (2) (2x100%) numbers of MB unit along with Two (2) (2x100%)
numbers air blowers with its drives and all accessories.
g) Two (2) (2 x 50%) numbers of UF feed Tank complete with all accessories,
three (3) nos. (3 x 50%) ultrafiltration feed pumps complete with drive
motors and accessories as required, two (2) nos. (2 x 100%) Ultrafiltration
skids complete with all necessary piping and instrumentation.
h) Two (2) nos.(2x100%) UF backwash pumps complete with drive motors

and accessories as required.
i) One (1) no. UF CIP system for chemical cleaning with tanks, agitators with
motor, piping arrangements with accessories, Two (2) nos. (2x100%) CIP
pumps complete with drive motors.
j) Complete Hydrochloric acid handling, Alkali handling, measuring tanks and

dosage system etc.
k) Two (2) numbers of safety shower units and adequate number of Eye-
fountains to protect against any chemical hazard.
l) Brine Solution Preparation Tank and Brine transfer pumps, piping and
valves etc.
m) Provision of hot water supply to the ACF units from the hot water tank shall
be made for rejuvenation of activated carbon and the DM regeneration
pumps to be sized considering above requirement in addition to require for
regeneration.
n) Headers shall be designed such that both DM streams can run

simultaneously during exigency utilizing the stand-by pumps.
4) RO BASED DM PLANT
A. ULTRAFILTRATION (UF) SYSTEM
a) UF skids (3x50%) (Pressurized type), Simplex strainers (2x100%)

(1W+1S) for each stream, UF backwash pumps (2x100%) (1W+1S) along

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CLAUSE NO.
with flushing tanks and pumps, CEB & CIP systems, UF permeate water
storage tanks (2 nos), UF permeate transfer pumps (3x50%) (2W+1S) etc.
b) (3x50%) (2W+1S) Micron Cartridge Filter (MCF).
c) Headers shall be designed such that all three UF streams can run
B. RO SYSTEM
a) High Pressure (HP)-RO feed pumps (3x50%) (2W+1S) with one(1) store
standby, RO Streams/trains (3x50%)(2W+1S) with module rack
assemblies, RO permeate water storage tanks (2 nos), RO Permeate
transfer pumps (3x50%) (2W+1S), sampling facilities, reject control
valves, Complete system for Chemical cleaning (CIP) and Flushing system
comprising of necessary tanks and pumps for RO trains/streams etc.
b) Complete Degassifier system for removal of CO2 in permeate water from

RO units, consisting of minimum one (1) Degasser tower, Degasser/RO
permeate water storage tank (2), Degassed Water Pumps (3x100%), RO
Chemical dosing system consisting of Anti-oxidant dosing tank and pumps,
Anti-scalant dosing tank and pumps etc., etc.
c) Degasser Blowers for Degasser (2x100%) (1W+1S), RO permeate

transfer pumps (W+1S) etc.
d) Mixed bed (MB) units (4x50%) (2W+2S) along with air blowers (2x100%)
and complete regeneration system etc.
e) Headers shall be designed such that all three RO & MB streams can run
5) OTHER REQUIREMENTS FOR DM PLANT
a) Complete Hydrochloric acid handling, measuring tanks and dosage system

etc.
b) Complete Alkali handling, storage and dosage system etc.
c) Two (2) numbers of DM water storage tanks with all accessories.
d) Two (2) numbers (2x100%) (1W+1S) DM water pumps for regeneration

system.
e) Neutralizing waste disposal system- DM plant Effluent drains shall be

connected to the N-Pit and shall be led suitably to owner’s Ash handling
system.
f) Backwash waste disposal system for DM plant - Backwash water from AC

filters and fast/final rinse waste water of DM plant shall be connected to
the backwash collection pit (DM), UF back wash shall also be led to this
backwash pit. Back wash water shall be pumped to the inlet channel of
PT-DM clarifier.

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CLAUSE NO.
g) Two (2) (2x100%) (1W+1S) numbers of backwash disposal pumps shall

be provided. Two (2) numbers air blowers (2x100%) (1W+1S) for the air
agitation system of the filter backwash pit shall be provided.
h) First fill of filter media for AC filters and first fill of resins for all Ion
Exchange units shall be provided.
i) Provision of hot water supply to the ACF units from the hot water tank shall
be made for rejuvenation of activated carbon and the DM regeneration
pumps to be sized considering above requirement in addition to
requirement for regeneration.
j) Suitable MS Epoxy Painted elevated access platform to be provided for

internal inspection of all the AC Filters, Ion Exchanger vessels, UF, RO
skids, Hot water tank, dosing tanks, degasser tower and tank etc.
k) Supply of Anti-scalant and Anti-oxidant as offered for RO skids for a period

of one (1) year from the date of successful commissioning of WTP plant
shall be provided by the bidder.
l) RO Reject shall be led to owner’s Coal handling plant for reuse in dust
suppression system.
m) The effluent of RO chemical cleaning shall be led to the sludge pit.
n) Each set of UF Cartridge filters, HP pump skids and RO membrane units

shall be aligned in a row forming a RO train/stream for RO system.
o) Adequate space for access and maintenance shall be provided for HP

Pumps (at the end of the pump bay) and RO membrane (at the sides) of
assembly.
p) CIP & Flushing System skids shall be provided at suitable location.
q) Sufficient numbers of portable type ladders with platform to be supplied for

ease of maintenance.
r) DM Plant shall be kept under shed with side covered and equipment
inside the shed shall be protected against sunlight and rain. Height of the
shed(s) shall be adequate to have sufficient head room for erection and
maintenance. DM plant regeneration area shall be kept under steel shed.
6) Any other equipment required to meet the system requirement for complete
Water- treatment plant and as envisaged by the contractor shall also be
provided.
7) All wetted parts in the plant shall be constructed with suitable corrosion
resistant material suiting to the fluid.
8) Facilities for maintenance of the pumps by means of mobile cranes or jib

crane or gantry cranes shall be provided based on pumps layout.

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CLAUSE NO.
1.05.00 Fire Detection and Protection System
1.05.01 General Design Criteria
i) The fire protection system shall consist of fire water storage tanks, fire water
pumping system, fire water hydrant and spray system serving the whole station
including Employer's plant/ facilities/ buildings.
ii) All major equipment/system components in the entire fire protection &
detection system shall have the approval from one of the following:
a) Underwriters Laboratories of USA
b) LPCB –UK
c ) VDS
d) BIS (for the approval of pumps and valves)
e) FM - USA
However, design and installation of complete system and requirements shall

be approved by TAC accredited professional(s)-India.
iii) Any other additional equipment not specifically mentioned in the technical
specification but are found necessary to meet the requirements of TAC and
also for safe and sound operation of the plant are to be included at no extra
cost to Employer.
1.05.02 Hydrant System
Design philosophy (minimum requirement)
i) Category of Hazard and minimum terminal pressure shall be as per TAC

norms.
ii) At least two hydrant ring mains shall be provided. Separate ring main for the
main plant (including transformer yard) to be provided. Isolation valves (gate
valves) between various ring mains shall be provided so that ring mains can be
interconnected and water from any of the ring main can flow to other mains.
iii) Coal conveyors at ground level shall be provided with external ground level
hydrant valves at required intervals. At locations where water cannot reach
conveyors through ground level hydrants, water monitors (with isolation gate
valve) at required intervals shall be provided. In addition to above fire hydrant
to be provided inside conveyor gallery on both the sides in all inclined conveyor
(running at elevation more than 30M from ground level) at 45 Mtr. (viz in
conveyor 1A at 90 meter interval, at conveyor 1B at 90 meter interval, but in
staggered way so that from one hydrant to other hydrant distance is
approximately 45 meters). Risers for these hydrant valves shall be supported

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CLAUSE NO.
through conveyor gallery legs/columns. For ESP area both ground hydrants
(with landing valves) and fixed water monitors (with isolation gate valve) shall
be provided. Further, fixed water monitors ((with isolation gate valve)) shall
also be provided for coal conveyors / transfer points, etc. having elevation 20M
or more.
iv) All the landings of boiler staircases, turbine building, CHP transfer point
houses, bunker floors, service building and other multi-storied structures of the
plant shall be provided with hydrant landing valves.
v) Each of the landing valves and external hydrant valves associated with the
main plant (transformer yard, TG building, boiler and ESP area) areas shall be
provided with a hose box. Each hose box shall contain two (2) numbers of 15M
long hoses & coupling, branch pipes & nozzles, spanner, etc. as per TAC
guidelines.
For landing valves of various off-site buildings, the hose box shall have two (2)
numbers 7.5 m long hoses, branch pipes, couplings, nozzles, spanners, etc. as
per TAC guidelines.
vi) The pipelines routed in RCC trenches shall be provided with coating and
wrapping. Road, Rail or pipe trench crossing be through trestle/RCC hume
pipes of appropriate pressure class and the pipe lines shall be provided with
coating and wrapping as per specification.
vii) Isolation Valve (Gate Valve) shall be provided in each riser of hydrant system.
1.05.03 HVW & MVW Spray System
Design Philosophy (Minimum Requirements)
i) Design discharge density shall be as per the rules of TAC and/or NFPA
standards.
ii) Deluge valve along with trims like pressure gauge, water motor gong, etc. shall
be UL/FM or equivalent approved / listed. The deluge valve (auto resetting
type) assembly shall consist of accessories such as water motor gong, alarm
test valves, drip/drain valves, strainers for these valves, hydraulic releasing
system, solenoid valves, etc. Further, the design features and make of all the
projectors / spray nozzles shall be UL/FM or equivalent approved / listed.
iii) A strainer ('Y' type) be provided at upstream of deluge valve. Each deluge
valve shall be provided with isolation gate valves (with limit switch) upstream &
downstream.
iv) Pressure switches be provided in spray and detector piping to exhibit "FIRE"
and "SPRAY ON" annunciations and as well as for interlock.

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CLAUSE NO.
v) Wet type pipe detector network shall be provided for spray system using
quartzoid bulb detectors.
vi) Each of the outdoor deluge valve and accessories shall be provided with
housing.
vii) Remote manual operation of the deluge valves shall be possible from the
respective fire alarm cum control panel through the keyboard operation of PC
monitoring station when the system is selected in remote manual mode. The
remote manual selection for the operation of spray system on any equipment
or any zone shall also be through the monitoring station of the respective
panel. Apart from the automatic operation of the deluge valve, the system shall
have provision for manual operation of the deluge valve by means of hand
operated lever close to the deluge valve assembly. There shall also be a
provision to operate deluge valve electrically from a nearby local panel.
1.05.04 Bladder tank Foam Protection System
Design Philosophy (Minimum Requirements)
i) Complete system shall be designed as per NFPA -11 and TAC.
ii) Water for the foam system may be tapped off from the hydrant system.
iii) The operation of foam system shall be automatic with the aid of fire detection
system provided for the HFO (if applicable) & LDO tanks with a provision for
manual operation. Auto/Manual selection switch shall be provided at the local
panel.
iv) Foam concentrate shall be of 100% AFFF type and shall be provided in
2x100% capacity foam concentrate tanks.
v) The minimum effective capacity of each foam bladder tank shall be designed
considering the following:
a) Simultaneous protection of any of the fuel oil tank (if applicable) or LDO tanks
and operation of two hydrants for 60 minutes
or
b) Minimum capacity if specified elsewhere.
viii) A design margin of atleast 10% shall be considered over the calculated foam
concentrate capacity and tank capacity.
vii) Foam bladder tank assembly shall consist of 2x100% foam concentrate
tanks with bladder, fill & drain valve for water and foam concentrate, foam
proportioner/ratio controllers along with concentrate supply control valve

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CLAUSE NO.
(hydraulically operated ball valves), vent valves, required instrumentation,

etc. Horizontally mounted Tanks shall be of carbon steel as per IS:2062
Grade ‘B’/ASME A516 Gr 70 and designed as per ASME code Section VIII
for pressure vessels. Bladder tanks shall also be provided with sight gauge
with shut-off & drain valve, ladder, pressure relief valve and filling kit.
viii) One number foam proportioner of adequate size shall be provided for each
HFO (if applicable) & LDO tanks.
ix) Besides these, one additional foam proportioner of adequate size shall be
provided for foam hydrant rings around dyke area. All the proportioners are
interconnected by isolation valves (manually operated), in such a way that
any of proportioner may cater to the requirement of others. Further, separate
isolation gate valves (manually operated) shall be provided for each
proportioner for maintenance.
x) Automatic solenoid valve shall be provided in foam supply line to each of the
HFO (if applicable)) & LDO tanks at the upstream of foam proportioner. In
the event of detection of fire, the signal shall operate the deluge valve and
water inlet valve to the designated foam proportioners of the tank, and as
well as open the foam solution inlet valve to foam proportioner and thereby
foam is injected to the tank under fire from foam makers discharge outlets.
xi) Apart from feeding the individual tank, each set of foam inductors shall
deliver foam solution to foam hydrant piping ring around the tank dyke
whenever foam injection system is initiated so that spill fires if any may be
extinguished by means of foam hydrants, hoses & monitor.
xii) Foam monitor shall conform to relevant International standard /

manufacturer’s standard.
xiii) The maximum spacing of the foam hydrants around the dyke area shall be
similar to that of water hydrant system.
xiv) The minimum foam application rate of 3% foam solution shall be 6.1
lpm/Sq.m (complete surface area) for fixed roof type tanks.
xv) The system shall incorporate features such as non-return valves to avoid
mixing water with foam concentrate pipelines, isolation valves of ratio
proportioning devices etc.
xvi) Foam concentrate piping shall be of Stainless Steel (seamless) as per

ASTM-A-312, TP-304, Schedule-40s. Fittings shall be of SS forged to ASTM-
A-182, F-304 for sizes 15NB to 40NB and S.S. seamless to ASTM-A-403,
WP-304, Schedule-40 for sizes 50NB & above. All the piping shall be laid
over ground on RCC pedestals. Further, all valves, foam proportioners, etc.
in foam concentrate line shall be of stainless steel construction.
xvii) Three (3) Nos. Foam Makers shall be provided for each LDO tank.

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CLAUSE NO.
1.05.05 Fire Detection, Alarm and Control System
Design Philosophy (Fire Alarm and Detection System)
i. The PLC based panel at fire water pump house and Remote IO panel at
Booster pump house shall indicate the status of each pump, system
pressure, operation of hydrant and/ or spray system, failure of starting of
pumps, healthiness & failure of batteries/ chargers, main supply, low level of
fuel oil of diesel engines, tripping of pumps, low level / very low level of water
in the water supply system, status of batteries & chargers of panels and
diesel engines etc. Alarms from these panels shall also be available to
operator at fire alarm addressable panels, central monitoring station and
DDCMIS.
ii. The addressable type panels at control equipment rooms shall receive signal
from sensors from various areas/ equipment’s of the respective units.
iii. The panel at coal handling plant control room shall exhibit alarms from
detection and protection from coal handling plant and all other auxiliary
buildings/areas. Further, panel provided at stacker-reclaimer machines shall
also be hooked-up with fire alarm panel at CHP control room for alarm
purpose.
iv. The central monitoring station to be located at Central Control Room shall
cover the fire detection and protection system of the complete (all the areas)
plant. This shall give audio-visual annunciations for fire in each of the risk
area / equipment / status of the fire protection system as well as system
operator open / short circuit status of detector or control cabling, etc.
Further, this shall activate a hooter/sounder in each of the area provided with
fire/smoke detection system.
v. Alarms from all the panels shall be repeated simultaneously in repeater panel
at Fire station.
vi. The addressable panel shall evaluate the signals received from the
detectors, transmit the fire or trouble alarms (audio-visual) to prearranged
points, supervise and monitor the complete fire detection & extinguishing
circuits, initiate control functions like shutdown of draft fans, air-conditioning
and ventilation plant/equipment, closure of Fire dampers in A/C & Ventilation
system etc. Opening smoke extraction vents, switching on smoke extraction
equipment emergency lighting, tripping of transformer lockout relays etc.
vii. All the circuits from the detectors to the panels and the circuits from the
panels to the actuating devices (such as solenoid valves, deluge valves,
push buttons etc.) shall be closed loop type and shall be supervised for open
and short circuiting. The trouble signal also be annunciated in the respective
panels.
viii. Facilities shall be provided on the fire alarm panel for simulating fire
conditions, sensitivity adjustment, isolation of detectors etc. from the panel.

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CLAUSE NO.
1.06.00 AIR CONDITIONING AND VENTILATION SYSTEM
1.06.01 GENERAL REQUIREMENTS
1. All equipment shall be located indoor unless otherwise agreed to by the

Employer. The equipment and layout shall generally be in accordance with the
General Layout Plant drawings.
2. The layout of all equipment and accessories shall be developed in a way to

facilitate easy accessibility and maintenance of all equipment.
3. Each equipment shall be provided with suitable lifting arrangement, e.g. Lifting
lugs, eye bolts, etc to facilitate maintenance.
1.06.02 DESIGN PHILOSOPHY - AIR CONDITIONING & VENTILATION SYSTEM
1. Design ambient conditions shall be as indicated below:
Season Dry Bulb Temp. (Deg. Wet Bulb Temp. (Deg.

C) C)
Summer 45 23
Monsoon 35.8 28.3
Winter 2 0
2. All equipments of Air Conditioning system shall be designed for continuous duty.
3. All air conditioned areas like control room, control equipment rooms, Service
building, administrative building etc. shall be maintained at 24 deg. C ± (plus or
minus) 1 deg. C and relative humidity of 50% ± (plus or minus) 5%.
4. The fresh air quantity for air-conditioned areas of Water System Control Building,
etc. shall be 0.45 M3/minutes/person or 1.0 air change per hour whichever is
greater. Fresh air fan capacity shall be minimum 10% of the total CMH value of
working indoor units.
5. Lighting load shall be one (1) Watts/Sq.feet or actual whichever is higher.
6. The occupancy for general area shall be minimum one person per 10 Sq. M and
for conference room the same shall be one per 3 Sq.M. In the control rooms,
control, equipment rooms etc, the occupancy may be one person per 25 Sq.M
(Minimum).
7. In Air conditioning system the return air shall be through ducts and use of
plenum space for return air shall be avoided.

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CLAUSE NO.
8. The supply and return air ducts shall be provided with automatic (motorised) fire
dampers (of 90 minutes fire rating) at locations where ducts pass through walls &
floors. Operation of these dampers shall be interlocked with the fire alarm system
and shall also be possible to operate manually from the remote control panel.
Required electrical contacts shall be provided in control panel of A/C plant by the
Contractor for further wiring upto fire alarm panels.
9. Soft water make up (if required) for complete air conditioning and ventilation
system shall be provided by the bidder.
10. Coil face area of Air Handling units shall be designed considering a face velocity
of not more than 2.5 m/sec.
11. Air distribution system shall be sized to have a constant frictional drop along its
length and velocity through ducts shall not exceed 7.6 m/sec.
12. Requirement of Underdeck Insulation (for A/C area)
13. Underdeck insulation of 50 mm nominal thickness of glass wool (32 Kg/cu.m) or

rock wool (48 Kg/cu.m) shall be provided if
i) Non A/C area is located just above the A/C area. In this case, underdeck
insulation shall be provided underneath of the ceiling of A/C area.
ii) Non A/C area is located just below the A/C area. In this case, underdeck
insulation shall be provided underneath of the ceiling of Non A/C area.
iii) Underneath the ceiling of AHU room located below the non-A/C area or
exposed to Atmosphere.
14. AHU’s shall be provided with two stage of filtration i.e. pre and fine filter. All fresh
air supply fans shall also be filtered using pre and fine filter.
15. A minimum design margin of ten (10) % shall be considered in design of A/C
Plant Capacity for each area.
16. For other areas, where A/C load is of the order of 25-60 TR, Direct Expansion
(D-X) type air cooled condensing units along with AHUs shall be provided
depending on the availability of space/ layout etc. For areas, where A/C load is of
the order of 5-25TR, ductable split/packaged A/C shall be provided. Smaller
areas which are away from the D-X type condensing unit /central chilling units
which may require air conditioning upto 5 TR rating shall be served with Hi-wall
Split/Cassette air conditioner units as per requirement.
17. Minimum Air changes per hour in evaporative/ mechanically ventilated areas
i) General areas like pump houses, cable galleries, etc. - 20

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CLAUSE NO.
ii) MCC/ Switchgear rooms and Battery - 30

rooms & other areas where
gaseous fumes/vapors are generated
18. However, in areas producing lot of heat, temperature shall be the criteria as
follows:
 Inside temperature shall be minimum 3 deg.C below the design ambient
temperature during summer for evaporative cooled areas.
 Inside Temperature shall be maximum 3 deg.C above the design ambient
temperature during summer for mechanically ventilated areas.
Note: Dry bulb temperature during summer season is 45 degC. The criteria which
gives higher number of air changes/higher quantity of air of either of
condition (Cl. 17 or 18) flow shall be selected.
19. All ventilation systems shall operate on 100% fresh air. All mechanically
ventilated areas shall be positively ventilated by means of supply air fans fitted
with filters and/or gravity operated back draft dampers and exhaust fans for
ventilation of heat generating areas combination of supply air fans with exhaust
air fans shall be provided. MCC / switchgear and cable gallery areas shall be
provided with gravity operated back draft dampers in association with supply air
fans in order to maintain positive pressure. Battery rooms and other fumes/odour
generating areas shall be negatively ventilated by means of exhaust air fans and
intake louvers. All other areas like pump house, etc. shall be positively ventilated
by a combination of supply air fan and exhaust air fans. Fan envisaged for MCC
& Switchgear rooms shall be provided with pre-filters and fine filters and for other
areas shall be provided with pre-filter only.
20. All the equipment of ventilation system shall be designed for continuous duty.
21. Type of ventilation for various buildings shall be as follows:
S.No Area Type of Ventilation system
(i) General area like pump house, Combination of Supply air fan &
chemical house, etc. Exhaust air fans
(ii) MCCs and Switchgear room, etc. Supply air fans & Back draft
dampers
(iii) Battery rooms Combination of Air Intake

Louvers & Exhaust air fans
(iv) Cable Galleries Supply air fans & Back draft

dampers
(v) Toilet/pantry etc. Exhaust air fans

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CLAUSE NO.
22. Supply air fans, exhaust air fans for ventilations of each area shall be provided
with local starter panels.

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SUB-SECTION–IIIA-02
CW SYSTEM

CLAUSE NO.
(A) CW PUMPS
This Chapter describes the System description, Basic Design Criteria and Minimum
Technical Requirements of the Circulating Water (CW) System and associated equipment.
(1) SYSTEM DESCRIPTION
In addition to the requirements specified in Part A of Technical Specifications, the CW
System shall meet following system design requirements:
(i) CW system shall be Re-circulating type with Induced Draft Cooling Towers. Each unit
shall be provided with its own dedicated cooling tower and CW System.
(ii) Water from CW sump will be pumped out into steel lined concrete ducts. The duct shall
be connected to the pump discharge flange through a carbon steel pipe, hydraulically
actuated butterfly valve, expansion joint and distance piece (if applicable). From the
ducts steel pipes shall carry water to and from the condenser.
(iii) The outlet pipes from condenser shall be joined to ducts. This duct shall lead hot water
upto the base of cooling tower. From base of the cooling tower steel pipes shall take
water upto the hot water distribution system of the cooling tower.
(iv) From cooling tower the cold water shall flow back to the CW sump through open
channel by gravity.
(v) For each unit, individual intake ducts from the CW pumps to the condenser and
discharge ducts from condenser to cooling towers shall be provided. However, the
supply ducts of all the modules shall be interconnected by means of motor actuated
butterfly valves at the CW pump house end. The CW duct interconnecting valves shall
be kept normally open.
(vi) Blow down from CW system shall be taken from CW Pump discharge, Clarified water
would be given as make up water to C.W. system from the Water Pre-treatment Plant.
(vii) The CW blow down water shall be tapped from the common pipe header tapped from
the CW inlet ducts of individual unit and the same shall be used for filling of Service
water tank, Fire water tank and to supply water to CHP dust suppression system &
chlorination water pumps. If necessary, booster pump shall be provided to deliver CW
blow down water & meet terminal point requirements. Excess CW blow down water
shall be led upto the Central monitoring basin of Effluent Treatment plant. Chlorine di-
oxide shall be dosed in the fore-bay of CW pump house as a biocide agent.
(viii) A common Re-circulation to CW pumping system shall be provided from the discharge
duct of each of the unit. The re-circulation line shall be led up to the CW channel
through a Butterfly valve which shall be provided with a motor actuator.
(ix) CW pumps shall be located in open CW pump house.
x) Gantry crane shall be provided for CW pump house.

SUB SECTION-IIIA-02 PAGE
(2X660 MW) SECTION – VI, PART-B
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WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 CW, RW & CWT SYSTEM
CLAUSE NO.
(2) TECHNICAL REQUIREMENTS OF CW PUMPS AND ASSOCIATED EQUIPMENTS:

The minimum technical requirements related to the design, manufacturing, testing etc. of the
following equipment are furnished below.
1) Part - 1: Technical Requirements of Vertical wet pit type CW pumps
2) Part - 2: Technical Requirements of concrete volute/ metallic volute with concrete
encasement CW pumps
3) Part - 3: Technical Requirements of Electro-hydraulic Actuators.
4) Part – 4: Technical Requirements of “Cranes and hoists”. The Gantry crane should be
sized to handle heaviest component to be handled with 25% margin and should comply to
IS: 3177.
5) Piping, valves and Rubber expansion joint – As per LP Piping Sub Section.
6) Painting – As per ‘Painting’ Subsection
7) AC and Ventilation - As per AC and ventilation sub section.

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PART- 1
TECHNICAL REQUIREMENTS OF CW PUMPS (VERTICAL WET PIT TYPE)
1.00.00 CODES AND STANDARDS
1.01.00 The design, manufacture, inspection and testing shall comply with all currently applicable
standards.
2.00.00 DESIGN AND CONSTRUCTION REQUIREMENTS
2.01.00 Design Criteria
2.01.01 The pumps shall be vertical, constant speed, wet pit, mixed flow design, with single stage
impeller, suitable for continuous heavy duty.
2.01.02 The pump shall be directly driven by a constant speed squirrel cage induction motor.
2.01.03 The pump shall have a flanged discharge connection.
2.01.04 Suitable arrangement shall be provided to take care of the discharge hydraulic thrust due to
an untied expansion joint. This may be achieved either by sizing pump discharge head and
base plate adequately to take care of the discharge hydraulic thrust or by providing a thrust
block assembly to restrain the discharge hydraulic thrust.
2.01.05 The design, construction and speed of the pumps shall be such as to minimize cavitation and
ensure a long and trouble free service. The "suction specific speed required" i.e specific
speed calculated with NPSH required, shall not exceed 12,000 (US Units).
2.01.06 The "system suction specific speed" i.e. specific speed calculated with NPSH available, shall
not be greater than 8500 US units at minimum water level. Pump speed shall be based on
the above "suction specific speed" available.
2.01.07 Net positive suction head required shall be less than net positive suction head available
during all operating conditions including run-out condition.
2.01.08 The pumps shall have stable head capacity characteristic continuously rising towards shut off
conditions. Characteristics of the maximum and minimum diameter impellers, which may be
fitted to the pump casing, shall also be indicated by the Bidder.
2.01.09 All the pumps shall be identical to one another, shall have identical characteristic curves and
shall be capable of running in parallel continuously without any restrictions.
2.01.10 The pump shaft shall be designed such that the complete pump and motor assembly
satisfies the following: The operating speed shall not be too close to the first critical speed,
i.e. N should be less than 0.8 times NC1 or N should be more than 1.3 times NC1, where N
is the operating Speed and NC1 first Critical speed.
2.01.11 Critical speed of pump-motor assembly shall be more than the maximum reverse run away
speed.
2.01.12 The column pipe shall have a wall thickness of not less than 12 mm.
2.01.13 Design life (minimum) of equipment supplied by contractor shall be 25 years.
2.02.00 Constructional Features
2.02.01 Material & construction of the pump & column shall be such as to resist corrosion & erosion
and give a long and satisfactory life to the plant. The materials used in construction of the
various components shall not be inferior to those given below:

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CLAUSE NO.
a. Suction Bell : 2% Ni Cast Iron, IS:210 Grade FG 260; S-0.1% max. P-

0.15% max.
b. Casing : - do -
c. Casing Liner : Stainless steel
d. Impeller : Austenitic stainless steel ASTM A743/CF8M Grade
(i). Impeller guide
piece(_if Austenitic stainless steel ASTM A743/CF8M Grade
applicable)
e. Wearing rings : Stainless steel of suitable grade as per manufacturer's

proven practice.
f. Pump shaft : Hardened stainless steel conforming to ASTM A276 Gr.410
g. Line shaft : Hardened stainless steel conforming to ASTM A276 Gr.410
h. Shaft coupling : Stainless steel type 410, ASTM A276, Heat treated &
hardened
i. Shaft sleeve : Stainless steel type 410, ASTMA 276, hardened as per
manufacturer's proven practice.
j. Line shaft bearing : Cutless rubber with bronze retainer / Thordon type bearing.
k. Thrust pads : Carbon steel with white metal lining
l. Fasteners : Stainless steel AISI type 304/316 for fasteners in contact
with water. Others shall be of high tension carbon steel.
m. Gland packing : Impregnated teflon
2.02.02 A ladder and platform arrangement shall be provided for each CW pump & motor for
inspection and maintenance of the thrust bearing .and for approach to any other part of the
pump / motor requiring frequent inspection.
2.02.03 Bearing lubrication
Forced Water Lubrication:
i) The line shaft shall be provided with shaft enclosing tube to exclude the pumped
water from shaft and bearings.
ii) The lubricating water required for the pump bearings shall be taken from the
storage tanks to be provided near the pump house. The lubricating water pumps
shall take suction from overground storage tank.
iii) The contractor shall provide a float valve at inlet, overflow, drain and vent
connections, level indicator and level switches to give an alarm on the panel.
iv) Two numbers of 100% capacities (2 x 100%) (Each lubrication water pump capable
of meeting the total lubricating water flow requirement for one CW pump) horizontal
bearing lubricating water pumps along with drives shall also be provided for each

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CLAUSE NO.
CW pump. The lubricating water pumps shall be designed to supply sufficient
quantity of water even during reverse rotation of the main pumps.
v) During initial filling and normal operation the lubricating water shall be tapped from
water filling line/potable/nearest source and fed to overground tank. The backup
source shall be tapped from a common header formed by taking a tapping from
discharge of all CW pumps. This water shall pass through 2 x 100% duplex filters
and fed to overground tank.
2.02.04 Thrust Bearing
i) Pump design with single thrust bearing at motor top or separate thrust bearings at
pump and motor (as per contractor's standard practice) is acceptable.
ii) Pump Thrust Bearing OR Single Thrust bearing at Motor top shall be of oil-
lubricated, centrally pivoted tilting pad type (Mitchell or Kingsbury) capable of
absorbing axial thrust in both directions of rotation. However, separate Motor Thrust
bearing as per motor manufacturer’s practice is acceptable. Water required for
cooling of thrust bearing shall be taken from main pump discharge. Hence CW pump
shall be suitable for starting without cooling water for thrust bearing.
iii) The thrust bearing shall be rated for continuous operation with thrust as developed
when impeller clearance is worn out upto four times the clearance when pump is new
and working under shut off condition.
2.02.05 Column and Shaft
The pump column shall be provided with flanged joints to permit easy disassembly. The line
shaft coupling shall be of muff type or approved equivalent. Columns shall be provided with
seating/lifting lugs.
2.02.06 Stuffing Box
Gland packing shall be provided at the top of the line shaft. Shaft sleeves shall be provided at
the stuffing box. The packing glands shall be split type to facilitate re-packing of the stuffing
boxes.
2.02.07 Wearing Rings
Replaceable wearing rings/casing liners shall be provided in impeller and casing. Design of
wearing rings / casing liners may be as per manufacturer's standard practice. The diametrical
clearance between casing and impeller at the wearing ring(s) when the pump is new shall not
be less than 1.2 mm.
2.02.08 Coupling
The pump shall be connected to the motor shaft by a suitable coupling.
2.02.09 Base Plate
Each pump shall be provided with a heavy structural steel base plate.
2.02.10 Vibration limits
The vibration limits of the pump set when measured at location as indicated in HIS shall not
exceed 100 microns (maximum).
2.02.11 Pump Motor Rating
Continuous motor rating (at 50 deg C ambient) for pump shall be at least ten percent (10%)
above the maximum load demand of the driven equipment in the complete operating range

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CLAUSE NO.
(including run-out condition of the pump and shut off condition in case pumps are envisaged
to be started with the discharge valve closed) to take care of the system frequency variation.
3.00.00 CONTROL PHILOSOPHY
3.01.00 The CW Pumps shall be controlled as specified in relevant chapters of Control &
Instrumentation
3.02.00 A local push button switch shall be used for emergency tripping of the motor.
3.03.00 The pump can be started either with pump discharge valve partially open or in closed
position depending upon contractor's standard practice.
3.04.00 Pump can be started only when either at least one of the flow circuits through the respective
condenser to the discharge duct and cooling tower is established or re-circulation line to
pump sump is open.
3.05.00 Low flow of either pump or motor bearing cooling water when the pump is running will give
alarm(s) and trip the pump with alarm in case of sustained low value over a preset time.
3.06.00 In case of high pressure at pump discharge due to accidental closure of any of the butterfly
valves in the CW system, an alarm shall be generated.
3.07.00 In case of normal stopping, when a CW pump control switch is turned 'OFF', the butterfly
valve at its discharge shall first close (25-30)% before the respective pump motor is de-
energized.
3.08.00 On tripping of motor due to any reason, the butterfly valve at the discharge shall close fully
automatically.
3.09.00 If water level in pump sump is low, an alarm shall be initiated. Pump shall be tripped in case
of very low level of water in the intake sumps and very high discharge header pressure.
3.10.00 Regulating the CW system makeup valve shall control the water level in the sump/fore-bay.
3.11.00 Pump shall be tripped from very high winding temperature of motor and very high metal
temperature of thrust bearings. Alarm shall be provided for high motor winding temperature
and high motor/ pump bearing temperature.
3.12.00 The operation philosophy as detailed above is suggestive only and bidder shall furnish the
complete control and interlock scheme for CW System equipment proposed by him along-
with the bid. The control and interlock scheme to be adopted shall be finalised in consultation
with the successful bidder after award of contract and shall be subject to Employer's
approval.
4.00.00 INSTRUMENTATION
4.01.00 Bidder shall provide the necessary vibration monitoring system.
4.02.00 Minimum instrumentation required for the Circulating Water pumps & pump house shall be
as per philosophy described in the Table below:
Name of Instruments Location Purpose Quantity
Pressure Gauges Discharge of Pumps Local Indicator 01 no for each
pump
Temperature Gauges Pumps Thrust Bearings Local Indicator 02 no for each
Lube oil (as applicable) pump

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CLAUSE NO.

Lube oil of other Local Indicator 01 no for each
Bearings (as pump
applicable)
Level Gauge i) Thrust Bearings oil Local Indication 01 no for each
tank pump
ii) Sump level Local Indication 01 no for each
sump
Ultrasonic type level Pump Sump Interlock/ 03 for each sump
transmitter Protection/
Annunciation
Pump house Forebay Indication/ 01 for each
level Annunciation Forebay
Overhead tank Indication/ 3 no
Interlock
Drainage pit of Pump Indication/ 01 no. per pit
house (in case of CV Interlock
type CW pump)
Diff. pressure level Pump Lube oil tank level Indication 01 no. per oil tank
transmitter
RTDs Pumps bearing (if Remote 03 nos. duplex for

applicable) each bearing
Pump motor winding, Remote As mentioned in
motor bearing monitoring electrical sub
section
Pressure Transmitters Pump Discharge Interlock/ 03 nos. for each
Protection/ CW pump
Annunciation
Common discharge Remote 02Nos
header of seal/lube
water pumps of each
CW pumps
Drainage water pump Remote 01 No each pump
discharge (in case of CV
type CW pumps)
Reverse Rotation Pump house Interlock/ 01 no. for each
indicator Annunciation pump
Flow indicator Flow indicator cooling Local indication 01 no at each

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CLAUSE NO.

water/ Lube oil Lube/Seal outlet
from CW pump and
motor
Electronic flow meter CW blowdown common Indication 01 No
header
Common discharge of 01 No
seal /Lube water pumps Remote
of each CW pump
Temperature Pump house Remote 01 nos. for each
Transmitter RTD
However, apart from the above required instruments to meet the system requirement and for
safe and reliable operation of the plant/system shall be supplied by the Contractor during
detailed engineering at no additional cost.
5.00.00 HYDRAULIC TRANSIENT ANALYSIS
5.01.00 For complete CW system, Bidder shall carry out a detailed hydraulic transient analysis.
Bidder shall decide the following based on the hydraulic transient analysis for entire CW
System:
a) Pump discharge-valve closing sequence and rate of closure for pump stopping and
pump tripping conditions
b) Size, location and quantity of air release valves in the discharge pipe and CW duct.
c) Pump discharge valve opening sequence and rate of opening during pump start-up
condition.
Based on the recommendations of such a study, Bidder shall take corrective measures and
provide suitable surge suppression devices in the complete CW System.
6.00.00 MODEL TEST OF CW PUMPS
a) For the offered pump, bidder should have carried out the model test. Bidder shall furnish
the above test results along with the tender. The model test should have been conducted
as per Japanese standard JIS-B-8327 and specific speed of the model tested pump shall
lie within ± 5% of the specific speed of the pump offered.
b) If the bidder has not conducted such a model test for the offered pump, bidder shall
conduct the test as per the procedure given below at no extra cost to the Employer.
c) A homologous model of the CW pump shall be tested at manufacturer's works in the
presence of Employer's representative to predict the performance of the prototype.
Model test shall include the cavitation test & Net Positive Suction Head Required
(NPSHR) test. In general these tests shall be conducted as per Japanese standard JIS-
B8327 (latest version).
7.00.00 INTAKE AND SUMP
a) The design details related to fore-bay, intake, etc shall be as per the relevant Civil
Works specified elsewhere and shall be finalised as per the Sump Model Study to be
carried out by the Bidder.

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b) Center to center distance of pumps, sump depth, distance from bottom of bowl (where
water enters the pump) upto the sump invert level etc shall be designed as per
recommendations specified in latest HIS, USA. However submergence from minimum
(design) water level shall have minimum 1 meter margin over the recommendations
specified in HIS, USA (latest)
c) CFD modeling
The Contractor shall engage developer of CFD code (which is proposed to be used for
CFD modeling) or reputed institutes like IITs, etc who have previous experience of
conductance of CFD modeling studies. The agency engaged by the contractor shall
conduct computer model based study using CFD modeling techniques. The CFD
modeling shall configure CW sump including forebay, transition zone, CW channel from
cooling tower to CW pump house. The computer model shall incorporate details of CW
channel, pump sump, stoplog, trashrack etc.
In this process the modeling shall investigate the flow characteristics and suggest
modification to achieve the desired flow pattern.
The results of CFD modeling shall be validated with the physical model test results and
any correction/updation in the CFD model to establish validation of CFD results shall be
carried out.
8.00.00 PERFORMANCE TESTS
8.01.00 Performance tests shall be carried out in two stages. After manufacture of the pump, the first
prototype pump shall be tested at shop and performance shall be verified.
8.02.00 After installation of all the pumps, the second stage of performance test shall be conducted at
site along with the initial operation.
8.03.00 Pump Performance (I Stage) Tests at Shop
8.03.01 After the manufacture, first CW pump shall be subjected to Prototype guarantee test at the
manufacturer's works which will include establishing the pump performance curves (Head -
Capacity, Power -Capacity, Efficiency-Capacity) and verifying the guaranteed parameters in
the presence of Employer's representative and pump supplier/ manufacturer.
8.03.02 The responsibility for conducting the test will be with the Contractor and Contractor shall
make all the arrangements for carrying out tests at site and all costs associated with the
above test shall be borne by the contractor.
8.03.03 Prototype guarantee test shall be carried out as per requirements of Hydraulic Institute
standard (HIS) and approved test procedure. Performance test at design duty point shall be
done keeping minimum submergence of pump identical to that specified for site conditions.
8.03.04 Bidder shall submit the test procedure for Employer's approval within six months of award. In
case such test facilities are not available at manufacturer's works, the test may be carried out
at any other test facility with the approval of Employer. All cost associated with testing at
contractor's works or at any other test facility shall be included in the contract price.
8.03.05 It may be noted that during the performance tests, no negative tolerance shall be permitted
on head, capacity and the pump efficiency.
8.03.06 Accuracy of instruments used shall be ± 1.5% or better for measurement of flow and ± 0.5%
or better for measurement of pressure and power.
Calibration of instruments to be used in the test shall be carried out by an independent
agency

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8.03.07 For carrying out performance test at shop actual motor shall be used. The test result will be
evaluated at actual speed achieved and speed correction shall be made only if there is a
supply frequency variation with respect to 50 Hz.
8.03.08 Shop test shall also include measurement of vibration, noise level and bearing temperature
rise for reference.
8.03.09 Strip down examination shall be carried out to check mechanical damages after Test.
8.04.00 Performance (II Stage) Tests at Site
8.04.01 Performance Test at site shall be conducted on all CW along with the initial operation in the
presence of Employer's representative and pump supplier/ manufacturer. Should the results
of the test deviate from the guaranteed values the contractor shall be given opportunity to
modify the equipment as required to enable it to meet the guarantees. In such cases the Test
shall be repeated within one month from the date on which the equipment is ready for retest
and the cost of modification, including labour, materials and cost of additional testing shall be
borne by the contractor.
8.04.02 The chance for repeat testing will be given only once during the contract period. All the
modification carried out in one pump to meet the contractual requirements shall be carried
out in other pumps also, covered under this contract, free of cost to the Employer.
8.04.04 Bidder shall submit Performance Guarantee Test procedure for Employer's approval.
8.04.05 The following parameters of the pumps will be measured during test and shall be in line with
approved data /manual.
a) Current, Voltage and Frequency
b) Speed of the pump
c) Suction level in sump/ Fore bay
d) Power at motor terminals
e) Discharge Pressure / head
f) Vibration and Noise level
g) Bearing temperature and Motor winding temperature
8.04.06 All interlocks and protections relating to the pumps, motors and motorized valves shall be
demonstrated /tested as per control logic.
8.04.07 Parallel operation of the pumps shall be demonstrated / tested. There should be equal load
sharing between pumps running in parallel with no abnormal vibrations, sound or hunting of
head and flow. Load sharing between any pumps running in parallel should be within 10%.
8.04.08 Vibration check shall be carried out as per HIS at locations indicated in above standard. The
acceptable vibration limits shall be as specified in relevant clause of this Chapter. The
instrument used would be IRD 308 or equivalent with velocity pickup.
8.04.09 Noise level shall be he less than 85 db A. Noise measurement will be done as per Hydraulic
Institute Standard. The measurement shall be carried out with calibrated integrating sound
level meter meeting the requirement of EC-651 or BS- 5969. Sound pressure level with be
measured all around the pump and motor set at a distance of 1 m from the nearest surface of

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the machine and at a height of 1m from the floor level. A minimum of six points should be
covered for measurement. The measurement shall be done with a slow response on the A-
weighted scale. The average of the A-weighted sound pressure level measurement
expressed in decibels to a reference of 0.0002 microbar shall not exceed the specified value.
The tests shall be carried out with the machine operating at rated speeds and throughout the
operation range. Correction for background noise and correction on account of test
environment will be considered in line with HIS. For this purpose all the additional data
required as per HIS should necessarily be collected during the test.
8.04.10 Opening and closing time of discharge butterfly valve will be checked and it should be as per
the approved data sheet. The capacity of the accumulator will be checked by opening and
closing of valve after switching off the electric supply to the oil pump. It should be able to
open and close the valve as per the specification requirement.
8.04.11 Accuracy of instruments to be provided by the Contractor for testing shall be as follows:
S. No. Parameters to be measured Instruments Accuracy
1. Power (motor input power) Wattmeter ± 0.5%
AC-Voltmeter ± 0.5%
AC-Ammeter ± 0.5%
Frequency meter ± 0.5%
2. Speed Tachometer non- ± 1 rpm
contact type
3. Temperature Digital Thermometer ± 0.1deg.C
4. Vibration IRD 308 or Equivalent ± 3%
5. Noise Level Sound level meter ± 2 dB
6. Pressure Measurement Bourdon type gauge / ± 0.5%
Pressure transmitter
7. Level gauge Plant instrumentation
8. Time Stop Watch ± 0.5%
9. Flow Flow element ± 1.5%
The above list is not exhaustive. Any other instrument required for the test will be arranged
by the contractor along with valid calibration certificate.

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PART- 2
TECHNICAL REQUIREMENTS OF CW PUMPS
(CONCRETE VOLUTE/ METALLIC VOLUTE WITH CONCRETE ENCASEMENT)
1.01.00 The design, manufacture, inspection and testing shall comply with all currently applicable
standards.
2.00.00 DESIGN AND CONSTRUCTION REQUIREMENTS
2.01.01 The CW pumps shall be of concrete volute/ metallic volute with concrete encasement,
concrete draft tube, vertical shaft, constant speed, single entry, centrifugal or mixed flow
design, with single stage impeller, suitable for continuous heavy duty.
2.01.02 The pumps shall be designed to meet the duty conditions specified elsewhere.
2.01.03 The impellers shall be of semi open / enclosed design.
2.01.04 The pump shall be directly driven by a constant speed squirrel cage induction motor.
2.01.05 The pump shall have a flanged discharge connection. Further, the pumps shall be provided
with the following parts as per the standard practice of the manufacturer:
a) Concrete Volute or metallic Volute.
b) Concrete Draft tube or metallic draft tube embedded in concrete
c) Embedded parts (cast or fabricated) in the concrete (i.e. cut water, suction part and
upper part) shall be suitable for the quality of water being pumped.
d) A casing cover bolted to the upper part of the pump.
e) A replaceable type sealing wearing ring bolted on to the suction part.
f) Anchor bolts on the embedded parts.
g) Steel set ring/ puddle flanges anchored in concrete and locked with reinforcements
on the discharge side.
2.01.06 The motor shall be mounted on the operating floor which is above maximum water level.
2.01.07 a) The design, construction and speed of the pumps shall be such as to minimize cavitation
and ensure a long and trouble free service. The "suction specific speed required" i.e. specific
speed calculated with NPSH required, shall not exceed 12,000 (US Units).
2.01.07 b) The system suction specific speed (i.e. specific speed calculated with NPSH available)
shall not be greater than 8500 US units at minimum water level. Pump speed shall be based
on the above suction specific speed available. “Net Positive Suction Head (NPSH) Required”
shall be less than “NPSH Available” during all operating conditions including run-out
condition.
2.01.08 The pumps shall have stable head capacity characteristic continuously rising towards shut off
conditions. Characteristics of the maximum and minimum diameter impellers, which may be
fitted to the volute, shall also be indicated by the Bidder.
2.01.09 The design shall ensure equal load sharing among the pumps operating in parallel. All
pumps shall be identical having identical characteristic curves and shall be capable of
running in parallel continuously without any restrictions.

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2.01.10 Necessary speed switches to detect reverse rotation shall be provided to prevent motor
switching on while rotating in reverse direction. The indication shall also be provided for this
purpose.
2.01.11 The shaft shall be designed such that the complete pump and motor assembly satisfies the
following: The operating speed shall not be too close to the first critical speed, i.e. N should
be less than 0.8 NC1 or N should be more than 1.3 NC1 Where N is the Operating Speed
and NC1 First Critical speed.
2.01.12 Critical speed of pump-motor assembly shall be more than the maximum reverse run away
speed.
2.01.13 Design life (minimum) of equipment supplied by contractor shall be 25 years.
2.02.00 Constructional Features
2.02.01 For concrete volute type design, the suction draft tube and pump volute casing shall be of
cast-in-situ concrete construction. The draft tube and volute construction with prefabricated
concrete elements are also permissible. For Metallic Volute type design, the Volute and the
draft tube can either be cast steel/cast iron or fabricated carbon steel construction as per the
standard practice of the manufacturer. The metallic draft tube shall be embedded on
concrete.
2.02.02 The inner-side of pre-cast elements must have a constant shape good surface, smoothness
and a high degree of water tightness and shall be constructed according to following
specifications.
a) Reinforcing Steel : Fe-415 conforming to IS:1786
b) Concrete Quality : M25 / M30 conforming to IS:456-2000
c) Cement : As per D-01 (Civil Works) sub-section
d) Concrete cover : Minimum 50mm inner side and minimum 25mm outside
e) Wall thickness : According to structural calculation. Minimum 125 mm
2.02.03 The outside of prefabricated elements shall be rough in order to get a good grip with the
surrounding concrete work.
2.02.04 The following parts must form an integral part of the prefabricated elements
- Cast iron trays of anchor bolts at suction side with steel anchors for suction wear ring.
- One steel foundation ring on discharge side for fixing the discharge wear ring.
2.02.05 Curves in more than two planes should be avoided in the development of the volute and inlet,
with the exception of short radius blending fillets.
2.02.06 Final finishing of the surface of the draft tube and volute shall be carried out by the bidder
with epoxy paint or mortar so as to meet the surface finish as required by the pump
manufacturer.
2.02.07 Materials of Construction
Material & construction of the pump & column shall be such as to resist corrosion & erosion
and give a long and satisfactory life to the plant. The materials used in construction of the
various components shall not be inferior to those given below:

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a) Casing and draft Cast in situ concrete / Pre-cast concrete elements for concrete
tube volute type pumps
OR
Cast steel/Cast iron or Fabricated carbon steel for metallic volute
type pumps
b) Impeller Austenitic stainless steel ASTM A743/CF 8M grade or
Equivalent.
c) Wearing rings Stainless steel of suitable grade as per manufacturer’s proven
practice.
d) Pump shaft Hardened stainless steel conforming to ASTM A 276 Grade 410
e) Line shaft As per manufacturer’s standard
f) Shaft sleeve Stainless steel ASTM A276 grade 410 hardened as per
manufacturer’s proven practice.
g) Cut water Ni resist Cast Iron
h) Casing cover Fabricated steel or 2% Ni cast Iron, D2 type
i) Shaft coupling Stainless steel ASTM A 276 grade 410.
j) Bearing Babbited with oil lubrication.
k) Bolts, nuts and Stainless steel AISI type 304 coming in contact with water and
lock washers others of high tension carbon steel.
l) Gland packing Impregnated Teflon.
m) Stuffing box IS : 210 grade 260, 2% Ni C.I.
housing
2.02.08 A ladder and platform arrangement shall be provided for each CW pump & motor for
inspection and maintenance of the thrust bearing and for approach to any other of pump /
motor requiring frequent inspection.
2.02.09 Thrust Bearing
a) Pump design with single thrust bearing at motor top or separate thrust bearings for
pump and motor (as per bidder’s standard practice) is acceptable. In case the thrust
bearing is located in the pump it shall be located just above the guide bearing and the
coupling shall be flexible type in such a case.
b) Thrust bearing shall be of oil-lubricated, centrally pivoted tilting pad type (Mitchel or
Kingsbury) capable of absorbing axial thrust in both directions of rotation continuously.
Water required for cooling of thrust bearing shall be taken from main pump discharge.
Necessary pumps, filters, piping, valves, accessories, specialties as required for such
cooling purpose is in the scope of Bidder. However pump design shall be suitable for
starting without cooling water for thrust bearing.
c) The thrust bearings shall be rated for continuous operation with thrust as developed
when impeller clearance is worn out up to four times the clearance when pumps is new
and working under shut off condition.

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2.02.10 Wearing Rings & Shaft Sleeves

a) Replaceable wearing rings/ liners shall be provided between impeller and casing. The
suction wearing ring /liner shall be bolted in a holder which shall be grouted in concrete
with non-shrinking mortar.
b) During grouting of this ring, the top section shall be grouted with two pack moulding
mass of synthetic resin, minimum layer thickness 3 mm so as to provide water tight
finish.
c) The diametrical clearance between casing and impeller wearing ring(s) when the pump
is new shall not be less than 1.2 mm.
d) Casing wearing ring at suction shall be held in a metallic carrier grouted in concrete,
which shall permit final adjustment after completion of civil works, wearing rings shall be
removable from the carrier.
e) Suitable shaft sleeves shall be provided between the shaft and impeller to protect the
shaft. Interfaces between components on the shaft assembly, where it would otherwise
be exposed to water, shall be provided with suitable seals.
2.02.11 Coupling
The pump shall be connected to the motor shaft by a suitable coupling.
2.02.12 Sealing Arrangement
a) A mechanical seal or stuffing box with packing flushed with water shall be provided in
line with the standard practice of the manufacturer.
b) A seal flushing system shall be provided which will supply the glands with flushing water
both during pump start-up / shutdown and also while the pump is running.
c) The seal flushing water shall be filtered by the provision of 2x100% basket type strainers
with isolation valves for each pump set.
d) Bidder shall make necessary arrangement for proper drainage of the seal area by
providing drainage pumps.
e) Mechanical seal (if provided) shall be of approved design. This shall have a minimum life
between overhauls of 16,000 operating hours. The seal design shall be of cartridge
construction for ease of maintenance and shall be able to accommodate the shaft
deflections.
f) 2x100% capacity seal water pumps shall be provided for each CW pump. The seal water
pumps shall conform to relevant Sub-section titled “Horizontal Centrifugal Pumps” of this
specification.
g) The stuffing box housing shall be of axially split design so as to facilitate easy removal of
packing.
2.02.13 Journal Bearings
a) The guide bearings for CW pump shall be of journal bearing type. Adequate bearing
lubrication shall be provided for all operating conditions. The bearings housing shall be
designed to exclude the ingress of dust and water, and shall have suitable provision for
breathing and be adequately sealed to prevent leakage of oil.

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b) The main pump guide bearing shall be babbitt lined bronze bearing sleeve located as
close to the impeller as possible. Guide bearings shall be oil lubricated. . The guide
bearing & thrust bearing shall be protected against water splashes and in particular
against gland packing leaks.
c) The guide bearing shall be of journal bearing type. It shall be out of water, cooled &
lubricated by self circulated oil. The bush bearings (if provided) shall be lubricated with
filtered pump fluid.
d) Alternately, bearings with grease lubrication are also acceptable provided these are
standard design of manufacturer
e) All bearings shall be out of water and should be easily accessible for maintenance
purpose. Adequate access shall be provided for maintenance of bearings.
f) The bearing bracket shall be designed to ensure maximum rigidity of the bearing
support. (The bearing support shall be centered on & bolted to the casing cover).
g) The guide bearing shall be lubricated by an automatic oil circulating system with fixed
scoops dipping into a rotating vat coupled to the shaft.
h) The guide bearing housing shall be of axially split design so as to facilitate ease of
maintenance.
2.02.14 Pump Shaft
a) The shaft shall be designed to transmit the maximum rated power at the pump operating
speed and shall be of ample stiffness to minimise deflection of the shaft during starting
conditions or any other operating condition.
b) The shaft shall preferably have all components key driven including impeller, collar and
coupling. Where the pump shaft is exposed to water (i.e.) to effects of corrosion, it shall
be adequately protected by replaceable sleeves.
2.02.15 Lubrication System
a) The design of the lubricating system shall be such that the bearing performance is
insensitive to small changes in oil levels.
b) Material of construction of Cooling coils if fitted shall be of Stainless steel
c) The bearing lubricating system must be designed to permit easy filling and drainage of
lubricating oil. Easy access shall be provided for the addition of lubricating oil with the
pumps in service. All associated pipe work shall be of stainless steel.
d) Required level sensors shall be provided for measurement/interlock & alarm purpose.
2.02.16 Gland Drainage
a) In case the design of pump is with gland packing, bidder shall provide suitable means of
adequately draining the gland area in view of the fact that the same shall be below
operating floor level. The system shall be complete with vertical type pumps, float switch,
discharge piping, valves etc.
b) Four (4) numbers of such drainage pump shall be provided in the CW pump house. The
minimum capacity of each pump shall be 50 m3/hr & the corresponding head shall not be
less than 10 MWC. These pumps shall also be used for drainage of leakages from the
gland or from any other source.
2.02.17 Manhole

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Each pump shall be equipped with an inspection manhole (Minimum diameter of 1000 mm)
with steel cover plate at discharge side. Suitable access provision shall be made for the
manhole from the operating floor.
2.02.18 Vibration limits
The maximum vibration limits of the pumps set when measured at locations as indicated in
HIS shall not exceed 25 microns.
2.02.19 Pump Motor Rating
Continuous motor rating (at 50 deg C ambient) for pump shall be at least ten percent (10%)
(including run-out condition of the pump and shut off condition in case pumps are envisaged
to be started with the discharge valve closed) to take care of the system frequency variation.
3.00.00 OPERATION PHILOSOPHY
Control & Operation philosophy and Instrumentation shall be as described in Part-I above.
4.00.00 HYDRAULIC TRANSIENT ANALYSIS
For complete CW system, Bidder shall carry out a detailed hydraulic transient analysis.
Bidder shall decide the following based on the hydraulic transient analysis for entire CW
System:
a) Pump discharge-valve closing sequence and rate of closure for pump stopping and
pump tripping conditions
b) Size, location and quantity of air release valves in the discharge pipe and CW duct.
c) Pump discharge valve opening sequence and rate of opening during pump start-up
condition.
Based on the recommendations of such a study, Bidder shall take corrective measures and
provide suitable surge suppression devices in the complete CW System.
5.00.0 MODEL TEST OF CW PUMPS
5.01.0 A homologous model of the CW pump shall be tested at manufacturer’s/bidder’s work in the
presence of Owner’s representative to predict the performance of the prototype. Model test
shall include the cavitation test and NPSHR test. In general these tests shall be conducted as
per Japanese Standard JIS – B- 8327 (latest version).
5.02.0 The procedure to be followed for model test shall be mutually discussed and agreed before
conducting the test.
Contractor shall submit a procedure for ensuring & demonstrating the similarity of the
impeller vane profile \ volute profile for the model pump & the prototype.
6.00.00 INTAKE AND SUMP
a) The design details related to fore-bay, intake, etc shall be as per the relevant Civil
Works specified elsewhere and shall be finalised as per the Sump Model Study to be
carried out by the Bidder.
b) Center to center distance of pumps, sump depth, distance etc shall be designed as per
recommendations specified in latest HIS, USA. However submergence from minimum
(design) water level shall have minimum 1 meter margin over the recommendations
specified in HIS, USA (latest)

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c) CFD modeling
The Contractor shall engage developer of CFD code (which is proposed to be used for
CFD modeling) or reputed institutes like IITs, etc who have previous experience of
conductance of CFD modeling studies. The agency engaged by the contractor shall
conduct computer model based study using CFD modeling techniques. The CFD
modeling shall configure CW sump including forebay, transition zone, CW channel from
cooling tower to CW pump house. The computer model shall incorporate details of CW
channel, pump sump, stoplog, trashrack etc.,
In this process the modeling shall investigate the flow characteristics and suggest
modification to achieve the desired flow pattern
The results of CFD modeling shall be validated with the physical model test results and
any correction/updation in the CFD model to establish validation of CFD results shall be
carried out.
7.01.00 Performance tests shall be carried out in two stages. After installation of the pump at site,
one of the pumps to be chosen by the Employer, shall be subjected to performance test at
site and performance shall be verified, which will include establishing the pump performance
curves (Head - Capacity, Power - Capacity, Efficiency -Capacity) and verifying the
guaranteed parameters in the presence of Employer's representative and pump supplier/
manufacturer.
7.02.00 After installation of all the pumps, the second stage of performance test shall be conducted
at site along with the initial operation.
7.03.00 Performance (I Stage) Tests at Site
7.03.01 Guarantee test on one of the CW pumps shall include establishing the pump performance
curve (head, capacity, power –capacity, efficiency capacity) and verifying the guaranteed
parameters in the presence of Employer's representative and pump supplier/manufacturer.
7.03.02 The responsibility for conducting the test will be with the Contractor who shall furnish
detailed site test procedures for Owners approval, Contractor shall make all the
arrangements for carrying out tests at site and all costs associated with the above test
arrangement shall be borne by the contractor.
7.03.03 Performance guarantee test shall be carried out as per requirements of Hydraulic Institute
standard (HIS) of USA and approved test procedure. Performance test at design duty point
shall be done keeping minimum submergence of the pump identical to that specified for the
site conditions.
7.03.04 Contractor shall submit details of the proposed testing arrangement, methodology of flow
measurement etc for Employer’s approval.
7.03.05 It may be noted that during the performance tests, no negative tolerance shall be permitted
on head, capacity and the pump efficiency.
7.03.06 The test shall include measurement of vibration, noise level and bearing temperature rise.
7.03.07 Accuracy of instruments to be provided by the Contractor for testing shall be same as that
indicated elsewhere
7.03.08 Flow measurement at site shall be carried out using re-circulation line. Additional temporary
pipelines / RCC chamber, if any, are required to be provided, for testing the pump for the

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complete measurement range, the same shall be provided by the Contractor. The Contractor
shall install flow measuring instruments of specified accuracy level in this pipeline(s).
a) Calibration of instruments to be used in the test shall be carried out by an independent
agency. Calibration of instruments should be carried out prior to the test. The calibration
certificate of the instruments should be valid for the period of test
7.03.09 The test result will be evaluated at actual speed achieved and speed correction shall be
made only if there is a supply frequency variation with respect to 50 Hz.
7.04.00 Performance (II Stage) Tests at Site
7.04.01 Performance Guarantee test at site shall be conducted on all the CW pumps along with the
initial operation in the presence of Employer's representative and pump
supplier/manufacturer. Should the results of the test deviate from the guaranteed values the
contractor shall be given opportunity to modify the equipment as required to enable it to meet
the guarantees. In such cases the PG test shall be repeated within one month from the date
on which the equipment is ready for retest and the cost of modification, including labour,
materials and cost of additional testing shall be borne by the contractor.
7.04.02 The chance for repeat testing will be given only once during the contract period. All the
modification carried out in one pump to meet the contractual requirements shall be carried
out in other pumps also, covered under this contract, free of cost to the Employer.
7.04.04 Bidder shall submit detailed Performance Test procedure for Employer's approval.
7.04.05 The following parameters of the pumps will be measured during test and shall be in line with
approved data /manual.
a) Current, Voltage and Frequency
b) Speed of the pump
c) Suction level in sump/ Forebay
d) Pump input power at motor terminals
e) Discharge Pressure / head
f) Vibration and Noise level
g) Bearing temperature and Motor winding temperature
7.04.06 All interlocks and protections relating to the pumps, motors and motorized valves shall be
demonstrated /tested as per control logic.
7.04.07 Parallel operation of the pumps shall be demonstrated / tested. There should be equal load
sharing between pumps running in parallel with no abnormal vibrations, sound or hunting of
head and flow. Load sharing between any pumps running in parallel should be within 10%.
7.04.08 Vibration check shall be carried out as per HIS at locations indicated in above standard. The
acceptable vibration limits shall be as specified in relevant clause of this Sub-section. The
instrument used would be IRD 308 or equivalent with velocity pickup.
7.04.09 Noise level shall be he less than 85 db A. Noise measurement will be done as per Hydraulic
Institute Standard. The measurement shall be carried out with calibrated integrating should

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level meter meeting the requirement of EC-651 or BS- 5969. Sound pressure level with be
measured all around the pump and motor set at a distance of 1 m from the floor level. a
minimum of six points should be covered for measurement. The measurement shall be done
with a slow response on the A-weighted scale. The average of the A-weighted sound
pressure level measurement expressed) in decibels to a reference of 0.0002 microbar shall
not exceed the specified value. The tests shall be carried out with the machine operating at
rated speeds and throughout the operation range. Correction for background noise and
correction on account of test environment will be considered in line with HIS. For this purpose
all the additional data required as per HIS should necessary be collected during the test.
7.04.10 Opening and closing time of discharge butterfly valve will be checked and it should be as per
the approved data sheet. The capacity of the accumulator will be checked by opening and
closing of valve after switching off the electric supply to the oil pump. It should be able to
open and close the valve as per the specification requirement.
7.04.11 Accuracy of instruments to be provided by the Contractor for testing shall be same as that
indicated at Part-I.
The above list is not exhaustive. Any other instrument required for the test will be arranged
by the contractor along with valid calibration certificate.
7.04.12 Calibration of instruments that are to be used in the test shall be carried out by an
independent agency.

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PART- 3
TECHNICAL REQUIREMENTS OF ELECTRO-HYDRAULIC ACTUATORS
1.00.00 DESIGN CRITERIA
1.01.00 Each electro-hydraulic actuator shall be provided with its own power pack. Each actuator
shall consist of a double acting cylinder, control cabinet and accessories to cater for following
operational requirements.
1.02.00 In the closed position the valve shall be held closed by a substantial counter weight or by any
other mechanical device.
1.03.00 Valve shall remain open during normal running of the pump.
1.04.00 A limit switch be provided (set at about 3 deg from open position) to sense the creeping.
Switch shall start the oil pump and return the valve to the fully open position.
1.05.00 When the valve is fully open and electric supply in the valve control system fails the butterfly
valve shall remain open while the CW pump continues to deliver water.
1.06.00 In case of any fault causing pump motor trip the corresponding butterfly valve shall start
closing at a fast rate initially and thereafter at a slow rate. The emergency closing facilities
shall be duplicated each with its own solenoid valve in the hydraulic circuit.
1.07.00 Provision for local manual operation shall be made.
1.08.00 A locking device shall be provided so that the valve can be maintained in open/shut position
during maintenance and inspection.
1.09.00 The hydraulic controls for each valve shall be housed in independent cabinet located on an
operating floor near the valve. This shall consist of pumping unit, oil tank, and accumulator of
adequate capacity to hold the valve disc at any position and to prevent any surge including
disc flutter during valve travel and to fully open position. Accumulator will also have enough
capacity for one cycle (open & close operation) of operation without external electric AC
power. The hydraulic power pack will consist of necessary pressure switches, pressure
gauges, flow regulators, solenoid valves; transformers, rectifiers etc. for DC power supply for
solenoid valves; contactors, relays, fuses, indicating lamps, push buttons etc. for control of
solenoid valves and pumping units; throttle valve, filters, non-return valves etc. arranged in a
logical circuit to meet operation requirement.
1.10.00 The electrical controls for the valve such as relays, contactors and fuses shall be housed in
the common control panel (local) for CW pumps or in a separate panel. Reversible starters
for the valves shall however, be provided by the Employer.
1.11.00 Each butterfly valve shall have four limit switches, each capable of being set of at any point
between full open to full close position to meet desired functions. In addition, one more extra
limit switch to be set at an intermediate position shall be provided. each limit switch shall
have 2 NO and 2 NC contacts. Limit switch enclosure shall conform to NEMA 4 x standard.
1.12.00 Each butterfly valve shall have Two nos. non-contact type 24 V DC 4-20 mA output position
transmitters .The bidder shall submit with his offer full details of valve operating mechanism
and hydraulic diagram with description.

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PART-4
CRANES AND HOISTS
1.00.00 INTENT OF SPECIFICATION
1.01.00 This specification is intended to cover design, engineering manufacture, assembly,

inspection, testing at manufacturer works, painting & forwarding duly packed for
transportation, and performance testing at site of one no. Electrically operated overhead
Traveling crane (EOT)/ Gantry Crane complete with all accessories as specified herein.
2.00.00 EOT CRANES/GANTRY CRANES
2.01.00 Electric Overhead Traveling (EOT) /Gantry crane shall take care of erection/ maintenance
requirement of pumps/blowers/machines and their associated auxiliaries for which these
are being installed. The capacity of the crane shall and not be less than 25% above the
weight of the heaviest item envisaged to be lifted during erection and maintenance.
2.02.00 The EOT /Gantry crane shall be remote control operated. The power shall be supplied
from a single electrical power supply point at a suitable location on the operation floor of
pump house.
2.03.00 The design code for EOT/Gantry crane shall be IS: 3177 latest edition.
2.04.00 However, the speed for the various motions shall be as follows :
Main hoist 1.6 m/min
Trolley Travel (Cross Travel) 4.0 m/min
Crane Travel (Long Travel) 8.0 m/min
2.05.00 Creep speed arrangement shall be provided for all motions of EOT/Gantry Crane. This
shall be 10% of rated speed. (Creep speed to be achieved through pony motor &
planetary gear box or through variable voltage variable frequency(VVVF) system Hoist
brake shall not be used for this motion).
2.06.00 The crane shall be electrically operated, overhead travelling / Gantry type as shown in
tender drawings. Design and duty of Crane structure, main hoist, cross-travel and long-
travel shall be in accordance with class M5 of IS: 3177 (latest amendment) and shall be
suitable for indoor operation.
2.07.00 The crane shall be complete with trolley and truck, wheels and axles, Drive mechanisms,
Hoisting Drums, Brakes, Creep Speed Arrangement, Lifting tackles, Buffers, Electric
Motors, Controls, Switch Board and cabling, horns, warning lights, Limit switches etc. Any
item not mentioned herein but required to make the system complete for the satisfactory
performance of the crane shall also be included.
2.08.00 The main hoist, trolley travel and crane travel for each movement shall be motor driven.
Proper allowance shall be made for impact and wear in the design of the crane and in no
case shall the factor of safety in any part be less than six (6), as per IS: 3177 based on
the ultimate strength of the materials used at design duty. The design duty of crane
structure, main hoist, cross travel and long travel shall conform to class - II for the Indian

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Standard IS: 3177 (latest edition) or superior. The crane as a whole shall comply with the
Indian Standard IS: 3177/IS: 807 or approved equivalent international standard (latest
edition).
2.09.00 Mechanical and Electrical equipment of each crane shall be of simple robust design, easy
for correction adjustment, readily accessible for maintenance and elegant in appearance.
All steel used in the crane shall be tested to requirements.
2.10.00 The hoist motors shall be provided with DC electro-magnetic brakes as well as Electro-
hydraulic thrust brakes. Electro-hydraulic thrust brakes shall be provided for cross travel &
long travel.
2.11.00 Creep speed drives shall be provided for all the motions viz. bridge motion, trolley motion
and hoist motion to enable attain the creep speeds of 10% of the main speeds.
2.12.00 Safe means of access shall be provided and to every place of crane where
examination/maintenance of any component is involved. A platform shall extend to full
length of the crane bridge on both sides of the bridge girder. The platform shall be made
of chequered Steel plate. A double tire hand -rail of height 1100 mm shall be provided
along the outer edge of the platform and 75mm high toe-guards shall be provided all
along the platforms and wherever else required from safety consideration. The width of
platform shall not be less than 800mm in width and Guard rails shall be provided on the
crab side of the bridge platform.
2.13.00 LADDERS:
For EOT Crane: Necessary access ladders shall be provided for access on to crane
bridge platform from the gantry girder level, from crane bridge platform to trolley platform
and from operating floor of pump house to gantry girder level.
For Gantry crane: Necessary access ladders shall be provided for access on to crane
bridge platform from operating floor and from crane bridge platform to trolley platform.
2.14.00 The lifting tackle shall consist of a safety type lower pulley block, hook, necessary sheave
and flexible steel wire ropes. The lower block sheaves and ropes shall be of adequate
design and size to handle the specified loads. The hooks shall be of forged steel. The
hook shall be of Ramshorn type conforming to IS: 5749 (latest edition) or as per codal
requirement. The factor of safety for the rope shall not be less than six (6). The sheaves
shall be of heavy duty with deep flanges made of cast steel and shall be properly grooved
to fit the rope and adequately guarded.
2.15.00 Each crane shall be equipped with motor of ample capacity for the duties and speeds
specified conforming to IS: 325 (latest edition). The motor shall also meet the
requirements as specified in IS: 3177 (latest edition). Rated capacity of each motor shall
be such that its full load torque shall not be exceeded in giving the specified performance
of the crane. The motor speed shall not exceed 1000 RPM. The break down torque of the
motors shall not be less than 275 percent of the full load torque with rated voltage and
frequency applied. The bearings shall have ample strength to withstand the heavy shocks
and vibrations to which they will be subjected. Other design and constructional features of
the motors shall in general conform to motor specification requirements mentioned
elsewhere in the specification.
2.16.00 Motors:
2.16.01 Three phase Squirrel Cage Induction motors to be operated from VFD system shall be
suitable for speed range and torque without exceeding temperature rise limits as specified
elsewhere in this specification. These motors shall be provided with VPI insulation and

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insulated bearing on one side and shall be suitable for Inverter duty. Motors shall conform
to latest revision of IS 325, IS 3177 and motor sub-section of this specification.
2.17.00 Controls:
2.17.01 Speed control of EOT/Gantry crane shall be through Variable Voltage Variable Frequency
System (VVVF) with minimum six (6) pulse design.
2.17.02 Necessary input & output devices to be provided to reduce harmonics, as per IEE519, at
supply side of the drive at the switchgear.
2.17.03 All necessary protections e.g. Input phase loss, earth-fault, over-voltage, output short
circuit, load loss, input transient protection, over-load, etc. to be provided.
2.17.04 VVVF system shall be capable of generating suitable starting torque (upto 400% typical)
with / without encoder, however starting current shall not exceed 150% of the rated
torque.
2.17.05 VVVF system shall be capable of withstanding upto 50 deg C temp without derating.
2.17.06 Provision for controlling the motion from operator pendant as well as remote control shall
be available.
2.17.07 Squirrel cage Induction motor with VPI insulation shall be provided with VVVF system.
2.17.08 Protective Panel to be provided with isolating switch, power contactor control and
indication to switch ON/OFF power to starter panels, control and lighting transformer.
2.17.09 Starter Panel: Separate VVVF system panels to be provided for CT, LT and hoist motion
(main and auxiliary drives).
a) Contactors: AC 4 duty for reversing application AC 3 duty for non reversing

application.
b) Switches: AC 23 for motor application, AC 22 for other application.
c) Fuses: HRC
d) Resistors: Stainless steel punched grid (strip) type.
e) Overload relay: Temperature compensated, bimetallic with single phasing

Preventer.
f) Panel shall be fabricated out of 1.6 mm thick rolled sheet steel. IP 52 degree of
protection. Paint shade shall be RAL 9002 for front & rear and RAL 5012 for side
covers. Space heaters to be provided.
2.18.00 Remote Control of EOT/Gantry Crane:
2.18.01 The equipment should have facility to control EOT/Gantry crane by radio frequency based
wireless remote unit. The equipment should be supplied with transmitter unit, receiver
unit, encoder unit, decoder unit, interface panel, coupling system, battery unit and any
other control gear if required.
2.18.02 The equipment should be based upon the microprocessor based digital technology with
almost nil hard wiring.

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2.18.03 The remote unit should communicate up to the distance of approximately 100 mtrs. A
spare remote control unit is also to be provided.
2.18.04 The system has to integrate with the control system of crane, which operates at
110 V AC, Single phase.
2.18.05 The remote unit should have transmitter which can be mounted on shoulder by suitable
belt. Main controls can be of single joystick movement or double joystick movement type
stepped control with spring return. The Micro control should be toggle switch type or push
control type.
2.18.06 Initial frequency allotment if required, for radio remote unit from Govt. of India, Deptt. of
Telecommunication or any other agency should be done by supplier. Necessary request
with other details will be forwarded to Employer.
2.18.07 The transmitter and receiver unit should have its own frequency and address code with
each system having its own security code so that one particular set becomes unique and
there is no interference from any other remote unit device. A microprocessor should check
all security codes. The processor should have its own watchdog circuit. The receiver FM
band should be sufficiently narrow to allow only passing of desired frequency and valid
command. Any error should shut down the system immediately.
2.18.08 The remote unit should have safety key to prevent any unauthorized operation. All the
crane operations should stop at once the communication break down occurs.
2.18.09 On local unit (receiver side), the system should be provided with one selector switch so
that EOT/Gantry crane can be operated either from Operator pendant or remote unit.
2.18.10 In case tandem operation is envisaged, a suitable selector switch shall be provided for
selection of Tandem/normal operation.
2.18.11 The receiver unit along with I/O interface unit should be able to bear the vibrations and
shocks encountered in normal usage of EOT /Gantry crane.
2.18.12 The system should have very fast response time typically of the order of 100 milliseconds
for executing all commands.
2.19.00 Each crane shall be controlled individually for all its motions remote. A minimum two (2)
numbers 150W HPSV under bridge lights are to be provided for proper illumination.
Suitable numbers bulkhead light on crane bridge passage along with separate ON/OFF
switches (to be made ON while crane maintenance is undertaken) to be provided. A
minimum clear space of 500mm shall be available in front of all bridge mounted control
panels & resistance boxes. RYB phase indication lamp & Voltmeter with selector switch to
be provided on main protection panel. One number lamp with switch and one number 15A
socket with switch to be provided in each protection & control panel. For safety one
emergency stay-put switch at each of the four (4) corners of Bridge near buffer location to
be provided and one indication lamp on pendant to indicate emergency switch operation
to be provided.
2.20.00 Each crane shall have a permanent inscription of English on each side, readily visible
from the ground level, stating the safe working loads in tonnes for both the hooks, year of
manufacture, crane serial number and manufacturer's name.

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2.21.00 POWER CONDUCTORS: -
DOWN SHOP LEADS (Runway Conductors): -
(a.) Four numbers (3 phase and Earth) of Conductors of Aluminium (with stainless
steel contact surface) or Copper of adequate size, supported on insulators and
suspended from crane run way girders shall be provided. Adequate allowance
(minimum 20%) shall be kept for wear and tear while sizing the conductor.
Protection guards to live electrical wirings, conductors shall be provided to full
lengths. The voltage drop across the down shop leads shall be within 2% of the
value measured at the switch box at operating floor with the crane at the farthest
position. DSL arrangement to have R, Y, B phase indication lamps with fuses, at
both extreme ends.
(b.) Suitable connections for receiving the incoming cable of main power supply shall
be furnished along with the runway conductor.
A maintenance cage is to be provided for EOT/Gantry cranes above 15 T capacity with

proper approach on one side of the bridge without any safety hazard to maintenance and
operation personnel. The maximum temperature shall not exceed 70 deg C. considering
ambient temperature of 50 degree C and testing (structural portion of Cranes and Hoists).
2.22.00 Power collector system (Down Shop Lead): Bidder shall provide a proven insulated (PVC
covered) mobile collector and current collector system complete with all installation,
accessories and special tools and tackles.
2.23.00 Cross conductor on bridge: EPR flexible trailing cable system maintained on suitable
supports shall be provided. This shall comply to IS-9968.
2.24.00 The vertical deflection of crane girder shall not exceed 1/800 of the span, as per IS: 807.
The girder shall be of box type and construction shall ensure non-accumulation of
water/oil inside the box.
2.25.00 Performance Guarantee
The equipment shall be guaranteed to meet the performance requirements by this

specification.
2.26.00 Special Cleaning, Protection & Painting
2.26.01 Cleaning and Painting before Shipment
Before shipment of the equipment to be supplied under this specification, the necessary
cleaning, flushing etc., as per Manufacturer's standard shall be done. Shop coats of rust
inhibiting paints, lacquers etc. shall be applied to various parts as necessary as per code
and final coat after erection at site. Final coat of all electrical items shall be as per shade
692 (smoke grey) of IS:5.
2.26.02 Packing for Shipment
The equipment shall be suitably protected in respective packing for the shipping distance
and the water conditions involved.
3.00.00 MONORAIL HOISTS (ELECTRICALLY OPERATED)
3.01.00 Codes & Standards

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The design, manufacture, shop testing, erection, testing & commissioning at site of the
Monorail Hoists (Electrically Operated) shall in general conform to the latest revisions of
the following Indian Standards. In addition to other standards mentioned elsewhere in the
tender documents subject to any modification & requirement specified hereinafter.
i) IS:2266 Specification for steel wire ropes for General Engineering

purposes.
ii) IS:594 Technical supply conditions for wire ropes and strands.
iii) IS:1835 Specification for Round steel wire for ropes.
iv) IS:3938 Specification for electric wire rope hoists.
v) IS:7847 General Characteristics of Lifting hook.
vi) IS:3815 Specifications for point hook with shank for general
engineering purposes.
vii) IS:2429 Calibrated hand chain for long travel & cross travel.
viii) IS:807 Code of practice for design, Manufacture, erection & testing
(Structural Portion of cranes & hoists)
3.02.00 Design Features
3.02.01 Electrically operated Trolley suspended, mono girder type hoists shall consist of the
following major components :
(a.) Electrically operated trolley complete with drive motor (Trolley travel, speed 10-15
m/min).
(b.) Hoisting cable, hoisting block and hooks complete with drive motor (Hoisting
Speed 1.5 m/min).
(c.) Limit switches over travel while hoisting and lowering of the hook.
(d.) Limit switches to prevent over travel of hoist assembly at both ends.
(e.) Runway conductors for feeding power to trolley assembly.
(f.) Erection hardware.
(g.) Pendent control station suspended from hoist.
(h.) Monorails for the travelling of hoist assembly.
3.02.02 The hoist shall be designed and constructed in accordance with latest revision of IS: 3938
and class of design shall be 2 as per the IS: 3938. The complete hoist assembly, wire
rope, hook etc. shall be ISI stamped approved.
3.02.03 Trolley movement and hoisting shall be effected by using two (2) different electric motors.
The technical requirements of electric motors shall conform to IS: 3938.

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3.02.04 Trolley shall be designed so as to accommodate a wide range (minimum three different
sizes of ISMB standards) of I beams and capable of travelling on straight as well as
curved monorails, the design shall be such that it can maintain uniform distribution of
pressure on the flange of the monorail to avoid bending of the same.
3.02.05 The geared trolley shall have two (2) pair of wheels, a pair of which shall be driven
through chain. The wheel shall have taper/parallel treads with flange or any other means
to guide hoist trolley effectively to prevent derailment. Wheels shall be mounted on anti-
friction bearings and shall be easily removable for repair and replacement. The track
wheels shall be cast/forged/rolled steel suitably heat treated to have hardness of not more
than 200 BHN.
3.02.06 The hoist mechanism shall consist of a grooved rope drum using single layer winding of
rope and driven through gears through electric motor. Each end of the rope shall be
anchored to the drum with two single hold down plate in such a way that the anchorage is
readily accessible for maintenance. Each rope shall not have less than two (2) full turns
on the drum when the hook is at its lowest position and one (1) spare groove for each
rope lead when the hook is at its highest position. Suitable design procedure should
assure that the leading rope taken by the drum does not slope side ways when slack and
it is not caught between the gear wheel. The drum shall be flanged at both ends if rope
guides are not provided; in which case, the flanges shall project to a distance of not less
than two (2) rope diameters above the rope. A spur or other wheel secured to the drum
may be regarded as forming one of the flanges. The fleet angle of the rope shall not
exceed 50C.
3.02.07 Rope Drums, gear box, hoist block shall be made of cast steel or mild steel as suitable for
duty conditions.
3.02.08 All gears and pinions shall be hardened and tempered steel with machine cut, teeth in
metric modules as per relevant Indian Standards. Surface hardening is not acceptable.
Preferably Helical gear shall be used. Worm and bevel gearing is not permitted.
3.02.09 Provision shall be made for lubrication of all moving parts and bearings while the hoist is
in service except where life lubricated bearings are used. Ball and Roller bearings shall in
addition be lubricated before assembly. Lubricating nipples and adopters shall be easily
accessible and shall generally comply with relevant Indian Standards. All exposed
bearings shall be suitably sealed or shielded. All gear drives with the exception of travel
runner wheels of geared type and their driving pinions shall be enclosed and provided with
oil bath lubrication.
3.02.10 An electro-mechanical brake of fail safe type shall be provided for hoisting motion that can
provide restraining torque of 125% (minimum) or greater than the torque transmitted to the
brake drum from the suspended load upto the test load, the friction in the transmission
mechanism between the load and the brake not being taken into consideration. Brake
shall be provided with a simple and accessible means of adjustment to compensate for
wear. Suitable provision shall be made for holding the load in the event of the slippage of
chain etc. The operating arrangements shall be such that the brakes cannot be released
accidentally.
3.02.11 The interconnection of hoist assembly and bottom block shall be through anti-friction
thrust bearings. The bottom block shall be enclosed type and shall have guard against
rope jamming in normal use. It shall have standard forged swivel shank of suitable grade
of either circular or standard trapezoidal section, point hook suitably heat treated with
adequate lifting capacity and safe working load as per relevant Indian Standard. Swiveling
hooks shall be mounted on thrust bearings and protective skirt shall be provided to

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enclose the bearing. The hook shall swivel through 360 degree rotation with full load. The
swivel hook shall not be locked with set screw or split pin to prevent it from coming out.
The hoist hook shall be provided with safety locking arrangements to provide accidental
unhooking.
3.02.12 All running shafts and wheels running on fixed axis or pins shall be fitted with ball or roller
bearings. Ball and roller bearings of suitable dimensions shall be used. Ball and roller
bearing shall have a rated life of not less than 20 years calculated in accordance with
manufacturer’s recommendations and based on the equivalent running time given in IS:
3938.
3.02.13 The design and construction of shafts, shaft sleeves, shaft sleeve guards equalising
sleeves, if provided, etc. shall conform to IS: 3938.
3.02.14 Lifting bar of adequate design, and suspend type load indicator shall be supplied along
with the monorail hoist.
3.02.15 Wire rope bright wire, with independent wire rope core (IWRCI) Lang's lay preformed,
parallel laid type shall be of 6X37 (18/12/61) OR 6x36 (14-7+7-7-1) construction and
with a tensile designation of 1770 N/mm3. Reverse bends of wire rope is not acceptable.
Direction of rope lay shall be suitable to the grooving in the drum. The wire rope shall
preferably be supplied separately and installed at site. The effective length of wire rope
shall depend on the overall lift of the hoist. The wire rope shall conform to relevant Indian
Standards.
3.02.16 All parts requiring replacement or inspection lubrication shall be easily accessible without
the need for dismantling of other parts, equipment and structures.
3.02.17 Robust construction and ample rating margins with experience have shown to be
necessary shall be ensured throughout the design & manufacture.
3.02.18 All components of hoists of identical capacity and duty shall be interchangeable so that
the stock of spares can be reduced to a minimum. All hoists of same capacity and duty
shall be identical in all respects except the length and hand chains which may of course,
vary depending upon specification requirements.
3.02.19 All machinery and equipment included under this specification must be equipped with
safety devices and clearances to comply with recognised standards and specification
requirements. Nominal clearance between the lowest flange of the monorail and the
trolley must be minimum 20 mm.
3.02.20 Cast lron parts, wherever used shall conform to IS:210 grade 30 (minimum). No wood or
other combustible material shall be used.
3.02.21 All bolts except those with nylon nuts shall be provided with grip lock nuts and spring
washers or similar locking device. Bolts in tension should be avoided. Bolts and set
screws in rotating parts should be locked.
3.02.22 Defects in materials like fractures, cracks, blow holes, laminations pitting etc. are not
allowable. Rectification of any flaw is permissible only with the approval of Employer.
3.02.23 Hoists shall have a permanent name plate on each side readily recognisable from floor
level, as per IS:3938.
3.02.24 Bidder will terminate two feeders of 415 V AC electrical power supply near one end of the
monorail beam at ground level. All cabling (Power & Control) shall be supplied by the
contractor.

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3.02.25 Pendent control shall be provided with up/down/forward travel/ reverse travel push buttons
indicating lamps etc. Pendant to be earthed using separate core. Control supply to be
used shall not be more than 24V AC. Control Transformers and other
transforming/rectifying devices etc. for power and control supply shall be in the scope of
vendor.
3.02.26 All the electrical characteristics of the hoist assembly shall conform to IS: 3938. The
motors shall be designed for an ambient temp. of 50 deg. C and the class of insulation
shall be Class B. The temperature rise shall not exceed the limits specified in IS: 325.
3.02.27 The enclosure shall suit the working of the electrical equipment for outdoor duty. The
class of enclosure shall be IP:55.
3.02.28 The pendent control switch, limit switch etc. shall conform to IS: 3938.
3.02.29 The overload protection type shall be of thermal overload relays with high rupturing
capacity fuses and number of overload devices shall conform to IS: 3938. The control
panel shall be wall mounted type and easily approachable from floor by a standing man.
3.02.30 Cables under the scope of vendor shall be of PVC insulated and EPR insulated for trailing
cables.
3.02.31 G.A. drawing, Cross-sectional drawing, Technical Data Sheets for hoist / motors,
Electrical circuit diagram and other applicable technical documents shall be submitted for
Employer's approval.

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( B ) Raw Water System

1.00.00 This Chapter describes the System Description, Basic Design Criteria and Minimum
Technical Requirements of the Raw water System and associated equipments.
2.00.00 SYSTEM DESCRIPTION
2.01.00 The Contractor shall provide the systems described below:
a) Raw Water System to PT Plant and Ash Water Makeup

b) Various Sump Pumps, Drainage Pumps and Submersible Pumps
2.02.00 Raw Water System to Water PT Plant and Ash Handling Plant (AHP)
a) From the raw water reservoirs, in the Plant, raw water shall be drawn to the Raw
Water pump house sumps through an intake channel and forebay OR through Intake
Pipes.
b) 3 x 50 % raw water pumps (PT) shall be provided to supply water upto the Water PT
Plant through one number Carbon steel pipeline. 2 x 100 % raw water pumps (ash)
shall be provided to supply water upto the Ash water tank through one number
Carbon steel pipeline. The normal makeup to ash handling when ash water
recirculation is under operation will be from CW blow down. The raw water pumps
(ash) will cater to makeup required during initial operation without ash water
recirculation. The pumps, drives & associated valves, controls shall be located in the
Raw Water Pump House.
c) For each sump of Raw Water Pump House, the Contractor shall provide a set of
Trash rack, stop log gate to filter out debris etc.
2.03.00 Various Sump Pumps, Drainage Pumps and Submersible Pumps

a) For de-watering of drain pits in underground pump sumps of raw water pump house,
CW pump house, other pump houses, pipe/cable trenches etc. sump pumps,
drainage pumps and submersible pumps shall be used.
b) Each pit shall be provided with two numbers (2 x 100% Capacity) of respective type
pumps so that the entire pit is evacuated within 15-20 minutes and the operation of
the pumps shall be interlocked through with level measurements devices to be
installed in the pit/sump.
c) For other areas, where occasional draining is to be carried out for maintenance
purpose, two numbers of portable submersible type pumps with trolleys, power &
Control cable drums, power / control box etc for each area/pits/pump houses shall be
provided so that the same may be used as and when required.
d) Casing, Gland and Stuffing box of pumps shall be of Cast Iron. Internal wetted parts
such as shaft, impeller, strainers, check valve (of self priming type), strainers, shaft
sleeves, fasteners etc. shall be of stainless steel. Discharge, suction and column
pipes shall be heavy grade Carbon steel of IS: 2062 lined with epoxy or galvanized.

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3.01.00 Pumps
3.01.01 General Design and Construction features of various Horizontal pumps, Vertical Pumps
and Submersible pumps shall be as per the Annexure-1, Annexure-2 & Annexure-3 & 4
respectively as enclosed with this Chapter.
3.01.02 Specific Design Features of various pumps shall be as elaborated below.
Raw Water Pumps to PT Plant and Ash water makeup
S. No. Description Parameters
1. Total Number of Pumps : Refer Part A of Section VI.
2. Number of operating pumps : Refer Part A of Section VI.
3. Number of standby pump : Refer Part A of Section VI.
4. Flow of each pump (minimum) : Refer Part B of Section VI.
5. Total Head (Guaranteed) : System requirement + 10% margin on friction
head.
For raw water pump (ash), terminal head
requirement of 10 mwc near ash water sump
at FGL may be considered, while calculating
total head.
6. Operating Speed (Maximum) : 1500 rpm.
7. Service of duty : Continuous
8. Type of pump : Vertical wet pit & Non-Pull out
design/Submersible type
9. Type of Impeller : Semi-open/enclosed impeller

i) Specific Criteria for vertical pumps
10. Type of lubrication(for vertical : Forced Water

type)
11. Maximum Water Level in sump : Same as Maximum Water Level in Raw
Water Reservoir.
12. Minimum Water Level in sump : Same as Minimum Water Level in Raw
Water Reservoir.
13. Minimum Pump Submergence : As per "Pump Intake Design' of Hydraulic
Institute – USA plus 0.5 m margin.
14. Sump Invert level : As per HIS, Hydraulic Institute Standards
15. Operating floor level : Min. 0.5 M above finished ground level

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S. No. Description Parameters

16. Other dimensions of sump, : As per HIS and as per the description in
Fore-bay etc relevant chapters of Civil Works.
17. Suction condition : Submerged
18. Type of shaft coupling : Flexible/Rigid as per manufacturer's standard.

19. Pump re-circulation : To be sized for a flow of about 30% - 50% of
respective pump capacity.
20. Accessories to be provided : a) Required Instrumentation
with each pump b) Anchor bolts, nuts, sleeves and inserts to
be embedded to concrete.
c) Companion flanges with nuts, bolts and
gaskets
d) Internal piping with valves, filters &
Instruments for sealing/ cooling/
lubrication system upto and including
isolating valve etc.
e) Positioning dowels
f) Eye bolts, lifting etc.
21. Material of Construction
i. Suction Bell : 2% Nickel Cast Iron, IS: 210 Grade FG 260;
S-0.1% max. P-0.15% max.
ii. Casing : 2% Nickel Cast Iron, IS: 210 Grade FG 260;
S-0.1% max. P-0.15% max.
iii. Casing Liner : Stainless steel (SS)
iv. Impeller : Austenitic SS ASTM A743/ CF8M Grade
v. Wearing rings : SS-316
vi. Impeller Shaft, Pump & line : SS - ASTM A 276 Gr. 410.
shaft
vii. Shaft coupling : Stainless steel type 410, ASTM A 276,
viii. Shaft sleeves : SS - ASTM -A 276 – 410
ix. Shaft bearings : Cutless rubber with bronze retainer for below
minimum water level and Thordon type for
above minimum water level.
x. Shaft Coupling : SS - ASTM -A 276 – 410
xii. Column pipe : Fabricated steel as per IS: 2062 (minimum
thickness - 10 mm) with 2 coats of epoxy
coating inside & outside.

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Note: Plant duty may require operation of one or two raw water pumps in common pipeline.
The operating range and drive rating shall be suitable for same. For Raw water pumps of PT
system, the range of operation and drive rating shall accommodate normal operation of one
pump with one pipeline and as well as operation of two pumps in one pipeline.
4.00.00 CONTROL PHILOSOPHY

a) The pump re-circulation valves and discharge valves shall be motor actuated type to
enable remote operation.
b) Pump suction valves, re-circulation valves and discharge valves shall be provided
with required limit switches for interlock & control.
c) The pumps shall be designed to operate under discharge valve open and close
condition.
d) Wherever more than one sump/tank is provided, Suction header shall be
interconnected such a way that any of the sump/tank may be selected through the
control system for operation.
e) Any of the pump shall be selectable as standby duty. Standby pump shall come into
operation whenever tripping of working pump or inadequate pressure at the
discharge header.
f) Automatic inlet valves shall be provided at supply line to each of the tank/sump so
that the valves shall open and close at low-level and very high-level respectively.
g) Operation of Discharge valves & re-circulation valves of pumps to interlock with
start/stop of respective pumps.
h) Local emergency stop provision of each pump shall be kept.
i) All the working pumps shall be interlocked with the suction level or suction pressure
condition as the case may be Ultrasonic type Level transmitters to be provided for
sump level measurement.
j) The starting of pumps (wherever applicable) which are provided with forced water
lubrication shall be interlocked with the availability of lube water by means of starting
of lubrication water pumps, availability of adequate flow, pressure etc. The standby
lubrication pump shall be started automatically during inadequate pressure or while
tripping of working pump(s).
k) Detailed Interlock & protection logic shall be as finalized during detailed engineering.

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Annexure-1 to “Raw Water System"
HORIZONTAL CENTRIFUGAL PUMPS

1.00.00 SCOPE
General requirements in respect of design, material, constructional features, manufacture,
inspection, testing the performance at the Vendor's/ Sub-Vendor's works and delivery to site
erection, field testing and commissioning of Horizontal Centrifugal Pumps.
2.01.00 Design, material, construction manufacture inspection and performance testing of Horizontal
Centrifugal Pumps shall comply with all currently applicable statutes, regulations and safety
codes in the locality where the equipment will be installed. The equipment supplied shall
comply with the latest applicable Indian standards listed below. Other National Standards are
acceptable, if they are established to be equal or superior to the Indian Standards.
2.02.00 List of Applicable Standards
i) IS : 1520 - Horizontal Centrifugal Pumps for clear cold fresh water.
ii) IS : 5120 - Technical requirements of roto-dynamic special purpose pumps
iii) API - 610 - Centrifugal pumps for general refinery service.
iv) IS : 5639 - Pumps Handling Chemicals & corrosion liquids.
v) IS : 5659 - Pumps for process water
vi) HIS - Hydraulic Institute Standards; USA
vii) ASTM-I-165-65 - Standards Methods for Liquid Penetration Inspection.
2.03.00 In case of any contradiction with aforesaid standards and the stipulations as per the technical
specifications as specified hereinafter the stipulations of the technical specifications shall
prevail.
3.00.00 DESIGN REQUIREMENTS
3.01.00 The maximum efficiency of pumps shall be preferably within + 10% of the rated design flow
indicated in data sheets.
3.02.00 Total head capacity curve shall be continuously rising from the operating point towards shut -
off without any zone of instability and with a minimum shut off head of 15% more than design
head.
3.03.00 Pumps of a particular category shall be identical and shall be suitable for parallel operation
with equal load division. The head Vs capacity and BHP Vs capacity characteristics should
match to ensure even load sharing and trouble free operation throughout the range.
Components of identical pumps shall be interchangeable.

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3.04.00 Pumps shall run smoothly without undue noise and vibration. Peak to peak vibration limits
shall be restricted to the following values during operation.
Speed Antifriction bearing Sleeve bearing
1500 rpm and below 75.0 micron 75.0 micron
3000 rpm 50.0 micron 65.0 micron
The noise level shall not exceed 85 dBA. Overall sound pressure level reference 0.0002
microbar (the standard pressure reference for air sound measurement) at a distance of 1M
from the equipment surface.
3.05.00 The pumps shall be capable of starting with discharge valve fully open and close condition.
4.00.00 DESIGN CONSTRUCTION
4.02.00 Pump casing shall have radially/axially split type construction. The casing shall be designed
to withstand the maximum shut - off pressure developed by the pump at the pumping
temperature.
4.03.00 Pump casing shall be provided with a vent connection and piping with fittings & valves
Casing drain as required shall be provided complete with drain valves, piping and plugs. It
shall be provided with a connection for suction and discharge pr. Gauge as standard feature.
4.04.00 Impeller
Impeller shall be closed or semi-closed as specified elsewhere and designed in conformance
with the detailed analysis of the liquid being handled. The impeller shall be secured to the
shaft, and shall be retained against circumferential movement by keying pinning or lock rings.
4.05.00 Impeller/ Casing Wearing Rings
Replaceable type wearing rings shall be provided at suitable locations pumps. Suitable
method of locking the wearing ring shall be used.
4.06.00 Shaft
The critical speed shall be well away from the operating speed and in no case less than
130% of the rated speed.
4.07.00 Shaft Sleeves
Shaft sleeves shall be fastened to the shaft to prevent any leakage or loosening shaft and
shaft sleeve assembly should ensure concentric rotation.
4.08.00 Bearings
Heavy duty bearings, adequately designed for the type of service specified in the enclosed
pump data sheet and for long, trouble - free operation shall be furnished.
The bearings offered shall be capable of taking both the radial and axial thrust coming into
play during operation. In case, sleeve bearings are offered additional thrust bearings shall be
provided. Anti-friction bearings of standard type, if provided, shall be selected for a minimum
life 16,000 hours of continuous operation at maximum axial and a radial loads and rated
speed.
Proper lubricating arrangement for the bearings shall be provided such that lubricating
element does not contaminate the liquid pumped. Where there is a possibility of liquid
entering the bearings suitable arrangement in the form of deflectors or any other suitable
arrangement must be provided ahead of bearing assembly.

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Bearings shall be easily accessible without disturbing the pump assembly. A drain plug shall
be provided at the bottom of each bearing housing.
4.09.00 Stuffing Boxes
Stuffing boxes of packed ring construction type shall be provided wherever specified. Packed
ring stuffing boxes shall be properly lubricated and sealed as per service requirements and
manufacturer's standard. If external gland sealing is required, it shall be done from the pump
discharge. The Bidder shall provide the necessary piping, valves, fitting etc. for the sealing
connection.
4.10.00 Mechanical Seals:
Wherever specified in pump data sheet, mechanical seals shall be provided The sealing face
should be highly lapped surfaces of material known for their low frictional co-efficient &
resistance to corrosion against the liquid being pumped.
4.11.00 Pump Shaft Motor Shaft Coupling
The Pump and motor shaft shall be connected with a adequately sized flexible coupling of
proven design with a spacer to facilitate dismantling of the pump without disturbing the motor.
4.12.00 Base Plate
A common base plate mounting both for the pump and motor shall be furnished. The base
plate shall be of fabricated steel and of rigid construction, suitable ribbed and reinforced.
4.13.00 Assembly and Dismantling
Assembly and dismantling of each pump with drive motor shall be possible without disturbing
the grouting base plate or alignment.
4.14.00 Drive Motor (Prime Mover)
The KW rating of the drive shall be based on continuously driving the connected equipment
for the conditions specified. In case, where parallel operation of the pumps is specified, the
actual motor rating is to be selected considering overloading of the pump in the event of
tripping of operating pumps. Continuous motor rating (at 50 deg. Cent, ambient) for pump
shall be at least 10% above the maximum load demand of the driven equipment in the
complete range.

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CLAUSE NO.

VERTICAL PUMPS
1.00.00 SCOPE
1.01.00 This specification covers general requirements in respect of design, construction features,
manufacture, inspection and performance at Vendor's / sub-vendor's works delivery to site,
erection field testing and commissioning of Makeup Water & Raw Water Pumps.
2.01.00 The design, material, construction, manufacture, inspection, testing and performance of
Vertical Pumps shall comply with all currently applicable statutes, regulations and safety
codes in the locality where the equipment will be installed. The equipment supplied shall
comply with the latest applicable Standards listed below. Other national standards are
acceptable, if they are established to be equal or superior to the listed standards.
2.02.00 List of Applicable Standards
IS: 1710 : Vertical Turbine Pumps for clear cold fresh water.
IS: 5120 : Technical requirement of rotor dynamic special purpose pumps.
HIS : Hydraulic Institute Standards U.S.A.
PTC 82 : Centrifugal pumps-power test code
API 610 : Centrifugal pumps for general refinery purposes.
In case of any contradiction with aforesaid standards and the specifications requirements as
specified hereinafter the stipulations of the technical specifications shall prevail.
3.00.00 DESIGN AND PERFORMANCE REQUIREMENTS
3.01.00 The maximum efficiency point of the pumps shall preferably lie within 10% of the rated
design flow.
3.02.00 Pumps of a particular category shall be identical, suitable for parallel operation and provided
with interchangeable components. Head vs. capacity and BHP vs. Capacity characteristic
should match to ensure even load sharing and trouble free operation throughout the range.
3.03.00 The pumps shall have stable Head vs. Capacity characteristic continuously rising towards
shut-off with the highest at shut-off and with an approximate shut-off head of 15% or more
than the design head for radial flow pumps and 25% more than the design head for mixed
flow/ turbine type pumps.
3.04.00 The operating range of operation of pumps shall generally be 40% to 120% of rated flow for
sustained period of operation.
3.05.00 The power requirement of the pump shall be non-over loading type for mixed flow/ turbine
type pumps.
3.06.00 The critical speed of the pump shall be less than 80% of the rated speed or more than 130%
of the rated speed. Also, the critical speed of the pump-motor assembly shall be more than
the maximum reverse run-away speed.
3.07.00 Pump shall run smoothly without undue noise and vibration. The vibration limit measured at
motor end shall not exceed the limit specified in Hydraulic Institute Standards. The noise

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level shall not exceed 85 dBA overall sound pressure level reference 0.0002 microbar (the
standard pressure reference for air sound measurement) at a distance of 1M from the
equipment surface.
3.08.00 The base plate, foundation bolts, motor stool and other components shall be designed to
take the full force coming on the discharge elbow under shut-off condition due to provision of
expansion joint (untied condition prevailing) ) on the discharge pipe.
3.09.00 Water for motor cooling and thrust bearing cooling, if required, shall be tapped from the
discharge of the pumps and/or fed from an over-head tank. All piping, valves, strainer,
instruments etc. required for this purpose and line shaft bearing lubrication (if required) shall
be provided by the Contractor. Hence the coolers shall be designed to operate satisfactorily
with the cooling water discharge pressure available. Cooling water if required during starting
of the pumps shall be arranged by the bidder by provision of water supply tank, valves piping
etc.
3.10.00 Reverse Rotation
a) The pump shall be provided with an approved mechanical device to protect reverse
rotation on loss of drive motor power and failure of discharge valve to close.
b) It is possible that the pump may rotate in the reverse direction in case the discharge
butterfly valve is not fully closed or is passing. Hence to prevent starting of the pump,
a reverse rotation detection switch shall be provided to prevent starting of motor
while rotating in reverse direction.
3.11.00 Motor Rating
The pumps shall be capable of starting with discharge valve fully closed as well as fully open
conditions. Motors shall be selected to suit to the above requirements. Continuous motor
rating (at 50oC ambient) for all pumps shall be at least ten per cent (10%) above the
maximum load demand of the driven equipment in the complete operating range (including
run out condition) to take care of the system frequency/voltage variation.
Drive motors shall be connected directly to the line shaft of the pump.
4.00.00 DESIGN AND CONSTRUCTION
4.01.00 Pump Type
Pumps shall be of vertical shaft, single stage/multi-stage, submerged suction, complete with
bowl, column & head assembly and drive assembly. The pump design shall be of
pullout/non-pull-out type as specified
4.02.00 Discharge head
The pump discharge shall be of above-floor type/sub- floor type as indicated. In certain cases
of pump installation where expansion joint is located immediately at the pump discharge, the
pump assembly will be subjected to the unbalanced hydraulic thrust. A thrust pad will be built
in with the discharge head for transmitting the hydraulic thrust to external structures such that
this hydraulic thrust is not transmitted to the foundation bolts for which they may not be
designed.
4.03.00 Column Pipe
Column pipes shall be flanged and bolted and shall be complete with gaskets, nuts and bolts.

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4.04.00 Impeller
The impeller shall be closed, or semi-open or open as specified elsewhere.
4.05.00 Wearing Rings
Replaceable type wearing rings shall be provided for both casing and the impeller. For open
impellers replaceable casing liners shall also be provided. The difference in hardness of the
casing & impeller wearing rings shall be minimum 50 BHN.
4.06.00 Impeller & Line Shaft
Shaft size selected on the basis of maximum combined shear stress must take into
consideration the critical speed as per API - 610.
4.07.00 Pump & Shaft Bearings - lubrication
4.07.01 Adequate number of properly designed bearings shall be furnished. All interconnected piping,
valves, instruments and fittings for bearing lubrication shall be provided. The type of
lubrication i.e. self water lubrication or forced water lubrication shall be provided as per the
data specified elsewhere in this Sub-section.
4.07.02 Self water Lubrication System
The line shaft bearings shall be lubricated by the water being pumped. The main pump and
line shaft bearings which are above minimum water level shall be of 'Thordon' type/
equivalent. For other line shaft bearings located below minimum water level, cutless rubber
bearings can be used.
4.07.03 Forced water lubrication system
The line shaft shall be provided with shaft enclosing tube to exclude pumped water from shaft
and bearings.
Lubricating water pumps (type, nos. & capacity as indicated in data sheet enclosed) shall be
provided to supply lubricating water for bearings. These lubricating water pumps shall get
supply from the overhead water storage tank. This tank shall be fed water from the pump
discharge header as indicated in tender drawings. Strainers downstream of each lubrication
water pumps shall be provided to ensure clean water for the bearings. The lubrication water
pumps shall conform to Specification titled "Horizontal Centrifugal Pumps" Complete
instrumentation, piping, valves to ensure reliable operation of lubrication system shall be
provided. During initial filling and normal operation the lubricating water shall be tapped from
water filling line/potable/nearest source and fed to overhead tank.
4.08.00 Thrust Bearings
Single thrust bearing at motor top or separate thrust bearings at pump and motor shall be
provided to take care of hydraulic thrust and weight of the rotating assembly.
Thrust bearing shall be spherical roller type or superior, capable of absorbing axial thrust in
both directions of rotation. Water required for cooling of thrust bearing shall be taken from
pump discharge, wherever applicable.
The thrust bearing shall be rated for continuous operation with thrust as developed in shut-off
condition with clearance between the wearing rings in worn out condition to be at least four
(4) times the clearance between the wearing rings in new condition.

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CLAUSE NO.
4.09.00 Pump Motor Supports, Base plate etc.
The pump and motor shall have a common support. The necessary supporting frame, base
plates, mounting plates etc. as required shall be supplied under this specification.
4.10.00 Stuffing Box
Gland packing shall be provided at the top of the line shaft. Shaft sleeves shall be provided at
the stuffing box. The stuffing box shall be of sufficient depth to provide ample packing. The
packing glands shall be split type to facilitate repackaging of the stuffing boxes. The space
between motor and the stuffing box shall be sufficient to permit removal of gland packing and
insertion of new gland packing without dismantling of pump.
4.11.00 Assembly and Dismantling
Assembly and dismantling of each pump with drive motor shall be possible without disturbing
the grouted base/sole plate or alignment.
5.00.00 MATERIALS OF CONSTRUCTION
Materials of construction of the pumps shall be as specified elsewhere in this chapter.
6.00.00 OPERATION PHILOSOPHY
6.01.00 The Pumps shall be controlled from the Central Control Room (CCR). The start/stop
commands of these pumps, all associated auxiliaries/drives including all the motor operated
discharge valves, shall be routed through control system where all interlocks & permissive
shall be implemented and start/stop signals shall be issued to MCC/Switchgear. The
operation of interconnecting valve and any other common drive shall be possible from pump
house as well as DDCMIS. The exact details of the same shall be finalised during detailed
engineering.
6.02.00 A local pushbutton switch shall be used for emergency tripping of the motor.
6.03.00 The pump can be started either with pump discharge valve partially open or in closed
position depending upon contractor's standard practice.
6.04.00 An interlock shall prevent the starting of pump unless bearing lubricating water flow and
motor bearing cooling water flow has been established over a period of time. Low flow of
either pump or motor bearing cooling water when the pump is running will give alarm(s) and
trip the pump with alarm in case of sustained low value over a preset time.
6.05.00 In case of high pressure at pump discharge due to accidental closure of any of the butterfly
valves, an alarm shall be generated.
6.06.00 In case of normal stopping, when a pump control switch is turned 'OFF', the butterfly valve at
its discharge first closes (25-30) % before the respective pump motor is de-energised.
6.07.00 On tripping of motor due to any reason, the butterfly valve at the discharge shall close fully
automatically.
6.08.00 If water level in pump sump is low, an alarm shall be initiated. Pump shall be tripped in case
of very low level of water in the intake sumps and very high discharge header pressure.
Ultrasonic type Level transmitters to be provided for sump level measurement.
6.09.00 Pump shall be tripped from very high winding temperature of motor and very high metal
temperature of thrust bearings. Alarm shall be provided for high motor winding temperature
and high motor/ pump bearing temperature.

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6.10.00 The operation philosophy as detailed above is suggestive only. .The control and interlock
scheme to be adopted shall be finalised in consultation with the successful bidder after award
of contract and shall be subject to Employer's approval.
7.00.00 INSTRUMENTATION
7.00.01 Bidder shall provide the necessary vibration monitoring system if the Raw water pumps are
HT motor driven.
7.00.02 Minimum instrumentation required for the Raw Water pumps & pump house shall be as per
philosophy described in the Table below:
Name of Location Purpose Quantity
Instruments
Pressure Gauges Discharge of Pumps Local Indicator 01 no for each

pump
Temperature Gauges Pumps Thrust Bearings Lube oil (if Local Indicator 01 no for each
applicable) pump
Lube oil of other Bearings (if Local Indicator 01 no for each

applicable) pump
Level Gauge Thrust Bearings oil tank (if applicable) Local Indication 01 no for each
pump
Overhead/ Overground tank for Local Indication 01 no.

Lubrication system (if applicable)
Ultrasonic type level Pump Sump Interlock/ 01 for each

transmitter Protection/ sump
Annunciation
Pump house Forebay level Indication/ 01 for each

Annunciation Forebay
Overhead/ Overground tank for Indication/ 03 nos.

Lubrication system (if applicable) Interlock
Diff. pressure level Pump Lube oil tank level (if applicable) Indication 01 no. per oil
transmitter tank
RTDs Pumps bearing (if applicable) Remote 01 nos. duplex

for each
bearing
Pump motor winding, motor bearing Remote As mentioned

monitoring in electrical sub
section
Pressure Pump Discharge Interlock/ 01 no. for each

Transmitters Protection/ RW pump
Annunciation
Pumps Discharge header Remote 01 no. for each

discharge
header

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Name of Location Purpose Quantity

Instruments
Discharge header of lube water pumps Remote 02 nos. for

(if applicable) each discharge
header
Reverse Rotation Pump house Interlock/ 01 no. for each

indicator Annunciation pump
Flow indicator Flow indicator cooling water/ Lube oil Local indication 01 no at each
Lube/Seal
outlet from RW
pump and
motor
Electronic flow meter Common lube inlet line of each RW 01 No.

pump
Common discharge header/ Supply Remote 01 no. for each
line from Raw water pump house
Discharge
header/ Supply
line.
Temperature Pump house Remote 01 nos. for

Transmitter each RTD
However, apart from the above, required instruments to meet the system requirement and for
safe and reliable operation of the plant/system shall be supplied by the Contractor during
detailed engineering at no additional cost.
The requirements of Performance Tests of pumps shall be same as that Performance Test
specified for the CW Pump of Vertical wet pit type as referred in relevant clauses of
Technical Specification.

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RAW WATER PUMPS (SUBMERSIBLE)
1.00.00 SCOPE
1.01.00 This specification covers general requirements in respect of design, material, manufacture,
construction, testing & inspection at Vendor's / sub-vendor's delivery to side, of submersible
pumps.
2.00.00 CODES AND STANDARD

The design manufacture and performance of submersible pumps shall comply with all
currently applicable statues, regulation, and safely codes in the locality where the Equipment
will be installed. The Equipment shall also conform to the latest applicable Indian standards
listed below/equivalent standards.
2.01.00 List of Applicable Indian Standards
IS: 5120 - Technical requirement of Rotodynamic Special Purpose pumps.
In case of any contradiction with aforesaid standards and the technical specification
requirements, the stipulation of the technical specification shall prevail.
3.00.00 General
3.01.00 The submersible pumps shall be of proven design. The pump set shall be suitable for pumping
raw water with high turbidity and soft solids / fibrous solids which are generally observed in
contaminated rivers / canal water. Components of Identical pumps shall be interchangeable.
It shall be with a specially designed base stand suitable for installation directly on the
reservoir bed.
3.02.00 Pumps shall have continuously rising head characteristics. The pump sets shall be suitable for
parallel operation as well as solo operation in the system. The performance characteristics of
the pumps running in parallel shall be identical. The manufacturer shall have to submit the
parallel operation curve superimposed with system resistance curve to know the exact point
of pump operation with various combinations.
4.00.00 FEATURES OF CONSTRUCTION
a) The pumpset shall be single stage, submersible type, monoblock, volute type
driven by squirrel cage induction motor. The motor shall be an integral part of the
pumpset. It shall be a totally sealed unit suitable for completely as well as partially
submerged condition. The pump shall operate continuously even if the water level
in the sump is low (motor portion not in submerged condition). The pump shall be
suitable for reverse rotation and shall not have any adverse effect on the
operation of mechanical seal or any other component.
b) Pumps shall be able to pass through solids upto 40 mm.
c) The impeller shall be multi vane. The impeller shall not get blocked with solids.
The impeller shall be keyed on shaft, retained with an expansion ring. The
impellers shall be dynamically balanced to the grade 6.3 as per ISO 1940.

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d) Coupling device when provided shall ensure leak proof joint between the pump
and discharge elbow. This shall also enable pump to be removed from the sumps
without the necessity of dismantling any nuts, bolts etc.
e) Pumps shall be portable/ fixed type and capable of using in any sump as and
when required. Pump shall be provided with required stool, flexible hose, chain
connection etc. for easy installation, removal and maintenance. Adequate length
of chain required for lowering the pump into the sump and flexible type discharge
pipe or duck foot shall be provided.
f) Bearing:
The shaft shall rotate on grease lubricated bearings. The upper bearing, provided
for radial forces, shall be a single roller bearing. The lower bearing shall consist of
at least one roller bearing for radial forces and one angular contact ball bearing
for axial thrust.
The bearings shall be pre-lubricated and packed for life. External lubrication for
any of the bearings will not be accepted.
The lower bearing housing shall include an independent thermal sensor to
monitor the bearing temperature. If a high temperature occurs, the sensor shall
activate an alarm and shut the pump down.
g) Sealing:
Each pump shall be provided with a mechanical seal assemblies. The seal faces
shall be of corrosion resistant tungsten carbide. The seal shall not require any
maintenance or adjustment and shall be bi-directional. Should the seals fail and
allow fluid to enter the stator housing, the fluid shall not come in contact with the
lower bearing or stator.
h) Shaft:
The pump shaft and motor shaft shall be one piece construction. The pump shaft
is an extension of motor shaft and no coupling for pump shaft and motor shaft is
allowed. The shaft should not come in direct contact with pumped liquid. Use of
stainless steel sleeves will not be considered as substitute for stainless steel
shaft.
i) Installation Accessories
For transportable type of installation, a suitable stand / base frame type of
arrangement shall be provided in such a way that in no case the pump will tilt.
Each pumpset shall be provided with the suitable length of stainless steel lifting
chain.
Following accessories to be included in scope of supply for pumps supported on
discharge bend:
i. Pump pedestal and discharge connection(“duck foot’ type discharge
bend)
ii. guide rails, guide rail support brackets and lifting chain as appropriate
iii. fasteners and anchor bolts
j) The major pump components shall be of material mentioned at Cl 9.00.00 of this

sub-section and shall be with smooth surfaces, free of blow holes or other casting
irregularities.

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5.00.00 MOTOR RATING
Continuous motor rating (at 50 deg. C ambient) for pumps shall be at least ten percent (10%)
(including run out condition) to take care of the system frequency variations.
6.00.00 Painting Details of Pump
All metal surfaces coming in contact with the pumping media, other than stainless steel
shall be protected by factory applied water based primer and finally covered by a two
component high-solid top coating.
7.00.00 Control and Monitoring

The pump monitoring shall consist of sensors mounted in the pump and a pump memory
bringing factory pre-loaded information. The sensors and the pump memory shall be
connected to an electronic monitoring unit, with the ability to stop the pump, present alarms
and communicate information both locally and remotely to facilitate fault tracing and service.
The monitoring unit shall be mounted in the control panel. The pump memory unit mounted
inside the pump shall bring factory preloaded information used to correctly set up the
monitoring unit, to provide name plate information such as pump serial number and to store
operational data like running time and number of starts.
The electric supply of the pumpset shall be monitored by using a power analyzer. Monitored
quantities shall include voltage in three phases, current in three phases, active power,
power factor, phase unbalance (voltage and current) and energy consumption. The power
analyzer shall have an ability to transmit the measurement results using Modbus or any
other commonly used protocol for serial communication.
8.00.00 PERFORMANCE GUARANTEE TESTS
8.01.00 Shop Test
8.01.01 After the manufacture, all the pumps shall be subjected for performance test at the
manufacturer's works to determine the power consumption and the head capacity
characteristic in the presence of Employer’s representative, as per requirements of Hydraulic
Institute Standards, (HIS 11.6)
8.01.02 Hydrostatic test to be conducted to demonstrate that the hydraulic end, when assembled to
the motor, will not leak or fail structurally when subjected to hydrostatic pressure as per HIS
11.6. NPSHR test also to be conducted to demonstrate the NPSHR requirement of pump.
8.01.03 Contractor shall submit along with his offer details of the proposed test facilities available for
testing the pumps. The details must include the capacity, head, maximum motor rating,
voltage level, sanctioned load and permissible starting current.
8.01.04 It may be noted that during shop tests no negative tolerance shall be permitted on head (H),
capacity (Q) and the pump efficiency (n). Instruments accuracy used shall be plus or minus
1.5% or better for measurement of flow and plus or minus 0.5% or better for measurement of
pressure and power.
8.01.05 Apart from the above, any testing if specified in subsection titled “Functional Guarantees and
Liquidated damages” [subsection –IV of Part-A] of this Technical Specification shall also be
conducted.

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8.02.00 Site Test
a) Manufacturer shall demonstrate at site the trouble free mechanical running of

individual pumps.
b) The following parameters shall be measured during the demonstration test.
i) Current, Voltage and Motor Input Power.
ii) Frequency & Speed
iii) Bearing temperature & Motor winding temperature.
c) All interlocks and protections relating to the pumps, motors and motorised valves
shall be tested.
c) Parallel operation:
There should be equal load sharing between pumps running in parallel with no
abnormal vibrations, sound or hunting of head and flow. Load sharing between any
pumps running in parallel should be within 10%.
9.00.00 SUBMERSIBLE PUMPS DATASHEET
NO DESCRIPTION PARAMETERS PARAMETERS

1) Designation Raw Water pumps Raw Water pumps
(PT) (Ash)
2) Type of pump Submersible Submersible
3) Total Number of Pumps Three (3) Two (2)
4) Number of operating Two (2) One (1)

pumps
5) Number of stand by pump One (1) One (1)
6) Guaranteed Flow See Part B “Equipment sizing criteria” chapter

7) Total head (Guaranteed) As per criteria given elsewhere
8) Operating Speed 1500 rpm (maximum)
9) Location of pumps Raw water sump
10) Service of duty Continuous
11) Type of pump Fixed submersible mono-block type

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12) Type of Working Fluid Raw water
13) Type of impeller Closed/ Semi- open
14) Suction condition Submerged
15) Minimum Water level Same as Minimum Water Level in Raw Water
Reservoir
16) Maximum Water level Same as Maximum Water Level in Raw Water
Reservoir
17) Bed Invert level As per civil drawing
18) Accessories to be provided a) Required Instrumentation as per approved P &

with each pump IDs during detailed engineering stage.
b) AISI 316 lifting chain of minimum 10 m length
and lifting shackle.
c) Bottom Stand
d) All fasteners required for fitting of accessories
e) Motor Control Panel with soft Starter, Indicating
meters, display units for motor controls wherever
required, Power analyzer, indicating lamps,
MCBs/MCCBs and other control / indicating equipment
as required.
f) The panel shall be foot mounted type.
g) motor over-temperature protection device
h) Seal failure detectors and associated cores in
cables.
19) Material of Construction :
a) Casing 2% Nickel Cast Iron, IS:210 Grade FG 260; S-0.1%

max. P-0.15% max.
b) Impeller ASTM A351 CF8M Grade
c) Wearing rings (if SS–316

applicable)
d) Impeller Shaft SS ASTM A 276 Gr. 410.
e) Shaft mechanical seal and SS ASTM A 276 Gr. 410.

seal spring

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f) Chains Stainless steel
g) guiderails Stainless steel
h) Discharge Head Fabricated steel as per IS:2062(minimum thickness

shall not be less than 10 mm) with 2 coats of epoxy
coating inside and outside, and flexible rubber hose
i) Bolts & nuts Stainless steel AISI type 304 for those coming in
contact with water and for others, material shall be
high tension carbon steel.
Note: Plant duty may require operation of one or two raw water pumps in common pipeline.
The operating range and drive rating shall be suitable for same. For Raw water pumps of PT
system, the range of operation and drive rating shall accommodate normal operation of one
pump with one pipeline and as well as operation of two pumps in one pipeline.

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CLAUSE NO.
SUBMERSIBLE PUMPS (other than raw water pumps)
1.00.00 SCOPE
1.01.00 This specification covers general requirements in respect of design, material, manufacture,
construction, testing & inspection at Vendor's / sub-vendor's delivery to side, of submersible
pumps.
2.00.00 CODES AND STANDARD
The design manufacture and performance of submersible pumps shall be comply with all
currently applicable statues, regulation, and safely codes in the locality where the Equipment
will be installed. The Equipment shall also conform to the latest applicable Indian standards
listed below/equivalent standards.
2.01.00 List of Applicable Indian Standards
IS: 8034 - Submersible pumps for clear cold fresh water
IS: 5120 - Technical requirement of Rotodynamic Special Purpose pumps.
In case of any contradiction with aforesaid standards and the technical specification
requirements, the stipulation of the technical specification shall prevail.
3.00.00 DESIGN AND PERFORMANCE REQUIREMENTS
a) The pump shall be of single stage mono - block type with non-clog design.
b) Components of Identical pumps shall be interchangeable.
c) Pumps shall have continuously rising head characteristics.
4.00.00 MOTOR RATING
Continuous motor rating (at 50 deg. C ambient) for pumps shall be at least ten percent (10%)
above the maximum load demand of the driven equipment in the complete operating range to
take care of the system frequency variations.
5.00.00 FEATURES OF CONSTRUCTION
a) Pumps shall be of Submersible, wet pit type.
b) Pumps shall be able to pass through solids up to 40 mm and capable of handling
waste water which may contain, sludge, plastic solids etc.
c) Coupling device shall ensure leak proof joint between the pump and discharge
elbow. This shall also enable pump to be removed from the sumps without the
necessity of dismantling any nuts, bolts etc.
d) Pumps shall be portable type and capable of using in any sump as and when
required. Pump shall be provided with required stool, flexible, hose chain connection
etc. for easy installation, removal and maintenance. Adequate length of chain
required for lowering the pump into the sump and flexible type discharge pipe shall
be provided.

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e) Impeller
The Impeller shall be as indicated in Data Sheets in this Sub-section. Enclosed
impellers shall be equipped with seal rings on their hubs. In case of open impeller,
the pump shall be design to take care of the additional thrust produced.
6.00.00 Equipment Data Sheet
Type of pump : Submersible type fixed inside pits/ sump

with guides /lifting chains
Type of Working Fluid : Drains with particle size upto 40 mm
Type of impeller : Open
Type of lubrication : Self / Grease / Oil
Speed : Preferably 1500 rpm (maximum)
Material of Construction
a) Casing : 2% Nickel Cast Iron, IS:210

Grade FG 260;
b) Impeller : SS-316 / CF8M
c) Shaft : SS- 410
d) Bolts & nuts : SS-316
e) Accessories : Suction Strainer, Pump stand, Adaptors for

discharge flange, Level measuring devices/
Controllers, Lifting hook & chain Handle to
agitate debris etc, Discharge hose
connected with piping upto the drains etc.
f) The discharge, suction /column pipes shall be heavy grade Carbon steel externally
lined with epoxy or galvanised.

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(C) CW Treatment System
1.00.00 The complete operation of CW Treatment programme (including supply of all chemicals such
as HEDP, PBTC , Polymeric dispersant, Bio-dispersant, Corrosion inhibitor (Zn) and any
other chemicals shall be carried out by the bidder.
In addition to the requirements specified in Part-A of Technical Specifications, the CW

treatment system shall include the following:
a) Complete sulphuric acid handling, storage, unloading and dosing system.

b) Chemical day tanks (1W+1S) for each of HEDP & PBTC (common), Polymeric
dispersant, Bio-dispersant, Corrosion inhibitor (Zn) & dosing System consisting of
dosing pumps piping, valves etc.
c) Chemical day tanks shall be of MSRL construction with stirrer (SS/FRP lined) and
Chemical adding facility from top (Preferably funnel type). Dosing pumps (2x100%)
for each of the above chemicals compatible with handling of these chemicals shall be
be provided. Capacity of each tank shall be adequate for minimum 1 day
requirement (minimum capacity of each tank 500 liters).
d) Three (3) Nos acid storage tank (H2SO4) of capacity adequate for minimum 15 days
requirement (minimum capacity of each tank 50 cum). The tank shall be Horizontal,
with dished (Torospherical) ends. Material of construction of tank will be MS.
e) Two (2) nos (1W + 1S) acid dilution water pumps of suitable capacity.
f) Monitoring equipments like depositor monitor/fouling monitor (01), bio-fouling monitor
(01), Corrosion test coupons with test racks (6 nos.), on-line instant corrosion rate
monitor (01) shall be provided.
g) Two (2) nos. safety shower units and adequate nos. of eye fountains to protect
against any chemical hazard.
h) The design C.O.C of the CW System shall be 5.0 (minimum) for design of Chemical
Treatment programme. Bidder shall include chemicals required (other than H2SO4,
HCl & NaClO2) for passivation of metals during commissioning also. Chemicals
required after a major shutdown for re-commissioning the system shall also form part
of the bidder’s scope of supply.
i) All the chemicals must be of proven type.
j) All interconnecting piping, valves, fittings including dosing piping, drain piping from
acid storage dyke to nearby drain through neutralization pit provided in the dyke
area, piping for monitoring equipments such as pH monitor/deposit monitor/
corrosion rack etc., flushing lines from nearest available water source, valves,
fittings and accessories.
k) The above facilities are to be provided near the Cooling Tower.
l) Design of all vertical cylindrical atmospheric storage tanks containing water, acid,
alkali and other chemicals shall conform to IS: 803.
m) Design of all horizontal cylindrical atmospheric storage tank containing water, acid,
alkali and other chemicals shall conform to BS: 2594. However, dished ends shall be
of Torispherical type.

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2.00.00 The bidder shall perform the performance & guarantee test regarding the performance of
chemical treatment programme for complete CW system to meet the guarantees. The
performance guarantee test will be carried out along with the initial operation. The O&M for
complete CW Treatment System shall be for one (1) year operation after PG test of complete
CW System, which includes above six months period. The entire system responsibility and
maintaining the guaranteed parameters of the system along with supply of chemicals shall
rest with bidder during this period. The bidder shall depute his engineer(s) (as required by
Owner) to continuously monitor the system and take corrective measures in this period.
Complete chemical analysis and micro-biological analysis of water is to be carried out by the
bidder periodically at least once in a fortnight. Periodic report on the performance of the
treatment program along with analysis report chemical consumption pattern and
observation/recommendation shall be furnished by bidder to site. At mutually agreed
intervals, the performance and guarantee of the scale, corrosion, fouling and bio-fouling shall
be monitored and verified.

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WATER TREATMENT PLANT

CLAUSE NO.
A). WATER TREATMENT PLANT
1.00.00 WATER TREATMENT PLANT

This Chapter describes the system description, minimum Technical
Requirements of the Water Treatment plant and associated equipment. The
minimum technical requirements for plant and equipment shall include, but not
be limited to the following:
1) The Pre-treatment plant would be designed to remove suspended/colloidal
matter in the raw water. Pre-treatment plant shall be provided for Circulating
water system (PT-CW System) and Demineralised water system (PT-DM
system). The plant shall consist of minimum three (3) clarifiers of reactor
type for PT-CW & one (1) clarifier of reactor type for PT-DM system. The
clarified water shall be taken as make-up to CW system by pumping or by
gravity. Clarified water makeup shall be used for various systems like HVAC
(Air conditioning & ventilation), FGD system, Ash vacuum pump sealing and
any other system as envisaged by the bidder. CW blow down water shall be
used for plant Service water system, CHP dust suppression system, Ash
handling system, FGD system etc. Provision of service water for CHP dust
suppression system shall also be kept. Gravity Filters (2x100%) shall be
envisaged for DM system. The filtered water shall be led to DM plant for
further treatment to produce demineralized water of specified quality. A
common chemical house shall be provided to store chemicals, dosing
equipment etc. Chemical house and Filter house shall be RCC buildings.
2) Chlorine di-oxide plant for CW system (CW-ClO2) & PT system (PT-ClO2)
shall be envisaged separately. However, both the systems (CW-ClO 2 & PT-
ClO2) shall preferably be installed in a common location/building, if layout
permits. Chlorine di-oxide shall be generated at site (in situ safe generation
that takes place completely in water) from Acid-Chlorite process using 33%
commercial grade HCl and 31% Sodium Chlorite (NaClO2) solution in
presence of motive water. The dosing plant shall be located indoor in a
building except the bulk chemical storage tanks & unloading systems which
will be kept outdoor. However, bulk storage tanks for NaClO 2 shall be kept
under shed. Neutralization system shall be provided for the ClO2 plant(s) to
neutralize chemicals from the plant. ClO2 Building(s) shall be of RCC
construction.
3) Sludge from all clarifiers/lamella clarifier/tube settlers etc. in Pre-treatment
plant shall be led to common sludge sump and further pumped to employer’s
Ash slurry sump/tank.
4) The contractor shall provide either Ion exchange based DM plant or RO
based DM plant.
5) The capacity of DM plant either by Ion exchange process or RO process
shall be sized to meet the makeup water requirement of the steam cycle,
make up water to close circuit equipment cooling water (ECW) system,

WATER TREATMENT 1 OF 152
WATER SYSTEM PACKAGE BID DOC NO.:THDC/RKSH/CC-9915-373
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stator water cooling system etc. and any other requirements as envisaged by
the Contractor.
6) In case Ion exchange based DM Plant is provided, the DM plant shall consist
of two (02) streams (2x100%) and shall comprise of Activated carbon filter,
Weak Acid Cation Exchangers, Strong Acid Cation Exchangers, Degasser
towers and Degassed water storage tanks, Degassed water pumps &
blowers, Weak Base Anion Exchangers, Strong Base Anion Exchangers,
Mixed Bed Exchangers, UF system including Ultra filtration skids (2x100%),
UF Feed tanks, pumps, CIP/CEB system etc. The Cation resins shall be
regenerated with hydrochloric acid and the Anion resins with sodium
hydroxide. The regeneration facilities shall consist of the bulk acid & alkali
storage tanks, pumps, alkali solution preparation system, acid & alkali
measuring tanks and dosing ejectors/pumps etc.
7) In case RO based DM plant is provided, the UF+RO+MB combination Plant
shall consist of Ultra filtration skids (3x50%), UF permeate water tanks,
Backwashing (CEB) system for UF, Clean-In place(CIP) for UF, RO feed
pumps, micron cartridge filters, RO High pressure pumps, complete skid
mounted RO block (3x50%), Degasser tower and RO permeate (Degassed)
water storage tanks, Degassed water pumps, Complete chemical dosing
systems for RO system, Chemical cleaning skid for RO system, Complete
flushing system for RO system, Mixed bed (MB) exchangers (4x50%) along
with regeneration system, acid/alkali dosing system, reject disposal system
etc. Reject from RO plant shall be recycled and reused in coal handling plant
suitably.
8) The DM water of specified quality after mixed bed units (MB units) &
polishing UF shall be taken to DM storage tanks. Two (02) numbers of DM
water storage tanks shall be provided to store DM water.
9) DM Plant (either by Ion exchange process or RO process) shall be kept
under steel shed open from side. DM plant regeneration area shall be kept
under steel shed. DM Pump house shall be kept in open.
10) Effluent treatment system for PT plant: The filter backwash water of PT Plant
shall be collected and recycled back to the PT-CW Clarifier. The filter
backwash water of DM Plant shall be collected and recycled back to the PT-
DM Clarifier.
11) Neutralizing waste disposal system for DM plant: The effluent waste from
DM Plant etc. shall be led to a Neutralizing pit (N-pit) and pumped to
employer’s Ash Slurry sump/tank.
12) Service water effluents etc. from various plant areas separately collected in
employer’s Area pit(s)/sump(s) and pumped up to the terminal points. Bidder
to tap off the above service water effluents from the terminal points up to the
Waste service water sump (WSWS) under the scope of this package.
Similarly, service water effluents etc. from various plant areas under this
package shall be separately collected Area pit(s)/sump(s) and shall be
pumped/routed to the Waste service water sump (WSWS). The effluents
shall further be pumped up to tube settlers/lamella clarifiers (2x50%) for
treatment. Treated service water shall be stored in Treated Water Tank/CMB
and pumped to service water tank for recycling/re-use for meeting and

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maintaining the zero liquid discharge (ZLD) of the plant. Portable type oil
skimmer(s) & a Portable oil centrifuge etc. shall be provided in WSWS.
13) CW blow down water (any excess quantity after meeting the plant
requirements) shall be collected in Treated Water Tank/CMB.
2.00.00 TECHNICAL REQUIREMENTS OF PRE-TREATMENT PLANT & ClO 2 PLANT
2.01.00 GENERAL
1) The aerator shall be of stepped design and shall allow water to flow
downward after spreading over inclined thin sheets and the turbulence is
secured by allowing the water to pass through a series of steps and baffles.
Cascade aerators shall be designed based on the surface flow rate of not
less than 0.03 m2/m3/hr. Exposure time shall be suitably designed by
providing adequate number of steps in the aerator.
2) The volume of stilling chamber shall have a retention time of minimum 1
minute and velocity of water rise through the stilling chamber shall be 0.05
m/sec.
3) The chlorine di-oxide dosing shall be done in stilling chamber and aerator by
using diffusers of proven design. Water from the aerator launder shall be led
into the stilling chamber. The stilling chamber shall be provided with a baffle
wall so that water shall enter the chamber from the bottom with the velocity
specified elsewhere. Draining arrangement with a valve shall be provided for
the stilling chamber.
4) The hydraulic circuit of the complete Pre-treatment plant shall be designed in
such a way that water from aerator shall flow by gravity up to the clarified
water tank under various flow rates up to maximum flow and the top water
level in the clarified water storage tank/distribution chamber shall be
maintained as +4.5 M (minimum) from the finished ground level.
5) All the clarifiers shall be designed to operate simultaneously.
6) Hydraulics of the Complete Pre-treatment Plant shall be designed to take an
occasional over loading of 20% over the design flow.
7) Pre-treatment plant shall be designed such that CW clarifiers can be
bypassed. A back-up line shall be provided between CW Clarifier outlet
channel & DM Clarifier.
8) Layout for Pre-treatment plant shall be designed in such a way that various
units (e.g. aerator, stilling chamber, clarifiers, channels, chemical house,
filter house operating floor, clarified water tank etc.) shall be interconnected
by at least 1 M wide walkways at the appropriate elevations with hand
railings.
9) All the chemicals to be used in the Pre-treatment plant shall generally
conform to the requirement of technical grade as per relevant IS.
10) Clarified water distribution chamber/tank shall be covered.
11) All the tanks shall be provided with vent, overflow, drain and sample
connections. Effective capacity for chemical tanks & water retaining
structures/tanks/sumps means the capacity between the bottoms of the

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overflow nozzle to the top of the outlet nozzle. Outlet nozzle center line shall
be kept at least 200 mm from the invert level of the chemical tanks/water
retaining structures/tanks/sumps. All the covered sumps/tanks shall be
provided with minimum two (2) numbers of manholes and suitable venting
provisions.
12) A minimum free board of 300 mm shall be provided in all the water retaining
structures of PT Plant (such as stilling chamber, channels, clarifiers, clarified
water storage tank, filtered water reservoir, filtered water sump, overhead
filtered water tank, service water tank, treated water tank/ CMB, sludge
sump, backwash sump etc.) above the maximum water level at design flow
condition/overflow level as the case may be excluding the thickness of the
slab/beam thickness if any.
13) All the sumps, tanks, reservoirs and other water retaining structures shall be
provided with approach ladders (i.e. step ladders with hand railings) from
operating platforms/ground level as the case may be.
14) Any other pumps, blowers required for the completeness of the system shall
be designed with a redundancy of N+1 unless stated otherwise (N=No of
working pumps, blowers).
2.02.00 REACTOR CLARIFIER UNITS
1) The clarifier shall be solid contact reactor type with integral variable speed
impeller/ turbine to internally re-circulate water and sludge at adjustable rate to
produce consistent water quality at varying hydraulic load and turbidity. The
unit shall be designed with a minimum retention time of 90 minutes in the
settling zone.
2) The overall area of the unit shall be based on an average flow velocity not
more than 3 M3/M2/hr. Weir loading shall not exceed 300 M3/m/day. For
uniform overflow over weirs, triangular notches (saw tooth weir) shall be
provided as necessary.
3) Design of the sludge removal system should be such as to reduce loss of
water during sludge blow off within 3% of rated flow.
4) Clarifiers shall be sized such that in the event, one (1) clarifier is out of service
for maintenance, the other clarifiers with 20% overload will be able to meet the
total clarified water requirement.
5) The clarifier periphery (all around) shall have a walkway (minimum width 850
mm) with handrail and access ladder (RCC) (at least from two locations) for
good approach. All the Reactor clarifiers shall be equipped with full bridge of
sufficient width. Permanent ladders shall also be provided (not rungs) for
approaching the sludge pipeline valves for maintenance. However, the sludge
valves shall be operatable from the top of the sludge chamber through head
stock and extended spindle arrangement.
6) Clarifiers shall be provided with radial launders.
7) Sludge blow off shall be effected by the static head of water in the clarifier unit.
Sludge outlet pipes from the concentrated sludge hopper shall be branched
into main disposal line and continuous sludge disposal line. Main sludge
disposal line, which includes a blow-off valve, shall drain sludge to the sludge

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disposal sump. Continuous sludge disposal line consists of telescopic stand

pipe, the top of which is maintained at a desired elevation to ensure trickle flow
of water or sludge water mixture to the sludge sump.
8) Each of the clarifier shall be provided with a gate at the outlet for isolation of
any of the clarifier for maintenance.
2.03.00 Not used.
2.04.00 FILTERS
2.04.01 GRAVITY FILTERS
1) The inlet channel from clarifiers to gravity filters shall be designed considering
operation of all the gravity filters including standby filters under exigency.
2) Filter box of gravity filters shall be of water tight RCC structure covered with
RCC roof. Gravity filters shall be twin section type complete with a rate of flow
indicator and a loss of head gauge.
3) Gravity filters shall be designed for surface flow rate not more than 5m 3/m2/hr.
4) Only one filter shall be backwashed at a time. Backwashing of filters shall be
done in not less than 24 hours.
5) The velocity of water during backwashing shall not exceed 35.0 m /hr, when
air scouring is employed.
6) Effective Capacity of both sections of the filter water reservoir (excl. common
sump) shall be adequate to store filtered water output from one complete filter
for one (1) hour.
7) At least 50% free board shall be left over the filtering media to facilitate
backwashing.
8) The filtering medium shall be washed, screened and hydraulically graded
anthracite coal or sand having an aggregated depth not less than 1200 mm.
9) Details of various layers of Gravity filter medium should be as follows:
150 mm of No. 7 size 60 mm X 50 mm
75 mm of No. 3 size 8 mm X 4.5 mm
50 mm of No. 2 size 4.5 mm X 2.8 mm
750 mm of No.1 size 0.45 mm to 0.7 mm effective size
Anthracite shall have the following properties: -
Uniformity coefficient 1.6
Hardness 2.5 to 3.5 (Mho. scale)
Dust content Less than 1%
Specific gravity 1.75 (Approx.)

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Anthracite shall be free from iron sulfide, clay, shale, long, thin or scale
pieces.
Sand shall have the following properties: - Sand shall be of hard and
resistant quartz or quartzite and free of clay particles, soft grains and dirt of
every description.
Effective size shall be 0.45 to 0.70 mm.
Uniformity coefficient shall not be more than 1.7 or less than 1.3
Ignition loss should not exceed 0.7 per cent by weight.
Soluble fraction in hydrochloric acid shall not exceed 5.0% by weight.
Silica content should not be less than 90%.
Wearing loss shall not exceed 3%.
Specific gravity shall be in the range between 2.55 to 2.65.
Sand should be clean and well graded. Sand filter shall have a HCl
solubility of less than 5% when tested in accordance with AWWA B 11.53.
10) Each filter bed shall be provided with a rate of flow indicator and a loss of
head gauge in a local instrumentation panel which shall be located at suitable
location on the operating platform of filters. Each filter bed outlet shall be
provided with rate of flow indicator & controller.
11) Each of the gravity filters shall be provided with drain connections with
isolating valves for draining complete filter water channel and filter bed.
Platform over each of the gravity filters with hand railing shall be provided for
the inspection of backwashing operation and filter bed.
12) The manual extension spindles of all the valves of filters shall be operatable
from the operating floor of filter bed. Extension spindles and C.I. head stocks
for operation of these valves shall be provided. Only valves shall be used for
different process of filters. Penstocks/Gates in filter beds will not be accepted.
13) The arrangement of Gravity Filters, filtered water reservoirs, filtered water
sump and filtered water pump house for PT-DM and PT-Potable system shall
be located together. However, operating floor level of both the filtered water
pump houses may be common.
2.04.02 Not used.
2.04.03 FILTER BACK WASHING
1) Filter Back Washing: An overhead storage water tank shall be provided on
top of chemical house. The capacity of the overhead filtered water tank shall
meet the water requirement for backwashing and backwash flow for
simultaneous backwash of one (1) number of gravity filter (both the sections)
of Potable System, one (1) number gravity filter (both the sections) of DM and
and preparation of chemicals etc. and any other requirements envisaged by
the contractor.
2) The inlet distribution and under drain collecting system shall be so designed
as to give uniform distribution and flow without channeling and obstruction.

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The under drain system shall either be of header lateral or manufacturer’s

standard design.
2.04.04 CARTRIDGE FILTERS
1) The filter elements shall be cylindrical cartridges constructed from
polypropylene fibers, which have a 1 micron nominal 95% efficient rating.
Cartridge shall be self-supporting with no reinforcing structures or resins.
Polypropylene material shall be 100% polypropylene with no binders, resins
lubricants or other residue from the manufacturing process. The filter vessel
shall be designed in accordance with ASME boiler and pressure vessel code
section VIII, division I. Filter Casing & Internals for Cartridge filters shall be
SS-316. Each vessel shall have type bolts and nuts of SS. Each vessel shall
have a cover gasket with Buna-N “O” rings. The vessel shall be provided with
both clean and dirty water drain nozzles, as well as an air vent at the top.
Each vessel shall be provided with a cover-lifting davit arrangement capable
of lifting the cover and swinging it to the side. A flanged inspection port shall
be installed on the clean side plenum 90 degree from the inlet center line.
2.04.05 AIR BLOWERS FOR FILTERS
1) Air blower shall be used for air scouring of filter bed. Blower shall be positive
displacement, twin lobed rotary blower. The blower shall be V-belt/directly
coupled with electric motor. The blowers shall be oil free type.
2.04.06 ULTRAFILTRATION SYSTEM (UF) PRIOR TO RO SYSTEM
UF system shall include, but not be limited to the following:
1) Ultra-filtration (UF) system complete with all equipment and components
except storage tanks shall be installed on skid(s). Bidder shall select the UF
membrane so that the system is capable of producing UF permeate by
removing colloidal silica level to the extent suitable for downstream reverse
osmosis (RO) unit.
2) The system shall be designed to allow multiple starts and stops without
affecting the service life of the membranes. The system may experience
extended periods of no flow; System design shall protect the system
against periods of no flow as recommended by membrane manufacturer.
3) 3x50% Ultra Filtration Units, complete with all accessories for chemical
treatment & cleaning inclusive of UF feed pumps, backwash pumps etc. shall
be provided.
4) Provisions for local grab sampling points shall be available at various points
throughout the system to monitor UF performance. Minimum sample points
with sample valves shall be provided on the UF system for, but not limited to:
i)UF feed
ii) Strainer backwash
iii)UF permeate water
iv)UF backwash
v) UF neutralized backwash water

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5) Each stream/train shall be provided with 2x100% automatic self-cleaning

strainers at inlet with about 100 micron size and shall be designed to clean
one section of the strainer media at a time, on differential pressure. The reject
shall be returned to the feed of the upstream of clarifier(s) in PT plant.
Strainer screen and strainer housing shall be of stainless steel.
6) UF membranes shall be hollow-fiber, pressurized type. Membrane materials
shall be Polyvinylidene di fluoride (PVDF) or Polyether sulfone (PES). Gross
maximum design flux rate shall not be more than 60 l/m 2/h. Filtration direction
shall be either Out-to-In or In-to-Out. Design UF recovery shall not be less
than 92%. Pore size of membrane shall not be more than 0.04 micron.
7) Provisions to check the integrity of the membranes shall be provided in
accordance with ASTM D 6908-06 Standard Practice for Integrity Testing
of Water Filtration Membrane Systems (Pressure Decay/Hold Test). In the
event of fiber breakage, the affected module shall be easily identifiable on the
Rack through use of clearly visible inspection window built into the filtrate
discharge pipe.
8) An on-line membrane flushing system shall be provided to flush the UF
membranes prior to shutting down.
9) Skid mounted Membrane cleaning system, CIP and chemically enhanced
backwashing (CEB) systems, as applicable shall be provided. Chemicals like
sodium hypochlorite, sodium hydroxide and hydrochloric acid shall be used
for backwashing/cleaning.
10) UF feed pumps and UF backwash pumps shall be provided with variable
speed drives (VFD).
11) UF permeate storage tanks shall store water to supply feed water to
Reverse Osmosis (through micron cartridge filter) system on continuous
basis and to provide water for backwashing of Ultra filtration membranes.
Capacity of this tank shall be calculated based on backwashing cycle and
time taken for backwashing and CEB cleanings. A margin of minimum 50%
of backwash water requirement shall be considered while calculating
capacity of the tanks.
12) CIP system shall be capable of being used for adding chemicals to
restore organically and inorganically fouled membranes including biocides
and membrane preservative chemicals in the event a membrane train will
be shut down for an extended period.
13) The cleaning system shall be connected to the UF trains with permanent
hard pipes.
14) Trans-membrane pressure drop shall initiate backwash of UF. During
backwashing, if the differential pressure across membranes exceeds a
set point, the UF system shall automatically shut down.
15) Filtration time (the time before backwashing is initiated), shall be
adjustable.
16) Inlet and outlet UF manifolds shall be provided with level transmitters and
on/off automatic valves to detect and vent trapped air in manifolds
and avoid hydraulic shocks to membranes.

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17) UF normal and chemical enhanced backwashing frequency shall be

adjustable individually and controlled from the control system including
number of cycles before chemically enhanced backwashing is initiated. Time
duration of these backwash cycles shall also be adjustable from the control
system.
18) Spent chemicals from the chemically enhanced backwashing & CIP shall be
neutralized in Neutralization pit.
19) Online Turbidity transmitter shall be provided to measure UF filtrate turbidity
with high turbidity alarm interlocked to shut down of UF system if high
turbidity is sustained for a pre-set time. Automatic on/off valves and filtrate
flow transmitters shall be provided to automatically conduct air integrity
test of UF membrane modules.
20) Membrane cleaning system shall be provided as per recommendation
membrane designer and membrane manufacturer. The effective capacity of
each cleaning tank shall be 120% of chemical required for one (1) cleaning
or 0.5 cum. whichever is higher. For each chemical, preparation cum dosing
tank shall be provided with agitator, level indicator and pump interlock. The
preparation cum dosing tank shall be of MSRL/FRP construction with
minimum 6.0 mm thickness.
21) After the manufacture, following tests for membrane shall be demonstrated
at membrane manufacturer’s works in the presence of Employer's
representative and contractor:
i). Bubble Point Test in one batch
ii). Integrity test (Pressure decay test/vacuum hold test) for 1 % of total
membrane population.
22) The responsibility for conducting the test (Bubble Point, Integrity) will be with
the Contractor and Contractor shall make all the arrangements for carrying
out tests at membrane manufacturer’s works. In case such test facilities are
not available at manufacturer's works, the test may be carried out at any
other test facility with the approval of Employer. All cost associated with
testing at contractor's works or at any other test facility shall be borne by the
contractor & shall be included in the contract price.
23) Integrity test shall be carried out in accordance with ASTM D 6908-06,
Standard Practice for Integrity Testing of Water Filtration Membrane
Systems (Pressure decay test/vacuum hold test) and approved test
procedure. Bidder shall submit the test procedure for Employer's approval
within two months of award.
24) Design calculations of Ultra filtration system shall be vetted by membrane
manufacturer during detailed engineering.
1) It is not the intent to pre-select any specific manufacturer of UF membranes.
UF membranes will be accepted by the Employer strictly on their merits. The
UF membrane shall be of reputed manufacturer with adequate past
record of successful service for not less than one year in similar application.

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Contractor shall submit all necessary data and information in this regard
along with his proposal. Some of these possible membrane manufacturers
are as follows:
DowChemicals/Toray/Hydranautics/Inge/Hyflux/Koch/Norrit-
Pentair/GE/Approved Equivalent.
Above listing is by no means exhaustive, and shall not be construed to be a
recommendation for their selection for this plant. Contractor shall fully satisfy
himself as to the suitability of the membranes system selected by him before
offering it in his proposal.
2.05.00 CHEMICAL HOUSE
A. CHEMICAL HOUSE FOR PT PLANT
1) Chemical dosing equipment, pumps, tanks, piping etc. of PT- CW, PT- DM
/RO plant (as applicable) & LETP shall be located in a common two (2) Storey
Chemical House. The Chemical House shall store chemicals in the ground
floor whereas equipment such as chemical preparation tanks and dosing
equipment shall be installed on the first floor. The chemical house shall be
located such a way that chemical dosing pipelines to PT plants, DM plant LET
plant are minimum.
2) Preparation & dosing equipment of each type of chemical shall be
isolated/segregated to avoid mixing of chemicals, facilitate safe operation,
easy movement of personnel during plant operation and emergency condition
like chemical leakage etc.
3) Suitable platforms, ladders etc. to facilitate approach to various tanks,
manholes/hand-holes, sight-glass, operation & maintenance of valves,
instruments etc. shall be provided. Chemical house shall have sufficient
unloading space, wide corridors for movement of chemicals, office and toilets.
4) Storage area (Alum, Lime, other chemicals etc.), Chemical preparation tanks
area, Chemical drain trench & dyke wall shall be provided with corrosion
resistant (AR) tiles/lining to protect the surface due to spillage/drains etc.
5) Drains from chemical storage & preparation facility/equipment shall be
designed so that the same are not mixed with storm water drainage.
6) Chemical house in the ground floor shall be designed to store the chemicals
for 15 days period considering working of all the clarifiers/tube settlers etc.
a) Alum as Al2(SO4)3 : 70 ppm on 100% basis
b) Lime as Ca(OH)2 : 30 ppm on 100% basis
c) Coagulant aid : 2 ppm
7) Lime slacking tanks: Each tank shall be sized for holding lime slurry (of about
10% W/V concentration from Quick lime of purity of 75% CaO) for 12 hours
requirement of all the clarifiers and tube settlers operating at design capacity
and a design dosage rate of 30 ppm minimum.
8) Lime solution preparation tanks: Each tank shall be sized for holding lime
solution (of about 6% W/V concentration) for 8 hours requirement of all the

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clarifiers and tube settlers operating at its design capacity and a design
dosage rate of 30 ppm minimum.
9) Alum Solution Preparation tank: Each tank shall be sized for holding alum
solution (of about 10% W/V concentration) for 8 hours requirement of all the
clarifiers and tube settlers operating at its design capacity and a design
dosage rate of 70 ppm minimum.
10) Coagulant aid (Poly electrolyte) Preparation tank: Each tank shall be sized for
holding coagulant for minimum 12 hours requirement of all the clarifiers
operating at design capacity and a design dosage rate of 2 ppm minimum.
11) FeCl3 (35–45 % conc.) Preparation & dosing system consisting of
preparation tanks, agitators (SS-316), coagulant unloading and transfer
pumps (2x100%) (1W+1S) dosing pumps (2x100%) (1W+1S) in case of PT-
RO.
12) PAC unloading, Preparation & dosing system consisting of at least two (2)
numbers of tanks, agitators (SS-316), unloading and transfer pumps
(2x100%) (1W+1S), dosing pumps (2x100%) (1W+1S) etc.
13) Any other system/equipment required to meet the System requirement shall
be provided.
B. CHEMICAL STORAGE & DOSING SYSTEM FOR RO PLANT
1) Bulk chemical storage of RO chemicals i.e. Coagulant aid, Anti-scalant and
Anti-oxidant etc. shall be located at ground floor level. Storage area shall have
suitable partitions, physical separations/segregations etc. for each chemical.
2) Bulk storage for Coagulant, acid and alkali shall be located outdoor near the
chemical house building. Coagulant/Acid/Alkali unloading pumps and alkali
transfer pumps shall be located near chemical storage. Spill containment wall
(dyke) shall be provided around chemical storage area in such a way that any
chemical spill, during unloading, breakage/failure of tanks etc. is isolated from
adjoining area by providing dyke wall. The height of dyke wall shall be
minimum 500 mm or to contain volume of biggest tank whichever is high.
3) Vehicular approach from plant roads shall be provided for easy unloading and
handling of chemicals delivered to the plant. This facility shall be located such
a way that chemical dosing pipelines to PT plant, DM plant, LET plant are
minimum.
4) Emergency safety showers with eye wash units shall be provided in the
Chemical Storage Handling facility at strategic locations such as Acid/Alkali
Storage area, outdoor Chemical storage area, Chlorination plant area and
Chemical preparation & doing equipment area.
5) Any other system/equipment required to meet the System requirement shall be
provided.
6) Layout of Chemical house and Chemical storage area shall be finalized during
detailed engineering.

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2.06.00 CHLORINE DI-OXIDE (ClO2) PLANT

2.06.01 DESIGN DATA
1) Chlorine di-oxide (ClO2) system of proven design & with operation
performance/experience shall be provided by the Contractor.
2) Design capacity of generator(s) for CW system & PT system shall meet
requirement for ClO2 dozing for the total circulating water flow to maintain a
free chlorine dioxide residual of at least 0.2 mg/l in the far reaches of the
distribution system at all times. However, the minimum capacity of chlorine
di-oxide plant(s) shall be as follows:
a) For CW System, shock dosing is proposed to be provided, which shall
be done minimum 3 times a day (once per shift). Minimum selected
capacity of the plant shall be 2 x 75 kg/hr (2W) for catering total
requirement of (2 x 660 MW) units.
b) For PT System, continuous dosing is proposed to be provided. Minimum
selected capacity of the plant shall be 2 x 10 kg/hr (1W+1S) for catering
total requirement of (2 x 660 MW) units.
3) No stand-by generator is proposed in ClO2 system for CW. However, stand-
by equipment w.r.t pumps, tanks, piping & valves etc shall be considered by
Contractor as shown in the scheme drawing & mentioned elsewhere in the
Technical specification.
4) The Chlorine-di-oxide generator system shall be designed and contractor
shall submit all calculations/details/catalogue to EMPLOYER for their
review/approval during detail Engineering and shall conform to
recommendations of the relevant International/Indian standards/codes. The
same shall be substantiated by relevant documents.
5) Chlorine-di-oxide dosing shall be provided at aerators, stilling chambers of PT
systems. For controlling organics in circulating water system, ClO2 dosing
may be provided in CW Forebay channel.
2.06.02 BASIC DESIGN CRITERIA & REQUIREMENTS
1) The chlorine di-oxide generators (Submerged / encapsulated type) shall
ensure that the formation of the ClO2 solution takes place completely
underwater and the reaction chamber shall be completely surrounded by
water in order to avoid any ClO2 gas leak.
2) The Contractor shall offer only proven design in successful operation in similar
application at previous installations.
3) The ClO2 shall be generated in diluted solution of concentration of ≤ 1500 mg/l.
Vendor shall submit the complete details and track record of the system for
approval before order/installation.
4) The generator/reactor shall have a yield of 90% or higher. For consumption of
reagents, 90% yield should be considered. Provision for measuring the yield
shall be provided. The system shall also have necessary sampling valve for
periodic measurement of concentration of ClO2 at the generator outlet to prove
and monitor the conversion efficiency of ClO2 generator.

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5) The design of Chlorine Di-oxide generating reaction chamber and system

should be as per National & International guidelines and safety requirements.
The design of chlorine dioxide system should include safety, handling of
precursor chemicals viz NaClO2 and HCl, water source, chlorine dioxide
distribution and physical location of all generation equipment & associated
accessories. The contractor must include all the necessary additional features,
functions & equipment for safe & consistent operation of chlorine di-oxide
system.
6) Certifications/ Statutory clearances from directorate of explosives or any other
authorities; if any required, shall be obtained by the contractor.
7) The ClO2 generation system shall have variable dosing rate of 10% to 100% of
the design dosing rate or better.
8) The ClO2 generating system should be provided with all the necessary
instrumentation and control system including necessary check points,
measuring on-line instruments, sampling point to draw a sample of chlorine
dioxide solution produced, control valves, interlock, trip facility and to be
operated on fully auto mode through DDCMIS based system.
9) The single generating system shall have one or maximum two generators for
ClO2 generation.
10) The ClO2 generator should have an auto function to trip the dosing pumps of
sodium chlorite and hydrochloric acid when flow of water is not adequate or
there is no flow of water or any of the chemicals. The chlorine dioxide
generator should have online indicators for pressure and flow of
motive/injection water.
11) Each reaction chamber must have suitable flow transmitters to ensure
uniform flow of chlorine dioxide into the water as per requirement and should
have necessary isolation arrangement so that it can be handled safely for any
maintenance, repair work or for inspection etc.
12) To have optimum accuracy, the dosing pumps used shall be with powerful
variable speed stepper motor with internal stroke speed control and have a
minimum turn down ratio of 1:800 for precise control of ClO2 generation.
Accuracy should be +/-1 % or better. Dosing pump should have LCD display
to see the capacity set and alarms if any.
13) Dilution water pumps shall be equipped with suitable VFD to control the speed
for varying the flow rate.
14) Contractor shall suggest suitable neutralizing chemical for HCl and NaClO2
and shall design the neutralization system with all required accessories.
15) Separate Neutralization pits for HCl and NaClO2 shall be provided. Discharge
pumps (one working + One Standby) shall be provided in neutralization pit
with online pH meter. Storage facility shall be provided for all neutralizing
chemical within the plant. Chemical preparation tanks with necessary agitation
requirement shall be provided as required. After neutralization, the neutralized
waste water shall be pumped to DM plant N-pit.
16) The bulk storage Tanks shall be provided with dyke wall of suitable height
(minimum 500mm). The dyke area shall be provided with Acid proof lining. The

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Unloading Pumps area shall be provided with a kerb wall and the kerbed area
shall also be provided with Acid proof lining. Suitable dyke wall/barrier shall
also be given in between HCl & NaClO2 tanks to avoid any kind of mixing.
17) Arrangements shall be made to transfer the chemical from one tank to another
for greater flexibility & in case of leakage; provision shall be made to recycle
the chemicals back to tanks from the dyke area for both chemicals (NaClO2 &
HCl).
18) Bidder shall take full responsibility that all the materials and components of
valves, pumps, piping and any other equipment and appurtenances shall be
proven and compatible with the respective fluid therein.
19) The dosing skids for the system shall be equipped with all necessary
arrangements/ facilities to detect and control leakages and avoid mixing of the
Reagents inside the room.
20) ClO2 leak sensor with detector shall be installed inside the room. The least
count of sensor shall be 0.1 ppm or better and the complete ClO2 generation
system including the dosing pumps shall stop automatically. The ClO2 leak
sensor shall be of reputed make with proven track record. Industrial type high
decibel hooters shall be provided for each of the ClO2 plants (PT & CW).
21) The Chlorine dioxide dosing system shall be provided with automatic dosage
rate control based on the residual levels in CW system & PT system.
22) Air contact with chlorine dioxide solution should be controlled to limit the
potential for explosive concentrations possibly building up within the reactor.
23) The skid MOC shall be of carbon steel with suitable painting/coating having
sufficient strength and rigidity to support the equipment contained in the skid.
24) Following controls shall be provided with the following instruments as a
minimum.
a) pH in Chlorine di-oxide solution dosing line.
b) Residual chlorine di-oxide (ClO2) analyzer.
c) Flow meters on all chemical feed lines, dilution water lines, and
chlorine dioxide solution lines.
d) Pressure indicator & controller on the water inlet line to ClO2
generators, chlorine dioxide dosing controller, low vacuum switch,
solenoid valves, etc., all complete and as required shall be provided.
e) The dosing in inlet shall be automatically controlled based on the
signal received from residual chlorine dioxide analyzer in the
header.
f) All chemical storage tanks shall have automatic high and low level
cut off.
g) Chlorine di-oxide leak detection system.
h) In case of water supply to the generator stops, the chemical dosing
pumps shall also stop automatically.

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i) Generator must be equipped with systems of dosing and/ or

measurement for reagents and diluting water. These systems must
be able to shut down the operation of the generator in case any of
the supplies is cut off.
2.06.03 MATERIAL OF CONSTRUCTION
Material of construction of components of Chlorine-dioxide plant shall be as
follows:
Components Material of construction
ClO2 generator PVDF sandwiched with FRP protection
for better reliability/Equiv. PVDF
Piping & Valves Industrial Grade CPVC
Chemical Storage Tanks FRP
2.06.04 APPLICABLE CODES AND STANDARDS
The design, material, construction, manufacture, inspection, testing and
performance of the chlorine-dioxide plant shall comply with all currently
applicable statutes, regulations and safety codes in the locality where the
equipment will be installed. The equipment shall also conform to the latest
editions of all standards and codes (along with all addenda), mentioned below
and elsewhere in the specification. Nothing in this specification shall be
construed to relieve the contractor of this responsibility.
i) ASME Standards for various tests and materials.
ii) ASME – Boiler and Pressure Vessels Code Section VIII, Div.1 and sect. IX.
iii) ANSI B 16.5 Standard for Steel pipe flanges and flanged fittings.
iv) IS – 5120 – Technical requirement for Rotodynamic pumps.
v) Chlorine Institute Manual of USA
vi) ASTM D 1784 and F 441 & F 439 - CPVC Pipe and Fittings.
vii) ASTM and BIS Specifications for CPVC, PP, FRP
2.06.05 PIPING
a) Industrial grade CPVC Schedule-80 piping shall be used which can withstand
a temperature of minimum 60C.
b) The arrangement of piping and valves should be for ease of service and
operation. Cleaning connections are to be provided for flushing.
c) Piping should be lighter in weight with no corrosion and high fire
performance. The piping should be easy to fabricate and assemble and in
case of any damages, it should be easily replaceable.
2.06.06 VALVES
a) All valves in Chemical dosing lines (Acid, Sodium chlorite, chlorine dioxide
etc.) shall be of industrial grade CPVC PN16 rating (minimum).

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b) Type of valves and material of construction for various other applications in

the ClO2 plant shall be selected by the Contractor as per its proven
practice. However, all the valves in contact with chlorine dioxide solution
should be leak tight and preferably of diaphragm valves with Teflon
diaphragm.
2.07.00 OTHER DESIGN & CONSTRUCTION FEATURES
1) All the metallic parts of equipments of Complete Pre-treatment and LET
system, which are embedded in concrete or in contact with water, shall be
painted with bitumastic heavy duty paint over a coat of primer with total
thickness of 400 microns. All the other parts of the PT plant shall be painted
with one coat of primer and three coats of chlorinated rubber paint and total
thickness shall be 200 microns.
2.07.01 The maximum support length in meters for MS pipe as follows
a) PIPE DIA (MM) 1200 1000 800
b) SPAN (METERS) 12 10 10
For pipe sizes less than 800 NB, span shall be provided as per ANSI B31.1
2.07.02 The overflow & drains from the various chemical tanks and floor wash drains of
chemical house building shall be led to sludge sump.
3.00.00 CONTROL PHILOSOPHY OF WATER TREATMENT PLANT
3.01.00 The control & operation of various systems described below is indicative only
and the actual control & operation philosophy shall be finalized with during
detailed engineering. However for all the systems, following basic process
related interlocks, alarms /pre-warning signals shall be implemented in the
control system as per system requirement.
a) Among the equipment, it shall be possible to select a specific pump or tank
or sump for working/standby/ maintenance etc. through control system.
b) Permissive & Interlocks:
1) Starting & tripping of pumps with respect to liquid level in the respective
sump/tanks or liquid pressure in the suction lines.
2) Starting & tripping of agitators with respect to liquid level in the respective
sump/tanks.
3) Starting & tripping of pumps (which are provided with forced water
lubrication) with respect to lubricating water flow (through low pressure/
low flow signal as the case may be).
4) Tripping of pumps when the discharge pressure is very high to avoid
operation of the pump under shutoff head.
5) Stopping/ tripping of equipment due to abnormal parameters related to
safety of equipment like high vibration, very high bearing lubrication
water (and /or oil) temperature to the drive/pumps, very high bearing
temperature of the of pump/drive etc as applicable based on the
recommendations of Equipment Supplier.

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6) Automatic opening of the re-circulation valve to pre-set percentage, in

case of failure of opening of pump(s) discharge valve to ensure minimum
flow through the pump, as per the recommendation of manufacturer.
7) Automatic starting of standby pumps upon failure of starting of selected
pump or tripping of running pump as the case may be.
c) Alarms /Signals
1) Abnormal parameters such as low & high level in tanks/sumps, high
pressure at pump discharge, low header pressure, low lubrication water
flow to pumps (provided with forced water lubrication system) etc.
2) Failure of starting of equipment such as pumps, blowers etc. upon start
command.
3) Tripping of equipment due to protection logic.
In addition, the control system shall facilitate the operator to know the status of
various equipment (Whether equipment is running or stopped or tripped etc,
whether the equipment is selected for operation/ standby duty /maintenance
mode etc as the case may be).
3.02.00 SYSTEM OPERATION AND CONTROL PHILOSOPHY (PT PLANT)
1) CLARIFICATION PLANT
The motor operated inlet control valve to clarifiers shall be regulated with
respect to the water level in the clarified water storage tank. A variable
frequency drive (VFD) shall be provided for turbine/impeller drive of all the
clarifiers to control the speed for varying the recirculation rate. The scrapper
drives of clarifiers shall be interlocked with torque limit switches on the
motors.
2) CHEMICAL HOUSE
1) All the pumps shall be interlocked with the level at sump/reservoir/tank for
pumps start permissive as well as pump protection. Annunciation prior to
trip shall also be provided.
2) Agitator can be started only when the level in the corresponding dosing
tank is adequate. The agitator shall trip when the level in the dosing tank
comes below a pre-defined set point.
3) Capacity of the metering pump shall be controllable from 10-100%
continuously by adjusting the stroke length manually by a micro meter dial
calibrated for 0–100% of pump capacity integral with the pump.
4) Various annunciations related to low level of the chemical tanks shall be
provided.
4.00.00 LIQUID EFFLUENT TREATMENT SYSTEM
4.01.00 All liquid effluent emerging out of the power plant shall be collected and treated
(as required) to meet the latest effluent norms of statutory authority.
A. PT PLANT CLARIFIER SLUDGE DISPOSAL SYSTEM
1) One (1) number RCC sludge pit in two (2) sections to collect sludge from all
the clarifiers of PT-CW, PT-DM system & Lamella clarifiers/tube settlers etc.

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shall be provided. Sludge pit shall be able to store the sludge generated in
water treatment plant clarifiers and any other drain/effluent connected to this
sump (in case envisaged). Sludge pit shall be provided with agitation by
recirculation (jetting nozzles) system and air agitation system.
2) Air blowers (2x100%) shall be used for the air agitation system of the sludge
pit to avoid settlement of solids. Sludge pumps (3x50%) (Vertical sump
pumps) shall be provided to pump sludge to Ash slurry sump/tank.
B. FILTER BACK WASH WASTE DISPOSAL SYSTEM
1) One (1) number RCC Filter backwash waste collection pit in two (2) sections
of shall be provided to collect the backwash water from all the filters. The
filters backwash water of shall be collected and recycled back to the clarifiers.
2) Backwash disposal pumps (2x100%) shall be provided. Each pump shall be
capable of evacuating the capacity of complete pit within 1 hour.
C. WASTE SERVICE WATER TREATMENT SYSTEM
1) Service water effluents (after floor washing etc.), other plant effluents etc.
having high-suspended solids require treatment for removal of total
suspended solids (TSS). It is proposed to reuse/recycle waste service water
after treatment by means of Waste Service Water Treatment System. The
system broadly consists of Collection sumps, Tube settlers/Lamella clarifiers,
oil skimmers, oil centrifuge, pumps, chemical storage, handling and dosing
equipment etc.
2) One (1) number RCC waste service water sump (WSWS) in two (2) sections
(each of 200 cum capacity minimum) shall be provided for collection of waste
service water. Service water effluents from various areas shall be routed to
this waste service water sump. Waste service water from the other plant
areas shall be terminated at terminal points as specified elsewhere. Further,
from this terminal points, waste service water shall be led to the above waste
service water sump (WSWS) with all the associated piping, valves etc. which
shall be in contractor’s scope.
3) Waste service water transfer pumps (3x50%) shall be installed in WSWS to
pump waste service water to a set of Tube settlers/Lamella clarifiers.
4) Chemical dosing (Alum & lime) shall be provided for these Tube
settlers/Lamella clarifiers in the chemical house. The treated water form Tube
settlers/Lamella clarifiers shall be led to Treated water tank /Central
monitoring basin (CMB) & Service Water tank either by gravity or pumping.
Provision for clarified water shall also be kept in service water tank. Sludge
from the tube settlers/lamella clarifiers shall also be led to the common sludge
pit provided.
5) One (1) number of RCC treated water tank/CMB in twin section with common
sump for collection of treated water. Capacity of each section shall be suitable
for storing 60 minutes of discharge from one settlers/lamella. Treated Service
water transfer pumps shall be provided as specified elsewhere for plant
service water network etc.
6) Suitable oil skimmers shall be provided in the waste service water sump so
that oil impurities floating on the sump is skimmed and collected in a tank

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located over ground. Facility shall be provided to collect free oil from this
sump to a MS oil drum of 200 litre capacity.
7) A Portable oil centrifuge (Trolley mounted) of suitable capacity shall be
provided to collect and purify the oil of the Waste Service Water System.
D. TUBE SETTLER/ LAMELLA CLARIFIERS
1) Two (2) (2x50%) numbers of Lamella Clarifier/tube settlers of capacity to
match with discharge capacity of working waste service water pumps shall be
provided to treat the service water, plant water collected from different areas
in the plant. Lamella Clarifier/tube settler shall be provided with one (1) flash
mixer and Flocculation Chamber (RCC construction) at its upstream. Flash
mixer shall provide minimum one (1) minute storage at the design flow rate.
The water from flash mixer shall flow to a flocculation chamber and from the
bottom of flocculation chamber water shall flow to the Lamella Clarifier/tube
settler by gravity. The flocculation chamber shall provide 10 minute (min.)
storage at the design flow rate. Suitable mechanical stirrer driven by electric
motor through speed reducing gearbox shall be provided in each flash mixer
and flocculation chamber.
2) The Lamella Clarifiers/tube settlers units shall be designed with side water
depth of 4 M minimum. The overall area of unit shall be based on an average
flow velocity not more than 5 m 3/hr/m2. The length of the plates through which
the water flow shall not be less than 1.5 M. The plates shall be inclined by 50-
80 deg. angle to the horizontal. The material of plates shall be UV inhibited
virgin PVC. Design of the sludge removal system should be such as to reduce
loss of water during sludge blow off within 5% of rated flow.
3) The tube settlers/Lamella Clarifiers shall be of RCC and of proven design.
The tube settlers/ Lamella Clarifiers shall be circular/rectangular with distinct
tube/plate separation zones, sludge thickener zone, clear water zone and oil
skimming zone. The tube settler/Lamella Clarifiers shall be counter flow or
cross flow type. Co-flow type units are not acceptable.
4) The tube settlers/Lamella Clarifiers shall employ positive removal system of
consistent density, central sludge concentrating sump, water flushing nozzles
etc. as per the standard design of manufacturer. Sludge removal system shall
be designed to thicken the sludge to minimum 2% consistency before
disposing from separator bottom. All the pipelines carrying the sludge shall be
provided with suitable flushing connection. Angle of inclination of sludge
hopper shall be minimum 55 deg. to horizontal plane for effective collection of
sludge.
5) The tube settlers Lamella Clarifiers periphery shall have a walkway of
sufficient width along-with hand-railing and access ladders for general
inspection. However, the manual sludge valves shall be operatable from the
top of the sludge chamber through head stock and extended spindle
arrangement.
6) Suitable sampling connections shall be provided for performance monitoring.
7) To remove settled particles from the plates/tubes suitable water jet
arrangement shall be provided. Pumping and piping arrangement shall be
separately provided for this purpose. The tube/ plates shall be easily

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accessible for the cleaning purpose. The tube pack/ plates shall be placed
inside the separator such that these may be individually removed for
maintenance even when separator is operating.
8) Design Conditions for Lamella clarifiers/tube settlers:
Inlet quality Outlet quality
TSS 500 ppm (max) 10 ppm (max)
Oil content 50 ppm (max) 5 ppm (max)
E. TREATED WATER TANK CUM CENTRAL MONITORING BASIN (CMB)
1) One (1) number (in 2 sections) CMB of RCC construction shall be provided
to receive treated water of Lamella Clarifiers/tube settlers. Sizing of each
compartment of the basin will be such that enough dilution water is stored to
keep the TDS and other parameters of the treated effluent below the
permissible limit. A raw/clarified water line of suitable size shall be provided
for dilution.
2) Treated effluent conforming to the prescribed standard shall only be
recirculated & reused within the plant. There shall be no discharge outside
the plant boundary.
3) Final effluent quality monitoring station with instruments such as pH meter,
turbidity meter, flow meter, instrument for TDS measurement (conductivity
meter) etc. as shown in the tender drawing shall be provided. Any other
instruments as prescribed by SPCB/CPCB to meet statutory norms shall
also be provided by the bidder. Suitable sampling connections shall be
located near Central effluent monitoring basin.
5.00.00 TECHNICAL REQUIREMENTS OF DEMINERALISATION PLANT

5.01.00 DM PLANT (ION EXCHANGE DEMINERALISATION PLANT)
1) Each stream of DM plant (Ion Exchange process) shall comprise of Activated
carbon filter, Weak acid Cation exchanger unit, Strong acid Cation
exchanger unit, Degasser system comprising of Degasser Tower, Degasser
storage tank, Air Blowers (2x100%) per degasser tower, Weak base Anion
exchanger unit, Strong base Anion exchanger unit, Mixed bed unit along with
air blowers (2x100%) with drives, required accessories etc. Degassed water
transfer pumps (3x100%) shall be provided.
2) Regeneration facility shall comprise of Acid and Alkali bulk Storage facility,
Chemical unloading pumps, Alkali & Acid preparation/measuring tanks,
Chemical Dosing system Regeneration pumps etc. shall be provided as per
follows:
a) Bulk acid storage tank (HCl-30-33% Conc.): Minimum three (3) numbers
to hold one (1) month requirement of acid for regeneration of all operating
DM streams operated at its rated capacity, with specified service cycle,
regeneration period and using guaranteed chemical consumption plus any
other requirements as envisaged by the contractor to be met through
these tanks.

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b) Bulk Alkali storage tank (NaOH 48% Conc.): Minimum two (2) numbers to
hold one (1) month requirement of alkali required for regeneration of all
operating DM streams operated at its rated capacity, with specified
service cycle, regeneration period and using guaranteed chemical
consumption plus any other requirements as envisaged by the contractor
to be met through these tanks.
c) Acid unloading pumps, Alkali unloading pumps, Alkali transfer cum
recirculation Pumps shall be provided.
d) Two (2) Acid Measuring Tanks shall be provided with effective capacity to
hold adequate chemical for 125% of one (1) regeneration of one (1) DM
Stream (both Cation & Mixed bed).
e) Two (2) Alkali Day Tanks shall be provided with effective capacity to hold
adequate chemical for 125% of one (1) regeneration of one (1) DM
Stream (both Anion & Mixed bed).
f) Two (2) Alkali Preparation tanks each of effective capacity of 5 Cu.m and
One (1) number Alkali Diluent Water Heating Tank of effective Capacity of
10 Cu.m shall be provided.
g) Three (3) numbers of Degassed Water Pumps (3x100%) with gross
capacity of each DM stream (minimum) and Two (2) numbers of DM
Regeneration pumps (2x100%) (1W+1S) shall be provided.
h) In addition to regeneration system, a set of Brine preparation tank (1) and
brine transfer pumps (2x100%) for pumping brine solution to Anion
exchanger vessels to facilitate removal of organics as and when required
shall be provided.
i) Neutralizing waste disposal system (DM plant) - All DM plant (Ion
Exchange/RO) effluent drains shall be connected to one (1) number of
RCC Neutralization pit (in two (2) sections) with acid/alkali resistant lining.
Each section of the pit shall hold 150% of waste water generated during
regeneration of UF, RO & MB exchanger/one (1) stream of DM Plant or
150 Cu.M whichever is higher. Recycling/disposal pumps (3x100%) shall
be provided, each pump capable of evacuating the capacity of each
section of the pit within 3 hours.
j) Backwash water from AC filters, rinse waste water and fast/final rinse
waste water of Ion-Exchangers units shall be connected to the backwash
sump and same shall be led to DM clarifier.
k) First fill of filter media for AC filters, First fill of resins for all Ion Exchange
units shall be provided.
OTHER DESIGN & CONSTRUCTION FEATURES
1) All the vessel internals of activated carbon filters, Ion Exchange units and
Degasser units such as inlet distributor, regenerant distributor, under drain
system etc. shall be of proven design.
2) The valves under automatic operation of DM Plant shall be operated
pneumatically by diaphragm actuator. Valves shall be spring to close or
spring to open or double acting type as may be required by process

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consideration. The valves on effluent outlet as well as regenerant inlet of

filters and ion-exchangers shall be of spring to close (Air to open) type only.
Limit switches shall be provided for all the valves under automatic operation.
3) In case strainer-on-plate design is used for under drain system, additional
manhole shall be provided to give access below the bed plate for all units of
filters, lon Exchange Units etc.
4) All valves used with vessels shall be suitably arranged in the front in
accessible position, for manual operation in case of emergency.
5) All demineralising streams shall be designed to run continuously at its rated
capacity and simultaneously under parallel operation.
6) Activated Carbon Filters (ACF)
a) Design and Fabrication of the vessel should be according to IS: 2825
or equivalent.
b) Maximum velocity of filtration shall be 15 m/hr at design capacity.
c) The activated carbon shall meet the following requirements:
(i) Total surface area (m 2/g) : Not less than 850
(ii) Particle density (wetted in water) g/cc : 1.3-1.4
d) The selected Activated Carbon Filter (ACF) shall be able to operate
continuously for a period not less than three years without any
regeneration / activation.
e) Suitable (at least 75%) free board shall be provided over the filtering
medium below the backwash outlet nozzle and in straight portion of
vessel to facilitate backwashing.
f) Each filter shall be provided with AC filter media trap in effluent line.
Media trap shall be provided on backwash outlet line also.
5.02.00 ION EXCHANGE UNITS
1) Design and Fabrication of the vessels should be according to IS: 2825 or
equivalent.
2) Material of construction shall be mild steel with rubber lining (MSRL) and
rubber covered (RC).
3) Under drainage system shall be header lateral or strainer-on-plate type. In
case of header lateral system, header shall be mild steel "rubber lined inside
and rubber covered outside" (MSRL & RC) and lateral of polypropylene.
4) For Mixed-Bed Exchanger, separate distributor shall be provided for
influent and regenerant entry. The influent and alkali regenerant distributor
and acid regenerant distributor shall be MSRL & RC. The interface collector
& distributor shall be of suitable acid/alkali resistant material. The under
drain collector system shall be header lateral or strainer-on-plate type and
shall be adequately designed to ensure uniform distribution of flow.
5) The regenerant distributor and middle collector shall be mild steel rubber
lined inside and rubber covered outside. All internal studs /nuts/washers

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shall be of AISI 304L/SS-316 for alkali service and Hastelloy-B for acid
service.
6) At least 100% free board shall be provided over resin bed below the
backwash outlet nozzle and in straight portion of vessel to allow for
expansion during backwashing and for addition of extra resin, if required.
7) Each exchanger unit shall be provided with resin traps on treated water
outlet line. Resin traps shall also be provided both on the backwash and
regenerant outlet lines.
5.03.00 SURFACE FLOW RATE FOR ION–EXCHANGERS
The following shall be maximum surface flow rates for the various Ion-
Exchangers at the design capacity.
i) Cation unit – 35 m 3/hr/m2 (for both weak and strong Cation)
ii) Anion unit – 35 m3 /hr/m2 (for both weak and strong Anion)
iii) Mixed bed unit – 40 m 3/hr/m2.
1) In case the contractor offers both weak and strong Ion-exchange units (for
Cation and/or Anion unit), the surface flow rate for the strong ion exchange
unit(s) only may be increased as indicated below, if contractor has
adequate experience of designing Demineralisation plants of such higher
surface flow rate.
Maximum surface flow rate:-
i) Strong Cation unit – 40 m 3/hr/m2.
ii) Strong Anion unit – 40 m 3/hr/m2.
5.04.00 REGENERATION SYSTEM
1) The ion exchange resin shall be regenerated by employing optimum
regeneration level to prevent leakage of ions. Cation resins shall be
regenerated by hydrochloric acid (30-33% w/v technical grade IS: 265) and
anion resins by sodium hydroxide (48% w/v rayon grade in flakes or lye
form as per IS: 252).
2) Regeneration system should be designed such that AC filter, cation, anion
and mixed bed units of a particular stream can be regenerated
simultaneously/ separately at a time.
3) For calculation of anion capacity and silica leakage the temperature of alkali
regenerant shall be taken as 25 deg.C. Co-current or counter-current
regeneration technique shall be adopted provided the same technique of
regeneration was adopted in other plants executed by the contractor. The
chemical consumption figures must be supported by relevant published
data such as performance of the resin system and /or actual field
performances of plants using a similar technique, indicating the quantity of
chemicals required for regeneration, in particular, besides other
parameters.
4) The process calculation shall be furnished indicating the various steps of
regeneration, regeneration level employed, total and used exchange
capacity of resins in various exchangers, resin quantity provided in ion

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exchange vessel etc. The relevant resin literature & curves indicating
various parameters and exchange capacity and regeneration levels
selected shall also be furnished during detailed engineering.
5) Regeneration facilities offered shall be complete with acid/alkali measuring
tanks, pumps/ejectors for dosing of chemicals.
6) For heating of alkali diluent water, 2x50% electrical heating coil in a tank of
mild steel rubber lined construction shall be provided. Design and
fabrication of the tank should be according to technical specification for
Pressure and Storage vessel. The tank shall be sized based on 125% of the
regeneration water requirement of one anion and one mixed bed unit
7) The heaters shall be sized for heating the water from a minimum
temperature of 15 deg. C to such a temperature that a maximum
temperature 50°C can be achieved at the outlet of Alkali ejector. The
duration of filling and heating the tank shall not be more than four hours.
5.05.00 ION EXCHANGE RESIN
1) Cation and anion resin shall be of reputed make and must have been in use
in demineralising plants capable of producing water of quality as specified or
better, for a period of not less than three (3) years.
2) The cation exchanger resin used in the strong cation unit and mixed bed
exchanger shall be strongly acidic, high capacity polystyrene resin in the
bead form.
3) The anion exchanger resin used in strong anion unit & mixed bed shall be
strongly basic, high capacity resin (Type-I) in bead form. The anion resin
shall be able to withstand a temperature of 60 deg. C (minimum)
continuously. Type-II anion resin shall not be accepted. Strong Base Anion
resin (or weak base Anion in case of hookup) shall be MACROPOROUS
type only.
4) Weak & strong resins may be regenerated in thoroughfare. Weak and strong
resins contained in same vessel will not be accepted.
5) DM water chains shall be designed in such a way that any chain can be
regenerated without the necessity of other chain being put into operation.
5.06.0 0 WASTE WATER NEUTRALIZING ARRANGEMENT (DM plant)
1) The demineralising plant shall be designed in such a way that the
regenerant effluent is self neutralising. Provision shall however be made to
dose acid, alkali and lime to neutralise the effluent, whenever required
during operation. One (1) no. of twin compartment RCC pit for waste
neutralization (N-pit) shall be provided. Effluent disposal pumps shall be
provided for recirculation as well as disposal of waste.
2) Suitable proven agitation system (e.g. air agitation/venturi mixing etc.) shall
be provided for proper mixing and maintaining uniform pH value of the
waste water in addition to recirculation system.
5.07.00 ULTRA FILTRATION SYSTEM (POLISHING UF)
The UF system provided for removal of colloidal silica (non-reactive) at the
downstream of MB units shall include, but not be limited to the following:

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1) Two (2) UF Feed tanks of capacity as specified in the datasheet to collect

demineralized water from the Mixed Bed Vessels for removal of colloidal
silica through the Polishing UF skids.
2) Three (3) (2W+1S) UF Feed Pumps of horizontal centrifugal type to pump
water from the UF Feed tank through the polishing UF skids for removal of
colloidal silica and collection of this filtered water in the DM water Storage
tanks.
3) Ultra-filtration (UF) system complete with all equipment and components
except storage tanks shall be installed on skid(s). The exact number of
ultrafiltration modules shall be decided by the Bidder.
4) The system shall be designed to allow multiple starts and stops without
affecting the service life of the membranes. The system may experience
extended periods of no flow. System design shall protect the system
against periods of no flow as recommended by membrane
manufacturer.
5) Provisions for local grab sampling points shall be available at various points
throughout the system to monitor UF performance. Minimum sample points
with sample valves shall be provided on the UF system for, but not limited
to:
i)UF feed
ii)Strainer backwash
iii) UF permeate water
iv)UF backwash
v)UF neutralized backwash water
6) Commercially proven hollow-fiber, high volume pressurized type UF
membranes of Polysulfone, Poly Vinylidene Di Fluoride (PVDF) or Poly
Ether Sulfone (PES) with spiral glass outer wraps shall be supplied. Gross
maximum design flux rate shall not be more than 60 l/m2/h. Filtration
direction may be either Out-to-In or In-to-Out. Minimum design UF recovery
shall be at least 92% of the influent with a colloidal silica rejection of not less
than 99.5%. Maximum Membrane pore size shall be 10000 Dalton MWCO
(Molecular weight cut off).
7) Provisions to check the integrity of the membranes shall be provided
in accordance with ASTM D 6908-06 Standard Practice for Integrity
Testing of Water Filtration Membrane Systems (Pressure Decay/Hold Test).
In the event of fiber breakage, the affected module shall be easily
identifiable on the Rack through use of clearly visible inspection window built
into the filtrate discharge pipe.
8) An on-line membrane flushing system shall be provided to flush the UF
membranes prior to shutting down.
9) Skid mounted Membrane cleaning system, CIP and chemically enhanced
backwashing (CEB) systems, as applicable shall be provided. Chemicals
like sodium hypochlorite, sodium hydroxide and hydrochloric acid shall be
used for cleaning/backwashing.

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10) CIP system shall be capable of being used for adding chemicals to
restore organically and inorganically fouled membranes including biocides
and membrane preservative chemicals in the event a membrane train will
be shut down for an extended period.
11) The cleaning system shall be connected to the UF trains with permanent
hard pipes.
12) Trans-membrane pressure drop shall initiate backwash of UF. During
backwashing if the differential pressure across membranes exceeds a
set point, the UF system shall be automatically shut down.
13) Filtration time (the time before backwashing is initiated), shall be
adjustable.
14) Inlet and outlet UF manifolds shall be provided with level transmitters and
on/off automatic valves to detect and vent trapped air in manifolds
and avoid hydraulic shocks to membranes.
15) UF normal and chemical enhanced backwashing frequency shall be
adjustable individually and controlled from the control system including
number of cycles before chemically enhanced backwashing is initiated. Time
duration of these backwash cycles shall also be adjustable from the control
system.
16) Spent chemicals from the chemically enhanced backwashing & CIP and all
chemical cleaning and backflushedback flushed wastewater from UF system
shall be neutralized in neutralization pit of DM plant.
17) Automatic on/off valves and filtrate flow transmitters shall be provided
to automatically conduct air integrity test of UF membrane modules.
18) After the manufacture, following tests for membrane shall be demonstrated
at membrane manufacturer’s works in the presence of Employer's
representative and contractor:
i). Bubble Point Test in one batch
ii). Integrity test (Pressure decay test/vacuum hold test) for 1 % of total
membrane population.
19) The responsibility for conducting the test (Bubble Point, Integrity) will be with
the Contractor and Contractor shall make all the arrangements for carrying
out tests at membrane manufacturer’s works. In case such test facilities are
not available at manufacturer's works, the test may be carried out at any
other test facility with the approval of Employer. All cost associated with
testing at manufacturer's works or at any other test facility shall be borne by
the contractor & shall be included in the contract price.
Integrity test shall be carried out in accordance with ASTM D 6908-06,
Standard Practice for Integrity Testing of Water Filtration Membrane
Systems (Pressure decay test/vacuum hold test) and approved test
procedure. Bidder shall submit the test procedure for Employer's approval
within two months of award.
20) Design calculations of Ultra filtration system shall be vetted by membrane
manufacturer during detailed engineering.

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21) It is not the intent to pre-select any specific manufacturer of UF membranes.

UF membranes will be accepted by the Employer strictly on their merits.
The UF membrane shall be of reputed manufacturer with adequate past
are as follows:
DowChemicals/Toray/Hydranautics/Inge/Hyflux/Koch/Norrit-
Pentair/GE/Approved Equivalent.
Above listing is by no means exhaustive, and shall not be construed to be a
recommendation for their selection for this plant. Contractor shall fully
satisfy himself as to the suitability of the membranes system selected by him
before offering it in his proposal.
5.08.00 CONTROL & OPERATION OF THE DM PLANT
1) The control & operation of various systems described below is indicative
only and the actual control & operation philosophy shall be finalized with
during detailed engineering.
2) Actual logic shall be built in the control system during detailed engineering.
Operation of the complete DM Plant (both Service cycle & regeneration
cycle) for all streams shall be through the control system.
3) Only basic type of control required is specified. The Contractor has to
submit the complete details of the system offered by him like the extent of
automation offered, operation of the complete system, logic/flow diagrams,
drives/instrument list etc.
4) The sequence startup mode shall be of the following types
i) Automatic Mode:-In this mode of operation, the sequence shall progress
without involving any action from the operator. The sequence start/stop
command shall be issued from the LVS/OWS.
ii) Semi-Automatic Mode:-In this mode of operation, once the sequence is
initialized, the step progressing shall be displayed on the LVS/OWS. But the
step execution command shall be prevented and shall be sent by the
operator via the mouse. It shall be possible to bypass and/ or simulate one
or more criteria to enable the program to proceed. This facility shall allow
the program to be executed even if some criteria are not fulfilled because of
defective switching device, etc., while the plant condition is satisfactory. All
the criteria bypassed shall be logged and displayed. It shall be possible to
put the system on the Auto-mode after operating it on semi-automatic mode
for some steps or vice-versa, without disturbance to the sequence
operation.
iii) Operator Guide Mode/Test Mode:- It shall be possible to use the
sequential control in operator guide mode/ test mode i.e. the complete
system runs and receives input from the plant and the individual push
button stations (where provided)/ mouse but its command output is
blocked. The whole program in this case shall run in manual mode. This
mode shall allow the operator to practice manual operation using step and

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criteria indications. The actual protection should remain valid during this
mode of operation also.
5) Complete DM Plant operation shall be through mimics on OWS/LVS. The
mimics shall indicate the operating status of different filters, exchange units,
pumps, tanks, valves, blowers etc. Colour coding, (as per ENGINEER’S
standard coding system which will be furnished) shall be used to
differentiate lines for different service such as normal water line, backwash
line, rinse line, acid alkali line etc.
6) The system shall have necessary safety system, locking system and
manual emergency system. The Safety system for any sequence/step shall
check the opening of the required valves and closure of remaining valves of
the plant to avoid mal operation. During automatic sequential operation, if
any pre-requisite criteria is not fulfilled or is missing for a pre-determined
time interval, the steps should not proceed further and an alarm shall be
annunciated to let the operator know that the system is blocked.
7) In case of control supply failure, valves of the stream being regenerated
shall close automatically and on restoration of supply, further sequence of
regeneration shall proceed through operator initiated command.
8) In case of failure of control system, the DM plant valves shall be operated
manually by means of manual operator of solenoid valves (as well as by
hand wheel of valves) locally.
9) Acid and alkali unloading pumps, agitators of alkali preparation tanks & day
tanks and alkali transfer pumps shall have provisions of local start also.
10) Complete stream shall be isolated automatically from SERVICE in case any
of the following take place and an alarm displayed.
11) Differential conductivity of the effluent is less or totalised flow and sodium
leakage from the cation is high.
12) Conductivity of the effluent or totalised flows from anion is high.
13) Conductivity or silica content of the effluent or totalised flow from mixed bed
is high.
14) The operation of alkali/acid inlet valves at ejectors shall be interlocked with
the availability of dilution water in the respective ejectors.
15) Common conductivity meter shall be employed for measuring conductivity
in the effluent line and rinse lines for anion and mixed bed exchangers.
During rinsing of anion and mixed bed unit, the respective analyzer shall be
connected to rinse line automatically, in the end of the rinse cycle.
16) During rinsing of mixed bed unit, the analyzer of silica shall automatically be
connected to the stream which is under regeneration to ascertain the
completion of rinsing operation.
17) Only one stream shall be regenerated at a time. However, all the streams
can be put to service simultaneously.
18) The alkali diluent heater shall be controlled by measuring the temperature
of water in the heater.

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19) For all the pumps, blowers etc. which form part of the automatic operation,
facilities through control system shall be provided for Auto/remote
manual/Local mode selection wherever specified. Wherever standby
equipments are provided, selection of the same shall be possible from the
control system. The selected standby equipments shall start automatically
in case of failure of working equipment. For, other drives which are not
involved in continuous running or automatic operation, facilities through
control system shall be provided for remote/local selection.
20) The agitators of the alkali tanks shall be interlocked with the required level
in the respective tanks.
21) All the pumps shall be interlocked with the required level in the tanks.
5.07.01 BACKWASH PIT AND PUMPING SCHEME
At a specific water level in the sump, selected pump(s) shall start and
backwash waste water shall be recycled back to the clarifiers. Upon reaching
predetermined low level, one of the operating pumps shall be stopped and
further reduction in level shall result into stoppage of all the operating pumps.
The pit level shall be available to operator and in case of very high level, the
operator shall be alerted to avoid starting of backwash/rinse operation so that
the pit do not overflow.
6.00.00 NEUTRALISATION PIT AND PUMPING SCHEME
1) At a specific water level in the sump, selected pump (s) shall start and
backwash waste water shall be recycled back to the pit and after achieving
desired pH level, the waste water shall be pumped out to Ash slurry sump &
CMB. Upon reaching predetermined low level, operating pumps shall be
stopped and further reduction in level shall result into stoppage of all the
operating pumps.
2) The pit(s) level status shall be available to operator and in case of very high
level; the operator shall be alerted to avoid starting of regeneration operation
so that the pits do not overflow.
7.00.00 DM PLANT (RO BASED PLANT)
1) Complete UF+RO+MB combination Plant (Skid mounted) shall comprise of
UF skids (3x50%), UF permeate water tanks, automatic type simplex
strainers, UF permeate transfer pumps (2W+1S), UF backwash pumps
(2x100%), CEB and CIP system complete with tanks and dosing system,
micron cartridge filters (3x50%), RO High pressure pumps (3x50%),
Complete skid mounted RO blocks (2W+1S) (3x50%), Degasser tower(s),
Degassed/RO permeate water storage tanks, RO permeate transfer pumps
(2W+1S), RO chemical dosing system consisting of anti-oxidant dosing
tanks & pumps, anti-scalant dosing tanks & pumps, RO Chemical cleaning
skid (CIP), Mixed bed (MB) exchangers (4x50%) along with regeneration
system including acid/alkali unloading Pumps (2x100%), Acid/Alkali storage
tanks, Acid measuring tanks & Acid/Alkali dosing pumps (2x100%), Reject
disposal system, pumps, blowers, interconnecting piping, fittings, valves
etc.

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2) For design purpose, minimum feed pressure at inlet of UF shall be

considered as 2.5 Kg/cm2(g).
7.01.00 REVERSE OSMOSIS SYSTEM
1) Each RO stream shall be provided with a dedicated HP pump and one (1)
HP pump shall be provided as a store stand-by. The HP pump shall be able
to discharge reject against a backpressure without the need for additional
pumping equipment. At the discharge side of the HP feed pump a pressure
control valve shall be installed to regulate the feed pressure to the
membrane assembly according to the salinity of the feed water. The HP
pump shall be designed to operate in the entire range of operation of the
feed system.
2) Brine leaving the permeate outlet connection at a pressure close to the feed
pressure shall be controlled by a flow control valve. The permeate water is
discharged to product water system where it is treated for removal of
excess CO2, correction of pH, correction of alkalinity (for Potablisation, if
applicable) etc. and stored.
3) Permeate shall be delivered to respective Degassifier thru suck-back
arrangement (as applicable)
4) Cleaning and Flushing systems shall be provided for membrane protection.
While the cleaning system facilitate cleaning of the fouled membranes and
the flushing system flushes the membranes off high TDS water with low
TDS water during shutdown operation.
5) Each RO train or stream shall be a self-contained section, with its own feed,
brine and product flow control equipment, operable thru control system.
Each train /stream shall be cleaned and treated separately, independent of
other trains/streams production. Each block (membrane assembly unit)
shall be provided with necessary valves and piping to facilitate block wise
isolation, monitoring and cleaning facility.
6) A train/stream is composed of one or more blocks (membrane assembly
unit) connected in parallel and each block comprise group of modules in
parallel. Each RO module is basically cylindrical pressure vessel containing
membrane elements. The term element means a single RO membrane
element (permeators). Each block (membrane assembly unit) shall be
provided with necessary valves and piping to facilitate block wise isolation,
monitoring and cleaning facility.
The RO skid shall contain all necessary supports, fixings and clamps
required to support the permeators, headers and related piping.
7) Each stream shall be capable of operating either independently or in
combination with the other ones. The streams shall be skid-mounted and be
furnished complete with all headers and related piping, mounted on the
skid. The skid shall contain all necessary supports, fixings and clamps
required to support the permeators, headers and related piping. The skid
shall be designed to provide ample room for servicing and monitoring the
equipment.

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8) The removal of a single permeator or a major piece of the equipment must

be possible, without removing surrounding equipment. The isolation or
removal of an individual permeator for testing or servicing shall be possible
while the RO-train is in operation, by means of flexible, self-closing
couplings.
9) Stream/train to be divided into certain number of equal blocks which
independently can operate facilitating the following advantages:
i) Repair/maintenance of permeators/pipes/valves and chemical cleaning
in a particular block can be carried out without shutdown the whole stream.
ii) For easier Performance monitoring of permeators, simpler fault
identification to render permeators replacement activities easier.
10) Turn Down Capability: One, two or all the trains shall be operable as per
requirement.
7.02.00 RO MEMBRANE
1) The Reverse osmosis membrane shall be Polyamide, spiral wound type.
The membrane shall be non-telescopic, non-flexing and leak free. Diameter
and length shall be as per manufacturer’s standard. Average flux rate shall
be less than 20 L/M2h.
2) Number of Membrane (Block) per Train shall be two or more as per design.
Number of Membranes per module shall be 6-8.
3) Fouling Allowance for design shall be considered as minimum 5% per year
and salt passage increase is minimum 10% per year. End connectors shall
be Victaulic coupling (SS) or approved equivalent.
4) The RO membranes shall be supplied from manufacturers well experienced
in RO plant design (Brackish water RO) of train/stream capacity comparable
that of this project. This shall be demonstrated by the contractor with
adequate references of his selected membrane manufacturer(s). Contractor
shall furnish design calculation of the RO plant by his preferred
manufacturer(s).
5) The membrane system process design shall be provided by the Contractor
and such calculation shall be vetted by the membrane manufacturer. The
process design shall take into consideration specified fouling allowance and
salt passage during the guaranteed (specified) life of the membrane. The
process design shall adopt to produce the specified capacity of permeate
with an average flux rate as specified. Further, all the calculations of RO
elements shall be justified with the software projections. This software shall
also be made available as part of O&M Manual for Employer’s future usage
during O&M.
6) It is not the intent to pre-select any specific manufacturer of RO membranes.
RO membranes will be accepted by the Employer strictly on their merits.
The RO membrane shall be of reputed manufacturer with adequate past

PLANT
CLAUSE NO.
are as follows:
Dow Chemicals-Filmtec / Hydronautics / KOCH / Toray / GE / Approved
Equivalent.
Above listing is by no means exhaustive and shall not be construed to be a
recommendation for their selection for this plant. Contractor shall fully
satisfy himself as to the suitability of the membranes system selected by him
before offering it in his proposal.
7) The average flux rate shall be calculated on the basis of effective membrane
area considering standard length & diameter element. Contractor shall
ensure that standard Length & diameter of membrane used for design
should be available at least three of the above mentioned manufacturers so
that during operation stage of the plant, employer may install membranes
from other manufacturers. Further, during detail engineering, the contractor
shall furnish design calculation from at least three membrane manufacturers
to confirm the availability & compatibility of alternate membranes. The
design calculation shall furnish data regarding change in parameters of the
RO plant such as design net output, recovery, energy consumption etc. in
case such alternate membranes are used later by Employer in the
Membrane Assembly supplied by Contractor.
7.03.00 PRESSURE VESSELS
1) Pressure vessels shall have a diameter and length so as to contain required
numbers standard diameter, standard length spiral wound elements.
2) Materials to be selected shall meet the following minimum requirements:
a) Membranes- As per manufacturer
b) Pressure vessels PP or proven material as per
manufacturer
c)End caps or plates Non-metallic material of proven
Reliability may also be used subject to
approval; Fliberglass epoxy as minimum
requirement
d) Segmental rings Corrosion resistant material conforming
Connectors to ASTM A312 SS-316 L or
equivalent.
3) Details of the design, fabrication, and testing requirements for the pressure
vessels shall be in accordance with ASME Section X to allow a code stamp
or meet the minimum requirements of ASME Section X.
4) Vessels shall be designed to allow membrane elements to be connected to
a permeate port at both ends of the vessel so that permeate can be taken
from either ends. The unused pressure vessel permeate port shall be
available and piped to permit probing. End closures shall be approved for
use in pressure vessel construction to the code requirements.

PLANT
CLAUSE NO.
7.04.00 HIGH PRESSURE PUMP

1) The HP feed pump (SS-316) shall be of a centrifugal type. The high-
pressure pump shall be designed not to introduce flow and/or pressure
pulsation in the feed or brine stream. The reverse osmosis system has to be
operated with fluctuating feed salinity and feed temperature. An appropriate
regulation of the feed pressure for each reverse osmosis train separately by
a corresponding design of the high-pressure pumps with VFD and
automatic feed pressure control is required.
2) Energy recovery units permeate booster pumps and associated system
may be provided as required. The Contractor shall take care of the
concentrate back pressure requirement at downstream of the energy
recovery unit as applicable.
3) Selection of parameters (Capacity & Head) of HP Pump, its drive shall take
into account requirements of membrane manufacturer and shall be
designed to deliver required parameters throughout the design life of
membrane. The power consumption to be guaranteed for the HP Pump
shall be based on its parameters at the end of guaranteed membrane life.
4) The contractor shall take care of the concentrate back pressure requirement
at downstream of the energy recovery unit.
5) The complete unit shall include the pump, motor drive and the lubrication
system on a common base plate.
7.05.00 CLEAN- IN- PLACE SYSTEM
1) The cleaning system shall be designed for cleaning and sterilizing of
minimum one train of the RO system separately.
2) The RO-plant shall be provided with fixed pipe connections. The flexible
couplings from the cleaning pipework to the RO-trains shall be reached
from the ground level or sufficient and safe facilities for easy handling of the
coupling of the permanently installed cleaning pipework at the RO-racks
and the flexible cleaning pipework of the cleaning equipment is to be
provided.
3) The cleaning system shall be of skid-mounted type and comprise all
necessary equipment for control of the necessary flow rate and pressure
during cleaning and enable the recycling of brine and product to the
cleaning tank, or alternately, the discharge of these two effluents during the
cleaning procedure.
4) The tank volume shall be sufficient to clean in minimum one RO
train/stream by utilization of only a single batch of cleaning solution.
5) Sizing considerations also shall include the minimization of batch
temperature and variation in solution concentration caused by blending
cleaning solution with displaced feedwater contained in the RO permeators.
6) One set cartridge filter (3 micron) shall be provided in the cleaning system
to prevent the reintroduction of any insoluble material into the membranes.
A temperature control system shall be provided to prevent re-circulated fluid

PLANT
CLAUSE NO.
temperature from exceeding the maximum recommended operating

temperature of the membrane.
7) The cleaning tanks shall be provided with level measurement for safe
operation i.e. tripping of cleaning system pumps under low water level.
8) For easy, safe and efficient handling of chemicals, a service platform shall
be provided if necessary. Sufficient venting equipment also is to be included
in the scope of delivery. Sufficient safeguard provisions shall be included, to
prevent the accidental over pressurization of cleaning system piping due to
inherent interconnections with high pressure RO feed and brine piping.
9) Provisions must be made for the neutralization and disposal of chemical
cleaning waste via the brine reject.
10) Two (2x100%) (1W+1S) Chemical cleaning pumps (SS-316), one (1)
Cartridge filter (Casing SS-316) shall be provided.
7.06.00 FLUSHING SYSTEM
1) Flushing system consisting flushing pumps (2x100%)(1W+1S) (SS-316)
shall be provided to enable flush-out of the RO unit stream including HP
pump with Low TDS permeate water during shut down of the stream.
2) During flushing the rinse water discharge from the permeator shall be
drained into the reject water tanks. The flushing water feed pipeline and the
drain lines shall be designed for the high flow rate that is expected during
flushing.
3) The flushing water feed lines shall be connected upstream of the each HP
pump inlet and the flushing feed line shall be provided with a motorized
flush feed valve. The shutdown program shall automatically initiate the
flushing feed valve to open and flush the RO train when required.
7.07.00 SAMPLE PANEL
a) Each RO unit/train shall be fitted with a fiberglass sample board, which shall
be mounted adjacent to the unit. The panel and supports shall have all
fiberglass constructions with a minimum 8” wide trough under the sample
cocks with 1” PVC drainpipe routed to the trenches. Sample tubing shall be
black tubing. The sample panel shall use ¼” SS sample cocks to sample the
following
i) Feed (locate on common manifold)
ii) Concentrate (locate on common manifold)
iii) Permeate (locate on common manifold)
iv) Permeate from each pressure vessel
b) Sample valves shall be SS white snap-action valves and shall be fitted with
plastic nozzles tubes as approved by the engineer.
7.08.00 DEGASSER SYSTEM
1) Degasser tower shall be designed to reduce dissolved Carbon-dioxide
(CO2) in treated water. Fill Material of degasser tower shall be
Polypropylene or equivalent. Blowers shall be provided to remove CO 2 from

PLANT
CLAUSE NO.
water. Degasser tower shall be provided with storage tank to store

degassed water. Degasser tower & degassed water tank shall be internally
rubber lined of minimum thickness of 4.5 mm and externally painted with
epoxy as defined elsewhere. Degassed water pumps shall be provided to
supply water to the downstream exchangers in the chain.
7.09.00 MIXED BED (MB) POLISHER UNITS
1) Design surface flow rate at design flow shall not be more than 35 m 3/m2/hr
2) Resins-strongly acidic and strongly basic Type-I, both the resin shall be of
high capacity polystyrene resins in bead form. Total resin bed depth shall
be 1.0 M (min)
3) Minimum two (2x100%) Air-blowers for mixed beds shall be provided.
4) Mixed Bed shall be regenerated after minimum 30 hours of operation
followed by regeneration period not exceeding 6 hours.
8.00.00 UF & RO SYSTEM (CONTROL & OPERATION PHILOSOPHY)
1) It is not the intent to specify here the complete details of the control system.
Basic type of controls required has been specified below. The contractor
shall submit the complete detail of the system offered by him like the extent
of automation offered, operation of the complete system, logic/flow
diagrams, type and details of the presentation of information, the type of
mimic, hardware details etc. along with detailed circuit descriptions.
2) Normally drawl of product water (either raw water or DM water) requirement
plant shall be from a single tank while the other tanks shall be in filling mode
from the RO streams/trains as the case may be. Operation of pumps which
draw water from the storage tanks shall be interlocked with the tank level
and /or pressure at the suction header, high pressure at the discharge
header as the case may be. The field instruments provided by Contractor
along with tanks & suction header shall be used for implementation of such
logic.
3) It shall be possible by the Operator one or more tanks for drawl mode and
other for filling mode. In auto mode, the tank (s) under drawl mode shall
switch over to filling mode at a pre-set level in tank and drawl for the plant
shall be continued from the tanks which were under filling mode. Upon
reaching high level in all the storage tanks, the running streams/trains shall
be shut-down in sequence. Similarly the low level in all the tanks shall
initiate starting of stream(s) in sequence which are under standby
mode/stopped.
4) POST TREATMENT OF RO
a) Water flow to degassers shall be interlocked with the level in degassed
water storage tanks as well as pH of permeate.
b) Degasser blowers operation shall be interlinked with the operation of
associated degasser tower. The standby blower associated with the tower
in operation shall come into operation in the event of failure of running
blower.

PLANT
CLAUSE NO.
c) The operation of pumps shall be interlocked with the level of the degassed
water tank.
d) The performance of respective degasser shall be monitored thru
measurement of conductivity & pH of product water.
5) RO SYSTEM.
a) RO plant shall be operated and controlled thru control system. All
necessary field instruments, analyzers and controls shall be provided by
Contractor. Facility for starting and stopping of pumps, selection of stream
shall be provided in the control system.
b) The system shall provide the following:
i) Alarms for high permeate conductivity of each skid, Low pH of feed
water, High pH of feed water, high feed water temperature, availability
of chemical dosing system such as low level in dosing tanks, status of
dosing pumps etc.
ii) Continuous monitoring for Feed temperature, Feed pH, conductivity of
feed water & permeate, SDI of Feed water, pressure of Feed water,
permeate & concentrate, flow of feed water, Permeate & concentrate,
residual chlorine of feed water.
c) The HP pumps shall be operated thru control system. Start/ Stop of HP
pump shall be interlocked with opening & closing of suction & discharge
valves. The pump shall start with its discharge valve closed and on
stop/trip command the discharge shall be interlocked to close before the
pump stops. Low pressure in the pump suction and high pressure in the
pump discharge shall raise an alarm and trip the pump.
d) The operation and control philosophy & instrumentation of Variable
Frequency Drive (VFD) and Energy recovery units (ERU) (if applicable)
shall be as per the recommendation of the manufacturer.
6) PERMEATE TRANSFER PUMPS.
The pump shall be provided with interlocks to trip the pump on Low
suction level. The low-pressure signal from pressure transmitter in the
discharge header shall start the standby pump, when the system is in
auto mode.
a) Motor drives provided with winding temperature measurement & bearing
temperature shall sense high & very high temperature for alarm and
tripping receptively thru control system.
b) The HP pumps and motor bearings shall be provided with vibration
monitoring for measuring vibration levels and vibration “High” and “High-
High” alarm shall be annunciated.
c) Additionally HP pump shall be tripped/shutdown under High conductivity
in the RO permeate line, high pH in the Feed water line, high feed water
temperature, low level in chemical dosing tank, high feed pressure, high
differential pressure across permeators, high residual chlorine of feed
water, high SDI in feed water and failure of flow control valve,

PLANT
CLAUSE NO.
7) The following control and instrumentation shall be provided in each of the

permeator assembly unit:
a) A pressure control valve on the pump discharge line to control feed
pressure during operation, during start-up and control salinity during
normal operation.
b) Flow control valve on the concentrate line to set the recovery and for ratio
control.
c) Conductivity analyzer in permeate and concentrate line to sense, indicate
of TDS & salt passage and to derive the recovery of the unit.
d) The RC analyzer signal shall activate an alarm and can used to shut
down the HP pump when chlorine is detected
e) A pressure element transmitter in the permeate line to measure, indicate
pressure.
f) pH analyzer in permeate and concentrate lines to sense, indicate pH
values.
g) Flow element/transmitter in the permeate line to measure, indicate and
provide analysis flow in the permeate line and provide the control signal
for the control valve in the concentrate line.
h) Flow element/transmitter in the feed line to measure feed flow.
i) Automatic drain valve/dump valve in the permeate line to provide
permeate drain when the TDS in permeate exceed the design limits.
j) Automatic valves in the feed and concentrate lines to connect a clean-in-
place and flushing system.
k) Differential pressure element/transmitter mounted with connection on the
concentrate brine and feed line to measure, indicate pressure drop in the
permeator i.e. to measure severity of fouling.
l) Local Pressure indicator in the feed, concentrate and the permeate
m) Temperature element/transmitter in the feed to measure, indicate and
analyze feed temperature.
n) Local Temperature indicators in feed line.
o) Automatic valve on the feed, concentrate and permeate line to facilitate
selection/isolation of streams/trains.
p) Sample ports on the feed, concentrate and permeate (to enable
evaluation of system performance).
q) Sample port on each pressure vessel permeate outlet to facilitate
troubleshooting.
r) Trend analysis shall be possible for various parameters being measured
thru instruments as listed above thru control system.
8) CLEAN-IN-PLACE SYSTEM
The operation of agitators/mixers of chemical tank can also be initiated
manually by means of local start/stop envisaged under DDCMIS, apart

PLANT
CLAUSE NO.
from automatic operation. (Option for local/remote control shall be selected

through OWS of the control system.) During normal operation mixing shall
be automatically started on the initiation of cleaning operation. The
cleaning system pumps shall be started during the cleaning cycle
progress. The pumps shall be provided with interlocks to trip on low level
of chemical tanks. The cartridge filter shall be provided with a differential
pressure measurement to monitor the pressure drop across the filter.
Selection of RO block/train to be cleaned shall be manual through control
system.
9) FLUSHING SYSTEM
These pumps shall be selected started and stopped either locally,
envisaged under DDCMIS or remotely thru control system (Option for local
/ remote control shall be selected through OWS of the control system.)
During normal operation pump operation shall be automatically started on
the initiation of flushing operation. Auto / manual selection switch is
provided to select the mode of operation. The pump shall be provided with
interlocks to trip the pump on Low suction level. The low-pressure signal
from Pressure transmitter in the discharge header shall start the standby
pump, when the system is in auto mode. Selection of RO block / train to be
flushed cleaned shall be shall be manual through control system.
10) SUCK-BACK (IF APPLICABLE)
The operation of suck-back shall be automatic.
9.00.00 A. UF SYSTEM
a) The control & operation of various systems described below is indicative
only and the actual control & operation philosophy shall be finalized with
b) UF plant shall be operated and controlled thru control system. All
necessary field instruments, analysers and controls shall be provided by
Contractor. Facility for starting and stopping of pumps, selection of stream
shall be provided in the control system.
c) The system shall provide the following:
i) Alarms for, High permeate SDI, availability of chemical dosing
system such as low level in dosing tanks, status of dosing pumps
etc.
ii) Continuous monitoring for pressure of Feed water, flow of feed
water & Permeate.
d) The feed pumps shall be operated thru control system. Start/ Stop of feed
pump shall be interlocked with opening & closing of suction & discharge
valves The pump shall start with its discharge valve closed and on stop/trip
command the discharge shall be interlocked to close before the pump
stops. Low pressure in the pump suction and high pressure in the pump
discharge shall raise an alarm and trip the pump.

PLANT
CLAUSE NO.
e) The operation and control philosophy & instrumentation of variable

frequency drive for UF units (VFD) (If applicable) shall be as per the
recommendation of the manufacturer.
f) Also feed pump shall be tripped/shutdown under high feed pressure, high
Differential pressure across permeators.
g) The following control and instrumentation are provided in each of the
permeator assembly unit :
1. A pressure control valve on the pump discharge line & Flow control
valve on the concentrate line to set the recovery in case the
contractor’s process envisages.
2. SDI analyzer in permeate line to sense, indicate of turbidity
3. Flow element/transmitter in the permeate line to measure, indicate and
provide analysis flow in the permeate line.
4. Flow element/transmitter in the feed line to measure feed flow.
5. Automatic drain valve/dump valve in the permeate line to provide
permeate drain when the SDI in permeate exceed the design limits.
6. Automatic valves in the feed and concentrate lines to connect CEB and
flushing system.
7. Differential pressure element/transmitter
8. Automatic valve on the feed, concentrate and permeate line to facilitate
selection/isolation of streams/trains.
9. Sample ports on the feed, concentrate and permeate (to enable
evaluation of system performance).
10. Sample port on each pressure vessel permeate outlet to facilitate
troubleshooting.
11. Trend analysis shall be possible for various parameters being
measured thru instruments as listed above thru control system.
B. FLUSHING SYSTEM
a) These pumps shall be selected started and stopped either locally
envisaged under employer’s DDCMIS or remotely thru control system
(Option for local / remote control shall be selected through OWS of the
control system.) During normal operation pump operation shall be
automatically started on the initiation of flushing operation. Auto / manual
selection switch is provided to select the mode of operation. The pump
shall be provided with interlocks to trip the pump on Low suction level.
The low-pressure signal from Pressure transmitter in the discharge
header shall start the standby pump, when the system is in auto mode.
Selection of UF block/train to be flushed cleaned shall be shall be
manual through control system.
b) Filter backwash operation shall be initiated whenever head loss across
the filter reaches preset point or after specified filtration cycle or at the
specified effluent quality of high SDI. The logic to be selected shall be
decided by Operator through control system. Upon initiation, filter

PLANT
CLAUSE NO.
backwash shall proceed automatically by opening and closure of various

valves, starting and stopping of blowers etc. putting the filter
stream/trains shall be automatic.

PLANT
CLAUSE NO.
10.00.00 (COMMON FOR BOTH OPTIONS UNLESS SPECIFICALLY MENTIONED)
NO DESCRIPTION PT-CW PT-DM System

System
Option 1 Option 2 –
– Ion UF+RO+MB
Exch. + Based
UF
Based
I INLET PIPE, CONTROL VALVES & ISOLATION VALVES
I –A) INLET PIPE
1) Size -------------- Refer Tender Drawing -----
2) Material of Construction Carbon steel
I –B) ISOLATION VALVES
1) Size ------------ Same as that of pipe size ------
2) Type --------Manually operated Butterfly

Valves---
3) Design Code -------Refer Technical Specification---
II AERATOR, STILLING CHAMBER AND INLET CHANNEL
II – Aerator PT-CW PT-DM System

A) System
Option 1 Option 2 –
– Ion UF+RO+MB
Exch. + Based
UF
Based
1) Type --------------------Cascade Type ----------

-----------
2) Number One One One
3) Material of Construction RCC RCC RCC
4) Design Flow 4000m 3/h + 250m3/h + 3% for sludge

3% for
sludge
II – Stilling Chamber

PLANT
CLAUSE NO.
B)
1) Number One One One
2) Material of Construction --------------- RCC ---------------
3) Type of Construction -----------------Circular / Rectangular --------

------

3% for
sludge
II – Inlet Channel
C)
1) Number 3 1 1
2) Material of Construction --------------- RCC -------------

3% for
sludge
II) CLARIFIERS
1) Type --------------- Circular Reactor type --------
2) Number 3 1 1
3) Design Flow (Net output) 1650 m3/h 250 m3/h 250 m3/h
4) Material of Construction ---------------------------- RCC ------------------

--------
5) Material of pipe from Inlet Carbon steel pipe encased with concrete
channel to clarifier for buried portion and externally epoxy
painted inside the clarifiers
6) Sludge Blow-off to Sludge Sump
a)Type ------------------------------- By gravity -------

-----------------------
b)Pipe material --------------- C I Class A as per IS : 1536

---------------
c) Constant Bleed ----------------------- Required -----------------

arrangement with telescope ------
device

PLANT
CLAUSE NO.
d)Flushing connection ----------------------- Required -----------------

------
7) Reaction Turbine With variable frequency drive as per Mfr.

Std.
8) Clarifier Scrapper
a) Number ------------One (1) assembly per Clarifier --

-------
b) Material of Construction ----------- Mild steel with rubber inserts ----

------
(with bitumastic paint protective coating)
c) Drive Slow speed motor driven through

reduction gear unit or variable frequency
drive as per manufacturer’s standard
9) Overflow Weir/Notch
Location To be fixed in the radial launders of

Clarifier
Material --------- Mild steel/RCC ---------

PLANT
CLAUSE NO.
NO DESCRIPTION PT-DM System PT-

Potable
Option 1 – Ion Option 2 – water
Exch. + UF UF+RO+MB System
Based Based
III) GRAVITY FILTERS
1) Type Twin Section
2) No. of filters 2 2 2
3) Design flow per 120 m3/h 150 m3/h 100 m3/h

gravity filter (net
output)
4) Maximum flow per 120 m3/h + 2% 150 m3/h + 2% 100m3/h+

gravity filter 2%
5) Material of --------------- R.C.C. ---------------

construction
6) Surface medium ----------- Anthracite/ Sand ------
7) Filter Flow rate at ----Not more than 5m3/m2/h----

max. flow rate
8) Supporting material ------------ Graded Gravel ---------
9) Air Scour Blowers
i) Number of blowers 3 Nos. (2W+1S)
ii) Type Rotary Twin lobe / centrifugal
iii) Capacity & Head of 1500m3/h (minimum) Head as required

each blower
iv) Material of
Construction
1) Casing, cover & Cast Iron IS : 210 Gr. FG 260

stator
2) Impeller / Lobe Cast Iron IS : 210 Gr FG 260
3) Shaft Carbon steel BS – 970 En-8/ANSI-I045

PLANT
CLAUSE NO.
4) Accessories Suction filler, safety valve, check valve, Base

required per frame, anti-vibratory Panels, V-belt guard and
blower foundation bolts etc.
IV) OVERHEAD FILTERED WATER STORAGE TANK (Roof of Chemical

House)
1) Number --------------One --------------
2) Material of Construction ---------------RCC-------------
3) Effective Capacity -------- 300 m³ (minimum)-------
4) Float operated level control valve
Number & Size One No. (1) same as that of line

size
Type Angular (Stem & lever operated)

rubber seated valve
a) Body & Bonnet -------------Cast Iron ------------
b) Float --------- Copper / Brass ---------
c) Stem ------------ SS-304 ----------
V) FILTERED WATER PT – DM PT – POTABLE

RESERVOIR/ SUMP/
PUMP HOUSE
1) Number of reservoirs One in two sections One in two sections
2) Material of RCC RCC

Construction of
reservoirs
3) Effective capacity of 240 m3 100 m3

each reservoir
(Including sump)
4) Filtered Water Sump
a) Number of sump One(1) One(1)
b) Material of RCC RCC

construction of

PLANT
CLAUSE NO.
sump
c) Effective Capacity Refer Tender drawing
5) Electric Monorail hoist in Filtered Water Pump house
a) Number ----------One (1) (Common)----------
b) Minimum ----------- 2T ----------

Capacity
VI) CLARIFIED WATER STORAGE TANK AND PUMP HOUSE (Above

Ground) – (PT-CW System)
1) Number of Storage One (1)

tank
2) Material of RCC with cover

Construction
3) Size (Minimum) & Not less than 500 Cu.m

Capacity of Tank
4) Size of Pump House As required
VII) SLUDGE PIT/ SUMP & PUMP HOUSE (Common for all the clarifiers
& Tube Settler/ Lamella Clarifiers)
1) Number of Sludge pits One in two sections with common sump

interconnected through valves
2) Material of RCC
Construction
3) Effective capacity of Not less than 200 Cu.m

each section
4) Sludge Pump house
a) Number One(1)
5) Air Scour Blowers 2 nos (1W+1S); 400m3/h (min) and head as

required.
IX) BACKWASH WATER PIT/SUMP & PUMP HOUSE(Common for PT-

DM & PT-Potable)
1) Number of pits One(1) in two sections with common sump

interconnected through valves

PLANT
CLAUSE NO.
2) Material of RCC
Construction
3) Effective capacity of Not less than 100 Cu.M

each section
4) Backwash water Pump house
a) Number One (1)
X) CHEMICAL HOUSE EQUIPMENT
X-1) Weighing Scales
1) Type Platform & Dial type / Electronic type
2) Number & Capacity One (1) of 0 -500 Kg & One (1) of 0-2000 Kg
X-2) Monorail hoist
1) Type Electrically operated
2) Number and Capacity Two numbers each of 1 Ton capacity
X-3) Chemical Tanks Lime Slaking Lime Solution Alum

Tanks Preparation Solution
Tanks Preparati
on Tanks
1) Number Two (2) Three (3) Four (4)
2) Material of RCC (with 2 coats of Bitumastic RCC (with

construction paint over 2 coats of primer) Acid/Alkali
resistant
tiles)
3) Effective Capacity of 24m³ at 10% 24m³ at 6% W/V 24m³ at

each tank W/V strength strength
10%W/V
strength
4) Agitator & Number Motorized with reduction gear unit ; 1 per tank
5) Dissolving Chamber ---------Required (Stainless steel Material) -------

for each tank

PLANT
CLAUSE NO.
6) Agitator shaft Material ----------------------- SS – 316--------------------------
7) Agitator Impeller ---------------------- SS – 316----------------------

Material
XI) Chlorination (ClO2) Plant
A) ClO2 Plant/ System CW System PT System
1) Capacity 2 x 75 kg/h (2W) 2 x 10 kg/h (1W+1S)
Waste Service Water

XII ) Not less than 200 Cu.m
Treatment System
A) Sumps/ Tanks Waste Service Water Sump
1) Number of service Water One in two sections with common sump

Sump /Tank interconnected through Valves
2) Capacity & Size Sump /Tank
3) Material of construction -------------------RCC--------------------
4) Oil skimmer Required, with oil drum for collection of oil
5) Waste Service Water

Refer Pump data elsewhere
Transfer Pumps
6) Oil Centrifuge Capacity as required
Tube settlers/ Lamella

B)
clarifiers
i) Numbers 2
ii) Design Flow (Net 150 m³/h for each Tube settler/ Lamella
output) Clarifier
iii) Material of RCC

Construction
iv) No of Flash Mixer One number per tube settler/Lamella

clarifiers with required agitator
v) Material of Stainless Steel SS-316

Construction of
Agitator

PLANT
CLAUSE NO.
C) Treated Service Water System
Treated Water Tank/ CMB

(Above Ground)
Number of Treated Water

One(1) in two(2) sections
Tank
Material of construction --------------------RCC ---------------
Treated Service Water

As specified
Pumps
XIII) Not used
XIV) Service Water Tank & Pump House
1) Number of Basin One (1) number in twin sections
2) Material of RCC
Construction
3) Effective Capacity 250 Cu.m

each section
4) APH Wash Water Refer Pump data elsewhere

Pumps/ Service Water
Pumps
XIV) Not used
XV) DATA SHEET OF PUMPS
XV-1) Vertical Sump Pumps
NO DESCRIPTION PARAMETERS PARAMETERS
1) Designation : Sludge Pumps Backwash Water

(Clarifiers) Pumps (Filters)
2) Location : In Clarifier Sludge In Filter Backwash

sump Sump
3) Total Number of : Three (3) (2W+1S) Three (2)

Pumps (1W+1S)
4) Guaranteed Flow of : 100 m³/h 50 m³/h

each pump

PLANT
CLAUSE NO.
5) Total head : As required. As required.

(Guaranteed)
6) Operating Speed : ------------------Max 1500 rpm-----------
7) Pumps & Drives to be : ---------------- Outdoor Duty ----------------

designed for
8) Service of duty : ------------------- Intermittent -----------------
9) Type of pump : ------Vertical, non-clog, Sump pumps ----
10) Type of Working Fluid : Sludge Water with Turbid Backwash

particle size upto water from filters
10mm
11) Type of Discharge : --------- Above Floor discharge --------

(With Separate discharge pipe in
addition to the column pipe)
12) Type of impeller : ---------------------- Open ---------------------
13) Type of lubrication : ------------------ Grease -------------------
14) Suction condition : -------------------- Submerged ----------------
15) Maximum Water level : -------- Local Finished Grade level---------
16) Operating floor level : -------Minimum 500 mm above FGL-------
17) Type of shaft coupling : ---------------Flexible / Rigid -----------------
a) Suction Bell : 2% Nickel Cast Iron, IS: 210 Grade

/Casing FG 260; S-0.1% max. P-0.15% max.
b) Impeller : ASTM A351 CF8M
c) Shaft, Shaft : --------------------- SS-410 --------------------

Sleeves
d) Shaft coupling : --------------------- SS-410 --------------------
e) Column pipe & : CS as per IS: 2062 or Eq.

Discharge Pipe
f) Shaft enclosing : ------------do ------------

tube(if

PLANT
CLAUSE NO.
applicable)
g) Stuffing box : 2% Nickel CI,IS:210 Grade FG 260;
h) Gland : 2% Nickel CI,IS:210 Grade FG 260;
i) Gland packing : -----------------TIW A ----------------
j) Gaskets : ---------- Neoprene Rubber --------
k) Bolts & nuts : SS for those coming in contact with

water and for others, material shall
be high tension carbon steel.
l) Base plate and : Carbon steel (Minimum 10 mm

Soleplate thick)
XV-2) Drainage Pumps
NO DESCRIPTION PARAMETERS
1) Designation : Drainage Pumps
2) Location : For dewatering of various pits/sumps of

WTP & ETP
3) Total Number of : Six (6)

Pumps
4) Flow of each pump : 40 M³/h
5) Total head : 20 MWC
7) Pumps & Drives to be : --------------- Outdoor Duty -----------------

designed for
8) Service of duty : ------------------- Intermittent-------------------
9) Type of pump : Submersible & Portable type
10) Type of Working Fluid : ----Drains with particle size upto 40 mm--
11) Type of impeller : ---------------------- Open -----------------------
12) Type of lubrication : ----------------Self / Grease / Oil --------------

PLANT
CLAUSE NO.
13) Material of :
Construction :
a) Casing : 2.5 % Nickel Cast Iron, IS:210 Grade

FG 260; S-0.1% max. P-0.15% max.
b) Impeller : ------------------- SS-316 ----------------
c) Shaft : ------------------- SS- 410 ---------------
d) Bolts & nuts : ------------------- SS-316 ----------------
14) Accessories to be : Suction Strainer, Trolley, Discharge

provided with each hose (atleast 30 m), Adaptors for
pump discharge flange, Level Switches/
Controllers, Water proof cables (50 m)
Lifting hook & chain etc
15) Other Technical : Refer subsection titled ”Submersible

Requirements Pumps” in Part-B of Technical
Specification
XV-3.1Vertical Wet Pit Type Pumps
NO DESCRIPTION Potable Water Potable Water

Pumps(Colony) Pumps(Plant)
1) Location : In Filtered Water In Filtered

Pump house (PT- Water Pump
Potable) house (PT-
Potable)
2) Total Number of Pumps : Two (2) (1W+1S) Two (2)

(1W+1S)
3) Guaranteed Flow of each : 75 m³/h 25 m³/h

pump
4) Total head* (Guaranteed) : 80 MWC 70 MWC
5) Operating Speed : ---------- 1500 rpm (nominal) ----------

(Maximum)
6) Pumps & Drives to be : ------------Outdoor Duty ------------------

designed for

PLANT
CLAUSE NO.
7) Service of duty : ------------------Continuous ---------------
8) Type of pump : Vertical wet pit, non-pull out type.
9) Type of Working Fluid : Filtered Water
10) Type of Discharge : ---------Above Floor discharge ---------
11) Type of impeller : ---------------Closed / Semi-open ------
12) Type of lubrication : ------------------Self water ---------------
13) Suction condition : ------------------Submerged --------------
14) Minimum Water level : ---------------------- By Bidder ------------
15) Maximum Water level : --------Local Finished Grade Level

(FGL) -----
16) Operating floor level : ---------Minimum 500 mm above FGL

---------
17) Type of shaft coupling : ----------Flexible / Rigid --------
i) Suction Bell : 2.5 %NiCI; IS:210Gr FG 260;S-

0.1%&P-0.15% max
ii) Casing / Bowl :
iii) Impeller : ASTM A351 CF8M
iv) Wearing rings (if applicable) : --As per manufacturer’s Std ---
v) Impeller Shaft, Pump & line : -----SS ASTM A 276 Gr. 410. ----
shaft
vi) Shaft coupling, Shaft : ----- SS ASTM A 276 Gr. 410 ---
Sleeves
vii) Shaft bearings : Cutless rubber with bronze retainer

for bearings below minimum water
level and Thordon type bearing for
bearings above minimum water
level.
viii) Column pipe : Fabricated steel as per IS: 2062

(minimum thickness shall not be less
than 8 mm) with 2 coats of epoxy

PLANT
CLAUSE NO.
coating inside & outside.
ix) Discharge Head : Fabricated steel as per IS:2062

(minimum thickness shall not be less
than 8 mm) or Cast Iron with 2 coats
of epoxy coating inside and outside.
x) Distance piece (if : Fabricated steel as per IS:2062

applicable) (minimum thickness shall not be less
than 10 mm) with 2 coats of epoxy
coating inside.
xi) Matching flanges : Fabricated steel as per IS:2062
xii) Stuffing box : 2.5% Ni-CI to IS:210 FG-260
xiii) Gland : 2.5% Ni-CI to IS:210 FG-260
xiv) Gland packing : Impregnated TEFLON
xv) Gaskets : Wire reinforced rubber gasket /

Neoprene rubber / Compressed
Asbestos Fiber
xvi) Bolts & nuts : Stainless steel AISI type 304/316 for
those coming in contact with water
and for others, material shall be high
tension carbon steel.
xvii) Base plate and Soleplate : Fabricated steel as per IS : 2062
xviii) Accessories to be provided : a) Companion flanges with nuts,

with each pump bolts and gaskets, Positioning
dowels, Eye bolts, lifting etc.
b) Internal piping with valves filters &
lubrication system upto and
including isolating valve etc as per
requirement.
c) Non –reverse ratchet shall be
provided as per manufacturer’s
standard practice.
24 Other Technical : Refer sub-section titled “Vertical (wet

Requirements pit) Pumps” in Part-B of Technical
Specification
*Note: Losses through the pump column and discharge elbows and
entry loss at suction & exit loss at discharge are not included in

PLANT
CLAUSE NO.
the specified Total Head and the same should be added by

Bidder to arrive at the bowl head. The Total head of pumps
specified above is equal to total pressure (including velocity
head available at the centre line of the pump discharge flange)
at pump discharge flange plus level difference between
minimum water level in the sump to the center line of pump
discharge.
(XV-4.1) – Horizontal Centrifugal Pumps
NO Designation : Clarified HVAC & Lime Lime

Water Make- FGD Slurry Dosing
up Pumps Makeup Transf Pumps
Pumps er
(if required)
Pumps
1) Location : In Clarified Water Pump Chemical House

house
2) Total Number of : Two (2) Two (2) Two Two (2)

Pumps (1W+1S) (1W+1S) (2) (1W+1S)
(1W+1
S)
3) Guaranteed : 3000 m³/h 85 m³/h 36 m³/h 36 m³/h

Flow per pump (min.)
4) Total head : As required 100 As required

(Guaranteed) MWC
5) Operating : --------------- 1500 rpm (nominal) ---------------

Speed
6) Pumps and : ------------------Outdoor Duty ------------------

drives to be
designed for
7) Service of duty : ------------------Continuous -------------------
8) Type of pump : ----------Preferably Radially Split type ----------

casing
9) Type of Working : Clarified Water Lime Lime

Fluid Solutio Solution
n (10% (6% w/v)
w/v)
10) Type of : Closed/ Semi Open Semi Open

impeller

PLANT
CLAUSE NO.
11) Type of : -----------------------Grease -----------------------

lubrication
12) Suction : -------------------Flooded suction -------------------

condition
13) Type of Shaft : ----------------Gland Packing ------------------------

Sealing
14) Type of coupling : -----------------------Flexible ---------------------

(motor & pump)
i) Casing : ----------- 2.5% Ni CI IS210 Gr FG 260 --------
ii) Impeller : ASTM A351 CF8M SS – 316
Wearing rings (if : SS – 316 SS – 316

applicable)
iii) Shaft, Shaft Sleeves : SS-410 SS-410
iv) Stuffing box : ----------- 2.5% Ni CI IS210 Gr FG 260 --------
v) Gland : ----------- 2.5% Ni CI IS210 Gr FG 260 --------
vi) Bolts & nuts : Stainless steel for those coming in contact
with water and for others, material shall be
vii) Base plate : -------------------Carbon steel -------------------
16) Accessories to be : a) Companion flanges with nuts, bolts and

provided with each gaskets, Internal piping with valves filters &
pump Instruments for sealing/ cooling/ lubrication
system upto and including isolating valve
etc,
b) Positioning dowels, drain plugs, vent valve
etc
c) Coupling guards, Eye bolts, lifting etc.
17) Other Technical : Refer sub-section titled “Horizontal Pumps” in

Requirements Part-B of Technical Specification
(XV- Designation : Treated Water Pumps

4.2)

PLANT
CLAUSE NO.
1) Location : Treated water pump house
2) Total Number of : Three (3) (2W+1S)

Pumps
3) Guaranteed Flow of : 150 m³/h

each pump
4) Total head : As required

(Guaranteed)
5) Operating Speed : 1500 rpm

(nominal)
6) Pumps and drives to : ---------------- Indoor Duty --------------

be designed for
7) Service of duty : ------------------Continuous -------------------
8) Type of pump casing : ----------Preferably Radially Split type --------
9) Type of Working Fluid : Clarified Water
10) Type of impeller : -------------Closed / Semi Open ---------
11) Type of lubrication : -----------------------Grease -----------------------
12) Suction condition : -------------------Flooded suction -------------------
13) Type of Shaft Sealing : ----------------Gland Packing ------------------------
14) Type of coupling : -----------------------Flexible -----------------------

(motor & pump)
i) Casing : ----------- 2.5% Ni CI IS210 Gr FG 260 --------
ii) Impeller : SS – 316/ASTM A351 CF8M
W earing rings : SS – 316

(if applicable)
iii) Shaft, Shaft : SS-410

sleeves
iv) Stuffing box : ----------- 2.5% Ni CI IS210 Gr FG 260 --------

PLANT
CLAUSE NO.
v) Gland : ----------- 2.5% Ni CI IS210 Gr FG 260 --------
vi) Gland packing : TIWA
vii) Gaskets : Neoprene Rubber
viii) Bolts & nuts : Stainless steel for those coming in

contact with water and for others,
material shall be high tension carbon
steel.
ix) Base plate : -------------------Carbon steel -------------
16) Accessories to be : a) Companion flanges with nuts, bolts and

provided with each gaskets, Internal piping with valves filters
pump & Instruments for sealing/ cooling/
lubrication system upto and including
isolating valve etc,
b) Positioning dowels, drain plugs, vent valve
etc
c) Coupling guards, Eye bolts, lifting etc.
17) Other Technical : Refer sub-section titled “Horizontal

Specification
(XV-4.3) – Horizontal Centrifugal Pumps – Contd
NO Designation : Service Air Pre-heater

Water Wash Water
Pumps Pumps
1) Location : In Service Water Pump house
2) Total Number of Pumps : Three (3) Two (2)(1W+1S)

(2W+1S)
3) Guaranteed Flow per pump : 150 M³/h 500 M³/h
4) Total head (Guaranteed) : 80 MWC 110 M WC
5) Operating Speed : ------------ 1500 rpm (nominal) ------
6) Pumps and drives to be : ---------------- Outdoor Duty -------------

designed for
7) Service of duty : ------------------Continuous ---------------

PLANT
CLAUSE NO.
8) Type of pump casing : ------Preferably Radially Split type ---
9) Type of Working Fluid : Clarified water/ Treated water
10) Type of impeller : -------------Closed / Semi Open --------
11) Type of lubrication : -------------------Grease -------------------
12) Suction condition : -----------Flooded suction ----------------
13) Type of Shaft Sealing : --------Gland Packing ------------------
14) Type of coupling (motor & : -----------------Flexible ---------------

pump)
i) Casing : ------ 2.5% Ni CI IS210 Gr FG 260 -
ii) Impeller : SS – 316 SS – 316
W earing rings : SS – 316 SS – 316

(if applicable)
iii) Shaft, Shaft Sleeves : SS-410 SS-410
v) Stuffing box : --- 2.5% Ni CI IS210 Gr FG 260 -----
vi) Gland : --- 2.5% Ni CI IS210 Gr FG 260 -----
x) Bolts & nuts : Stainless steel for those coming

in contact with water and for
others, material shall be high
xi) Base plate : --------Carbon steel ----------------
16) Accessories to be provided : a) Companion flanges with nuts,

with each pump bolts and gaskets, Internal
piping with valves filters &
Instruments for sealing/
cooling/ lubrication system
upto and including isolating
valve etc,
b) Positioning dowels, drain
plugs, vent valve etc
c) Coupling guards, Eye bolts,
lifting etc.

PLANT
CLAUSE NO.
17) Other Technical : Refer sub-section titled

Requirements “Horizontal Pumps” in Part-B of
Technical Specification
(XV-5) – METERING PUMPS – ALUM DOSING PUMPS
NO Designation : PT-CW System PT- DM System For Tube

Settlers
(Option-1 only)
1) Total Number of : Four (4) Two (2) Two (2)

Pumps
2) Number of : Three (3) One (1) One (1)

operating
pumps
3) Type : ---------Simplex hydraulically operated Diaphragm

type -----
4) Capacity : 1500 liters /hour 300 liters /hour 300 liters

(minimum) /hour
5) Head : As required As required As

required
6) Liquid to : --------------------------- Alum solution 10% W/V -------

handled and ----------
concentration
7) Capacity : 10 --100% of capacity manually by micrometer dial

control
8) Pump stroke : --------------------------- Maximum 100 --------------------

speed per ----------
minute
9) Material of Construction:
a) Liquid end : -------------------------------- AISI -316 ---------------------

(pump head --------
valve, valve
housing, etc),
valve spring
b) Diaphragm : ----------------------------- PTFE -----------------------------

----------
c) Packing : -------------------------------- PTFE --------------------------

------

PLANT
CLAUSE NO.
d) Shaft : ----------- Hardened steel EN8-BS-970)/ AISI-316 -

---------
10) Accessories : Pressure Dampeners, Safety Relief valves etc

required
11) Other Technical : Refer sub-section titled “Metering Pumps” in Part-B

Requirements of Technical Specification
XV-6) Vertical Sump Pumps
NO DESCRIPTION Waste Service Water Transfer Pumps
1) Location : In Waste Service Water Sump
2) Total Number of : Three(3) (2W+1S)

Pumps
3) Guaranteed Flow of : 150 M³/h

each pump

(Guaranteed)
6) Pumps & Drives to be : ---------------- Outdoor Duty --------------------

designed for
7) Service of duty : ------------------- Continuous --------------------
8) Type of pump : ------Vertical, non-clog, Sump pumps -------
9) Type of Working Fluid : Untreated drain water
10) Type of Discharge : ------------- Above Floor discharge ------------
11) Type of impeller : ---------------------- Open ------------------------
12) Type of lubrication : ------------ Grease -------------
13) Suction condition : -------------------- Submerged -------------------
14) Maximum Water level : -------- Local Finished Grade level----------
15) Operating floor level : -------Minimum 500 mm above FGL-------
16) Type of shaft coupling : --------------Flexible / Rigid -----------------

PLANT
CLAUSE NO.
a) Suction Bell : 2% Nickel Cast Iron, IS:210 Grade

/Casing FG 260; S-0.1% max. P-0.15% max.
b) Impeller : ASTM A351 CF8M
c) Shaft, Shaft : --------------------- SS-410 ---------------------

Sleeves
d) Shaft coupling : --------------------- SS-410 ---------------------
e) Column pipe, : CS as per IS: 2062 or Eq

Discharge
Pipe
f) Shaft enclosing : ------------do ------------

tube (if
applicable)
g) Stuffing box : 2% Nickel CI,IS:210 Grade FG 260;
h) Gland : 2% Nickel CI,IS:210 Grade FG 260;
i) Gland packing : --------------------TIWA ------------------
j) Gaskets : ------------- Neoprene Rubber ----------
k) Bolts & nuts : Stainless steel for those coming in

steel.
l) Base plate and : Carbon steel (Minimum 10 mm

Soleplate thick)

PLANT
CLAUSE NO.
11.00.00 OPTION I - ION EXCHANGE DEMINERALISING PLANT

DATA SHEETS
I DM PLANT STREAMS
1) Stream Capacity 110 m³/hr.
2) Number of Streams Two (2)
II Filtered Water Transfer Pumps Refer data given under Vertical

Wet Pit Pumps
III ACTIVATED CARBON FILTER
1) Type Vertical shell type with dished ends
2) Numbers required Two (2)
3) Number of units per stream One (1)
4) Design Flow per unit (Net) 110 m³ /hr
5) Guaranteed Effluent Quality Refer Subsection-IV of Part-A of

6) Period between two (Design) 24 hours

successive backwash
7) Net output between two back 2640m³

washes
8) Design surface flow at design flow 15 m3 /hr/m2

(maximum)
9) Design Pressure of Vessel 8 Kg/cm² (g)

(minimum)
10) Filter Media / Resin Activated Carbon
11) Minimum bed depth of filter media/ 1200 mm

Resin
12) Supporting material for the fill Graded gravel
13) Shell & dished end material Mild Steel as per specified code
14) Internal painting Epoxy Paint

PLANT
CLAUSE NO.
15) External painting Chlorinated Rubber Paint
16) Number of Manhole per Vessel Minimum Two (2)
17) Number of Sight windows with Minimum Two (2)

minimum clear width of 75 mm
IV ION Cation Unit Anion Unit Mixed Bed

EXCHANGE unit
R UNITS Weak Strong Weak Strong
1) Type --------Vertical shell type with torispherical dished

ends -----
2) Number of Two (2) Two (2) Two (2) Two (2) Two (2)
Streams
3) Number of -------------------One (1)------------------------

units per DM
stream
4) Design Flow 110 110 110

per unit (Net)
in m³/h
5) Guaranteed Refer Subsection-IV of Part-A of Technical

Effluent Quality Specification
6) Period 12 12 108
between two
(Design)
successive
regenerations
in hours
7) Net output 1320 1320 11880

between two
successive
regenerations
in m³
8) Design surface As specified elsewhere

flow at design
flow
(maximum)

PLANT
CLAUSE NO.
9) Resin Weakly Strongly Tertiary Strong Strongly

Acidic acidic, Ammonia base, acidic and
Carboxylic high Group Type-I, Strongly
Group capacity high basic Type-I
polystyren capacity resins.
e resin in polystyr Both resins
bead form ene of high
resin in capacity
bead polystyrene
form resins in
bead form.
10) Resin Depth
a) Minimum bed ---------------------- 1000 mm --------------- --------

depth of Resin
for Counter
current
regenerated
vessels over
bed
plate/header
lateral .
b) Minimum bed --------------------- 800 mm ---------------- --------

depth of filter
Resin for Co-
current
regenerated
vessels over
bed
plate/header
lateral .
c) Minimum ---------------------------------------------------------- 1000 mm

(Total) bed
depth of Resin
over bed
plate/header
lateral
11) Shell & dished --------------------Mild Steel as per specified code ------------
end material
12) Design -------------------- 8 Kg/cm² (g) (minimum) --------------------

Pressure of
Vessels
13) Shell (Internal) -------------------- Rubber & minimum 4.5 mm (thick) ---------
lining Material

PLANT
CLAUSE NO.
& Thickness
14) External --------------------Chlorinated Rubber Paint --------------------

painting
15) Number of --------------------Minimum Two (2) --------------------

Manhole per
Vessel
16) No of Sight -------------------- Minimum Two (2) --------------------

windows with
minimum clear
width of 75mm
17) Regeneration By HCl By NaOH By HCl &

NaOH
V DEGASSER SYSTEM
V-A DEGASSER TOWERS
1) Type Forced draft type
3) Number of units per DM stream One (1)
4) Design Flow per unit (Net) 110 M³ /hr
5) Guaranteed Effluent Quality Refer Subsection-IV of Part-A of

6) Fill Material Polypropylene or equivalent
7) Shell material Mild Steel as per specified code
8) Shell (Internal) lining Material & Rubber & minimum 4.5 mm

Thickness
9) External painting Epoxy Paint
10) Accessories Manhole for the tank Stair-case &

platform
V-B DEGASSED WATER STORAGE

TANK
1) Type Horizontal cylindrical atmospheric

with dished ends

PLANT
CLAUSE NO.
2) Design Standard (for diameter, As per BS:2594. However dished

length & thickness) ends shall be of Torispherical
type
4) Number of units per DM stream One (1)
5) Location Outdoor
6) Useful (Effective) Capacity 50 M³

Thickness
10) Accessories a) Manhole for the tank Stair-

case & platform
b) Vent, Overflow and drain
connections with required valves
V-C DEGASSED WATER Refer data given under Horizontal

PUMPS Centrifugal Pumps
V-D BLOWERS For Degasser Units For Mixed

Bed Units
1) Type Centrifugal Centrifugal/

Twin lobe
type
2) Numbers required Four (4); Two per Degasser Two (2)

unit (2 W+ 2 S)
(1 W+ 1 S)
3) Duty Continuous Intermittent
4) Location Outdoor Inside DM

plant (vessel
area)
5) Capacity of each 100% requirement of one 400 M³/h

Blower degasser tower (minimum)
6) Head As required. As required.

PLANT
CLAUSE NO.
7) Maximum Speed of 1500 rpm 1500 rpm

Blower
8) Accessories required V-belt guard etc. Suction filler,

for each Blower silencers,
(indicative) Relief valves,
, anti-
vibratory
Panels,
V-belt guard
etc.
VI ULTRAFILTRATION
(POLISHING UF at
downstream of MB
units) SYSTEM
No Description Parameters/ Data
A UF FEED TANKS (Downstream of the Mixed Bed Vessels)
1) Type Vertical Cylindrical atmospheric
2) Design Standard IS :803
3) Effective Capacity, in 100 M3

m³
4) Numbers required Two(2)
5) Location Outdoor
6) Nature of Fluid DM Water

Handled
8) Shell thickness Bottom most Course -10 mm

(minimum)
Balance Courses - 8 mm
9) Bottom Plate 10 mm
Thickness (minimum)
10) Roof Plate Thickness 6 mm

(minimum)
11) Internal Protection Solvent free epoxy coating

PLANT
CLAUSE NO.
13) Manhole Minimum 2 numbers (one on the shell and

other on the roof )
14) Accessories a) Stair-case & platform

b) Vent, Overflow and drain connections
c) Overflow seal
d) CO2 absorbers in vent line
e)Hand railing on the roof of the tank all
around the tank
15) Additional nozzle Two Numbers one of 250 NB size & another
connections for of 150 NB size at bottom level (for suction).
Employer
Two numbers one of 150 NB size & another
of 100 NB size at the top level (for future
filling).
B. UF Feed Pumps
1) Numbers Three (3), 2W+1S
2) Location Indoor (under shed)
3) Type of Pumps Horizontal Centrifugal
4) Capacity & Head As reqd.
5) Operating Speed 1500 rpm

(nominal)
6) Material of
Construction
Casing, Impeller ASTM A CF8M
Shaft, Shaft Sleeves SS 410
C. Ultrafiltration (UF) Skids
1) Nos. 2 x 50% (2W)
2) Net Recovery from UF 92%
3) Colloidal Silica
99.9% (minimum)
Rejection

PLANT
CLAUSE NO.
4) UF Treated (Filtrate) 100 m³/h + 1.05 times of (water required for

Flow per UF stream backwashing of UF membranes + chemical
preparation requirements)
5) Type of Operation Automatic Backwash
6) Type of membrane Hollow Fiber
7) Type of membrane
Horizontal/Vertical
mounting
8) Flux Rate <60 LMH
9) MOC of membranes Polysulfone/Polyether Sulfone/PVDF
10) MOC of Membrane

PVC
Housing
11) MOC of Pressure

FRP
Tubes (if required)
D Basket Strainer
1) One Working per UF Stream + One Common

Number
Standby
2) MOC SS-316
3) Size 100 Microns
4) Strainer shall be sized for rated flow of UF

Filtration Capacity
filter water pump
E CEB-1 (HCl) DOSING

SYSTEM
A) DOSING TANK
1) No. 2W
2) Capacity of each tank As required
3) MOC MSRL / FRP
B) DOSING PUMPS
1) No. 2(1W+1S)
2) Type Positive displacement

PLANT
CLAUSE NO.
3) Flow Rate, Discharge

As required
Head
4) MOC PP or SS
F) CEB-2 (NaOH)
DOSING SYSTEM
A) DOSING TANK
1) No. 2W
3) MOC FRP
4) Tank Mixer/Agitator Turbine Agitator
5) MOC of Mixer/Agitator SS-316
B) DOSING PUMPS
1) No. 2(1W+1S)
3) Flow Rate, Discharge

As required
Head
4) MOC PP
G) CEB-3 (NaOCl)
DOSING TANK
A) DOSING TANK
1) No. 2W
3) MOC MSRL / FRP
B) DOSING PUMPS
1) No. 2(1W+1S)
3) Flow Rate, Discharge As required

PLANT
CLAUSE NO.
Head
4) MOC PP
H. UF Backwash water Pumps
1) Purpose For backwashing and

CEB of UF skids
2) Type of pumps Horizontal Centrifugal
3) Number of Pumps(Working+ Standby) Two (2) (1 W + 1 S )
4) Flow Rate, Discharge Head As required
5) Maximum pump operating speed 1500 rpm
6) Pumps and drives to be designed for Outdoor Duty, Under

Shed
7) Service Duty Continuous
8) Type of pump casing As per manufacturer’s

standard
9) Type of impeller Closed / Semi-open
10) Type of lubrication Grease/oil
11) Suction condition Flooded
12) Type of Shaft ling Gland packing or

Mechanical l as per mfr
standard
13) Type of coupling (motor& pump) As per manufacturer’s

standard
14) Accessories to be provided with each pump Companion flanges with

nuts, bolts and gaskets,
Coupling guards, Eye
bolts etc as applicable.
15) Other Technical Requirements Refer sub-section titled

“Horizontal Pumps” in
Part-B of Technical
Specification

PLANT
CLAUSE NO.
16) Material of Construction
i) Casing ASTM A CF 8M
ii) Impeller ASTM A CF 8M
iii) W earing rings (if applicable) SS -316
iv) Shaft SS -410 /SS 316
v) Shaft sleeves SS – 410 /SS 316
vi) Mechanical Seal SS
vii) Bolts & nuts Stainless steel for

those coming in
contact with water
and for others,
material shall be high
viii) Base plate Carbon steel/ Cast

Iron
VI REGENERATION (CHEMICAL HANDLING / UNLOADING &

STORAGE) SYSTEM
VI-A) Chemical Unloading Pumps Acid Alkali
1) Type Horizontal Horizontal

Centrifugal Centrifugal
2) Numbers required Total- Two (2) Total- Two (2)

(1 W+ 1 S) (1 W+ 1 S)
3) Duty Intermittent Intermittent
4) Location Outdoor Outdoor
5) Capacity 15 M³/h 15 M³/h
6) Head 15 m WC 15m WC
(minimum) (minimum)
7) Maximum Speed of Blower 1500 rpm 1500 rpm

PLANT
CLAUSE NO.
1) Casing, Impeller PP SS 316
2) Wearing Rings PP SS 316
3) Shaft PP/ EN-8 SS 316
4) Shaft Sleeve PP/ Mfr std SS 316
5) Type Of Shaft Sealing Mechanical Mechanical Seal

Seal
6) Sets of Hoses with coupling & Diaphragm type Isolation Valves
Number of Sets Required Two (2) Two (2)
Length of hoses 20 m 20 m (minimum)

(minimum
)
Material of hose Chemical Chemical

resistant, UV resistant, UV
inhibited PVC inhibited PVC
7) Accessories Required for Pump Coupling guard, drain plugs, vent

valves and Y- type Strainer in
Suction pipe etc.
8) Other Technical Requirements Refer sub-section titled “Horizontal

Pumps” in Part-B of Technical
Specification
VI-B) Bulk Storage Tanks Acid Alkali
1) Type Horizontal Cylindrical atmospheric with dished

ends.
2) Design Standard (for As per BS:2594. However dished ends shall be

diameter, length & of Torispherical type
thickness)
3) Numbers required Total - Three (3) Total - Two (2)
4) Liquid to be handled HCl 30-33% Conc NaOH 48% Conc
5) Location Outdoor Outdoor
6) Useful (Effective) 50m³ each 50m³ each

Capacity

PLANT
CLAUSE NO.
7) Shell material Mild Steel Mild Steel
8) Shell (Internal) lining Rubber Lining (4.5 Rubber Lining (4.5 mm

Material & Thickness mm Thick) Thick)
9) External painting Refer Sub Section titled “Pressure and Storage

Vessels”
10) Accessories a) Manhole for tanks

b) Stair-case, Platform
d) Fume Absorbers
e) Vent, Overflow & drain connection with
required valves.
VII REGENERATION (CHEMICAL PREPARATION & DOSING) SYSTEM
VII-A) Alkali transfer cum recirculation

Pumps
1) Type Horizontal Centrifugal
2) Numbers required Total - Two (2) (1 W+ 1 S)
3) Duty Intermittent
4) Location In regeneration shed
5) Liquid to be Handled 48% NaOH
6) Capacity & Head of each Pump 15 M3/hr @ 15 m WC
7) Suction Condition Flooded
8) Maximum Pump Speed 1500 rpm
9) Type of Coupling between pump & As per manufacturer’s standard

motor drive practice
10) Type of Sealing Mechanical Seal
11) Type of Suction Strainer Y- Type
1) Casing, Impeller Stainless Steel-316
2) Wearing rings (as applicable) SS-316

PLANT
CLAUSE NO.
3) Shaft, Shaft Sleeves SS-410
13) Accessories Required for Pump Coupling guard, drain plugs, vent
valves and Y- type Strainer in
Suction pipe etc
VII-B) Tanks / Vessels Acid Alkali Alkali Day Tank

Measuring Preparation
Tank Tank
2) Numbers required Two (2) Two(2) Two (2)
3) Liquid to be HCl NaOH NaOH

handled
4) Minimum 2 M³ or to 5M³ 2 M³ or to hold

(Effective) hold adequate adequate
Capacity chemical for chemical for
125% of one 125% of one
regeneration regeneration of
of one Stream one Stream
(both Cation (both Anion &
& Mixed bed) Mixed bed)
whichever is whichever is
higher higher
5) Location ------------ To be designed for outdoor duty (Located

under a roof without side walls) -----------
6) Shell material --------- Mild Steel as per specified code --------
7) Shell (Internal) ---------Rubber & minimum 4.5 mm ---------

lining Material &
Thickness
8) External painting ---------Chlorinated Rubber Paint ---------
9) Material of Not applicable SS -316 SS -316

Dissolving basket
10) Number of Not applicable Motor driven with reduction gear

Stirrers/agitator unit ; One per tank

PLANT
CLAUSE NO.
11) Accessories
a) Vent, Overflow & --------------------------- Required --------------------------

drain Connections
with valves
b) Other Accessories Fume ----------- CO2 absorbers --------------

absorbers
VII-C) Tanks / Vessels AC Filter for Alkali Alkali Diluent Water Heating
–Contd. Tank
1) Type Vertical Cylindrical Pressure vessel with dished ends
2) Numbers One (1) One (1)

required
3) Liquid to be NaOH Hot Water

handled
4) Type of Heater Not Applicable Electric (2 x 50%)
5) Location To be designed for outdoor duty (Located under a roof

without side walls)
6) Capacity 10 M³/h (Design flow 10 M³ excluding dished ends

rate) volume
7) Design surface 15 m3/h/m2 Not applicable (NA)

flow
8) Design ------------------ 8 kg/cm² (minimum) ------------------

Pressure of
Vessel
9) Filter media Activated carbon NA
10) Minimum bed 1000 mm NA

depth
11) Supporting Graded gravel NA

material for fill
12) Shell material --------- Mild Steel as per specified code --------
13) Shell (Internal) Epoxy Rubber & minimum 4.5 mm

lining/painting thickness

PLANT
CLAUSE NO.
Material
14) External ---------Chlorinated Rubber Paint ---------

painting
15) Accessories Manhole, hand holes, Vent, Overflow & drain

Vent, & drain connection with required
connection with valves.
required valves.
VII-D) Dosing Acid Alkali

Ejectors
1) Numbers Two each of 100% capacity; Two each of 100% capacity;

required One for Cation and One for One for Anion and One for
Mixed Bed Mixed Bed
2) Capacity Capable of meeting Capable of meeting

of each regeneration requirement of regeneration requirement of
ejector respective cation / MB unit. respective cation / MB unit.
3) Material ------------------ Carbon steel ebonite lined ------------------

of
constructi
on
VIII) NEUTRALISING SYSTEM
VIII-A) Neutralising Pit
1) Number One in two Sections
2) Material of Construction R.C.C
3) Effective Capacity of each 150m3/hr

section
4) Corrosion Protection Acid/Alkali proof chlorinated, painted &

rubber lined.
VIII-B) Waste Recirculation cum Disposal Pumps
1) Location Near Neutralisation Pit
2) Type of Pumps Horizontal centrifugal single stage with

priming system
3) Total Number of Pumps Three (1Working+ 1 Standby + 1 Maint.

Spare)

PLANT
CLAUSE NO.
4) Liquid to be Handled DM Plant Regeneration waste
5) Pumps and drives to be For Outdoor duty

designed
6) Suction condition Suction from priming chamber /

submerged (suction from pit)
7) Guaranteed Flow of each Not less than 75 m3/h

pump
8) Total head (Guaranteed) 60 MWC (min)
9) Maximum pump Speed 1500 rpm (nominal)
10) Type of pump casing Preferably Radially Split type
11) Type of impeller Closed / Semi Open
12) Type of lubrication Grease
13) Type of Coupling (pump & As per manufacturer’s standard practice

motor)
14) Type of Shaft Sealing Mechanical Seal
Casing Rubber lined, Cast iron IS : 210 Grade

FG 260
Impeller Rubber lined, Cast iron IS : 210 Grade

FG 260
Wearing rings SS - 316

(if applicable)
Shaft SS - 410
Shaft sleeves SS – 410
Mechanical Seal As per manufacturer’s standard suiting to

the liquid being pumped
Bolts & nuts SS for those coming in contact with


PLANT
CLAUSE NO.
Base plate Carbon steel (Epoxy coated)
16) Accessories to be provided a) Companion flanges with nuts, bolts

with each pump and gaskets, Internal piping with
valves filters & Instruments for
sealing/ cooling/ lubrication system
upto and including isolating valve etc,
b) Coupling guards, Eye bolts, lifting etc.
17) Other Technical Refer sub-section titled “Horizontal

Specification
VIII-C Chemical (Lime) Tanks For Neutralization
1) Numbers required One
2) Type of construction RCC
3) Effective Capacity 2 M³
4) Inside protection Epoxy
5) Dissolving basket Material SS - 316.
6) Agitator SS-316 Construction; Motor driven with

reduction gear unit; This shall have two
sets of blade mounted on single shaft.
7) Accessories To be provided with platform as required,

overflow, drain etc.
IX BACKWASH WATER & RINSE WASTE (From filters& exchangers)

WATER COLLECTION & RECYLING SYSTEM
IX-A Back Wash Waste water Collection Pit & Sump
1) Number One (Twin sections) with a common

sump
2) Material of construction R.C.C. with Acid / Alkali proof lining
3) Effective capacity of both the 150 m³

sections and common sump
4) Corrosion Protection for gates Acid/Alkali proof chlorinated paint &

rubber lined.

PLANT
CLAUSE NO.
IX-B) Back Wash Waste Water Recirculation cum disposal pump (Vertical
Sump Pumps)
NO DESCRIPTION Backwash Water Pumps
1) Location : In Filter Backwash Sump
2) Total Number of Pumps : Two (2)
3) Number of operating pumps : One (1)
4) Number of stand by pump : One (1)
5) Guaranteed Flow of each pump : Not less than 75 m3/h
6) Total head : As reqd
7) Operating Speed : ------------- Max 1500 rpm-----------
8) Pumps & Drives to be designed : ------------ Outdoor Duty -------------

for
9) Service of duty : ---------- Continuous --------------
10) Type of pump : -Vertical, non-clog, Sump pumps --
11) Type of Working Fluid : -Drains with particle size up to 40

mm ---
12) Type of Discharge : ----- Above Floor discharge ---------
13) Type of impeller : ------------ Open ---------------------
15) Suction condition : --------- Submerged ------------
16) Maximum Water level : -------- Local Finished Grade level--

----------
17) Operating floor level : ----------Minimum 500 mm above

FGL-------
18) Type of shaft coupling : --------------Flexible / Rigid -----------
Suction Bell /Casing : Stainless Steel – 316

PLANT
CLAUSE NO.
Impeller : Stainless Steel – 316
Shaft, Shaft Sleeves, Shaft : Stainless Steel – 410

Coupling
Column pipe & Discharge Pipe : Stainless Steel – 316
Shaft enclosing tube (if : Stainless Steel – 316

applicable)
Stuffing box : SS
Gland : SS
Gland packing : --------------------TIWA ------------------
Gaskets : ---------- Neoprene Rubber ----------
Bolts & nuts : Stainless steel for those coming in

material shall be high tension
carbon steel.
Base plate and Soleplate : Carbon steel (Epoxy Coated)
X BRINE PREPATION & PUMPING SYSTEM
X-A Brine Solution Preparation Tank
1) Number One
2) Material of construction Mild steel (Internally rubber lined and

externally painted with epoxy paint)
3) Effective Capacity 3 m³
4) Dissolving basket Material SS -316.
5) Agitator Motor driven with reduction gear unit

SS-316 Construction.
This shall have two sets of blade
mounted on single shaft.
6) Accessories To be provided with platform, ladder,

manhole, overflow, drain etc.

PLANT
CLAUSE NO.
X-B Brine Solution Transfer Pumps
1) Number Two (1 Working +1 Standby)
2) Type of Pump Horizontal Centrifugal
3) Fluid Handled Brine (Solution of NaCl and NaOH)
5) Capacity 10 M³/h
6) Head 15 m WC (minimum)
8) Material of Construction of SS -316 with Mechanical Seal

pump components
XI DM WATER STORAGE
TANKS
3) Size of Each Tank 16 m (diameter) x 10.5 m (Ht)
5) Location Outdoor
7) Shell thickness (minimum) Bottom most Course -10 mm

Balance Courses – 8 mm
8) Bottom Plate Thickness 10 mm

(minimum)

(minimum)
12) Manhole Minimum 2 numbers (one on the shell

PLANT
CLAUSE NO.
and other on the roof )

connections
c) Overflow seal
d) CO2 absorbers in vent line
e) Hand railing on the roof of the tank
all around the tank
14) Additional nozzle connections Two Numbers one of 250 NB size &
for Employer another of 150 NB size at bottom level
(for suction).
Two numbers one of 150 NB size &
another of 100 NB size at the top level
(for future filling)
XII– HORIZONTAL CENTRIFUGAL PUMPS
XII– HORIZONTAL CENTRIFUGAL PUMPS- Contd
NO DESCRIPTION Degassed DM DM Makeup Boiler Fill

Water Regenerat Pump Pumps
Pumps ion pump
1) Location Near In DM Water Pump House located near

Degasser DM Tank area
Units
2) Working Fluid De-

cationised
water
3) Total Number of Three (3) Two(2) Three(3) Two (2)

Pumps
4) Number of Two (2) One(1) Two(2) One (1)

operating
pumps
5) Number of One (1) One (1) One (1) One (1)

stand by pump
6) Guaranteed 110 M3/hr 40 M3/hr 100 M3/hr 175 M3/hr

Flow of each
(minimum)
pump

PLANT
CLAUSE NO.
7) Total head As required. As 70 m WC 150 MWC

(Guaranteed) required.
8) Operating ----------------------- 1500 rpm (nominal) ---------------------

Speed
9) Pumps and -------------------------- Outdoor duty ------------------------

drives to be
designed for
10) Service of duty -------------------------- Continuous ------------------------
11) Type of pump ------------ Preferably Radially Split type -----------------

casing
12) Type of impeller ------------------ Closed / Semi Open -------------------------
13) Type of ------------------------ Grease -------------------------------

lubrication
14) Suction --------------------- Flooded suction -----------------------

condition
15) Type of Shaft ----------------- Mechanical Seal ---------------------------

Sealing
16) Type of --------- As per manufacturer’s standard practice -------

coupling
(motor& pump)
i) Casing, -------------------------- ASTM A CF 8M -----------------------

Impeller -----
ii) W earing rings -------------------------- SS -316 ----------------------------

(if applicable)
iii) Shaft -------------------------- SS -410 ----------------------------
iv) Shaft sleeves -------------------------- SS – 410 ----------------------------
v) Mechanical As per manufacturer’s standard suiting to the liquid

Seal being pumped
vi) Bolts & nuts Stainless steel for those coming in contact with
water and for others, material shall be high

PLANT
CLAUSE NO.
vii) Base plate ---------- Carbon steel (Epoxy painted) --------------
18) Accessories to a) Companion flanges with nuts, bolts and gaskets,

be provided Internal piping with valves filters & Instruments for
with each pump sealing/ cooling/ lubrication system upto and
including isolating valve etc,
b) Coupling guards, Eye bolts, lifting etc.
19) Other Technical Refer sub-section titled “Horizontal Pumps” in Part-B of

Requirements Technical Specification
XIII DESCRIPTION PARAMETERS
Designation : FILTERED WATER SUPPLY PUMPS
1) Location : In Filtered water pump house
2) Total Number of : Three (3)

Pumps
(One for each of the two streams and one common
standby)
3) Number of : One (1)

operating
pumps per
stream

stand by pump
5) Guaranteed : 110 m³/h

Flow of each
pump
6) Total head : As required.

(Guaranteed)
(Refer Note - 1 below)
7) Operating : --------- 1500 rpm (nominal) ---------

Speed
(Maximum)
8) Pumps & Drives : ---------------- Outdoor Duty -----------------

to be designed
for
9) Service of duty : ----------------- Continuous ------------------

PLANT
CLAUSE NO.
11) Type of : Filtered Water

Working Fluid
12) Type of : ------------------------- Above Floor discharge -----------

Discharge
13) Type of impeller : ---------------------------Closed / Semi-open ---------------

-
14) Type of : ------------------------------ Self water ------------------------

lubrication ----
15) Suction : ---------------------------------- Submerged ------------------

condition --------
16) Max Water level : --- Local Finished Grade Level (FGL) --
17) Operating floor : ----- Minimum 500 mm above FGL ----------------

level
18) Type of shaft : --------------------------Flexible / Rigid -----------------------

coupling -
i) Suction Bell : --------------2% Nickel Cast Iron, IS:210 Grade

FG 260; S-0.1% max. P-0.15% max ------------
--.
ii) Casing / Bowl : --------------2% Nickel Cast Iron, IS:210

Grade FG 260; S-0.1% max. P-0.15% max. --
------------
iii) Impeller : ------ASTM A351 CF8M ----
iv) W earing rings : SS–316 (for SS impeller) or bronze as the

(if applicable) case may be
v) Impeller : ---------------SS ASTM A 276 Gr. 410. ---------------

Shaft, Pump
& line shaft
vi) Shaft : ------- SS ASTM A 276 Gr. 410 -----------------------

coupling
vii) Shaft sleeves : -----------SS - ASTM –A 276 – 410 -------------------
viii) Shaft : Cutless rubber with bronze retainer for

bearings bearings below minimum water level and
Thordon type bearing for bearings above

PLANT
CLAUSE NO.
minimum water level.
ix) Column pipe : Fabricated steel as per IS: 2062 (minimum

thickness shall not be less than 8 mm) with 2
coats of epoxy coating inside & outside.
x) Shaft : -------------------Not applicable ----------------------

enclosing
tube
xi) Discharge : Fabricated steel as per IS:2062 (minimum

Head thickness shall not be less than 8 mm) or
Cast Iron with 2 coats of epoxy coating inside
and outside.
xii) Distance : Fabricated steel as per IS:2062(minimum

piece (if thickness shall not be less than 10 mm) with
applicable) 2 coats of epoxy coating inside.
xiii) Matching : ------ Fabricated steel as per IS:2062 -------------

flanges
xiv) Stuffing box : ------------- 2.5% NI-CI to IS:210 FG-260 -----------
xv) Gland : ---------2.5% NI-CI to IS:210 FG-260 -------------
xvi) Gland : ----------- Impregnated TEFLON ----------------------

packing
xvii) Gaskets : Wire reinforced rubber gasket / Neoprene

rubber / Compressed Asbestos Fiber
xviii) Bolts & nuts : Stainless steel AISI type 304/316 for those
coming in contact with water and for others,
material shall be high tension carbon steel.
xix) Base plate : ----------- Fabricated steel as per IS : 2062 ------

and
Soleplate
20) Accessories to : a) Companion flanges with nuts, bolts and

be provided gaskets, Positioning dowels, Eye bolts, lifting
with each pump etc
b) Internal piping with valves filters & Instruments
for sealing/ cooling/ lubrication system upto and
including isolating valve etc as per requirement.
c) Non –reverse ratchet shall be provided as per
manufacturer’s standard practice.

PLANT
CLAUSE NO.
21) Other Technical : Refer sub-section titled “Vertical (wet pit) Pumps” in
Requirements Part-B of Technical Specification
Notes :
1) Losses through the pump column and discharge elbows and entry loss at
suction & exit loss at discharge are not included in the specified Total Head
and the same should be added by Bidder to arrive at the bowl head. The
Total head of pumps specified above is equal to total pressure (including
velocity head available at the centre line of the pump discharge flange) at
pump discharge flange plus level difference between minimum water level in
the sump to the center line of pump discharge.
2) Bidder to provide forced water lubrication pumps for these applications near
the respective Pump house. Shaft enclosing tube shall be applicable for such
design. Bidder to provide set of lubrication water pumps [Three (3) x 100%
capacity] for each set of main pumps. Each lubricating water pumps shall be
suitable for providing lubrication water for all the working pumps. In addition a
lubrication water storage tank of two hours storage shall also be provided by
the Bidder for each application.

PLANT
CLAUSE NO.
OPTION -2
12.00.00 ULTRAFILTRATION , REVERSE OSMOSIS & MIXED BED DEMINERALISING
PLANT
I DESCRIPTION PARAMETERS
Designation : UF Feed (Filter Water Supply Pumps)
1) Location : In Filtered water pump house in PT plant

area
2) Total Number of Pumps : Three(3)
3) Number of operating : Two(2)

pumps
4) Number of stand by pump : One (1)
5) Guaranteed Flow of each : 75 m³/h

pump (min.)
6) Total head (Guaranteed) : As required(Refer Note - 1 below)
7) Operating Speed : ----------1500 rpm (nominal) ---------

(Maximum)
8) Pumps & Drives to be : -------------- Outdoor Duty --------------------

designed for
9) Service of duty : ------------------ Continuous ------------
11) Type of Working Fluid : Filtered Water
12) Type of Discharge : ---------- Above Floor discharge -----------
13) Type of impeller : --------------Closed / Semi-open ------------
14) Type of lubrication : ----------------- Self water --------------------
15) Suction condition : ----------- Submerged -----------------
16) Max Water level : ---- Local Finished Grade Level (FGL) --
17) Operating floor level : ----- Minimum 500 mm above FGL ------

PLANT
CLAUSE NO.
18) Type of shaft coupling : --------------Flexible / Rigid -----------------
i) Suction Bell : --------------2% Nickel Cast Iron,

IS:210 Grade FG 260; S-0.1% max.
P-0.15% max --------------.
ii) Casing / Bowl : --------------2% Nickel Cast Iron,

IS:210 Grade FG 260; S-0.1% max.
P-0.15% max. --------------
iii) Impeller : ------ASTM A351 CF8M ----
iv) W earing rings (if : SS–316 (for SS impeller) or bronze

applicable) as the case may be
v) Impeller Shaft, Pump : ---------SS ASTM A 276 Gr. 410. --

& line shaft
vi) Shaft coupling : ------ SS ASTM A 276 Gr. 410 ----
vii) Shaft sleeves : ---------SS - ASTM –A 276 – 410 ------
viii) Shaft bearings : Cutless rubber with bronze retainer

for bearings below minimum water
level and Thordon type bearing for
bearings above minimum water
level.
ix) Column pipe : Fabricated steel as per IS: 2062

(minimum thickness shall not be
less than 8 mm) with 2 coats of
epoxy coating inside & outside.
x) Shaft enclosing tube : -----------Not applicable ------------
xi) Discharge Head : Fabricated steel as per IS:2062

(minimum thickness shall not be
less than 8 mm) or Cast Iron with 2
coats of epoxy coating inside and
outside.

PLANT
CLAUSE NO.
xii) Distance piece (if : Fabricated steel as per

applicable) IS:2062(minimum thickness shall
not be less than 10 mm) with 2
coats of epoxy coating inside.
xiii) Matching flanges : -- Fabricated steel as per IS:2062 --
xiv) Stuffing box : ---------2.5% NI-CI to IS:210 FG-260 ----
xv) Gland : -----2.5% NI-CI to IS:210 FG-260 -----
xvi) Gland packing : ------ Impregnated TEFLON -----
xvii) Gaskets : W ire reinforced rubber gasket /

Neoprene rubber / Compressed
Asbestos Fiber
xviii) Bolts & nuts : Stainless steel AISI type 304/316

for those coming in contact with
xix) Base plate and : -- Fabricated steel as per IS :2062 -

Soleplate
20) Accessories to be : d) Companion flanges with nuts, bolts

provided with each pump and gaskets, Positioning dowels,
Eye bolts, lifting etc
e) Internal piping with valves filters &
lubrication system upto and
including isolating valve etc as per
requirement.
f) Non –reverse ratchet shall be
provided as per manufacturer’s
standard practice.
21) Other Technical : Refer sub-section titled “Vertical (wet

Requirements pit) Pumps” in Part-B of Technical
Specification

PLANT
CLAUSE NO.
Notes :
1) Losses through the pump column and discharge elbows and entry loss at
suction & exit loss at discharge are not included in the specified Total Head
and the same should be added by Bidder to arrive at the bowl head. The
Total head of pumps specified above is equal to total pressure (including
velocity head available at the centre line of the pump discharge flange) at
pump discharge flange plus level difference between minimum water level
in the sump to the center line of pump discharge.
2) Bidder to provide forced water lubrication pumps for these applications near
the respective Pump house. Shaft enclosing tube shall be applicable for
such design. Bidder to provide set of lubrication water pumps [Three (3) x
100% capacity] for each set of main pumps. Each lubricating water pumps
shall be suitable for providing lubrication water for all the working pumps.
In addition a lubrication water storage tank of two hours storage shall also
be provided by the Bidder for each application.
13.00.00 ULTRAFILTRATION SYSTEM:

I) ULTRAFILTRATION (UF):
I-A)- Ultrafiltration
1) Nos. 3 x 50% (2W+1S)
2) Recovery from UF 92%
3) UF Treated (Filtrate) Flow Capacity of each UF to match with gross

capacity of RO + water required for
backwashing of UF membrane +
chemical preparation requirements plus
5% margin over the above total
requirements (Minimum 70 m³/hr.)
4) Type of Operation Automatic Back wash
5) Type of membrane Hollow Fiber
6) Type of membrane
Horizontal/ Vertical
mounting
7) Flux Rate <60 LMH

PLANT
CLAUSE NO.
8) Membrane Pore Size Not more than 0.04 micron
9) MOC of membranes Polysulfone/Polyether Sulfone/PVDF
10) MOC of Membrane Housing PVC
11) MOC of Pressure Tubes if

FRP
required
I-AI) Basket Strainer
1) Number 3W+1S
2) MOC SS-316
3) Size 100 Microns
4) Strainer shall be sized for rated flow of

Filtration Capacity
UF filter water pump
I-B) CEB-1(HCL) DOSING

SYSTEM
A) DOSING TANK
1) No. 2W
2) Capacity 500 Lit (Min)
3) MOC MSRL / FRP
B) DOSING PUMPS
1) No. 2(1W+1S)
4) MOC PP or SS
I-C) CEB-2 (NAOH) DOSING

SYSTEM
A) DOSING TANK
1) No. 2W

PLANT
CLAUSE NO.
3) MOC FRP
4) Tank Mixer/Agitator Turbine Agitator
5) MOC of Mixer/Agitator SS-316
B) DOSING PUMPS
1) No. 2(1W+1S)
4) MOC PP
I-D) CEB-3 (NaOCl) DOSING

TANK
A) DOSING TANK
1) No. 2W
3) MOC MSRL / FRP
B) DOSING PUMPS
1) No. 2(1W+1S)
4) MOC PP
II- UF PERMEATE WATER STORAGE TANKS
1) Fluid to be Stored Permeate Water produced from UF
2) Type of Tanks Vertical Cylindrical Atmospheric

PLANT
CLAUSE NO.
4) Size of Each Tank To meet the gross requirements of

simultaneous operation of RO & UF
Backwash systems,
Min. 5m (d) x 4.5m(ht.)
6) Location Outdoor
8) Shell thickness (minimum) As per IS : 803

(minimum)
10) Shell thickness(mm) Bottom most layer -10mm

Balance layers – 8mm

(minimum)
13) External Protection epoxy coating


b) Vent, Overflow and drain connections
c) Overflow Seal
d)Hand railing on the roof of the tank all
around the tank
16) Filling connection Size To be decided by Bidder.
17) Additional nozzle a) Two Numbers; one of 100 NB size &

connections for Employer another of 80 NB size at bottom level (for
suction).
b) Two numbers; one of 100 NB size &
another of 80 NB size at the top level (for
future filling)

PLANT
CLAUSE NO.
III – UF Permeate Transfer Pumps
1) Purpose To pump UF permeate to RO units via

cartridge filters
2) Type of pumps Horizontal Centrifugal (With VFD)
3) Number of Three (3) (2 W + 1 S )

Pumps(Working+
Standby)
4) Design flow (M³/hr) rate To suit the gross capacity of RO system

of each pump requirements
5) Rated Head of pump in As required.

m WC
6) Maximum pump 1500 rpm

operating speed
7) Pumps and drives to be Under Shed

designed for
9) Type of pump casing As per manufacturer’s standard
13) Type of Shaft sealing Gland packing or Mechanical seal as per

manufacturer standard
14) Type of coupling As per manufacturer’s standard

(motor& pump)
15) Accessories to be Companion flanges with nuts, bolts and

provided with each pump gaskets, Coupling guards, Eye bolts etc as
applicable.
16) Other Technical Refer sub-section titled “Horizontal Pumps”

Requirements in Part-B of Technical Specification

PLANT
CLAUSE NO.
` Material of Construction
i) Casing 2.5% Ni CI IS 210 Gr FG 260
iii) Wearing rings (if SS -316

applicable)
iv) Shaft, Shaft SS -420 /SS 316

Sleeves
v) Mechanical Seal SS
vi) Bolts & nuts Stainless steel for those coming in

steel.
vii) Base plate Carbon steel/ Cast Iron
IV – UF Backwash water Pumps
1) Purpose For backwashing and CEB of UF skids
2) Type of pumps Horizontal Centrifugal (With VFD)
3) Number of Two (2) (1 W + 1 S )

Pumps(Working+
Standby)
4) Design flow (m³/hr) rate As required

of each pump
5) Rated Head of pump in As required

m WC
6) Maximum pump 1500 rpm

operating speed

designed for

PLANT
CLAUSE NO.
13) Type of Shaft sealing Gland packing or Mechanical seal as per

mfr standard
14) Type of coupling As per manufacturer’s standard

(motor& pump)

provided with each pump gaskets, Coupling guards, Eye bolts etc as
applicable.

Requirements in Part-B of Technical Specification
17) Material of
Construction
i) Casing 2.5% Ni CI IS 210 Gr FG 260
iii) Wearing rings (if SS -316

applicable)
iv) Shaft, Shaft SS -420 /SS 316

Sleeves
v) Mechanical Seal SS
vi) Bolts & nuts Stainless steel for those coming in

steel.
vii) Base plate Carbon steel/ Cast Iron
V) Cartridge Filters
1) Fluid Handled Permeate of UF system
2) Type of Filtration unit Horizontal / Vertical type , as per layout
3) Numbers (Working + Three (3) (2 W+ 1 S)

Standby)

PLANT
CLAUSE NO.
4) Filtration Capacity of Capacity of one Cartridge filter same as

each Filter capacity of one UF
5) Filtration Efficiency 95% down to 1 microns
a) Filter Element Polypropylene (continuously wound)
b) Filter Casing & SS -316

Internals
VI) RO High Pressure Feed Pump
1) Purpose To pump filtered water at the downstream

of Cartridge filters up to the Degasser
towers through RO trains.
2) Number of pumps One(1) per RO train with a common

standby
3) Type of Pumps Horizontal Centrifugal (With VFD)
4) Design flow rate of each To suit the Gross capacity of each RO train
Pump
5) Rated Head 1.10 x (RO train Feed Pressure + frictional

loss in the system)
6) Maximum pump 1500 rpm/2900 rpm

operating speed

designed for
13) Type of Shaft sealing Mechanical
14) Type of coupling (motor& As per manufacturer’s standard

pump)

PLANT
CLAUSE NO.
15) Material of
Construction
a) Casing, Impeller ASTM A351, CF8M
b) Shaft SS-316
c) Shaft sleeves AISI 420 or eq.
d) Mechanical Seal SS
e) Wear rings SS -316
f) Sleeves ASTM A451, grade CF8M or equivalent
g) Bolting Stainless steel for those coming in

steel.
h) Base plate Carbon steel

provided with each pump gaskets, Coupling guards, Eye bolts, lifting
etc as applicable.

Requirements & sub-section titled “Reverse Osmosis
System” in Part-B of Technical
Specification
VII) RO Trains /Streams
1) Number (Working + Standby) of Three (3x50%) (2W+1S)

trains
2) Turn Down Capability One, Two or all three trains

shall be operable as per
requirement
3) Design Net Capacity of each Train 50 m³/h

(Permeate flow)
4) Gross capacity of each Train 50 m³/h + internal

consumption of RO Skids

PLANT
CLAUSE NO.
5) Membrane Assembly Unit(Block)
a) Number of Membrane (Block) One or more as per design

per Train
b) Number of Membranes per 6 - 8

module
c) Guaranteed Design Recovery Not less than 85%
d) Module
i)Internal Diameter As per manufacturer Std.
ii)Length As per manufacturer to suit

the element
e) Elements
i) Membrane type Polyamide, Spiral wound
ii) Length, Diameter As per manufacturer std
iii) Average Flux <20 L/M2h
iv) Fouling Allowance for Minimum 5% per year

design
v) Salt passage increase Minimum 10% per year
f) End connectors Victaulic coupling or

Equivalent

“Reverse Osmosis System”
in Part-B of Technical
Specification
VII-A - RO PERMEATE WATER STORAGE TANKS
1) Fluid to be Stored Permeate Water produced from RO
2) Type of Tanks Vertical Cylindrical Atmospheric
4) Size of Each Tank To meet the gross requirements of

PLANT
CLAUSE NO.
simultaneous operation of MB & RO

chemical cleaning systems, Min. 4.5m
(d) x 4.5m (ht.)
6) Location Outdoor
8) Shell thickness As per IS : 803

(minimum)

(minimum)
10) Shell thickness(mm) Bottom most layer -10mm

Balance layers – 8mm

(minimum)
13) External Protection Epoxy coating


connections
c) Overflow
e)Hand railing on the roof of the tank all
around the tank
16) Additional nozzle a) Two Numbers; one of 100 NB size &

connections for another of 80 NB size at bottom level
Employer (for suction).
b) Two numbers; one of 100 NB size &
another of 80 NB size at the top level
(for future filling)
VIII) Chemical Cleaning System
1) Chemical Tanks

PLANT
CLAUSE NO.
a) Numbers Required One (1)
b) Effective Capacity Total Piping + Volume of

one RO Train
c) Material of Construction FRP or Mild steel with 4.5

mm thick rubber lined
d) Accessories One mixer of SS-316

material per tank; Motor
driven with reduction gear
unit ;
Chemical Filling, Overflow
& drain Connections with
valves
2) Chemical Cleaning Pumps
a) Numbers Required Two (2) (1 W +1 S)
b) Type Horizontal Centrifugal
c) Design flow rate of each Pump Suitable for cleaning of one

RO train/stream at a time
d) Rated Head of pump As required
e) Material of Construction of SS 316/As per proven

wetted parts practice of RO plant
supplier
3) Cartridge filters (for chemical

cleaning)
a) Numbers Required (W + S) One(1)
b) Capacity of each filter To suit chemical cleaning

pump capacity
c) Filtering Efficiency 90% down to 5 microns
d) Filter Element Polypropylene wound

filament
e) Material of Filter Casing SS 316/As per proven

practice of RO plant
supplier

PLANT
CLAUSE NO.
IX) Flushing System
1) Flushing Pumps
a) Numbers Required (W + S) Two (2) (1 W + 1 S)
b) Type Horizontal Centrifugal
c) Design flow rate of each Pump Suitable for cleaning of one

RO train/stream at a time
d) Rated Head of pump As Required
e) Material of Construction As per proven practice of

RO plant supplier
X) Coagulant (FeCl3) Unloading cum Transfer Pumps
1) Purpose To pump Coagulant from

Tankers to Bulk Coagulant
Storage Tanks and as well
as to transfer Coagulant
from Bulk Coagulant
Storage Tanks to
Coagulant Preparation
tanks
2) Chemical to be used Ferric Chloride of 35 – 45

% concentration
4) Numbers required (Working Two (2) (1 W+ 1 S)

+Standby )
6) Design flow rate of each pump As required
7) Rated Head of pump As required
a. Casing, Impeller FRP/ PP / CPVC

PLANT
CLAUSE NO.
i) Number of Sets Required Two (2)
ii) Size of hose/ Valve 80 mm NB
iii) Length of hoses 20 meters (minimum)
iv) Material of hose Chemical resistant, UV

inhibited PVC
11) Accessories Required for Pump Coupling guard, drain

plugs, vent valves etc

“Horizontal Pumps” in Part-
B of Technical Specification
XI) Bulk Coagulant (FeCl3) Storage & Preparation Tanks
No Description Bulk Tanks Preparation Tanks
1) Purpose To store one To prepare & store one

month day requirement of
requirement Coagulant
of Coagulant
2) Chemical to handled Ferric Ferric Chloride of 10 %

Chloride of concentration
35–45%
concentration
3) Number of tanks Two (2) Two (2)
4) Design Dosage rate As required
5) Design Quantity of Total flow of DM Clarifiers

Water to be dosed
6) Capacity of each tank To store 15 To hold 12 hours

days requirement
requirement
or 20m³
whichever is
higher
7) Type of Tank Vertical (As Vertical, atmospheric;

per IS-803) or
Covered
Horizontal

PLANT
CLAUSE NO.
atmospheric
vessel (As
per BS-2594)
; Covered
8) Material of Construction MSRL MSRL/ FRP
9) Number of agitators NA One per tank
10) Shaft Material of NA SS 316 L / MS with

Agitator FRP lining
11) Impeller Material of NA SS 316 L / MS with

Agitator FRP lining
12) Accessories Manholes / Hand holes, Filling

Connection, Vent, overflow, drains,
platform, ladders etc as applicable
XII) Coagulant Dosing Pumps
1) Purpose For dosing Coagulant

solution in PT System
2) Chemical to dosed Ferric Chloride 10 %

concentration
3) Type Simplex hydraulically

operated Diaphragm type
4) Numbers required (Working Two (2) (1W+ 1S)

+Standby )
5) Duty Continuous
6) Design flow rate of each dosing To suit minimum dosage

pump rate of 15 ppm
8) Capacity control 0 --100% of capacity by

micrometer dial
9) Pump stroke speed per minute 100 maximum

PLANT
CLAUSE NO.
a) Liquid end (pump head valve, PP / FRP/ CPVC/ Rubber

valve housing, etc) ,valve spring lined steel
b) Diaphragm TEFLON
c) Packing As per manufacturer’s

Standard suiting to
Chemical
d) Shaft As per manufacturer’s

Standard suiting to
Chemical
11) Accessories Check valves, Pressure

Dampeners, Safety Relief
valves etc as required
XIII) Bulk Coagulant Aid (Polyelectrolyte) Storage & Preparation

Tanks
No Description Bulk Storage Preparation Tanks
1) Design Storage To store one To prepare & store one

Capacity to be month 12 hrs. requirement of
considered requirement Coagulant –aid
of Coagulant- solution
aid
2) Chemical to handled Polyelectrolyt Polyelectrolyte - As

e - As recommended by RO
recommende plant –0.5% solution
d by RO plant
- 100%
Solution
3) Method of storage / To be stored In Tanks

Preparation in the form of
50 Kg
Carboys
4) Number of tanks Not Two (2)

Applicable
5) Design Dosage rate ------- Minimum 2 ppm ---------
6) Design Quantity Total flow of DM Clarifiers

PLANT
CLAUSE NO.
7) Type of Tank Vertical, atmospheric; Covered
8) Material of Construction MSRL/ FRP
9) Agitator & Number One per tank
10) Agitator shaft Material SS 316 L / MS with FRP lining
11) Agitator Impeller SS 316 L / MS with FRP lining

Material

valves operating platform, ladders etc
as applicable
XIV) Coagulant Aid Dosing Pumps
1) Purpose For dosing Coagulant aid

solution in PT System
2) Chemical to dosed Polyelectrolyte solution of

0.5 % concentration
3) Type Simplex hydraulically

operated Diaphragm type

+Standby)
5) Duty Continuous
6) Design Quantity of Water to be Total flow of DM Clarifiers

dosed
7) Design flow rate of each dosing As required

pump
9) Capacity control 0 --100% of capacity by

micrometer dial
10) Pump stroke speed per minute 100 maximum

PLANT
CLAUSE NO.
a) Liquid end (pump head valve, PP / FRP/ CPVC

valve housing, etc) ,valve spring
b) Diaphragm TEFLON
c) Packing As per manufacturer’s

Standard suiting to
Chemical
d) Shaft As per manufacturer’s

Standard suiting to
Chemical
12) Accessories Check valves, Pressure

Dampeners, Safety Relief
valves etc as required
XV) Bulk Anti-Scalant Storage & Preparation Tanks
1) Design Storage To store one To prepare & store 12

Capacity to be month hrs. requirement of
considered requirement Anti-Scalant solution
of Anti-
Scalant
2) Chemical to handled As required As required
3) Method of storage / As applicable In Tanks

Preparation
4) Number of tanks NA Two (2)
5) Design Dosage rate ------- Minimum 5 ppm ---------

Material

PLANT
CLAUSE NO.

as applicable
XVI) Anti-Scalant Dosing Pumps
1) Purpose For dosing Anti-Scalant solution in RO

feed
2) Chemical to dosed Antiscalant solution of 5 %

concentration
3) Type Simplex hydraulically operated

Diaphragm type
4) Numbers required Two (2) (1 W+ 1 S)

(Working +Standby )
5) Duty Continuous
6) Design flow rate of each To suit minimum dosage rate of 5 ppm

dosing pump
8) Capacity control 0 --100% of capacity by micrometer dial
9) Pump stroke speed per 100 maximum

minute
a) Liquid end (pump PP / FRP /CPVC

head valve, valve
housing, etc) ,valve
spring
b) Diaphragm TEFLON
c) Packing As per manufacturer’s Standard suiting

to Chemical
d) Shaft As per manufacturer’s Standard suiting

to Chemical
11) Accessories Check valves, Pressure Dampeners,

PLANT
CLAUSE NO.
Safety Relief valves etc as required
XVII) Bulk Anti-Oxidant Storage & Preparation Tanks
1) Design Storage To store one To prepare & store 12

Capacity to be month hrs requirement of
considered requirement Anti-Oxidant solution
of Anti-
Oxidant
2) Method of storage / To be stored In Tanks

Preparation in the form of
50 Kg
Carboys
3) Number of tanks As required Two (2)
4) Design Dosage rate ---- To suit removal of chlorine

(Minimum 5 ppm )----

Material

as applicable
XVIII Anti-Oxidant Dosing Pumps
1) Purpose For dosing Anti-oxidant solution in RO

feed
2) Chemical to dosed Anti oxidant solution of 10 %

concentration
3) Type Simplex hydraulically operated

Diaphragm type

PLANT
CLAUSE NO.
4) Numbers required Two (2) (1 W+ 1 S)

(Working +Standby )
5) Duty Continuous
6) Design Quantity Total flow of two RO Plant Feed HP

Pumps RO units
7) Design flow rate of each To suit minimum dosage rate of 5 ppm

dosing pump
8) Rated Head of pump As required As required
9) Capacity control 0 --100% of capacity by micrometer dial
10) Pump stroke speed per 100 maximum

minute
11) Material of
Construction
a) Liquid end (pump PP / FRP /CPVC

head valve, valve
housing, etc) ,valve
spring
b) Diaphragm TEFLON
c) Packing As per manufacturer’s Standard suiting

to Chemical
d) Shaft As per manufacturer’s Standard suiting

to Chemical
12) Accessories Check valves, Pressure Dampeners,

Safety Relief valves etc as required
XIX Acid Unloading cum Transfer Pumps
1) Purpose To pump Acid from Tankers

to Bulk Acid Storage Tanks
and as well as to transfer
Acid from Bulk Acid
Storage Tanks to
Measuring tanks
2) Chemical to be used Hydrochloric Acid – 30-

PLANT
CLAUSE NO.
33% Concentration

+Standby)
6) Design flow rate of each pump As required
a) Casing PP
b) Impeller PP
c) Wearing Rings As per manufacturer’s

standard
d) Shaft PP / EN-8
e) Shaft Sleeve PP/ As per manufacturer’s

standard
10) Type of Shaft Sealing Mechanical Seal as per Mfr

Std
11) Sets of Hoses with coupling &

Diaphragm type Isolation Valves
Number of Sets Required Two (2)
Size of hose/ Valve 80 mm NB
Length of hoses 20 meters (minimum)
Material of hose Chemical resistant, UV

inhibited PVC
12) Accessories Required for Pump Coupling guard, drain

plugs, vent valves etc

“Horizontal Pumps” in Part-

PLANT
CLAUSE NO.
B of Technical Specification
XX Bulk Acid Storage & Preparation Tanks
No Description Bulk Tanks Measuring Tanks
MB RO
1) Chemical to Hydrochloric Acid of 30–33% HCl of 5%

be handled concentration concentration
2) Capacity of To store one month To prepare To prepare &

each tank requirement of Acid & store store acid for
required for MB and acid 24hrs
RO requirements requiremen requirement
(minimum 20 cum) t for one for pH control
MB
regeneratio
n
3) Number of Two (2) One (1) One (1)

tanks
4) Design Total volume to be As per Total volume

Dosage rate sized for dosing of regeneratio to be sized for
(Dosage rate 25 ppm in PT Plant n level dosing of 25
indicated are of RO (at the employed ppm in PT
minimum) upstream of for MB unit Plant of RO
Cartridge filters) plus (at the
dosage rate for upstream of
regeneration of Cartridge
Mixed Bed Ion filters)
Exchangers
5) Type of Horizontal / vertical Vertical, Vertical,

Tank atmospheric vessel atmospheri atmospheric;
c; Covered Covered
6) Material of MSRL MSRL/ MSRL/ FRP

Construction FRP
7) Accessories Manholes / Hand holes, Filling Connection, Vent,

overflow, drains, Fume absorbers, valves operating
platform, ladders etc as applicable
No Description Parameters/ Data Parameters/ Data
1) Pump Acid Dosing Pumps – Acid Dosing

Designation RO Pumps – MB (if
applicable)

PLANT
CLAUSE NO.
2) Purpose For dosing Acid solution For regeneration of

at upstream of cartridge Cation resins of
filters - RO plant Mixed Bed
Exchangers
3) Chemical to Hydrochloric Acid of Hydrochloric Acid of

dosed about 5% concentration required
concentration
4) Type Simplex hydraulically operated Diaphragm type
5) Numbers Two (2) (1W+ 1S) Two (2) (1W+ 1S)

required (W+S)
7) Design flow rate As required As per regeneration

of each dosing level employed
pump
8) Rated Head of As required As per regeneration

pump level employed
9) Capacity -- 0 -100% of capacity by micrometer dial ------

control
10) Pump stroke ----------- 100 maximum ----------------------

speed per
minute
11) Material of
Construction
a) Liquid end -------------------------- PVC --------------------------

(pump head
valve, valve
housing, etc)
,valve spring
b) Diaphragm -------------- TEFLON --------------------------
c) Packing --------------- TEFLON --------------------------
d) Shaft Hardened steel EN8-BS-970 / As per

manufacturer’s Standard suiting to Chemical
12) Accessories Check valves, Pressure Dampeners, Safety

Relief valves etc as required

PLANT
CLAUSE NO.
XXII Alkali Unloading Pumps & Alkali transfer cum recirculation

pumps
No Description Unloading Transfer cum

Pumps recirculation pumps
1) Purpose To pump a)To pump Alkali from

Alkali from Bulk Alkali Storage
Tankers to Tanks and
Bulk Alkali preparation tanks.
Storage
b) To pump alkali
Tanks.
prepared using flakes
from alkali
preparation tanks to
Bulk alkali storage
tanks
2) Chemical to be used ----- Sodium Hydroxide (48% Conc) -----
3) Type --------Horizontal Centrifugal --
4) Numbers required Two (2) Two (2) (1W+ 1S)

(Working +Standby) (1W+ 1S)
5) Duty Intermittent Intermittent
6) Design flow rate of each 15 M³/h 10 M³/hr

pump
7) Rated Head of pump As required As required
8) Maximum Pump Speed ------------1500 rpm -------
a) Casing, Impeller ---------------- SS-316 ----------------
b) Wearing Rings SS-316
c) Shaft, Shaft SS-410

Sleeves
10) Type of Shaft sealing Mechanical seal as per Mfr Std
Number of Sets Two (2) NA

Required

PLANT
CLAUSE NO.
Size of hose/ Valve 80 mm NB NA
Length of hoses 20 meters NA

(minimu
m)
Material of hose Chemical NA

resistant, UV
inhibited
PVC
12) Accessories Required Coupling guard, drain plugs, vent

for Pump valves etc

Specification
XXIII Bulk Alkali Storage Tanks & Preparation Tanks
No Description Bulk Alkali Tanks Alkali

Preparation
Tanks
1) Capacity of each tank To store one month To Prepare

requirement of Alkali alkali from
flakes
2) Chemical to handled Sodium Hydroxide of 48%

concentration
3) Number of tanks Two (2) One (1)
4) Capacity of Tank To be designed for 2 M³

design dosage rate &
design flow for one
month
5) Design Dosage rate a)For dosing in -------

(Dosage rate indicated permeate of RO for pH
are minimum) control ( minimum 5
ppm)
b)Dosage rate for
regeneration of
Mixed Bed Ion
Exchangers
6) Design Quantity of a) For permeate pH -------

Water to be dosed with control, gross

PLANT
CLAUSE NO.
alkali for estimation of capacity of all the

storage volume streams of RO to be
considered;
For MB regeneration
alkali required as per
process calculation to
be considered
7) Type of Tank Horizontal atmospheric Vertical,

vessel atmospheric;
Covered
8) Material of Construction MSRL MSRL
9) Number of agitators NA One (1)
10) Shaft Material of NA SS-316

Agitator
11) Impeller Material of NA SS-316

Agitator

Connection, Vent, overflow, drains, CO2
absorbers, valves operating platform,
ladders etc as applicable
XXIV Alkali Measuring Tanks
No Description Measuring Tanks Measuring

(for MB Exchangers) Tanks
(for RO
Plants)
1) Purpose To store alkali for To prepare &

regeneration of MB store alkali for
exchanger unit pH control of
permeate
2) Chemical to handled Sodium Hydroxide of Sodium

48% concentration Hydroxide of
5%
concentration
3) Number of tanks One (1) One (1)
4) Design Dosage rate As per regeneration Total volume

(Dosage rate indicated level employed for MB to be

PLANT
CLAUSE NO.
are minimum) unit sized for

dosing of
5 ppm in
permeate
of RO for
pH
Control
5) Design Quantity of For MB regeneration, For permeate

Water to be dosed with alkali required as per pH control,
acid for estimation of process calculation to capacity of all
storage volume be considered the trains of
RO
6) Capacity of each tank To hold alkali required To hold 12

for one regeneration of hours
one MB unit requirement
8) Number of agitators One (1)
9) Material Of Construction
Tank MSRL/ FRP
Agitator Shaft SS-316 SS-316
Agitator Impeller SS-316 SS-316

Connection, Vent, overflow, drains, CO2
absorbers, valves operating platform,
ladders etc
XXV Alkali Dosing Pumps
No Description Parameters/ Data Parameters/ Data
1) Pump Alkali Dosing Pumps – Alkali Dosing Pumps

Designation RO – MB (if applicable)
2) Purpose For dosing Alkali For regeneration

solution in permeate of Anion exchanger –
RO plant MB Exchanger
3) Chemical to Sodium Hydroxide Sodium Hydroxide

dosed solution of about 5% solution of required

PLANT
CLAUSE NO.
concentration concentration
4) Type Simplex hydraulically operated Diaphragm type
5) Numbers Two (2)(1 W+ 1 S) Two (2) (1 W+ 1 S)

required (W+S)
7) Design Quantity Total permeate flow of As per regeneration

of Water to be all RO trains/streams level employed
dosed
8) Design flow rate To suit minimum design As per regeneration

of each dosing dosage rate of 5 ppm level employed
pump
9) Rated Head of As required As required

pump
10) Capacity ---- 0 --100% of capacity by micrometer dial -----

control
11) Pump stroke ----------- 100 maximum --------------------

speed per
minute
12) Material of
Construction
e) Liquid end -------------------- SS-316 --------------------------

(pump head
valve, valve
housing, etc)
,valve spring
f) Diaphragm -------------------------- TEFLON -----------------------

---
g) Packing -------------------------- TEFLON -----------------------

---
h) Shaft Hardened steel EN8-BS-970 / As per

manufacturer’s Standard suiting to Chemical
13) Accessories Check valves, Pressure Dampeners, Safety

Relief valves etc as required

PLANT
CLAUSE NO.
XXVI Activated Carbon Filter for Alkali
No Description AC Filter
1) Purpose To filter impurities from

alkali.
2) Chemical to handled NaOH
3) Number One (1 )
4) Capacity of filter 10 m³/hr
5) Design surface flow rate 12 m³/hr/m²
6) Type of Vessel Vertical Cylindrical

Pressure vessel with dished
ends
7) Filter media Activated Carbon
8) Properties of Media a) Total surface area

(m2/g): min 850.
b) Particle density (wetted
in water) 1.3-1.4 g/cc
c) Mean particle Diameter
is0.6 - 0.8 mm In case
of needle / cylindrical
type and 1.5 - 2.0 mm
in case of Granular
type.
d) Iodine Number shall be
not less than 1000 mg/g
e) Abrasion Number shall
be minimum 95 by
ASTM Method .
f) Ash content shall be
maximum 7%
g) Mean particle length in
case of needle /
cylindrical type shall be
2.2 - 2.4 mm
h) Size in case of

PLANT
CLAUSE NO.
Granular type shall be 4

- 16 mesh
9) Minimum bed depth of AC media 1000 mm
10) Free Board over media depth 75%
11) Material of Construction MSRL
12) Accessories Manholes / Hand holes,

Vent, overflow, drains,
valves operating platform,
ladders etc as applicable
XXVII DEGASSER SYSTEM
A) DEGASSER TOWERS
1) Type Forced draft type
2) Number Required One (1)
3) Design Flow per unit (Net) Net output of all streams of

RO
4) Guaranteed Effluent Quality Effluent from Degasser

should not have CO2
content more than 5 ppm
5) Fill Material Polypropylene or equivalent
6) Shell material Mild Steel as per specified

code

Thickness
9) Accessories Manhole for the tank Stair-

case & Platform
B) DEGASSER BLOWERS
1) Type Centrifugal
2) Numbers required Two (2) per degasser unit

(1W+1S)
3) Duty Continuous

PLANT
CLAUSE NO.
4) Location Outdoor
5) Capacity of each Blower 100% requirement of one

degasser tower
6) Head As required
7) Maximum Speed of Blower 1500 rpm
8) Material of Construction As per manufactured

Standard
9) Accessories required for each V-belt guard etc.

Blower
XXVIII MIXED BED (MB) POLISHER UNITS

A)
a) Type Vertical shell type with

dished ends
b) Number of units Four (4) (2W+2S)
c) Design flow per unit (net) 50 m3/hr.
d) Gross flow rate per MB unit To be decided by bidder

considering DM water
required for regeneration.
e) Service Cycle (period between 30hrs.

two successive regenerations)
f) Net output during service cycle 1500 M³
g) Design surface flow rate at Not more than 35 M3/M2/hr

design flow
h) Shell & dished end material Mild steel as per specified

code
i) Shell lining
a)Material Rubber
b)Thickness 4.5 mm (minimum)
j) External painting Chlorinated rubber paint
k) Manhole Two (2) per vessel (Min.)

PLANT
CLAUSE NO.
l) Sight windows Two (2) minimum per

vessel (Minimum clear
width shall be 75 mm)
m) Resins
a)Type Strongly acidic and strongly

basic Type-I, both the resin
shall be of high capacity
polystyrene resins in bead
form.
b)Regeneration By HCI and NaOH
c)Total resin bed depth 1.0 M (min)
XXVIII Air-blowers for Mixed Beds

B)
a) Number Two (2x100%)
b) Type Centrifugal/Twin lobe type
c) Duty Intermittent
d) Capacity & Head As required
e) Location Outdoor
XXIX Dosing Ejectors (if Acid Alkali

applicable)
1) Numbers required Two Two each of 100% capacity;

each of
100%
capacity;
2) Capacity of each Capable Capable of meeting

ejector of regeneration requirement of
meeting respective MB unit.
regener
ation
requirem
ent of
respecti

PLANT
CLAUSE NO.
ve MB
unit.
3) Material of construction ------------------ Carbon steel ebonite

lined ------------------
XXX NEUTRALISING SYSTEM
XXX-A) Neutralising Pit
1) Number One in two Sections
2) Material of Construction R.C.C
3) Effective Capacity of 150m3/hr

each section
4) Corrosion Protection Acid/Alkali proof chlorinated painted &

rubber lined.
XXX-B) Waste Recirculation cum Disposal Pumps
1) Location Near Neutralisation Pit
2) Type of Pumps Horizontal centrifugal single stage with

priming system
3) Total Number of Pumps Three (1Working+ 1 Standby + 1 Maint

Spare)
4) Liquid to be Handled DM Plant Regeneration waste
5) Pumps and drives to be For Outdoor duty

designed
6) Suction condition Suction from priming chamber /

submerged (suction from pit)
7) Guaranteed Flow of Not less than 75 m 3/h

each pump
8) Total head 60 MWC (min)

(Guaranteed)
9) Maximum pump Speed 1500 rpm (nominal)
10) Type of pump casing Preferably Radially Split type
11) Type of impeller Closed / Semi Open

PLANT
CLAUSE NO.
12) Type of lubrication Grease
13) Type of Coupling (pump As per manufacturer’s standard

& motor) practice
14) Type of Shaft Sealing Mechanical Seal
15) Material of
Construction
Casing, Impeller Rubber lined, Cast iron IS : 210 Grade

FG 260
Wearing rings (if SS -316

applicable)
Shaft, Shaft Sleeves SS -410
Mechanical Seal As per manufacturer’s standard suiting

to the liquid being pumped
Bolts & nuts Stainless steel for those coming in

material shall be high tension
carbon steel.
Base plate Carbon steel (Epoxy coated)
16) Accessories to be a) Companion flanges with nuts, bolts

provided with each and gaskets, Internal piping with valves
pump filters & Instruments for sealing/
cooling/ lubrication system upto and
including isolating valve etc,
b) Coupling guards, Eye bolts, lifting
etc.

Specification
XXX-C Chemical (Lime) Tanks For Neutralisation
1) Numbers. required One
2) Type of construction RCC
3) Effective Capacity 2 M³

PLANT
CLAUSE NO.
4) Inside protection Epoxy
5) Dissolving basket SS -316.

Material
6) Agitator SS-316 Construction; Motor driven with

reduction gear unit; This shall have two
sets of blade mounted on single shaft.
7) Accessories To be provided with platform as

required, overflow, drain etc.
XXXI BACKWASH WATER & RINSE WASTE (From filters &

exchangers) WATER COLLECTION & RECYLING SYSTEM
XXXI- Back Wash Waste water Collection Pit & Sump

A
1) Number One (Twin sections) with a common

sump
2) Material of construction R.C.C. with Acid / Alkali proof lining
3) Effective capacity of 75m³

each section
4) Corrosion Protection for Acid/Alkali proof chlorinated paint &

gates rubber lined.
XXXI-B) Back Wash Waste Water Recirculation cum disposal pump

(Vertical Sump Pumps)
NO DESCRIPTION Backwash Water Pumps (Filters)
1) Location : In Filter Backwash Sump
2) Total Number of : Two (2)

Pumps

operating pumps
4) Number of stand : One (1)

by pump
5) Guaranteed Flow : 50 m³/h

of each pump

PLANT
CLAUSE NO.
7) Operating Speed : ----------------- Max 1500 rpm-----------
8) Pumps & Drives to : ---------------- Outdoor Duty -------------------

be designed for -
9) Service of duty : ------------------- Continuous -------------------

-
10) Type of pump : ------Vertical, non-clog, Sump pumps ------

-
11) Type of Working : ---Drains with particle size upto 40 mm ---

Fluid
12) Type of Discharge : ------------- Above Floor discharge -----------

-
13) Type of impeller : ---------------------- Open ------------------------

-
15) Suction condition : -------------------- Submerged -------------------

-
16) Minimum Water : ----------------------By Bidder --------------------

level -
17) Maximum Water : -------- Local Finished Grade level-----------

level -
18) Operating floor : ----------Minimum 500 mm above FGL------

level -
19) Type of shaft : ------------------Flexible / Rigid ----------------

coupling -
20) Material of
Construction :
Suction Bell : Stainless Steel – 316

/Casing
Impeller : Stainless Steel – 316
Shaft, Shaft : Stainless Steel – 410

Sleeves

PLANT
CLAUSE NO.
Shaft coupling : Stainless Steel – 410
Column pipe & : Stainless Steel – 316

Discharge Pipe
Shaft enclosing : Stainless Steel – 316

tube (if
applicable)
Stuffing box : SS
Gland : SS
Gland packing : --------------------TIWA ------------------
Gaskets : ------------- Neoprene Rubber ----------
Bolts & nuts : Stainless steel for those coming in contact

with water and for others, material shall
Base plate and : Carbon steel (Epoxy Coated)

Soleplate
21) Discharge pipe : 100 NB MS as per IS 1239 heavy grade

from the Pumps
up to terminal
point
XXXII BRINE PREPATION & PUMPING SYSTEM
XXXII-A Brine Solution Preparation Tank
1) Number One
2) Material of construction Mild steel (Internally rubber lined and

externally painted with epoxy paint)
3) Effective Capacity 3m³
4) Dissolving basket SS -316.

Material
5) Agitator Motor driven with reduction gear unit

SS-316 Construction.
This shall have two sets of blade
mounted on single shaft.

PLANT
CLAUSE NO.
6) Accessories To be provided with platform, ladder,

manhole, overflow, drain etc.
XXXII-B Brine Solution Transfer Pumps
1) Number Two (1 Working +1

Standby)
2) Type of Pump Horizontal Centrifugal
3) Fluid Handled Brine (Solution of NaCl and

NaOH)
5) Capacity 10 M³/h
6) Head 15 m WC (minimum)
8) Material of Construction of pump SS -316. with Mechanical

components Seal
XXXIII DM WATER STORAGE TANKS
16) Type Vertical Cylindrical

atmospheric
18) Size of Each Tank 16 m (diameter) x 12 m

(Ht)
20) Location Outdoor
21) Shell material Mild Steel as per specified

code
22) Shell thickness (minimum) Bottom most Course -10

mm
Balance Courses – 8 mm
23) Bottom Plate Thickness (minimum) 10 mm
24) Roof Plate Thickness (minimum) 6 mm

PLANT
CLAUSE NO.
27) Manhole Minimum 2 numbers (one

on the shell and other on
the roof )

connections
c) Overflow seal
d) CO2 absorbers in vent
line
e)Hand railing on the roof
of the tank all around the
tank
29) Additional nozzle connections for Two Numbers one of 250

Employer NB size & another of 150
NB size at bottom level (for
suction).
Two numbers one of 150
NB size & another of 100
NB size at the top level (for
future filling)
XXXIV– HORIZONTAL CENTRIFUGAL PUMPS
NO DESCRIPTI RO DM DM Boiler Fill

ON Permeat Regene- Makeup Pumps
e ration Pump
Transfer pump
Pumps
1) Location Near In DM Water Pump House located near

Degasse DM Tank area
r Units
2) Working RO --------------- DM Water ---------------

Fluid permeat
e
3) Total Three Two(2) Three (3) Two (2)

Number of (3)
Pumps

PLANT
CLAUSE NO.
4) Number of Two (2) One(1) Two (2) One (1)

operating
pumps
5) Number of One (1) One (1) One (1) One (1)

stand by
pump
6) Guaranteed 50 M3/hr 40 M3/hr 100 M3/hr 175 M3/hr

Flow of each
(min)
pump
7) Total head As As 70 m WC 150m WC

(Guaranteed Required Required
)
8) Operating ------------- 1500 rpm (nominal) ---------------

Speed
9) Pumps and ----------------- Outdoor duty -------------------

drives to be
designed for
10) Service of ------------------- Continuous --------------------

duty
11) Type of ------------- Preferably Radially Split type ------------

pump casing
12) Type of ----------------- Closed / Semi Open ------------

impeller
13) Type of ------------------ Grease --------------------------------

lubrication
14) Suction ---------------------- Flooded suction -----------

condition
15) Type of ----------------- Mechanical Seal --------------

Shaft
Sealing
16) Type of ------ As per manufacturer’s standard practice ----

coupling
(motor&
pump)

PLANT
CLAUSE NO.
i) Casing ------------- ASTM A CF 8M -------------------
ii) Impeller ------------------ ASTM A CF 8M -------------------------
iii) W earing -------------------------- SS -316 ----------------------------

rings (if
applicable)
iv) Shaft -------------------------- SS -410 ----------------------------
v) Shaft -------------------- SS – 410 ----------------------------

sleeves
vi) Mechanical As per manufacturer’s standard suiting to the liquid

Seal being pumped
vii) Bolts & Stainless steel for those coming in contact

nuts with water and for others, material shall be
viii) Base plate ---------- Carbon steel (Epoxy painted) -------
18) Accessories c) Companion flanges with nuts, bolts and gaskets,

to be Internal piping with valves filters & Instruments
provided for sealing/ cooling/ lubrication system upto and
with each including isolating valve etc,
pump
d) Coupling guards, Eye bolts, lifting etc.
19) Other Refer sub-section titled “Horizontal Pumps” in Part-

Technical B of Technical Specification
Requirement
s
14.00.00 NOT USED.

15.00.00 GENERAL DESIGN CRITERIA FOR WATER TREATMENT PLANT
a) The chemical storage facilities shall be able to hold one (1) month
requirements, chemical dosing tanks shall be able to hold one (1) day
requirement (at least two (2) tanks in total or specified elsewhere),
chemical dosage rate shall be as per the process requirement however,
minimum chemical dosage rate shall be maintained as specified
elsewhere.
b) All materials and components of valves, pumps, piping and other
equipment and appurtenances shall be compatible with the respective
fluid herein.

PLANT
CLAUSE NO.
c) All the pumps shall have isolation valve at suction and electrically
actuated isolation valve at discharge along with NRV. Further,
recirculation line to be provided along with valves for all pumping
systems.
d) General Design and Construction features of various Horizontal pumps,
Vertical Pumps and Submersible pumps shall be generally conforming to
the requirements specified in the Chapter titled ‘CW System' unless
otherwise mentioned.
e) All the pump sumps shall be provided with re-circulation system from the
pump discharge and agitation arrangement by with the pumped fluid
(perforated pipes/ network of recirculation pipes as the case may be) so
that the effluents are properly mixed. Sumps handling sludge/thick slurry
etc. (other than clear fluid) shall be provided with agitation system with
(2x100% capacity) blowers.
f) Sumps/tanks shall generally consist of two (2) sections with a common
sump interconnected with valves.
g) Vertical wet pit type pumps handling waste service water and decanted
water shall be provided with forced water lubrication using a set of
lubrication water pumps and an overhead tank filled from plant service
water system.
h) Facilities for maintenance of the pumps by means of mobile cranes shall
be provided as specified.
i) Storage tanks shall be provided with vent, overflow, drain connections
with required valves. Stair case, operating platform etc. shall be
provided. Agitators shall be of SS-316 construction with motor driven
reduction gear units.
j) Fasteners like bolts, nuts etc. shall be stainless steel for those coming in
contact with water and for others high tensile carbon steel.
k) Base plate, sole plates for pumps, blowers etc. shall be carbon steel with
epoxy coated.
l) Suitable permanent flushing connections shall be provided for all
pipelines carrying sludge, acid and alkali.
m) The pipelines which are immersed inside the drain trench or in
Neutralization pits shall be rubber lined to a height of at least 600 mm
from the maximum liquid level apart from internal rubber lining.
n) All valves used with vessels shall be suitably arranged in the front in
accessible position, for manual operation in case of emergency.
o) The valves under automatic operation of DM Plant shall be operated
pneumatically by diaphragm actuator. Valves shall be spring to close or
spring to open or double acting type as may be required by process
consideration. The valves on effluent outlet as well as regenerant inlet of
filters and ion-exchangers shall be of spring to close (Air to open) type
only. Limit switches shall be provided for all the valves under automatic
operation.

PLANT
CLAUSE NO.
p) The solenoid valve shall be housed in a separate enclosure and shall be

located near the respective vessels. The valves shall be provided with all
accessories such as isolating cocks, air supply headers etc. and shall
have facility for operation from rack itself. Name plate with tag number
shall be provided for each and every valve.
q) Rotary type actuators for butterfly valves are also acceptable.
16.00.00 GENERAL REQUIREMENTS OF PIPING & VALVES FOR WATER
TREATMENT PLANT
A. Piping
All the piping shall generally be conforming to the requirements specified in the
Chapter titled “Low Pressure Piping” considering the following aspects as minimum
requirement:
S.No Service Material of Construction
1 Raw water & Clarified Carbon Steel: IS: 1239 Part-I (Heavy grade-
water Black), ASTM-A-53 Type-E Grade B / ASTM A 36 /
IS: 3589 - Grade 410; / IS-2062 Gr.-B (for
fabricated from plates) / Equivalent
2 Filtered Water Stainless Steel: Stainless Steel ASTM A 312 Gr.

304 Sch. 40 /Equivalent Seamless for Sizes 50 and
above and welded for sizes 65 mm NB and above.
3 Air Galvanised steel
4 RO high pressure SS-316 (Sch.40 min)

discharge/ permeate
5 Demineralised Water Stainless Steel:

Stainless steel to ASTM A312, Gr. 304 Sch.40s
(Seamless for sizes 50mm and below and welded
for sizes 65 mm NB and above).
6 Degasified Water Rubber lined Carbon Steel:

(RO Plant)
IS:1239 Part-I (Heavy grade-Black), ASTM-A-53
Decationised & De-
Type-E Grade B / ASTM A 36 / IS:3589 - Grade
anionsed water
410;/ ASTM A-36/ASTM - 53 Type- E, Grade B/
Equivalent and Galvanized to IS: 4736 or
Equivalent internally lined with 3 mm thick Rubber
of shore hardness 65 ± 5°A)
Note: The inside surface of pipes shall be
completely de-beaded and made suitable for
rubber lining.

PLANT
CLAUSE NO.
7 Concentrated 1) PP lined Carbon Steel: IS:1239 Part-I (Heavy

Hydrochloric Acid grade-Black), ASTM-A-53 Type-E Grade B /
ASTM A 36 / IS:3589 - Grade 410;/ Equivalent
(5-30% Conc.)
and Galvanized to IS: 4736 or Equivalent
internally lined with 3 mm thick Polypropylene)
2) CPVC as per ASTM F441 CPVC 4120
8 Dilute Hydrochloric 1) Rubber lined Carbon Steel: IS:1239 Part-I

Acid (Heavy grade-Black), ASTM-A-53 Type-E Grade
B / ASTM A 36 / IS:3589 - Grade 410;/
(Less than 5% Conc.)
Equivalent internally lined with 3 mm thick
Rubber of shore hardness 65 ± 5°A)
2) Chlorinated Polyvinyl chloride (CPVC) as per
ASTM F441 CPVC 4120
9 Sulfuric Acid Carbon steel/PP lined steel/Equivalent (Butt-

welded fittings shall be used)
a) Strong (Conc.)
b) Dilute (upto 10%) Polypropylene lined steel/Alloy 20/Equivalent
10 Alkali (Sodium
Hydroxide)
Stainless Steel SS-316
a) Strong (5% and
above)
b) Dilute (below 5%) Polypropylene lined steel/CPVC as per ASTM

F441 CPVC 4120 Schedule 80
11 Coagulant (Alum ) Rubber lined Steel/CPVC Schedule 80

PAC Solution CPVC Schedule 80
12 Lime slurry/Solution/ Galvanised Steel / CPVC as per ASTM F441

Suspensions CPVC 4120 Sch. 80
13 Coagulant (Ferric CPVC as per ASTM F441 CPVC 4120 Sch.80 or

Chloride), Anti- Equivalent
oxidant, Anti-scalant
& NaOCl solution
14 Coagulant aid Rubber lined Steel (as referred above)/CPVC as

Solution per ASTM F441 CPVC 4120, Schedule
80/equivalent.
15 UF Feed / permeate / CPVC Schedule 80 / SS-304 Schedule 40(min)

backwash / chemical

PLANT
CLAUSE NO.

backwash
16 Resin water slurry Stainless Steel Type-304 (Sch.40 min)
17 Sludge 1) GRP as per ASTM D3517/ AWWA C950-

88/AWWA M45
2) HDPE as per ASTM D3350 CL 34543C, FM
Class 150/ IS:4984 or Equivalent for buried
portion
3) Cast Iron (Class A as per IS: 1536) / Ductile Iron
18 Chemical Waste from 1) Rubber lined Steel (as referred above)

vessels and tanks
2) HDPE as per ASTM D3350 CL 34543C, FM
Class 150/ IS: 4984 or Equivalent for buried
portion.
19 Cleaning Solution SS316 Sch. 40 /CPVC as per ASTM F441 CPVC

Line 4120 Schedule 80/equivalent.
20 Brine (RO reject) GRP as per ASTM D3517/AWWA C950-88 /

AWWA M45 or SS-316 sch 40 min.
Note:
1. Irrespective of the recommended piping material as mentioned above,
Bidder shall supply the material of pipes indicated in Scope of Works (Part-
A) and in tender Drawings.
2. CPVC pipes mentioned above shall be of Industrial grade CPVC Sch-80
minimum.
B. Valves:
All the valves shall generally be conforming to the requirements specified in the
Chapter titled “Low Pressure Piping” considering the following aspects as
minimum requirement:
S.No Service Type of Valves / Material of Construction
1. Low pressure CPVC as per ASTM F441

(in case of CPVC piping) CPVC 4120 Sch. 80

PLANT
CLAUSE NO.
2. High pressure Feed 5.1 – Type of Valves

water of RO plant (From For Isolation
discharge of HP Feed
a) Gate or Sluice or Ball or Globe type for
pumps of RO plant upto
Sizes upto 50 mm NB
degasser inlet)
b) Gate or Sluice or Ball or Butterfly type for
Sizes 65 mm NB to 200 mm NB
c) Butterfly type for Sizes 250 mm NB &
above
For Regulation /Control
a) Globe type for Sizes upto 50 mm NB
b) Globe or Butterfly type for Sizes 65 mm
NB & above
For non-return / Check
Swing Check or Dual Plate type valve
5.2 – Material of Construction Valves

Sluice & Gate Valves
a) Stem, seat ring and wedge facing ring of
shall be of stainless steel (SS 316)
construction
b) Body/Bonnet shall be Stainless steel of
ASTM A 351 Gr. CF 8M/ ASTM A 182
S30451/Eqvt.
c) All other internal parts shall be epoxy
coated against corrosion by sea water
Butterfly Valves & Globe Valves
a) Body & Disc shall be Stainless steel of
S30451/Eqvt.
b) Shaft shall be of Stainless steel to ASTM.
A 276 Gr S41000 / ASTM A 473 S41000
/. ASTM A 351 Gr.CF 8M / Eqvt.
c) Seat shall be ASTM A182 F317/ASTM A
276 S31700/ASTM A 890 J93370 or
Equivalent
d) Seals shall be Nitrile rubber, EPDM
(Ethylene propylene rubber), Hypalon
Ball Valves

PLANT
CLAUSE NO.

a) Body shall be of Stainless steel of ASTM
A 351 Gr. CF 8M/ ASTM A 182 S30451
b) Ball shall be Stainless steel to ASTM. A
276 Gr S31600 / ASTM A 473
S31600/.Eqvt
c) Stem shall be ASTM A276 Gr
S41000/ASTM A473 S41000 /Eqvt.
d) Seat Ring shall be PTFE /Equivalent.
e) Seats shall be ASTM A182 F316 /ASTM
A 276 S31600/ Equivalent
Check Valves
a) Body & Cover, Hinge Disk/Door shall be
S30451
b) Hinge Pin and Door/Disc Pin shall be of
Stainless steel to ASTM. A 276 Gr S3160
/ ASTM A 473 S31600/Equivalent.
c) Bearing bushes, Disc facing ring and
Body Seat rings shall be ASTM. A 276 Gr
S30400 / ASTM A 473
S30400/Equivalent.
d) Material of construction of spring in dual
plate type valve shall be of INCONEL or
better
3. Degasified & Deminera- 6.1 – Type of Valves

lised water in RO Plant
For Isolation
a) Butterfly or Saunder’s Patented
Diaphragm Valves upto 200 mm NB
b) Butterfly type for Sizes 250 mm NB &
above
For Regulation /Control
a) Globe type for Sizes upto 50 mm NB
b) Globe or Butterfly type for Sizes 65 mm
NB to 200 mm NB
a) Lift Check type/Swing Check /Dual Plate
type for sizes upto 40 mm NB
b) Swing Check or Dual Plate type valve for

PLANT
CLAUSE NO.

sizes 50 mm NB & above
6.2 - Material of Construction Valves

Diaphragm Valves
a) Body shall be Cast Iron to IS: 210 Gr FG
260 OR Cast Steel to ASTM. A 216 GR.
WCB/Equivalent. and Body shall be
internally lined with Soft Natural rubber,
Ebonite or Polypropylene
b) Diaphragm shall be Reinforced rubber,
Hypalon/approved equivalent. Stem,
Compressor & Bush shall be of Stainless
steel Construction.
Butterfly Valves
a) Body shall be Cast Iron to ASTM A 48
Cl.40; BS: 1452 Gr.220 SG Iron - BS:
2789; Cast Iron to IS: 210 Gr FG
260/Equiv. OR Cast Steel - ASTM. A 216
GR. WCB; BS:1504 Eq.Gr/Equivalent OR
Fabricated Steel as per ASTM A515
Gr.60/80 and Body shall be internally
lined with natural rubber, Ebonite or
Polypropylene
b) Disc shall be Cast Iron IS: 210 Gr FG
260; ASTM A 48 Cl.40; BS: 1452, Gr.220,
SG Iron - BS:2789 OR Cast Steel - ASTM
A 216 Gr. WCB; BS:1504
Eq.Gr/Equivalent OR Fabricated Steel as
per ASTM A515 Gr.60/80 and Disc shall
be internally lined with PVDF, natural
rubber or Polypropylene. Alternatively
Disc of Stainless Steel-316 construction is
also acceptable.

PLANT
CLAUSE NO.

c) Shaft shall be of Stainless steel to ASTM.
A 296 Gr. CF8M/AISI 316/ AISI 420
/BS:970 Gr.316; BS: 970 Gr.420 S45.
d) Seat rings shall be Nitrile rubber
/Hypalon/Eqvt.
Globe Valves
a) Body & Disc shall be Cast iron Cast Iron
to IS: 210 Gr FG 260 or Eqvt. and
internally lined with natural rubber,
Ebonite or Polypropylene.
b) Stem shall be Stainless steel AISI 410/
13% chrome steel
c) Packing shall be PTFE
d) Seat & Seat rings shall be Nitrile rubber
or Hypalon
e) Hand wheel shall be Cast Iron or
Equivalent.
Check Valves
Cast Iron to IS: 210 Gr FG 260/ BS:1452
Gr.220 or Eqvt and shall be lined with
natural Rubber, PTFE or Viton or
Stainless Steel – 316
Cast steel ASTM A 216 Gr. WCB and
shall be coated with PVDF, or suitable
elastomer or Stainless Steel – 316
c) Disc facing ring and Body Seat rings shall
be Stainless Steel
d) Bearing bushes shall be SS – 316.
e) Material of construction of spring in dual
type valve shall be of INCONEL or better
4. Decationised, 7.1 -- Type of Valves

De-anionsed & Same as specified under 6.1 above
Demineralised Water
7.2 -- Material of Construction
Same as specified under 6.2 above

PLANT
CLAUSE NO.
5. Acid (Hydrochloric) 8.1 – Type of Valves

Service
For Isolation
Saunder’s Patented Diaphragm Valves
Flap type/Swing Check type /Dual Plate type

Diaphragm Valves
260/ ASTM A 48 Cl.40; BS: 1452 Gr.220
OR Cast Steel to ASTM. A 216 GR. WCB
and Body shall be internally lined with
Soft Natural rubber, Ebonite or
Polypropylene
b) Diaphragm shall be shall be of reinforced
TEFLON, EPDM/Black Butyl/approved
equivalent
c) Stem, Compressor & Bush shall be
Stainless steel Construction
Check Valves
Cast Iron to IS: 210 Gr FG 260/BS:1452
Gr.220 or Equivalent and internally lined
with natural Rubber, PTFE or Viton or
Hastalloy –B
steel with PVDF, or suitable elastomer
be SS-317 L or resilient materials such as
natural rubber, PTFE or Viton
d) Bearing bushes shall be PTFE or
Equivalent
6. Alkali Services 9.1 – Type of Valves

For Isolation

PLANT
CLAUSE NO.

Swing Check type /Dual Plate type

Diaphragm Valves
260/ ASTM A 48 Cl.40; BS: 1452 Gr.220
and Body shall be internally lined with
Soft Natural rubber, Ebonite or
Polypropylene
Neoprene/Hypalon/ /Equivalent
d) Hand wheel shall be of Cast Iron
Check Valves
The complete valve shall be of stainless steel
construction (AISI-316L)
7. Acid 10.1 – Type of Valves

(Sulphuric) Service For Isolation

Diaphragm Valves
260 /ASTM A 48 Cl.40; BS: 1452 Gr.220
b) For Diluted Sulfuric acid, body shall be
Teflon lined/Alloy 20/Hastelloy C/Eqvt.
c) Diaphragm shall be of reinforced
TEFLON/ Equivalent.
d) Stem, Compressor & Bush shall be
Stainless steel Construction, Hand wheel

PLANT
CLAUSE NO.

shall be of Cast Iron
Check Valves
The complete valve shall be of Alloy-
20/Hastelloy C / Equivalent
8. Coagulant (Alum) and 11.1 – Type of Valves

Coagulant aid Services
For Isolation
a) Saunder’s Patented Diaphragm Valves
b) Ball Valves in CPVC pipes

Diaphragm Valves
260/ ASTM A 48 Cl.40 ; BS: 1452 Gr.220/
Equivalent. OR Cast Steel to ASTM. A
216 GR. WCB and Body shall be
internally lined with Soft Natural rubber,
Ebonite or Polypropylene
rubber /Hypalon/ approved equivalent
Ball Valves in CPVC Pipe lines
a) Body , Ball & stem shall be of CPVC
b) Seat ring & Packing shall be EPDM / or
equivalent
Check Valves
Cast Iron to IS: 210 Gr FG 260/ ASTM A
48 Cl.40; BS: 1452 Gr.220 or Eqvt and
shall be lined with natural Rubber, PTFE
or Viton or Stainless Steel – 316

PLANT
CLAUSE NO.

be Stainless Steel
d) Bearing bushes shall be SS – 316
9. Lime slurry/Solution/ 12.1 – Type of Valves

Suspensions
For Isolation
Non-lubricated Plug Valves

Plug Valves
260 / ASTM A 48 Cl.40; BS: 1452 Gr.220
or Eqvt
b) Plug shall be Stainless steel to AISI 316
c) Body Sleeve & Seat shall be PTFE
d) Gland & Gland nut shall be SS 304/316
e) Cover shall be of Cast Steel to ASTM A
216 Gr WCB
Check Valves
Cast Iron to IS: 210 Gr FG 260 / ASTM A
48 Cl.40; BS: 1452 Gr.220 or Eqvt and
shall be lined with natural Rubber, PTFE
or Viton or Stainless Steel – 316
be Stainless Steel
d) Bearing bushes shall be SS-316

PLANT
CLAUSE NO.
10. Coagulant Aid (Ferric 13.1 – Type of Valves

Chloride), Anti-Oxidant
For Isolation
& Anti- Scalant
a) Saunder’s Patented Diaphragm Valves
b) Ball Valves in CPVC pipeline

Diaphragm Valves
260/ ASTM A 48 Cl.40; BS: 1452 Gr.220
OR Cast Steel to ASTM. A 216 GR.
WCB/Eqvt. and Body shall be internally
lined with Soft Natural rubber, Ebonite or
Polypropylene or Stainless Steel
b) Diaphragm shall be of reinforced
Neoprene/Hypalon/ approved equivalent
Stainless steel Construction.
d) Hand wheel shall be of Cast Iron
Ball Valves in CPVC Pipe lines
a) Body , Ball & stem shall be of CPVC
b) Seat ring & Packing shall be EPDM / or
equivalent
Check Valves
The complete valve shall be of CPVC.
11. Sludge 17.1 -- Type of Valves

For Isolation
Gate or Sluice or Knife edge type Slide
Valves

Gate / Sluice / Knife Edge Slide Valve
a) Body,Disc : Cast Iron

PLANT
CLAUSE NO.

b) Stem : Stainless Steel AISI 420
d) Packing : PTFE
e) Gland & Gland nut : AISI 420
f) Hand wheel :Cast Iron
Check Valves
Cast Iron BS:1452 Gr.220 or Eqvt
Cast steel ASTM A 216 Gr. WCB / High
tensile Brass or BS: 2872 equivalent.
be Stainless Steel.
d) Bearing bushes shall be Leaded tin
Bronze.
12. Not used -
13. Ion Exchange resin 19.1 Type of Valves

water slurry line (for
a) Two way eccentric plug valve as
resin transfer
manufactured by DeZerik or approved equal
application)
b) Ball valves of full bore type.
19.2 Material of Construction
The complete valve shall be of stainless steel
construction (AISI-316)
14. Back wash/Rinse water 20.1 Type of Valves

(from discharge of back
wash water pumps)
15. Waste effluent 21.1 Type of Valves

(neutralized)


PLANT
CLAUSE NO.
C. Other Requirements:
a) Valves for liquid and gas service on the chlorine supply side of the
installation shall be as per approved design of the chlorine Institute, USA.
b) Butterfly valves shall conform to design standard latest revision of AWWA
C-504/EN 593/equivalent standard of required class/rating.
c) Plug valves shall be designed as per BS: 5353 Class150 or equivalent.
d) Valves for alum solution shall be Saunders’s patented Diaphragm type
designed as per BS: 5156 or approved equivalent standard
e) Sluice/Gate Valves shall conform to BS: 5150 (BS: 5163 PN 16) PN16, IS:
14846 of rating PN 1.6 (min.). Stem, seat ring and wedge facing ring shall
be of stainless steel construction. Other parts shall be as per IS: 14846 /BS:
5163). Flanges shall be designed as per ANSI B 16.5 Cl. 150 (min.) to meet
with the piping flanges. Valves shall be of outside screw and rising stem
type. Gate valves for sizes below 50 NB and below shall conforms to IS:
778 Class-2/ANSI B16.34 straight, rising stem; without side screw.
f) Sluice/Gate valves shall be provided with the following accessories in
addition to the standard items:
1) Hand wheel
2) Manual Gear reduction unit operator for valves 200 NB and above
3) Bypass valve for valve of sizes 350 NB and above.
4) Draining arrangement wherever required.
5) Arrow indicating flow direction.
6) Position indicator.
7) Sluice/Gate Valves shall be provided with back seating bush to
facilitate gland renewal during full open condition.
g) Design standard for Gates shall be IS: 3042 or Equivalent.
1) Frame and Door : Cast Iron IS:210 Gr.260
2) Spindles, bolts & nuts: M.S. to IS:2062
3) Face & seat rings : Gun metal (as per IS: 3042).
h) All the parts of gates shall be applied with the coats of heavy duty
bitumastic paint. Each of the gates shall be provided with hand wheel and a
position indicator. The gates for DM plant drains shall be rubber lined to a
minimum thickness of 4.5 mm.
i) Sluice valve/knife edge type slide valves shall design by IS 14846. Plug
valves shall be used for the application of lime slurry/lime solutions
conforming to BS: 5353 Class 150 or Equivalent.
j) Valves will be used to start/stop or control flow. Gates will be primarily used
for isolation of flow in open channels although these should be capable of

PLANT
CLAUSE NO.
throttling the flow too. However, contractor can provide either isolation gates
or butterfly valves in various RCC tanks/pits/sumps such as sludge pit, filter
backwash pit, waste service water sump, clarified water storage tank,
service water tank, Treated water tank/ CMB etc. Sample valves will be
used in sample collection lines. Unless otherwise specified all the valves
shall be supplied with counter flanges by the Contractor.
k) All valves shall be suitable for service conditions i.e. flow, temperature and
pressure under which they are required to operate. All the valves shall be of
standard pressure rating of the relevant design standard. Nonstandard
pressure rating shall not be accepted. The pressure and temperature rating
of the valve shall not be less than the maximum expected pressure and
temperature plus 5% additional margin of the system in which valves are
proposed to be installed. The pressure rating of individual piping system
component such as valves, flanges etc. shall however be not less than that
specified.
24.00.00 DESIGN FEATURES OF “PRESSURE AND STORAGE VESSELS”
1) Design of all pressure vessels shall conform to ASME Section VIII or
acceptable equivalent standard. Design pressure shall be the maximum
expected pressure to which the vessels may be subjected to plus 5%
additional margin. Maximum expected pressure for vessels placed in the
discharge line of pumps shall be based on the shut-off head of the pumps
plus static head at pumps suction if any. For all other pressure vessels,
design pressure shall be at least 8 Kg/cm² (g).
2) Design of all vertical cylindrical atmospheric storage tanks containing water,
acid, alkali and other chemicals shall conform to IS: 803.
3) Design of all horizontal cylindrical atmospheric storage tank containing
water, acid, alkali and other chemicals shall conform to BS: 2594.
4) Design temperature of all pressure vessels and storage tanks shall be 10
deg. C higher than the maximum temperature that any part of the
vessel/tank is likely to attain during operation. In case, tank is subjected to
vacuum, the same shall be taken care in designing the tank.
5) The design of DM water storage tanks (Vertical type) shall conform to IS:
803. Supporting frame where required shall be in accordance with IS: 800.
The tank shall be "Non-pressure" fixed roof type with atmospheric vents.
6) All vessels/tanks without inside rubber lining shall have a corrosion
allowance of minimum 2 mm and mill allowance (minimum 0.3 mm) for shell
and dished ends. Thinning allowance of 2 mm (minimum) shall be
considered for dished end.
7) All the atmospheric tanks shall have sufficient free board above the “Level
High”/ “Normal Level” as the case may be. The overflow level shall be kept
at least 20 cm or 10% of vessel height above the “Level High”/”Normal
Level” for all the tanks except for the DM tanks for which a minimum height
of 300 mm shall be provided over the “High Level”. Further, a minimum 100
mm free board shall be provided above the top of overflow level to the bottom
of roof of the tank. Wall thickness of atmospheric tanks shall not be less than
6 mm.

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CLAUSE NO.
8) Vessels coming under preview of IBR shall be designed accordingly.

i) The pressure vessels shall be fabricated from carbon steel plates
conforms to SA 515 Gr.70 or SA 516 Gr. 70 if the pressure vessels are
designed as per ASME Section VIII.
ii) If the pressure vessels are designed as per IS 2825 following criterion
shall be followed: The pressure vessels shall be fabricated of steel as per
IS: 2002 Gr. 3 (normalized condition) or SA: 515/516 Gr. 70
(normalized), in case the vessels are designed as per Class 1 or Class 2
of IS: 2825. If the pressure vessels are designed as per Class 3 of IS:
2825, the material of construction shall conform to IS: 2062 or IS: 2002
Gr. 3 (Normalized quality).or SA 515 /516 Gr. 70
iii) All atmospheric tanks shall be fabricated of steel conforming to IS:
2062.
iv) The pipe flanges, manhole/manhole covers reinforcement pads etc. shall
be fabricated out of the same material as that one used for the
vessel/tank.
10) Fabrication
a) The vessel ends for storage tanks of vertical type shall have flat bottom.
However, the ends of horizontal storage tanks, and all the pressure
vessels shall be dished design of Torispherial type designed and
constructed by forging, pressing or spinning. The dished ends shall have
a minimum straight flange length of 60 mm. Conical or flat (with or
without reinforcement) ends shall not be accepted.
b) The plates to be used for fabrication shall preferably have a minimum
width of 1500 mm. All welding shall be performed by ASME qualified
welders under Section-IX of ASME Boiler and Pressure Vessel code and
welding electrodes shall be as per relevant Codes/Standards viz. AISC
Section 1.17 etc.
c) All pressure vessels and storage tanks except DM water storage tanks,
UF, RO Permeate water tanks shall be fabricated complete and tested at
manufacturer’s works to ensure better workmanship.
11) Appurtances, Connections, Lifting lugs
a) Manholes/Hand Holes: All the pressure vessels and horizontal type
storage tanks shall be provided with at least one manhole of 500 mm
diameter. The vertical type storage tanks shall be provided with a
manhole of 500 mm dia on the top cover, if the diameter of the tank is
1200 mm or more. For the vertical cylindrical atmospheric tanks,
manholes shall be provided as per IS: 803.
b) All the vessels and tanks shall be normally provided with a hand hole of
150 mm gasketted located near the bottom of the straight side.
c) All lined vessels connections shall be conform to required class/rating.
Nozzle material shall be ASTM-106 Grade B, Schedule 80.

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d) All vessels of internal, diameter of 1200 mm or greater shall be provided

with minimum four (4) lifting lugs for safe and effective handling during
erection. Smaller vessels shall be provided with at least two (2) lifting
lugs. Material of construction for these vessel supports, saddles, lugs
shall conform to IS: 2062 of tested quality.
18.00.00 Painting : Painting shall conform to the requirements specified elsewhere in
technical specification.

PLANT
COOLING TOWER

CLAUSE NO.
COOLING TOWERS - INDUCED DRAFT (MECHANICAL)

1.00.00 GENERAL
1.01.00 This specification covers the design, engineering, manufacture, shop fabrication,
testing at works, transportation to site, unloading and storage at site, fabrication at
site, Installation, testing and commissioning of induced draught RCC/ Pultruded
FRP cooling towers for power plant cooling system.
2.01.00 The design, manufacture, inspection and testing shall comply with all currently
applicable standards. The equipment shall also conform to the latest applicable
British/American standards. In particular the equipment shall conform to the latest
edition of the following standards:-
1) Cooling Tower Institute Publications.
2) BS 4485 – Specification for Water Cooling Towers.
2.02.00 Codes and Standards for FRP components
The design of FRP components of cooling tower shall comply with the requirements
stipulated in CTI STD- 131, CTI STD -137, CTI ESG-152. The cooling tower and its
components shall be designed to withstand the most onerous loading case /
combination resulting from the various loading cases / combinations stipulated in
CTI ESG 152. All material properties, stresses and their reduction factors, deflection
criteria, material service factors, connection details and their tolerances etc., as
applicable as per CTI codes CTI STD- 131, CTI STD -137, CTI ESG-152, shall be
so considered such that the cooling tower and its components withstand the
severest temperatures in the place of installation and application and serve a
reasonably long life not less than CTI indicated life expectancy.
3.00.00 DESIGN REQUIREMENTS / CRITERIA
3.01.00 Each cooling tower shall be complete with tower, basin, foundations and
mechanical equipment as described below. The tower shall be of single inlet, cross
flow or counter flow type with type of fill as specified in technical data sheets. The
tower shall be of induced draught type with the fan located on top of the tower.
3.02.00 The cooling tower shall be designed to meet the duty conditions as specified
elsewhere in this specification. Employer may get the verification and review of
contractor's design done through third party (who can be employer's
consultant/reputed designer/ National or International Technological
Institute/National or International body on cooling tower & it’s components), if
required (during detailed engineering). All necessary data/ details/ drawings shall be
provided by the contractor to get the same carried out.

SUB-SECTION-IIIA-04 PAGE
INDUCED DRAUGHT 1 OF 32
COOLING TOWERS
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3.03.00 Number of operating cells in the cooling tower shall not be less than eight (8).
Bidder shall provide spare cells (Minimum four (4) per tower) in the cooling tower to
facilitate maintenance without affecting the tower performance.
3.04.00 The water distribution basin and piping system shall be so designed that when any
two cells (other than standby cells) are out of operation for maintenance etc. the
remaining cells shall be capable of handling the full quantity of water as indicated in
technical data sheet.
3.05.00 All cells of the tower shall be identical. Thermal design of the cooling towers shall be
such that the guaranteed performance is met without operating spare cells.
3.06.00 No booster pumping shall be considered in the CW System. The Bidder shall
consider the height of the highest point of the hot water distribution system (with
respect to the finished ground level), including head loss due to friction and other
losses in the hot water headers and entire piping system to the hydraulically
remotest point of the Cooling Tower without considering any siphon recovery while
calculating the CW pumps head.
3.07.00 For counter flow tower the area covered by the projected circle at 45 deg. angle
from the fan cylinder opening on the drift eliminator plan area shall not be less than
80% of the drift eliminator plan area.
3.08.00 The layout of the cooling tower in the plant area and the wind rose is indicated in
the drawings titled “General Layout Plan” and “Layout of Cooling Tower”. The
Bidder shall examine the proposed layout of the tower and accordingly determine
the recirculation which must be taken into consideration for the purpose of design of
the tower to ensure that the design parameters of the tower are maintained when all
the cooling towers in the plant are operating simultaneously. Bidder must apply a
correction factor to the design wet bulb ambient temperature to accommodate the
recirculation effect. Minimum value of this recirculation correction factor shall be as
given in technical data sheets.
3.09.00 The length of the cooling tower shall be decided based on GLP drawing. However,
the maximum length of the tower excluding space required for stair cases at both
ends shall not exceed 220m for cooling towers.
3.10.00 Sensible heat of evaporated water shall be taken into consideration in the thermal
design of the cooling tower. The air flow requirement shall not be less than that
worked out by the formula given below:
G x H = L (T1-T2) + EvT2
where,
L = Water flow rate in Kg/Hr
T1 = Water inlet temperature to the tower in deg.C.

COOLING TOWERS
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T2 = Water outlet temperature from the tower in deg.C
Ev = Evaporation loss in Kg/hr.

To compute this factor the ambient RH shall be taken as specified in
technical data sheets.
G = Air rate in Kg/hr
H = Change in enthalpy of air in Kcal/Kg
3.11.00 Calculations justifying the selected air flow and evaporation loss shall be enclosed
with the bid. International/National standard table of properties of air shall be used
and a copy of the table clearly indicating the standard used shall be enclosed with
the bid.
3.12.00 The bidder shall furnish in his bid the following :-
a) Heat balance calculations and air requirements for cooling tower as per
format given elsewhere.
b) Available tower characteristics (KaV/L - as a function of air & water rates, fill
geometry, hot water temperature, air velocity etc.) based on field
performance tests. The relationship shall be of general form of equation
given below and shall include values of the constants “C” and “n”. The
equation shall cover range of L/G values from atleast 20% above to atleast
20% below design.
KaV/L = C(L/G)n
The bidder shall also submit an equation and / or curve defining the demand
requirement at design approach, range and wet bulb temperature. The
design L/G value shall be identified.
c) Various pressures drop in the air circuit of the cooling tower to arrive at
discharge pressure of fan.
d) Calculations for arriving at the design power consumption.
e) Calculations for pumping head in the format given in elsewhere.
f) Tower Performance curves (for both ambient and inlet WBT.)
Bidders may note that the calculations/curves specified above must be enclosed
with the offer without which bids run the risk of rejection. In case, these calculations
are based on the collaborator's design, then these calculations should be duly
vetted by collaborator. The Bidder shall show/explain and prove the validity and the
basis of procedures and methods used in the calculations.
3.13.00 The tower configuration shall be such that it shall offer minimum restriction to air
flow.

COOLING TOWERS
CLAUSE NO.
3.14.00 To ensure uniform and stable distribution of entering air, the velocity pressure ratio shall not
be less than 5 (Five). Velocity pressure ratio is defined as the ratio of system pressure drop
(i.e from air inlet to the drift eliminator) to the velocity pressure at the inlet. For counter flow
towers, the velocity at air inlet shall be calculated based on the clear air entry area available
in vertical plane at the inner face of cooling tower wall. For purpose of calculating the
velocity pressure ratio, the air velocity shall be computed considering the total air flow
entering the individual cell and the total gross inlet air area of the individual cell. This will be
calculated independently for each cell and the value calculated for each cell shall not be less
than 5. For towers provided with over-dimensioned cold water basin, the inlet air area shall
be computed considering the water level in the cold water basin at normal water level.
3.15.00 The exit air velocity of the fan recovery stack outlet shall not be less than 6m/s.
3.16.00 Maximum air Inlet velocity should be 5m/s.
3.17.00 For design of Cooling tower, CT outlet temperature shall be considered as 32 deg.C.
4.00.00 CONSTRUCTIONAL FEATURES

4.01.00 Material of Construction
Wood/timber shall not be used as construction material in any part of the cooling
tower. Bidder may offer MOC of components different than that specified below
based on his proven practices, however allowing of such MOC shall be under
employer’s discretion.
S.N Component Material of Construction

Description
RCC IDCT Pultruded FRP IDCT
a) Hot water header MS to IS:2062/ GRP (around cooling tower)

b) Hot water distribution PVC (IS 4985 Class 3) / GRP / HDPE (IS 4984
pipes for counter-flow PN6, Grade PE 80)/ as per Bidder's proven
tower practice
c) Hot water basin for RCC Pultruded FRP
cross flow
d) Cooling tower shell/ RCC Pultruded FRP
structure
e) Cooling tower basin RCC (Refer Civil specifications)
f) Drift Eliminators PVC
g) Louvers Bidder’s proven practice
h) Fill PVC/ PP/ as per Bidder's proven practice
i) Fill supports SS:316 grid
j) Fan blades Fiber glass reinforced polyester/ Epoxy (hollow
cast)

COOLING TOWERS
CLAUSE NO.
S.N Component Material of Construction

Description
RCC IDCT Pultruded FRP IDCT
k) Fan Hub Heavily Galvanized M.S

l) Fan Deck RCC Pultruded FRP
m) Drive shaft and Stainless steel conforming to AISI 304 or Carbon
coupling fiber Composite material with SS 304 couplings.
n) Base frame and base Heavily Galvanized MS
plate for gear box and
motor/ Torque Tube
Support
o) Stair case RCC Pultruded FRP
p) Recovery Stack RCC Pultruded FRP/ GRP
q) Stop logs Refer civil specifications.
r) Any other hardware Stainless steel conforming to AISI: 304 or
such as fasteners, equivalent.
clamps, supports etc
in direct contact with
water
s) Any other mild steel Heavily galvanized (610 gm/m 2) in accordance
parts used in cooling with IS:2629 with corrosion resistant protective
tower or its vicinity coating Surface preparation in accordance with
IS:6129
t) Hand Rails Refer civil Deck Level –
specifications. Pultruded FRP
Others – Refer civil
specifications.
u) Misc. Structure(s) Refer civil specifications.
v) Nozzles/ Splash cups PVC/ PP/ Gun metal as per IS:318 Gr. VI
w) Cladding Sheets RCC FRP
4.02.00 Pultruded FRP structural components

The Pultruded FRP structural members shall be proven for use in Cooling Towers
application. Documentary evidence about past experience of parties in respect of
design, manufacture, supply, erection & satisfactory operation of Pultruded structure
shall be submitted to the employer.
4.02.01 Manufacturing Process
a) Pultrusion: The process of pulling continuous forms of reinforcing materials,
such as glass-fiber rovings, glass-fiber mats and various surfacing veils through

COOLING TOWERS
CLAUSE NO.
a bath of liquid resin. The mass of fully wetted-out material then continues to a
performer and directly into a healed forming and curing die where a chemical
reaction is initiated which causes the thermosetting resin to harden and the
composite structural shape is formed. An optional method of cure is to pass the
wetted-out composite through a radio frequency (RF) preheated. The RF preheat
initiates the cure process prior to entering the heated forming die. This process is
particularly useful for heavy section processing. The hardened (or cured) shape
is cooled in line by water or air and then enters a pulling device where
continuous pulling is maintained. Both caterpillar type and reciprocating pullers
are used in pultrusion. Upon exiting the puller, the composite structural shape is
cut to the desired length.
b) Definition of terms relative to pultrusion can be found in ASTM D-883 and ASTM
D- 3918.
c) Other forms or combinations of reinforcements such as carbon fiber, aramid

fiber, etc. can also be utilized when different mechanical and physical properties
are required. Specific mechanical and physical properties should be negotiated
between the pultrusion supplier and cooling tower
4.02.02 Design Temperature

For members in cooling towers which are subjected to extended periods of operation in
temperatures greater than 77°F, the pultrusion suppliers published allowable design
values for flexural and compressive loads shall be reduced to account for reduced
properties at the higher temperatures. These correction factors are published in Table II
of CTI STD-137. For Type IV products, pultrusion suppliers are to supply the cooling
tower manufacturer with temperature-moisture correction factors. All structural
components for the tower should be selected to account for maximum expected hot
water temperature including any upset conditions as a minimum (i.e., maximum hot
water temperature +10°). This will account for the possible the effects of fan off
operation, tower idle in hot weather and load excursions. A statement indicating the
design temperature should be included as part of the cooling tower manufacturer’s
proposal.
4.02.03 Materials
a) Glass fiber-reinforcements may be either continuous roving’s, continuous strand
mats, woven or non-woven fabrics, uni-directional fabrics or combinations of these.
Glass fibers shall be made for A, C, E or S-type glass. Other reinforcements may be
specified for custom applications.
b) The resin grade shall either be a Grade I isophthalic polyester resin or Grade 3 vinyl
ester resin as per Section 4.2 of CTI Std. 137. The resin may contain additives for
various purposes such as flame retardancy. UV stabilization, pigmentation or smoke
reduction. These additives should be selected so as to add to the overall
performance of the product without affecting the structural properties, chemical
resistance an/or longevity of the part.
c) Surfacing veils shall be used to improve surface appearance, assistance in chemical

resistance, improved weatherability and to prevent glass fibres from coming to the
surface as a result of wear or UV attack. Surfacing veils are thin tissue-type
products incorporated during the pultrusion manufacturing operation as the

COOLING TOWERS
CLAUSE NO.
outermost surface layer of non-resinous material. All exterior surfaces of Pultruded

members shall have a minimum surface veil of 10mil and shall have UV inhibitors to
protect against UV degradation. Heavier surface veils may be provided on supplier’s
discretion. The final degree of UV protection is a function of the total manufactured
thickness of the surfacing veils and/or surface coatings. Glass fibres exposed during
fabrication process and/ or installation shall be gel coated and sealed to prevent
wicking
4.02.04 Physical Properties

Physical properties should be in line with CTI specifications, CTI-STD-137. Moreover,
the pultruded FRP structural components shall be fire retardant with the resin composite
having a flame spread rating less than 25 as per ASTM E 84 standards.
4.02.05 Mechanical Properties from Coupons

Minimum mechanical properties (taken from coupons) shall be as per CTI
specifications CTI-STD-137
4.02.06 Applicable Documents

a) CTI STD-137: Fiberglass Pultruded Structural Products for use in Cooling Towers
b) CTI STD-152: Structural Design of FRP components
c) ASTM D-4385 Practice for Classifying Visual Defects in Thermosetting Reinforced

Plastic Pultruded Products.
d) ASTM D-3647 Practice for Classifying Reinforced Plastic Pultruded Shapes

According to Composition.
e) ASTM D-3917 Specification for Dimensional Tolerance of Thermosetting Glass-

Reinforced Plastic Putlruded Shapes.
f) ASTM D-3918 Definitions of Terms Relating to Reinforced Plastic Pultruded Products.
4.02.07 Ultraviolet exposure test for 300 hours to be carried out at reputed third party
laboratory once as per ASTM G-154 and Impact resistance test before & after UV
exposure shall be conducted as per ASTM D-256. This will be applicable to
Pultruded as well as moulded FRP components.
4.03.00 Cooling Tower Basin and Super Structure
4.03.01 The material of cooling tower basin and super structure shall be as mentioned
above. The depth of basin shall be at least 1.0 m from normal water level with free
board of at least 0.3 m above maximum water level unless otherwise indicated in
relevant tender drawing. The Velocity of water at the outlet of the cooling tower
should not exceed 1(one) m/sec. If required, the basin may be suitably depressed to
meet this requirement.
4.04.00 Cold Water Basin Drainage Arrangement
4.04.01 Cold water from the basin shall flow by gravity to Cooling water channel through the
outlet channel.

COOLING TOWERS
CLAUSE NO.
4.04.02 Provision shall be made to completely drain the basin. For this purpose the basin
floor shall slope towards the drain sump in the Cooling Tower as shown in the
relevant tender drawing. Water shall flow from the drain sump into an external
sludge sump through a 300 mm NB GRP pipe 12mm thick and a gate valve of size
300mm NB with extended spindle. Two sludge sumps shall be provided for each
tower. The sludge sump shall be atleast 2m x 2m plan area and minimum 2.5m
deep. One number sludge disposal pump of capacity 150 cum/hr and suitable head
shall be supplied for each sludge sump. Sludge Pumps can be of fixed type or
submersible type with proper handling arrangement.
4.05.00 Inlet Louvers
The water loss in the inlet air openings shall be prevented with provision of
adequate number of louvers of proper slope, width and spacing or alternatively by
over dimensioning the cold water basin by minimum 1.0 meter all-around. Louvers,
if provided, must be properly designed to give uniform distribution of air with
minimum pressure drop and must be able to withstand the corrosive atmosphere.
4.06.00 Cooling Tower Fill and Fill Supports
4.06.01 The fill shall be of non clogging type fills like modular splash/trickle grid/turbo splash
or splash type fills like V-bar splash/splash grid and easily installable. The fills shall
be adequately supported to prevent sagging and damage. The tower shall be
leveled so that water will be uniformly distributed over the fills and does not cause
channeling.
The non clogging type fills shall be in modular form. These fills are to be
mechanically assembled without use of any adhesives. Assembling by other proven
method(s) is also acceptable. The fill shall be freely rested and bottom supported to
prevent any sagging and damage.
The splash type fills shall be placed horizontally.
4.06.02 The fill material shall promote a high rate of heat transfer, provide low resistance to
air flow and maintain uniform water and air distribution throughout the fill volume.
The fill material shall be highly resistant to deterioration and shall be fire retardant.
PVC/PP fill, shall be of proven quality. The make and its properties shall be subject
to Employer’s approval. Bidder shall furnish details of PVC/PP fill regarding fire
retarding properties, ageing effect, vibration caused by water and wind effects. The
property of PVC /PP fill shall be in line with CTI 136 : 2010.
In case of PVC/PP fill, the material should be ultra violet ray stabilized and only
virgin PVC/PP material should be used.
4.06.03 The type of fill to be supplied for this package shall be of proven design. Necessary
supporting data for this shall be enclosed along with the bid.
4.06.04 Preferably, the fill shall not be extended into the air inlet area. In case the bidder’s
standard design calls for such an arrangement, then field performance test results

COOLING TOWERS
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of towers with comparable fill arrangement supplied by the bidder duly certified by
the user shall be furnished along with the bid to establish the design.
a) Type Test of PVC/PP Material
In addition to the routine tests specified in Sub-section-III E-01 of Part-B of this
Technical specification, ultra-violet exposure for 500 hours on the PVC/PP
material shall be carried out for this contract once as per ASTM-G155, Test
Method 3 and Impact resistance test before and after UV exposure shall be
conducted as per ASTM D-256. The above type test shall be carried out by the
Contractor at reputed third-party laboratory.
4.06.05 Offered fills shall be tested by an independent reputed laboratory approved by

Employer to validate thermal characteristic and pressure drop correlation of the
offered fill. In case the bidder has their own established test facility where such tests
have been conducted for other reputed clients in the past, the same is also
acceptable subject to employer’s approval.
Test bed shall have fill height preferably same as the offered fill height. During
testing water and air loading as well as the air velocities shall be maintained same as
the duty conditions and in the range of performance guarantee conditions for which
tower is designed.
4.07.00 Inlet Water Distribution System
4.07.01 General Requirements: The hot water distribution system of the tower shall be
designed to ensure uniform distribution to all operating cells and also to all areas in
a cell. For cross flow type of towers a minimum free board of 50 mm shall be
provided with the standby cell not in service. Each cell shall be able to operate
independently. Suitable valves for isolation of any cell for any maintenance or
repair work and to regulate the flow of water to individual cells shall be provided.
The water shall be discharged throughout the plan area of the packing. For counter
flow towers sufficient head room (minimum 1.8M) shall be provided between the
water distribution system and drift eliminator for inspection and maintenance. Fill
cone down spray/up spray water distribution system should be provided so that
there is no interference between the nozzle exit and top of fill.
4.07.02 Special requirements of distribution Nozzles:
The Nozzles shall be arranged in a uniform pattern with proper distance to produce
15% overlapping of the individual sprays.
Selected nozzle characteristics like ‘Head vs Flow’ and ‘Head vs Spread area’ at
three or four distances from nozzle bottom to fill top shall be furnished based on
the ‘Single nozzle test’ and ‘Four nozzle test’. Previous test reports are to be
furnished covering all tests along with the offer. In case the test was not conducted
in the past, the above tests shall be carried out in presence of the Employer.
Single Nozzle Test: The nozzle shall be placed at the bottom of the overhead tank.
The head in the tank can be maintained at different head of 0.1 m, 0.2 m and 0.3 m
by adjusting the inlet flow. The water spread area for different heads and flow can

COOLING TOWERS
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be measured with the help of spread measuring instrument (scale) in LHS and
RHS.
Four Nozzle Test: The nozzle shall be placed at the bottom of tank. The water
collecting compartment shall be placed at the bottom and center of spray nozzles.
For different head the quantity of water collected in the collecting compartments for
30 seconds/ 60 seconds shall be measured and this shall be verified with the
design prediction/ assumption.
Nozzle connection with internal hot water distribution pipes shall be preferably by
fasteners. Fasteners shall be of stainless steel. Push on fit type connection is not
acceptable.
4.07.03 Specific Requirements for cross flow towers: The hot water distribution basin shall
be provided with a suitable cover to avoid direct sun rays falling on the distribution
trough/basin to minimize algae growth and to prevent choking of distribution
nozzles. The covers provided shall be easily openable for inspection and
maintenance of the distribution system.
4.07.04 Specific Requirements for counter flow towers: All distribution pipe work shall be
adequately supported. The pipe supports shall accommodate thermal movement
while ensuring the pipe joints do not fail when subjected to pressure surges. The
Bidder shall submit the details of the proposed method of supporting distribution
system. The design calculations for sizing of the system shall be furnished by the
Bidder for Employer’s approval during detailed engineering stage.
4.07.04 Specific Requirements for Pultruded FRP Cooling Towers: Each riser pipe in case of
Pultruded FRP Cooling Towers shall be connected to the Cooling Tower shell
through a rubber expansion joint of the dia same as that of the riser pipe and
meeting the requirement of REJ as specified elsewhere in this specification.
4.08.00 Drift Eliminators
The drift eliminators shall be designed to keep the drift loss to a maximum of
0.007% of total water in circulation. The drift eliminators shall be of profile type and
gluing is not allowed. The air pressure drop across the eliminators shall be kept to a
minimum by providing proper number of air flow direction changes across the
eliminators. The water collected in the eliminators shall be returned to the tower
basin and shall not mix with the discharge air system.
4.09.00 Recovery Stack
Recovery stack shall be of proper shape to improve the fan performance. The
height of the stack shall be sufficient to recover the velocity and discharge the
humid air to a sufficiently high level to minimize recirculation. The maximum
efficiency of the stack for velocity recovery to be considered for calculation of fan
power consumption shall be 75%. No credit shall be given during bid evaluation
for efficiency of the stack for velocity recovery beyond the specified
efficiency. In case, Fan power consumption figure (quoted by the bidder) is
derived considering higher velocity recovery, the same shall be corrected for

COOLING TOWERS
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evaluation purpose. A minimum clearance between the stack and fan blades shall
be maintained along the entire periphery of the stack to prevent the rubbing of fan
blades while rotating.
4.10.00 Fan Deck
4.10.01 Fan deck shall act as an access platform for the mechanical equipment.
4.10.02 Adequate access for roof deck, fan deck, distribution level, drift eliminators shall be
provided. For counter flow towers there shall be provision for access to water
distribution level of each cell from tower roof deck or through stair case provided at
each cased face of the tower. Walkways with platforms and suitable hand and knee
rails and toe guards shall be provided inside towers.
4.10.03 Handrails shall be provided all around the periphery of the cooling tower fan deck.
Pipes shall be of 32 NB (Medium class). Handrails provided elsewhere should also
conform to the above specification.
4.11.00 Internal Walkways.
For Cross Flow Towers: Walkways with permanents and suitable hand rails shall be
provided inside the towers. The drift eliminators shall be easily accessible from
these walkways. One door at each cased face of the tower shall be provided.
4.12.00 Stair Case
For access upto the top (roof) of the cooling tower, two numbers of stair cases one
at each face of the tower shall be provided for cooling tower. The stair cases shall
be constructed adequately away from the face of cooling tower in order to prevent
splashing of water on the stairs.
4.13.00 Gear Box
4.13.01 The fans shall be motor driven through suitable reduction gear. Flexible coupling
shall be provided both at motor and reducer to minimize the effect of misalignment
on account of any setting and/or warping. Flexible couplings should be pin and
bush type. The support structure of the reduction gear shall be rigid. The reduction
gear shall be heavy duty type suitable for installation in outdoor and humid
environment. The gear drive shall be of spiral bevel or worm type and the reduction
may be accomplished either in single stage or multi stages.
4.13.02 The gearbox shall be of proven design. Design rating of the gear box shall be
arrived at after considering a service factor of minimum 3.0 on motor rating. In
selecting the gear box design rating the thermal derating effects at 50 degree C
shall also be considered. Detailed gear box sizing calculation shall be furnished for
Employer's approval during detailed engineering. In no case the design thermal
rating of the gear box shall be less than 125% of the name plate kW rating of the
selected drive motor. Also, the mechanical rating shall be checked so that minimum
25% margin is available at Pull Out Torque of the motor.

COOLING TOWERS
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4.13.03 The piping for oil level gauge/dipstick and thermometer shall be arranged in such a
way that oil can be drained and refilled from outside the stack. This pipe shall have
proper supports at frequent intervals and shall be insulated. Further, a breather
connection shall be provided in the gear box. The breather provided shall be such
that it prevents moisture from entering the gear box. The breather arrangement and
details of oil seals shall be to Employer’s approval. Oil temperature gauge should be
located outside the cell through a capillary tube which is connected to gear box
stub.
4.13.04 The gear box design should be such that the temperature of oil shall be within the
manufacturer’s recommended limits during all operating conditions.
4.13.05 The gear boxes shall utilize non-hygroscopic oil for lubrication so that its lubricating
properties are not lost if contaminated with water vapour.
4.13.06 Each gear box shall be provided with a base plate. The vibration measurement
sensors shall be mounted on the gear box. Vibration probe should not be mentioned
on the inspection cover of the gearbox.
4.13.07 Bidder shall furnish the maximum temperature that the lube oil can withstand and
shall guarantee the maximum value of lube oil temperature when the gear reducer
is in operation.
4.13.08 Offered gearbox (minimum one no.) shall be tested at full load at manufacturer’s
own or any third party testing facility to demonstrate its thermal performance.
4.14.00 Drive Shaft
The drive shaft shall be of tubular construction. The design of the shaft shall take
into consideration a factor of safety of 2 (minimum) over the torque to be transmitted
at design duty conditions. The fan shaft shall be designed in such a way that the
first critical speed shall be atleast 120% of the operating speed of the shaft. Shaft
design requiring intermediate bearings are not acceptable. The beams at fan deck
level should be designed based on dynamic analysis. The bearings shall be of
proven design and shall be suitable for operation in the humid condition prevalent in
the fan stack. The minimum life of bearing shall not be less than 30,000 working
hours. The drive shaft design shall be such that the fan blades should not be
damaged in case of shaft failure.
In case of Carbon fiber composite material, drive shaft shall have the following
additional requirements.
1) Shaft flanges shall be preferably of Carbon fiber composite material.
2) Bonding between shaft and shaft flange shall be done by a proven method.
3) The Carbon fiber composite material should be ultra violet ray stabilized.

COOLING TOWERS
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4.15.00 Fans
4.15.01 Induced draught fans of suitable capacity shall be provided. Fans shall be
axial/propeller type with blades which can be adjusted so that pitch can be altered
+/- 5 deg. from the normal setting. For adjusting the fan blades, graduated stop
marks with suitable locking arrangements shall be provided on the hub so that all
the blades can be set to the same angle accurately. The fan blades shall be easily
removable. These shall be of aero-foil section and shall provide uniform air velocity
from hub to tip with low noise and vibration. Fan shall be manufactured as per the
processes listed below:
 Hand Moulded Seamless FRP fan blades using ballooning method. The
method of hand moulding with parting plane is not acceptable.
 Hand moulded FRP fan blades with PU foam core and hot forming.
 Pultruded FRP fan blades.
4.15.02 Stack shall be provided to eliminate air turbulence in the throat area. Blades,
shanks and hubs shall be suitably insulated to prevent electrolytic corrosion.
4.15.03 The number of blades shall not exceed twelve (12) and the blade tip velocity shall
not exceed 65 m/Sec. Each fan shall be driven by an electric motor.
4.15.04 Fans to be supplied for this package shall be of proven design and make and shall
be subject to approval of Employer.
4.15.05 Fan for each cooling tower cell shall be sized (fan design point at test block) to have
at least 5% margin on flow and min 10% margin on total head over and above the
maximum cooling tower fan air flow and total head required (cooling tower fan duty
point), to meet the specified / guaranteed cooling tower performance. Bidder shall
submit detailed cooling tower fan calculation, characteristic curves etc. for the fan
sizing as per the above.
4.15.05 A scaled down model test of the fan offered shall be carried out by the contractor at
the fan supplier test facility or at any other identified / recognized fan test facility to
establish the rated parameters such as efficiency, power consumption etc. of the
fan. Scale of model shall be minimum 1:10. The test should be carried out prior to
start of manufacturing of the fan and shall be conforming to requirement of ANSI /
AMCA A 210 or equivalent code.
4.16.00 Fan Maintenance Facilities
4.16.01 For maintenance of drive equipment (Fan, motor, gear reducer, etc.) following
arrangements shall be furnished.
4.16.02 Each cell of cooling tower shall be provided with a monorail. In addition 3 numbers
of manually operated chain pulley blocks along with travelling trolley for each of the
cooling towers shall be provided. The capacity of the hoist shall be such as to be
able to lift the heaviest portion of the fan motor assembly, but in no case less than
2.0 MT. Out of these specified numbers of monorail hoists, one will be used to lift

COOLING TOWERS
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equipment from ground level to tower top and accordingly the lift shall be provided.
Balance two numbers of hoists shall be used for handling equipment for two (2)
numbers of cells simultaneously during maintenance. The lift of these two (2) hoists
shall be selected accordingly. In addition to the above a hand trolley which is sized
to carry the heaviest and largest single piece of equipment shall also be provided
for the cooling tower. This trolley will be used on the fan deck to transport
equipment from each cell to and from the end of tower where the monorail hoist is
located to lift equipment from ground level to tower top. For cross flow type of tower
care shall be taken so that the equipment to be lifted does not need to be carried
over the distribution basin. Suitable platforms/ scaffoldings (for atleast 2 fans) for
doing maintenance work in situ for gear reducer, fan and motor shall also be
provided in addition to permanent walkways as specified elsewhere in the
specification.
4.16.03 Alternative arrangements are also acceptable, if the arrangement provided is
adequate to carry out maintenance on atleast two cells of the tower simultaneously.
In such a case the complete equipment for easy removal of equipment from fan
flume and bringing it down to ground level shall be furnished. The arrangement
proposed shall be clearly brought out in the offer by the bidder.
4.17.00 Fan Motor
Each electric motor shall be provided with a base plate and a base frame. Fan
motor shall have atleast 10% margin over the maximum power requirement of the
fan when the fan is operating at its test block condition and at 50 deg C ambient
temperature as required at gear box input end.
4.18.00 Handling facility for Stoplog Gate
4.18.01 For isolation of the cold water basin of the tower, groove for steel stop log gate shall
be provided in the cold water outlet channel of each tower. Number of stoplogs to be
supplied by bidder shall be as mentioned in the civil section.
4.18.02 To handle the stop log gate a monorail beam at sufficient height shall be provided
across each cold water channel. A hand operated chain pulley block with travelling
trolley of adequate capacity (as mentioned in relevant sub-sections of civil sections
of this specifications) to handle the stop log gate shall be provided for each tower.
The capacity of hoist however shall in no case be less than 125% the weight of the
stoplog gate.
4.19.00 Torque Tube Support (in case of Pultruded FRP Tower)
4.19.01 The torque tube support shall be designed to stabilize the fan within the fan cylinder
and maintain constant alignment between the motor and gear reducer. The pipe,
heavy angles and plates shall be hot dip galvanized after assembly. It shall be
properly fastened to the structure.

COOLING TOWERS
CLAUSE NO.
5.00.00 MISCELLANEOUS
5.01.00 Necessary stub connections for pitot tube shall be provided in the hot water header
of cooling tower for measurement of flow using pitot tube as defined in mechanical
and C&I chapters.
5.02.00 Any special equipment tools and tackles required for the successful completion of
the Performance & Guarantee Test shall be included by the bidder in his scope.
6.00.00 TESTS AT SITE
6.01.00 After Installation at site, the complete systems/equipment will be operated at site to
show satisfactory performance as required by the applicable clauses of the
specification. Further, all piping shall be hydraulically tested at site.
7.00.00 PERFORMANCE & GUARANTEE TEST AT SITE
7.01.00 Bidder shall guarantee that the equipment offered shall meet the ratings and
performance requirements stipulated for various equipment covered in these
specifications.
7.02.00 The cold water temperature as specified in technical data sheets shall be
guaranteed for the design conditions of CW flow, range, ambient WBT specified in
technical data sheet and design power consumption indicated by the bidder.
7.03.00 Main Cooling Towers
The test circulating water flow shall be corrected for change in test fan power
consumption as compared to the design fan power consumption using the cube root
formula. “Predicted cold water temperature” shall then be arrived at from the
guaranteed cold water temperature by correcting the same for the test conditions of
range, ambient conditions and corrected circulating water flow using the
performance curves furnished by the contractor. In case the “Test cold water
temperature is higher than the “Predicted cold water temperature”, Employer
reserves the right to reject/accept the tower after assessing the liquidated damages.
The liquidated damages for not meeting the guarantee(s) have been specified
elsewhere.
7.04.00 The performance test of one of the Cooling Tower shall be carried out by the
Contractor through CTI approved/listed testing agency in presence of Employer. The
testing agency proposed by the Contractor shall be approved by the Employer. The
tower to be tested through CTI testing agency shall be decided / chosen by
Employer. For the balance cooling towers the demonstration performance test shall
be conducted as per the same approved PG Test procedure by the contractor
himself or by experienced reputed third party. In no case, the thermal performance of
these towers should be less than that of the tower tested by CTI agency. In case it is
found to be less, the contractor shall take appropriate measures and correct the
tower to improve its performance at least up to the level of performance of tower
tested by CTI agency, failing which the contractual obligation will not be completed.

COOLING TOWERS
CLAUSE NO.
The data logged in the data logger shall be given to EMPLOYER in soft form for
reference immediately after the test, which should be readable in EMPLOYER
computer. In case, any software is required, the same shall be supplied to employer
without any extra cost to employer. The CTI agency shall simultaneously submit
their final report to both Contractor as well as the client (EMPLOYER ).
7.05.00 To ascertain the fulfillment of Guarantees of the Cooling Towers, the test results of
the tower tested through CTI approved testing agency shall be considered for PG
test evaluation and based on the test result, the liquidated damage if applicable shall
be levied for all the Cooling Towers.
EMPLOYER approved PG test procedure to be followed and other conditions shall
be as given below.
7.05.01 Scope
Acceptance test procedure shall cover the determination of thermal performance
(i.e. cold water temperature at CT outlet) and verification of all the guarantee figures
of all the cooling tower(s) supplied for the project.
7.05.02 Purpose
The purpose of this test procedure is to describe instrumentation and procedures for
the testing and performance evaluation of water cooling towers.
7.05.03 Codes
The following codes and standards shall be applicable for conducting the tests
unless otherwise modified or supplemented by this procedure and mutually agreed
to between the Employer and Contractor
a) Code ATC-105 - Acceptance test code for water cooling towers(latest
Version).
b) BS-4485 - Specification for water cooling towers
c) BS-1042 - Methods for the measurement of fluid flow in pipes.
d) BS-3435 - Measurement of electrical power and energy in acceptance
testing.
e) ASME 19.5 - Supplements on instruments and apparatus.
7.05.04 Conduct of Tests
i) Test shall be conducted by accredited representatives of contractor/CTI
approved test agency as the case may be in presence of the Employer. The
detailed test procedure shall be submitted by the contractor in consultation
with the CTI approved/listed agency and approved by Employer. The
Contractor shall be given permission to inspect the tower in advance and
ready it for the test. Contractor’s representatives shall witness all phases of
the test and record the data jointly with the Employer’s representative in the
formats mutually agreed.

COOLING TOWERS
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ii) Test Instruments

a) The responsibility for conducting the test will be with the contractor.
b) All test instruments required for the PG Test will be provided by the
CTI approved testing agency for the tower to be tested by them and
by the contractor for the balance towers. Calibration of test
instruments shall be the responsibility of the contractor. All stubs/
tapping points are also to be provided by the contractor.
c) Calibration of instruments to be used in the test shall be carried out
by an approved independent agency. Calibration of instruments
should be carried out previous to, but not more than six months
before the test. The calibration certificate of the instruments should
be valid for the period of test.
d) List of instruments to be arranged by the contractor along with the
calibration certificates of the instruments to be used and
psychrometric charts and tables should be submitted to the Employer
for approval at least one month prior to commencement of PG test.
iii) PG test shall be carried out by the contractor along with successful
completion of trial operation of the cooling tower and at a time when the
atmospheric conditions are within limits of deviation from the design
conditions as specified in this section preferably in the period from May to
September.
iv) Performance Test shall be carried out based on ambient W.B.T (Wet Bulb
temperature). The performance curves of the towers showing variation in
performance with change in ambient wet bulb temperature, cooling range,
relative humidity (if applicable), water loading of the tower etc., required to
ascertain the performance of the tower shall be furnished alongwith the bid.
Performance curves applicable to 90%, 100% and 110% of the design water
flow rate shall be furnished. Each set shall consist of three or more cooling
range curves and atleast four relative humidity curves (if applicable),
arranged to show the effects of wet bulb temperature, relative humidity (if
applicable) and cooling range on outlet water temperature. The range curves
shall be presented in uniform increments of 0.5 deg. C, with sufficient scope
to cover approximately ± 20% of design range. The relative humidity curves
shall be presented for spaced increments to cover the extent of expected
conditions such as 5%, 20%, 40%, 60% and 100% relative humidity. The
design conditions shall be indicated on the set applicable to design water
flow rate. The dry bulb temperature associated with the wet bulb on each
fixed relative humidity graph shall be included (if applicable). The curves
shall fully cover (but not necessarily be limited to) the range of variations
specified in clause 7.05.06 (a) to (d) of this procedure. All performance
curves shall be based on ambient wet bulb temperature. Inlet W.B.T. shall

COOLING TOWERS
CLAUSE NO.
be measured for demonstration purpose only for induced draught towers.

For natural draft towers inlet wet bulb temperature need not be measured.
v) The guaranteed performance of the equipments shall be demonstrated by
the contractor after evaluating the P.G. Test. Should the result of the test
deviate from the guaranteed values the contractor shall be given an
opportunity to modify the equipment as required to enable it to meet the
guarantees. In such cases the P.G. Test shall be repeated within one month
from the date on which the equipment is ready for retest and cost of
modification, including labour, materials and cost of additional testing shall be
borne by the Contractor. The chance for repeat testing will be given only
once during the contract period. All the modifications carried out by the
Contractor in one cooling tower to meet the contractual requirements shall be
carried out free of cost to the Employer in other towers (if applicable for the
package).
vi) In case the test cold water temperature as determined from the PG Test is
higher than the predicted value (based on the performance curves),
Employer reserves the right to reject/accept the Tower after assessing the
liquidated damages as specified.
vii) A maximum tolerance of 0.3 deg C in the cold water temperature shall be
allowed to take care of design and instrument inaccuracies. No other
tolerances will be permitted.
7.05.05 Conditions of Equipment
At the time of the test the tower shall be in good operating condition. Tower may be
inspected and repaired, (if necessary) by the contractor, before the test to ensure
the following:-
a) Water distribution system shall be essentially clear and free of foreign
materials, which may impede the normal water flow.
b) Mechanical equipment shall be in good working order. Fans shall be rotating
in the correct direction, with proper orientation of leading and trailing edges.
Fan blades shall be adjusted to a uniform angle so that the test power
consumption is as close as possible to guaranteed power consumption.
guaranteed power consumption. Contractor shall ensure that the set blade
angle is not more than the design blade angle as per approved data sheet. In
addition, fans shall be free of foreign material and properly secured to the
shafts.
c) Drift eliminators shall be essentially clear and free of algae and other
deposits, which may impede normal air-flow.
d) Fill shall be essentially free of foreign materials such as oil, tar, scale or
algae.

COOLING TOWERS
CLAUSE NO.
e) Water level in cold water basin shall be at normal operating elevation and
shall be maintained substantially constant during the test.
f) Before conductance of the test, a joint protocol involving Contractor and
EMPLOYER representatives shall be made regarding readiness of the
tower for the test.
7.05.06 Operating Conditions
The test shall be conducted within the following limitations. Every effort shall be
made to run the test under design conditions, or as close to design conditions as
possible. The following variations from design conditions shall not be exceeded :-
a) Wet bulb temperature ± 8.5 deg. C
b) Dry bulb temperature (if applicable) ± 10 deg. C
c) Range ± 20%
d) Circulating water flow ± 10%
e) Heat load ± 20%
f) Fan power consumption ± 10%
For multi-cell towers, one or more cells may be shut down, provided the circulating
water flow to each operating cell is within the limits. The water distribution to all-
operating cells and/or parts of the tower shall be as envisaged in the design. The
ambient wind velocity shall be measured in accordance with subsequent Clause of
this test produce shall not exceed the following:-
Average wind velocity : 18 kmph
One minute duration : 25 kmph
7.05.07 Duration of test
After reaching steady state conditions, the duration of the test run shall not be less
than one hour. If thermal lag time is greater than five minutes, the time for the tests
period shall be at least one hour plus thermal lag time. For calculation of thermal lag
time refer Annexure –II of this Sub-section.
7.05.08 Frequency of observations
Readings shall be taken at regular intervals & recorded in the units and to the
number of significant figures as shown in the following tabulation:-
----------------------------------------------------------------------------------------------------------------
Sl No Measurement Minimum number Unit Record to
each hour station nearest
----------------------------------------------------------------------------------------------------------------
1. Wet bulb temperature 12 deg C 0.05

COOLING TOWERS
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2. Dry bulb temperature * 12 deg C 0.05
3. Cold water temperature 12 deg C 0.05

4. Hot water temperature 12 deg C 0.05
5. Fan power input 1 KW ---
6. Wind Velocity 6 KMPH ---

7. Circulating Water Flow** 3 — —
Note :
*If applicable.
**Single center point readings for comparison with full traverse reading taken before
test (when measurement is made by Pitot Tube). One full traverse shall be made
immediately preceding the test and a minimum of three center point readings shall
be taken during the test.
7.05.09 Constancy of test condition
For a valid test, variations in the test conditions shall be within the following limits:-
a) Circulating water flow shall not vary by more than 5%.
b) Heat load shall not vary by more than 5%.
c) Range shall not vary by more than 5%.

d) Instantaneous air temperature readings may fluctuate, but variations in the
averages during the test period shall not exceed 1 deg C per hour for Wet
bulb temperature and 3 deg C per hour for Dry bulb temperature (if
applicable).
7.05.10 Test Instruments, their Location & Method of Measurements
A) Wet Bulb Temperature
i) The wet bulb temperature shall be measured with calibrated RTDs accurate to
+0.5°C with measurement increments of not more than 0.1°C and each
meeting the following requirements:-
a) The temperature sensitive element shall be shielded from direct sunlight
or from other significant sources of radiant heat. Shielding devices shall
be substantially at the dry bulb temperature.
b) The temperature sensitive element shall be covered with a wick that is
continuously fed form a reservoir of distilled water.
c) The temperature of the distilled water used to wet the wick shall be at
approximately the wet bulb temperature being measured. This may be

COOLING TOWERS
CLAUSE NO.
obtained in practice by allowing adequate ventilated wick between the

water supply and the temperature sensitive element.
d) The wick shall fit snugly over the temperature sensitive element and
extend at least two centimeters past the element over the stem. It shall
be kept clean while in use.
e) The air velocity over the temperature sensitive element shall be
maintained between 290 and 320 meters per minute.
ii) Number of stations and their location
a) Ambient wet bulb temperature
The ambient wet bulb temperature shall be determined as the
arithmetical average of measurements taken at not less than three
locations approximately 1.5 meters above basin curb elevation, not less
than 15 meters or more than 100 meters to windward of the equipment,
and equally spread along a line substantially breaking the flow of air to
the tower, typical locations are shown in Fig. 1. If such location is
inaccessible or the area surrounding the tower contains elements which
can affect the ambient wet bulb temperature, a suitable location shall be
mutually agreed upon.
b) Inlet wet bulb temperature
For measurement of inlet wet bulb temperature, the instrument shall be
located within 1.5 M of the air intakes(s). A sufficient no. of measurement
stations shall be designated to ensure that the test average is an
accurate representation of the true average inlet wet bulb temperature.
The minimum number of stations for each air intake side may be
determined from the equation:
0.4
n =0.517 (A)
Where,
n = is the minimum no. of stations for each side of air intake.
A = is the area to be traversed in sq. meter.
(The area to be traversed applies to each individual air inlet area on each
side of the cooling tower, rather than the total area applicable for the
cooling tower). Each intake should be divided into `n' number of
imaginary rectangles and one wet bulb measurement station shall be
located in the mid point of each rectangle. Typical locations are shown in
Fig. 2 and 3 for counter-flow and cross flow towers respectively.
iii) The average of 3 successive readings taken at 10 second intervals at each
station shall be considered to wet bulb temperature at that time at that

COOLING TOWERS
CLAUSE NO.
instrument station. The station averages shall be averaged to obtain the

effective wet bulb temperature for that run. Such runs shall be made every 5
minutes during the test period and the arithmetic average of these runs shall
be considered the ambient or inlet wet bulb temperature, as the case may
be, and shall be used for the evaluation of results.
B) Dry Bulb Temperature: (If applicable)
i) The ambient dry bulb temperature shall be measured calibrated
RTDs accurate to +0.5 deg.C with measurement increments of not
more than 0.1 deg C and each meeting the following requirements:
a) The temperature sensitive element shall be shielded from
direct sunlight or from other significant sources of radiant heat.
Shielding devices shall be substantially at the dry bulb
temperature.
ii) For the measurement of ambient dry bulb temperatures, instrument
location, the number of station, the frequency of readings and the
reading and the averaging procedures shall be same as that of the
procedure described in previous clauses for wet bulb temperature.
C) Cold Water Temperature
i) Calibrated RTDs accurate to +0.5 deg.C with measurement
increments of not more than 0.1 deg C shall be used for measuring
cold water temperature.
ii) The cold water temperature should be measured directly at the
location where circulating water is discharged from the basin. A
minimum of 9 nos measurement points in the form of grid should be
used across the width & depth of the channel at the measurement
location, the average cold water temperature being determined by
simultaneous test reading across the section.
D) Hot Water Temperature:
i) Calibrated RTDs accurate to +0.5 deg.C with measurement
increments of not more than 0.1 deg C shall be used for hot water
temperature measurement.
ii) Hot water temperature measurement shall be made in the tower
risers or at the discharge of inlet risers into the flume or distribution
system or for a multi-cell tower in the supply header just upstream of
the first riser. If the source is a mixture of two or more streams of
different temperatures, complete mixing must be ensured at the point
of measurement.

COOLING TOWERS
CLAUSE NO.
E) Circulating Water Flow:

i) Wherever adequate upstream and down stream straight lengths are
available, suitable pitot probes, shall be used for the flow
measurement. Pitot probes shall conform either to ASME (19.5)
Section 4 (latest revision) or ISO 3966-1977. The probes shall be
provided with calibration carried out in a laboratory approved by
Employer. Pitot tube not conforming to the above codes but
fabricated by Indian Institute of Technology Bombay, Delhi/Indian
Institute of Science, Bangalore with recent calibration certificate could
be used after obtaining prior approval of Employer.
ii) In case adequate upstream and downstream straight lengths are not
available, the probe should conform to ISO-3966-1977. In addition
for velocity measurement, a `Yaw-probe' shall be required as per
ISO-7194-1983 for the measurement of swirl angle. Alternatively,
special probe developed by IIT/IISc for simultaneous measurement of
velocity and swirl angle can be used.
iii) For obtaining swirl free and fully developed flow condition the
minimum upstream and downstream straight lengths at the measuring
cross section shall be 20 pipe diameter and 5 pipe diameter
respectively. To meet the above criteria, it will be necessary to
provide the stubs alongwith the isolating valves in the underground
portion of the circulating water pipe/ducts leading hot water to the
tower. It is proposed to provide the stub connections in hot water
duct coming in Employer's scope of supply. Typical arrangement is
shown in Fig. 4. Provision shall be made for traversing two
diameters, at right angles to each other.
iv) In case it is not possible to comply with the straight length
requirement the stubs shall be located in hot water pipes where
maximum straight length is available. The flow shall be asymmetric
and traversing of 3 or 4 diameters shall be necessary depending
upon the available straight length and the type of disturbance.
v) For the measurement of differential pressure, inclined manometer
with low density liquid shall be used to minimize the reading error. In
case special probe developed by IIT/IISc is used, another manometer
with low density liquid shall be required for orienting the probe in the
flow direction.
F) Fan Power
i) Power consumption of the cooling tower shall be measured by two
watt-meter method using power analyzer at MCC incomer (after
switching off other miscellaneous load such as lighting, ventilation,

COOLING TOWERS
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etc) or at individual fan modules at MCC end and correction for power
loss in cable for each motor shall be computed as I2R. Current
measurement of individual fan shall be carried out by clipon meter &
resistance of cables shall be computed at (ambient temperature +
20deg.C.) for PVC cables & (ambient temperature + 40deg.C) for
XLPE cables. Power loss in the cable shall be computed by I2R
equation.
ii) Wherever power measurement as indicated at (i) above is not
feasible power input to one fan motor shall be measured by two watt
meter method and current & voltage by clip on meters. Power factor
of the fan shall be computed by the measured values of power,
current, voltage & using equation P = 3 V x I Cos Ø. Voltage &
current for other motors shall be measured by same clip on meters
used for first fan.
iii) Power consumption of the other fans shall be calculated using above
computed power factor.
iv) Correction for power loss in cable shall be calculated as discussed in
(i) above.
v) In case of dispute CT/VT error shall be estimated at EMPLOYER
site lab by comparison with higher accuracy class (standard) meters,
in the operating current region. Only CT and VT used for watt meter
need to be checked.
G) Wind Velocity
i) Wind Velocity shall be measured by a rotating cup type anemometer.
ii) Measurement shall be made in an open and unobstructed location
within 30 meters of and to windward of the tower at a point 1.5 meters
above the basin curb elevation. This location shall apply to check the
requirement specified in para titled “Operating conditions” in previous
clauses.
iii) For the measurement of ambient wet bulb temperature as indicated in
Fig. 1, direction of the wind shall be determined by the anemometer,
to fix the location of measurement stations.
7.05.11 Computation of Water Flow
The water flow for each radius traversed shall be determined separately by graphical
integration method. The curves shall be plotted between (radius) versus (radius x
velocity) on millimeter graph-sheets on large scale (not less than 1:5) to minimise
the computation error. The water flow is computed from the following equation:
Water flow (M3/S) = 2 x Pi( x Area under the curve.

COOLING TOWERS
CLAUSE NO.
The average flow of all radii traversed is the actual flow throughout the pipe.
The computed area by graphical integration shall be cross checked with calculated
area by numerical integration method. The area obtained by the two methods, may
differ depending upon the smoothening carried out while drawing the curves.
7.05.12 CALCULATION OF TOWER PERFORMANCE
Determination of predicted Cold Water temperature for CT
The cold water temperature shall be read from the performance curves for 90%,
100% and 110% of rated flows at test wet bulb temperature, range and relative
humidity (for natural draught tower only). The three points thus obtained from
performance curves are plotted to obtain a cross plot, which is a relation between
water flow and cold water temperature.
The test water flow is corrected for difference in fan power consumption from design
value as follows :
Corrected test water flow
= (Test Water Flow) x (Design power Consumption)1/3
(Test Power Consumption) 1/3
Power consumption figures used above shall be motor input power.
From the cross plot obtained above the predicted cold water temperature shall be
read at corrected test water flow.
7.05.13 Acceptance Criteria
For Cooling tower if the test cold water temperature is less than or equal to predicted
cold water temperature as detailed in above, the tower is deemed to have met the
guarantee.
8.00.00 CONTROL AND OPERATION PHILOSOPHY
This control write-up and operation philosophy detail the requirements of the
interlocks and sequence related to the operation of fans for the cooling towers. This
gives only a general guideline and the contractor shall furnish his proposed
philosophy write-up during detailed engineering based on Contractor’s
system/equipment design and the same shall be as per approval of Employer.
8.01.00 Modes of Operation:
The fans can be started in SOLO mode or in GROUP mode. The selection for
individual and Group operation shall be made from OWS. Further, each fan can be
put either in STANDBY mode or NOT IN STANDBY mode.

COOLING TOWERS
CLAUSE NO.
8.01.01 Group Mode

START In Group Mode:
On receipt of the GROUP START command from OWS, all pre-selected fans
(except for the fans selected as “STANDBY”) would start sequentially one after
another after pre-defined time gap between start of the fans.
STOP in GROUP Mode:
On receipt of the GROUP STOP command from OWS, all the running fans will be
tripped simultaneously. GROUP STOP command will have priority over and already
executing GROUP START command.
8.01.02 SOLO Mode:
In the OWS, for each individual FAN, a separate START/STOP facility will be
provided. The START facility will be enabled only when the SOLO mode is selected.
A fan can be started in SOLO mode immediately by pressing the START button. The
fan can be stopped either by STOP (of the corresponding Fan) or GROUP STOP.
8.02.00 Interlock and Protection
Following are the Start-up permissive for the fans:
1. MCC Healthy
2. Oil Level Not Very Low
3. Emergency PB not pressed
4. Gear box oil Temperature not high
Following are the protections for Fan tripping:
1. Oil Level Very Low
2. Emergency PB Pressed
3. Vibration Very High
4. Motor Overload
5. Gear box Temperature very high
Control system shall issue only OPEN/CLOSE command for Electrical Breaker
operation and shall monitor status. Necessary interlocks as finalised during detailed
engineering shall be implemented.
The close status of butterfly valves of each cell and the ON/OFF /TRIP status of fans
shall be indicated in the OWS. Operator shall be alerted through audio visual
indication during the condition when the fan of any cell is ON and the corresponding
cell isolation valve is closed or vice-versa.

COOLING TOWERS
CLAUSE NO.
8.03.00 Modification Of Set-Points etc.

In OWS, there should be a provision to modify the ALARM and TRIP setpoint for the
vibration monitoring system as well as for the sequence times under proper
password protection and available only to the system maintenance engineer/
administrator. The operators can, however, view the settings.
9.00.00 FOLLOWING FIGURES/SKETCHES REFERRED IN THIS SUB-SECTION ARE
ENCLOSED AT THE END OF THIS SUB-SECTION.
Sl. Drawing No. Sht Nos Drawing Title

No.
1. Fig:1 1 Sheet Location of Ambient Wet Bulb

Temperature Stations
2. Fig:2 1 Sheet Location of inlet Wet Bulb

Temperature for Counter Flow
Towers
3. Fig:3 1 Sheet Location of inlet Wet Bulb

Temperature for Cross Flow Towers
4. Fig :4 1 Sheet Stub Detail for Pitot tube traverse in

CW ducts

COOLING TOWERS
CLAUSE NO.
ANNEXURE-II
CALCULATION OF THERMAL LAG TIME
Normally the interval from the time the cold water reaches the collecting basin to the
time it reaches the cold water temperature measurement station is small, and
computation of thermal lag is not required. If this time interval determined by the
following equation, is greater than five minutes, the test duration shall be lengthened
by a like amount, and the test averages shall be based on compensating time spans,
so that the readings chosen shall represent the true tower performance.
Vb
S=
F
Where,
S = Thermal lag time in minutes
Vb = Volume of water in basin during test in M3
F = Test water flow, Cu.M/minute
For proper compensation for thermal lag, the following readings will be averaged
over the first part (usually 60 minutes) of the total duration (except at (e))
a) hot water temperature
b) Dry bulb temperature (if required)
c) Wet bulb temperature
d) Water flow
e) Cold water temperature (first “S” minutes readings to be omitted for the
average. Test averages will be averaged only over the remainder of the test
period)
Thermal lag less than five minutes may be ignored.

COOLING TOWERS
CLAUSE NO.

COOLING TOWERS
CLAUSE NO.

COOLING TOWERS
CLAUSE NO.

COOLING TOWERS
CLAUSE NO.

COOLING TOWERS
METERING PUMP

CLAUSE NO.
METERING PUMPS
1.00.00 GENERAL
This specification provides guidelines for design, manufacturing and testing of

positive displacement pumps with variable capacity to inject chemicals, generally
used in the treatment of water in metered amounts.
2.00.00 GENERAL DESIGN FEATURES
a) Pumps shall be simplex displacement hydraulically operated diaphragm

design, driven by squirrel cage induction motor through suitable speed
reduction unit. Maximum pump stroke speed shall not exceed 100 per
minute.
b) The stroke shall be continuously adjustable to give a capacity variation 10-

100% range while the pumps is running or stopped. Adjustment of capacity
shall be done by automatically from remote location and / or manually
(micrometric adjusting type) locally for each of the pump as described
elsewhere..
c) Capacity variation may be effected by changing eccentricity of the driving

crank or by suitable hydraulic circuit. Pump accuracy shall be industry
standard + 1% of capacity setting.
d) Pumps shall be provided with an integral relief valve, spring operated, to

release pressure when delivery line blockage occurs.
e) Crank case shall be constructed of high quality cast iron which will also
house the gear box and guides for cross head.
f) Guided, controlled travel, double-ball check valves or equivalent, shall be

provided both on the suction and discharge sides.
g) Material of construction of the various parts shall be as per the data sheets.
h) Suitable gland seal be provided to prevent leakage.
3.00.00 TEST AT SITE
After erection at site pumps as detailed under different groups shall be operated to
prove satisfactory performance as individual equipment as well as a system. If the
performance at site is found to be not to the requirements, then the equipment shall
be rectified or replaced by the vendor at no extra cost to the Employer.

PAGE
(2X660 MW) SECTION – VI, PART-B SUB-SECTION-IIIA-05
1 OF 1
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 METERING PUMPS
LOW PRESSURE PIPING

CLAUSE NO.
LOW PRESSURE PIPING
1.00.00 EQUIPMENT SIZING CRITERIA
1.01.00 All the piping systems and equipment supplied under this package shall be designed to
operate without replacement and with normal maintenance for a plant service life of 30 years,
and shall withstand the operating parameter fluctuations and cycling which can be normally
expected during this period.
1.02.00 For all Low Pressure piping systems covered under this specification, sizing and system
design shall be to the requirements of relevant codes and standard indicated. In addition to
this, requirements of any statutory code as applicable shall also be taken into consideration.
1.03.00 Inside diameters of piping shall be calculated for the flow requirements of various systems.
The velocities for calculating the inside diameters shall be limited to the following:
a) Water Application
Water Velocity in m/sec

Pipe Size Below 50-150 200 mm
50 mm mm & above
(a) Pump suction ------ 1.2-1.5 1.2-1.8
(b) Pump discharge

and recirculation 1.2-1.8 1.8-2.4 2.1-2.5
(c) Header ------ 1.5-2.4 2.1-2.4
Pipe line under gravity flow shall be restricted to a flow velocity of 1 m/sec generally.
Channels under gravity flow shall be sized for a maximum flow velocity of 0.6 m/sec.
WILLIAM & HAZEN formula shall be used for calculating the friction loss in piping
systems with the following "C" value:
(i) Carbon steel pipe 100
(ii) Ductile Iron. 140
(iii) Rubber lined steel pipe 120
(iv) Stainless steel pipe 100
For calculating the required pump head for pump selection, at least 10% margin
shall be taken over the pipe friction losses and static head shall be calculated from
the minimum water level of the tank/ sump/ reservoir from which the pumps draw
water.
(b) Compressed Air Application
Compressed air 15.0 m/sec.(under Average Pressure & Temp. conditions)

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WATER SYSTEM PACKAGE BID DOC NO.:THDC/RKSH/CC-9915-373 (LOW PRESSURE PIPING)
CLAUSE NO.
1.04.00 The pipes shall be sized for the worst (i.e. maximum flow, temp. and pressure values)
operating conditions.
1.05.00 Based on the inside dia. so established, thickness calculation shall be made as per ANSI B
31.1 OD and thickness of pipes shall than be selected as per ANSI B 36.10/IS-1239 Heavy
grade/IS-3589/ASTM-A-53/API-5L/ANSI B 36.19 as the case may be.
1.06.00 Corrosion allowance of 1.6 mm will be added to the calculated thickness being considered
(except stainless steel piping).
1.07.00 Bend thinning allowance/manufacturing allowance etc. shall be as per the requirement of the
design code provision.
1.08.00 High points in piping system shall be provided with vents along with valves as per the system
requirement. Low points shall be provided with drains along with drain valves as per the
system requirement. Drain lines shall be adequately sized so as to clear condensate in the
lines. Material for drain and vent lines shall be compatible with that of the parent pipe
material.
1.09.00 Material of construction for pipes carrying various fluids shall be as specified elsewhere.
1.10.00 Compressed air pipe work shall be adequately drained to prevent internal moisture
accumulation and moisture traps shall be provided at strategic locations in the piping
systems.
1.11.00 Depending upon the size and system pressure, joints in compressed air pipe work shall be
screwed or flanged. The flange shall be welded with the parent pipe at shop and shall be hot
dip galvanized before dispatch to site. Alternatively, the flanges on GI pipes may be screwed-
on flanges also.
1.12.00 Threaded joints shall be provided with Teflon sealant tapes.
1.13.00 Following types of valves shall be used for the system/service indicated.
SYSTEM TYPES OF VALVES
Butterfly Gate Globe Check Ball Plug
Water x x x x x
Air x x x x
Drains & vents x x x
Fuel oil (if any) x x x x x
1.14.0 Recirculation pipes along with valves, breakdown orifices etc. shall be provided for
important pumping systems as indicated in respective process and instrumentation diagrams
(P&IDs). The recirculation pipe shall be sized for minimum 30%design flow of single pump
operation or the recommended flow of the pump manufacturer whichever is higher.

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CLAUSE NO.
2.00.00 TECHNICAL SPECIFICATION
2.01.00 GENERAL
Specific technical requirements of low-pressure piping, fittings, supports, valves, specialties

and tanks etc. have been covered under this Sub-section. It includes details pertaining to
design and material of construction for piping, fittings, valves, equipment, etc.
cleaning/surface preparation application of primer and painting on over ground piping. It also
includes detailed technical requirement of laying underground/buried piping including water
proofing/anti corrosive protection. It also covers design, engineering, manufacturing,
fabrication, technical details of piping, valves, specialties, piping hangers / supports, tanks
etc.
2.02.00 Pipes and fittings
2.02.01 All low pressure piping systems shall be capable of withstanding the maximum pressure in
the corresponding lines at the relevant temperatures. However, the minimum thickness as
specified in the following clauses and or respective codes for pipes and fittings shall be
adhered to. The bidder shall furnish the pipe sizing/ thickness calculation as per the criteria
mentioned above under LP piping equipment sizing criteria of this Technical Specification.
2.02.02 Piping and fittings coming under the purview of IBR shall be designed satisfying the
requirements of IBR as a minimum.
2.02.03 Supporting arrangement of piping systems shall be properly designed for systems where
hydraulic shocks and pressure surges may arise in the system during operation. Bidder
should provide necessary protective arrangement like anchor blocks/anchor bolt etc. for the
safeguard of the piping systems under above mentioned conditions. The requirement will be,
however, worked out by the contractor and he will submit the detailed drawings for
thrust/anchor block to the Employer. External, and internal, attachments to piping shall be
designed so as not to cause flattening of pipes and excessive localized bending stresses.
2.02.04 Bends, loops, off sets, expansion or flexible joints shall be used as required in order to
prevent overstressing the piping system and to provide adequate flexibility. Flexibility
analysis (using software packages such as Caesar-II etc.) shall be carried out for sufficiently
long piping (straight run more than 300M).
2.02.05 Wherever Bidder's piping coming under this specification, terminates at an equipments or
terminal point not included in this specification, the reaction and the thermal movement
imposed by bidder's piping on equipment terminal point shall be within limits to be approved
by the Employer.
2.02.06 The hot lines shall be supported with flexible connections to permit axial and lateral
movements. Flexibility analysis shall be carried out for pipelines which have considerable
straight run as indicated above and necessary loops/ expansion joint etc. shall be provided
as may be necessary depending on layout.
2.02.07 Piping and fittings shall be manufactured by an approved manufacturer of repute. They
should be truly cylindrical of clear internal diameter, of uniform thickness, smooth and strong,
free from dents, cracks and holes and other defects.
2.02.08 For rubber lined ERW pipes, beads shall be removed for pipe size 80 NB and above.

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CLAUSE NO.
2.02.09 Inspection holes shall be provided at suitable locations for pipes 800 Nb and above as
required for periodic observations and inspection purposes.
2.02.10 At all intersection joints, it is Contractor's responsibility to design and provide suitable
reinforcements as per the applicable codes and standards.
2.02.11 For large size pipes/ducts, at high point and bends/change of direction of flow, air release
valves shall be provided as dictated by the system requirement and operation philosophy &
tripping conditions of pumping system. Sizing criteria for air release valves shall be generally
on the basis of valve size to pipe diameter ratio of 1:8. Requirement shall be decided as per
relevant code.
Transient analysis /surge analysis where ever specified and required shall be conducted in
order to determine the location , number and size of the Air-Release valve on certain long
distance/high volume piping systems, if applicable within the scope of work of the package.
2.03.00 Material
2.03.01 Alternate materials offered by Bidder against those specified. shall either be equal to or
superior to those specified, The responsibility for establishing equality or superiority of the
alternate materials offered rests entirely with the Bidder and any standard code required for
establishing the same shall be in English language.
2.03.02 No extra credit would be given to offers containing materials superior to those specified.
Likewise no extra credit would be given to offers containing pipe thickness more than
specified.
2.03.03 All materials shall be new and procured directly from the manufacturers. Materials procured
from traders or stockists are not acceptable.
2.03.04 All materials shall be certified by proper material test certificates. All material test certificates
shall carry proper heat number or other acceptable references to enable identification of the
certificate that certifies the material.
2.03.05 Material of construction for pipes carrying various fluids shall be as follows:
Sl No Type of Fluid Material

1. i) Ordinary Water (Raw Water, IS-2062 Gr.-E-250B/ASTM A-36/ASTM A-53
Clarified Water, etc.) type 'E'Gr.B/IS-3589 Gr. 410 /IS-1239 Heavy.
2. i) Demineralised water, Stainless Steel to ASTM A312, Gr. 304

welded for sizes 65 mm NB and above.
Stainless steel to ASTM A312, Gr. 304
sch.40s seamless for sizes 50mm and below
3. i) Drinking (potable) water ASTM A-53 type E Gr. B galvanized/ IS 1239
ii)Compressed air (Instrument & Gr heavy galvanized/IS 3589 Gr 410
service air) galvanized. Galvanized shall be to IS- 4736
or equivalent.
4. Effluents from Neutralization pit MSRL

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CLAUSE NO.
2.03.06 In water lines, pipes upto 150mm Nb shall conform to ANSI B36.10/ASTM-A-53, Type-E Gr.B
/IS:1239 Gr. Heavy and minimum selected thickness shall not be less than IS:1239 Grade
Heavy except for demineralised water, drinking water and condensate spill lines.
2.03.07 Pipes of above 150mm Nb shall be to AWWA-C200/ANSI B 36.10/ASTM A-53/IS 3589

Gr.410. Pipe to be fabricated by the bidder shall be rolled and butt welded from plates
conforming to ASTM A-53 type 'E' Gr. B/IS 2062 Gr.E-250B/ASTM-A-36. However, larger
pipes, i.e. 1000mm Nb and above shall be made from plates conforming to ASTM A 36/IS
2062 Gr.E-250B and shall meet the requirements of AWWA-M-11 (for deflection & buckling
criteria considering water filled pipe as well as vacuum condition that may prevail during
transient/surge conditions, truck-load, rail-load and weight density for compacted soil or any
other load as the case may be).
2.03.08 In demineralised water service, the pipes upto 50 Nb shall be of stainless steel ASTM A 312,
Gr. 304 sch. 40 Seamless. The size for these pipes shall be to ANSI B 36.19. These shall be
socket welded. The material for pipe from 65mm NB upto and including 400 NB shall be to
ASTM A 312, Gr. 304 (welded). In no case the thickness of fittings shall be less than parent
pipe thickness.
Bidder/Contractor shall note that pipes offered as per a particular code shall conform to that
code in all respects i.e. Dimension, tolerances, manufacturing methods, material, heat
treatment, testing requirements, etc. unless otherwise mentioned elsewhere in the
specification.
2.03.09 Instrument air, Plant (service) air lines and Drinking water lines shall be to ASTM A 53 type E
grade B/ANSI B 36. 10/IS 3589, Gr. 410 / IS: 1239 Heavy (in case thickness calculated is
more than gr. Heavy, ANSI B 36.10 Schedule numbers shall be followed) and galvanized to
IS 4736 or any equivalent internationally reputed standard. The material of the pipes shall be
to ASTM A 53 type 'E' Gr. B / IS: 3589, Gr. 410 / IS: 1239 Gr. Heavy. The fittings shall be of
either same as parent material or malleable iron to IS-1879 (galvanized).
2.03.10 Spiral welded pipes as per API-5L/IS-3589 are also acceptable for pipe of size above 150
NB. However minimum thickness of the pipes shall be as elaborated in above clauses.
2.03.11 Condensate lines shall be to ASTM A 106 Gr. B and dimension to ANSI B 36.10 schedule
"standard" as minimum to be maintained.
2.03.12 If carbon steel plates of thickness more than 12 mm are used for manufacture of pipes,
fittings and other appurtenances, then the same shall be control-cooled or normalized as the
case may be following the guidelines of the governing code.
2.04.00 Field routed pipes:
2.04.01 Pipe lines of NB 50 size and below are regarded as field run piping. It is Bidder's
responsibility to plan suitable layouts for these system insitu. Bidder shall prepare drawings
indicating the layout of field run pipe work. These drawings shall be approved by Project
Manager to the installation of the field run pipe work. Based on these approved layouts the
Bidder shall prepare the BOQ of field run-pipes and submit to Employer for approval.
2.05.00 Slope/Drains and Vents
2.05.01 Suitable slope shall be provided for all pipelines towards drain points. It is Bidder
responsibility to identify the requirements of drains and vents, and supply the necessary pipe
work, valves, fittings, hangers and supports etc. As per the system requirement low points in
the pipelines shall be provided with suitable draining arrangement and high points shall be
provided with vent connections where air or gas pockets may occur. Vent for use during
hydrostatic test shall be plugged after the completion of the test. Vent shall not be less than
15mm size. Drains shall be provided at low points and at pockets in piping such that

5 OF 16
CLAUSE NO.
complete drainage of all systems is possible. Drain shall not be less than 15mm for line size
up to 150mm, not less than 20mm up to 300mm and not less than 25mm for 350mm to
600mm pipes and not less than 50mm for 600mm and above pipes.
2.05.02 Air piping shall be sloped so that any part of the system can be drained through the shut-off
drain valve or drain plugs.
2.06.00 Pipe Joints
In general all water lines 65mm NB and above, are to be joined generally by butt welding
except the locations where valves/fittings are to be installed with flanged connections and
50mm and below by socket welding unless mentioned otherwise specifically. All air lines
shall be of screwed connection and rubber lined pipes of flanged connections.
2.06.01 Screwed Joints
(a) Threading of pipes shall be carried out after bending, heat treatment etc. If not
possible, threading may be done prior to these operations but proper care should be
taken to protect them from damage. Threads shall be to ANSI B 2.1 (taper) NPT/
ANSI B1.20.1 (taper) NPT / IS: 554 unless specified otherwise.
(b) Galvanized pipe shall generally be joined by screwing into sockets. The exposed
threaded portion on the outside of the pipes shall be given a zinc silicate coating.
Galvanized pipes shall not be field joined by welding for protection of Galvanising
Zinc layer. Screwed ends of GI pipes shall be thoroughly cleaned and painted with a
mixture of red and white lead before jointing. For galvanized pipe sizes above 150
mm NB, screw & socket jointing as per ASTM-A-865 shall be employed for both
pipe-to-pipe and pipe-to-fitting jointing. For pipe to fitting connection since no direct
threading can be done on the fittings (supplied as per ASTM-A-234 Gr. WPB and
ANSI B-16.9) necessary straight pipe lengths acting as match pieces shall be welded
to the fitting at both ends and subsequently the free ends of the straight lengths shall
be threaded as per ASTM A-865 for jointing with main pipe. Once welding of fittings
with match pieces and threading of free ends of match pieces are over, the entire
fabricated piece shall be galvanized, or in case match pipes and fittings are already
galvanized before the above mentioned fabrication then suitable application of Zinc-
Silicate paste adequately at the welded surface (both in side & out side) after welding
with zinc rich electrode, along with the nascent threaded metal portions at both free
ends given the same application of Zinc Silicate paste. Alternatively flanged jointing
may be employed for pipe sizes 100 NB and above. However, the bidder shall
ensure the galvanized pipe joints do not fail during hydro test.
(c) Teflon tapes shall be used to seal out screwed joints and shall be applied to the male
threads only. Threaded parts shall be wiped clean of oil or grease with appropriate
solvent if necessary and allowing proper time for drying before applying the sealant.
Pipe ends shall be reamed and all chips shall be removed. Screwed flanges shall be
attached by screwing the pipe through the flange and the pipe and flange shall be
refaced accurately.
(d) For pipe sizes from 350 mm NB to 550 mm NB (including 350 NB & 550 NB) the GI
pipes shall be of flanged connection. However, the pipes after welding of flanges
shall be completely galvanized. Any site welding done on galvanized pipes shall be
done with zinc-rich special electrodes and the welded surfaces whether inside or
outside shall be coated with zinc-silicate paste. Seal welding of flanges with zinc-rich
electrode will be permitted only when any flange is leak-prone during hydro testing.
(e) For pipe sizes 600 mm NB and above, the GI pipes shall be of welded connection
(with zinc-rich special electrodes) followed by application of zinc silicate coating at
welded surfaces both inside and outside the pipe, except for the last blank/blind

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CLAUSE NO.
flange, or, equipment connection where application of zinc-silicate paste after

welding cannot be done due to inaccessibility of the inside welded surface and where
galvanic protection has been impaired due to welding of pipe-to-pipe joint. Thus the
last erection joint shall be flanged joint.
2.06.02 Welded Joints
(a) For making up welded joints (butt weld or socket weld) the welding shall be
performed by manual shielded metal arc process in accordance with the
requirements specified elsewhere in the spec. Any welder employed for carrying butt
welding shall be qualified as per ASME section IX for the type of joints he is going to
weld. Jointing by butt weld, or socket weld shall depend upon the respective piping
material specifications.
2.06.03 Flanged Joints
(a) Flanged connections for pipes are to be kept to the minimum and used only for
connections to vessel, equipments, flanged valves and other fittings like
strainer/traps/orifices etc. for ease of connection and maintenance etc. Rubber lined
pipes shall be flange joined only.
(b) All flanged valves intended for installation on steel piping system, shall have their
flanges drilled to ANSI B 16.5 (or equivalent) and according to the pressure class
stated in their respective piping material specification.
(c) Drilling on flanges of flanged valves must correspond to the drilling of flanges on the
piping system on which the valves are installed.
2.07.00 Bends/elbows/mitre bends/ Tees/ Reducers & other fittings
2.07.01 For pipe fittings such as elbows (long radius), reducers, tees, etc. the material shall be to
ASTM-A-234 Gr. WPB/ASTM-105 up to 300 NB. For pipe fittings above 300 NB, the fittings
may be fabricated conforming to parent pipe material. Provision of compensation pads shall
be kept as per ANSI B 31.1. The fitting shall conform to the dimensional standard of ANSI B-
16.9/ 16.11.Further branching in pipes for sizes 65nb and above is also acceptable (ANSI B
31.1).
However, for pipes up to 150 NB, pipe fittings may be supplied with material and dimension
conforming to IS 1239 in case parent pipes also conform to IS 1239.
2.07.02 For pipe size 350Nb and above mitre bends may be used for all pipes except rubber lined
pipes. However, mitre bends are also acceptable for rubber lined pipes above 1200 NB. The
bend radius shall be 1½ times the nominal pipe diameter. 90 deg. bends (mitre) shall be in 4
pieces (3 cuts) and 45 deg. mitre bends shall be in 3 pieces 22½ deg. Fabrication of mitre
bends shall be as detailed in BS 2633/BS534.
2.07.03 For pipes, above 1200 NB, reducer and tees shall be to dimensional standard of AWWA-C-
208.
2.07.04 Stainless steel fittings shall conform to either ASTM-A-182 Gr. 304 or ASTM-A-403 Grade
WP. 304 Class-S, for sizes upto and including 50 mm NB, i.e. the fittings shall be of
seamless construction. However, for stainless fittings above 50 mm NB, the same shall
conform to ASTM-A-403 Gr. WP 304 Class W i.e. the fittings shall be of welded construction
strictly in accordance with ASTM-A-403.
2.07.07 In no case, the thickness of fittings shall be less than the thickness of parent pipe,
irrespective of material of construction.

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CLAUSE NO.
2.08.00 Flanges
2.08.01 Flanges shall be slip on type or weld neck type. Welding of flanges in tension is not
permitted.
2.08.02 All flanges and-flanged drilling shall be to ANSI B 16.5 / BS EN-1092 / AWWA C - 207 of
relevant pressure/temperature class. Flanges shall be fabricated from steel plates
conforming to ASTM A 105/IS 2062 Gr. E-250B. However stainless steel flanges shall be
fabricated from SS plates to ASTM-A-240, Gr. 304 or equivalent.
2.09.00 Specific technical requirement of laying buried pipe with anti-corrosive treatment
The pipe in general shall be laid with the top of the pipe minimum 1.0 (one) meter below
finished general ground level.
2.09.01 Trenching
(a) The trench shall be cut true to the line and level and shall follow the gradient of the
pipeline. The width of the trench shall be sufficient to give free working space on
each side of the pipe. Trenches shall conform to IS 5822 or any international
standard.
2.09.02 Preparation and cleaning of piping
(a) The pipeline shall be thoroughly cleaned of all rust, grease, dirt, weld scales and
weld burrs etc. moisture or other foreign matter by power cleaning method such as
sand or grit blasting, power tool cleaning, etc. Grease or heavy oil shall be removed
by washing with a volatile solvent such as gasoline. Certain inaccessible portions of
the pipeline (which otherwise not possible to be cleaned by power cleaning methods)
may be scrubbed manually with a stiff wire brush and scrapped where necessary
with specific permission of the Project Manager.
(b) On the internal surface for pipes 1000 Nb and above, a coat of primer followed by a
hot coal-tar enamel or coal tar epoxy painting (cold) shall be applied.
2.09.03 Coating and wrapping/ Anti corrosive Protection Coal tar tape
a. Buried piping shall be coated and wrapped, as per specification, after completion of
welded and/or flanged connections, and after completion and approval of Hydro
testing. Materials to be used for coating and wrapping of underground pipelines are:
(1) Coating primer (coal tar primer)
(2) Coating enamel (coal tar enamel)
(3) Wrapping materials.
All primer/coating/wrapping materials and methods of application shall conform to IS:

10221 except asphalt/bitumen material. Materials (primer/coating/wrapping) as per
AWWA-C-203 are also acceptable.
Protective coating shall consist of coal tar primer, coal tar enamel coating, glass
fiber, tissue inner wrap followed by glass fiber or coal tar impregnated Kraft outer
wrap or finish coat.
Number of coats and wraps, minimum thickness for each layer of application shall be
as per IS-10221. Number of. Coats and wraps shall be decided based on soil

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CLAUSE NO.
corrosivity/resistivity as indicated in IS-10221. Soil data-for this purpose shall be

made available.
Total thickness of completed coating and wrapping shall not be less than 4.0 mm.
b. Alternatively, the anti-corrosive protection for buried pipes can consist of anti-
corrosive protection Coal-tar tapes. Material and application of tapes shall conform to
IS 15337 or equivalent. These-tapes shall be applied hot over the cold coal tar
primer in steps of 2mm thickness so as to cover the spiral edges of the first tape by
the application of second tape. The total thickness of the finished protective coating
shall be 4.0 mm minimum.
2.09.04 Trench bed preparation and back filling
Prior to lowering and laying pipe in any excavated trench, the bottom of the trench may
require to be back filled and compacted (or as the case may be) to provide an acceptable
bed for placing the pipe. Bed preparation in general shall be as per IS: 5822.
2.09.05 Laying of galvanized steel (GI) pipes
All the joints shall be screwed with socket or flanged. Screwed ends of GI pipes shall be
thoroughly cleaned and painted with a mixture of red and white lead before jointing Threaded
portion on either side of the socket joint shall be applied with Zinc silicate paste.
All the provisions for trenching' bed preparation' laying the pipe application of primer' coating'
wrapping with tapes and back filling etc. as indicated for "laying of buried piping" and " anti
corrosive protection for buried piping" are applicable for buried galvanized steel (GI) pipes
also.
2.10.00 Cleaning and flushing
2.10.01 All piping shall be cleaned by the Bidder before and after erection to remove grease, dirt,
dust, scale and welding slag.
2.10.02 Before erection all pipe work, assemblies, sub-assemblies, fittings, and components, etc.
shall be thoroughly cleaned internally and externally by blast cleaning or by power driven
wire brushes and followed by air-blowing . However for pipe sizes below 100nb the pipes
may be cleaned internally by compressed air blowing as an alternative to internal blast
cleaning. The brushes shall be of the same or similar material as the metal being cleaned.
Cleaning of Galvanized pipes shall be done by air blowing only.
2.10.03 After erection, all water lines shall be mass flushed with water. The cleaning velocities in
water lines shall be 1.2-1.5 times the operating velocities in the pipelines.
2.10.04 All compressed air pipe work shall be cleaned by blowing compressed air.
2.11.00 Specification for hangers and supports
2.11.01 All supports and parts shall conform to the requirement of power piping code ANSI B 31.1 or
approved equivalent.
2.11.02 The maximum spans of the supports of straight length shall not exceed the recommended
values indicated in ANSI B 31.1.
2.11.03 At all sliding surfaces of supports suitable arrangement is to be provided to minimize sliding
friction.

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CLAUSE NO.
2.12.00 Design/Construction/Material Particulars of Gate/ Globe /Check /Butterfly / Ball / Air

release /Float valves / Moisture Traps.
2.12.01 GENERAL
(a) All valves shall have indicators or direction clearly marked on the hand-wheel so that
the valves opening/closing can be readily determined.
(b) Special attention shall be given to operating mechanism for large size valves with a
view to obtaining quick and easy operation ensuring that a minimum of maintenance
is required.
(c) The valves coming in vacuum lines shall be of extended gland type and/or water
sealed.
(d) The actuator-operated valves shall be designed on the basis of the following:
(1) The internal parts shall be suitable to support the pressure caused by the
actuators;
(2) The valve-actuator unit shall be suitably stiff so as not to cause vibrations,
misalignments, etc.
(3) All actuator-operated valves shall be provided with hand operated gearing
mechanism also.
(4) All actuators operated valves shall open/ close fully within time required
by the process.
(e) Valves coming under the purview of IBR shall meet IBR requirements.
(f) All valves shall be provided with embossed name plate giving details such as tag
number, type, size etc.
(g) Wherever required valves shall be provided with chain operator, extension spindles
and floor stands or any other arrangement approved by employer so that they can be
operated with ease from the nearest operating floor. Wherever necessary for safety
purpose locking device shall be provided. Further, necessary small platforms for
facilitating easy valve operation shall be provided by the contractor wherever
necessary in consultation with project manager within the bid price at no extra cost to
employer
2.12.02 VALVE BODY MATERIAL
Valve body material for various services shall be as follows:
Valve body material for water application like Secondary circuit auxiliary cooling water of
ECW system, Raw water, Ash water make-up, service water, clarified water, DM cooling
water (pH corrected) , drinking water etc. shall be cast iron for sizes 65NB and above; gun-
metal for sizes 50 Nb and below.
For compressed air application, valve body material shall be cast carbon steel or forged
carbon steel for sizes 65 mm NB & above and Gun metal for sizes 50 NB and below.
DM water: SS body and disc along with SS internals. However for butterfly valves, Cast Iron
/Ductile Iron/SG iron/carbon steel body and disc with elastomer lining are also acceptable.

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CLAUSE NO.
Condensate: Cast Carbon Steel / Forged Carbon Steel.
2.12.03 The design, material, construction, manufacture, inspection, testing and performance of
valves shall comply with all currently applicable statutes, regulations and safety codes in the
locality where the valves will be installed. The valves shall conform to the latest editions of
applicable codes and standards as mentioned elsewhere. Nothing in this specification shall
be construed to relieve the Bidder of his responsibility. Valves in general shall conform to the
requirements of the following standards.
Standards and Codes
AWWA-C-504 Rubber seated butterfly valves.
BS-5155/EN-593 Cast iron and steel body butterfly valves for general
purpose.
IS-778 Gun-metal gate, globe and check valves for general

purpose.
BS-5154 Copper alloy globe/globe stop and check and gate

valves for general purpose.
IS-780 Sluice valves for water works purpose (50-300 mm size)
IS-2906 Sluice valves for water works purpose (350-1200 mm size)
IS-5150 Cast iron wedge and double disc gate for general
purpose.
BS-5152 Specification for cast iron globe valves.
BS-5153 Cast iron check valves for general purpose.
IS-5312 Swing check type reflux (non-return) valves.
ANSI B 16.34 Standard for valves.
API-594 Standard for Dual-check valves.
API-600 Steel gate valves.
ANSI-B-16.10 Valves face to face and other relevant dimension.
API-598 Valves inspection test.
2.12.04 End Connections
The end connections, shall comply with the following:
Socket welding (SW) - ANSI B 16.11
Butt Welding (BW) - ANSI B 16.25.
Threaded (SC) - ANSI B 2.1
Flanged (FL) - ANSI B 16.5& AWWA-C-207 (steel flanges), ANSI B 16.1 (Cast Iron flanges).

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CLAUSE NO.
2.13.00 Gate/Globe/Check Valves
(a) All cast iron body valves (gate, globe and non-return) shall have flanged end
connections; (screwed ends for Ductile D.2NI body valves are not acceptable).
(b) All steel and stainless steel body valves of sizes 65 mm and above shall have
flanged or butt welding ends. Valves of sizes below 65mm shall have flanged or
socket welded ends. Compatibility of welding between valve body material and
connecting pipe material is a pre-requisite in case of butt-welded joints.
(c) All gun metal body valves shall have screwed ends.
(d) All flanged end valves/specialties. shall be furnished along with matching counter
flanges, fasteners, gaskets etc. as required to complete the joints.
(e) Gate/sluice valves shall be used for isolation of flow. All gate valves shall be of the
full-way type, and when in the full open position the bore of the valve shall not be
constricted by any part of the gate.
Gate valves shall be of the solid/elastic or articulated wedge disc. Gate valves shall
be provided with the following accessories in addition to other standard items:
(1) Hand wheel
(2) Position indicator (for above 50 mm NB valve size)
(3) Draining arrangement wherever required.
(f) Globe valves shall be used for regulation purposes. They shall be provided with hand
wheel, position indicator, draining arrangement (wherever required) and arrow
indicating flow direction. Preferably, the valves shall be of the vertical stem type.
Globe valves shall preferably have radiused or spherical seating and discs shall be
free to revolve on the spindle.
The pressure shall preferably be under the disc of the valve. However, globe valves,
with pressure over the disc shall also be accepted provided (i) no possibility exists
that flow from above the disc can remove either the disc from stem or component
from disc (ii) manual globe valves can easily be operated by hand. If the fluid load on
the top of the disc is higher than 40-60 KN, bypass valve shall be provided which
permits the downstream system to be pressurized before the globe valve is opened.
(g) Check valves shall be used for non-return service. They shall be swing. check type
or double door (Dual plate)check type with a permanent arrow inscription on the
valve body indicating the fluid flow direction. In long distance pipes lines with
possibility of surge-occurrence, dual plate check valves are preferable for its spring
controlled opening /closing of flaps/doors against flow reversals. However, dual plate
check valves shall not be used for sizes more than 600mm NB.
(h) For bore greater than 2" the valves must be swing check type or dual plate check
type suitable for installation in all positions (vertical and horizontal);
(i) For bore smaller than or equal to 2" the valves must be of the piston type to be
installed, in horizontal position.
(j) All gate and globe valves shall be provided with back seating arrangement to enable
on line changing of gland packing. The valves shall be preferably outside screw &
yoke type.

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CLAUSE NO.
(k) All gate and globe valves shall be rising stem type and shall have limit switches for
full OPEN and full CLOSED indication wherever required. This will include motor-
operated valves also wherever required. In such cases the limit switches shall form
an integral part of the valve. Stop-gap arrangement in this respect is not acceptable.
(l) All valves except those with rising stems shall be provided with continuous
mechanical position indicators; rising stem valves shall have only visual indication
through plastic/metallic stem cover for sizes above 50 mm nominal bore.
(m) For Cl gate, globe and check valves wherever thickness of body/bonnet is not
mentioned in the valves standards, thickness mentioned in IS- 1538 for fitting shall
be applicable.
2.13.01 MATERIAL OF CONSTRUCTION (GATE/GLOBE/CHECK VALVE)
(a) The materials shall generally comply with the following:

(1) Cast Steel Valves
Body & bonnet ASTM A 216 Gr. WCB/

ASTM A 105
Disc for non-return ASTM A 216 Gr. WCB/

Valves ASTM A 105
Trim. ASTM A 182 Gr. F6 or Equivalent
(2) Stainless steel valves
Body & Bonnet SS 304
Disc -do-
Trim. SS 316
(3) Cast iron valves
Body & bonnet BS 1452 Gr. 14/ IS-210 Gr. FG 260
Seating surfaces and rings 13% chromium steel/ 13% Chrome

overlay
Disc for non-return valves BS 1452 Gr. 14/IS-210 Gr FG 260
Hinge pin for non-return valves AISI 316
Stem for gate globe valves 13% chromium steel or Equivalent
Back seat 13 % chromium steel / 13% Chrome

overlay
(4) Gun Metal valves
Body and bonnet IS 318 Gr. 2/ Equivalent

Standard
Trim. -do-

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CLAUSE NO.
(b) Cast iron body valves shall have high alloy steel stem and seat.
(c) Material for counter flanges shall be the same as for the piping.
(d) Forged carbon steel valves are also acceptable in place of Gun metal valves.
2.14.00 Air Release Valve
(a) The air release valves shall be of automatic double air valve with two orifices and two
floats. The float shall not close the valve at higher air velocities. The orifice contact
joint with the float shall be leak tight joint.
(b) The valve shall efficiently discharge the displaced air automatically from ducts/pipes
while filling them and admit air automatically into the ducts/pipes while they are being
emptied. The valve shall also automatically release trapped air from ducts/pipes
during operation at the normal working pressure.
(c) Body material of automatic air release valves shall comply generally with BS 1452
Gr. 14/IS: 210 Gr. FG 260. and spindle shall conform to high tensile brass.
(d) Air release valves shall not have any integral isolation device within them. Each Air
release valve shall be mounted, preceded by a separate isolation gate/ butterfly
valve.
2.15.00 Butterfly valves
2.15.01 Design/Construction
(a) The valves shall be designed for the design pressure/temperature of the system on
which it is installed and in accordance with AWWA-C-504, EN-593 or any other
approved equivalent standard latest edition. Fabricated steel (IS: 2062 GR. E-250B)
butterfly valves instead of cast iron body valves are also acceptable for size above
300 mm nb diameter.
(b) The valves shall be suitable for installation in any position (horizontal/vertical etc.)
and shall be generally of double-flanged construction. However for sizes 600 NB
and below the valves of Wafer construction are also acceptable
(c) Valves-350Nb and above shall have pressure equalizing bypass valves, wherever
system parameters warrant the same.
(d) Valves-200Nb and above shall also be provided with gear operator arrangement as a
standard practice suitable for manual operation. Manual operation of valve shall be
through gear arrangement having totally enclosed gearing with hand wheel diameter
and gear ratio designed to meet the required operating torque It shall be designed to
hold the valve disc in intermediate position between full open and full closed position
without creeping or fluttering. Adjustable stops shall be provided to prevent over
travel in either direction.
Limit and torque switches (if applicable) shall be enclosed in water tight enclosures
along with suitable space heaters for motor actuated valves, which may be either for
On-Off operation or inching operation with position transmitter.

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CLAUSE NO.
2.15.02 Material of Construction (Butterfly Valves)
Materials and other design details shall be as indicated below :
(a) Cast Iron Butterfly Valves
Body & Disc ASTM A48, Gr. 40 with 2% Ni /

IS: 210. Gr. FG-260, with 2% Ni / SG iron BSEN 1563, Gr
EN GJS-400-15 with 2%Ni and epoxy coated
Shaft BS 970 431 S: 291 / EN 57, or

AISI-410 or AWWA-permitted shaft
material equivalent to EN-57/AISI-410 or better.
Seat ring 18-8 Stainless steel
Seal Nitrile Rubber
(b) Stainless Steel Butterfly Valves
Body & Disc SS 304

.
Shaft SS 316
Seat Rings EPT/BUNA-N/Neoprene
(c) Carbon steel Butterfly Valves
Body & Disc ASTM A 216, Gr. WCB
Shaft SS 304
Disc & Seat Rings EPT/BUNA-N/Neoprene
(d) Elastomer lined Butterfly Valves
Body & Disc ASTM A48, Gr. 40 / IS: 210. Gr. FG-260 / SG Iron (ductile
iron) IS 1865 Gr 400-15 or BSEN 1563, Gr EN GJS-400-15
/ ASTM A 216, Gr. WCB with elastomer lining.
Shaft SS 316
2.15.03 Proof of Design Test (Type Test) for Butterfly Valves
Proof of Design (P.O.D.) test certificates shall be furnished by the bidder for all applicable
size-ranges and classes of Butterfly valves supplied by him, in the absence of which actual
P.O.D. test shall be conducted by the bidder.
All valves that are designed and manufactured as per AWWA-C-504 / AWWA-C-516 shall be
governed by the relevant clauses of P.O.D test in AWWA-C-504/AWWA-C-516. For Butterfly
valves, designed and manufactured to EN-593 or equivalent, the P.O.D. test methods and
procedures shall generally follow the guidelines of AWWA-C-504 in all respect except that
Body & seat hydro test and disc-strength test shall be conducted at the pressures specified in
EN-593 or the applicable code. Actuators shall also meet requirements of P.O.D. test of
AWWA-C-504/AWWA-C-516.

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CLAUSE NO.
2.16.00 Float operated valves
(a) Valve shall automatically control the rate of filling and will shut off when a
predetermined level is reached and close to prevent over flow on pre-set maximum
water level. Valve shall also open and close in direct proportion to rise or fall of water
level.
(b) DESIGN AND CONSTRUCTION FEATURES
The following design and construction feature of the valve shall be the minimum
acceptable.
(c) Valves shall be right-angled or globe pattern.
(d) Valves shall be balance piston type with float ball.
(e) Leather liner shall not be provided.
(f) The body and cover material shall be cast iron conforming to ASTM-A 126 Grade 'B'
or IS: 210 Grade 200 or equivalent, and Float shall be of copper with epoxy painting
of two (2) coats.
(g) Valves shall be suitable for flow velocities of 2 to 2.5m/sec.
(h) The valves shall have flanged connections.
2.17.00 Surface preparation and Painting for external piping surfaces .
a) Surface preparation - Power tool cleaning / Shot blasting/ abrasive blasting

b) Type of Primer - Red Oxide Zinc Phosphate primer (Alkyd base) to IS
12744 (2 X 25 microns)
c) Intermediate Coat – Synthetic Enamel (long oil alkyd) to IS2932 (1 X 30
microns)
d) Final Coat - Synthetic Enamel (long oil alkyd) to IS2932 (2 X 35
microns)
e) Min. Total DFT (Microns)

to be maintained – 150 (Min) and Color shall be as per EMPLOYER
Color Coding Scheme
Note: No painting required for Stainless steel, Galvanized steel and gun metal surfaces.

16 OF 16
FIRE DETECTION & PROTECTION

SYSTEM

CLAUSE NO.
FIRE PROTECTION AND DETECTION SYSTEM

1.00.00 GENERAL DESCRIPTION
1.01.00 A comprehensive Fire Detection and Protection System covering all the areas of
entire power plant including Employer's facilities/ system /buildings, service
building, Canteen, Administrative Building, O&M workshop, etc.
1.02.00 The complete Fire Detection and Protection Systems shall be as per the guidelines/
codes/ standards / rules of TAC/ NFPA / IS: 3034 / OISD etc. and all the systems,
equipments and installation shall be got approved from TAC accredited
professional(s)-India.
1.03.00 Fire Water Source
Water for the Fire Protection system shall be drawn from fire water storage tanks to
be provided by the Bidder. Water for filling up the fire water storage tanks shall be
drawn from the following two sources:
a) From Circulating System blow down
b) From raw water header as second source.
Fill in line from above two sources shall be in the scope of fire fighting vendor.
Bidder shall interconnect the same to each of the fire water tank through individual
motorised isolation valve. Raw water make-up line to tanks shall be provided with
Basket strainer & an isolation valve of suitable size.
1.04.00 Pressurization System
This system consists of two (2) nos. electric motor driven jockey pumps (1 no.
working + 1 no. stand-by).
2.00.00 HYDRANT SYSTEM
Hydrant system shall consist of Hydrant pumps, pressurization arrangement, water
mains network, hydrant valves, landing valve, water monitors, hoses, branch pipes,
nozzle, hose boxes, central hose houses etc.
2.01.00 Areas to be Covered
Complete main plant, & off site areas including CHP, PT & DM plant, Ash handling
plant including its conveying system, FGD, Ash silo area and Air compressor
house, CPU regeneration area, ACW, ESP building & chimney area, FGD area,
CHP area, Fuel oil pumping area, switchyard (GIS Building), water treatment area,
and other auxiliary & miscellaneous buildings/areas of entire power project.
3.00.00 HVW AND MVW SPRAY SYSTEM
3.01.00 General
It shall consist of: Spray pumps, pressurization arrangements, spray water mains
network, deluge valves, alarm valves, flow switches, isolation valves, Y-type
strainers, spray nozzles/projectors, spray nozzles piping network, detection system,
instrumentation, local control panels, cables etc.
3.02.00 Spray system shall mainly comprise of the following:
KHURJA SUPER THERMAL POWER SUB SECTION-IIIA-07

TECHNICAL SPECIFICATION Fire Detection &
PROJECT (2X660 MW) Page 1 of 33
SECTION – VI, PART-B Protection System
WATER SYSTEM PACKAGE BID DOC. NO.: THDC/RKSH/CC-9915-373
CLAUSE NO.
 Automatic deluge valve (DV) assembly suitable size and trims

 Isolation Valve (Gate Valve) at the upstream & downstream of each DV
 Y-strainer of suitable size at upstream of each dv
 S.S Spray nozzles
 QB Detectors
 Solenoids valve for each DV
 One (01) no. pressure switch each in detection line & spray discharge
 One (01) no. limit switch for each isolation valve
 Local control Panel with relays and interface units for each DV
 GI piping for spray network at downstream of DV
 25NB M.S. Black wet detection piping network.
3.03.00 Areas to be covered by HVW Spray System
i) All transformers located in transformer yard of main plant.
ii) All other transformers having oil capacity above 2000Ltrs & located with-in
plant boundary.
iii) Steam Turbine Lube oil storage tanks, oil coolers and purifier units.
iv) Central Lube oil tanks (Both Clean oil & dirty oil units) and purifier units.
v) Boiler Feed Pumps lube oil tanks, coolers, purifier, consoles, etc.
vi) Generator seal oil system tanks, cooler assembly, etc.
vii) Turbine Oil canal pipelines in main plant.
viii) Boiler burner fronts including fuel oil racks at boiler.
ix) Apart from above any other equipments/systems having requirements of HVW
spray protection.
3.04.00 Areas to be covered under MVW Spray System
i) All cable galleries/ cable vault/ cable spreader room in main plant including
ESP control room building, FGD control building and switchyard control room,
etc.
ii) Coal transfer points, coal conveyors (excluding open coal conveyors), coal
crusher house, etc.
iv) All the fuel oil pumping station and DG set oil tanks.
v) For Stacker-Reclaimer machines, MVW spray system shall cover both boom
conveyor & intermediate &/or tripper conveyors and associated structure.
Water for spray system shall be tapped from hydrant header running along the
stock-yard. For this, combination of butterfly valves & quick cam couplings
(SS-304construction) with one end flanged shall be provided at every 20M

CLAUSE NO.
interval in the hydrant header running along the stock yard. Whenever,
Stacker-reclaimer is in stationary condition, a flexible hose (SS-304
construction) with suitable end coupling shall be connected to quick cam
coupling installed on hydrant header. The other end of flexible hose shall be
permanently connected to Deluge valve.
vi) Apart from above any other equipments/systems having requirements of
MVW spray protection.
Note:Criteria for taking two (2) spray pumps in service: While designing the
HVW/MVW spray system for crusher house, cable galleries TG Building &
ESP Building, etc. where flow of one spray pump of 410m3/hr may not be
adequate, operation of two (2) spray pumps shall be considered. In such a
situation, suitable arrangement shall be done to start the second spray pump
automatically from PLC/Fire alarm panel on receipt of fire signal from
respective areas.
4.00.00 FIRE EXTINGUISHERS
4.01.00 As indicated in Bidder’s Scope (Refer Relevant Sub-section, Part A, Section VI).
5.00.00 FIRE DETECTION, ALARM AND CONTROL SYSTEM
5.01.00 Codes and Standards
a. The design, manufacture, testing, performance, etc. of the various
components of the analog addressable Fire Detection and Alarm System shall
comply with all currently applicable statutes, regulations and safety codes in
the locality where the equipment will be installed. Nothing in this specification
shall be construed to relieve the contractor of this responsibility.
b. Unless otherwise specified, the Fire Detection and Alarm System and the
components shall conform to the latest applicable Indian or IEC Standards.
Equipment complying with any other authoritative National Standards such as
British, USA, VDE, etc. will also be considered, provided the parameters
specified are equivalent or better than the corresponding IS.
c. The Contractor shall be solely responsible for obtaining the required approval
and clearance for the different components and systems of the Fire Detection
and Alarm System from the following authorities, as applicable:
i. Department of Atomic Energy (Certification of safety from Radioactivity).
ii. Central Building Research Institute, Roorkee.
iii. Central Mining Research Station, Dhanbad.
iv. Local Fire Authorities.
d. The equipment and the system shall be of types approved by any of the
following bodies, as applicable:
i. Loss Prevention Council, (LPC), U.K.
ii. National Fire Protection Association, (NFPA), USA
iii. Under-writers laboratories, (UL), USA
iv. Factory mutual (FM)

CLAUSE NO.
5.02.00 Areas to be covered under Fire detection and alarm System
a) Multisensor type detection system (Above and below the false ceiling or
below the false flooring as the case may be)
i) All switchgear / MCC/battery rooms of main plant, ESP, FGD, Switchyard
control room building, various auxiliary buildings like ash handling
system, water treatment plant, pump houses, service building, Canteen,
etc.
ii) Cable galleries of main plant, ESP, FGD & switchyard control room
building protected by MVW spray system.
iii) Above and Below false ceiling areas of all air-conditioned rooms of ESP
building, FGD control building, service building, administrative &
auditorium building, canteen,various control rooms of auxiliaries as
defined in Sl. No. (i) above.
b) Linear heat sensing cable detection system
Coal conveyors, Boom & Tripper/ Intermediate conveyor of stacker-reclaimer
machines and various Cable Galleries covered under MVW Spray System.
Further, Limestone & Gypsum conveyors shall also be provided with LHS
cable.
c) Quartzoid bulb heat detection system
Equipments protected by HVW spray system and all equipments/areas
(except cable galleries) protected by MVW spray system.
e) For buildings/enclosures with High height like Auditorium, etc. Beam
Detectors shall be provided for fire detection system.
f) Minimum twelve (12) nos. Infrared Detectors (IRDs) shall be provided at
strategic location of various coal conveyors and other conveyor. Location of
IRDs shall be finalized during detailed engineering.
5.03.00 General requirements for all types of Detectors
5.03.01 Detectors shall be housed or mounted in suitable enclosure in such a way that their
performance is in no way affected. Special maintenance procedures if any required
for the satisfactory operation of the detectors shall be clearly stated in the bid.
5.03.02 Necessary mounting accessories shall be provided for all the detectors.
5.03.03 In case the detectors are offered with their output (on sensing a fire) in the form of
an electrical contact, it shall be noted that the contact shall be ‘NC’ type such that
under fire conditions, this contact will open to initiate the fire alarm system.
5.03.04 Detectors shall preferably be designed as plug-in units, which fit into various bases
according to place and type of mounting. This would also enable interchangeability.

CLAUSE NO.
5.03.05 Detectors shall be provided with the necessary compression type cable terminating
glands for the incoming cables of flameproof type or PVC/metallic flexible/rigid
conduits.
5.03.06 Depending upon the environmental conditions in which detectors are installed,
chlorinated rubber based or epoxy or equivalent paint shall be used for finishing the
surface of the enclosure.
5.03.07 The coverage or the zone of protection afforded by the detector and recommended
height of mounting shall be furnished by the Bidder. The bidder shall furnish the test
certificate in support of this.
5.03.08 Any metal parts used for detector construction shall be inherently resistant to
corrosion or shall be plated or otherwise suitably treated to afford protection against
corrosion. The plating or treatment shall in no way affect the detector performance.
5.03.09 Any plastic material or any sealing compound used in the detector shall be such as
it will not deform or fail under the maximum temperature to be expected.
5.03.10 No detector shall contain any moving parts subject to wear and tear and must be
able to operate afresh after each alarm release, without its exchange or adjustment.
5.03.11 The detector shall be located where the largest combustion gas concentration can
be expected.
5.03.12 Adequate compensation and considerations shall be made for effects for wind
velocities such as air-conditioning system and exhaust fans where dilution of
particles of combustion is greater.
5.03.13 The exact location of detectors shall be coordinated with other services like air-
conditioning grills, light fittings, cable trays etc. to provide aesthetically pleasing
appearance. The return air paths of air-conditioning shall be avoided for detector
location.
5.03.14 The detectors shall not be affected by temperature, humidity; air flow or by drift
failures and shall not give any false alarm due to above.
5.03.15 The detectors shall not be sensitive to vibrations. Any special mounting
arrangements required to counteract vibration shall be included in the contractor
scope.
5.03.16 The quantity of multisensor detectors in each zone shall be based on the
coverage factor of 25-sq. meter per detector. However, the actual quantity of
detectors required, taking into consideration obstructions due to floor beams,
ventilation, doors, windows etc., shall be worked out and supplied (based on the
actual layout) and installed by the contractor.
5.03.17 The detectors shall not give false alarm due to high humidity, temperature, and
velocity of air in the surroundings and static electricity conditions.

CLAUSE NO.
5.03.18 Process actuated switch devices such as pressure switches, flow switches, level
switches, etc. shall be provided with suitable individual addressable interface (local
or remote) units or modules so that these devices are addressable from the panel.
5.04.00 Infra-red Detectors
Application Detection of Moving Fire on Coal Conveyor as well as hot

spot beneath the surface
Sensor type Infrared
Working 24 V DC
voltage(detection)
Working 230 V AC
voltage(purging)
Purging type Air purging
Location Head of the conveyor
Features 1. Ability to detect both black body and diffusion flame

radiation.
2. Reject electric arc, heaters, artificial light sources and

sunlight etc
3. Ability to function in heavily coal-dust prone

atmosphere without regular maintenance
4. Insensitive to vibrations
Annunciations Trouble in purging, Fault Alarm, Trip LED, Power supply ON
Output Controls Two nos. Change over contacts for Alarm & Trip
Accessories Air purge unit including blowers, starter for blowers, hose
pipe etc
5.05.00 Linear Heat Sensor Cables
Application Detection of Stationary fire
Type Digital
Operating voltage 24 V DC
Approval FM/UL
Conductor material Steel

CLAUSE NO.
Insulation Heat sensitive polymer
Outer Sheath Black or colored PVC or flouropolymer suitable for the

application environment
Alarm Temperature Cable Galleries/Vault and Lime & Gypsum Conveyors: 70

DegC
Coal Conveyors: 90 DegC
Installation features for LHSC/IR detectors
1. Mounting arrangement have been indicated in tender drawing.
2. The detection zone/loop divisions of LHSC system shall match with MVW
spray zones. Conveyors where LHSC shall be installed shall be divided into
no. of various zones whereas conveyor for which IR detector is installed shall
be considered as one zone.
3. Linear heat sensing cable detector shall run in a zigzag fashion (with an
included angle of 90 deg) on each top cable tray, bottom tray and every
alternate intermediate trays of each section of cable tray without undue
sagging and interfering the normal operations. All supporting materials for
mounting of LHSC shall be provided by the bidder.
5.06.00 Addressable Analog Intelligent Detectors

In addition to the features specified under the item General requirements for all
types of Detectors, the Addressable Analog Intelligent Detectors shall be provided
with the following features:
a) Detectors not specifically listed for sensitivity testing from the control panel are
not acceptable due to the expense involved with manual testing as required by
NFPA 72E.
b) The detector shall be suitable for two-wire operation and two-way

communication on the intelligent analog signaling circuit.
c) The detector shall display a steady LED when in the Alarm State. The LED
shall flash when in stand by or normal mode.
d) Each detector in a loop shall have short circuit isolator suitable for style-7 wiring
as per NFPA-72.
e) Address and sensitivity assignments shall be set preferably electronically.

However, dip switches / rotary switches for the same are acceptable. The
detectors shall be assigned a sensitivity level based on environment, time of
day or any programmable function as required by the system user, and shall
respond at that level whether in the “on line” or “default” mode.

CLAUSE NO.
f) The fire alarm control panel shall permit detector sensitivity adjustment through
field programming of the system.
g) The detectors furnished shall be listed for use in environments as covered by

Factory Mutual and UL and shall be installed according to the requirements of
NFPA 72E for open area coverage.
5.07.00 Multi sensor Detectors

5.07.01 Multi sensor detectors shall incorporate a heat detection element and a
photoelectric detection element. Both the elements shall be incorporated in a single
unit. Both the elements shall be operative at all times and the fire signal shall be
available from any or both elements combined together.
5.07.02 The detectors shall be sensitive to very low smoke densities of the order of say 0.05
g/m3. Also it shall be possible to adjust this sensitivity on a step less basis over a
range so that the optimum sensitivity could be selected at site to suit the conditions
of installations. The coverage area of the smoke detection under standard NFPA
test conditions shall not be less than 80-90m2.
5.07.03 The detectors shall be complete with a mounting base that includes a terminal box
into which the detector can be plugged in. Terminals for looping of the cables shall
be provided.
5.07.04 All detectors shall be provided with built-in response and indicating lamps which
shall give local visual indication, when it has operated in dense smoke conditions.
The failure of lamp shall not prevent the function of detector.
5.07.05 In areas such as false ceiling where detectors themselves are not easily accessible,
the remote response indicators outside the enclosed areas shall be provided to
indicate the fire condition.
5.07.06 It shall be possible to replace any type of detector head by a different type
detector without requiring change in cabling/panel wiring and condition of the
zone, originally covered by the detector.
5.08.00 System Configuration
5.08.01 Each of the Addressable Fire Alarm panel shall be able to communicate with one
another as well as with repeater annunciation panel and PLC based control panels
located at different places. The detectors or other devices of any other unit/area
shall be addressable only from the respective Addressable Fire Alarm Panel, so
that each of the Addressable Fire Alarm Panel is under the control of designated
operating personnel at that location. Facility to operate pumps of booster pump
house and fire water pump house shall be provided from PC based monitoring
station.
5.08.02 At least one spare loop shall be provided in each of the addressable type fire alarm
panel located in control equipment room and in CHP control room with complete
loop card and all other accessories so that Employer can expand the system in
future. Further, at least 10% of loop capacity be left free in each of the connected

CLAUSE NO.
loop in all the panels, so that, additional devices may be connected to the system in
any of the loop by Employer in future.
5.08.03 Fire system (as a whole including PLC control systems) shall be provided with
necessary interface hardware and software for dual fibre optic connectivity &
interconnection with station wide LAN for two –way transfer of signals for
information sharing. The information shall be made available through Ethernet link
following TCP/IP standard. The system shall be OPC compliant. All required plant
data shall be transferred ensuring complete security. The exact number of points
shall be finalized during detailed engineering.
5.09.00 Analog Addressable Fire Detection and Alarm System
5.09.01 General Requirements
5.09.02 This specification in general covers the functional requirements, and general design
aspects of Microprocessor based, Analog Addressable Fire Detection Alarm /
Annunciation and Control System.
5.09.03 The following description intends to describe only the brief hardware and functional
requirements, scope of hardware requirements etc. but the actual configuration of
the system shall be in line with the prevalent normal practices in the industry and
shall conform to latest product range of selected manufacturer.
The fire detection and control system offered shall be complete in all respects for
the safe and reliable operation of the entire system. Any additional
hardware/software than those mentioned herein required to make the system
complete shall be included in the scope of the Bidder.
5.09.04 All the system and its equipment specifically detectors, interface modules, panels,
power supply, battery chargers etc. shall be furnished from a single source and the
same shall be new and latest state of the art products of manufacturer engaged in
the manufacture of Integrated Microprocessor based Analog Addressable Fire
Detection and Alarm System.
5.09.05 All equipments such as detectors, panels etc shall be approved and listed by
UL/FM/LPCB/VDS.
5.09.06 All types of smoke detectors shall be of analogue addressable type. Conventional
detectors with interface modules are not acceptable. Each zone of LHSC detector
and each IR detector shall be provided with interface module.
5.09.07 All the fire detection systems, process actuated switch devices such as
pressure/flow/temperature switches and relays of control functions shall be hooked
up with the analogue addressable fire detection and alarm system. Required
addressable interface units shall be provided for various switch devices by the
bidder to make them addressable.
5.09.08 The wiring shall be of class-A as per NFPA-72.
5.09.09 Bidder shall provide isolators at the start & end of the loop.

CLAUSE NO.
5.09.10 The complete system shall include, but not be limited to the following:
a) Master system CPU.
b) Analog Addressable Fire Detection and Alarm System panels including

alarm modules, system supervisory control modules, auxiliary output control
modules etc.
c) PC based monitoring station with colour graphic display terminal with

programming and historical archiving facility along with laser printer.
d) Power supplies, batteries and battery chargers.
e) Analog addressable type smoke detectors.
f) Non addressable type conventional detectors (Linear heat sensing cable

detector/ infra red type heat detector) and switching devices each with its
own addressable interface modules.
g) Software and hardware as required for complete operation of the system.
h) Complete Wiring/cabling including its conduits/trays/fixtures etc.
i) The fire alarm control panel shall function as a communication interface

between central processing unit and sensors. This panel shall have facility
to process the input signal and to control all the input data received from
initiating and indicating devices.
j) Fire alarm control panel shall have filters to ignore false alarm and increase
sensitivity to real fire from sensors. The sensitivity of each detector should
be automatically raised if detectors are gradually polluted due to dust and
dirt entering inside the detector. If detectors are more polluted the control
panel shall give a warning. The trouble report shall indicate the location of
device requiring service.
k) Fire alarm control panel shall have printer to print out the alarm/ trouble
occurrences.
l) The CPU shall serve as the systems central processor. Software shall be
designed especially for fire alarm annunciation system applications and
shall monitor status of processing alarms according to priorities,
controlling/processing communications and synchronizing all system
activities.
n) The system shall be able to recognize and indicate an alarm condition in a

degrade mode of operation, in the event of processor failure or the loss of
system communications to the circuit interface panels.
o) All devices shall be individually identifiable for its type, its zone location,
alarm set value, alarm and trouble indication by an unique alpha numerical
label.

CLAUSE NO.
p) The software logic modules and system database shall be programmable
using a MS - Windows compatible program (latest version) on PC at site
and required hardware shall be included in scope of supply. The system
software programme shall be password protected and shall include full
upload and download capability and during program upload or download
through the PC, the capability of alarm reporting shall be retained. The
software shall be downloaded to a PC for editing. The software shall enable
Employer to add the spare loop provided in the fire alarm panels or addition
of additional devices/detectors in any of the fire alarm panel.
q) The system shall support the use of Color Graphic display terminal for the
display of information in an appropriate format.
r) The system shall include software for system data base, historical event log,
logic, and operating system. The system shall require no manual input to
initialise in the event of a complete power down condition. It shall return to
an on line state as an operating system performing all programmed
functions upon power restoration.
s) Activation of any fire alarm initiating device shall display (LCD alpha numeric
display) message in describing the device originating the alarm condition at
the Central monitoring station, at alarm panel, simultaneously at the
repeater annunciation panel and shall initiate the associated protection
systems & other related control functions. Similarly activation of any
supervisory circuit, (supervised valve closure, air pressure abnormal, fire
pump trouble, water pressure low, etc.) or receipt of trouble report (primary
power loss, open or grounded initiating or signaling circuit wiring, battery
disconnect etc) shall display at the fire alarm control panel the origin of
supervisory condition or origin of trouble condition as the case may be. It
shall also record the occurrence of the event, the time of occurrence and the
device initiating the same.
t) System configuration shall be menu driven and capable of being operated

by, a person with no previous computer programming experience.
5.10.00 System Functional Requirements

5.10.01 The fire alarm panel shall evaluate the signals received from the detectors and shall
handle the following functions:
1. System self monitoring and fault signaling.
2. Transmission of alarm and fault signals to the respective fire alarm panels
and as well as in the repeater panel in fire station. Further, the panel shall
activate a hooter/sounds in each of the area locally provided with fire/smoke
detection system. Further, the system shall enable operation of spray
system from the panel through monitoring station when the system
operation is selected under remote, manual mode.
3. Initiate control functions like stoppage of conveyor, closure of fire doors,
shutdown of draft fans, air-conditioning and ventilation plant/ equipment,
opening smoke extraction vents, switching on smoke extraction equipment,
emergency lighting etc.

CLAUSE NO.
4. Triggering stationary extinguishing systems such as clean agent system.
5. Supervising of unauthorised removal of a detector head from its base and

giving a fault alarm on the control panel.
6. Supervising and monitoring the detection cabling, to indicate fault conditions

in case of open/short circuit in the wiring.
7. Supervising by a separate annunciation window, changeover from mains

supply to battery supply. “Mains On” indication shall be continuously on, as
long as the main supply is available.
8. Facilitating simulation of fire conditions to enable the testing of circuits

(without creating actual fire) under the test mode from the fire Alarm panel.
9. The control unit shall contain all the systems main switches lamps and
fuses. Switches and lamps shall be easily identified even in closed casings.
10. All the circuits from the detectors to the panels and the circuits from panels
to the actuating/operating devices of the respective extinguishing system
shall be of closed loop type and shall be supervised for open-circuiting and
short-circuiting of cables. The cable fault shall be audio-visually
annunciated on the panels. Separate hooters with different tones shall be
provided for ‘fault’ alarms and ‘fire’ alarms.
11. Actuate solenoid valve in spray system in case of fire from respective fire
alarm panel. For achieving this if any additional hardware is required like
relays, power supply and cables, the same may be provided.
5.10.02 Analog Addressable Fire Detection and Alarm System shall also meet the
following functional requirements:
i. Each of the system shall support analog addressable detectors of all
types, non-addressable type detectors/devices along with its addressable
interface units/modules, Video display units etc.
ii. Each of the devices and/or detectors shall be individually, uniquely and
continuously addressable by the panel to which it is connected.
iii. Detectors shall be interrogated for sensitivity settings from the control
panel, logged for sensitivity changes indicating the requirement for
cleaning and tested by a single technician using the field test routine.
Sensitivity of each of the detectors made available in the panel shall be
adjustable from the panel.
iv. The system shall be capable of self-adjustment to compensate for the

accumulation of contaminants that would change the detector sensitivity
in either a more or less sensitive direction to prevent false indications or
failure to alarm in the actual fire conditions. The system shall annunciate
a trouble condition when any analog addressable smoke detector
reaches 80% of its alarm threshold due to gradual contamination,
signaling the need for service and eliminating unwanted alarm.

CLAUSE NO.
v. Continuous supervision/monitoring of all the circuits and its components

shall be made available from the panel for open, short circuits and
grounding.
vi. The system shall be able to recognize and indicate and alarm condition
in a degraded mode of operation, in the event of processor failure or the
loss of system communications to the circuit interface panels.
vii.
The system shall be programmable at site and required hardware shall
be included in the scope of supply. The system software Programs shall
be password protected and shall include full upload and download
capability. During program upload or download the system shall retain
the capability for alarm reporting. The system shall download to a PC for
program editing. The software shall eligible employer to add the spare
loop provided in the fire alarm panel or addition of additional
devices/detectors in and of loop in any of the fire alarm panel.
viii.
The system shall support the use of color interactive History Reporting
video display terminal for the display of information in an appropriate
format.
ix.
The system shall include software for system database, historical event
log, logic and operating system. The system shall require no manual
input to initialize in the event of a complete power down condition. It shall
return to an on line state performing all programmed functions upon
power restoration.
x.
Software logic modules and system database shall be programmable
using a windows compatible program on PC. It shall be possible to
program or edit the system database off site after down loading from the
panel.
xi.
All detectors shall incorporate internal automatic temperature
compensation to overcome the effects of either high or low ambient
temperatures in the installed environment on the detector sensitivity. The
detectors shall be tested at a specified frequency by raising the detector
sensitivity level to the alarm threshold, to check the operation of the
detector without system alarming automatically by the control panel.
xii. In an alarm or trouble condition the following shall occur on the

monitoring station:
1. Sound an audible.
2. Write details of the actuation to a system log file on the PC.
3. Print the details of the actuation to the system printer.
4. Activate the color graphic display system controls, providing
functions such as zooming, scrolling of Alarms, troubles, etc.

CLAUSE NO.
xiii. System configuration shall be menu driven and capable of being

operated by a person with no previous computer programming
experience.
5.11.00 Panel Display Requirements.
System display shall consist of minimum 80 character back lighted alphanumeric

LCD display readable at any angle. Thirty-two character customer defined custom
messages shall describe the location of the active device. In addition to the above,
the following features shall be available.
a. The system shall be capable of programming to allow troubles occurred and

restored in the system to be automatically removed from the display queue,
eliminating the necessity for individual acknowledging of these events. This
feature shall not affect the historical logging of events as programmed.
b. As a minimum an LED display for “Alarm”, “Audible Silenced”, “Supervisory”,

“Trouble”, “Security”, “Power On”, And “Partial System Disabled”.
c. Touch activated membrane switches for “Alarm Acknowledge”, “Audible

Silence”, “Supervisory Acknowledge”, “Security Acknowledge”, “Reset”,
“Display Hold”, And “Display Next”.
d. All membrane switches shall be tactile with audible feedback when pressed.
5.12.00 System Software Requirements
i) The software shall control the operation, function and display of the graphic
system and provide for automatic boot up and run from the hard disk drive
of the computer.
ii) All project specifics actuating device programming shall be capable of

being carried out on site via password access.
iii) The system shall monitor all alarm, supervisory; trouble and security
conditions detected by the fire alarm control panel and provide separate
disk based files, for each condition. These logs may be enabled, disabled,
or cleared with password access.
This log information is not to be lost upon power failure or fire alarm control
panel reset. A utility file shall be provided to sort the log data by date or by
device and display this information either on the screen or the system
printer.
iv) Selective memory storage up to 800 events, shall be stored in flash

memory and displayed, printed or downloaded by classification for selective
event reports.
a. Software shall allow selection of events to be logged, including; inputs

as alarms, troubles, supervisors, securities, status changes and
device verification; out puts, as audible control and output activation;

CLAUSE NO.
action, as reset, set sensitivity, arm/disarm, override, password, set
time and acknowledge.
b. Audible and visual indications shall be generated when memory is

80% and 90% full to allow downloading of data. The system shall be
programmable circular logging, assuring that at least the last 400
events will always be stored in non-volatile memory.
v) Software has driven logic for adjusting the alarm threshold windows on
detectors to compensate for accumulating contamination and keep detector
response sensitivity constant. The software shall compensate for either
over-sensitized or desensitized units, raising a system flag when a detector
approaches the allowable limits of adjustment, indicating a requirement for
cleaning.
a. Values shall be stored in non-volatile memory allowing activation of

all tracking functions within 90 sec of system initiation from a "cold
boot". During the boot sequence, alarms from detectors programmed
with the feature shall be suppressed.
When the full data history is active all devices shall be checked and
any active alarms displayed.
b. The control panel shall place each detector in the system in an alarm
condition, transparent to the system user, every twenty-four hours as
a dynamic check of the accuracy of the alarm threshold setting. Upon
reception of the alarm report, the system detector shall be restored to
its pretest state.
c. The system shall be capable of monitoring the stage of detectors and

displaying a message when a detector is approaching the limits of
adjustment as a result of contaminates. A second message shall be
displayed when the detector reaches the limits of adjustment due to
these contaminate.
d. The system shall be capable of recognizing that a detector has been

cleaned, initiating a series of tests to determine if the cleaning was
successful and display a detector cleaned message, readjusting that
detectors normal sensitivity setting reference.
vi) When an alarm or trouble is registered at the fire alarm control panel the
graphics system shall display the first screen image for the first actuated
device. The system shall be capable of zooming in for further information if
required. At all times when in the alarm or trouble mode the fire control
panel status i.e. number of current alarms and or troubles is to be displayed
on the graphics screen.

CLAUSE NO.
5.13.00 Power Supply for Fire Alarm Panels & Repeater Alarm Panel
5.13.01 One set of 24V DC redundant power supply system comprising of 2 x 100%
chargers and 1 x 100% batteries shall be provided for each fire alarm panel and
repeater alarm panel. The batteries for fire alarm system shall be sealed
maintenance free lead acid type. The battery backup for each fire alarm panel and
repeater alarm panel shall be 24 hours and 30 minutes (in alarm conditions). At
least 25% of the devices shall be considered to be active in alarm conditions. Each
of the redundant chargers shall be sized to meet connected load requirements and
keep the connected batteries full charged (Float Mode). Furthermore, the charger
shall be sized to enable the boost charge of a fully discharged battery in 10 hours
while feeding the load.
5.13.02 The batteries shall be sized as per relevant IEEE standard. For battery sizing
calculation, an aging factor of 0.8, a temperature correction factor (based on
temperature of 4 deg. C), voltage drop of 2V in cables. Capacity factor, Float
Correction Factor, as per Battery Supplier Standard, shall be taken into
consideration, if applicable and ambient temperature shall be considered as the
electrolytic temperature. The sizing of the battery shall be as approved by Employer
5.13.03 The battery chargers and batteries shall be placed at a suitable location inside the
fire alarm panel with partitions.
5.13.04 The detailed specification related to power supply system of fire detection &
protection system shall be as specified in other sections of the technical
specification.
5.14.00 Control & Instrumentation requirements
5.14.01 The specification for PLC control system for fire protection system shall be as
specified in other sections of the technical specification.
5.14.02 The specification for PC, printer and other HMI items shall be as specified in other
sections of the technical specification.
5.14.03 The specification related to Basic design criteria, Measuring Instruments, Process
connection & piping, Control panels, Type test requirements etc shall be as
specified in other sections of the technical specification.
5.15.00 Cabling for fire alarm system
All instrumentation cables twisted & shielded, FRLS PVC insulated and sheathed
data highway / fibre optical cables, short term fire proof cables including
prefabricated cables (with plug-in connectors) etc shall be provided by Contractor.
The contractor shall follow the cable philosophy as below:
Application Type of cable
From To
PLC cabinets PC, Printers As Mfr.’s Standard. However, connection
etc. between PLC and the remote I/Os shall be
through fibre optic cable by Bidder if length
is>300 M & coaxial cable if length<300 M
Detectors Detector Shielded, Twisted, PVC Cu. FRLS cables type

CLAUSE NO.
(including (including “S” Refer Note 2, 3, 4 and 5 below.

detectors detectors
mounted mounted inside
inside panels) panels) /
/Any loop Isolator/
device Interface unit
Detectors JB Shielded, Twisted, PVC Cu. FRLS cables type
(including “S” Refer Note 2, 3, 4 and 5 below.
detectors
mounted
inside panels)
/ Isolator /
Interface Unit
JB Fire alarm Shielded, Twisted, PVC Cu. FRLS cables type
Panel “S” Refer Note 2, 3, 4 and 5 below.
Notes:
1. 10% spare pair shall be provided for all cables having more than four pairs.
2. Type “S” cable shall be multicore control cable having overall shielding &
specification similar to instrumentation cable except insulation thickness and
voltage grade which shall be 1100 V. Type “S” cable shall also satisfy
requirements of Article 760 of NFPA 70.
3. Over and above, contractor may note that short term fire proof cables shall be
provided for coal handling plant. Short term fire proof cables shall be Mineral
insulated copper conductor and copper sheathed type satisfying requirements
of Fire resistance, safety in the industrial application areas mentioned in the
specification and also, shall be approved by UL standards and certified by
LPCB. The contractor shall provide all the cables so as to complete the
system
4. Cable size of 2 core 1.5 sq.mm shall be used for loop wiring in-case of both
control cable and short term fire proof cable.
5. Cable size of 2 core 2.5 sq.mm shall be used to provide power supply to
various devices in the loop in-case of both control cable and short term fire
proof cable.
6. The detailed specification of instrumentation cables and optical fiber cable shall
be as specified in other sections of the technical specification.
7. Detector cables outside the building shall be corrugated steel taped armoured
laid through cable trays wherever available and for rest of the areas, cable
shall be buried at 600 mm depth with sand filling and brick covering at the top.
8. Detector cable within the building shall be either unarmoured & laid through
galvanized iron (GI) conduits or armoured cables, as per the standard and
proven practice of the manufacturer.

CLAUSE NO.
5.16.00 Detection System for Coal Conveyors
i) Linear Heat Sensor Cables:
a) The LHS cable detector for each conveyor to be provided for both forward and
return conveyors and shall be mounted as per the standard practice of the
manufacturer/ supplier. Suspension of LHSC through flexible chains is a
preferred arrangement. Further, LHS cable shall also be provided for return
side of conveyors inside the bunker house.
b) The detection zone/loop divisions of LHSC system shall match with the MVW
spray system.
c) Upon detection of fire either by QB detector or LHSC detector, the spray
system shall be initiated. It shall also initiate spray system for the two adjacent
zones after a time delay settable at site.
d) The LHSC detector shall be provided with suitable interface unit, which shall
generate/ make the signal compatible with fire alarm panel.
(e.) Type: Digital, Operating Voltage: 24V DC, Conductor Material: Steel,
Approval: FM/UL
ii) Infra Red Detector:
(a.) The infra red type (IR) detectors shall be suitable for detecting moving fires in
coal conveyors. The IR detector shall stop the conveyor upon detection of fire
and give audio-visual annunciation locally and in fire alarm panel.
(b.) Each of the IR detector shall be provided with its own purging arrangement
using blowers, hoses, etc and required power supply shall be derived from the
fire alarm panel. Alternatively, bidder may offer separate blowers (2x100%) for
purge air supply for all the detectors and the complete air piping from the
blowers to each of the IR detector shall be provided by the bidder.
5.17.00 Detection System of Cable Galleries
i) In cable galleries, MVW spray system shall be actuated either by detection of
fire by Linear Heat sensing cable detectors or by fire signal from Multisensor
detection system. Apart from the automatic operation of spray system in the
detected zone, the adjacent two zones shall also be sprayed with water
automatically after a set time delay simultaneously.
ii) LHSC detector shall run in a zig-zag fashion (with an included angle of
minimum 90o atleast) in each of the top tray, bottom tray and in every
alternate trays. The mounting arrangement of LHSC detector shall be as per
manufacturer’s standard practice.
iii) The detection zone/ loop divisions shall match with MVW spray zones.
5.18.00 Multisensor Detection System

CLAUSE NO.
i) Upon detection of fire, multisensor detector shall be annunciated in the
respective panels and shall activate a local hooter/sounder in the areas where
fire is activated and this fire signal shall be employed to initiate the fire
extinguishing system of that area such as automatic MVW spray system of
cable galleries, fire extinguishing system of Control rooms/Control Equipment
Rooms.
ii) Cross zoning of the signal from two adjacent multisensor detectors shall be
employed to initiate the MVW spray system of cable galleries.
iv) The design coverage area for detectors (to be considered) shall not exceed
25 Sq.M. for each detector.
6.00.00 CLEAN AGENT DIRECT / INDIRECT LOW PRESSURE AUTOMATIC FIRE

DETECTION & SUPPRESSION SYSTEM WITH LINEAR PNEUMATIC HEAT
DETECTION TUBE
6.01.00 Regulatory Requirement
(a) The clean agent automatic direct / indirect low pressure fire suppression
system shall be approved by UL/FM/VDS/LPCB.
(b) Clean agent used should be NOVEC-1230
6.02.00 System Description
(a) The clean agent automatic direct / indirect system consists of the following
major components:
- Clean agent (NOVEC-1230) cylinder & valve assembly along with

cylinder mounting arrangement.
- Linear heat detection/discharge tube along with necessary fittings.
- Discharge Network (applicable for indirect system) composed of copper

tubing / stainless steel tubing / braided hose, necessary fittings and
appropriate nozzles.
- Pressure switch, End of line adapters, Audio-visual indication unit.
(b) Each clean agent extinguishing unit shall be equipped with its own automatic
(non electric) detection/discharge tubing system, which when actuated,
automatically releases the suppression agent into the electrical panel.
(c) Clean agent cylinder / container shall be a part of UL/FM/VDS/LPCB

listed/approved system. Further, cylinders shall have approval by Chief
Controller of Explosives (CCOE) – India (if applicable).Each container shall be
equipped with a valve, a pressure gauge to monitor container pressure, etc.
(d) Detection/discharge tubing shall be installed within the limitations stated in the
manufacturer’s manual.

CLAUSE NO.
(e) A pressure switch shall be connected at the other end of detector/discharge
tubing or on main valve to monitor system pressure and/or signal of system
actuation, etc.
6.03.00 Design Requirement:
(a) Design concentration of clean agent used shall be as per NFPA-2001 /

manufacturer’s recommendation.
(b) All documents/drawings related to design of the system shall be vetted by

the system manufacturer before submission to EMPLOYER for approval.
7.00.00 FIRE WATER STORAGE, PUMPS & PUMP HOUSE

i) Horizontal type centrifugal pumps shall be provided for hydrant, spray and
jockey pumps. Maximum speed of the pumps shall be 1500 rpm.
However, for jockey pumps the speed upto 3000 rpm is acceptable. The
motor driven pump and the corresponding diesel engine driven pump shall
completely interchangeable in respect of speed, impeller diameter, etc.
ii) Capacity, discharge pressure & quantity of pumps for the hydrant water
system and spray water system shall be individually designed as per Tariff
Advisory committee (TAC) guidelines. However, for minimum design
requirement please refer Annexure- II.
iii) Atleast one hydrant pump of identical capacity be provided as standby pump
so that in case any of the working hydrant pump is not available, the total
requirement can be met by the standby pump.
iv) Atleast one spray pump of identical capacity be provided as standby pump
apart from the working spray pumps.
v) The standby hydrant and spray system pumps shall be of diesel engine
driven.
vi) The headers of spray and hydrant system shall be interconnected with an
isolation and a non-return valve so that hydrant pumps can feed to spray
system not vice-versa.
vii) The diesel engine drive of the pump shall conform to the requirements of
TAC. Each of the diesel engine shall be provided with batteries (2x100%)
and battery chargers (2x100%).
viii) Battery of the diesel engine shall be lead acid type as per IS and shall be
large enough to crank the engine twelve times successively, each for a
duration of 10 sec. without any charging in between.
ix) Each engine shall be provided with fuel oil tank having adequate capacity to
hold sufficient fuel oil for a minimum of twelve (12) hours of full load run. The
fuel oil tank shall preferably be mounted on the engine. No fuel oil tank will
be provided by the Employer.

CLAUSE NO.
x) Continuous drive motor rating (at 500C ambient) shall be at least 10% (ten
percent) above the maximum load demand of the pump in the entire
operating range of the pump.
xi) The feeding line of the spray system from the header shall be provided with
2x100% capacity basket type filters to avoid any particles in the spray
system.
xii) The system shall be complete with required instrumentation, control
recirculation pipe line with valves for each of the pumps, NRV in discharge
outlet etc.
xiii) Pumps shall be designed for continuous operation at its best efficiency point
to meet the specific requirements of the system for which it is to be
employed. Pumps of each category shall be suitable for parallel operation.
xiv) Fire water booster pump house: Two sets of Hydrant & Spray booster
pumps (one motor driven & one diesel driven pump) alongwith associated
equipment shall be installed in fire water booster pump house. Tapping shall
be taken from nearest hydrant and spray header.
xvi) Fire water storage tank: Two numbers each of 50% capacity vertical
cylindrical column supported fixed cone roof type fire water storage tanks
made of MS shall be provided by the bidder. To avoid vacuum creation
inside the tank, two (2) nos. vents each of size 300 NB shall be provided on
the roof of the tanks. Bidder shall ensure that the total capacity of fire water
storage tank shall be as per the recommendation of TAC with a minimum
capacity of each tank equal to 2300 m3.
8.00.00 PIPING AND VALVES
8.01.00 General Data for Pipes etc.
i) Mild steel as per IS:1239 (Part-I) medium grade (upto 150 NB) & as per
IS:3589 Gr 410 (above 200 NB) or Equivalent for pipes normally filled with
water.
ii) Mild steel as per IS:1239 (Part-I) medium grade (upto 150 NB) & as per
IS:3589 Gr.410 (above 200 NB) or Equivalent and galvanised as per
IS:4736 for pipes normally empty and periodically charged with water and
foam system application.
iii) Pipe protection shall be as follows:
To prevent soil corrosion buried pipes / pipes in trench shall be properly
lagged with corrosion protective tapes of coal tar type as per IS:15337 or
AWWA C 203. The total thickness of protective tapes to be applied on buried
pipes / pipes in trench shall be 4.0mm. This can be achieved by using
4.0mm thick tape in single layer or 2.0mm thick tape in double layer.
iv) Pipe thickness:
a) For Pipe sizes upto 150 NB and above: As per IS:1239 Part-I medium
grade.
b) For Pipe sizes 200 NB and above refer Annexure-I.

CLAUSE NO.
v) All valves shall be as per applicable IS/BS codes & approved by TAC for
specific fire protection system and shall be provided with locking
arrangement (with locks) in open or close condition. Further, all
gate/butterfly valves of size 200 mm & above shall be provided with spur
gear reduction unit.
vi) All the flanges and counter flanges shall conform to ANSI B 16.5 CI 150.
vii) Strainer Body as per IS: 2062 (tested).
viii) Pipe Fittings
1) The material shall conform to ASTM A 234 Gr WPB or ASTM A 105 or
equivalent and dimensional standard conforming to ANSI B 16.11
(socket & threaded type), ANSI B 16.9 (for butt welded fittings) and
ANSI B 16.5 (for flanges and flanged fittings) as the case may be.
Further, galvanised malleable cast iron fittings as per IS:1879 in Cast
iron fitting as per BS-1641 are also acceptable.
2) Grooved couplings: Vendor may also use mechanical grooved
couplings type fittings in GI pipe lines for HVW / MVW spray system. All
materials and products shall be either Underwriters Laboratories (UL)
Listed or Factory Mutual (FM) Approved and installed in accordance
with NFPA Standard 13 / equivalent Standard.
3) The fittings shall be galvanised as per IS: 4736 for galvanised pipe
application. In case of branching connections from GI mains for spray
piping network, socket may be welded for more than two pipe reduction
instead of standard tees.
4) Fabricated fittings shall not acceptable up to pipe size to 300 NB. For
sizes 350 NB and above, fittings may be fabricated as per BS: 2633/BS:
534.
ix) Welding of galvanised iron pipes/fittings would be permitted provided the
same is carried out by means of special electrodes suitable for the above
application and the same shall be approved by Employer. After, welding,
welded portions shall be applied with three coats of zinc silicate
treatment/rich paint over one coat of suitable primer. Further, the Contractor
shall provide proper zinc paint at the point of welding.
9.00.00 PAINTING
9.01.00 All the Equipments shall be protected against external corrosion by providing
suitable painting.
9.02.00 The surfaces of stainless steel, Gunmetal, brass, bronze and non-metallic
components shall not be applied with any painting.

CLAUSE NO.
9.03.00 Fire Water Storage Tanks:
i) The Contractor shall clean the tank plates and structure steel before
erection by wire brushing and air blowing. After erection of tank and hydro
testing, tanks are subjected to surface preparation and painting as per
procedure detailed below:
ii) Surface Preparation: Outside/inside surface preparation shall be carried
out by shot blasting as per SA2 ½.
iii) Inside surface painting: One coat of epoxy zinc phosphate primer of min.
DFT of 30-35 micron followed by three (3) coats of epoxy resin based finish
paint with 25 micron as thickness of each coat.
iv) Outside surface painting: One coat of epoxy zinc phosphate primer of
min. DFT of 30-35 micron followed by three (3) coats of epoxy resin based
finish paint with 25 micron as thickness of each coat.
v) Outside bottom surface painting: One coat of epoxy zinc phosphate
primer of min. DFT of 30-35 micron followed by three (3) coats of coal tar
epoxy paint with 25 micron as thickness of each coat.
9.04.00 All Steel Surfaces (external) exposed to atmosphere (outdoor installation)
(i) Surface Preparation: The steel surfaces to be applied with painting shall be
thoroughly cleaned before painting by wire brushing, air blowing, etc.
(ii) Painting: One (1) Coat of red oxide primer of thickness 30 to 35 microns
followed up with three (3) coats synthetic enamel paint, with 25 microns as
thickness of each coat. For plant at coastal area, epoxy resin based zinc
phosphate primer followed by epoxy resin based paint pigmented with
titanium di-oxide shall be used in place of enamel paints.
9.05.00 All Steel Surfaces (external) inside the building (indoor installation)
(i) Surface Preparation: The steel surfaces to be applied with painting shall be
thoroughly cleaned before painting by wire brushing, air blowing, etc.
(ii) Painting: One (1) Coat of red oxide primer of thickness 30 to 35 microns
followed up with two (2) coats synthetic enamel paint, with 25 microns as
thickness of each coat. For plant at coastal area, epoxy resin based zinc
phosphate primer followed by epoxy resin based paint pigmented with
9.06.00 Deluge Valves, Alarm Valves, Foam monitors, Water monitors, Foam
Proportioning equipments, Foam makers, etc.
Painting of all equipments/.components of FDPS package shall be as per
manufacturer’s standard practice or as detailed below whichever is superior in
quality.

CLAUSE NO.
Environment Paint scheme Total DFT

Normal / Mild Corrosive Primer- zinc filled epoxy Min 125
Environment Finish – Aliphatic Polyurethane microns
(shade RAL3000)(P.O Red)
Corrosive Environment Primer- zinc filled epoxy Min 200
(as in coastal areas) Intermediate – Epoxy MIO microns
Finish – Aliphatic Polyurethane
(shade RAL3000)(P.O Red)
10.00.00 The hydrant and spray lines shall be overground. It shall be laid either on pedestals,
trestles etc. However, if the layout does not permit laying of overground pipe in that
case it shall be laid underground with the approval of Engineer.
11.00.00 MULTIPURPOSE NOZZLE
The multipurpose nozzle should be such that water under pressure is applied on
fire in the form of a jet, spray or fog. Material of construction for multipurpose nozzle
shall be as per manufacturer’s standard.
12.00.00 TYPE OF BUILDINGS
Sl.
Area/Facility Type of building
No.
1. Fire Water Pump The fire water pump house shall be single storeyed
House and single bay RCC superstructure. The building shall
be fully covered with external brick wall with provision
for doors, windows, rolling shutters and supply &
exhaust air fans.
2. Fire Water Booster The fire water Booster pump House shall be housed
Pump House in a shed. Sides shall be fully covered with external
brick wall with provision for doors, windows, rolling
shutters and supply & exhaust air fans.
3. Foam System Shed with roof covering and side walls shall be
Shed provided for foam system including associated civil
works for foam bladder tank foundations, grade slab,
pipe pedestals, etc.
13.00.00 Technical Design Data: Refer Annexure-III to this Sub Section-A-18.

CLAUSE NO.
ANNEXURE-I
PIPING THICKNESS:
Pipes for sizes 200 NB & above shall confirm to IS: 3589 Grade 410. The final
thickness shall not be less than that specified as per IS: 3589 as indicated below.
Nominal pipe Outside Diameter Wall Thickness

(mm) (mm)
Size (mm)
200 NB 219.1 6.3
250 NB 273 6.3
300 NB 323.9 7.1
350 NB 355.6 8.0
400 NB 406.4 8.0
450 NB 457 8.0
500 NB 508 8.0
600 NB 610 8.0

CLAUSE NO.
Annexure-II
Technical Data:
1. Fire Hydrant Spray Booster Booster Jockey

water Hydrant Spray
pumps
Number of 4(3 motor 3 (2 motor 2 (1 motor 2 (1 motor 2 (both
pumps driven & 1 driven & 1 driven & 1 driven & 1 motor
diesel diesel diesel diesel driven)
engine engine engine engine
driven) driven) driven) driven)
Design 410 m3/hr 410 m3/hr 171 m3/hr 410 m3/hr 75 m3/hr
Capacity
TDH of 105 (min) or 105 (min) or 45 (min) or 45 (min) 105 (min)
pump as per as per as per or as per or as per
(MWC) system reqt. system reqt. system reqt. system system
reqt. reqt.
MOC Casing:IS:210 Gr. FG 260 (2.5% Ni), Impeller: Bronze IS:318 Gr.II,
Impeller shaft, coupling :SS316
2. Hydrant Oblique female type as per IS:5290
Valve
MOC: Body/bonnet/stop valve/valve seat/trim : SS304/SS316
3. Water As per IS:8442 Type-I, Size: 75mm, Nozzle dia: 38mm
monitor MOC: Water barrel/reducer/elbow: CS (seamless)/SS
Nozzle: Copper alloy / SS confirm in to IS:3444
4. Water As per IS:903 / IS:2871
branch MOC: Branch pipe: SS316 (Gr 4 of IS:3444) (both ends)
pipe & Nozzle : SS316 (Gr 4 of IS:3444), Size: min 16mm & max 25mm
nozzle
5. Water - Design Code: a) IS:14846 or BS:5150 (for valves coming inside
line Gate fire water pump house)
/ Sluice b) BS:5150 (for valves at other locations)
Valve - Pressure rating: PN1.6 (as per IS:14846) / PN16 (as per BS:5150)
-Working Pr. :12Kg/cm2
MOC: Body/bonnet/Yoke/Wedge: CI to IS:210 FG-200
Spindle: SS to ASTM-A-276 type 410
6. Check Below 50NB size 50NB & above
Valve Design Code; IS:778 (below 50NB) IS:5312 / BS:5153
MOC: Body/cover/flap: Leaded tin CI to IS:210 FG-200
bronze to IS:318 Gr. LTB-2
7. Butterfly Design Code: Double flanged or lugged wafer type of low leakage
Valve rate confirming to BS:EN:593/API-609/AWWA C-504
Pressure class: PN 16
MOC: Body & Disc: Cast Iron, Shaft: SS 410 / SS 420
Seat Rings : EPDM

CLAUSE NO.
ANNEXURE-III
Tentative Technical Design Data (for tender purpose only) to be considered for fire
detection & protection system for areas/equipments not covered in WS Package
I) Coal, Limestone & Gypsum Handling Plant Area:
1. For Coal, Limestone & Gypsum Handling Plant Layout: Refer relevant Tender Drawing.
2. Details of Transfer Points (TPs) and Crusher House of CHP Area:
Building Details
TP-1 12 x 12 x 17 Meters (High)

[Floors at 0.00m, (+) 4.0m & (+) 12m]
[Floors at 0.0, (+) 4.0 m & (+)16.0m]
[Floors at 0.0, (+) 5.0m & (+) 15.0m]
[Floors at 0.00, (+) 5.0m & (+)15.0m]
[Floors at 0.00, (+) 8.0m & (+)16.0m]
TP-6 12x 12 x 35.0 Meters (High)
[Floors at 0.00, (+) 22.00m & (+) 30.00m]
TP-7 12x 12 x 76 Meters (High)
[Floors at 0.00, (+) 58.00 & (+)70.00m]
TP-12 12x10x12.5 Meters (High)
(floors at (+)7.5m, 0.0 m)
[Floors at (+) 7.5m & (+) 0.0m]
[Floors at 0.0m & (+) 7.5m]
Crusher House 30 x 32 x 32 Meters (High)
4 Floors
3. Stacker Re-claimer machines: 2 No., Capacity = 1600 TPH each.

4. Width of Coal Conveyors = 1400 mm
5. Transformers: 11/3.45KV; 2 Nos., Rating: 12.5 MVA each.
6. Details of MCC/Switchgear and CHP Control Room Building:
Building Details
MCC-A Building (near wagon tippler): 15 x 8 x 4m + 8 x 6 x 4m (A/C RI/O room)
MCC-B Building (near crusher house): 15 x 8 x 4 m + 8 x 6 x 4m (A/C RI/O room)
35 x 10 x 4.5 m +
HT Switchgear + MCC-C: 5 x 5 x 4 m battery room (for C&I) +
8 x 5 x 4 m battery room (for Elect.)
MCC-D building (near CSSP): 15 x 8 x 4 m+ 8 x 6 x 4m (A/C RI/O room)
CHP Control Room Building: 15 x 10 x 4 m

CLAUSE NO.
II) Details of Electrical Panels of MCC/Switchgear of Stacker-Reclaimers:
Approx. No. Volume of each

Description
of Panels panel
Motor Control Centre (MCC) Panel 8 Panel-1: 0.92 m3
details for each Stacker-Reclaimer. Panel-2: 1.21 m3
Panel-3: 0.87 m3
Panel-4: 0.92 m3
Panel-5: 1.21 m3
Panel-6: 1.21 m3
Panel-7: 0.87 m3
Panel-8: 1.84 m3
III) Switchyard Area:
1. Bus Reactor (80 MVAR): 1 No. and Line Reactor (80 MVAR): 1 No.
2. Switchyard Control Room Building (Single Storey): 39x23.5x4.5 m + 19.5x6x4.5 m
IV) Main Plant Area:
Transformers
Rating Quantity (Nos.)
16MVA (UAT) 04
16 MVA (AHT) 02
12.5 MVA (FGD) 02
4 MVA (AWRS) 02
260MVA, 420KV 07
125 MVAR, 420KV 01
45 MVA 04
120 MVA, 400KV 04
Building Details
AHP Control Panel Room 10 m x 10 m
FGD Control Room 10 m x 15 m
V) Miscellaneous Buildings
Building Nos. of Floors Total Area of all Floor

Service Building Ground + 4 4500 m2
Administrative Building Ground + 4 4500 m2
Auditorium Single Storey 1000 m2
Canteen Building Single Storey 1000 m2
O&M Store Ground + 1 3700 m2
O&M Workshop Ground + 1 3700 m2
ANNEXURE-IV

CLAUSE NO.
1.00.00 MONORAIL HOISTS (ELECTRICALLY OPERATED)

The design, manufacture, shop testing, erection, testing & commissioning at site of
the Monorail Hoists (Electrically Operated) shall in general conform to the latest
revisions of the following Indian Standards. In addition to other standards
mentioned elsewhere in the tender documents subject to any modification &
requirement specified hereinafter.
IS:2266- Specification for steel wire ropes for General Engineering purposes.
IS:594- Technical Supply conditions for wire ropes and strands.
IS:1835- Specification for Round steel wire for ropes.
IS:3938- Specification for electric wire rope hoists.
IS:7847- General Characteristics of Lifting hook.
IS:3815- Specification for point hook with shank for general engineering purposes.
IS:2429- Calibrated hand chain for long travel & cross travel.
IS:807- Code of practice for design, Manufacture, erection & testing (Structural
Portion of cranes & hoists)
Indian Electricity Rules.

1.02.01 Electrically operated Trolley suspended, mono girder type hoists of capacity of
minimum 5 tonnes and not less than 25% above the weight of the heaviest item
envisaged shall consist of the following major components :
a) Electrically operated trolley complete with drive motor (Trolley travel, speed 10-
15 m/min). Hoisting cable, hoisting block and hooks complete with drive motor
(Hoisting Speed 1.5 m/min).
b) Limit switches over travel while hoisting and lowering of the hook.
c) Limit switches to prevent over travel of hoist assembly at both ends.
d) Runway conductors for feeding power to trolley assembly.
e) Erection hardware.
f) Pendent control stations suspended from hoist. Monorails for the travelling of
hoist assembly.
1.02.02 The hoist shall be designed and constructed in accordance with latest revision of
IS:3938 and class of design shall be 2 as per the IS:3938. The complete hoist
assembly, wire rope, hook etc. shall be ISI stamped approved.
1.02.03 Trolley movement and hoisting shall be effected by using two (2) different electric
motors. The technical requirements of electric motors shall conform to IS:3938.

CLAUSE NO.
1.02.04 Trolley shall be designed so as to accommodate a wide range (minimum three

different size of ISMB standards) of I beams and capable of travelling on straight as
well as curved monorails, the design shall be such that it can maintain uniform
distribution of pressure on the flange of the monorail to avoid bending of the same.
1.03.05 The geared trolley shall have two (2) pair of wheels, a pair of which shall be driven
through chain. The wheel shall have taper/parallel treads with flange or any other
means to guide hoist trolley effectively to prevent derailment. Wheels shall be
mounted on anti-friction bearings and shall be easily removable for repair and
replacement. The track wheels shall be cast/forged/rolled steel suitably heat treated
to have hardness of not more than 200 BHN.
1.03.06 The hoist mechanism shall consist of a grooved rope drum using single layer
winding of rope and driven through gears through electric motor. Each end of the
rope shall be anchored to the drum with two single hold down plate in such a way
that the anchorage is readily accessible for maintenance. Each rope shall not have
less than two (2) full turns on the drum when the hook is at its lowest position and
one (1) spare groove for each rope lead when the hook is at its highest position.
Suitable design procedure should assure that the leading rope taken by the drum
does not slope side ways when slack and it is not caught between the gear wheel.
The drum shall be flanged at both ends if rope guides are not provided; in which
case, the flanges shall project to a distance of not less than two (2) rope diameters
above the rope. A spur or other wheel secured to the drum may be regarded as
forming one of the flanges. The fleet angle of the rope shall not exceed 50C.
1.03.07 Rope Drums, gear box, hoist block shall be made of cast steel or mild steel as
suitable for duty conditions.
1.03.08 All gears and pinions shall be hardened and tempered steel with machine cut, teeth
in metric modules as per relevant Indian Standards. Surface hardening is not
acceptable. Preferably Helical gear shall be used. Worm and bevel gearing is not
permitted.
1.03.09 Provision shall be made for lubrication of all moving parts and bearings while the
hoist is in service except where life lubricated bearings are used. Ball and Roller
bearings shall in addition be lubricated before assembly. Lubricating nipples and
adopters shall be easily accessible and shall generally comply with relevant Indian
Standards. All exposed bearings shall be suitably sealed or shielded. All gear drives
with the exception of travel runner wheels of geared type and their driving pinions
shall be enclosed and provided with oil bath lubrication.
1.03.10 An electro-mechanical brake of fail safe type shall be provided for hoisting motion
that can provide restraining torque of 125% (minimum) or greater than the torque
transmitted to the brake drum from the suspended load upto the test load, the
friction in the transmission mechanism between the load and the brake not being
taken into consideration. Brake shall be provided with a simple and accessible
means of adjustment to compensate for wear. Suitable provision shall be made for
holding the load in the event of the slippage of chain etc. The operating
arrangements shall be such that the brakes cannot be released accidentally.
1.03.11 The interconnection of hoist assembly and bottom block shall be through anti-

CLAUSE NO.
friction thrust bearings. The bottom block shall be enclosed type and shall have
guard against rope jamming in normal use. It shall have standard forged swivel
shank of suitable grade of either circular or standard trapezoidal section, point hook
suitably heat treated with adequate lifting capacity and safe working load as per
relevant Indian Standard. Swiveling hooks shall be mounted on thrust bearings and
protective skirt shall be provided to enclose the bearing. The hook shall swivel
through 360 deg. rotation with full load. The swivel hook shall not be locked with set
screw or split pin to prevent it from coming out. The hoist hook shall be provided
with safety locking arrangements to provide accidental unhooking.
1.03.12 All running shafts and wheels running on fixed axis or pins shall be fitted with ball or
roller bearings. Ball and roller bearings of suitable dimensions shall be used. Ball
and roller bearing shall have a rated life of not less than 20 years calculated in
accordance with manufacturer’s recommendations and based on the equivalent
running time given in IS:3938.
1.03.13 The design and construction of shafts, shaft sleeves, shaft sleeve guards equalising
sleeves, if provided, etc. shall conform to IS:3938.
1.03.14 Lifting bar of adequate design, and suspend type load indicator shall be supplied
along with the monorail hoist.
1.03.15 Wire rope bright wire, with independent wire rope core (IWRCI) Lang's lay
preformed, parallel laid type shall be of 6/37 (18/12/61) construction and with a
tensile designation of 1770 N/mm3. Reverse bends of wire rope is not acceptable.
Direction of rope lay shall be suitable to the grooving in the drum. The wire rope
shall preferably be supplied separately and installed at site. The effective length of
wire rope shall depend on the overall lift of the hoist. The wire rope shall conform to
relevant Indian Standards.
1.03.16 All parts requiring replacement or inspection lubrication shall be easily accessible
without the need for dismantling of other parts, equipment and structures.
1.03.17 Robust construction and ample rating margins with experience has shown to be
necessary shall be ensured throughout the design & manufacture.
1.03.18 All components of hoists of identical capacity and duty shall be interchangeable so
that the stock of spares can be reduced to a minimum. All hoists of same capacity
and duty shall be identical in all respects except the length and hand chains which
may of course, vary depending upon specification requirements.
1.03.19 All machinery and equipment included under this specification must be equipped
with safety devices and clearances to comply with recognised standards and
specification requirements. Nominal clearance between the lowest flange of the
monorail and the trolley must be minimum 20 mm.
1.03.20 Cast lron parts, wherever used shall conform to IS:210 grade 30 (minimum). No
wood or other combustible material shall be used.
1.03.21 All bolts except those with nylon nuts shall be provided with grip lock nuts and
spring washers or similar locking device. Bolts in tension should be avoided. Bolts
and set screws in rotating parts should be locked.
1.03.22 Defects in materials like fractures, cracks, blow holes, laminations pitting etc. are
not allowable. Rectification of any flaw is permissible only with the approval of

CLAUSE NO.
Employer.
1.03.23 Hoists shall have a permanent name plate on each side readily recognisable from
floor level, as per IS:3938.
1.03.24 Pendent control panel shall be provided with up/down/forward travel/ reverse travel
push buttons indicating lamps etc. Control supply to be used shall not be more than
24V/AC. Control Transformers and other transforming/rectifying devices etc. for
power and control supply shall be in the scope of vendor.
1.03.25 All the electrical characteristics of the hoist assembly shall conform to IS:3938. The
motors shall be designed for an ambient temp. of 50 deg. C and the class of
insulation shall be Class B. The temperature rise shall not exceed the limits
specified in IS:325.
1.03.26 The enclosure shall suit the working of the electrical equipment for outdoor duty.
The class of enclosure shall be IP:55.
1.03.27 The pendent control switch, limit switch etc. shall conform to IS:3938.
1.03.28 The overload protection type shall be of thermal overload relays with high rupturing
capacity fuses and number of overload devices shall conform to IS:3938. The
control panel shall be wall mounted type and easily approachable from floor by a
standing man.
1.03.29 G.A. drg., cross sectional drg. Technical Data Sheets for hoist/ motors, electrical
circuit diagram and other applicable technical documents shall be submitted for
Employer's approval.
ANNEXURE-V

CLAUSE NO.
TECHNICAL SPECIFICATION OF CHAIN PULLEY BLOCK

1.01.00 All chain pulley blocks shall be designed to IS: 3832, the operating hand chain shall
confirm to IS: 2429 grade 30 pitched and polished and the load chain to IS:6216
grade 80. The chain pulley block shall be suitable for duty class 2. Hooks shall be
as per IS: 8610 & with antifriction bearing for bottom hook.
1.02.00 All chain pulley blocks shall be selected to have minimum headroom and shall be
selected to lift heaviest piece of equipment. Further, it shall be possible to handle
any equipment without disturbing other equipment.
1.03.00 The hand chain wheels shall be of cast steel, thw wheels shall be with flanges and
designed to ensure effective operation of hand chain. Further, suitable local brake
shall be provided as per IS: 3832 to arrest and sustain loads in all working
positions.
1.04.00 The velocity rates, effort on chain required to raise the safe working load and travel
and speed shall be within the limit specified in IS: 3832. Proof load test shall be
carried out as per IS: 3832.
1.05.00 All gears and pinions shall be of hardened and tempered steel with machine cut
teeth in metric modules. Surface hardening of steel is not acceptable.

AIR CONDITIONING & VENTILATION

SYSTEM

CLAUSE NO.
AIR CONDITIONING & VENTILATION SYSTEM

1.00.00 GENERAL
1.01.00 This section of specification covers details of system specifications, detailing the areas to be
air conditioned, basis of design, brief description of the system, equipment and services to
be furnished by bidder. The supply, delivery and erection of the entire equipment listed here
shall be in bidder’s scope of work.
2.00.00 AREAS TO BE COVERED UNDER AIR CONDITIONING & VENTILATION SYSTEM
2.01.00 The areas to be air-conditioned shall be as follows:
a) Water System Control Room Building

b) Fire water pump house control room.
c) Fire water booster pump house control room.
d) Chemical lab building
e) Cooling tower Control/RIO room
f) Other auxiliary control room/control room buildings/RIO rooms not listed above but
covered in the scope of Bidder.
g) Apart from the above, any area/building which are in the scope of the bidder and require
air conditioning.
2.02.0 The areas to be ventilated shall be as follows:
a) All the pump houses like fire water pump house, hydrant & spray booster pump house,
etc.
b) Chemical house
c) All switchgear rooms/MCC/Battery rooms/Cable Vault/Stores
d) All Toilets & Pantries
e) Other auxiliary areas not listed above but covered in the scope of Bidder and require
ventilation.
3.00.00 REDUNDANCY OF EQUIPMENTS

3.01.00 Redundancy of various A/C system equipments shall be as follows:
a) Water System Control Room Building:
i) Air cooled (D-X Type) condensing units: 2X100%
ii) AHUs: 2x100%
h) 100% standby shall be provided for control rooms/RIO room/etc. served by ductable
split/package and non-ductable split (cassette / Hi-wall) type air conditioners. No stand-
by shall be provided for office areas of other buildings.
i) Fresh air fans shall be 1 x 100 % capacity for each AHU room.
KHURJA SUPER THERMAL POWER TECHNICAL SPECIFICATION SUB SECTION-IIIA-08

PROJECT (2X660 MW) SECTION – VI, PART-B AIR CONDITIONING & PAGE 1 OF 17
WATER SYSTEM PACKAGE BID DOC. NO.: THDC/RKSH/CC-9915-373 VENTILATION SYSTEM
CLAUSE NO.
4.00.00 EQUIPMENT DESCRIPTION – AIR CONDITIONING SYSTEM
4.01.00 Condensing Unit -Air-Cooled (D-X type)
Condensing unit
Type : Air cooled scroll type
Vibration isolators : Steel spring / Neoprene rubber cushy foot type with
isolation efficiency not less than 85%.
Compressor
Type : The Compressor shall be scroll, serviceable, either

hermetic type or semi-hermetic type with automatic
capacity control (minimum 3 steps).
Type of drive : Motor driven.
Refrigerant : The refrigerant shall be R-134a/ R-410A/R-407C or any

other environment friendly refrigerant.
Accessories : High/Low pressure cutouts, oil pressure switches, relief
valves, pressure gauges at each stage, lube oil and
control oil pressure gauges, suction & discharge stop
valves, Muffler, Crank case heaters, oil filters, magnetic oil
separators, temperature indicators for lube oil/heaters, oil
level indicators, safety thermostat for crank case heater,
vibration isolators, etc.
Capacity : Minimum capacity shall be suitable for the
identified/selected at evaporating temperature and
condensing temperature and shall be indicated.
4.02.00 Air Handling Unit (AHU)
4.02.01 Each AHU shall consist of casing, fan impeller section, cooling coil section, damper section,
steel frame with anti vibration mountings (AVMs) having minimum 85% vibration dampening
efficiency and flame retardant, water proof neoprene impregnated flexible connection on fan
discharge. Isolation dampers at the suction and discharge of each AHU shall be provided, in
case return air duct is directly connected to AHU. However, in case AHU room is used for
return air, isolation dampers are required to be provided only at AHU discharge of each
AHU. Pre-filter at the suction and fine (micro-vee type) and absolute (HEPA type) filters
(wherever applicable) at the discharge of each individual AHU, and heater section in the
common discharge of AHUs. NRD shall be provided at outlet of each AHU when multiple
AHU used for a common plenum.
4.02.02 The casing of AHUs shall be of double skin construction. Double skin sandwich panels
(inside and outside) shall be fabricated using minimum 0.63 mm (24g) galvanized steel
sheet (thickness of galvanization as per manufacturer’s standard) , with 25mm thick
polyurethane foam insulation of minimum 38 Kg/Cum density in between. Suitable
reinforcements shall be provided to give structural strength to prevent any
deformation/buckling.
4.02.03 Sloping condensate drain pan shall be made of minimum 1.2 mm thick Stainless Sheet
Steel. It shall be isolated from bottom floor panel through 25mm thick heavy duty treated for

CLAUSE NO.
Fire (TF) quality expanded polystyrene or polyurethane foam. Drain pan shall extend
beyond the coil.
4.02.04 Cooling coil (min. 4 row deep) shall be made of seamless copper tubes with aluminium fins
firmly bonded to copper tubes and shall be provided with suitable drains and vents
connections.
4.02.05 All filter plenum shall be provided with a walking platform inside the plenum chamber for
filter cleaning purpose. Inspection door shall be provided at the plenum chamber and a
removable type ladder shall be attached to plenum.
4.02.06 Centrifugal fan
a) Fan Type : Double Width Double Inlet (DWDI) Centrifugal

Type
b) Fan impeller : Backward curved blades
c) Casing material : GI /Mild steel with minimum thickness of 3 mm.
d) Impeller material : Carbon steel
e) Shaft : EN 8 Steel
f) Fan bearings : Self aligning type, permanently lubricated, heavy

duty with a design life of 10,000 operating hours.
g) Critical speed : First critical speed of rotating assembly shall be at

least 25% above the operating speed.
h) Drive : Motor driven with removable belt guard. Motor

rating (at 50 deg.C ambient) shall be atleast fifteen
percent (15%) above the maximum load demand of
drives at the design duty point.
i) Fans : For AHUs of capacity 50,000 CMH and above,

Bidder may offer two (2) Nos. centrifugal fans of
equal capacity for each AHU provided all such
AHUs are accommodated within the space
identified by the Employer.
4.02.07 Mixing Box:

Mixing box shall be complete with fresh and return air dampers. Mixing box shall be
provided whenever the return air is ducted back to the AHU.
4.02.08 Pan Humidifier:
Pan humidifier shall be made of 22 gauge SS 304 tank, duly insulated with 25 mm thick
resin bonded fiber glass insulation (min. 24 Kg/m3 density) with 0.5 mm GSS cladding. The
humidifier shall be complete with stainless steel immersion heaters, safety thermostat, float
valve with stainless steel ball, sight glass, overflow and drain connections, steam outlet

CLAUSE NO.
nozzle and float switch. Step controller shall be provided for switching on / off heater banks
as per system requirement.
4.03.00 NON DUCTABLE SPLIT (HI-WALL/CASSETTE), DUCTABLE SPLIT, PACKAGED AIR-
CONDITIONERS
4.03.01 Air conditioners shall in general consist of the following:
i) Casing
ii) Hermetically sealed rotary/scroll Compressor
iii) Air-cooled condenser
iv) Evaporator and condenser cooling fan
v) Cooling coil
vi) Filters
vii) Piping, valves, refrigerant strainer, etc.
viii) Controls, instruments, control panel/starter panels.
ix) Vibration isolator pads, ducting (if applicable), etc. as required.
x) Refrigerant as per manufacturer practice.
4.03.02 Indoor unit of Ceiling Mounted Cassette Type Unit (Multi Flow Type):
The housing of the unit shall be powder coated galvanized steel. All the indoor units
regardless of their difference in capacity should have same decorative panel size for
harmonious aesthetic point of view.
Unit shall have four-way supply air grills on sides and return air grill in center.
Each unit shall have high lift drain pump and very low operating sound.
4.03.03 PACKAGED AIR-CONDITIONERS
(a) Packaged air conditioners shall be an encased assembly as a self-contained unit

primarily for floor mounting, designed to provide free delivery of conditioned air to the
conditioned space. It shall include a primary source of refrigeration for cooling and
dehumidification, means for circulating and cleaning air and means for heating and
humidifying air. Fresh air fan shall be provided in PAC Room.
(b) The cabinet, housing the components of packaged air conditioners, shall be of heavy
gauge sheet steel and suitable for floor mounting. The access panels shall be of easily
removable type. The entire casing shall be thermally insulated with 25 mm thick
insulation of totally flame proof type (T.F. type). Suitable drain connection shall be
provided for removal of condensate collected inside a tray under cooling coil.

CLAUSE NO.
(c) Controls shall be so provided that failure of one equipment of PAC will automatically trip
that PAC unit.
(d) HP and LP cutout shall be provided for compressor protection. A thermostat with
adjustable setting shall also be provided in the return air circuit to control the room
temperature by ON-OFF mode.
(e) Provision shall also be made for manual re-starting and stopping of the compressor.
(f) Interlock shall be provided such that compressor can start only starting the air handling
fan.
(g) Interlock shall be provided so that compressor can start only if condenser fan in running.
Further if the condenser fan stops, the compressor shall also trip.
(h) To control the humidity throughout the year, the humidistat shall be interlocked with
humidifier and reheater.
5.01.00 Material of Construction for Piping & Fittings
b) Refrigerant piping : : Seamless steel tubes conforming heavy grade IS:1239
or copper tubes as per IS:2501 (copper material as per
IS:191 hard copper grade).
Drain piping : Same as (a) above & galvanized as per IS:4736.

c)
d) Fittings : 1) The steel fittings shall conform to ASTM A234 Gr.

WPB and dimensional standard to ANSI B 16.9/ANSI
B16.11 / equivalent for sizes 65 NB and above.
2) For sizes 50 NB and below, the material shall
conform to ASTM A-105.
3) All steel flanges shall be of slip on type and shall
conform to ANSI B 16.5
4) For pipe sizes above 350 NB, fabricated fittings from
sheets of adequate thickness may be used. The
bend radius in case of mitre bends shall be minimum
1.5 times the nominal pipe diameter and angle
between two adjacent sections shall not be more
than 22.5 deg and shall be as per BS:2633/BS:534.
5) Fittings, flanges and pipe joints of refrigerant piping
shall conform to ANSI B31.5
5.02.00 VALVES
5.02.01 Valves shall have full sizes port and suitable for horizontal and as well as vertical
installation.
5.02.02 Valves for regulating duty shall be of globe type suitable for controlling throughout its lift.
5.02.03 All safety /relief valves shall be so constructed that the failure of any part does not obstruct
the free discharge.
5.02.04 Valves shall be furnished with back seating arrangement for repacking while working under
full working pressure.

CLAUSE NO.
5.02.05 All valves shall be supplied with companion flanges, nut, bolts & washers, etc.
5.02.06 The refrigerant line valves shall have steel or brass body with TEFLON gland packing. The
construction of disc shall be either globe or angle type. The valve seat shall have white
metal lining or equivalent.
5.03.00 AIR FILTERS
5.03.01 Pre Filter
1) Type : Flange / Cassette
2) Fabric Filter:
Pre-filter shall contain washable non-woven synthetic fiber or High density

Polyethylene (HDPE) media having 18G GSS / 16G Al alloy frame. The filter media
shall be supported with HDPE mesh on air inlet side & Aluminium expanded metal on
exit side or G.I. wire mesh on both sides.
3) Other requirements : (as applicable)
a) Suitable aluminium spacers be provided for uniform air flow;
b) Casing shall be provided with neoprene sponge rubber sealing.
c) Capable of being cleaned by water flushing.
d) Density of filter medium shall increase in the direction of air flow in case of
metallic filter.
e) Filter media shall be fire retardant and resistant to moisture, fungi, bacteria &
frost.
4) Efficiency :
Average arrestance of 65 - 80 % when tested in accordance with BS:6540/ASHRAE –

52 – 76 / EN-779.
5) Minimum thickness : 50 mm
6) Face Velocity : Not more than 2.5 m/sec.
7) Pressure drop : Initial pressure drop - Not to exceed 5.0 mm WC at rated

flow.
Final pressure drop - Upto 7.5 mm WC.
8) Location : a) At the suction of each AHUs
: b) At the suction of each Fresh air fan
: c) At the suction of each Supply air fan
5.03.02 Fine Filters (Microvee type)

CLAUSE NO.
1) Type : Flange / Cassette
2) Fine filter shall contain washable non-woven synthetic fibre or High density
Polyethylene (HDPE) media having 18G GSS / 16G Al alloy frame. The filter media
shall be supported with HDPE mesh on air inlet side & Aluminium expanded metal
on exit side or G.I. wire mesh on both sides.
a) A neoprene sponge rubber sealing shall be
3) Other requirements :
provided on either face of the filter frame.
b) Capable of being cleaned by air or water flushing.
c) Filter media shall be fire retardant and resistant to
moisture, fungi, bacteria & frost.
4) Efficiency : Average arrestance > 90% when tested in accordance

with BS:6540/ASHRAE–52-76 / EN-779.
5) Minimum thickness : 150 mm or 300 mm.
6) Face Velocity : Not more than 1.2 m/sec for 150 mm and not more
than 2.4 m/sec. for 300 mm.
7) Pressure drop : Initial pressure drop - Not to exceed 10 mm WC at

rated flow ; Final pressure drop-Up to 25 mm WC.
8) Location : i) At the discharge of each individual AHU.
ii) At the discharge of each Fresh air fan.
iii) At the discharge of each supply air fan having static

pressure 30mmWC or more.
5.03.00 LOW PRESSURE AIR DISTRIBUTION SYSTEM
5.03.01 Material of air distribution system shall be through galvanized steel sheet (Conforming to
Class 275 of IS: 277) or Aluminium alloy (grade 19000 / SIC or 3100 / NS3 of IS: 737)
5.03.02 Thickness of rectangular ducts shall be as follows:
Larger Dimension of duct (mm) Thickness of GI Thickness of Aluminium sheet

sheet(mm) (mm)
up to 750 mm 0.63 (24 G) 0.80
751 to 1500 0.80 (22 G) 1.00
1501 to 2250 1.00 (20 G) 1.50
2251 & above 1.25 (18 G) 1.80
5.03.03 Thickness of round ducts shall be as follows :
Diameter of Round duct Thickness of GI sheet(mm) Thickness of Aluminium

(mm) sheet (mm)

CLAUSE NO.
150 to 500 0.63 0.80
501 to 750 0.80 1.00
751 to 1000
0.80 1.00
1001 to 1250 1.00 1.50
1251 & above 1.25 1.80
5.03.04 Duct Fabrication and Supports:
a) Duct fabrication shall be as per the latest relevant BIS/SMACNA standard.
b) Ducts for A/C system may be site fabricated or factory fabricated and installed at
site. However, in case of partly used factory fabricated ducts, vendor shall take
back the unused ducts.
c) The ducts routed inside the buildings with larger side greater than 2250 mm shall be
supported by 16mm MS rods and 50x50x3 mm MS double Angles while those
below 2250 mm shall be supported by 10mm MS Rods and 40x40x3 MS angles.
The duct supports shall be at a distance of not more than 2000 mm for A/C system.
The MS rods for these ducts routed inside the building shall be hung from the
existing floor beams/wall beams/roof beams/columns as provided by the Employer
with provision of necessary auxiliary or special steel members or by hooks or can
be provided by contractor by dash fasteners fixed to the ceiling slab. No supports
shall be taken from horizontal/vertical bracings of the structures. All items of duct
support including MS rods, MS angles and double angles, auxiliary or special steel
members, hooks, dash fasteners coach screws and all other supporting material
required shall be provided by the bidder.
d) Where the sheet metal duct connects to the intake or discharge of fan units a flexi-
ble connection of fire retarding, at least 150 mm width shall be provided of closely
woven, rubber impregnated double layer asbestos/canvas or neoprene coated fibre
glass.
e) All curves, bends, off-sets and other transformations shall be made for easy and
noiseless flow of air. The throat of every branch duct shall be sized to have the
same velocity as in the main duct to which the branch duct is connected.
f) Wherever duct passes through a wall, the opening between masonry and duct work
shall be neatly caulked or sealed to prevent movement of air from one space to the
adjoining space.
g) Wherever pipe hangers or rods pass through the ducts, light and streamline ease-
ment around the same shall be provided to maintain smooth flow of air.
h) Access doors shall be provided in the duct work or casing on the both sides of the
equipment to be serviced. All access doors shall be of adequate size and shall be
lined with substantial felt edging to prevent air leakage. Access doors shall be of
built up construction, structurally strong and each shall have at least two hinges.
Access doors shall have two rust proof window sash of approved type. All doors

CLAUSE NO.
shall be set so as to flush with insulation or plaster finish on the duct.
i) Where ever horizontal ducts are running outside the building and or at locations
where it is not possible to support the ducts from Employers ceiling/floor due to non-
availability of the same, the base steel frame/truss work for supporting the ducts
between two columns shall be provided by Employer. However, all other auxiliary
steel members, hooks, rods, etc. for supporting the duct work with the base
frame/truss work shall be provided by the bidder. For vertical ducts running outside
the building, bidder to take support from building columns and beams which is in
Employer scope. However, all other auxiliary steel members, hooks, rods, etc. for
supporting the duct work with the employers beam & columns shall be provided by
the bidder.
5.03.05 Splitters and dampers shall be provided for equipment/area isolation and for proportional
volume control of system. The same shall be minimum 16 gauge GS sheet of quadrant type
with suitable locking device, mounted outside of duct in accessible position.
5.04.00 Factory fabricated ducts:

i) All ducting shall be fabricated of LFQ (Lock Forming Quality) grade prime G.I.
ii) Unless otherwise specified here, the construction, erection, testing and performance
of the ducting system shall conform to the SMACNA-1995 standards (“HVAC Duct
Construction Standards-Metal and Flexible-Second Edition-1995” SMACNA)
iii) All ductwork including straight sections, tapers, elbows, branches, show pieces,
collars, terminal boxes and other transformation pieces must be factory fabricated
by utilizing the machines and processes as specified in SMACNA or by equivalent
technology. In equivalent method, the fabrication shall be done by utilizing the
following machines and process to provide the requisite quality of ducts and speed
of supply:
a. Coil lines to ensure location of longitudinal seams at corners/folded edges only

to obtain the required duct rigidity and low leakage characteristics. No
longitudinal seams permitted along any face side of the duct.
b. All ducts, transformation pieces and fittings to be made on CNC profile cutters
for required accuracy of dimensions, location and dimensions of notches at the
folding lines.
c. All edges to be machine treated using lock formers, flangers and roll-bending
for turning up edges.
d. Sealant dispensing equipment should be used for applying built-in sealant in

Pittsburgh lock where sealing of longitudinal joints are specified. Sealing of
longitudinal joint is compulsory for the ducts over 2” w.g. static pressure
iv) All transverse connectors shall be 4-bolt slip-on flange system with built-in sealant, if
any. To avoid any leakage additional sealant shall be used.
v) Factory fabricated ducts shall have the thickness of the sheet as follows:
Sl.No.
Size of Duct Sheet Thickness
i) upto 750 mm 0.63 mm
ii) 751 mm to 1500 mm 0.80 mm
iii) 1501 mm to 2250 mm 1.00 mm
iv) 2251 mm and above 1.25 mm
CLAUSE NO.
5.05.00 Diffusers, Grills & Dampers:
5.05.01 Supply air diffusers/grills with factory fitted volume control dampers be provided for all air-
conditioned areas.
5.05.02 Return air diffusers of air conditioned areas shall be without volume control dampers.
5.05.03 The diffusers/grills shall be of extruded Aluminum of minimum 2 mm thick with powder
coating. The color of power coating shall be as per the interior Décor.
5.05.04 Supply air grills shall be of double deflection type and return air grills shall be of single
deflection type.
5.05.05 The nozzle type diffusers shall be fabricated from minimum 1.5mm aluminium sheet. The
base shall be fixed type. The nozzle shall be of volute design with the Spout diameter being
half the base dia. and designed for low noise and long throw. The nozzle shall be able to
rotate to any angle within the base. The whole assembly shall be powder coated as per
interior decor.
5.05.06 All volume control (VC) damper shall be operated by a key from the front of the
grills/diffusers and shall be of GI sheet.
5.05.07 The thickness of VC dampers shall be of minimum 20 gauge and thickness of louvers shall
be of minimum 22 gauge.
5.05.08 Suitable vanes shall be provided in the duct collar to have uniform and proper air
distribution. Bank of Baffles wherever required shall also be provided.
5.05.09 Fire dampers shall be motor operated type and shall have fire rating of minimum 90
minutes.
5.05.10 All plenum chambers of connections to fans, dampers etc. shall be constructed in 18 gauge
GS sheet and supported on MS angle frames,
5.05.11 All ducting surfaces coming in contact with corrosive fumes or gases shall be painted with
three coats of epoxy paint over a coat of suitable primer.
5.05.12 Suitable number of VAV box (if applicable) shall be provided for optimum use of VFD driven
AHU.
5.06.00 Thermal and Acoustic Insulation
5.06.01 A) Application with Glass Wool

CLAUSE NO.
(a.) All surfaces to be insulated both thermally and acoustically shall be thoroughly
cleaned, dried and an adhesive (CPRX compound of Shalimar Tar Products or
Equivalent) be applied @ 1.5 Kg /Sqm on the surface.
(b.) Insulation material (either expanded polystyrene foam or Glass Wool/ Glass fiber or
Equivalent) shall be struck to the surface. All the joints shall be sealed with bitumen.
(c.) Insulation mass to be covered with 500 gauge polythene sheet with 50 mm overlaps
and sealing all joints on hot side.
(d.) Insulation Finish of types specified under shall be provided thereafter.
B) Application with Nitrile Rubber:
(a) All surfaces to be insulated shall be properly cleaned.
(b) A suitable adhesive such as SR 998 or equivalent shall be applied over the surfaces to
be insulated and insulation material surfaces.
(c) Insulating material shall than be pasted onto the surfaces in a manner to avoid
stretching and any air entrapment within.
(d) Two layers of Glass Cloth with a suitable adhesive as SR 998 or equivalent shall be
then applied over the insulating material to avoid surface weathering.
C) Application with Polyurethane Foam & Polyisocyanurate Foam
(a) All surfaces to be insulated shall be cleaned.
(b) A suitable adhesive such as CPRX or Loid Bond 83 or equivalent shall be applied over
the surface to be insulated and insulation material surfaces.
(c) Insulating material with aluminum foil lamination shall then be pasted onto the surface
in a manner to avoid stretching and any air entrapment within.
(d) Two layers of Glass Cloth with a suitable adhesive as Loid Bond 130 shall be then
applied over the insulating material, to avoid surface weathering.
(e) Insulation Finish of types specified under shall be provided thereafter.
5.06.02 Type of Insulation & Finish
Surface Insulation Material Insulation Finish (mm)

Form Thick
Sl. (mm)
No.
1. Supply & return Resin bonded glass Roll /Slab 50 F-3

air duct of AC wool
System
or
Closed Cell sheet 19 As per

Elastomeric Nitrile manufacturer

CLAUSE NO.
Surface Insulation Material Insulation Finish (mm)

Form Thick
Sl. (mm)
No.
Rubber std.
or
Polyisocyanurate Slab 30 F-3

Foam
2. Refrigerant Closed Cell tube 19 As per

(Suction and Elastomeric Nitrile manufacturer
liquid lines) Rubber std.
or
Rigid Polyurethane Pipe 50 F-1 (a)

Foam Section
3. AHU drain pipe Closed Cell tube 19 As per

Elastomeric Nitrile manufacturer
Rubber std.
or
Rigid Polyurethane Pipe 50 F-1 (a)

Foam Section
4. AHU Mineral wool or Slab 25 As per

condensate pan resin bonded glass manufacturer
(insulation if wool std.
required)
5. Exposed air Resin bonded Roll/Slab 50 F-4

duct Glass
wool/Rockwool
or Slab 50 F-4(a)
Polyisocyanurate
Foam
5.06.03 Specification for insulation shall be as follows: -

CLAUSE NO.
Insulation Material Code Thermal Density Kg/m3

conductivity
(w/m/oC
Resin bonded glass wool IS:8183 0.049 at 50oC i) 24 (For Glass

wool)
ii) 48 (For Rockwool)
iii) 48(For acoustic

insulation)
0.043 at 50oC
Mineral wool pipe IS:9842 0.043 at 50oC 144
section. Min.Gr.2
Closed Cell Elastomeric 0.036 at 20oC 40 – 60

Nitrile Rubber
Polyurethane Foam 0.03 at 50 oC 34 + 2

IS12436
Polyisocyanurate Foam 0.03 at 50 oC 34 + 2
Note : Insulation used for HVAC application shall be CFC/HCFC free
5.06.04 The specification for various finishes shall be as follows
a) Finish F-1 ( with Resin Bonded Glass Wool/Resin Bonded Mineral Wool)
Step-1 Wrapping of Poly-Bonded Hessain (PBH – to act as vapour seal) on outer

surface of insulation with 50 mm overlap stitching and sealing of overlap
with synthetic adhesive like CPRX or Equivalent compound.
Step-2 The surface then shall be wrapped with 19 mm mesh 24 SWG GI wire
netting, butting all the joints and laced down with 22 SWG lacing wire.
Step-3 Sand cement (4:1) plaster shall be applied in two layers totalling to 12.5
mm thick, the second layer being brought to a smooth finish. A water
proofing compound shall be added to the cement before its application.
aa) Finish F-1(a) (With Polyurethane Foam & Polyisocyanurate Foam)
Wrapping of two layers of 7 mil 10 x 10 mesh glass cloth dipped in suitable

adhesive such as SR 998 or Loid Bond 130 equivalent
b) Finish F-2
Step-1 Insulation shall be covered with 500g polythene with 50mm overlap and
sealing of overlap with synthetic adhesive like CPRX/ Loid Bond 83 or
Equivalent compound.

CLAUSE NO.
Step-2 Same as Step-2 of Finish F-1 above.
c) Finish F-3
Step-1 Same as Step-1 of Finish F-2 above
Step-2 The polythene shall be covered with 26 gauge Aluminium sheet and
locking of joints with self-locking screws at a pitch of minimum 100 mm.
d) Finish F-4
Step-4 Application of 3 mm thick coat of suitable water proofing compound and
wrapped with fibre glass RP tissue followed by final coat of 3 mm thick
water proofing compound over the RP tissue.
Step-5 After the above treatment, 22G Aluminium sheet cladding, properly stiched
at all joints shall be provided over the external surface.
dd) Finish F-4(a) (With FR Closed Cell Chemically Cross Linked Polyethylene)
Application of aluminium sheet 22G cladding to be provided over the XLPE
insulating material. Cladding sheet is held in position with SDST screws @
150 mm C/c over tongue-in-groove joints applied with a felt for sealing joint
against water ingress.
All sheet joints to be done in a manner to shed water.
5.06.05 For all inspection covers and hatches on equipment, pump casing, valve bodies and
flanges (100 mm and above), insulation shall be applied so as to facilitate removal without
minimum damage to the insulation by encasing the insulation in 24 gauge GI box or 22
gauge Aluminium sheet metal boxes which are bolted together around the equipment.
However continuity of the vapour seal between the static and removable portions of the
insulation is to be maintained.
5.06.06 ACOUSTIC INSULATION

a) All ducts up to a distance of 5 meters from AHU shall be acoustically lined from
inside with 25 mm thick resin bonded glass wool of 48 Kg/Cu.M. density and 30
gauge perforated aluminium sheet having 5 mm dia perforation at 8 to 10 mm
centre-to-centre distance. Insulation shall be fixed on wooden frame of 600 x 600
mm dimension.
b) Fibre glass tissue sheet shall be applied over the outer surface of insulation
before applying perforated aluminium sheet. Application of acoustic insulation shall

be inline with the requirements specified above.

CLAUSE NO.
5.07.00 AXIAL FANS (FRESH AIR FANS/SUPPLY AIR FANS/EXHAUST AIR FANS)
a) These fans shall have fixed / variable pitch cast aluminum blades of aerofoil design.
b) The fan casing shall be of heavy gauge sheet steel construction.
c) Necessary rain protection cowl, inlet and outlet cones, bird protection screen,
adjustable damper, vibration isolators, back draft dampers etc. shall be provided.
d) The speed of the fan shall not exceed 1000 rpm for fan with impeller diameter
above 450 mm and 1500 rpm for fan with impeller diameter 450 mm or less.
However for fans having static pressure of 30 mm WC or above the speed of the
fan shall not exceed 1500 rpm for fan with impeller diameter of above 450 mm and
3000 rpm for fan with impeller diameter of 450 mm or less. The first critical speed of
rotating assembly shall be atleast 25% above the operating speed.
e) All other accessories like supporting structure etc. as required shall be provided.
6.00.00 PLANT CONTROL

6.01.00 Brief scheme of controlling the operation is described below. Detailed description of the
control system for safe and efficient operation of the plant shall be elaborated, got approved
from employer. The descriptions in the sub-sections of the control & instrument sections
shall also be referred to.
6.02.00 Control Scheme for Air-Conditioning System
6.02.01 All the functional requirements specified below and general control logic specified under this
section shall be implemented in the respective control system.
6.02.02 The basic function of the system shall be to closely control and monitor temperature and
humidity conditions inside the air-conditioned spaces, to optimize / minimize energy
consumption by automated operation, to provide remote centralized monitoring & control for
various mechanical facilities including sequential start/stop of the whole Air conditioning
System, automatically calculate record and cooling load for each hour /day/season, to
generate maintenance data & alarms, to maintain records of plant operation & energy
consumption for varying loads, duty cycling to operate all the equipment including standby
equipment for equal duration, automatic startup of standby equipment in case of failure of
operating unit and displaying fault alarm status of the tripped unit.
6.02.03 Air conditioning system for water system control room building shall be controlled through
microprocessor based Distributed Digital Control Monitoring and Monitoring System
(DDCMIS). This DDCMIS shall perform all functions such as auto/manual operation of
drives, local/remote selection of operation, status indication, annunciation, interlock and
protection of drives, etc.
6.03.00 Air Handling Unit
a) Humidity sensor and gyserstat located in the return air duct shall actuate the PAN
humidifier to obtain the desired degree of humidification.
b) Humidity and temp. sensor shall be provided and interlocked in steps with winter heater
/ re-heater / strip heaters for monsoon and winter re-heating or heating as the case may
be.

CLAUSE NO.
c) Heater banks shall be interlocked with the running of AHU, temperature of return air,
humidity of return air and safety thermostat (airstat - located in front of the each heater
in the supply air duct)
d) AHU shall be started either locally or from the control room of A/C system by means of
Remote / Manual selection facility.
e) The closure of fire dampers, automatic tripping of AHU fans and fresh air fans shall be
interlocked with fire detection system.
6.04.00 D-X Air-Conditioning System

a) Further the compressor starting/running shall be interlocked with the flow switches in
condenser water circuit and as well as with AHU motors.
b) The standby AHU shall be started automatically when the working equipments are
stopped/tripped. Auto/Manual selector Switches and working / standby selector switches
for AHU shall be provided in the panel.
6.05.00 Packaged/ Split Air Conditioners

Control and interlocks for these type of units shall be as per manufacturer’s standard
practice.
6.06.00 Miscellaneous Control Requirements

a) Separate emergency local stop push button shall be provided for each, compressor,
fans etc. of A/C system.
b) Status shall be provided of each compressor, fans etc. of A/C system on HMI system at
control room.
c) All the annunciations related to failure of equipments, tripping of equipments, source of
failure / reason due to which the equipment is stopped/tripped, low & high limits of
parameters such as level, temperature, pressure drop, pressure etc. shall be provided
for each fan, compressor, AHU, PAC, etc. of centralized A/C system.
d) The fans (both supply and exhaust fans) associated with mechanical ventilation system
shall be operated locally.
7.00.00 PAINTING:
7.01.00 All the Equipments shall be protected against external corrosion by providing suitable
painting.
7.02.00 The surfaces of stainless steel, Galvanized steel, Gunmetal, brass, bronze and non-metallic
components shall not be applied with any painting. The Contractor shall clean the external
surfaces and internal surfaces before Erection by wire brushing and air blowing. The steel
surface to be applied with painting shall be thoroughly cleaned before applying painting by
brushing, shot blasting, etc. as per the agreed procedure.
7.03.00 For all the steel surfaces (external) exposed to atmosphere (outdoor installation), one (1)
coat of red oxide primer of thickness 30 to 35 microns followed up with three (3) coats of
synthetic enamel paint, with 25 microns as thickness of each coat, shall be applied. For
plant at coastal area, epoxy resin based zinc phosphate primer followed by epoxy resin
based paint pigmented with titanium di-oxide shall be used in place of enamel paints.
7.04.00 For all the steel surfaces inside the building (indoor installation), One (1) Coat of red oxide
primer of thickness 30 to 35 microns followed up with two (2) coats synthetic enamel paint,

CLAUSE NO.
with 25 microns as thickness of each coat shall be applied. For plant at coastal area, epoxy
resin based zinc phosphate primer followed by epoxy resin based paint pigmented with
7.05.00 For centrifugal fans - Casing shall have hot dip/ spray galvanization (minimum 60 micron
DFT).
8.00.00 CODES & STANDARDS
8.01.00 The design, manufacture and performance of equipment shall comply with all currently
applicable statues, regulations and safety codes in the locality where the equipments are to
be installed. Nothing in this specification shall be considered to relieve the bidder of this
responsibility.
8.02.00 Unless otherwise specified, equipment shall conform to the latest applicable Indian or IEC
standard. Equipment complying with other authoritative standards such as British, USA,
ASHRAE etc. will also be considered if it ensures performance equivalent or superior to
Indian Standard.

PART-B (ELECTRICAL)

WATER SYSTEM PACKAGES
SUB-SECTION TITLE
PART – B (ELECTRICAL)
IIIB – 00 GENERAL ELECTRICAL SPECIFCIATION
IIIB – 01 MOTORS
IIIB – 02 LT SWITCHGEARS & LT BUSDUCTS
IIIB – 03 LT POWER CABLES
IIIB – 04 LT CONTROL CABLES
IIIB – 05 CABLING, EARTHING AND LIGHTNING PROTECTION
IIIB – 06 BATTERY
IIIB – 07 BATTERY CHARGER
IIIB – 08 OUTDOOR TRANSFORMER
IIIB – 09 HT POWER CABLES
IIIB – 10 FIRE PROOF CABLE PENETRATION SEALING
IIIB – 11 STATION LIGHTING

IIIB – 12 VARIABLE FREQUENCY DRIVES
IIIB – 13 CONSTRUCTION POWER

SUB-SECTION – IIIB-00
GENERAL ELECTRICAL
SPECIFCIATION

CLAUSE NO.
1.01.00 For the purpose of design of equipment/systems, an ambient temperature of 50 deg.

Centigrade and relative humidity of 95% shall be considered. The equipment shall operate in
a highly polluted environment. However, for equipment in air conditioned areas, design
ambient temperature shall be 35 deg.C, if 2x100% air conditioning system is provided.
1.02.00 All equipments shall be suitable for rated frequency of 50Hz with a variation of +3% & -5%,
and 10% combined variation of voltage and frequency unless specifically brought out in the
specification. The overall system shall be designed considering voltage variation of +/- 5%
and fault level of 50kA for 765KV system
1.03.00 Contractor shall provide fully compatible electrical system, equipments, accessories and
services for the entire station/plant in his scope as well as those specifically required by the
Employer.
1.04.00 All the equipment, material and systems shall, in general, conform to the latest edition of
relevant National and International Codes & Standards, especially the Indian Statutory
Regulations.
1.05.00 The auxiliary AC voltage supply arrangement shall have 11 kV, 3.3KV and 415V systems. It
shall be designed to limit voltage variations as given below under worst operating condition:
a) 11KV/3.3KV +/- 6%
b) 415 V/240 V +/- 10%

c) 220V/110V/48 V DC -15% to +10%
1.06.00 The voltage level for motors shall be as follows:
a) Upto 0.2 KW : Single phase 240V AC / 3 phase
415V AC
b) Above 0.2 KW and upto 200 KW : 3 phase, 415V AC
c) Above 200 KW and upto 1500 KW : 3 phase, 3.3 kV AC
d) Above 1500 KW : 11 kV
Bidder may offer 3.3 kV motors for drives above 160 kW . The voltage rating of the drives
indicated above is for basic guideline. Minor variations in above can be accepted on case to
case basis based on techno-economic considerations of the various sub-systems.
Voltage rating for special purpose motors viz, VFD and screw compressors, shall be as per
manufacturer’s standard.
1.07.00 The preferred AC control supply voltage shall be 110V for all 415 V non breaker controlled
feeders. Control supply voltages other than above may be offered by bidder based on the
bidder’s standard proven practice.
1.08.00 The designed fault levels for various voltage level shall be restricted to the following values:
11 KV systems - 40 kA rms for 1 second
3.3 KV systems - 40 kA rms for 1 second

SUB-SECTION-IIIB-00 PAGE
GENERAL ELECTRICAL 1 OF 7
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373
SPECIFCIATION
CLAUSE NO.
415 V systems --50 kA rms for 1 second
1.09.00 The nominal voltage of main DC system shall be 220V. DC batteries shall be designed for
continuous float operation with trickle charge, hence all the associated components like
batteries, battery chargers, DC motors, relays, contactors, timers etc shall be suitable for
continuous operation at the maximum continuous battery float voltage including suitable
temperature correction factors.
In addition, the bidder may propose 110V, 48V or 24V systems as per requirements of
control and instrumentation of his equipment and design.
1.10.00 The Contractor shall furnish calculations of maximum loading and fault levels under the most
onerous conditions for the various equipment/systems as defined elsewhere in the
specification to prove adequacy of their parameters. In case any equipment or system is
found to be inadequate, it shall be changed/ modified without any additional liability to the
Employer.
1.11.00 Transformer voltage ratios, taps, impedances and tolerances thereon, shall be so optimized
so that the auxiliary system voltages under various grid and loading conditions are always
within permissible limits and equipment are not subjected to unacceptable voltages during
operation and starting of motors etc. The vector groups of the transformers shall be so
selected that all the buses of particular voltage level have same vector within the plant.
1.12.00 In fire hazardous areas like gas/ liquid fuel storage/ handling areas, lighting fixtures,
switchgears shall be flame proof.
1.13.00 The responsibility of coordination with electrical agencies /TAC/Pollution control board and
obtaining all necessary clearances shall be of the contractor.
1.14.00 Provenness of the Equipment, system, being offered by the bidder should satisfy the criteria
Indicated in the “Provenness criteria” indicated elsewhere in the specification.
2.00.00 ELECTRICAL SCHEME FOR ELECTRICAL POWER DISTRIBUTION
For Electrical Power Distribution the electrical schemes for the project as conceived by the
Employer are indicated in tender SLD. The scheme with minor variations to above may also
be offered as long as they meet the redundancies indicated in the above drawings and sizing
criterion specified.
2.01.00 The power supply shall be designed with unitized and Station load concept. All
auxiliaries/systems required for operation of the unit shall be fed from respective unit’s power
supply system. Facilities/auxiliaries/systems required for more than one unit shall be fed from
Station/ different unit’s power supply system as shown in the Electrical Single Line Diagram.
2.02.00 The overall system shall be such that failure of any one unit auxiliary like transformer, DC
battery, Battery charger and DG set shall not reduce the plant's generating capability or
affect the safe shut down requirements of the unit.
3.00.00 SIZING & DESIGN
3.04.00 Transformers
All the transformers shall be sized based on the maximum load expected to be fed by them
under most onerous conditions or as per the rating indicated in the Aux Power Supply
Drawing No------999-POE-J-002. All transformers, except Generator Transformer (GT),
Station Transformer (ST), Unit Transformers (UT), Tie Transformer (TT) and Reactors are
classified as Auxiliary transformers.

SPECIFCIATION
CLAUSE NO.
All Auxiliary transformers (unless their ratings have been indicated in Single line Diagram or
for which sizing criteria has been indicated in the specification), shall be sized so as to have
10% margin at design ambient conditions after considering final load requirements, including
owner’s load (if applicable), at peak load conditions and the No Load Voltage Correction
Factor.
No Load Voltage Correction Factor (= Transformer No Load voltage/ rated bus Voltage) shall
be used for sizing of all transformers i.e.
The transformer size = the calculated size X no load voltage correction factor (11.5/11,
3.45/3.3, 0.433/0.415)
3.04.03 Auxiliary Transformers
Adequate number of auxiliary transformers shall be provided to meet the demand on 11KV,
3.3KV and 415V systems under most onerous conditions, with the criteria that each 3.3KV /
415 V switchgear / MCC / DB shall be fed by 2x100% or 3 X 50 % transformers / feeders,
and these shall be rated to carry the maximum load including owner’s load (if applicable)
expected to be imposed.
3.05.00 LV Switchgears
Sizing of LT Switchgears shall be in accordance with Clause No. 1.00.00 of Sub-section B-06
and its sub-clauses covering design considerations, performance / reliability criteria, spare
capacity requirements, standardization, etc.
All switchboards shall be metal enclosed, indoor, floor-mounted, free-standing type of bolted
design and shall be located in switchgear room. Entire bus bar system shall be insulated with
PVC sleeves. Cable terminations located in cable alley shall be designed to meet the Form
IVb (as per IEC 61439) for safety purpose.
All PCC/MCCs shall be fully draw out type. All ACDBs, DCDBs, Solenoid Valve DBs and
MCCs located on Travelling trippers shall be of Fixed Module type.
The Circuit Breakers / Contactors shall be of air break type & should conform to the
requirements of IS / IEC 60947. MCCB shall be provided for feeders upto 400A. Air circuit
breaker shall be provided for supply feeders above 400A.
For short circuit & Overload protection of motors below 30kW, MPCB shall be provided and
for motors from 30kW and below 110kW, MCCB with separate Overload relay shall be
provided. Motor feeders below 110kW shall be contactor controlled. The motor feeders for
110kW & above shall be Air Circuit Breaker controlled.
For 415V system, the switchboards fed from outdoor transformers of rating 1000kVA and
above shall be connected through busducts. For transformers of 1000kVA rating, cable
connection shall be acceptable only in case of layout constraints. For lower rated
transformers, the connection shall be through cables.
Numerical Relays Networking & Control Philosophy

The Design Philosophy shall be as follows:
(a) All the LT Incomers, Bus Ties , Bus couplers having Air Circuit Breakers shall be
controlled from Switchgear SCADA(Employer’s scope) and also from DDCMIS.

SPECIFCIATION
CLAUSE NO.
(b) The motor feeders shall be controlled from the DDCMIS only and analog/digital signals
pertaining to motor feeders shall be communicated on OPC from the switchgear
SCADA to DDCMIS.
(c) The Architecture of Switchgear SCADA shall be double Ethernet ring networks and dual
port Numerical Relays to ensure a high reliability SCADA network.
3.06.00 Cables and Bus Ducts

The minimum rating of cable/ bus ducts shall meet the following criteria:
All the cables and bus ducts feeding switchboards from transformers shall be sized based on
transformer rating and considering the maximum negative voltage variations envisaged in the
specifications. All the cables and bus ducts feeding transformers shall be sized based on
current ratings of transformer at the minimum voltage tap of the transformer. All other
cables/bus-ducts shall be sized based on the load demand under most onerous conditions.
Cables shall be selected to so as to limit maximum voltage drop at equipment terminals

during normal operation and starting conditions well within permissible values. Cables shall
be derated for the site ambient and ground temperatures, grouping and soil resistivity and
cable laying configuration.
All HT cables (except 132 KV voltage class) shall be of unearthed grade. The bidder shall
furnish detailed cable selection/sizing criteria for Employer’s approval.
3.07.00 Earthing & Lightning Protection System
The earthing system for plant shall be designed for a life expectancy of at least forty (40)
years, for a system fault current of 50 kA for 1.0 sec. The minimum rate of corrosion of steel
for selection of earthing conductor shall be 0.12mm per year.
Grounding and lightning protection for the entire power plant, switchyard and other areas or
buildings covered in the specification shall be provided in accordance with IS 3043, IS 2309,
IEEE 80 and IEEE 665.
3.08.00 D.C. Systems

Complete DC system, comprising of batteries, battery charges, relays, contactors, timers etc
shall be suitable for continuous operation at the maximum continuous float voltage including
suitable temperature correction factors.
The battery sizing shall be done based on different types of continuous and intermittent loads
including motor starting (wherever applicable) under complete blackout condition, for the
duration specified so as to meet the system requirement. The total DC load shall include load
for Employer’s facilities also (if applicable), as identified in the scope given at Section-VI,
Part-A Sub Section-IIB. All intermittent loads shall be considered with minimum 1 minute
duration. Nameplate ratings of DC motors shall be used in sizing. The battery shall be sized
O
considering a minimum electrolyte temperature of 15 C along with temperature correction
factors as per relevant standard. An ageing factor of 1.25 shall be considered. The no. of
cells, end cell voltage shall be considered based on the minimum and maximum voltage
window and cable drop etc. as per system requirement.
Each system shall comprise of two nos. of batteries and two nos. of float-cum-boost chargers
each rated for 100% capacity. DC scheme shall ensure that each critical consumer is fed

SPECIFCIATION
CLAUSE NO.
from two different bus sections. DCDBs shall provide adequate number of feeders on each
section.
Boost/ fast charging time shall be as per worst operating condition and would satisfy technical
requirements recommended by battery manufacturer. Each battery charger must be capable
of supplying all the continuous D.C. loads (fed through both section of DCDB) plus the trickle
charging current of both the batteries. In addition, each charger must have sufficient surplus
capacity for running of the largest D.C auxiliary so that the battery is not drained during
testing of the same. Battery charger should also be capable of boost/ fast charge the battery
from completely discharged condition to fully charged condition without imposing any
limitations under worse operating conditions.
The various DC Systems envisaged along with minimum battery bank ratings to be adopted
are indicated in the following table. Bidder may supply additional DC systems at offsite load
centers as per system requirement:
Area DC Load Minimum

Voltage Battery Bank
Rating
Water 220 V supply total DC load of the associated 150AH for lead
System area at an acceptable voltage for at least acid Plante type
30 minutes /90 AH for Ni-Cd
High Discharge
(KPH) type
batteries
6.00.00 INSULATION LEVEL
The insulation level for the transformer windings and bushings shall be as follows:
WINDING BUSHING
Highest System Rated Rated Rated Rated
Voltage Power lightning Power lightning
Freq. impulse freq. impulse
withstand withstand withstand withstand
Voltage voltage voltage voltage
(kVrms) (kVp) (kV rms) (kVp)
0.433 KV 3 - 3 -
3.6 kV 10 40 11 40
7.2 kV 20 60 22 60
12 kV 28 75 30 75
17.5 kV 38 95 42 95
24kV 50 125 55 125
36kV 70 170 77 170
72.5 kV 140 325 155 325

SPECIFCIATION
CLAUSE NO.
145kV 275/38* 650 305 650
245 kV 395/38* 950/1050** 505 1050/1050**
420 kV 630/38* 1425/1570** 750 1550/1570***
Switching Impulse withstand voltage, (kVp)
400 kV 1175kVp
* In case of non-uniformly insulated. ** Chopped wave BIL.
*** Suitable for chopped wave impulse test on transformers.
7.00.00 NEUTRAL GROUNDING
7.01.00 11KV/3.3KV system earthing shall be low resistance earthed type to limit earth fault current
to 600A. The resistor shall be rated to carry this current at least for 10 seconds.
7.02.00 Neutrals of LV Side of all LT Transformers (415V) shall be solidly earthed through bolted
links.
7.03.00 220V DC system shall be kept ungrounded.
7.04.00 Diesel generator shall also be kept ungrounded (earthing through PT).
9.00.00 FAULT LEVEL
Equipment through fault withstand capabilities under worst operating conditions duly taking
into account negative tolerances on transformer, generator & maximum fault levels of source
etc. shall be as follows :
i) All transformers - 2 seconds
ii) 11 kV busduct - 1 second
iii) Switchgears - 1 second
iv) Cables to the feeders protected by breakers Main protection fault

clearing time with 0.12
second minimum
v) Cables of all other feeders As per fuse operating

time
vi) 11KV & 3.3KV cable screen - 2 seconds for the

adopted ground fault
current
- 1 second for the adopted

ground fault current, for

SPECIFCIATION
CLAUSE NO.
cables connected to
miscellaneous switchgear/
transformer.
(** Note) Thermal withstand design time duration. The indicated values of time durations
are used in transformer design for ensuring thermal stability of the transformers and are to be
proven through calculations.

SPECIFCIATION
SUB-SECTION–IIIB-01
MOTORS

CLAUSE NO.
MOTORS

Centigrade and relative humidity of 95% (at 40 deg C) shall be considered. The
equipment shall operate in a highly polluted environment.
1.02.00 All equipment shall be suitable for rated frequency of 50 Hz with a variation of +3% &
-5%, and 10% combined variation of voltage and frequency unless specifically
brought out in the specification.
1.03.00 Contractor shall provide fully compatible electrical system, equipment, accessories
and services.
1.04.00 All the equipment, material and systems shall, in general, conform to the latest
edition of relevant National and international Codes & Standards, especially the
Indian Statutory Regulations.
1.05.00 Paint shade shall be as per RAL 5012 (Blue) for indoor and outdoor equipment.
1.06.00 The responsibility of coordination with electrical agencies and obtaining all
necessary clearances for contractors equipment and systems shall be under the
contractor scope.
1.07.00 Degree of Protection
Degree of protection for various enclosures as per IEC60034-05 shall be as follows:-
i) Indoor motors - IP 54
ii) Outdoor motors - IP 55

iii) Cable box-indoor area - IP 54
iv) Cable box-Outdoor area - IP 55
CW motors shall be provided with canopy.
1) Three phase induction motors : IS/IEC:60034
2) Single phase AC motors : IS/IEC:60034
3) Crane duty motors : IS:3177, IS/IEC:60034
4) DC motors/generators : IS/IEC:60034

1 OF 9
WATER SYSTEM PACKAGE BID DOC NO.:THDC/RKSH/CC-9915-373 MOTORS
CLAUSE NO.
5) Energy Efficient motors : IS 12615, IEC: 60034-30
3.00.00 TYPE
3.01.00 AC Motors:
a) Squirrel cage induction motor suitable for direct-on-line starting.
b) Continuous duty LT motors upto 200 KW Output rating (at 50 deg.C ambient
temperature), shall be Premium Efficiency class-IE3, conforming to IS 12615, or
IEC:60034-30. HT motors shall have minimum design efficiency of 95 %
Tolerance on efficiency value applicable as per IEC 60034.
c) Crane duty motors shall be squirrel cage Induction motor as per the
requirement.
d) Motor operating through variable frequency drives shall be suitable for inverter
duty with VPI insulation. Also these motors shall comply the requirements
stipulated in IEC: 60034-18-41 and IEC: 60034-18-42 as applicable.
e) Motors operating through variable frequency drives shall also meet the
requirements mentioned in subsection for VFD.
3.02.00 DC Motors Shunt wound
4.00.00 RATING
(a) Continuously rated (S1). However, crane motors shall be rated for S4 duty,
40% cyclic duration factor.
(b) Whenever the basis for motor or driven equipment ratings are not specified in
the corresponding mechanical specification sub-sections, maximum
continuous motor ratings shall be at least 10% above the maximum load
demand of the driven equipment under entire operating range including
voltage and frequency variations.
5.00.00 TEMPERATURE RISE
Air cooled motors
70 deg. C by resistance method for both thermal class 130(B) & 155(F) insulation.
Water cooled
80 deg. C over inlet cooling water temperature mentioned elsewhere, by resistance

method for both thermal class 130(B) & 155(F) insulation.

2 OF 9
CLAUSE NO.
41 deg.C over inlet cooling water maximum temperature of 39 deg.C for thermal
class 90 (Y) wet wound Boiler circulation pump motor.
6.00.00 OPERATIONAL REQUIREMENTS
6.01.00 Starting Time
6.01.01 For motors with starting time upto 20 secs. at minimum permissible voltage during
starting, the locked rotor withstand time under hot condition at highest voltage limit
shall be at least 2.5 secs. more than starting time.
6.01.02 For motors with starting time more than 20 secs. and upto 45 secs. at minimum
permissible voltage during starting, the locked rotor withstand time under hot
condition at highest voltage limit shall be at least 5 secs. more than starting time.
6.01.03 For motors with starting time more than 45 secs. at minimum permissible voltage
during starting, the locked rotor withstand time under hot condition at highest voltage
limit shall be more than starting time by at least 10% of the starting time.
6.01.04 Speed switches mounted on the motor shaft shall be provided in cases where above
requirements are not met.
6.02.00 Torque Requirements
6.02.01 Accelerating torque at any speed with the lowest permissible starting voltage shall
be at least 10% motor full load torque.
6.02.02 Pull out torque at rated voltage shall not be less than 205% of full load torque. It
shall be 275% for crane duty motors.
6.03.00 Starting voltage requirement
(a) Up to 85% of rated voltage for ratings below 110 KW
(b) Up to 80% of rated voltage for ratings from 110 KW to 200 KW
(c) Up to 85% of rated voltage for ratings from 201 KW to 1000 KW
(d) Up to 80% of rated voltage for ratings from 1001 KW to 4000 KW
(e) Up to 75 % of rated voltage for ratings above 4000KW
Except AOP & JOP motors running on D.G emergency supply, starting voltage shall
be 80%.

3 OF 9
CLAUSE NO.
7.00.00 DESIGN AND CONSTRUCTIONAL FEATURES
7.01.00 Suitable single phase space heaters shall be provided on motors rated 30KW and
above to maintain windings in dry condition when motor is standstill. Separate
terminal box for space heaters & RTDs shall be provided. However for flame proof
motors, space heater terminals inside the main terminal box may be acceptable.
7.02.00 All motors shall be either Totally enclosed fan cooled (TEFC) or totally enclosed tube
ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors
rated 3000KW or above can be Closed air circuit water cooled (CACW). The method
of movement of primary and secondary coolant shall be self-circulated by fan or
pump directly mounted on the rotor of the main motor as per IEC 60034-6. However
VFD driven motors can be offered with forced cooling type with machine mounted
fan or pump driven by separate electric motor. Motors and EPB located in hazardous
areas shall have flame proof enclosures conforming to IS: 2148 as detailed below
(a) Fuel oil area : Group – IIB
(b) Hydrogen generation : Group - IIC or (Group-I, Div-II as per plant

area NEC) or (Class-1, Group-B, Div-II as per
NEMA / IEC60034)
7.03.00 Winding and Insulation
(a) Type : Non-hygroscopic, oil resistant, flame resistant
(b) Starting duty : Two hot starts in succession, with motor

initially at normal running temperature.
(c) 11kV & 3.3 kV AC :

Thermal class 155 (F) insulation.
motors
The winding insulation process shall be
Global Vacuum Pressure Impregnated i.e.
resin poor method. The lightning Impulse &
interturn insulation surge withstand level shall
be as per IEC-60034 part-15.
However winding insulation for wet wound

Boiler circulation pump motor shall be thermal
class 90 (Y) or better.
(d) 240VAC, 415V AC : Thermal Class ( B ) or better
& 220V DC motors
7.04.00 Motors rated above 1000KW shall have insulated bearings/housing to prevent flow
of shaft currents.
7.05.00 Motors with heat exchangers shall have dial type thermometer with adjustable alarm
contacts to indicate inlet and outlet primary air temperature.

4 OF 9
CLAUSE NO.
7.06.00 Noise level for all the motors shall be limited to 85dB (A) except for BFP motor for
which the maximum limit shall be 90 dB(A). Vibration shall be limited within the limits
prescribed in IS/IEC 60034-14. Motors shall withstand vibrations produced by driven
equipment. HT motor bearing housings shall have flat surfaces, in both X and Y
directions, suitable for mounting 80mmX80mm vibration pads.
7.07.00 In HT motors, at least four numbers simplex / two numbers duplex platinum
resistance type temperature detectors shall be provided in each phase stator
winding. Each bearing of HT motor shall be provided with dial type thermometer and
2 numbers duplex platinum resistance type temperature detectors.
7.08.00 Motor body shall have two earthing points on opposite sides.
7.09.00 11 KV motors shall be offered with Separable Insulated Connector (SIC) as per
IEEE 386. The offered SIC terminations shall be provided with protective cover and
trifurcating sleeves. SIC termination kit shall be suitable for fault level of 25 KA for
0.17 seconds.
7.10.00 3.3 KV motors shall be offered with dust tight phase separated double walled
(metallic as well as insulated barrier) Terminal box. Suitable termination kit shall be
provided for the offered Terminal box. The offered Terminal Box shall be suitable for
fault level of 250 MVA for 0.12 sec. Removable gland plates of thickness 3 mm
(hot/cold rolled sheet steel) or 4 mm (non-magnetic material for single core cables)
shall be provided.
7.11.00 The spacing between gland plate & center of bottom terminal stud shall be as per
Table-I.
7.12.00 All motors shall be so designed that maximum inrush currents and locked rotor and
pullout torque developed by them at extreme voltage and frequency variations do
not endanger the motor and driven equipment.
7.13.00 The motors shall be suitable for bus transfer schemes provided on the 11kV, 3.3 kV
/415V systems without any injurious effect on its life.
7.14.00 For motors rated 2000 KW & above, neutral current transformers of PS class shall
be provided on each phase in a separate neutral terminal box.
7.15.00 The size and number of cables (for HT and LT motors) to be intimated to the
successful bidder during detailed engineering and the contractor shall provide
terminal box suitable for the same.
8.00.00 The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the
following (without any further tolerance) except for BFP motor.
(a) From 50KW & upto 110KW : 11.0

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(b) From 110 KW & upto 200 KW : 9.0
(c) Above 200 KW & upto 1000KW : 10.0
(d) From 1001KW & upto 4000KW : 9.0
(e) Above 4000KW : 6 to 6.5
9.00.00 CW motor shall be designed with minimum power factor of 0.8 at design duty point.
10.00.00 TYPE TEST
10.01.00 HT MOTORS
10.01.01 The contractor shall carry out the type tests as listed in this specification on the
equipment to be supplied under this contract. The bidder shall indicate the charges
for each of these type tests separately in the relevant schedule of Section - VII-
(BPS) and the same shall be considered for the evaluation of the bids. The type
tests charges shall be paid only for the test(s) actually conducted successfully under
this contract and upon certification by the employer’s engineer.
10.01.02 The type tests shall be carried out in presence of the employer’s representative, for
which minimum 15 days notice shall be given by the contractor. The contractor shall
obtain the employer’s approval for the type test procedure before conducting the
type test. The type test procedure shall clearly specify the test set–up, instruments to
be used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.
10.01.03 In case the contractor has conducted such specified type test(s) within last ten years
as on the date of bid opening, he may submit during detailed engineering the type
test reports to the employer for waival of conductance of such test(s). These reports
should be for the tests conducted on the equipment similar to those proposed to be
supplied under this contract and test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client. The employer
reserves the right to waive conducting of any or all the specified type test(s) under
this contract. In case type tests are waived, the type test charges shall not be
payable to the contractor.
10.01.04 Further the Contractor shall only submit the reports of the type tests as listed in
"LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED “and carried
out within last ten years from the date of bid opening. These reports should be for
the test conducted on the equipment similar to those proposed to be supplied under
this contract and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client. However if the contractor is
not able to submit report of the type test(s) conducted within last ten years from the
date of bid opening, or in the case of type test report(s) are not found to be meeting
the specification requirements, the contractor shall conduct all such tests under this

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contract at no additional cost to the employer either at third party lab or in presence
of client/ employer’s representative and submit the reports for approval.
10.01.05 LIST OF TYPE TESTS TO BE CONDUCTED
The following type tests shall be conducted on each type and rating of HT
motor
(a) No load saturation and loss curves upto approximately 115% of rated voltage
(b) Measurement of noise at no load.
(c) Momentary excess torque test (subject to test bed constraint).
(d) Full load test (subject to test bed constraint)
(e) Temperature rise test at rated conditions. During heat run test, bearing
temp., winding temp., coolant flow and its temp. shall also be measured. In
case the temperature rise test is carried at load other than rated load,
specific approval for the test method and procedure is required to be
obtained. Wherever ETD's are provided, the temperature shall be measured
by ETD's also for the record purpose.
10.01.06 LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED
The following type test reports shall be submitted for each type and rating of
HT motor
(a) Degree of protection test for the enclosure followed by IR, HV and no load
run test.
(b) Terminal box-fault level withstand test for each type of terminal box of HT
motors only.
(c) Lightning Impulse withstand test on the sample coil shall be as per clause no.
4.3 IEC-60034, part-15
(d) Surge-withstand test on interturn insulation shall be as per clause no. 4.2 of
IEC 60034, part-15
10.02.00 LT Motors
10.02.01 LT Motors supplied shall be of type tested design. During detailed engineering, the
contractor shall submit for employer’s approval the reports of all the type tests as
listed in this specification and carried out within last ten years from the date of bid
opening. These reports should be for the test conducted on the equipment similar to
those proposed to be supplied under this contract and the test(s) should have been

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either conducted at an independent laboratory or should have been witnessed by a

client.
10.02.02 However if the contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in the case of type test report(s)
are not found to be meeting the specification requirements, the contractor shall
conduct all such tests under this contract at no additional cost to the employer either
at third party lab or in presence of client/ employer’s representative and submit the
reports for approval.
The following type test reports shall be submitted for each type and rating of
LT motor of above 100 KW only
1. Measurement of resistance of windings of stator and wound rotor.
2. No load test at rated voltage to determine input current power and speed
3. Open circuit voltage ratio of wound rotor motors ( in case of Slip ring motors)
4. Full load test to determine efficiency power factor and slip.
5. Temperature rise test.
6. Momentary excess torque test.
7. High voltage test.
8. Test for vibration severity of motor.
9. Test for noise levels of motor(Shall be limited as per clause no 7.06.00 of this
section)
10. Test for degree of protection and
11. Over speed test.
12. Type test reports for motors located in fuel oil area having flame proof
enclosures as per IS 2148 / IEC 60079-1
10.03.00 All acceptance and routine tests as per the specification and relevant standards shall
be carried out. Charges for these shall be deemed to be included in the equipment
price.
10.04.00 The type test reports once approved shall be treated as reference. For subsequent
projects, an endorsement sheet will be furnished by the manufacturer confirming
similarity and “No design Change”. Minor changes if any shall be highlighted on the
endorsement sheet.

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TABLE - I
DIMENSIONS OF TERMINAL BOXES FOR LV MOTORS
Motor MCR in KW
Minimum distance between centre of
bottom terminal stud and gland plate
in mm
UP to 3 KW As per manufacturer's practice.
Above 3 KW - upto 7 KW 85
Above 125 KW-upto 200 KW 385/203 (For Single core

cables only)
For HT motors the distance between gland plate and the terminal studs shall not be
less than 500 mm.
PHASE TO PHASE/ PHASE TO EARTH AIR CLEARANCE:
NOTE: Minimum inter-phase and phase-earth air clearances for LT motors with lugs
installed shall be as follows:
Motor MCR in KW Clearance
UP to 110 KW 10mm
Above 110 KW and upto 150 KW 12.5mm
Above 150 KW 19mm

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LT SWITCHGEARS & BUSDUCTS

CLAUSE NO.
1.00.00 DESIGN PHILOSOPHY / PRACTICE FOR LV BOARD SIZING

The sizing of LV boards shall be dependent on conditions such as total load connected to a
board, diversity factors for various loads connected, Fault Level and Voltage Regulation
Considerations, etc.
As far as practicable the system shall provide segregated supplies to main and standby
auxiliaries so that the failure of supply to main auxiliary shall in no way jeopardize the
standby auxiliary feed. Automatic changeover at critical switchgear / MCC sections shall be
provided as necessary to prevent the loss of a unit or to ensure the equipment safety.
1.01.00 Design Considerations:

1.01.01 Sizing of LT boards
a) Input kVA for a Drive = (Rating in kW X Load Factor) / (Efficiency X Power Factor)
where values of load factor , power factor and efficiency are defined below:
Load (service) factor for 415 V loads is taken as 0.85 for continuous loads and as 0.1
for intermittent load like crane, hoist, etc.
Efficiency and power factor of LT motors shall be considered as per IS 12615.
b) The Finally selected Busbar ratings for Switchboards, MCCs, ACDBs and Busducts
shall include a 10% margin over the calculated values.
c) Lighting load of 50 kVA (Minimum) shall be considered on each section of main
switchgears with incomer from transformer as indicated in the tender SLD.
d) Busbar Ratings of Valve / Damper ACDBs shall be derived by addition of 5% of the
total kVA load connected and the rating of the largest Valve / Damper connected.
e) Welding sockets shall be connected from Welding DBs, which shall be fed through
1X100% Welding transformers.
f) ESP consumption for 100% BMCR operation shall be considered and further this load
shall be uniformly divided among ESP Switchgears.
g) The loads for mechanical auxiliary systems shall be met by auxiliary transformers
based on the criteria that each switchgear/MCC/Distribution board shall be fed either
by 2x100% or 3x50% transformers/feeders and, these shall be rated to carry the
maximum load expected to be imposed. Each of the above boards shall be
sectionalized.
h) The sizing of Unit Emergency boards shall be in according to the DG rating. The
Emergency board shall have tie to both sections of Unit Service Switchgear for
catering unit loads in Blackout Conditions.
i) For Main Plant (TG & SG areas) and Service Building, each Lighting DB shall have
1X100% transformer. For all other areas, each Lighting DB shall have 2X100%
transformers.
1.02.00 Layout Criteria
The switchboards can be split into two sections based on layout constraints in case of long
switchboards to optimize Switchgear room layouts. The two sections of the split shall be
connected by Busduct / Cable as per layout requirements.

LT SWITCHGEARS & LT 1 OF 58
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1.03.00 Spare capacity and Future Requirements

All LV Switchboard shall be provided with spare feeders / modules as specified in relevant
clause of Part-A of Technical Specification.
1.04.00 Standardization
It shall be preferred to have all LV Switchboards for the entire plant from a single
manufacturer from maintainability and spares management point of view.
It shall be preferred to follow a standardization of Terminal Numbers across all LV Modules
for ease of Interconnection and maintenance.
1.05.00 Plant control cable Interconnections
Control cable interconnections between switchgears and transformer marshalling boxes,
switchgears and motor terminal boxes / push button stations, and between various
switchgears shall be in the contractor’s scope.
(a) Standard control cable sizes shall be 1.5 mm2
(b) Cable size for motor space heater application shall be 2CX2.5 mm2
(c) Interconnections for Current Transformer terminals shall use two cores of 1.5mm2 size
per phase
(d) Core identification shall be using core colour for up to 5-core cable and core number
for cable with more cores
(e) Separate control cables shall be used for current transformers
(f) Separate control cables shall be laid for EPB (Emergency/Local Push Button) status
from EPB to Switchgear for the Switchgear and DCS.
2.01.00 All equipment shall, generally, comply with the updated issues of
(a.) Applicable Indian Standards
(b.) Indian Electricity Act.
(c.) Indian electricity rules

2.02.00 Equipment complying with any other authoritative / internationally recognized standards such
as IEC, British, U.S.A., German, etc. will also be considered if it ensures performance
equivalent or superior to Indian Standards. In such cases the contractor shall clearly indicate
the standard adopted and furnish the copy of latest English version of the same along with
the bid and bring out the salient features for comparison.
2.03.00 All standards, specifications and codes of practice referred to herein shall be the latest
editions including all applicable official amendments and revisions as published one month
prior to the date of opening of bids. In case of conflict between this specification and those
(IS codes, Standards etc.) referred to herein, the former shall prevail. All work shall be
carried out as per the following codes and standards.
IS: 5 Colours for ready-mixed paints and enamels.
IS: 694 PVC insulated cables for working voltages up to and including 1100V.
IS: 722 A.C. Electricity Meters

BUSDUCTS
CLAUSE NO.
IS: 1248 Electrical Indicating instruments
IS/IEC: 60947–1 Degree of protection provided by enclosures for low voltage Switchgear
and Control gear
IS/IEC: 60947-2 A.C. circuit Breakers
IS: 2551 Danger Notice Plates
IS: 2629 Hot dip galvanising
IS: 2705 Current Transformers
IS/IEC: IEC-60947-4- Contactors and motors starter for voltages not exceeding 1000 V AC or
1 1200 V DC
IS: 3043 Code of practice for earthing.
IS: 3072 Code of practice for installation and maintenance of Switchgear
IS: 3156 Voltage Transformers
IS: 3202 Code of practice for climate proofing of electrical equipment.
IS: 3231 Electrical relays for power system protection.
IS/IEC 60947 Air-Break Switches, air break disconnectors, air break disconnector
and fuse combination units for voltages not exceeding 1000V AC or
1200 V DC.
IS/IEC 60947-1 / General Requirements for Switchgear and Control gear for voltages not
IEC-60947-1 exceeding 1000 V.
IS: 5082 Wrought Aluminium and Aluminium alloys for electrical purposes.
IS: 6005 Code of practice of phosphating of iron and steel.
IS/IEC 60947-5-1 / LV switchgear and Control gear Control current devices and switching
IEC-60947-5-1 element.
IS: 8623 / IEC: Low Voltage Switchgear & Control gear assemblies
61439-1/2
IS: 8686 Static Relays
IS: 13703 / IEC: HRC Cartridge fuses

60269
IS: 10118 (4 parts) Code of practice for selection, installation and maintenance of
switchgear and control gear.
IS: 11171 Specification for dry type transformers.

BUSDUCTS
CLAUSE NO.
IEC: 60255 Electrical Relays
IEC: 61850 Communication networks and systems in substations
IS: 11353 Guide for uniform system of marking and identification of conductors
and apparatus terminals
IS: 12021 Specification of control transformers for switchgear and Control gear
for voltage not exceeding 1000V AC.
IEC: 60947-7-1 Terminal blocks for Copper conductors
IS :513 (2008) Cold Rolled Low Carbon Steel Sheets and Strips
IS:15652 Specification for Insulating mats for electrical purposes
3.00.00 TECHNICAL PARAMETERS
3.01.00 Power Supply
3.01.01 AC SYSTEM
1) Voltage 415 V + 10%,3 Phase, 4 wire, solidly

earthed
2) Frequency 50 Hz +/- 5%
3) Combined variation (in volts & 10% absolute sum

frequency)
4) Fault Level 50 kA(RMS)
3.01.02 DC SYSTEM
1) System Voltage 240 V DC 2-Wire, Unearthed
2) Fault Level 20 kA
3.01.03 CONTROL SUPPLY VOLTAGE
1) Trip & closing coil of circuit breaker 240 V DC/120 V DC
2) Spring charging motor 240 V DC/120 V DC
3) MCC control supply 110 V AC Neutral solidly earthed
4) Space heater & lighting 240 V AC Neutral solidly earthed

BUSDUCTS
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3.02.00 CUBICLE DATA
Busbar Rating
1) Continuous Current rating As per requirement
2) Short time rating where

a) CB is used as incomer 50 kA(RMS) for one sec
b) Fuse protection is used in Incomer Prospective current of 50
kA(RMS) for the fuse clearing
time
3) Dynamic Rating where
a) CB is used as incomer 105 kA(PEAK)
b) Fuse Protection is used in incomer Prospective current of 105 kA

(PEAK) as limited by fuse
4) Busbar insulation
a) For switchgear PVC Sleeve insulated
b) For MCC PVC Sleeve insulated
c) ACDB PVC Sleeve insulated
d) DCDB PVC Sleeve insulated
e) For fuse boards PVC Sleeve insulated/ epoxy

coated
3.03.00 CIRCUIT BREAKER
1) Type Air break spring charged stored

energy type
2) Operating duty O-3 min-CO-3 min-CO
3) Symmetrical interrupting 50 kA(RMS)
4) Short circuit rating 105 kA(PEAK)
5) Short Circuit Breaking current
a) AC Component 50 kA(RMS)
b) DC Component As per IS/IEC 60947
6) Short time withstand 50 kA(RMS) for 1 s
7) No of aux. contacts 4 NO + 4 NC for DDCMIS

interface

BUSDUCTS
CLAUSE NO.
3.04.00 METERS
1) Accuracy class 2.0
2) One min. power frequency withstand test 2.0 kV (rms)

voltage
3.05.00 Current Transformers
1) Type Cast Resin Bar Primary / Nylon

Casing
2) Voltage class and frequency 650 V, 50 HZ
3) Class of insulation E or better
4) Rated Secondary Current 1A
5) Accuracy class & burden
a) For protection 5P20, 5VA
PS Class for REF
b) For metering class 1.0, 5VA (min)
class 0.2s, 5VA (min) for feeders

indicated in SLD ,if any
6) Instrument Security Factor (ISF) for metering 5

CT
7) Short time withstand
a) For CT Associated with circuit 50 kA(RMS) for 1 sec

breaker
b) For CT Associated with fuse Prospective current of 50 kA(RMS)

protected feeders for the Fuse clearing time
8) Dynamic withstand
a) For CTs Associated with circuit breaker 105 kA(PEAK)
b) For CT Associated with fuse protected Prospective current of 105

feeders kA(PEAK) as Limited by fuse
3.06.00 BUSDUCT
1) Type Non-Segregated
2) One minute power frequency withstand voltage 2.5 kV
3) One second short ckt withstand current 50 kA(RMS)

BUSDUCTS
CLAUSE NO.
4) Momentary dynamic current withstand 105 kA(PEAK)
BUSDUCT (SANDWICH TYPE)
1) Type Bus Trunking
2) Rated Insulation voltage 1000V
3) One second short ckt withstand current 50KA(RMS)
4) Momentary dynamic current withstand 105KA(PEAK)
5) Power frequency withstand voltage 3.5kv
6) Impulse withstand voltage 8kV
7) Insulation Class F
3.07.00 VOLTAGE TRANSFORMERS
1) Type Cast Resin
2) Voltage Ratio 415 / 110 V for line PT
415/√3 / 110/√3 V for Bus PT
3) Method of Construction V-V
4) Accuracy Class 0.5
0.2 for feeders indicated in SLD ,if any
5) Rated Voltage factor 1.1continuous, 1.5 for 30 sec.
6) Class of insulation E or better
7) One minute power frequency 2.5 KV

withstand voltage
3.08.00 HRC FUSES
1) Voltage Class 650 Volts
2) Rupturing capacity 80 kA (rms) for AC ckt., 20 kA for

DC ckt.

BUSDUCTS
CLAUSE NO.
3.09.00 CONTACTORS
1) Type Air break electro magnetic
2) Utilising Category AC3 of IS/IEC 60947 for non reversible AC4

of IS/IEC 60947 for reversible drives
3.10.00 Relays
1) Power frequency withstand voltage 2.5 kV for 1 sec. or 2.0 kV for 1

min.
3.11.00 CONTROL TRANSFORMERS
1) Type Dry / Cast Resin
2) Voltage Ratio 415 / 110 with taps + 5% in steps

of 2.5%
3) Class of insulation Class-B or better
4) One minute power frequency withstand 2.5 kV

voltage
5) Rating 1.5 X Adequate for application.

3.12.00 LIGHTING TRANSFORMER / WELDING TRANSFORMER
1) Type & Rating Dry type / 100 KVA(Welding TRF),

50KVA(Minimum)(Lighting TRF)
2) Voltage Ratio 415/415V, +/- 5% taps in steps of

2.5%
3) Class of insulation B or better
4) One minute power frequency withstand 2.5 KV

voltage
5) Enclosure protection IP-42
3.13.00 TRANSDUCERS
1) Current transducers
a) Input 0-1 A (CT secondary)
b) Rated frequency 50 Hz

BUSDUCTS
CLAUSE NO.
c) Output 4-20 mA (2 Nos. decoupled)
d) Over current Transducer for motor current

ammeters shall be capable of
withstanding min. 6 times CT sec.
current of 1A for a min period of 30
seconds
e) Accuracy 1.0
2) Voltage Transducers
a) Input 500 V, 50 Hz (for AC) / 250 V /

125 V DC (for DC)
b) Output 4-20 mA (2 Nos. decoupled)
c) Accuracy 1.0
3.14.00 MCCB
1) Rated voltage 415V

2) Rated insulation level 690V
3) Rated ultimate &Service S.C. breaking capacity 50 kA
4) Rated making capacity 105 kA
5) Utilization category A
4.00.00 CONSTRUCTIONAL DETAILS OF SWITCHBOARDS
4.01.00 All Switchboards i.e., 415 V Switchgears, Motor Control Centres (MCCs), AC Distribution
Boards (ACDBs), 220 V DC Distribution Boards (DCDBs) and Solenoid Valve Distribution
Boards, shall be of metal enclosed, indoor, floor-mounted, free-standing type.
4.02.00 All switchboard frames and load bearing members shall be fabricated using suitable mild
steel structural sections or pressed and shaped cold-rolled sheet steel or Galvanised sheet
metal of thickness 2.0 mm. Frames shall be enclosed in cold-rolled sheet steel/Galvanised
sheet metal of thickness 1.6 mm. Doors and covers shall be of cold rolled sheet steel of
thickness 1.6 mm. Stiffeners shall be provided wherever necessary. The gland plate
thickness shall be 3.0 mm for hot / cold-rolled sheet steel/Galvanised sheet metal and 4.0
mm for non-magnetic material.
4.03.00 All panel edges and cover / door edges shall be reinforced against distortion by rolling,
bending or by the addition of welded reinforcement members. The top covers of the panels
should be designed such that they do not permanently bulge/ bend by the weight of
maintenance personnel working on it.
4.04.00 The switchboards shall be of bolted design. The complete structures shall be rigid, self-
supporting, and free from flaws, twists and bends. All cut-outs shall be true in shape and
devoid of sharp edges.
4.05.00 All switchboards shall be of dust-proof and vermin-proof construction and shall be provided
with a degree of protection of IP: 52 as per IS/IEC 60947. However, the busbar chambers
having a degree of protection of IP: 42 are also acceptable where continuous busbar rating is
1600A and above. Provision shall be made in all compartments for providing IP: 52 degree of

BUSDUCTS
CLAUSE NO.
protection, when circuit - breaker or module trolley has been removed. All cut-outs shall be
provided with EPDM / Neoprene gaskets.
4.06.00 Provision of louvers on switchboards would not be preferred. However, louvers backed with
metal screen are acceptable on the busbar chambers where continuous busbar rating is
1600 A and above.
4.07.00 The switchboards shall comply to the Internal arc fault containment tests of 50 kA for 0.3s.
4.08.00 The enclosure for outdoor panels shall be constructed of stainless steel sheets in order to
have protection against corrosion. The Degree of protection for outdoor panels shall be IP:
55. The panels shall be mounted on a pedestal at a height of 500mm from ground level.
4.09.00 All switchboards shall be of uniform height not exceeding 2450 mm. The height of the
operating handle, push buttons etc shall be restricted between 300mm and 2000mm.
4.10.00 Switchboards shall be easily extendable on both sides by the addition of vertical sections
after removing the end covers.
4.11.00 Switchboards shall be supplied with base frames made of structural steel sections, along
with all necessary mounting hardware required for welding down the base frame to the
foundation / steel insert plates. The base frame height shall be such that floor finishing (50
mm thick) to be done by Contractor after erection of the switchboards does not obstruct the
movement of doors, covers, withdrawable modules etc.
4.12.00 All switchboards shall be divided into distinct vertical sections (panels), each comprising of
the following compartments:
(a.) BUSBAR COMPARTMENT

A completely enclosed bus bar compartment shall be provided for the horizontal and vertical
bus bars. Bolted covers shall be provided for access to horizontal and vertical busbars and
all joints for repair and maintenance, which shall be feasible without disturbing any feeder
compartment. Auxiliary and power bus bars shall be in separate compartments.
(b.) SWITCHGEAR / FEEDER COMPARTMENT

All equipment associated with an incomer or outgoing feeder shall be housed in a separate
compartment of the vertical section. Two-tier breaker arrangement in a vertical section shall
be offered for outgoing breaker feeders of rating up to 1600A. The design of the vertical
section for such an arrangement shall ensure ease of termination of power cables of size &
quantity appropriate to respective feeder rating. The compartment shall be sheet steel
enclosed on all sides with the withdrawable units in position or removed. Insulating sheet at
rear of the compartment is also acceptable. No live parts shall be accessible with equipment
drawn out and degree of protection within the compartment shall be IP2X. The front of the
compartment shall be provided with the hinged single leaf door with captive screws for
positive closure.
(c.) CABLE COMPARTMENT OR CABLE ALLEY
A full-height vertical cable alley of adequate width shall be provided for power and control
cables. Cable alley shall have no exposed live parts and shall have no communication with
busbar compartment. Cable terminations located in cable alley shall be designed to meet the
Form 4b as per IEC 61439 for safety purpose. Necessary grommets shall be provided at the
cable entry of individual modules. Wherever cable alleys are not provided for distribution
boards, segregated cable boxes for individual feeders shall be provided at the rear for direct
termination of cables. For circuit breaker external cable connections, a separately enclosed
cable compartment shall also be acceptable. The contractor shall furnish suitable plugs to
cover the cable openings in the partition between feeder compartment and cable alley.
Cable alley door shall be hinged.

BUSDUCTS
CLAUSE NO.
(d.) CONTROL COMPARTMENT

A separate compartment shall be provided for relays and other control devices associated
with a circuit breaker.
4.13.00 Sheet steel barriers shall be provided between two adjacent vertical panels running to the full
height of the switchboard, except for the horizontal busbar compartment. EPDM / Neoprene
gasket shall be provided between the panel sections to avoid ingress of dust into panels.
4.14.00 After isolation of power and control circuit connections it shall be possible to safely carryout
maintenance in a compartment with the busbar and adjacent circuit live. Necessary
shrouding arrangement shall be provided for this purpose. Wherever two breaker
compartments are provided in the same vertical section insulating barriers and shrouds shall
be provided in the rear cable compartment to avoid accidental touch with the live parts of one
circuit when working on the other circuit.
4.15.00 All 415V switchgear (circuit-breaker) panels shall be of single-front type. MCCs and DBs
shall be of single-front / double-front construction as per the requirements. All single-front
switch boards shall be provided with single-leaf, hinged or bolted covers at the rear. The
bolts shall be of captive type. The covers shall be provided with "DANGER" labels. All panel
doors shall open by 90 deg or more. In case of double-front MCCs, if this cannot be achieved
for panels adjacent to a breaker panel, suitable dummy panel shall be provided by the
Contractor wherever necessary.
4.16.00 All ACDBs, DCDBs and Solenoid Valve DBs shall be of fixed module type. All 415V circuit-
breaker modules and contactor controlled motor modules shall be of fully draw-out type
having distinct 'Service' and 'Test' positions. The equipment pertaining to a draw-out type
incomer or feeder module shall be mounted on a fully withdrawable chassis which can be
drawn out without having to unscrew any wire or cable connection. Suitable arrangement
with cradle/ rollers, guides along with tool/lever operated racking in/out mechanism shall be
provided for smooth and effortless movement of the chassis. For modules of size more than
half the panel height, double guides shall be provided for smooth removal or insertion of
module. All identical module chassis of same size shall be fully interchangeable without
having to carry out any modifications. Suitable interlock shall be provided in DCDB for
prevention of opening of Isolator (Incomer) when the bus coupler is open and vice-versa.
4.17.00 All draw-out modules shall be provided with “Closed door operation” feature wherein
movement of the module from “Isolated” position to “Service” position & vice-versa and
power ON / OFF operation of the module shall be possible only with the module door closed
condition.
4.18.00 All disconnecting contacts for power and control circuits of draw-out modules shall be of
robust and proven design, fully self-aligning and spring-loaded. Both fixed and moving
contacts shall be silver-plated and replaceable. The spring-loaded power and control draw-
out contacts shall be on withdrawable chassis and the same on fixed portion shall not be
accepted.
4.19.00 Individual opening in the vertical bus enclosure shall permit the entry of moving contacts
from the draw-out modules into vertical droppers.
4.20.00 As indicated in schematic drawings of DDCMIS controlled modules, contractor shall supply &
mount two (2) coupling relays in the corresponding modules.
4.21.00 All equipment and components shall be neatly arranged and shall be easily accessible for
operation and maintenance. The internal layout of all modules shall be subject to Employer's
approval. The Contractor shall submit dimensional drawings showing complete internal
details of busbars and module components, for each type and rating for approval of
Employer.

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CLAUSE NO.
4.22.00 Employer reserves the right to alter the cable entries, if required during detailed engineering,
without any additional commercial implication.
4.23.00 Each switchboard shall be provided with undrilled, removable type gland plate, which shall
cover the entire cable alley. Contractor shall ensure that sufficient cable glanding space is
available for all the cables coming in a particular section through gland plate. For all single
core cables, gland plate shall be of non-magnetic material. The gland plate shall preferably
be provided in two distinct parts for the easy of terminating addition cables in future. The
gland plate shall be provided with gasket to ensure enclosure protection. Recommended
drilling chart of gland plates for all power and control cables in the vertical panels shall be
indicated by the Contractor in the respective G.A. drawings of the boards.
4.24.00 The Contractor shall consider layout of panels in a switchboard consisting of various feeder
modules in a straight line, unless specified otherwise. The actual composition and disposition
of various modules in a switchboard shall be finalised during detailed engineering. The
Contractor shall provide adopter panel / dummy panel required to meet various configuration
/ arrangement of busbars adopted by the Contractor. The Switchboards fed from indoor
transformer will be flange connected to the same and the same shall be located as close as
desirable to the transformer. The details of transformer flanges for those transformers not
being supplied under this package shall be given to the contractor for matching the
connections. The switchboards fed from outdoor transformers of rating 1000kVA and above
shall be connected through busducts. For transformers of 1000kVA rating, cable connection
may also be acceptable in case of layout constraints. For lower rated transformers, the
connection shall be through cables. Busduct connections wherever applicable shall be
preferably in a straight line alignment. Adopter panels and dummy panels shall be provided
wherever required.
4.25.00 CLEARANCES
The minimum clearance in air between phases and between phases and earth for the entire
run of horizontal and vertical busbars and bus-link connections at circuit-breaker shall be 25
mm. For all other components, the clearance between "two live parts", "a live part and an
earthed part", shall be at least ten (10) mm throughout. Wherever it is not possible to
maintain these clearances, insulation shall be provided by sleeving or barriers. However, for
horizontal and vertical busbars the clearances specified above should be maintained even
when the busbars are sleeved or insulated. All connections from the busbars up to switch /
fuses shall be fully shrouded / insulated and securely bolted to minimize the risk of phase to
phase and phase to earth short circuits.
5.00.00 PROTOTYPE PANELS
In order to establish the compliance with the requirements of this technical specification,
prototype panels shall be made and offered for the Employer’s inspection and approval
before the start of bulk manufacturing of panels for this project. The exact configuration of
such prototype panels shall be finalized during detailed engineering.
6.00.00 CONSTRUCTIONAL DETAILS OF AC & DC FUSE BOARDS
6.01.00 All fuse boards shall be metal enclosed, fixed type, non-compartmentalized construction,
suitable for indoor/ outdoor mounting on wall or steel structure.
6.02.00 The fuse board frame shall be fabricated using suitable mild steel structures or pressed and
shaped cold rolled sheet steel of thickness not less than 2.0 mm. The frames shall be
enclosed by cold rolled sheet steel of thickness not less than 1.6 mm.
6.03.00 The fuse boards shall be provided with doors on the front. The doors shall preferably be in
two halves with hinges at the extreme ends and locking facility at the centre.

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6.04.00 Suitable EPDM/Neoprene gaskets shall be provided to make fuse boards completely dust
and vermin-proof with a degree of protection of IP-52 for indoor and IP-54 for outdoor
application, as per IS/IEC 60947.
6.05.00 Each DC fuse board shall comprise of the following :
(a.) 1 no. 63 A switch as incomer
(b.) 100 A fully insulated (PVC sleeved or epoxy coated) busbars.
(c.) 8 nos. 16A outgoing Fuse feeders.
(d.) 1 no. auxiliary contactor for supply monitoring.
(e.) 1 no. indicating lamp with resistor and blue coloured lens.
6.06.00 Each AC fuse board shall comprise of the following :
(a.) 1 no. 63A TPN switch as incomer.
(b.) 100 A, 3-phase, 4-wire, fully insulated (PVC sleeved or epoxy coated) busbars.
(c.) 9 nos. 16 A single phase switch fuse units and 3 nos. 16 A TPN switch fuse units as
outgoing feeders.
(d.) 3 nos. indicating lamps with resistors and coloured lenses (R, Y, B) for incoming supply
monitoring.
6.07.00 The fuses shall be mounted in an insulating fuse carrier and it shall be possible to replace
the outgoing feeder fuses without disturbing the other feeders. The handle of incoming switch
shall be mounted on the door of the fuse board, with padlocking facility in both 'ON' and 'OFF'
positions. The outgoing feeder switches shall preferably be of rotary type.
6.08.00 Cable entry facilities shall be provided at bottom with removable gland plates of suitable
thickness. However, top cable entry may be allowed in case of layout constraints. All
incoming and outgoing cables shall be terminated on suitable terminal blocks.
7.00.00 POWER BUSBARS AND INSULATORS
7.01.00 All 415 V Switchboards, MCCs and ACDBs shall be provided with three phase and neutral
busbars. Two separate sets of vertical busbars shall be provided in each panel of double
front MCCs / DBs. Interleaving arrangement for busbars shall be adopted for switchboards
with a rating of more than 1600A. DCDBs shall be provided with two (2) busbars. Entire
busbar system shall be insulated with PVC sleeves. Busbar sleeves shall be compliant to
UL224 (Extruded insulating tubing), CE/UL certified, having fire retardant properties and
working temperature of 1050C.
7.02.00 Vertical busbars of non-breaker panels shall be completely phase segregated by suitable
insulating supports / walls made of fire-retardant, non-hygroscopic, track-resistant material to
minimise the occurrence of arc faults.
7.03.00 All busbars and jumper connections shall be of high conductivity Aluminium alloy / Copper of
adequate size.
7.04.00 The cross-section of the busbars shall be uniform throughout the length of switchboard
section and shall be adequately supported and braced to withstand the stresses due to the
specified short circuit currents. Neutral busbar short circuit strength shall be same as main
busbars.

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7.05.00 All busbars shall be adequately supported by non-hygroscopic, non-combustible, track-

resistant and high strength sheet moulded compound or equivalent type polyester fibre glass
moulded insulator. Separate supports shall be provided for each phase and neutral busbar. If
a common support is provided, anti-tracking barriers shall be provided between the supports.
Insulator and barriers of inflammable material such as Hylam shall not be accepted. The
busbar insulators shall be supported on the main structure.
7.06.00 All busbar joints shall be provided with high tensile steel bolts, belleville / spring washers and
nuts, so as to ensure good contacts at the joints. Non-silver plated busbar joints shall be
thoroughly cleaned at the jointed locations and suitable contact grease shall be applied just
before making a joint. All bolts shall be tightened by torque spanner to the recommended
value. The overlap of the busbars at each joint surface shall be such that the length of
overlap shall be equal to or greater than the width of the busbar. All Copper to Aluminium
joints shall be provided with suitable bimetallic washers.
7.07.00 All busbars shall be colour coded as per IS: 375.
7.08.00 The Contractor shall furnish calculations establishing the adequacy of bus bar sizes for
specified current ratings.
8.00.00 AUXILIARY BUSBARS AND CONTROL TRANSFORMERS
8.01.00 AC CONTROL SUPPLY BUSBAR
Each bus-section of all Switchgears and MCCs shall be provided with two (2) nos. 415V /
110V control transformers. The 110V AC control supply from the control transformers shall
be run through the MCC by means of two sets of control supply busbars of electrolytic
Copper. In case of one transformer failure, whole bus section can be fed through single
transformer. The control supply to different modules shall be tapped individually from the
control supply busbars.
8.02.00 DC CONTROL SUPPLY BUSBARS
Electrically controlled circuit breaker boards shall be provided with DC control supply
busbars. The manually controlled breakers shall also be provided with such busbars in case
relays are provided. Each section of the switchboard shall be provided with a DC supply by
the Contractor. The Contractor shall provide suitable terminals, switch-fuse etc. to receive
the DC supply and distribute the same through above mentioned control busbars to the
required modules of the respective section. The DC control supply bus of one section shall
be coupled to the control supply of other section through a switch located in the bus-coupler
breaker panel. The DC supply to the bus-coupler breaker may be given from any of the
control buses. For Emergency Switchgear, two DC supplies shall be provided along with
suitable diodes for deriving the control supply through diode auctioneering. Power Supply to
Numerical Relay and Ethernet switch shall be an independent circuit with switch and fuse
tapped from the panel DC supply. Exact scheme for segregation of switchgear & numerical
relay DC supplies shall be finalized during detailed engineering.
8.03.00 SPACE HEATER BUSBARS
Panel and motor space heaters shall be fed from separate AC auxiliary busbars running
throughout the switchboard. The supply for these busbars shall be tapped from incomer,
before the isolating switch/ circuit breaker. Incoming circuit to space-heater bus shall have an
isolating switch, HRC fuse and neutral link of suitable rating. Suitable terminals shall also be
provided to facilitate energisation of space-heater bus from outside during long shutdowns of
unit / switch-board.
8.04.00 CONTROL TRANSFORMERS
The control transformers shall be 415 V / 110 V with neutral point-earthed, of insulation class
'B' or better. The sizing of Control transformers shall be carried out by Contractor considering
the actual load of power contactors, auxiliary contactors, indicating lamps and other

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CLAUSE NO.
equipment in the module circuit. An additional load of 15 watts should also be considered for
each module, for remote auxiliary relays and lamps to be connected in the control circuit of
modules. Contractor shall also ensure that control transformers are adequately designed for
meeting the momentary loading requirements & the voltage drop during this condition shall
not be more than 5%.
9.00.00 EARTH BUS AND EARTHING
9.01.00 A galvanized steel / Copper / Aluminium earth bus shall be provided at the bottom of each
panel and shall extend throughout the length of each switchboard. It shall be welded / bolted
to the framework of each panel and breaker earthing contact bar. Vertical earth bus shall be
provided in each vertical section which shall in turn be bolted / welded to main horizontal
earth bus.
9.02.00 The earth bus shall have sufficient cross section to carry the momentary short circuit and
short time fault current to earth, as indicated in "Technical Parameters", without exceeding
the allowable temperature rise.
9.03.00 Suitable arrangements shall be provided at each end of the horizontal earth bus for bolting to
Contractor's earthing conductors. The horizontal earth bus shall project out of the
switchboard ends and shall have predrilled holes for this connection. All joint splices to earth
bus shall be made through at least two bolts, and taps by proper lug and bolt connection.
9.04.00 All non-current carrying metal work of the switchboard shall be effectively bonded to the
earth bus. Electrical conductivity of the whole switchgear enclosure framework and truck
shall be maintained even after painting.
9.05.00 The carriage and breaker frame shall get earthed while being inserted in the panel and
positive earthing of the breaker frame shall be maintained in all positions, i.e. SERVICE &
ISOLATED, as well as throughout the intermediate travel.
9.06.00 Each module frame shall get engaged to the vertical earth bus before the disconnecting
contacts on the module are engaged to the vertical busbars.
9.07.00 All metallic cases of relays, instruments and other panel-mounted equipment shall be
connected to earth by independent stranded Copper wires of size not less than 2.5 sq. mm.
All the equipment mounted on the door shall be earthed through flexible wire/braids.
Insulation colour code of earthing wires shall be green. Earthing wires shall be connected to
terminals with suitable clamp connectors, soldering is not acceptable. Looping of earth
connections, which would result in loss of earth connections to other devices, when a device
is removed, is not acceptable. However, looping of earth connections between equipment to
provide alternative paths to earth bus is acceptable.
9.08.00 VT and CT secondary neutral point earthing shall be at one place only, i.e. on the terminal
block. Such earthing shall be made through links so that earthing of one secondary circuit
shall be removed without disturbing the earthing of other circuit.
9.09.00 All hinged doors having potential carrying equipment mounted on it shall be earthed by
flexible wire/ braid. For doors not having potential carrying equipment mounted on it, earth
continuity through scraping hinges/ hinge pins of proven design may also acceptable. The
Contractor shall establish earth continuity at site also.
10.00.00 Circuit Breakers
10.01.00 Circuit breakers shall be three pole, air break, horizontal draw out type, and shall have fault
making and breaking capacities as specified in "Technical Parameters". The circuit breakers
which meet specified parameters of continuous current rating and fault making / breaking
capacity only after provision of cooling fans or special device shall not be acceptable.

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10.02.00 Circuit breakers along with its operating mechanism shall be provided with suitable
arrangement for easy withdrawal. Suitable guides shall be provided to minimize
misalignment of the breaker.
10.03.00 There shall be "SERVICE", "TEST" and "FULLY WITHDRAWN" positions for the breakers. In
"Test" position the circuit breaker shall be capable of being tested for operation without
energizing the power circuits i.e. the power contacts shall be disconnected, while the control
circuits shall remain undisturbed. Locking facilities shall be provided so as to prevent
movement of the circuit breaker from the "SERVICE", "TEST" or "FULLLY WITHDRAWN"
position The circuit breaker rack in and rack out from Service to Test, Test to Isolated
position or vice-versa shall be possible only in the door closed condition.
10.04.00 All circuit breakers shall be provided with "6 NO" and "6NC" potential free auxiliary contacts.
These contacts shall be in addition to those required, for internal mechanism of the breaker
and should be directly operated from breaker operating mechanism. In case the
manufacturer does not have a proven arrangement for providing the required number of
circuit breaker auxiliary contacts on the fixed portion of the cubicle, necessary electrically
reset latched relays shall be provided for multiplying the circuit breaker mounted auxiliary
contacts and provide additional 4 NO and 4 NC contacts for DDCMIS. Contacts dedicated for
DDCMIS shall give breaker ON/OFF feedback in service position and OFF feedback when
the breaker is not in service position. Separate limit switches, each having required numbers
of contacts shall be provided in both "SERVICE" and "TEST" position of the breaker. All
contacts shall be rated for making, continuously carrying and breaking 10 Amp at 240 V AC
and 1 Amp (Inductive) at 240 V DC respectively.
10.05.00 Suitable mechanical indications shall be provided on all circuit breakers to show "OPEN",
"CLOSE", "SERVICE ", "TEST" AND "SPRING CHARGED" positions.
10.06.00 Main poles of the circuit breakers shall operate simultaneously in such a way that the
maximum difference between the instants of contacts touching during closing shall not
exceed half a cycle of rated frequency.
10.07.00 All circuit breakers shall be provided with the following interlocks :
10.07.01 Movement of a circuit breaker between "SERVICE" and "TEST” position shall not be possible
unless it is in open position. Attempted withdrawal of a closed circuit breaker shall preferably
not trip the circuit breaker. In case the offered circuit breaker trips on attempted withdrawal
as a standard interlock, it shall be ensured that sufficient contact exists between the fixed
and draw out contact at the time of breaker trip so that no arcing takes place even with the
breaker carrying its full rated current.
10.07.02 Closing of a circuit breaker shall not be possible unless it is in "SERVICE” position, "TEST"
position or in "FULLY WITHDRAWN" position.
10.07.03 Circuit-breaker cubicles shall be provided with safety shutters operated automatically by the
movement of the circuit breaker carriage, to cover the stationary isolated contacts when the
breaker is withdrawn. It shall however be possible to open the shutters intentionally against
pressure for testing purposes.
10.07.04 A breaker of particular rating shall be prevented from insertion in a cubicle of a different
rating.
10.07.05 Circuit breakers shall be provided with coded key / electrical interlocking devices, as per
requirements.
10.08.00 Circuit breaker shall be provided with anti-pumping relay and trip free feature, even if
mechanical anti-pumping feature is provided.
10.09.00 Mechanical tripping shall be possible by means of front mounted Red "trip" push-button. In
case of electrically operated breakers these push buttons shall be shrouded to prevent
accidental operation.

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CLAUSE NO.
10.10.00 Complete shrouding / segregation shall be provided between incoming and outgoing bus
links of breakers. In case of bus coupler breaker panels the busbar connection to and from
the breaker terminals shall be segregated such that each connection can be approached and
maintained independently with the other bus section live. Dummy panels if required to
achieve the above feature shall be included in the Contractor's scope of supply.
10.11.00 Circuit breaker shall be provided with Power operated mechanism as follows.
1. Power operated mechanism shall be provided with a universal motor suitable for
operation on 240 V DC / 240 AC Control supply, with voltage variation from 198 V
to DC to 242 V DC . Motor insulation shall be class "E" or better.
2. The motor shall be such that it requires not more than 30 seconds for fully charging
the closing spring at minimum available control voltage.
3. Once the closing springs are discharged, after one closing operation of circuit
breaker, it shall automatically initiate recharging of the spring.
4. The mechanism shall be such that as long as power is available to the motor, a
continuous sequence of closing and opening operations shall be possible. After
failure of power supply at least one open-close-open operation shall be possible.
5. Provision shall be made for emergency manual charging and as soon as this
manual charging handle is coupled, the motor shall automatically get mechanically
decoupled.
6. All circuit breakers shall be provided with closing and trip coils. The closing coil
shall operate correctly at all values of voltage from 187-242 V DC. The trip coil
shall operate satisfactorily at all values of voltage from 154-242V DC /77 V-121 V
DC
7. Provision for mechanical closing of the breaker only in "Test" and "WITHDRAWN"
positions shall be made. Alternately, the mechanical closing facility shall be
normally made inaccessible; accessibility being rendered only after deliberate
removal of shrouds.
8. It shall not be possible to open the ACB panel door in breaker closed condition.
Note: The circuit breakers for DC applications shall have manually operated mechanism of
spring charged, stored energy type. The closing operation of the circuit breaker shall charge
the tripping spring. Necessary interlocks shall be provided to inhibit closing of the circuit
breaker unless the closing spring is fully charged.
11.00.00 TELESCOPIC TROLLEY
Telescopic trolley or suitable arrangement shall be provided for maintenance of circuit-
breaker module in a cubicle. The trolley shall be such that the top most breaker module can
be withdrawn on the trolley and can be lowered for maintenance purpose. The telescopic
trolley shall be such that all type, size and rating of breaker can be withdrawn /inserted of
particular switchgear. The quantity of telescopic trolleys to be supplied shall be 1 no. per
switchgear room.

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CLAUSE NO.
12.00.00 AIR BREAK SWITCHES

12.01.00 Air break switches shall be of heavy duty, single throw, group operated, load break, fault
make type when associated with fuses. All switches for motor circuits shall be of utilization
category AC-23A with 1NO +1NC auxiliary contact, which shall be wired to the control circuit
as shown in the schematic drawings. All switches for other outgoing feeders shall be of
utilization category AC-22A. All switches for DC circuits shall be suitable for 240 V DC and
shall be of DC-22 utilization category.
12.02.00 Continuous current rating of the switches shall be selected from the 'Module Selection tables'
for various feeders.
12.03.00 The combination of switch-fuse unit would be preferred. However, if separate switch and
fuses are provided, switch shall be located before fuses.
12.04.00 The main switches shall be operable from outside the module door. The switch handle shall
clearly indicate the position of switch. Switch operating handles shall be provided with
padlocking facilities. However, incomer switches of switchboards shall be provided with
padlocking facility in both 'ON' and 'OFF' positions.
12.05.00 Interlocks shall be provided such that the cubicle door will not open when the switch is in
closed position and the switch will close only when the door is closed.
12.06.00 Switches and fuses for AC/DC control supply and heater supply wherever required, shall be
mounted inside the cubicles. Toggle switch is not acceptable.
12.07.00 Even if a single phase feeder is required for certain applications, Contractor shall provide
TPN switch, fuse-bases and cable/ link connections between switch/fuse and vertical
busbars for all the three phases, so that changing from single phase feeder to three phase
feeder is possible without any modification other than inserting fuses at site.
13.00.00 MCCB
13.01.00 MCCB shall be fixed type / part of withdrawable feeder module as per specification, three
pole, air break type having trip free mechanism with quick make and quick break type
contacts. MCCB shall have current limiting feature. MCCB of identical ratings shall be
physically and electrically interchangeable. MCCB shall be provided with 1 NO and 1NC
auxiliary contacts.
13.02.00 MCCB shall be provided with Microprocessor based inbuilt front adjustable releases
(Overload & Short-circuit). The protection settings shall have suitable range to achieve the
required time & current settings. LED indications shall also be provided for faults, MCCB
status (on/off etc.).
13.03.00 MCCB terminals shall be shrouded and designed to receive cable lugs for cable sizes
relevant to circuit rating. Extended cable terminal arrangement for higher size cable may also
be offered. ON and OFF position of the operating handle of MCCB shall be displayed and the
rotary operating handle shall be mounted on the door of the compartment housing MCCB.
The compartment door shall be interlocked mechanically with the MCCB to prevent opening
of the door unless the MCCB is in OFF position. MCCB shall be provided with padlocking
facility to enable the operating mechanism to be padlocked. The MCCBs being offered shall
have common / interchangeable accessories for all ratings like aux. switch, shunt trip, alarm
switch etc. The MCCBs shall have the current discrimination up to full short circuit capacity
and shall be selected as per manufacturer’s discrimination table.
14.00.00 CONTROL AND SELECTOR SWITCHES
14.01.00 Control and selector switches shall be of heavy duty, rotary type with escutcheon plates
clearly marked to show the positions. The control & selector switches should be as per
IS/IEC 60947 Part V section 1. The switches shall be of sturdy construction suitable for

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CLAUSE NO.
mounting on panel front. Switches with shrouding of live parts and sealing of contacts against
dust ingress shall be preferred.
14.02.00 Ammeter and voltmeter selector switches shall have four stay put positions with adequate
number of contacts for 3-phase 4-wire system. These shall have oval handles. Ammeter
selector switches shall have make before break type contacts to prevent open circuiting of
CT secondary.
14.03.00 Contacts of the switches shall be spring assisted and shall be of suitable material to give a
long trouble free service.
14.04.00 The contact ratings shall be at least the following :
1. Make and carry, continuously, 10 A at 240 V DC and 110 V AC
2. Breaking current at 240 V DC, 1 A (inductive)
3. Breaking current at 110 V AC and 0.3 lagging p.f., 5A

15.00.00 CONTACTORS
15.01.00 Motor starter contactors shall be of air break, electromagnetic type rated for uninterrupted
duty as per IS/IEC 60947 Part-4 Section- 1.
15.02.00 Contactors shall be double-break, non-gravity type and their main contacts shall be silver
faced.
15.03.00 Direct-on-line contactors shall be of utilization category AC3. Reversing starters shall
comprise of Forward and Reverse contactors mechanically and electrically interlocked with
each other. These contactors shall be of utilization category AC4. DC contactors shall be of
DC3 utilization category. For CHP conveyor motors, minimum rating of power contactors
shall be 200% of full load current of the motors. For other CHP drives, minimum rating of
power contactors shall be 160% of full load current of motor.
15.04.00 The number of normally open (NO) and normally closed (NC) auxiliary contacts of a
contactor shall be as per requirement shown in the respective module drawings. It shall,
however, be not less than 2NO+2NC.
15.05.00 Operating coil of contactors shall be of 110 V AC unless otherwise specified elsewhere. The
contactor shall operate satisfactorily between 85% and 110% of the rated voltage. The
contactor shall not drop out at 70% of the rated voltage but shall definitely drop out at 20% of
the rated voltage.
15.06.00 Contactors for DC drives shall have a coil voltage of 240 V DC. DC operated contactor coil
shall have an economy resistor and shall be suitable for satisfactory continuous operation at
187-242 V DC/ 93.5-121 V
16.00.00 FUSES
16.01.00 All fuses shall be of HRC cartridge fuse link type. Screw type fuses shall not be accepted.
Fuses for AC circuits shall be rated for 80kA rms (prospective) breaking capacity at 415V AC.
and for DC circuits, 20kA rms breaking capacity at 240V DC.
16.02.00 Fuse shall have visible operation indicators. Insulating barriers shall be provided between
individual power fuses.
16.03.00 Fuse shall be mounted on insulated fuse carriers, which are mounted on fuse bases.
Wherever it is not possible to mount fuses on carriers, fuses shall be directly mounted on
plug-in type of bases. In such cases one set of insulated fuse pulling handles shall be
supplied with each switchboard.

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CLAUSE NO.
16.04.00 Fuse ratings shall be selected by the Contractor from the 'Module Selection Tables' for
various feeder ratings. However, the fuse ratings for motor feeders given in the 'Motor
Module Selection Table' are indicative only, and the same shall be coordinated by the
Contractor to achieve class-II protection coordination and also to match the motor
characteristics. Switch rating shall in no case be less than the fuse rating.
16.05.00 The Neutral links shall be mounted on fuse carriers which shall be mounted on fuse bases.
17.00.00 Instrument Transformers
17.01.00 All current and voltage transformers shall be of cast resin insulated type suitable for
continuous operation at the temperature prevailing inside the switchgear enclosure, when the
switchboard is operating at its rated condition and the specified ambient temperature. The
class of insulation shall be 'E' or better.
17.02.00 Alternatively, current transformers with unbreakable, flame retardant, self-extinguishing
Nylon casing of UL94 grade are also acceptable.
17.03.00 All instrument transformers shall be able to withstand the thermal and mechanical stresses
resulting from the maximum RMS short circuit breaking and peak making current ratings of
the associated switchgear.
17.04.00 All instrument transformers shall have clear indelible polarity markings. All secondary
terminals shall be wired to separate terminals on an accessible terminal block where star
point formation and earthing shall be done.
17.05.00 Current transformers may be multi or single-core type. All voltage transformers shall be
single phase type.
17.06.00 The bus VTs shall be housed in a separate compartment. All VTs shall have readily
accessible HRC current limiting fuses on both primary and secondary sides.
17.07.00 All CTs shall be provided with supports independent of busbar / busbar supports.
17.08.00 The CTs shall be located in such a way that they can be easily approached for maintenance
without necessitating shut down of adjacent feeders.
18.00.00 Numerical relays & networking
18.01.00 All circuit breaker feeders shall be provided with communicable numerical relays complying
with IEC-61850, having protection, control, measurement and monitoring features. These
relays shall be connected to the Switchgear SCADA System (Employer’s Scope), through
Ethernet switches. The relays shall be flush mounted on panel front with connections from
the inside. These numerical relays shall be of types as proven for the application and shall be
subject to Employer’s approval. Numerical relays shall have appropriate setting ranges,
accuracy, resetting ratio and other characteristics to provide required sensitivity. All
equipment shall have necessary protections as detailed in the standard scheme drawings /
module type descriptions.
18.02.00 Control of circuit breakers shall be carried out from DDCMIS through hardwired control
commands in the form of 24V DC signal. Preferably, binary input of all relays shall be
configurable to accept 24V DC signals directly from DDCMIS and no separate coupling
relays shall be provided. The Local control console of the relay flush mounted on the
switchgear would normally be used only for testing of circuit breaker in isolated position.
Provision for closing & tripping of the circuit breaker locally from laptop through serial port
shall be possible to facilitate commissioning activities. The basic control scheme of breaker
feeders shall be developed using the programmable (soft) logics in the relay.

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CLAUSE NO.
18.03.00 Each numerical relay shall be connected to the Ethernet switch provided in the Switchgear
through Cat5e Ethernet /FO cable..
18.04.00 The numerical relay shall be capable of measuring and storing values of a wide range of
quantities, events, faults and disturbance recordings. The alarm / status of each of protection
function and trip operation shall be communicated to Switchgear SCADA / DDCMIS. The
numerical relays shall have built in feature / hardware interface to provide such inputs to
Switchgear SCADA / DDCMIS for analog / digital values.
18.05.00 The required .ICD / .CID files of the Numerical relays under LT Switchgears for the
integration with the SCADA shall be provided by the Numerical relay vendor along with
necessary engineering support. At least one no. of each type of Numerical Relay shall be
made available during the Factory Acceptance Test (FAT) of the Switchgear SCADA system
along with the necessary engineering support from the Numerical Relay vendor.
18.06.00 All relays shall be rated for control supply voltage as mentioned elsewhere under parameters
and shall be capable of satisfactory continuous operation between 80-120% of the rated
voltage. Making, carrying and breaking current ratings of their contacts shall be adequate
for the circuits in which they are used. Contacts for breaker close and trip commands shall be
so rated as to be used directly used in the closing and tripping circuits of breaker without the
need of any interposing / master trip relays. Threshold voltage for binary inputs shall be
suitably selected to ensure avoidance of mal operation due to stray voltages and typically
shall be more than 70% of the rated control supply voltage.
18.07.00 One minute power frequency withstand test voltage for all numerical relays shall at least be
2kV (rms).
18.08.00 Failure of a control supply and de-energization of a relay shall not initiate any circuit breaker
operation.
18.09.00 Disturbance Record waveforms, event records & alarms shall be stored in Non-volatile
memory and failure of control supply shall not result in deletion of any of these data.
18.10.00 All IEDs shall have freely programmable optically isolated binary inputs (BI) and potential
free binary output (BO) contacts, the quantity of which shall be adequate to realize the
associated interlocks / feedbacks.
In case the offered IED does not have the required number of I/Os, the same can be
achieved through external I/O device of same make complying with the requirement stated
elsewhere in this specification.
18.11.00 All the numerical relays shall have communications on three ports, local front port for
communication with laptop and dual ports on IEC 61850 to communicate with the Switchgear
SCADA System.
18.12.00 All the numerical relays shall have adequate processor memory for implementing the
programmable scheme logic required for the realization of the protection / control schemes,
in addition to the built in protection algorithms.

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CLAUSE NO.
18.13.00 All Numerical relays shall have features for electrical measurements including voltage,
current, power (active & reactive), frequency, power-factor and energy parameters.
18.14.00 Relays shall have event recording feature, recording of abnormalities and operating
parameters with time stamping.
18.15.00 Master trip (86) and non-86 trips shall be software configurable to output contacts and no
separate master trip relay shall be used.
18.16.00 All numerical relays shall have provision of both current (CT) and voltage (VT) inputs. Relays
shall be suitable for both residually connected neutral CT input as well as CBCT input.
Relays shall be suitable for CT secondary current of 1A. Motor relays shall have 4 CT inputs.
Relays for Incomers, Bus-couplers & Ties shall have 4 CT inputs. All relays except incomers,
ties and bus-couplers shall have 3Nos of VT inputs. Relays used in incomers, ties and bus
couplers shall have provision of two sets of voltage inputs (3Nos for bus voltage & 1No. for
line voltage) for the purpose of synchronization.
18.17.00 All CT terminals on the relays shall be of fixed type suitable for connection of ring-type lugs
to avoid any hazard due to loose connection leading to CT open-circuit. In no circumstances
Plug-in type connectors shall be used for CT / VT connections.
18.18.00 All numerical relay shall have key pad / keys to allow relay settings from relay front. All hand
reset relays shall have reset button on the relay front. Relay to be self or hand reset shall be
software selectable. Manual resetting shall be possible from remote.
18.19.00 Relays shall have self-diagnostic feature with self-check for power failure, programmable
routines, memory and main CPU failures and a separate output contact for indication of any
failure.
18.20.00 Relays shall have at least two sets or groups of two different sets of adaptable settings.
Relays shall have multiple IEC / ANSI programmable characteristics.
18.21.00 Design of the relay must be immune to any kind of electromagnetic interference. Vendor
shall submit all related type test reports for the offered model along with the offer.
18.22.00 All cards / hardware of numerical relays shall be suitable for operation in Harsh
Environmental conditions with respect to high temperature, humidity & dust.
18.23.00 Relay shall be immune to capacitance effect due to long length of connected control cables.
Any external hardware, if required for avoiding mal operation of the relay due to cable
capacitance shall be included as a standard feature.
18.24.00 All I/Os shall have galvanic isolation. Analog inputs shall be protected against switching
surges, harmonics etc.
18.25.00 Numerical relays shall have two level password protections, one for read only and other for
authorization for modifying the setting etc.
18.26.00 Numerical relays shall have feature for Time synchronization through the Switchgear SCADA
System. The resolution of time synchronization shall be +/- 1.0 millisecond or better
throughout the entire system.

BUSDUCTS
CLAUSE NO.
18.27.00 Relays & Ethernet switches shall be suitable to accept both AC & DC supplies with range
110V or 220V with tolerance of 70 % to 120 % of rated voltage & shall be finalized during
18.28.00 ETHERNET SWITCH

18.28.01 Ethernet switches shall be ‘substation hardened‘, and shall comply with IEC61850 for
communications and environment requirements. The Ethernet switches shall be of managed
type with two (2) No of Fibre Optic cable ports and Sixteen / Eight Copper ports. The
Ethernet switches shall have features to support the dual redundant rings. These switches
shall be mounted inside the switchgear Panels and shall be suitable for accepting dual
redundant power supplies. The FO ports shall be Single-mode 1000Mbps ports. Copper
ports shall be 10/100Mbps ports.
18.29.00 Necessary software for configuration and real-time network monitoring shall be provided
along with the Ethernet switches.
18.30.00 LAN CABLE & CONNECTOR

18.30.01 Cat5e Ethernet cable shall be used for connecting the numerical relays to Ethernet switches.
In case FO ports are proposed on the numerical relays, Ethernet switches shall also have
adequate number of FO ports for connecting Numerical Relays to the Ethernet Switches in
the switchboards.
19.00.00 Other Protections and Control functions in the Relays
19.01.00 Trip circuit supervision shall be provided for all feeders to monitor the circuit breaker trip
circuit both in pre-trip and post-trip conditions.
19.02.00 Schematics requiring auxiliary relays / timers for protection function shall be a part of
numerical relay. The number of auxiliary relay and timer function for protection function shall
be as required. Timer functions shall be programmable for on/off delays.
19.03.00 Bus no volt condition shall be configured to an output contact of the relay of incomers for
suitably interfacing with DDCMIS wherever required.
19.04.00 The numerical relay shall be able to provide supervisory functions such as trip circuit
monitoring, circuit breaker state monitoring, VT and CT supervisions and recording facilities
with post fault analysis.
19.05.00 The numerical processor shall be capable of measuring and storing values of a wide range of
quantities, all events, faults and disturbance recordings with a time stamping using the
internal real time clock. Battery backup for real time clock in the event of power supply failure
shall be provided.
19.06.00 At least 200 time tagged events / records shall be stored with time stamping. Details of at
least 5 previous faults including the type of protection operated, operating time, all currents &
voltages and time of fault.
19.07.00 Diagnostics Automatic testing, power on diagnostics with continuous monitoring to ensure
high degree of reliability shall be shall be provided. The results of the self-reset functions
shall be stored in battery back memory. Test features such as examination of input

BUSDUCTS
CLAUSE NO.
quantities, status of digital inputs and relay outputs shall be shall be available on the user
interface.
19.08.00 The alarm/status of each individual protection function and trip operation shall be
communicated to Switchgear SCADA / DDCMIS.
19.09.00 Sequence of events shall have 1ms resolution at device level.
19.10.00 Measurement accuracy shall be 1 % for RMS Current and voltage.
19.11.00 It shall be possible to carryout open / close operation of breakers from a laptop by interfacing
from the relay front port during initial commissioning.
19.12.00 Circuit-breaker status, protection status, etc. required for control logics shall be hardwired to
DDCMIS. In addition, any other requirement of digital & analog signals for process controls
shall be taken care of.
19.13.00 TRAINING workshop at Site
19.13.01 The contractor shall arrange for training on design, engineering, Commissioning and
operation & maintenance of LV Switchgear, Numerical relays and Switchgear networking
system for a duration of two (2) man-months.
19.13.02 The scope shall include training for a batch of engineers and a separate batch of
Supervisors/Technicians at Project Site. One such Workshop shall be organized before the
commissioning of First LV Switchboard and the second workshop shall be conducted before
Unit Commissioning. Owner shall provide the required Infrastructure such as Training
Conference room, Projection systems etc.
20.00.00 INDICATING INSTRUMENTS
20.01.00 All indicating and integrating meters shall be flush mounted on panel front. The instruments
shall be of at least 96mm square size with 90 degree linear scale and shall have an accuracy
class of 1.0 or better. The covers and cases of instruments and meters shall provide a dust
and vermin proof construction.
20.02.00 All instruments shall be compensated for temperature errors and factory calibrated to directly
read the primary quantities. Means shall be provided for zero adjustment without removing or
dismantling the instruments.
20.03.00 All instruments shall have white dials with black numerals & lettering. Black knife edge
pointer shall be provided for meters.
20.04.00 Ammeters provided for motor feeders (for motors of rating ≥ 30kW & < 100kW) shall have a
compressed scale at the upper current region to cover the starting current up to 6.0 times the
CT primary current.
20.05.00 All motor feeders of rating ≥ 30 kW and < 110 kW shall be provided with Multifunction Digital
Energy Meter with communication facility to display the current, voltage, power factor, power
energy related data locally as well as communicate these for remote metering/audit/analysis
purposes. These meters shall The technical specification for Digital indicating energy meter

BUSDUCTS
CLAUSE NO.
a) Input Voltage:110VAC / 240VDC

b) Input Current:1A
c) Size:96X96 SQ.MM
d) Power & Energy Accuracy: 1.0
e) Mounting: Flush mounting
f) Type: True RMS 3-PHASE V,I, kW,PF & kWH indication
g) 4 Digit, seven segment LED display/LCD display, with floating decimal
h) Communication: In built RS 485 bus port
i) Operating Frequency: 45 HZ-65HZ
j) Dielectric Test: 2KV RMS for 1 minute
k) Over Current: 10 times for 3 sec.
l) Aux supply: 90V-300V AC/DC
m) Compliance: EMC/EMI
n) Field programmable CT ratio
o) Analog Current Output (4-20 mA)
21.00.00 PUSH BUTTONS
21.01.00 Push-buttons shall be of spring return, push-to-actuate type. Their contacts shall be rated to
make, continuously carry and break 10 A at 110 V AC and 1 A (inductive) at 240 V DC.
21.02.00 All push buttons shall have two (2) normally open and two (2) normally closed contact,
unless specified otherwise. The contact faces shall be of silver alloy.
21.03.00 All push-buttons shall be provided with integral escutcheon plates marked with its function.
21.04.00 The colour of the button shall as follows :
Green for motor START, breaker CLOSE , valve/ damper OPEN commands.
Red for motor trip, breaker open, valve / damper close commands.
Black for all annunciation functions, overload reset and miscellaneous commands
including reverse for clinker grinder etc.
21.05.00 All push buttons on panels shall be located in such a way that Red push button shall always
be to the left of Green push button. In case of clinker grinder etc. the push buttons would be
black - red-green from lift to right.
21.06.00 All emergency push buttons shall have mushroom knobs.
22.00.00 Indicating Lamps
22.01.00 Indicating lamps shall be of CLUSTER LED type. The lamps shall have escutcheon plates
marked with its function, wherever necessary.

BUSDUCTS
CLAUSE NO.
22.02.00 Lamps shall have translucent lamp-covers of the following colours, as warranted by the
application :
Red for motor ON, valve / damper OPEN, breaker CLOSE.
Green for motor OFF , valve / damper CLOSE, breaker OPEN.
White for motor AUTO TRIP.
Blue for all healthy conditions (e.g. control supply, and also for SPRING
CHARGED").
Amber for all Alarm Conditions (e.g. overload). Also for "SERVICE" and "TEST"
position indications.
22.03.00 Bulbs and lamp covers shall be easily replaceable from the front of the cubicle. The method
of mounting indicating lamp fittings on panels shall prevent their rotation under the action of
lamp removal or replacements, reliance upon the tightness of ring nut for the purpose is not
sufficient.
22.04.00 Indicating lamps should be located just above the associated push-button / control switches.
Red lamps shall invariably be located to the right of green lamps. In case a white lamp is also
provided, it shall be placed between the red and green lamps along the centre line of control
switch / push button pair. Blue and Amber should normally be located above the Red and
Green lamps.
22.05.00 When associated with push-buttons, red lamps shall be directly above the green push-button
and green lamp shall be directly above the red push button.
22.06.00 All indicating lamps shall be suitable for continuous operation at 90% to 110% of their rated
voltage.
23.00.00 Space Heater
23.01.00 Space heaters shall be provided in the switchboards wherever the manufacturer considers
them necessary and recommends their provision for preventing harmful moisture
condensation.
23.02.00 The space heaters shall be suitable for continuous operation on 240 V AC, 50 Hz, single
phase supply, and shall be automatically controlled by thermostats. Necessary switches and
fuses shall be provided.
23.03.00 The circuit for each panel and motor space heater should have an isolating switch, HRC fuse
and isolating link. In addition, the space heater circuit of each panel shall also have a
thermostat of suitable rating.
24.00.00 INTERNAL WIRING
24.01.00 All switchboards shall be supplied completely wired internally upto the terminals, ready to
receive external cables.
24.02.00 All inter-cubicle and inter-panel wiring and connections between panels of same switchboard
including all bus wiring for AC and DC supplies shall be provided by the Contractor.

BUSDUCTS
CLAUSE NO.
24.03.00 All auxiliary wiring shall be carried out with 650V grade, single core stranded Copper
conductor, colour coded, PVC insulated wires. Conductor size shall be 1.5 mm2 (min.) for
control circuit wiring and 2.5 mm2 (min) for CT and space heater circuits.
24.04.00 Extra flexible wires shall be used for wiring to devices mounted on moving parts such as
hinged doors. The wire bunches from the panel inside to the doors shall be properly sleeved
or taped.
24.05.00 All wiring shall be properly supported, neatly arranged, readily accessible and securely
connected to equipment terminals and terminal blocks.
24.06.00 All internal wiring terminations shall be made with solderless crimping type tinned Copper
lugs which shall firmly grip the conductor or an equally secure method. Similar lugs shall also
be provided at both ends of component to component wiring. Insulating sleeves shall be
provided over the exposed parts of lugs to the extent possible. Screw-less (spring loaded) /
cage clamp type terminal shall also be provided with lugs.
24.07.00 Printed single tube ferrules marked to correspond with panel wiring diagram shall be fitted at
both ends of each wire. The wire identification marking shall be in accordance with IS: 375.
Red Ferrules should be provided on trip circuit wiring.
24.08.00 Wiring for equipment, which are to be supplied by the Contractor and for which the
Contractor has to provide mounting arrangement in his panels, shall also be provided by the
Contractor, up to the terminal blocks.
24.09.00 All connections from vertical busbars for individual modules above 100 A shall be by Copper
/ Aluminium links only. The cable connections for modules less than 100 A shall be selected
in such a way that there will not be any melting / shorting in case of a short circuit inside the
module and the cable shall have current rating to carry the let through energy of the
corresponding fuses in case of a fault. The insulation of the cable and its cross section shall
be decided considering the high ambient temperature within the module. For all modules
where use of cable is envisaged by the Contractor specific approval from the Employer
regarding cable details are to be taken. For power wiring colour coded wire insulation / tapes
shall be provided.
25.00.00 CONTROL TERMINAL BLOCKS
25.01.00 Terminal blocks shall be 650V grade, 10Amps rated, made up of unbreakable polyamide 6.6
grade. The terminals shall be either screw type or screw-less (spring loaded) / cage clamp
type with lugs. Marking on terminal strips shall correspond to the terminal numbering in
wiring diagrams. All metal parts shall be of non-ferrous material. In case of screw type
terminals the screw shall be captive, preferably with screw locking design.
25.02.00 Terminal blocks for CT and VT secondary leads shall be of stud type, made up of
unbreakable polyamide 6.6 grade. They shall be provided with links to facilitate testing,
isolation star / delta formation and earthing. Terminal blocks for CT secondary shall have the
short circuiting facility. The terminals for remote ammeter connection etc. shall also be
disconnecting type only. All metal parts shall be of non-ferrous material. Screws shall be
captive.

BUSDUCTS
CLAUSE NO.
25.03.00 In all circuit breaker panels MCC modules at least 10% spare terminals for external
connections shall be provided and these spare terminals shall be uniformly distributed on all
terminal blocks.
25.04.00 All terminal blocks shall be suitable for terminating on each side two (2) nos. stranded
Copper conductors of size up to 2.5 sq. mm each, or alternatively, the terminal blocks shall
have the possibility of double shorting space to facilitate looping. However for DDCMIS
terminals shall be suitable for 1.5 mm2 cable.
25.05.00 All terminals shall be numbered for identification and grouped according to the function.
Engraved white-in-black labels shall be provided on the terminal blocks.
25.06.00 Wherever duplication of a terminal block is necessary it shall be achieved by solid bonding
links.
25.07.00 Terminal blocks shall be arranged with at least 100mm clearance between two sets of
terminal blocks. The minimum clearance between the first row of terminal blocks and the
associated cable gland plate shall be 250 mm.
26.00.00 Power Cable Termination
26.01.00 Cable termination compartment and arrangement for power cables shall be suitable for
heavy duty, 1.1 kV grade, stranded Aluminium conductor, PVC/ XLPE insulated, armored /
unarmored and PVC sheathed cables. The size and type of cable for individual modules
shall, preferably, be as indicated in the 'Module Selection Tables'. All necessary cable
terminating accessories such as supporting clamps and brackets, hardware etc. for cables
shall be provided by the contractor to suit the final cable sizes.
26.02.00 All power cable terminals shall be of stud type and the power cable lugs shall be of tinned
Copper solderless crimping ring type conforming to IS: 8309. All lugs shall be insulated/
sleeved.
27.00.00 LOCAL PUSH BUTTON STATIONS
27.01.00 The enclosure shall be provided with a hinged guard at the front, covering full length, to avoid
inadvertent operation of push buttons Support structure for mounting the LPBS shall also be
supplied by Contractor. The local push button stations shall be dust and vermin proof and
shall have a degree of protection of IP -55 as per IS/IEC 60947. The DOP shall be IP-65 in
case the same are located in dusty areas.
27.02.00 The local push button stations shall be metal enclosed, suitable for outdoor / indoor mounting
on wall or steel structures. The enclosure shall be die-cast Aluminium or cold-rolled sheet
steel of at least 1.6 mm thickness. LPBS shall be painted to shade no. RAL: 9002.
27.03.00 Local push button stations enclosure made of FRP (Fiberglass Reinforced Polymer) may
also be offered. The FRP enclosure shall be of SMC Hot press Moulded, Halogen free and
flame retardant as per UL94, V-0. The thickness of the FRP enclosure shall be at least 4mm.
The colour of the FRP type LPBS shall be of RAL 7035 and the hinges, nuts & bolts shall be
of Polyamide / Stainless Steel material.

BUSDUCTS
CLAUSE NO.
27.04.00 The push button stations shall be suitable for bottom cable entry and shall be provided with
removable undrilled gland plates or knockouts to facilitate termination of two numbers of
control cables. Adequate space shall be available inside the push button station enclosure
for terminating external cables directly on pushbutton terminals. Overall size of push button
stations shall be subject to Employer's approval.
27.05.00 The push button station shall comprise of a latched type EMERGENCY STOP push button
with two (2) NO and two (2) NC contacts.
27.06.00 Support structure for mounting in local push button stations shall be supplied by the
Contractor.
28.00.00 LOCAL MOTOR STARTERS
28.01.00 Local motor starters shall be suitable for manual switching of 415 V, 3-phase, squirrel cage
motors rated up to 5.5 kW. They shall have constructional features similar to those specified
for local push button stations.
28.02.00 Each starter shall comprise of :

1. A 3-pole contactor, mechanically latched type.
2. Start push button, coloured green.
3. Stop push button, coloured red.
4. Ambient temperature compensated, thermal over load relay with single
phasing protection. The continuously variable relay setting range shall be
suitable for the motor rating which shall be advised to the Contractor in due
course. The relay shall trip the contactor.
28.03.00 The start push button, when pressed, shall preferably remain in depressed position and shall
be released along with the contactor when the stop push button is pressed or when thermal
overload relay operates.
28.04.00 Local starters shall be suitable for loop-in and loop-out of incoming cable and for one
outgoing cable to motor. Support structure for mounting in local motor starters shall be
supplied by the Contractor.
29.00.00 Name Plates and Labels
29.01.00 All Switchgears, MCCs, Distribution Boards, Fuse boards, all feeders, local push-button
stations and local motor starters shall be provided with prominent, engraved identification
plates. The module identification plate shall clearly give the feeder number and feeder
designation. For single front switchboards, similar panel and board identification labels shall
be provided at the rear switchgear also.
29.02.00 All name plates shall be of non-rusting metal, with white engraved lettering on black
background. Letter size shall be of at least 10mm height.
29.03.00 Suitable stenciled paint mark shall be provided inside the panel/module for identification of all
equipment in addition to the plastic sticker labels, if provided. These labels shall be
positioned so as to be clearly visible and shall have the device number, as mentioned in the
module wiring drawings.

BUSDUCTS
CLAUSE NO.
29.04.00 Caution name plate "Caution Live Terminals" shall be provided at all points where the
terminals are likely to remain live and isolation is possible only at remote end.
30.00.00 METAL ENCLOSED NON SEGREGATED PHASE BUSDUCT(AIR INSULATED)
30.01.00 Three phase and neutral metal enclosed non segregated phase busduct assemblies shall be
supplied for incoming connections from the transformers to the switch boards and inter
connecting sections between switch boards, wherever applicable. The rating of the incoming
and interconnecting busducts shall be same as the rating of the switchboard.
30.02.00 The enclosure shall be made of minimum 3 mm thick Aluminium alloy. The section of the
busduct shall be rectangular. The design of the busduct enclosures shall be of sturdy
construction such that it will withstand the internal or external forces resulting from the
various operating conditions.
30.03.00 The entire busduct shall be designed for dust, vermin and weather proof construction. A
suitable Aluminium sheet flange-protection hood shall be provided to cover all outdoor
busduct enclosure joints to facilitate additional protection against rain water ingress. All
horizontal runs of busducts shall have a suitable sloped enclosure top to prevent retention of
water for both indoor and outdoor portion of busducts. Busduct enclosure shall have a
degree of protection of IP-55.
30.04.00 The inside of the bus enclosure may be treated with black paint to enable efficient heat
dissipation. The matt paint used shall be suitable for temperature experienced during
continuous loading of the bus conductor. The busduct exterior paint shade shall be RAL
5012.
30.05.00 Flexible expansion joints for the enclosure shall be provided wherever deemed necessary by
the Contractor. Necessary bonding shall be provided at the expansion joints if made of
insulating materials.
30.06.00 Enclosures shall be provided with flanged ends with drilling dimensions to suit the flanges at
the switchgear and transformer terminals. Any adapter boxes required for this purpose are in
the Contractor's scope of supply. The flanges shall be provided with gaskets, nuts, bolts,
etc. Details of the flanges provided on transformer ends will be furnished to the successful
Contractor.
30.07.00 Suitable Inspection covers shall be provided for periodic inspection of insulators. Handle
shall be provided on each inspection cover to facilitate easy lifting.
30.08.00 The EPDM / Neoprene gaskets shall be provided so as to satisfy the operating conditions
imposed by temperature, weathering, durability etc. Flange gaskets shall be provided at the
equipment terminal connections.
30.09.00 Necessary earthing arrangement as applicable shall be provided with clamps to receive
station earthing bus. All accessories and hardware required for the earthing arrangement
shall be provided by the Contractor. This shall be a GI strip of adequate size, continuously
running along the busduct and shall be earthed at both ends. Busduct enclosures shall be
bolted type.

BUSDUCTS
CLAUSE NO.
30.10.00 The material of the conductor shall be Aluminium. The minimum clearance in air between
phase to phase, phase to neutral and phase to earth for the entire run of busduct shall be 25
mm The bus bars shall be rated in accordance with the service conditions and the rated
continuous and short time current ratings calculated for specific application / specified
elsewhere.
30.11.00 All steel structures required for busduct support shall be hot dip galvanized.
30.12.00 Space heaters shall be provided in the busduct wherever the manufacturer considers them
necessary and recommends their provision for preventing harmful moisture condensation.
30.13.00 The space heaters shall be suitable for continuous operation on 240 V AC, 50 Hz single
phase supply and shall be automatically controlled by thermostats. Necessary wiring upto
junction boxes mounted on busduct and from junction boxes to switch boards shall be
provided by the Contractor.
31.00.00 BUS TRUNKING SYSTEM (SANDWICH TYPE BUSDUCT)
31.01.00 Three phase Bus trunking system conforming to IEC 61439-6 / IS 8623 (Parts 1 & 2) shall be
provided for connecting the Main and Standby DG sets to Unit Emergency Switchgears.
31.02.00 The enclosure shall be made of CRCA (1.6mm thick) / GI (1.6mm thick) / Aluminium (2.5mm
thick) sheet. The design of the bus duct enclosure shall be of sturdy construction such that it
will withstand the internal or external forces resulting from the various operating conditions.
31.03.00 The entire bus duct shall be designed for dust, vermin and weather proof construction. A
suitable aluminium sheet flange-protection hood shall be provided to cover all outdoor bus
duct enclosure joints to facilitate additional protection against rain water ingress. All
horizontal runs of bus ducts shall have a suitable sloped enclosure top to prevent retention of
water for both indoor and out door portion of busducts. Busduct enclosure shall have a
degree of protection of IP-55.
31.04.00 The busduct exterior paint shade shall be RAL 5012.
31.05.00 Enclosures shall be provided with flanged ends with drilling dimensions to suit the flanges at
the switchgear and DG terminals. Any adapter boxes required for this purpose are in the
contractor's scope of supply. The flanges shall be provided with gaskets, nuts, bolts, etc.
31.06.00 EPDM / Neoprene gaskets shall be provided so as to satisfy the operating conditions
imposed by temperature, weathering, durability etc. Flange gaskets shall be provided at the
equipment terminal connections.
31.07.00 Necessary earthing arrangement as applicable shall be provided with clamps to receive
station earthing bus. All accessories and hardware required for the earthing arrangement
shall be provided by the contractor. This shall be a GI strip of adequate size, continuously
running along the busduct and shall be earthed at both ends. busduct enclosures shall be
bolted type.

BUSDUCTS
CLAUSE NO.
31.08.00 The material of the conductor shall be high conductivity aluminum / copper. The busbars
shall be rated in accordance with the service conditions and the rated continuous and short
time current ratings specified elsewhere.
31.09.00 All steel structures required for busduct support shall be hot dip galvanized.
31.10.00 Space heaters shall be provided in the busduct wherever the manufacturer considers them
necessary and recommends their provision for preventing harmful moisture condensation.
31.11.00 The space heaters shall be suitable for continuous operation on 240 V AC, 50 Hz single
phase supply and shall be automatically controlled by thermostats. Necessary wiring upto
junction boxes mounted on busduct and from junction boxes to switch boards shall be
provided by the contractor.
32.00.00 LIGHTING / WELDING TRANSFORMERS

Each AC Lighting Distribution Board (LDB) shall be fed from 415V / 415V, 50kVA(minimum)
isolating transformer & Each Welding Distribution Board (LDB) shall be fed from 415V /
415V, 100kVA isolating transformer. The lighting / welding transformer may, preferably, be
located inside the LDB / Welding DB panel itself. Otherwise, the same shall be located by the
side of respective LDB / Welding DB. Lighting / Welding transformers shall be dry type,
natural air cooled with class B insulation or better. Impedance of lighting / Welding
transformer shall be so selected that the fault level of lighting /Welding system shall be
reduced to 3 to 5 KA. Lighting / Welding transformers shall be tested as per IS: 2026. Off-
circuit tap changer with ± 2.5% and ± 5% tapping shall be provided. In case the transformers
are not mounted inside the LDB panels, the same shall be housed in a separate 2 mm thick
CR sheet steel enclosure with IP-42 degree of protection as per IS/IEC 60947. However, the
transformer terminal box shall have IP-52 degree of protection.
33.00.00 PAINTING
All sheet steel work shall be pre-treated, in tanks, in accordance with IS: 6005. Degreasing
shall be done by alkaline cleaning. Rust and scales shall be removed by pickling with acid.
After pickling, the parts shall be washed in running water. Then these shall be rinsed in
slightly alkaline hot water and dried. The phosphate coating shall be "Class-C" as specified in
IS: 6005. The phosphated surfaces shall be rinsed and passivated. After passivation,
Electrostatic Powder Coating shall be used. Powder should meet requirements of IS 13871
(Powder costing specification). Finishing paint shade for complete panels excluding end
covers shall be RAL9002 & RAL5012 for extreme end covers of all boards, unless required
otherwise by the Employer. The paint thickness shall not be less than 50 microns. Finished
parts shall be suitably packed and wrapped with protective covering to protect the finished
surfaces from scratches, grease, dirt and oil spots during testing, transportation, handling
and erection.
34.00.00 GASKETS
The gaskets, wherever specified, shall be of good quality EPDM / Neoprene with good
ageing, compression and oil resistance characteristics suitable for panel applications.
35.00.00 TEMPERATURE –RISE

The temperature rise of the horizontal and vertical busbars and main bus links including all
power draw-out contacts when carrying 90% of the rated current along the full run shall in no
case exceed 550 C with silver plated joints and 400C with all other types of joints over an

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outside ambient temperature of 500C. The temperature rise of the accessible parts/external
enclosures expected to be touched in normal operation shall not exceed 200C. The
temperature rise of manual operating means shall not exceed 100C for metallic & 150C for
insulating material. Temperature rise for the busbars shall be carried out at 90% of the rated
current. The above temperature rise limits are applicable for busducts also without any
current derating.
36.00.00 DERATING OF EQUIPMENTS

The Contractor shall ensure that the equipment offered will carry the required load current at
site ambient conditions specified and perform the operating duties without exceeding the
permissible temperature as per Indian Standards / Specification. Continuous current rating at
500C ambient in no case shall be less than 90% of the normal rating specified.
The Contractor shall indicate clearly the derating factors if any employed for each component
and furnish the basis for arriving at these derating factors duly considering the specified
current ratings and ambient temperature of 500C.
37.00.00 PROTECTION CO-ORDINATION

It shall be the responsibility of the Contractor to fully coordinate the overload and short circuit
tripping of the circuit breakers with the upstream and downstream circuit breakers / fuses /
motor starters, to provide satisfactory discrimination. Further the various equipment supplied
shall meet the requirements of Type 2 class of Co-ordination as per IS: 8544.
38.00.00 TESTS AND TEST REPORTS
38.01.00 GENERAL
(a.) All equipment to be supplied shall be of type tested design. The Contractor shall
submit for Employer’s approval the reports of all the type tests as listed in this
specification and carried out not earlier than ten years prior to the date of bid
opening. These reports should be for the tests conducted on the equipment similar to
those proposed to be supplied under this contract and the test(s) should have been
either conducted at an independent laboratory or should have been witnessed by a
client.
(b.) In case the Contractor is not able to submit report of the type test(s) conducted not
earlier than ten years prior to the date of bid opening, or in case the type test
report(s) are not found to be meeting the specification requirements, the Contractor
shall conduct all such tests under this contract at no additional cost either at third
party lab or in presence of client/Employer’s representative and submit the reports
for approval.
(c.) All routine tests as per the specification and relevant standards shall be carried out.
38.02.00 The following type test certificates of LT Switchgear and MCC panels shall be submitted.
1) Circuit breaker of each rating
a) Test sequence 1
b) Combined test sequence (With Circuit breakers mounted inside the

Switchgear panel)

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2) Complete design verification of Switchgear/MCC Panels as per IEC 61439

Part-1, Annexure-D
3) Internal arc test for Personnel and Assembly Protection as per IEC/TR
61641
4) MCC modules of any three ratings, as selected by the Employer, for class - II
protection Co-ordination.
5) Test for single phasing protection feature on 3 nos. bimetallic thermal overload
relay selected by Employer. The relay shall be tested for compliance with
manufacturer's printed / declared characteristic curve.
38.03.00 Type test reports for the following equipment as per applicable standards shall also be
submitted.
(a.) LOCAL PUSH BUTTON STATION
(b.) LOCAL MOTOR STARTER
(c.) MCCB
38.04.00 Type test reports for the following tests on the model of the Numerical relays & Ethernet
switches being offered shall be submitted for Employer’s review.
S. TEST ITEMS Standard
No.
1 Dimensions of structure and visual inspection IEC 60297-3-101
2 Functional requirements: Relevant
– Steady-state simulation IEC 60255-100
– Dynamic simulation series
3 Product safety requirements IEC 60255-27
(including the dielectric tests and thermal short time
rating)
4 EMC requirements:
– Emission IEC 60255-26
– Immunity
5 Energizing quantities:
– Burden N/A
– Change of auxiliary energizing quantity IEC 60255-11
6 Contact performance N/A
7 Communication requirements Relevant IEC
protocol standards
8 Climatic environmental requirements: IEC 60068-2-14,
– Cold IEC 60068-2-1,
– Dry heat IEC 60068-2-2,
– Change of temperature IEC 60068-2-78,
– Damp heat IEC 60068-2-30,
IEC 60255-27
9 Mechanical requirements: – Shock IEC 60255-21-1,
– Vibration IEC 60255-21-2,
– Bump IEC 60255-21-3

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– Seismic
10 Enclosure protection IEC 60529,
IEC 60255-27
38.05.00 The type test reports once approved shall be treated as reference. For subsequent projects,
an endorsement sheet will be furnished by the manufacturer confirming similarity and “No
design Change”. Minor changes if any shall be highlighted on the endorsement sheet.
38.06.00 The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure
along with relevant supporting documents.
38.07.00 Routine checking to observe compliance to degree of protection, first numeral, on

switchboard enclosures and busbar chambers shall be as under :
1) IP -4 X It shall not be possible to insert a one mm dia. Steel wire into the
enclosure from any direction, without using force.
2) IP-5X It shall not be possible to insert a thin sheet of paper under gaskets
and through enclosure joints.
39.00.00 ERECTION / INSTALLATION OF SWITCHBOARDS AND OTHER EQUIPMENTS
39.01.00 Each equipment shall be installed in a neat, workman-like manner so that it is levelled,
plumbed, squared and properly aligned and oriented. Tolerances shall be as established in
Contractor's drawings or as stipulated by Employer. No equipment shall be permanently fixed
down to foundations until the alignment has been checked and found acceptable by the
Employer.
39.02.00 Contractor shall furnish all supervision, labour, tools, equipment, rigging materials, bolts,
wedges, anchors, etc., in proper time, required to completely install, test and commission the
equipment.
39.03.00 Manufacturer's and Employer's instructions and recommendations shall be correctly followed
in handling, setting, testing and commissioning of all equipment.
39.04.00 Contractor shall move all equipment into the respective rooms through the regular door or
openings specifically provided for this purpose. No part of the structure shall be utilised to lift
or erect any equipment without prior permission of Engineer.
39.05.00 All switchboards shall be installed in accordance with Indian Standard, IS: 3072, and
Employer's instructions.
39.06.00 Switchboard panels shall be installed on concrete floor or supported on steel channel / edge
angle in concrete trenches. The Contractor shall provide steel insert plates in the concrete
floor and / or steel channels / edge angle on the trenches as applicable. The base frame of
switchboards shall be welded to the insert plates by the Contractor. The Contractor shall be
required to install and align the panels using suitable metallic shims before welding the base
frame. In joining shipping sections of switchboards together, adjacent housing of panel

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sections or flanged throat sections shall be bolted together after alignment has been
completed.
39.07.00 Contractor shall take utmost care in handling instruments, relays and other delicate
mechanisms. Wherever the instruments and relays are supplied separately they shall be
mounted only after the associated panels have been erected and aligned. The blocking
materials employed for safe transit of instruments and relays shall be removed after
ensuring that panels have been completely installed and no further movement of the same
would be necessary. Any damage shall be immediately reported to Engineer.
39.08.00 Equipment furnished with finished coats of paint shall be touched up by Contractor if their
surface is spoiled or marred during erection / commissioning.
39.09.00 The room and floor finishing work would be done after erection of the panels and the
Contractor shall suitably cover up the panels to protect them from injury and marring of finish.
40.00.00 COMMISSIONING CHECKS / TESTS
40.01.00 After installation of panels, power and control wiring and connections, Contractor shall
perform operational tests on all switchboards, to verify proper operation of switchboards /
panels and correctness of all equipment in each and every respect.
40.02.00 The Contractor shall carry out the following commissioning checks, in addition to other
checks and tests recommended by the manufacturers.
40.03.00 GENERAL
(a.) Check name plate details according to the approved drawings.
(b.) Check for physical damage.
(c.) Check tightness of all bolted connections, by torque wrench.
(d.) Check earth connections.
(e.) Check cleanliness.
(f.) Check all moving parts for proper lubrication.
40.04.00 Circuit Breakers
(a.) Check alignment of breaker truck for free movement.
(b.) Check correct operation of shutters.
(c.) Check control wiring for correctness of connections, continuity And IR values.
(d.) Manual operation of breakers completely assembled.
(e.) Closing /opening operation, manually and electrically.
(f.) Trip free and anti-pumping operation.
(g.) I.R. values of contacts.

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(h.) Contact resistance.
(i.) Check on spring charging motor, correct operation of limit switches and time or
charging.
(j.) All functional checks
(k.) Breaker closing and tripping time, if required.
40.05.00 Current Transformers
(a.) Visual inspection.
(b.) IR Value
(c.) Ratio check.
(d.) Magnetising current.
(e.) Wiring connection.
(f.) Spare CT cores, if any, to be shorted and earthed
40.06.00 Voltage Transformers
(b.) IR Value
(c.) Ratio check
(d.) Magnetising current
(e.) Line connection as per connection diagram
40.07.00 Cubicle Wiring
(a.) Check all switch developments
(b.) Each wire shall be traced by continuity tests and it shall be ensured that the wiring is
as per relevant drawing. All inter-connections between panels / equipment shall be
similarly checked.
(c.) IR Value of all the wires shall be checked to earth.
(d.) Functional checking of all control circuit e.g., closing, tripping, control, interlock,
supervision and alarm circuit.
40.08.00 Relays
1. Check connections and wiring.
2. IR Value to be checked for
a) all terminals to body.
b) AC to DC terminals.

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3. Check operating characteristics by secondary injection.
4. Check minimum pick up voltage of DC coils.
5. Check operation of electrical / mechanical targets.
6. Relay settings.
7. Check CT and VT connections with particular reference to their polarities.
8. REF protection stability check for Incomer from Transformer
40.09.00 Meters
(b.) Check IR Value of all insulated partitions.
(c.) Check CT and VT connections with particular reference to their polarities for power
type meters.
(d.) Calibration.
41.00.00 AC MODULES DESCRIPTION
41.01.00 Module type DAE (Circuit Breaker Module)
(a.) One (1) Triple-pole circuit breaker, complete with all accessories and power operated
mechanism, as specified.
(b.) Three (3) Current transformers for Protection and metering.
(c.) One (1) DC isolating Switch
(d.) Six (6) HRC Control fuses.
(e.) Numerical relay for the following:
 Short Circuit Protection
 Earth Fault Protection
 Over Load protection
 Energy Metering
 Current and Voltage metering
 Trip Circuit Supervision
 CB Monitoring
 Synchronizing Check feature

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41.02.00 Module Type DAET (Circuit Breaker Incomer From Transformer)

Similar to module type DAE; but with additional PS Class Current transformers for
Restricted Earth Fault Protection. The Numerical relay shall have provision for REF
protection in addition to the features listed against module type DAE.Suitable Stabilizing
resistor and metrosil shall be provided for REF protection.
41.03.00 Module Type CC (Contactor Changeover Between Two In Coming Supplies)

(Note: Main and Reserve incomers shall be housed in separate draw-out modules, located
in different panels.)
The draw-out modules shall be provided with service position limit switch having 2 NO+2NC
contacts.
Main Incomer
One (1) Triple pole load break isolating switch .
One (1) Triple pole contactor with coil suitable for 415 V AC.
Two (2) Auxiliary contactors with coil suitable for 415 V AC.
One (1) Indicating lamp with resistor and coloured lens suitable for 415 V AC.
Three (3) HRC control fuses.
Reserve Incomer
One (1) Triple pole load break isolating switch
One (1) Triple pole contactor with coil suitable for 415 V AC.
One (1) Indicating lamp with resistor and coloured lens suitable for 415 V AC.
Two (2) HRC control fuses.
41.04.00 Module Type CS (AC Control Supply Module)
(Note: Module type CS will be of non-draw-out type)
Two (2) 415/110 V control transformers.
Four (4) 110V auxiliary relays.
Two (2) Earth links.
Eight (8) HRC Control fuses.
Two (2) Selector switches
41.05.00 Module Type DG (Circuit Breaker Incomer From DG Set)
(a.) One (1) Triple-pole circuit breaker, complete with all accessories and power
operated mechanism, as specified.
(b.) Three (3) Current transformers for protection & metering.

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(d.) Six (6) HRC control fuses
(e.) Numerical relay for the following:
 Differential protection
 Over Load protection
 Reverse Power Protection
 DG Neutral displacement
 Energy Metering
 Current and Voltage metering
 DG Monitoring
41.06.00 Module Type E/E1/E2 (Switch Fuse Module/MCCB)
(a) One (1) Triple pole switch-fuse unit with three pole isolating switch and three
/ one / two HRC fuses for E/E1/E2 modules, respectively.
(b) One (1) Neutral link.

(c) One (1) 3 pole MCCB (for feeder rating 100A and -upto 400A)
41.07.00 Module Type G1 (VT Module with Under Voltage / No Volt Relay)
(a.) Three (3) 415/√3 / 110/√3 V single phase voltage transformers, mounted on a
common draw-out chassis
(b.) Three (3) HRC fuses for VT primary.
(c.) Three (3) HRC control fuses.
41.08.00 Module Type H (Isolating Switch Module)
(a) One (1) Triple pole load break isolating switch
(b) One (1) Neutral link
41.09.00 Module type K1 (Non Reversible Motor Rated Below 30 kW Controlled from MCC)
(a) One (1) Triple pole fuse switch unit with three pole load break isolating
switch and three HRC fuses.
(b) One (1) Triple pole contactor.
(c) One (1) Bimetallic thermal overload relay with single phasing preventer. For
motor with high starting time, heavy duty overload relay shall be
provided.
(d) Two (2) Push buttons.
(e) Three (3) Indicating lamps with resistors and coloured lenses.
(f) One (1) HRC control fuse.

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(g) One (1) Control link.
41.10.00 Module Type K11 (Non reversible Motor Rated 30kW to 200kW Controlled from MCC)
Similar to module type K1 but with the following additions:
One (1) Current transformer for metering.
One (1) Ammeter
One (1) Single-pole switch and fuse for motor space heater.
41.11.00 Module type DK2 (Non Reversible Motor rated below 30kW Controlled from DDCMIS)
(a) One (1) Triple pole switch fuse unit with three pole load break
Isolating switch and three HRC fuses.
(b) One (1) Triple pole contactor.
(c) One (1) Bimetallic thermal overload relay with single phasing preventor.
Heater Modules requiring remote control shall be marked with *
(DK2* / PK2*) and shall not have this relay. For motor with high
starting time, heavy duty overload relay shall be provided.
(d) Three (3) Indicating lamps with resistors and coloured lenses.
(e) One (1) HRC control fuse.
(f) One (1) Control link
(g) One (1) Auxiliary contactor
(h) Two (2) Coupling relays suitable for 24V DC.

(i) One (1) digital energy meter with analog output of current (4-20 mA) for CHP dust
suppression motors.
41.12.00 Module Type DK21 (Non Reversible Motor rated 30kW to up to 110KW (* See Remark)
controlled from DDCMIS).
(*) Remark : For CHP Conveyor Motors –upto 160 KW
(a) Similar to module type DK2 but with the following additions :
(b) Three (3) Current transformers for metering.
(c) One (1) Ammeter (for motors of rating ≥ 30kW & < 110kW)
(d) One (1) Single-pole switch and fuse for motor space heater.
(e) One (1) Digital Energy Meter with Analog output of Current (4-20 mA) (for motors
of rating ≥ 30kW & < 110kW)
41.13.00 Module Type DN1 (Reversible Motor Controlled from DDCMIS)
(a.) One (1) Triple pole fuse switch unit with three pole load break solating switch and
three HRC fuses.

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(b.) Two (2) Triple pole mechanically interlocked, forward / reverse contactors.
(c.) One (1) Bimetallic thermal overload relay with single phasing preventor.
(d.) One (1) Indicating lamp with resistor and coloured lens.
(e.) One (1) HRC control fuse
(f.) One (1) Control link
(g.) One (1) Auxiliary contactor
(h.) Two (2) Coupling relays suitable for 24V DC.
41.14.00 Module Type VM (Voltmeter Module)
(a.) Three (3) HRC fuses.
(b.) One (1) Voltmeter (0-500 V.)
(c.) One (1) Four position voltmeter selector switch
(d.) One (1) 415 V auxiliary contactor with 2 NO + 2 NC contacts.
(e.) One (1) Voltage transducer with output of 4-20mA between R & Y phases
41.15.00 Module Type DM (Circuit Breaker (DDC /PLC Controlled) Motor Feeder for motor rated
110 KW & above (except for CHP Conveyor motors).
(a.) One (1) Triple-pole circuit breaker, complete with all accessories and power operated
mechanism, as specified.
(b.) Three (3) Current transformers for Protection and metering.
(d.) Six (6) HRC Control fuses.
(e.) One (1) Single-pole switch and fuse for motor space heater
(f.) Numerical relay for the following:
Short Circuit Protection (50)
Thermal Over Load protection(49)
Earth fault Protection(50N)
Negative sequence Protection(46)
Restart inhibit protection66
Locked Rotor Protection (50LR)
Undervoltage Protection(27M)
Energy Metering

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Current and Voltage metering
Trip Circuit Supervision
CB Monitoring
(g). 4-20mA Analog Output (May be provided as analog output from the Numerical relay or
may be generated using a suitable CT & Current transducer).
42.00.00 DC MODULES DESCRIPTION
42.01.00 Module Type -CH (Incomer )
(a) One (1) Double pole, 250 V DC fuse -switch unit
42.02.00 Module Type - DC
(a.) One (1) Double pole 250V DC switch / circuit breaker with 2NO+2NC auxiliary
contacts.
42.03.00 Module Type - HD (DC Isolating Switch / Circuit - Breaker Module)
(a.) One (1) Double pole , 250 V DC switch isolator / circuit breaker
42.04.00 Module Type-S (DC Metering and Protection Module )
(a.) One (1) Voltmeter, 0-300V DC
(b.) One (1) Three position voltmeter selector switch
(c.) One (1) Instantaneous under voltage relay (27) with a setting of 95% of 220V DC.
The resetting ratio of relay should not be more than 1.05.
(d.) One (1) Instantaneous over voltage relay (59) which shall operate at 110% of 240 V
DC. The resetting ratio of relay should not be less than 0.95.
(e.) One (1) Earth leakage relay having adjustable pick up range between 3 to 7mA. The
relay shall be suitable for 240V / 50V DC and 240V AC auxiliary supply.
(f.) Two (2) Indicating lamps with resistors & coloured lenses, one each for 'Earth fault'
and 'DC supply failure ' indications.
(g.) Three (3) HRC control fuses.
(h.) One (1) Neutral link
42.05.00 Module Type -X (DC Isolating Switch Fuse Module)
(a.) One (1) Double pole , 250 V DC fuse switch unit with two HRC fuses.

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43.00.00 SELECTION TABLES
43.01.00 Feeder Module, Other than Motor Selection Table (415 V AC)
Feeder Switch/MCCB Fuse

Sl.
Rating Rating Rating
No.
(Amp.) (Amp.) (Amp.)
1. 0-16 16 16
2. 17-32 32 32
3. 33-45 63 63
4. 46-63 63 63
5. 64-99 100 100
6. 100-125 125A MCCB
7. 126-160 160A MCCB
8. 161-250 250A MCCB
9. 251-400 400A MCCB
10. Above 400A Air Circuit Breaker

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43.02.00 Motor Module Selection table

Sl. Motor Max. Switch Fuse Contactor
No. rating Motor rating rating rating
kW Amp. Amp. Amp. Amp.
1. 1.1-1.5 3.5 16 6/16 16

2. 1.6.3.0 7 32 20 16
3. 3.1-5.5 11 32 32 16
4. 5.6-7.0 14.4 63 50 32
5. 7.1-13.0 27.3 63 63 32
6. 13.1-24.0 45 125 80/100 63
7. 24.1-37.0 70 125 125 70
(upto 30kW)
100
(above 30kW)
8. 37.1-55.0 100 250 160 100

(upto 40kW)
160
(upto 55kW)
9. 55.1-80.0 150 250 200 200
10. 80.1-100 180 As per Suitable 225
selected for type-II
fuse
12. 110.0- AIR CIRCUIT BREAKER

200.0

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43.03.00 Switch Fuse Module Selection Table (220 V DC)
For all 220 V DC modules other than for motors, the ratings of switches & fuses shall be
selected from the following table
Sl. Feeder Switch Fuse
No. rating rating rating
Amp. Amp. Amp.
1. 0-6 10 6
2. 6-10 16 10
3. 10-14 16 16
4. 14-19 32 32
5. 19-32 32 32
6. 32-53 63 63
7. 53-81 100 100
8. 81-114 125 125
9. 114-125 250 250
10. 215-340 400 400
11. 340-560 600 600
12. Above 560 Air Circuit Breaker
44.00.00 COMMISSIONING OF LT SWITCHGEARS
Commissioning of LT switchgears at site shall only be carried out either by the

switchgear manufacturer himself or under the supervision of the switchgear
manufacturer.
45.00.00 Insulating Mat
Insulating mat supplied for laying in front of LT Switchgears in switchgear rooms
shall be as per IS:15652.

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editions including all applicable official amendments and revisions as on date of opening of
bid. In case of conflict between this specification and those (IS : codes, standards, etc.)
referred to herein, the former shall prevail. All the cables shall conform to the requirements of
the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto
and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanised steel wires, formed wires and tapes for
armouring of cables.
IS : 5831 PVC insulation and sheath of electrical cables.
IS:7098 (Part -I) Cross linked polyethylene insulated PVC sheathed cables for
working voltages upto and including 1100V.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D -2843 Standard test method for density of smoke from the burning or
decomposition of plastics.
IEC-754 (Part-I) Tests on gases evolved during combustion of electric cables.
IEC-332 Tests on electric cables under fire conditions. Part-3: Tests on

bunched wires or cables (Category-B).
2.00.00 TECHNICAL REQUIREMENTS
2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under
ground buried installation with chances of flooding by water.

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2.02.00 All cables including EPR cables shall be flame retardant, low smoke (FRLS) type designed to
withstand all mechanical, electrical and thermal stresses developed under steady state and
transient operating conditions as specified elsewhere in this specification.
2.03.00 Aluminium conductor used in power cables shall have tensile strength of more than 100 N/
sq.mm. Conductors shall be stranded.
2.04.00 XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg. C and
short circuit conductor temperature of 250 deg C. PVC insulation shall be suitable for
continuous conductor temperature of 70 deg C and short circuit conductor temperature of
160 deg. C.
2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It shall
not stick to insulation and inner sheath. All the cables, other than single core unarmoured
cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831.
2.06.00 For single core armoured cables, armouring shall be of aluminium wires/ formed wires. For
multicore armoured cables, armouring shall be of galvanised steel as follows :
Calculated nominal dia. Size and Type of armour

of cable under armour
Upto 13 mm 1.4mm dia GS wire
Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm dia GS wire
Above 25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia GS wire
Above 40 & upto 55mm 1.4 mm thick GS formed wire /2.5mm dia GS wire
Above 55 & upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia GS wire
Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire
2.06.01 The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum
resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of aluminium armouring
shall be same as indicated above for galvanized steel.
2.06.02 The gap between armour wires / formed wires shall not exceed one armour wire / formed
wire space and there shall be no cross over / over-riding of armour wire / formed wire. The
minimum area of coverage of armouring shall be 90%. The breaking load of armour joint
shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be
applied on armour joint surface of G.S.wire/ formed wire.
2.07.00 Outer sheath shall be of PVC as per IS: 5831 & black in colour. In addition to meeting all the
requirements of Indian standards referred to, outer sheath of all the cables shall have the
following FRLS properties.
(a.) Oxygen index of min. 29 (as per IS 10810 Part-58).

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(b.) Acid gas emission of max. 20% (as per IEC-754-I).
(c.) Smoke density rating shall not be more than 60 % (as per ASTMD-2843).
2.08.00 Cores of the cables shall be identified by colouring of insulation. Following colour scheme
shall be adopted:
1 core - Red, Black, Yellow or Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
2.09.00 For reduced neutral conductors, the core shall be black.
2.10.00 In addition to manufacturer's identification on cables as per IS, following marking shall also
be provided over outer sheath.
(a.) Cable size and voltage grade - To be embossed
(b.) Word 'FRLS' at every 5 metre - To be embossed
(c.) Sequential marking of length of the cable in metres at every one metre -To be
embossed / printed
The embossing shall be progressive, automatic, in line and marking shall be legible and
indelible. For EPR cables identification shall be printed on outer sheath.
2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332 Part-3.
2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum, over
the declared value in the technical data sheets.
2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not
acceptable.
2.14.00 Cable selection & sizing
2.14.01 Cables shall be sized based on the following considerations:
(a) Rated current of the equipment
(b) The voltage drop in the cable, during motor starting condition, shall be limited to 10%
and during full load running condition, shall be limited to 3% of the rated voltage
(c) Short circuit withstand capability
This will depend on the feeder type. For a fuse protected circuit, cable should be
sized to withstand the letout energy of the fuse. For breaker controlled feeder, cable

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CLAUSE NO.
shall be capable of withstanding the system fault current level for total breaker
tripping time inclusive of relay pickup time.
2.14.02 Derating Factors
Derating factors for various conditions of installations including the following shall be
considered while selecting the cable sizes:
a) Variation in ambient temperature for cables laid in air
b) Grouping of cables
c) Variation in ground temperature and soil resistivity for buried cables.
2.14.03 Cable lengths shall be considered in such a way that straight through cable joints are
avoided.
2.14.04 All Cables shall be armoured type.
2.14.05 All LT power cables of sizes more than 120 sq.mm. shall be XLPE insulated and sizes shall
be 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm. However for cable sizes upto 120
sq.mm. both XLPE insulated & PVC insulated LT power cables are acceptable.
2.14.06 Same cable sizes to be used for same type of application & rating of motor i.e if
there are three pumps for one application, all three pumps motor should be provided
with same cables sizes.
3.01.00 1.1 KV Grade Power Cables
(a) 1.1 KV grade XLPE power cables shall have compacted aluminium conductor, XLPE
insulated, PVC inner-sheathed (as applicable), armoured, PVC outer-sheathed
conforming to IS:7098. (Part-I).
(b) 1.1KV grade PVC power cables shall have aluminium conductor(compacted type for
sizes above 10 sq.mm), PVC Insulated, PVC inner sheathed (as applicable)
armoured, PVC outer-sheathed conforming to IS:1554 (Part-I).
(c) 1.1 KV grade Trailing cables shall have tinned copper(class 5)conductor, insulated
with heat resistant elastomeric compound based on Ethylene Propyline
Rubber(EPR) suitable for withstanding 90 deg.C continuous conductor temperature
and 250deg C during short circuit, inner-sheathed with heat resistant elastomeric
compound, nylon cord reinforced, outer-sheathed with heat resistant, oil resistant
and flame retardant heavy duty elastomeric compound conforming to IS 9968.
4.00.00 CABLE DRUMS
(a) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be covered
with water proof cover. Both the ends of the cables shall be properly sealed with heat
shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water

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during transportation, storage and erection. Wood preservative anti-termite treatment

shall be applied to the entire drum. Wooden drums shall comply with IS: 10418.
(b) Each drum shall carry manufacturer's name, purchaser’s name, address and contract
number, item number and type, size and length of cable and net gross weight stencilled
on both sides of the drum. A tag containing same information shall be attached to the
leading end of the cable. An arrow and suitable accompanying wording shall be marked
on one end of the reel indicating the direction in which it should be rolled.
(c.) The standard drum length of LT power cable with a maximum tolerance of +/- 5%
may be decided by the bidder subject to condition that there shall not be any joint in
cable, where application length of cable is up to & including 1000 meter for single
core cable excluding 630 sqmm size, and 750 meter for multicore cable & single
core 630 sqmm
5.00.00 TESTS
1.0 All equipments to be supplied shall be of type tested design. During detailed
engineering, the contractor shall submit for Owner’s approval the reports of all the
type tests as listed in this specification and carried out within last ten years from the
date of bid opening. These reports should be for the test conducted on the
equipment similar to those proposed to be supplied under this contract and the
test(s) should have been either conducted at an independent laboratory or should
have been witnessed by a client.
2.0 However if the contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in the case of type test report(s)
are not found to be meeting the specification requirements, the contractor shall
conduct all such tests under this contract at no additional cost to the owner either at
third party lab or in presence of client /owners representative and submit the reports
for approval.
3.0 All acceptance and routine tests as per the specification and relevant standards shall
price.
4.0 The type test reports once approved shall be treated as reference. For subsequent
endorsement sheet.
5.01.00 Type Tests
5.01.01 The reports for the following type tests shall be submitted for one size each of LT XLPE and
LT PVC Power cables. Size shall be decided by the employer during detailed engineering:
S.No. Type test Remarks

For Conductor
1. Resistance test
2. Tensile test For circular non-compacted

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CLAUSE NO.
conductors only
3. Wrapping test For circular non-compacted only
For Armour Wires/ Formed Wires
4. Measurement of Dimensions
5. Tensile Test
6. Elongation test
7. Torsion test For round wires only
8. Wrapping test For aluminium wires / formed

wires only.
9. Resistance test
10(a) Mass of zinc coating test For GS Formed wires/wires only
10(b) Uniformity of zinc coating For GS Formed wires /wires only
11. Adhesion test For GS Formed wires/wires only
For PVC/XLPE insulation & PVC Sheath

12. Test for thickness
13. Tensile strength & elongation tests before ageing and after ageing
14. Ageing in air oven
15. Loss of mass test For PVC insulation and sheath only
16. Hot deformation test For PVC insulation and sheath only
17. Heat shock test For PVC insulation and sheath only
18. Shrinkage test
19. Thermal stability test For PVC insulation and sheath only
20. Hot set test For XLPE insulation only
21. Water absorption test For XLPE insulation only
22. Oxygen index test For outer sheath only
23. Smoke density test For outer sheath only
24. Acid gas generation test For outer sheath only

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For completed cables
25. Insulation resistance test

(Volume resistivity method)
26. High voltage test
27. Flammability test as per IEC-332 Part-3 (Category-B)
Indicative list of tests/checks, Routine and Acceptance tests shall be as per Quality
Assurance & Inspection table of LT power cables enclosed.

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LT CONTROL CABLES

CLAUSE NO.
editions including all applicable official amendments and revisions as on date of opening
of bid. In case of conflict between this specification and those (IS : codes, standards, etc.)
referred to herein, the former shall prevail. All the cables shall conform to the
requirements of the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages
upto and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanised steel wires, formed wires and tapes for
ASTM-D –2843 Standard test method for density of smoke from the burning or

ground buried installation with chances of flooding by water.
2.02.00 All cables including EPR cables shall be flame retardant, low smoke (FRLS) type
designed to withstand all mechanical, electrical and thermal stresses develop under
steady state and transient operating conditions as specified elsewhere in this
specification.
2.03.00 Conductor of control cables shall be made of stranded, plain annealed copper.
2.04.00 PVC insulation shall be suitable for continuous conductor temperature of 70 deg C and
short circuit conductor temperature of 160 deg. C.
2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It
shall not stick to insulation and inner sheath. All the cables, other than single core
unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per
IS: 5831.

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WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 LT CONTROL CABLES
CLAUSE NO.
2.06.00 For multicore armoured cables, the armouring shall be of galvanised steel as follows:
Calculated nominal dia of Size and Type of armour

cable under armour
Upto 13 mm 1.4mm dia GS wire
Above 13 upto 25 mm 0.8 mm thick GS formed wire / 1.6 mm dia GS wire
Above 25 upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia GS wire
Above 40 upto 55mm 1.4 mm thick GS formed wire/2.5mm dia GS wire
Above 55 upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia GS wire
Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire
The gap between armour wires / formed wires shall not exceed one armour wire / formed
wire space and there shall be no cross over / over-riding of armour wire / formed wire.
The minimum area of coverage of armouring shall be 90%. The breaking load of armour
joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall
be applied on armour joint surface.
2.07.00 Outer sheath shall be of PVC as per IS: 5831 and grey in colour. In addition to meeting all
the requirements of Indian Standards referred to, outer sheath of all the cables shall have
the following FRLS properties.
(a.) Oxygen index of min. 29. (As per IS 10810 Part-58)
(b.) Acid gas emission of max. 20% (As per IEC-754-I)
(c.) Smoke density rating shall not be more than 60% during Smoke Density Test as
per ASTMD-2843.
2.08.00 Cores of the cables of upto 5 cores shall be identified by colouring of insulation. Following
colour scheme shall be adopted.
1 core - Red, Black, Yellow or Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
5 core - Red, Yellow, Blue, Black and Grey
2.09.00 For cables having more than 5 cores, core identification shall be done by numbering the
insulation of cores sequentially, starting by number 1 in the inner layer (e.g. say for 10
core cable, core numbering shall be from 1 to 10). The number shall be printed in Hindu-
Arabic numerals on the outer surfaces of the cores. All the numbers shall be of the same
colour, which shall contrast with the colour of insulation. The colour of insulation for all the

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CLAUSE NO.
cores shall be grey only. The numerals shall be legible and indelible. The numbers shall
be repeated at regular intervals along the core, consecutive numbers being inverted in
relation to each other. When the number is a single numeral, a dash shall be placed
underneath it. If the number consists of two numerals, these shall be disposed one below
the other and a dash placed below the lower numeral. The spacing between consecutive
numbers shall not exceed 50 mm.
2.10.00 In addition to manufacturer's identification on cables as per IS, following marking shall
also be provided over outer sheath:
(c.) Sequential marking of length of the cable in metres at every one metre - To be
embossed / printed.
The embossing / printing shall be progressive, automatic, in line and marking shall be legible
and indelible. For EPR cables identification shall be printed on outer sheath.
2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC-332 Part-3.
2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum
over the declared value in the technical data sheets.
2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are
not acceptable.
Control cables shall be sized based on the following considerations:

(a) The minimum conductor cross-section shall be 1.5 sq.mm.
(b) The minimum number of spare cores in control cables shall be as follows:
No. of cores in cable Min. No. of spare cores
2C, 3C NIL
5C 1
7C-12C 2
14C & above 3
2.14.01 Cable lengths shall be considered in such a way that straight through cable joints are
avoided.

3.01.00 1.1 KV Grade Control Cables shall have stranded copper conductor and shall be
multicore PVC insulated, PVC inner sheathed, armoured / unarmoured, FRLS PVC outer
sheathed conforming to IS: 1554. (Part-I).
3.02.00 1.1 KV grade Trailing cables shall have tinned copper(class 5)conductor, insulated with heat
resistant elastomeric compound based on Ethylene Propyline Rubber(EPR) suitable for

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CLAUSE NO.
withstanding 90 deg.C continuous conductor temperature and 250deg C during short circuit,
inner-sheathed with heat resistant elastomeric compound, nylon cord reinforced, outer-
sheathed with heat resistant, oil resistant and flame retardant heavy duty elastomeric
compound conforming to IS 9968. Minimum conductor size shall be 2.5 sqmm.
4.00.00 CABLE DRUMS
(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be
covered with water proof cover. Both the ends of the cables shall be properly
sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to
eliminate ingress of water during transportation, storage and erection. Wood
preservative anti-termite treatment shall be applied to the entire drum. Wooden
drums shall comply with IS: 10418.
(b.) Each drum shall carry manufacturer's name, purchaser’s name, address and
contract number, item number and type, size and length of cable and net gross
weight stenciled on both the sides of the drum. A tag containing same information
shall be attached to the leading end of the cable. An arrow and suitable
accompanying wording shall be marked on one end of the reel indicating the
direction in which it should be rolled.
(c.) The standard drum length for control cables with a maximum tolerance of +/- 5%
may be decided by the bidder subject to condition that there shall not be any joint in
cable, where application length of cable is up to & including 1000 meter.
5.00.00 TESTS
All equipments to be supplied shall be of type tested design. During detailed engineering,
the contractor shall submit for Owner’s approval the reports of all the type tests as listed
in this specification and carried out within last ten years from the date of bid opening.
These reports should be for the test conducted on the equipment similar to those
proposed to be supplied under this contract and the test(s) should have been either
conducted at an independent laboratory or should have been witnessed by a client.
However if the contractor is not able to submit report of the type test(s) conducted within
last ten years from the date of bid opening, or in the case of type test report(s) are not
found to be meeting the specification requirements, the contractor shall conduct all such
tests under this contract at no additional cost to the owner either at third party lab or in
presence of client /owners representative and submit the reports for approval.
All acceptance and routine tests as per the specification and relevant standards shall be
carried out. Charges for these shall be deemed to be included in the equipment price
The type test reports once approved shall be treated as reference. For subsequent
projects, an endorsement sheet will be furnished by the manufacturer confirming similarity
and “No design Change”. Minor changes if any shall be highlighted on the endorsement
sheet.
5.01.00 TYPE TESTS
5.01.01 The reports for the following type tests shall be submitted for one size of control cables.
Size shall be decided by the employer during detailed engineering

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CLAUSE NO.
S. No. Type Test Remarks
For Conductor
1. Resistance test
For Armour Wires / Formed Wires (If applicable)
3. Tensile Test
4. Elongation test
5. Torsion test For round wire only
6. Wrapping test For aluminium wires / formed wires

only.
7. Resistance test
8(a). Mass of zinc Coating test For GS wires/formed wires only
8(b). Uniformity of zinc coating For GS wires/formed wires only
9. Adhesion test For GS wires/formed wires only
For PVC insulation & PVC

Sheath
11. Tensile strength and before ageing and after ageing

elongation test
13. Loss of mass test For PVC insulation and sheath

only
14. Hot deformation test For PVC insulation and sheath

only
15. Heat shock test For PVC insulation and sheath

only
16. Shrinkage test
17. Thermal stability test For PVC insulation and sheath

only
18. Oxygen index test For outer sheath only

5 OF 6
CLAUSE NO.
S. No. Type Test Remarks
19. Smoke density test For outer sheath only
20. Acid gas generation test For outer sheath only
For completed cables
21. Insulation resistance test(Volume resistivity method)
23. Flammability test as per IEC-332 Part-3 (Category-B)
5.02.00 Indicative list of tests/checks, Routine and Acceptance tests shall be as per Quality
Assurance & Inspection table of Control Cables enclosed.

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CABLING, EARTHING AND

LIGHTNING PROTECTION

CLAUSE NO.
bid. In case of conflict between this specification and those (IS codes, standards, etc.)
referred to herein, the former shall prevail. All work shall be carried out as per the following
standards/ codes as applicable .
IS:513 Cold rolled low carbon steel sheets and strips.
IS:802 Code of practice for the use of Structural Steel in Overhead

Transmission Line Towers.
IS:1079 Hot Rolled carbon steel sheet & strips
IS:1239 Mild steel tubes, tubulars and other wrought steel fittings
IS:1255 Code of practice for installation and maintenance of power

cables upto and including 33 KV rating
IS:1367 Part-13 Technical supply conditions for threaded Steel fasteners. (Hot
dip galvanized coatings on threaded fasteners).
IS:2147 Degree of protection provided by enclosures for low voltage

switchgear and control gear
IEC:62305 Code of Practice for the protection of building and allied

structures against lightning.
IS:2309 Code of Practice for the protection of building and allied

structures against lightning.
IS:2629 Recommended practice for hot dip galvanising of iron & steel
IS:2633 Method for testing uniformity of coating on zinc coated articles.
IS:3043 Code of practice for Earthing
IS:3063 Fasteners single coil rectangular section spring washers.
IS:6745 Methods for determination of mass of zinc coating on zinc coated

iron & steel articles.
IS:8308 Compression type tubular inline connectors for aluminium

conductors of insulated cables
IS:8309 Compression type tubular terminal ends for aluminium

conductors of insulated cables.
IS:9537 Conduits for electrical installation.
IS:9595 Metal - arc welding of carbon and carbon manganese steels -

recommendations.
IS:13573 Joints and terminations for polymeric cables.
BS:476 Fire tests on building materials and structures

CABLING, EARTHING & 1 OF 23
CLAUSE NO.
IEEE:80 IEEE guide for safety in AC substation grounding
IEEE:142 Grounding of Industrial & commercial power systems
DIN 46267 (Part-II) Non tension proof compression joints for Aluminium conductors.
DIN 46329 Cable lugs for compression connections, ring type ,for
Aluminium conductors
BS:6121 Specification for mechanical Cable glands for elastomers and

plastic insulated cables.
Indian Electricity Act.
Indian Electricity Rules.
1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, DIN,
USA, VDE, NEMA etc. will also be considered if they ensure performance and
constructional features equivalent or superior to standards listed above. In such a case, the
Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest
revision of the standards alongwith copies of all official amendments and revisions in force
as on date of opening of bid and shall clearly bring out the salient features for comparison.
2.00.00 DESIGN AND CONSTRUCTIONAL FEATURE
2.01.00 Inter Plant Cabling
2.01.01 Interplant cabling for main routes shall be laid along overhead trestles/duct banks. Cables
from main plant to switchyard control room shall be laid in overhead trestles or duct bank. In
case of Duct banks, pull-pits shall be filled with sand and provided with a PCC covering.
Directly buried cables, if essential, shall not have concentration of more than 4 cables in one
route. All HT, LT and Control cables shall be armored.
2.01.02 Transformer yard
In transformer yard cables shall be laid in overhead trestle. The main cable routes coming
out from Main plant building and crossing the Transformer yard shall be laid in overhead
trestles. In transformer yard, trestle height for rail/road crossing shall be suitable for
movement of Generator Transformer with bushing.
2.01.03 Trenches
PCC flooring of built up trenches shall be sloped for effective drainage with sump pits and
sump pumps.
2.01.04 No sub zero level cable vault/trenches shall be provided below control building/switchgear
rooms in main plant.
2.01.05 Cable Vault
The cable vault/ / cable spreader room space below the HT / LT switchgear room, Control
Rooms, unit control equipment room, Programmer room, UPS, Charger & Battery Rooms,
Boiler MCC room shall have 800 mm wide and 2.1 m high movement passage all around
the cable trays in the cable vault/ cable spreader room for easy laying/maintenance of
cables

CLAUSE NO.
Cable vaults shall be provided with adequate drainage facilities for drainage of fire water.
Each cable vault should have at least two doors.
Exit signs shall be provided near doors for personnel escape in case of emergency
2.01.06 Boiler Area
Two separate cable routes one on each side shall be provided for each boiler unit. Cables
for on set of auxiliaries such as ID, FD, PA fan & half of the coal mills shall be routed in one
route & for other set of auxiliaries through other route.
Cable trays in boiler & ESP area shall be supported from the boiler and ESP structures.
The same shall be coordinated with SG/ESP contractor.
Cable trays in these areas shall be in vertical formation to avoid dust accumulation. No
cable trenches shall be provided in boiler/ESP area.
2.01.07 Turbine Hall Area

a)Two separate cable routes shall be provided for cable routing of working and standby
drives or different set/group (say 50% capacity) of auxiliaries.
2.01.08 OffSite Area
In offsite pumphouses, overhead cable tray arrangement shall be followed. However cable
trenches may be considered below switchgear/mcc.
Trestle In fuel oil pump house, overhead cable tray arrangement shall be provided. RCC
trenches provided in MCC room shall be separated from fuel oil area to avoid oil
accumulation.
2.01.09 The cable slits to be used for motor/equipment power/control supply shall be sand filled &
covered with PCC after cabling.
2.01.10 Sizing criteria, derating factors for the cables shall be met as per respective chapters.
However for the power cables, the minimum conductor size shall be 6 sq.mm. for aluminium
conductor and 2.5 sq.mm. for copper conductor cable.
2.01.11 Conscious exceptions to the above guidelines may be accepted under special conditions
but suitable measures should be taken at such location to:
 Meet all safety requirements

 Safeguard against fire hazards, mechanical damage, flooding of water, oil accumulation,
electrical faults/interferences, etc
3.00.00 EQUIPMENT DESCRIPTION
3.01.00 Cable trays, Fittings & Accessories
3.01.01 Cable trays shall be ladder/perforated type as specified complete with matching fittings (like
brackets, elbows, bends, reducers, tees, crosses, etc.) accessories (like side coupler plates,
etc. and hardware (like bolts, nuts, washers, G.I. strap, hook etc.) as required. Cable tray
shall be ladder type for power & control cables and perforated for instrumentation cables.
3.01.02 Cable trays, fittings and accessories shall be fabricated out of rolled mild steel sheets free
from flaws such as laminations, rolling marks, pitting etc. These (including hardware) shall
be hot dip galvanized as per Clause No. 3.13.00 of this chapter.

CLAUSE NO.
3.01.03 Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard lengths
of 2.5 metre. Thickness of mild steel sheets used for fabrication of cable trays and fittings
shall be 2 mm. The thickness of side coupler plates shall be 3 mm.
3.01.04 Cable troughs shall be required for branching out few cables from main cable route. These
shall be U-shaped, fabricated of mild steel sheets of thickness 2 mm and shall be hot dip
galvanised as per Clause No. 3.13.00 of this chapter. Troughs shall be standard width of 50
mm & 75 mm with depth of 25 mm.
3.01.05 The tolerance for cable tray and accessories shall be as per IS 2102 (Part-1).
Tolerance Class: - Coarse
3.02.00 Support System for Cable Trays
3.02.01 Cable tray support system shall be pre-fabricated out of single sheet as per enclosed tender
drawings.
3.02.02 Support system for cable trays shall essentially comprise of the two components i.e. main
support channel and cantilever arms. The main support channel shall be of two types : (i)
C1:- having provision of supporting cable trays on one side and (ii) C2:-having provision of
supporting cable trays on both sides. The support system shall be the type described
hereunder
a. Cable supporting steel work for cable racks/cables shall comprise of various
channel sections, cantilever arms, various brackets, clamps, floor plates, all
hardwares such as lock washers, hexagon nuts, hexagon head bolt, support hooks,
stud nuts, hexagon head screw, channel nut, channel nut with springs, fixing studs,
etc.
b. The system shall be designed such that it allows easy assembly at site by using
bolting. All cable supporting steel work, hardwares fitings and accessories shall be
prefabricated factory galvanised.
c. The main support and cantilever arms shall be fixed at site using necessary
brackets, clamps, fittings, bolts, nuts and other hardware etc. to form various
arrangements required to support the cable trays. Welding of the components shall
not be allowed. However, welding of the bracket (to which the main support channel
is bolted) to the overhead beams, structural steel, insert plates or reinforcement
bars will be permitted. Any cutting or welding of the galvansied surface shall be
brushed and red lead primer, oil primer & aluminium paint shall be applied
d. All steel components, accessories, fittings and hardware shall be hot dip galvanised
after completing welding, cutting, drilling and other machining operation.
e. The typical arrangement of flexible support system is shown in the enclosed

drawings and described briefly below:
The main support channel and cantilever arms shall be fabricated out of 2.5 thick
rolled steel sheet conforming to IS 1079.
f. Cantilever arms of 320 mm, 620mm and 750 mm in length are required, and shall
be as shown in the enclosed drawing. The arm portion shall be suitable for
assembling the complete arm assembly on to component constructed of standard
channel section. The back plate shall allow sufficient clearance for fixing bolt to be
tightened with tray in position.
g. Support system shall be able to withstand

CLAUSE NO.
 weight of the cable trays

 weight of the cables (75 Kg/Metre run of each cable tray)
 Concentrated load of 75 Kg between every support span.
 Factor of safety of minimum 1.5 shall be considered.
3.02.03 The size of structural steel members or thickness of sheet steel of main support channel
and cantilever arms and other accessories as indicated above or in the enclosed drawings
are indicative only. Nevertheless, the support system shall be designed by the bidder to fully
meet the requirements of type tests as specified. In case the system fails in the tests, the
components design modification shall be done by the Bidder without any additional cost to
the Employer. The bidder shall submit the detailed drawings of the system offered by him
alongwith the bid.
3.02.04 Four legged structure shall be provided wherever there is change in elevation and change in
direction
3.03.04 FOR COAL, LIMESTONE AND GYPSUM HANDLING PLANT THE FOLLOWING SHALL
ALSO BE APPLICABLE:
a) All overhead cable routes shall be along the route of the conveyor gallery on
separate supporting structures and cables shall be laid in vertical trays. The bottom
of the steel shall be such that the existing facilities, movement of trucks/human
beings etc. does not get affected. The cable trestle shall have a minimum 600mm
clear walk way and shall have maintenance platforms as required. The bottom of
the steel supporting structure shall be generally at 3.0M above the grade level
except for rail/road crossings where it shall be at 8.0M above grade level. Tap offs
from the overhead cable trestle can be through shallow trenches with prior approval
of the Employer. Directly buried cable, if essential, shall not have concentration of
more than 4 cables on one route.
b) Cable trenches shall be provided only in Switchgear/MCC rooms.
c) Cables shall not be routed through the conveyor galleries except for the equipment
located in the conveyor galleries for a particular conveyor i.e. protection switches,
receptacles etc.
d) Cables for PCS and BSS shall be routed along the conveyors through GI conduits.
3.04.00 Pipes, Fittings & Accessories
3.03.01 Pipes offered shall be complete with fittings and accessories (like tees, elbows, bends,
check nuts, bushings, reducers, enlargers, coupling caps, nipples etc.) The size of the pipe
shall be selected on the basis of maximum 40% fill criteria
3.03.02 GI Pipes shall be of medium duty as per IS: 1239
3.03.03 Duct banks shall be PVC conduits encased in PCC (10% spare of each size, subject to
minimum one) with suitable water-proof manholes and with proper sealing arrangement
consisting of fire retardant sealing compound.
3.03.04 Hume pipes shall be NP3 type as per IS 458.
3.03.05 TERNE Coated Flexible Steel Conduits shall be water proof and rust proof made of
heat resistant lead coated steel. Conduit diameter shall be uniform throughout its
length. Internal surface of the conduit shall be free from burrs and sharp edges.

CLAUSE NO.
Conduits shall be complete with necessary accessories for proper termination of the
conduit with junction boxes and lighting fixtures.
3.03.06 HDPE pipes and conduits shall be PE-80, PN-10 type as per IS 4984/IS 8008 part-I.
3.04.00 Junction Boxes
3.04.01 Junction box shall be made of Fire retardant material. Material of JB shall be Thermoplastic
or thermosetting or FRP type. The box shall be provided with the terminal blocks, mounting
bracket and screws etc. The cable entry shall be through galvanized steel conduits of
suitable diameter. The JB shall have suitable for installing glands of suitable size on the
bottom of the box. The JB shall be suitable for surface mounting on ceiling/structures. The
JB shall be of grey color RAL 7035. All the metal parts shall be corrosion protected. Junction
box surface should be such that it is free from crazings, blisterings, wrinkling, colour
blots/striations. There should not be any mending or repair of surface. JB’s will be provided
with captive screws so that screws don’t fall off when cover is opened. JB’s mounting
brackets should be of powder coated MS. Type test reports for the following tests shall be
furnished:-
(a) Impact resistance for impact energy of 2 Joules (IK07)as per BS EN50102
(b) Thermal ageing at 70deg C for 96 hours as per IEC60068-2-2Bb.
(c) Class of protection shall be IP 55.
(d) HV test.
3.04.02 Terminal blocks shall be 1100V grade, of suitable current rating, made up of unbreakable
polyamide 6.6 grade. The terminals shall be screw type or screw-less (spring loaded) / cage
clamp type with lugs. Marking on terminal strips shall correspond to the terminal numbering
in wiring diagrams. All metal parts shall be of non-ferrous material. In case of screw type
terminals the screw shall be captive, preferably with screw locking design. All terminal
blocks shall be suitable for terminating on each side the required cables/wire size. All
internal wiring shall be of cu. Conductor PVC wire.
3.05.00 Terminations & Straight Through Joints
3.05.01 Termination and jointing kits for 33kV, 11 kV, 6.6 KV and 3.3 kV grade XLPE insulated
cables shall be of proven design and make which have already been extensively used and
type tested. Termination kits and jointing kits shall be Pre-moulded type or heat shrinkable
type. Further Cold shrinkable type termination and jointing kits are also acceptable. The
Cold shrinkable type kits shall be type tested as per relevant standards. Calculation to
withstand the required fault level shall also be furnished in case of cold shrinkable type kits.
33 kV, 11 kV, 6.6 KV and 3.3kV grade joints and terminations shall be type tested and Type
test reports as per IS:13573 Part-II and IEC60502 shall be furnished. Also, heat shrink
material shall comply with requirements of ESI 09-13 (external tests). Critical components
used in cable accessories shall be of tested and proven quality as per relevant product
specification/ESI specification. Cable joints and terminations should be with FRLS
properties as per IEC 60754-1&2. Kit contents shall be supplied from the same source as
were used for type testing. The kit shall be complete with the tinned copper solderless
crimping type cable lugs & ferrule or mechanical connectors (wherein bolts are tightened
that shear off at an appropriate torque) as per DIN standard suitable for aluminium
compacted conductor cables. (Tender drg. no 0000-211-POE –A-51-RA of cable lug
attached at the end of this chapter)..

CLAUSE NO.
3.05.02 Straight through joint and termination shall be capable of withstanding the fault level of 21
KA for 0.12 Sec. with dynamic peak of 52 KA for 33 KV system & of 40 kA for 0.12 sec with
a dynamic peak of 100 kA for 11 kV, 6.6 KV & 3.3 KV system. Straight through joints shall
have provisions for shield connection and earthing wherever required and complete with all
accessories and consumables suitable for storage without deterioration at a temperature of
50 deg. C with shelf life of more than five years. 1.1 kV grade straight through joints shall
also be of proven design
3.05.03 1.1 KV grade Straight Through Joint shall be of proven design.
3.06.00 Cable glands
3.06.01 Cable shall be terminated using double compression type cable glands. Testing
requirements of Cable glands shall conform to BS:6121 and gland shall be of robust
construction capable of clamping cable and cable armour (for armoured cables) firmly
without injury to insulation. Cable glands shall be made of heavy duty brass machine
finished and nickel chrome plated. Thickness of plating shall not be less than 10 micron. All
washers and hardware shall also be made of brass with nickel chrome plating Rubber
components shall be of neoprene or better synthetic material and of tested quality. Cable
glands shall be suitable for the sizes of cable supplied/erected.
3.07.00 Cable lugs/ferrules
3.07.01 Cable lugs/ferrules for power cables shall be tinned copper solderless crimping type suitable
for aluminium compacted conductor cables. Cable lugs and ferrules for control cables shall
be tinned copper type. The cable lugs for control cables shall be provided with insulating
sleeve and shall suit the type of terminals provided on the equipments. Cable lugs and
ferrule shall conform to DIN standards.
3.08.00 Trefoil clamps
3.08.01 Trefoil clamps for single core cables shall be pressure die cast aluminum or fibre glass or
nylon and shall include necessary fixing accessories like G.I. nuts, bolts, washers, etc.
Trefoil clamps shall have adequate mechanical strength, when installed at 1 mtr intervals,
to withstand the forces generated by the peak value of maximum system short circuit
current.
3.09.00 Cable Clamps & Ties

3.09.01 The cable clamps/ties required to clamp multicore cables shall be of SS-316 material, 12mm
wide, polyster coated ladder lock type. The clamps/ties shall have self locking arrangement
& shall have sufficient strength. The cable clamps/ties shall be supplied in finished individual
pieces of suitable length to meet the site requirements.
3.10.00 Receptacles
3.10.01 Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot dipped
gavanised or of die-cast aluminium alloy of thickness not less than 2.5 mm. The boxes shall
be provided with two nos. earthing terminals, gasket to achieve IP55 degree of protection,
terminal blocks for loop-in loop-out for cable of specified sizes, mounting brackets suitable
for surface mounting on wall/column/structure, gland plate etc. The ON-OFF switch shall be
rotary type heavy duty, double break,AC23 category, suitable for AC supply. Plug and
Socket shall be shrouded Die-cast aluminium. Socket shall be provided with lid safety cover.
Robust mechanical interlock shall be provided such that the switch can be put ON only
when the plug is fully engaged and plug can be withdrawn only when the switch is in OFF
position. Also cover can be opened only when the switch is in OFF position. Wiring shall be
carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of adequate
size. The Terminal blocks shall be of 1100 V grade. The Terminal blocks shall be of 1100 V

CLAUSE NO.
grade made up of unbreakable polymide 6.6 grade with adequate current rating and size.
The welding receptacles shall be provided with RCCB/RCD of 30mA sensitivity having
facility for manual testing/checking of operation of RCCB/RCD
3.12.00 Cable Drum Lifting Jack

The jack for cable drum lifting shall be of screw type with 10 ton capacity. The cable drum
jacks shall be manufactured from fabricated steel. The spindles supplied with the cable
drum jack shall be manufactured using BSEN-24 grade steel bar with locking collars. Jack
nests shall be of SG cast steel. Cable drum jack supplied shall have undergone load testing
and reports for the same shall be submitted. At least Two Nos. of jacks shall be supplied for
EMPLOYER use. Contractor has to make arrangements for his own jacks for cable
reeling/unreeling under his scope of installation.
3.13.00 Galvanising
3.13.01 Galvanising of steel components and accessories shall conform to IS:2629 , IS4759 &
IS:2633. Additionally galvanising shall be uniform, clean smooth, continuous and free from
acid spots.
3.13.02 The amount of zinc deposit over threaded portion of bolts, nuts, screws and washers shall
be as per IS:1367 . The removal of extra zinc on threaded portion of components shall be
carefully done to ensure that the threads shall have the required zinc coating on them as
specified
3.14.00 Welding
3.14.01 The welding shall be carried out in accordance with IS:9595. All welding procedures and
welders qualification shall also be followed strictly in line with IS:9595
4.00.00 INSTALLATION
4.01.00 Cable tray and Support System Installation
4.01.01 Cables shall run in cable trays mounted horizontally or vertically on cable tray support
system which in turn shall be supported from floor, ceiling, overhead structures, trestles,
pipe racks, trenches or other building structures.
4.01.02 Horizontally running cable trays shall be clamped by bolting to cantilever arms and vertically
running cable trays shall be bolted to main support channel by suitable bracket/clamps on
both top and bottom side rails at an interval of 2000 mm in general. For vertical cable
risers/shafts cable trays shall be supported at an interval of 1000mm in general. Fixing of
cable trays to cantilever arms or main support channel by welding shall not be accepted.
Cable tray installation shall generally be carried out as per the approved guidelines/
drawings. Vendor shall design the support system along with tray, spacing etc in line with
tray loadings/drawings.
4.01.03 The cantilever arms shall be positioned on the main support channel with a minimum
vertical spacing of 300 mm unless otherwise indicated.
4.01.04 The contractor shall fix the brackets/ clamps/ insert plates using anchor fasteners. Minimum
size of anchor fasteners shall be M 8 X 50 and material shall be stainless steel grade 316 or
better. Anchor fastener shall be fixed as recommended by manufacturer and as approved
by site engineer. For brick wall suitable anchor fasteners shall be used as per the
recommendations of manufacturer. Make of anchor fasteners subject to QA approval and
the same shall be finalized at pre-award stage.

CLAUSE NO.
4.01.05 All cable way sections shall have identification, designations as per cable way layout
drawings and painted/stenciled at each end of cable way and where there is a branch
connection to another cable way. Minimum height of letter shall be not less than 75 mm. For
long lengths of trays, the identification shall be painted at every 10 meter. Risers shall
additionally be painted/stenciled with identification numbers at every floor.
4.01.06 In certain cases it may be necessary to site fabricate portions of trays, supports and other
non standard bends where the normal prefabricated trays, supports and accessories may
not be suitable. Fabricated sections of trays, supports and accessories to make the
installation complete at site shall be neat in appearance and shall match with the
prefabricated sections in the dimensions. They shall be applied with one coat of red lead
primer, one coat of oil primer followed by two finishing coats of aluminium paint.
4.02.00 Conduits/Pipes/Ducts Installation
4.02.01 The Contractor shall ensure for properly embedding conduit pipe sleeves wherever
necessary for cabling work. All openings in the floor/roof/wall / cable tunnel/cable trenches
made for conduit installation shall be sealed and made water proof by the Contractor.
4.02.02 GI pull wire of adequate size shall be laid in all conduits before installation. Metallic conduit
runs at termination shall have two lock nuts wherever required for junction boxes etc.
4.02.03 Conduit runs/sleeves shall be provided with PVC bushings having round edge at each end.
All conduits/pipes shall have their ends closed by caps until cables are pulled. After cables
are pulled, the ends of conduits/pipes shall be sealed with Glass wool/Cement Mortar/Putty
to prevent entrance of moisture and foreign material
4.02.04 Exposed conduit/pipe shall be adequately supported by racks, clamps, straps or by other
approved means. Conduits /pipe support shall be installed square and true to line and grade
with an average spacing between the supports as given below, unless specified otherwise
Conduit /pipe size (dia). Spacing
Upto 40 mm 1M
50 mm 2.0 M
65-85 mm 2.5 M
100 mm and above 3.0 M
4.02.05 For bending of conduits, bending machine shall be arranged at site by the contractor to
facilitate cold bending. The bends formed shall be smooth.
4.03.00 Junction Boxes Installation
4.03.01 Junction boxes shall be mounted at a height of 1200mm above floor level or as specified in
the drawings and shall be adequately supported/mounted on masonry wall by means of
anchor fasteners/ expandable bolts or shall be mounted on an angle, plate or other
structural supports fixed to floor, wall, ceiling or equipment foundations.
4.04.00 Cable Installation
4.04.01 Cable installation shall be carried out as per IS:1255 and other applicable standards.
4.04.02 For Cable unloading, pulling etc following guidelines shall be followed in general:

CLAUSE NO.
a) Cable drums shall be unloaded, handled and stored in an approved manner on hard
and well drained surface so that they may not sink. In no case shall be drum be
stored flat i.e. with flange horizontal. Rolling of drums shall be avoided as far as
possible. For short distances, the drums may be rolled provided they are rolled
slowly and in proper direction as marked on the drum. In absence of any indication,
the drums may be rolled in the same direction as it was rolled during taking up the
cables. For unreeling the cable, the drum shall be mounted on suitable jacks or on
cable wheels and shall be rolled slowly so that cable comes out over the drum and
not from below. All possible care shall be taken during unreeling and laying to avoid
damage due to twist, kink or sharp bends. Cable ends shall be provided with sealed
plastic caps to prevent damage and ingress of moisture.
b) While laying cable, ground rollers shall be used at every 2 meter interval to avoid
cable touching ground. The cables shall be pushed over the rollers by a gang of
people positioned in between the rollers. Cables shall not be pulled from the end
without having intermediate pushing arrangements. Pulling tension shall not exceed
the values recommended by cable manufacturer. Selection of cable drums for each
run shall be so planned so as to avoid using straight through joints. Care should be
taken while laying the cables so as to avoid damage to cables. If any particular
cable is damaged, the same shall be repaired or changed to the satisfaction of
Project Manager.
4.04.03 Cables shall be laid on cable trays strictly in line with cable schedule . Where specific cable
layouts are not shown on drawings, Contractor shall route these as directed by the Project
Manager
4.04.04 Power and control cables shall be laid on separate tiers inline with the approved
guidelines/drawings. The laying of different voltage grade cables shall be on different tiers
according to the voltage grade of the cables. In horizontal tray stacks, H.T. cables shall be
laid on top most tier and cables of subsequent lower voltage grades on lower tiers of trays.
Single core cable in trefoil formation shall be laid with a distance of four times the diameter
of cable between trefoil center lines and clamped at every one metre. All multicore cables
shall be laid in touching formation. Power and control cables shall be secured fixed to
trays/support with cable clamps/ties with self locking arrangement. For horizontal trays
arrangements, multicore power cables and control cables shall be secured at every five
meter interval. For vertical tray arrangement, individual multicore power cables and control
cables shall be secured at every one meter. After completion of cable laying work in the
particular vertical tray, all the control cables shall be binded to trays/supports by cable
clamps/ties with self locking arrangement at every five meter interval and at every bend.
Fibre Optical cable shall be laid in trenches/trays or as decided by Employer.
4.04.05 Bending radii for cables shall be as per manufacturer's recommendations and IS:1255.
4.04.06 Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/ HDPE pipe.
4.04.07 No joints shall be allowed in trip circuits, protection circuits and CT/PT circuits. Also joints in
critical equipment in main plant area shall not be permitted. Vendor shall identify and
accordingly procure the cable drum length.
4.04.08 In each cable run some extra length shall be kept at suitable point to enable one LT/two HT
straight through joints to made, should the cable develop fault at a later stage. Control cable
termination inside equipment enclosure shall have sufficient lengths so that shifting of
termination in terminal blocks can be done without requiring any splicing.
4.04.09 Wherever few cables are branching out from main trunk route troughs shall be used.

CLAUSE NO.
4.04.10 Wind loading shall be considered for designing support as well Cable trays wherever
required.
4.04.11 Where there is a considerable risk of steam, hot oil or mechanical damage cable routes
shall be protected by barriers or enclosures.
4.04.12 The installation work shall be carried out in a neat workman like manner & areas of work
shall be cleaned of all scraps, water, etc. after the completion of work in each area every
day. Contractor shall replace RCC/Steel trench covers after the Installation work in that
particular area is completed or when further work is not likely to be taken up for some time.
4.04.13 Separation
At least 300mm clearance shall be provided between:
- HT power & LT power cables,
- LT power & LT control/instrumentation cables,
4.04.14 Segregation
1) Segregation means physical isolation to prevent fire jumping.
2) All cables associated with the unit shall be segregated from cables of other units.
3) Interplant cables of station auxiliaries and unit critical drives shall be segregated in
such a way that not more than half of the drives are lost in case of single incident of
fire. Power and control cables for AC drives and corresponding emergency AC or
DC drives shall be laid in segregated routes. Cable routes for one set of auxiliaries
of same unit shall be segregated from the other set.
4) In switchyard, control cables of each bay shall be laid on separate racks/trays.
4.04.15 Minimum number of spare cores required to be left for interconnection in control cables shall
be as follows:
Minimum number of spare cores required to be left for interconnection in control cables shall
be as follows:
No. of cores in cable No. of spare cores
2C,3C NIL
5C 1
7C-10C 2
14C and above 3
4.04.16 Directly Buried Cables
a) Cable trenches shall be constructed for directly buried cables. Construction of cable
trench for cables shall include excavation, preparation of sieved sand bedding,
riddled soil cover, supply and installation of brick or concrete protective covers,
back filling and compacting, supply and installation of route markers and joint
markers. Laying of cables and providing protective covering shall be as per IS:1255
and the enclosed drawings showing cabling details.

CLAUSE NO.
b) RCC cable route and RCC joint markers shall be provided wherever required. The
voltage grade of the higher voltage cables in route shall be engraved on the marker.
Location of underground cable joints shall be indicated with cable marker with an
additional inscription "Cable Joint". The marker shall project 150 mm above ground
and shall be spaced at an interval of 30 meters and at every change in direction.
They shall be located on both sides of road crossings and drain crossings. Top of
cable marker/joint marker shall be sloped to avoid accumulation of water/dust on
marker.
4.04.17 Cable tags shall be provided on all cables at each end (just before entering the equipment
enclosure), on both sides of a wall or floor crossing, on each duct/conduit entry, and at
every 20 meters in cable tray/trench runs. Cable tags shall also be provided inside the
switchgear, motor control centers, control and relay panels etc. where a number of cables
enter together through a gland plate. Cable tag shall be of rectangular shape for power
cables and control cables. Cable tag shall be of 2 mm thick aluminum with number punched
on it and securely attached to the cable by not less than two turns of 20 SWG GI wire
conforming to IS:280. Alternatively, the Contractor may also provide cable tags made of
nylon, cable marking ties with cable number heat stamped on the cable tags. The cable tag
requirements mentioned above shall prevail over Tag requirements mentioned elsewhere in
this document for HT power, LT power & control cables.
4.04.18 While crossing the floors, unarmoured cables shall be protected in conduits upto a height of
500 mm from floor level if not laid in tray.
4.05.00 Cable Terminations & Connections
4.05.01 The termination and connection of cables shall be done strictly in accordance with cable
termination kit manufacturer'' instructions, drawings and/or as directed by Project Manager.
Cable jointer shall be qualified to carryout satisfactory cable jointing/termination. Contractor
shall furnish for review documentary evidence/experience reports of the jointers to be
deployed at site.
4.05.02 Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumbing, soldering,
drilling, cutting, taping, preparation of cable end, crimping of lug, insulated sleeving over
control cable lugs, heat shrinking (where applicable), connecting to cable terminal, shorting
and grounding as required to complete the job to the satisfaction of the Project Manager.
4.05.03 The equipment will be generally provided with undrilled gland plates for cables/conduit
entry. The Contractor shall be responsible for punching of gland plates, painting and
touching up. Holes shall not be made by gas cutting. The holes shall be true in shape. All
cable entry points shall be sealed and made vermin and dust proof. Unused openings shall
be effectively sealed by 2mm thick aluminium sheets.
4.05.04 Control cable cores entering control panel/switchgear/MCC/miscellaneous panels shall be

neatly bunched, clamped and tied with self locking type nylon cable ties with de interlocking
facility to keep them in position.
4.05.05 All the cores of the control cable to be terminated shall have identification by providing
ferrules at either end of the core, each ferrule shall be indelible, printed single tube ferrule
and shall include the complete wire number and TB number as per the drawings. The ferrule
shall fit tightly on the core. Spare cores shall have similar ferrules with suffix sp1, sp2, ---etc
along with cable numbers and coiled up after end sealing.

CLAUSE NO.
4.05.06 All cable terminations shall be appropriately tightened to ensure secure and reliable
connections.
5.00.00 EARTHING SYSTEM
5.01.00 Earthing system shall be in strict accordance with IS:3043 and Indian Electricity Rules/Acts.
Earthing system network/earthmat shall be interconnected mesh of mild steel rods buried in
ground in the plant. All off-site areas shall be interconnected together by minimum two
parallel conductors. The Contractor shall furnish the detailed design and calculations for
Employer's approval. Contractor shall obtain all necessary statutory approvals for the
system.
5.02.00 The earth conductors shall be free from pitting, laminations, rust, scale and other electrical,
mechanical defects
5.03.00 The material of the earthing conductors shall be as follows :
1) Conductors above ground level - Galvanized steel

and in built up trenches.
2) Conductors buried in earth - Mild steel
3) Earth electrodes - Mild steel rod
5.04.00 The sizes of earthing conductors for various electrical equipments shall be as below:
Equipment Earth Earth conductor above

conductor ground level & in built-
buried in up trenches
earth
a) Main earth grid MS rod -Min 40 mm 65 x 8mm GS flat

dia.
or as per actual
calculation whichever
is more
b) 33kV/11kV/6.6kV/3.3 kV/ --- 65 x 8mm GS flat

switchgear equipment and
415V switchgear
c) 415 V MCC/ Distribution --- 50 x 6mm GS flat

boards / Transformers
d) LT Motors above 125 KW --- 50 x 6mm GS flat
25 KW to 125 KW --- 25 x 6mm GS flat
1KW to 25 KW --- 25 x 3mm GS flat
Fractional House power motor --- 8 SWG GS wire
e) Control panel & control desk --- 25 x 3 mm GS flat
f) Push button station / Junction --- 8 SWG GI wire

Box

CLAUSE NO.
g) Columns, structures, cable --- 50 x 6mm GS flat

trays and bus ducts enclosures
h) Crane, rails, rail tracks & other 25 x 6mm GS flat

non-current carrying metal parts
5.05.00 Metallic frame of all electrical equipment shall be earthed by two separate and distinct
connections to earthing system, each of 100% capacity, Crane rails, tracks, metal pipes and
conduits shall also be effectively earthed at two points. Steel RCC columns, metallic stairs,
and rails etc. of the building housing electrical equipment shall be connected to the nearby
earthing grid conductor by one earthing ensured by bonding the different sections of hand
rails and metallic stairs. Metallic sheaths/screens, and armour of multi-core cables shall be
earthed at both ends. Metallic Sheaths and armour of single core cables shall be earthed at
switchgear end only unless otherwise approved. Every alternate post of the switchyard
fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the
earthed post. Railway tracks within the plant area shall be bonded across fish plates and
connected to earthing grid at several locations. Portable tools, appliances and welding
equipment shall be earthed by flexible insulated cable.
5.06.00 Each continuous laid lengths of cable tray shall be earthed at minimum two places by G.S.
flats to earthing system, the distance between earthing points shall not exceed 30 meter.
Wherever earth mat is not available, necessary connections shall be done by driving an
earth electrode in the ground
5.07.00 Neutral points of HT transformer shall be earthed through NG resistors. The Contractor shall
connect the NGR earthing point to earth electrodes by suitable earth conductors.
5.08.00 Neutral connections and metallic conduits/pipes shall not be used for the equipment
earthing. Lightning protection system down conductors shall not be connected to other
earthing conductors above the ground level.
5.09.00 Connections between earth leads and equipment shall normally be of bolted type. Contact
surfaces shall be thoroughly cleaned before connections. Equipment bolted connections
after being tested and checked shall be painted with anti corrosive paint/compound.
5.10.00 Suitable earth risers as approved shall be provided above finished floor/ground level, if the
equipment is not available at the time of laying of main earth conductor.
5.11.00 Connections between equipment earthing leads and between main earthing conductors
shall be of welded type. For rust protection the welds should be treated with red lead
compound and afterwards thickly coated with bitumen compound. All welded connections
shall be made by electric arc welding.
5.12.00 Resistance of the joint shall not be more than the resistance of the equivalent length of
conductors.
5.13.00 Earthing conductors buried in ground shall be laid minimum 600 mm below grade level
unless otherwise indicated in the drawing. Back filling material to be placed over buried
conductors shall be free from stones and harmful mixtures. Back filling shall be placed in
layers of 150 mm.
5.14.00 Earthing conductors embedded in the concrete floor of the building shall have approximately
50 mm concrete cover.
5.15.00 A minimum earth coverage of 300 mm shall be provided between earth conductor and the
bottom of trench/foundation/underground pipes at crossings. Earthing conductors crossings

CLAUSE NO.
the road can be installed in pipes. Wherever earthing conductor crosses or runs at less than
300 mm distance along metallic structures such as gas, water, steam pipe lines, steel
reinforcement in concrete, it shall be bonded to the same.
5.16.00 Earthing conductors along their run on columns, walls, etc. shall be supported by suitable
welding / cleating at interval of 1000mm and 750mm respectively.
5.17.00 Earth pit shall be of treated type & shall be constructed as per IS:3043. Electrodes shall be
embedded below permanent moisture level. Minimum spacing between electrodes shall be
600mm. Earth pits shall be treated with salt and charcoal as per IS:3043. Test links shall be
provided with bolted arrangement alongwith each earth pit, in order to facilitate
measurement of earth resistance as & when required.
5.18.00 On completion of installation continuity of earth conductors and efficiency of all bonds and
joints shall be checked. Earth resistance at earth terminations shall be measured and
recorded. All equipment required for testing shall be furnished by contractor.
5.19.00 Earthing conductor shall be buried at least 2000mm outside the fence of electrical
installations. Every alternate post of the fences and all gates shall be connected to earthing
grid by one lead.
5.20.00 Other Requirements of Earthing System:
Standard/Code IEEE 80, IS 3043
Earthing System
Life expectancy 40 Years
System Fault Level As per system requirement (B0)
Soil resistivity Actual as per site conditions.
Min. Steel corrosion 0.12mm/year
Depth of burial of main earth conductor 600mm below grade level; where it crosses
trenches, pipes, ducts, tunnels, rail tracks, etc., it
shall be at least 300mm below them.
Conductor joints By electric arc welding, with resistance of joint

not more than that of the conductor.
Welds to be treated with red lead for rust protection and then coated with bitumen
compound for corrosion protection.
Surface resistivity - Gravel 3000 ohm-meter
- Concrete 500 ohm-meter
6.00.00 LIGHTNING PROTECTION SYSTEM
6.01.01 Lightning protection system shall be in strict accordance with IEC:62305 .
6.01.02 Lightning conductor shall be of 25x6mm GS strip when used above ground level and shall
be connected through test link with earth electrode/earthing system

CLAUSE NO.
6.01.03 Lightning system shall comprise of air terminations, down conductors, test links, earth
electrode etc. as per approved drawings.
6.02.00 Down Conductors
1. Down conductors shall be as short and straight as practicable and shall follow a
direct path to earth electrode.
2. Each down conductor shall be provided with a test link at 1000 mm above ground
level for testing but it shall be in accessible to interference. No connections other
than the one direct to an earth electrode shall be made below a test point.
3. All joints in the down conductors shall be welded type.
4. Down conductors shall be cleated on outer side of building wall, at 750 mm interval
or welded to outside building columns at 1000 mm interval.
5. Lightning conductor on roof shall not be directly cleated on surface of roof.
Supporting blocks of PCC/insulating compound shall be used for conductor fixing at
an interval of 1500 mm.
6. All metallic structures within a vicinity of two meters of the conductors shall be
bonded to conductors of lightning protection system.
7. Lightning conductors shall not pass through or run inside GI Conduits.
8. Testing link shall be made of galvanized steel of size 25x 6mm.
9. Pulser system for lightning shall not be accepted.
10. Hazardous areas handling inflammable/explosive materials and associated storage

areas shall be protected by a system of aerial earths.
7.00.00 TESTS
7.01.01 All equipment to be supplied shall be of type tested design. During detail engineering, the
contractor shall submit for Owner's approval the reports of all the type tests as listed in this
specification and carried out within last ten years from the date of bid opening. These
reports should be for the test conducted on the equipment similar to those proposed to be
supplied under this contract and the test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client.
7.01.02 However if the contractor is not able to submit report of the type test(s) conducted within
last ten years from the date of bid opening, or in the case of type test report(s) are not found
to be meeting the specification requirements, the contractor shall conduct all such tests
under this contract at no additional cost to the owner either at third party lab or in presence
of client/owners representative and submit the reports for approval.
7.01.03 All acceptance and routine tests as per the specification and relevant standards shall be
carried out. Charges for these shall be deemed to be included in the equipment price.
7.01.04 The type test reports once approved shall be treated as reference. For subsequent projects,
an endorsement sheet will be furnished by the manufacturer confirming similarity and “No
design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

CLAUSE NO.
7.02.00 Type Test reports shall be furnished for the following
7.02.01 Type tests on Cable Trays support system
a) Test 1A:
On main support channel type-C2 for cantilever arms fixed on one side only. A 3.5
meter length of main support channel shall be fixed vertically at each end to a rigid
structure as per the fixing arrangement as shown in the enclosed drawing. Eight (8) nos.
750 mm cantilever arms shall be fixed to the main channel and each arm shall be
loaded over the outboard 600 mm with a uniform working load of 100 kg. Subsequently
a point load of 100 kg shall be applied on arm 2. A uniform proof load on all the arms
equal to twice the working load shall be then be applied. Deflections shall be measured
at the points shown in the enclosed drawings and at the following load intervals:
i) Working load
ii) Working load + point load
iii) Off load
iv) Proof load + point load
v) Off load
The deflection measured at working loads shall not exceed 16mm. The permanent
deflection after removing the combination of working load and point load shall not
exceed 10 mm at the arm tips and 6 mm on the channel. No collapse of the structure
shall occur with a combination of proof load and point load applied.
B) Test 1B:
Test 1A shall be repeated with Eight Cantilever arms uniformly loaded and with the
same point load on arm 2
Test 2: On Main support channel type -C2 for cantilever arms fixed on both
sides
a) Test 2A: A 3.5 m length of main support channel C2 for cantilever arms fixing on
both sides shall be fixed at each end to rigid structure as per the fixing arrangement as
shown in the enclosed drawing. Six (6), 750 mm cantilever arms shall be attached to
each sides and each arm uniformly loaded to a working load of 100 kg over the out
board 600 mm. A point load of 100 kg shall than be applied to arm 2, followed by a
uniform proof load of twice the working load on all the arms; deflection shall be
measured at points shown in the enclosed drawings at the following load intervals.
i) Working load
ii) Working load + Point load
iii) Off load
iv) Proof load + Point load
v) Off load

CLAUSE NO.
deflection after removing the combination of working load and point load shall not
exceed 10 mm at the arm tips and 6 mm on the channel. No collapse of the structure
shall occur with a combination of proof load and point load applied
b) Test 2 B: The test 2 A shall be repeated with the assembly but with an asymmetrical
load on the C2 column and point load applied to arm 8. The 100 kg and 200 kg
uniformly distributed loads shall be applied to the upper three arms on one side and the
lower three arms on the opposite side.
Test 3 : Tests on Channel Fixed on Beam/Floor
A length of main support channel section shall be fixed to steel structure/floor and have
loads applied as shown in the drawing enclosed and as detailed below
a) Test 3A : A length of steel structure shall be rigidly supported. It should be fitted on a

meter length of channel section using beam clamps welded/bolted. A point
load of 1200 kg shall be applied to the centre point via two brackets. No
distortion or pulling of the components shall take place.
b) Test 3B: With the components assembled as in Test 3A, two perpendicular point loads
of 600 kg shall be simultaneously applied at positions 150 mm either side of
the centre line, no distortion or pulling of the components shall take place.
c) Test 3C: With the components assembled as in Test 3A, a perpendicular point load
shall be applied at a point 150 mm on one side of the centre line.
The load shall be gradually increased to the maximum value that can be
applied without causing distortion or pulling of the components. This value
shall be recorded.
Test 4 : Channel Insert Test
A 2.5 m length of C1 channel fixed to the concrete wall/ steel structure as per
actual site installation conditions. 6 nos. of 750 mm cantilever arms shall be
attached to C1 channel as shown in enclosed drawing. Each arm uniformly
loaded to a working load of 100 kg over the out board 600 mm. A point load of
100 kg shall than be applied to arm 2, followed by a uniform proof load of twice
the working load on all the arms; deflection shall be measured at points
shown in the enclosed drawings at the following load intervals.
i) Working Load
ii) Working Load + Point Load
iii) Off Load
iv) Proof Load + Point Load
v) Off load
deflection after removing the combination of working load and point load shall not exceed 10
mm at the arm tips and 6 mm on the channel. No collapse of the structure shall occur with a
combination of proof load and point load applied

CLAUSE NO.
Test 5 : Channel nut slip characteristics (what ever applicable)
Tests 5A1,5A2,5A3 : A length of channel C1 section 200mm long shall have fitted
bracket with the two bolt fixing as shown in drawing enclosed.
With loads applied at the position shown in drawing enclosed nut slip shall be
determined with bolt torque of 30NM, 50 NM and 65 NM No fewer than three
measurements shall be made for each torque setting.
A minimum loading of 720 kg shall be obtained before nut slip with bolt torque of 65
NM.
Tests 5B1,5B2,5B3: The length of channel C1 section 200 mm long shall have fitted
bracket with the one bolt fixing as shown in drawing enclosed. With loads applied at the
position shown in drawing, nut slip shall be determined with bolt torques of 30 NM, 50
NM and 65 NM. No fewer than three measurements shall be made for each torque
setting.
A minimum loading of 350 kg shall be obtained before nut slip with a bolt torque of 65
NM.
Test 6 Weld Integrity Test
After deflection test as per test 1A, 1B, 2, 3 & 4 weld integrity shall be checked by
magnetic particle inspection to detect sub-surface cracks developed, if any.
7.02.02 Cable termination kit and straight through joints should have been tested as per IS:13573
for 3.3kV grade & above.
7.03.00 Routine/ Acceptance Tests
7.03.01 Routine Tests
a) Routine tests as per specification and applicable standards shall be carried out on
all requirements/items covered in the specification.
b) Physical & dimensional check on all equipments as per approved

drawings/standards
.
c) HV/IR as applicable.
d) Check/measurement of thickness of paint/zinc coating/nickel-chrome plating as per

specification & applicable standard.
7.03.02 Acceptance Test
a) Galvanising Tests as per applicable standards
b) Welding checks
c) Deflection tests on cable trays:
d) One piece each of 2.5m length of cable tray of 300mm & above shall be taken as
sample from each offered lot. It shall be supported at both end & loaded with
uniform load of 76 kg/meter along the length of cable tray. The maximum deflection
at the mid-span of each size shall not exceed 7mm.

CLAUSE NO.
d) Proof load tests on cable tray support system
i) Tests on Main Support Channel shall be done if only C1 Channel are in scope of
supply and cantilever arms shall be fitted on one side. This test shall be same as
test 4 of type test.
ii) Test on Main Support Channel shall be done with C2 channel and cantilever arms
fitted on both sides, if C2 channels are in scope of supply. This test shall be same
as test 2A of type test. Then test (i) above shall not be done.
iii) Nut slip characteristic test (it shall support minimum load of 350kg before nut slips
with a bolt torque of 65 NM). This test shall be same as test 5B3 of type test.
The procedure for carrying out tests at “d” above shall be as per details given in
Type Tests in specification thereafter Die-Penetration test shall be carried out to
check weld integrity.
e) The above acceptance tests shall be done only on one sample from each offered
lot.
8.00.00 COMMISSIONING
8.01.01 The Contractor shall carry out the following commissioning tests and checks after
installation at site. In addition the Contractor shall carry out all other checks and tests as
recommended by the Manufacturers or else required for satisfactory performance..
8.01.02 Cables
a) Check for physical damage
b) Check for insulation resistance before and after termination/jointing.
c) HT cables shall be pressure tested (test voltage as per IS:7098) before

commissioning.
d) Check of continuity of all cores of the cables.
e) Check for correctness of all connections as per relevant wiring diagrams. Any minor
modification to the panel wiring like removing/inserting, shorting, change in terminal
connections, etc., shall be carried out by the Contractor.
f) Check for correct polarity and phasing of cable connections.
g) Check for proper earth connections for cable glands, cable boxes, cable armour,
screens, etc.
h) Check for provision of correct cable tags, core ferrules, tightness of connections.
8.02.00 Cable trays / supports and accessories
1) Check for proper galvanizing/painting and identification number of the cable

trays/supports and accessories.
2) Check for continuity of cable trays over the entire route.

CLAUSE NO.
3) Check that all sharp corners, burrs, and waste materials have been removed from
the trays supports.
4) Check for earth continuity and earth connection of cable trays.
8.03.00 Earthing and Lightning protection system
1) Earth continuity checks.
2) Earth resistance of the complete system as well as sub-system.
8.04.00 Below Ground Earth Mat:
The earthing system for plant shall be designed as per Clause No:- 3.07.00 of Sub Section
B-0 of Technical Specification Section-VI, Part-B
Grounding for TG and other areas or buildings covered in the specification shall be
provided in accordance with IS 3043, IEC 62305, IEEE 80.
Earthing system network/earthmat shall be interconnected mesh of mild steel rods buried
in ground in the plant. All areas under contractor scope of supply shall be interconnected
together by minimum two parallel conductors. The Contractor shall furnish the detailed
design and calculations for Employer's approval. Contractor shall obtain all necessary
statutory approvals for the system. All the columns shall be earthed by nearby risers and
earthmat grid spacing shall be maximum 10 X 10 mts.. Minimum two nos of risers shall be
provided for each equipment in his scope of area. Separate dedicated riser shall be
provided for C&I earthing purpose and also for Lightning down conductor connection
purpose. Sufficient nos of risers near the equipment shall be provided as per the system
requirement.
9.00.00 ELECTRICAL LAYOUT PHILOSOPHY:
While developing the layout the bidder must give due consideration to the following
requirements:
a) Adequate distance shall be maintained between the transformers. As basic
guidelines following norms will be adhered to:
1) Transformers shall be separated from the adjacent building/structures and from
each other by a minimum distance as defined below or by a fire wall of two
hours of fire resisting of height at least 600 mm above bushing / pressure relief
vent whichever is higher.
Oil capacity of individual transformer Clear separating distance
(in liters) (in meters)
5,000 to 10,000 8.0
10,001 to 20,000 10.0
20,001 to 30,000 12.5
Over 30,001 15.0

CLAUSE NO.
2) In case of auxiliary transformers having an aggregate oil capacity in excess of

2300 liters but individual oil capacity of less than 5000 liters, the maximum
separating distance between transformers and surrounding building shall be at
least 6M unless they are separated by fire separating walls or are protected by
high velocity spray system.
3.) Rail track shall be provided in Transformer yard for movement of each
transformer. The rail track in Transformer yard shall be connected with TG
area rail track The Foundation top of transformer & rail top shall be at EL +/-
0.0M. Bus duct support or Transformer body shall be at least 8.0M from A-Row
of TG building to clear the movement of GT/ Stator/UT/ST/UAT on rail line.
Jacking pads shall be provided where the rail track changes the direction.
Mooring post shall be provided on rail track for handling the transformers.
4) For each transformer a pit shall be provided all around at a distance of 1.5 m
(minimum) from transformer outer edge. A sump pit shall be provided for each
pit. A common oil retention pit per unit shall be provided to hold oil quantity of
the largest transformer (by volume) & 10 minutes of water quantity of HVW
spray system for the largest transformer. Sump pit of individual transformer
shall be connected to common oil retention pit of that unit.
5) Rail track shall be provided for all outdoor transformers up to road for movement
of each transformer of size more than or equal to 7.5MVA Transformer. Jacking
pads shall be provided where the rail track changes the direction. Jacking pad
shall also be provided at the location of installation of transformer and mooring
post shall be provided on rail track for handling the transformers.
6.) The Transformer fencing shall be at 1.0 M (minimum) distance from the pit wall.
The Height of fencing shall be 2.5 M (minimum) and fencing shall have personal
entry gate and removable type fencing/gate for transformer withdrawal.
7) The transformer firewall, pit sizing and clearances from adjacent

building/structures etc. shall be as per IS 1646/CBIP manual on Transformer
8) However, for all outdoor transformers of oil capacity less than 2000 litre, a trench
of suitable size shall be provided all around at a distance of 1.0 m (minimum)
from transformer outer edge. A sump pit shall be provided for each trench.
b) Layout requirements for Electrical MCC/switchgear rooms

1. Separate Switchgear Rooms shall be provided for each unit. For TG building, all HT
boards shall be provided in HT switchgear room at only one floor and all LT boards
shall be provided in LT switchgear room only.
2. The following clearances shall be maintained for HT Switchboard.
a.) Front Clearance
i) For one Row of Swgr. - 2.0 M (Min)
ii) For two Rows of Swgr. - 2.5 M (Min)

CLAUSE NO.
b.) Back Clearance - 1.5 M (Min.)
c.) Side Clearance

Min. 800 mm, however provision to be made for any additional panel in future at
both ends. Therefore end clearance shall be 800+width of panel (including spare
panels/dummy panels etc.)
3. The following clearances shall be maintained for LT Switchboard.

a.) Front Clearance
i) For one Row of Swgr - 1.5M (Min)
ii) For two Rows of Swgr - 1.5/1.75M depending upon the depth of
panels etc
b.) Back Clearance

i) For single front - 1.0M (Min)
ii) For double front - 1.5M (Min)
c.) Side Clearance
Min. 800 mm, however provision to be made for any additional panel in future at
both ends. Therefore end clearance shall be 800 mm + width of panel.
For offsite areas, HT Switchboard clearances shall be followed wherever both LT &
HT switch boards are in the same MCC room.
4. Height of HT/LT Switchgear Room and Boiler MCC room
i) With Bus Duct – 4.5 m (min)

ii) Without Bus Duct – 4.0 m (min)
Further no vertical bracings shall be envisaged in HT/LT switchgear room and

associated cable vault area.
5. Cable trench/Cable vault
For LT switchgear/MCC room at EL 0.0M, minimum 1400 wide x 1400 deep cable
trench shall be provided to route the cables. Horizontal cable trays shall be routed in
cable trenches.
c) Minimum clear working space 1200mm around the equipment
d) In buildings having MCC, minimum 2 fire door along with one rolling shutter of
adequate size/capacity shall be provided.
e) The cable entry and exit from switchgear room shall be from 1.5 mtr (minimum)
above FGL.

BATTERY

CLAUSE NO.
BATTERY
1.00.00 BATTERY RATINGS
1. For Ni-Cd Type Battery

220V/110V/48 V DC
a) Battery Voltage
As per Sizing Calculations
b) No. of Cells
c) Battery type
Stationary Nickel-Cadmium Pocket Plate
High discharge type (KPH)
d) As per requirement
Capacity for five(5)hour
rate
e) 1.2 V
Nominal discharge voltage
per Cell
As per manufacturer’s standards for float
f) Float voltage
application
2. For Lead Acid Plante type Battery
a) Battery Voltage 220V/110V/48 V DC
b) No. of Cells As per Sizing Calculations

Stationary Lead Acid Plante high discharge
c) Battery type
type
d) As per requirement
Capacity for ten(10)hour
rate
e) 2.0 V
Nominal voltage per cell
discharge
As per manufacturer’s standards for float
f) Float Voltage
application
1.01.00 Commissioning of Battery

Commissioning of each battery at site shall only be carried out either by the battery
manufacturer himself or under the supervision of the battery manufacturer.
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
HEALTH MONITORING 1 OF 11
SYSTEM
CLAUSE NO.
PART-A: NICKEL-CADMIUM BATTERY
2.01.00 All standards, specifications and codes of practice referred to herein, shall be the
latest editions including all applicable official amendments and revisions as on date
of opening of techno-commercial bid.
In case of conflict between this specification and those (IS codes, Standards etc.)
referred to herein, the former shall prevail. All works shall be carried out as per the
following standards and codes:
IEC 60623 / IS 10918 Specification for vented type Nickel Cadmium Batteries.
IS 1069 Quality tolerances for water for storage batteries
IEC 60993 Electrolyte for vented Nickel-Cadmium cells
Indian electricity rules

Indian Electricity Acts
2.02.00 Equipment complying with other internationally accepted standards such as IEC.,
BS, VDE etc. will also be considered if they ensure performance and constructional
features equivalent or superior to standards listed above. In such a case, the Bidder
shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest
revision of the standards along with copies of all official amendments and revisions
in force as on date of opening of techno-commercial bid and shall clearly bring out
the salient features for comparison.
3.00.00 GENERAL TECHNICAL REQUIREMENT
3.01.00 Equipments
(a.) DC Batteries shall be stationary Nickel Cadmium Pocket plate type (KPH)/
(KPL) conforming to IS 10918. The batteries shall be high discharge
performance type as specified. For the purpose of design an ambient
temperature of 50 degree centigrade and relative humidity of 85% shall be
considered.
(b.) DC batteries shall be suitable for standby duty. The batteries shall normally
be permanently connected to the load in parallel with a charger and shall
supply the load during emergency conditions when AC supplies are lost.
Batteries shall be suitable for a long life under continuous float operations
and occasional discharges. The batteries shall be boost charged at about
1.54 to 1.7 volts per cell maximum and float charged at about 1.42 V/cell.
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
SYSTEM
CLAUSE NO.
(c.) Batteries should be suitable for continuous operation for the maximum
ambient temperature as defined in technical parameters.
3.02.00 Construction Features
3.02.01 Containers
Containers shall be made of polypropylene plastic material. Containers shall be

robust, heat resistance, leak proof, non absorbent, alkali resistant, non-bulging type
and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level
lines shall be marked on container in case of translucent containers.
3.02.02 Vent Plugs
Vent plugs shall be provided in each cells. They shall be anti-splash type, having
more than one exit hole shall allow the gases to escape freely but shall prevent alkali
from coming out. The design shall be such that the water loss due to evaporation is
kept to minimum. In addition the ventilator shall be easily removed for topping up the
cells and of such dimensions that the syringe type hydrometer can be inserted into
the vent to take electrolyte samples.
3.02.03 Plates
The plates shall be designed for maximum durability during all service conditions
including high rate of discharge and rapid fluctuations of load. The construction of
plates shall conform to latest revisions of IS 10918.
The separators shall maintain the electrical insulation between the plates and shall
allow the electrolyte to flow freely. Separators should be suitable for continuous
immersion in the electrolyte without distortion.
The positive and negative terminal posts shall be clearly marked.
3.02.04 Sediment Space
Sufficient sediment space shall be provided so that cells will not have to be cleaned
during normal life and prevent shorts within the cells.
3.02.05 Electrolyte
The electrolyte shall be prepared from battery grade potassium hydroxide

conforming to IEC 60993.
The cells can be shipped either in charged condition or in dry condition.
Necessary electrolyte for make-up shall be supplied separately.
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
SYSTEM
CLAUSE NO.
3.02.06 Connectors and Fasteners
Nickel plated copper connectors shall be used for connecting adjacent cells and
PVC insulated flexible copper cables shall be used for inter-row / inter-tier / inter-
bank connections. Bolts, nuts and washers shall be Stainless Steel / Nickel coated
steel to prevent corrosion. The thickness of Nickel coating of connectors should be
not less than 0.02 mm. All the terminals and cells inter-connectors shall be fully
insulated or have insulation shrouds. End take off connections from positive and
negative poles of batteries shall be made by single core cables having stranded AL
conductors and XLPE insulation. Necessary supports and lugs for termination of
these cables on batteries shall also be supplied by the contractor. All connectors and
lugs shall be capable of continuously carrying the 30 minutes discharge current of
the respective batteries and through fault short circuit current which the battery can
produce and withstand for the period declared. Contractor shall furnish necessary
sizing calculations to prove compliance to the same. Suitable number of Inter-rack
connectors shall be supplied by the Bidder to suit the battery room layout during
3.02.07 Battery racks
Mild steel racks for all the batteries shall be provided. They shall be free standing
type mounted on porcelain/hard rubber/PVC pads insulators/High impact plastic
insulators. Batteries shall preferably be located in the single tier arrangement.
However, batteries having a complete cell weight of lower than 50 Kg could be
located in the double tier arrangement. The batteries racks and supports for cable
termination shall be coated with three (3) coats of anti-alkali paint of approved
shade. Name plates, resistant to alkali, for each cell shall be attached on to the
necessary racks. The bottom tier of the stand shall not be less than 150 mm above
the floor.
Wherever racks are transported in dismantled conditions, match markings shall be

provided to facilitate easy assembly.
3.02.08 Manufacturer’s Identification System
The following information shall be indelibly marked on outside of each cell.
(a.) Manufacturers’ name and trade marks
(b.) Country and year of manufacture.
(c.) Manufacturer type designation.
(d.) AH capacity at 5 hour discharge rate.
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
SYSTEM
CLAUSE NO.
(e.) Serial number
4.00.00 THE FOLLOWING INFORMATION SHALL BE GIVEN ON THE INSTRUCTION

CARDS SUPPLIED WITH THE BATTERY:
(a.) Manufacturer's instructions for filling and initial charging of the battery
together with starting and finishing charging rate.
(b.) Maintenance instructions.
(c.) Designation of cell in accordance with IS 10918.
(d.) Storing conditions of electrolyte.
5.00.00 TESTS
5.01.00 All equipment to be supplied shall be of type tested design. During detail
engineering, the contractor shall submit for Owner's approval the reports of all the
date of techno-commercial bid opening. These reports should be for the test
conducted on the equipment similar to those proposed to be supplied under this
contract and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client.
5.02.00 However, if the contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of techno-commercial bid opening, or in the case
of type test report(s) are not found to be meeting the specification requirements, the
contractor shall conduct all such tests under this contract at no additional cost to the
owner either at third party lab or in presence of client/owners representative and
submit the reports for approval.
price.
5.04.00 GENERAL
The Contractor shall submit for Owner’s approval the reports of all the type tests
carried out as per latest IS-1146 (for all applicable tests for containers) / IS-10918
(for Ni-Cd batteries). The complete type test reports shall be for any rating of battery
in a particular group, based on plate dimensions being manufactured by supplier.
5.05.00 Routine and Acceptance tests shall be as per Quality Assurance & Inspection table
of battery.
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BATTERY AND DC PAGE
SYSTEM
CLAUSE NO.
5.06.00 Commissioning Checks:
All tests as listed below shall be carried out on sample cell selected at random by
the employer at site after completion of installation.
(a.) Physical Examination
(b.) Dimensions, Mass & layout
(c.) MARKING
(d.) Polarity and absence of short circuit.
(e.) Ampere - hour capacity--4 Cycles
(f.) Insulation resistance
The Contractor shall arrange for all necessary equipment, including the variable
resistor, tools, tackles and instruments.
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
SYSTEM
CLAUSE NO.
PART-B: LEAD –ACID PLANTE BATTERY
6.01.00 All standards, specification and codes of practice, referred to herein, shall be the
latest edition including all applicable official amendments and revisions as on date of
opening of techno-commercial bid.
In case of conflict between this specification and those (IS Codes Standards etc.)
referred to herein, the former shall prevail. All works shall be carried out as per the
following standards and codes:
IEC 60896 Stationary Lead-Acid Batteries
IS 266 Specification for sulphuric acid
IS 1069 Specification for water for storage batteries
IS 1146 Specification for rubber & plastic containers for lead acid storage
batteries.
IS 1652 Specification for stationary cells and batteries, lead acid type (with
plante positive plates).
IS 3116 Specification for sealing compound for lead acid batteries.
IS 8320 General requirements and methods of tests for lead acid storage
batteries.
IS 6071 Specification for synthetic separators for lead acid batteries.
Indian Electricity Rules
6.02.00 Equipment complying with other internationally accepted standards such as IEC, BS,
VDE etc. will also be considered if they ensure performance and constructional
features equivalent or superior to standards listed above. In such a case, the Bidder
shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest
revision of the standards alongwith copies of all official amendments and revisions in
force as on date of opening of techno-commercial bid and shall clearly bring out the
salient features for comparison.
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
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CLAUSE NO.
7.00.00 GENERAL TECHNICAL REQUIREMENTS
7.01.00 Equipments
DC Batteries shall be stationary lead acid Plante positive plate type conforming to IS
1652. The battery shall be high discharge performance type. For the purpose of
design an ambient temperature of 50 degree centigrade and relative humidity of
85% shall be considered.
DC Batteries shall be suitable for standby duty. The Batteries shall normally be
permanently connected to the load in parallel with a charger and shall supply the
load during emergency conditions when AC supplies are lost. Batteries shall be
suitable for a long life under continuous float operations and occasional discharges.
The batteries shall be boost charged at about 2.7 volts per cell maximum and float
charged at about 2.25 V/cell:
Batteries should be suitable for continuous operation for the maximum ambient
temperature as defined in technical parameters.
7.02.00 Construction Features
7.02.01 Containers
Containers shall be made of transparent glass, hard rubber, suitable robust, heat
resistance, leak proof, non absorbent, acid resistant, non-bulging type and free from
flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines shall be
marked on container in case of transparent containers. Float type level indicator
shall be provided in case of opaque containers. The stem portion of the float should
be long enough to prevent falling of the float inside the container even if there is no
electrolyte in the container. The marking for the electrolyte level should be for the
upper and lower limits. The material of level indicator shall be acid proof and
oxidation proof. Container shall be closed/sealed lid type. Lid and sealing compound
shall be non-cracking type. The container made of hard rubber and plastics shall be
type tested as per IS 1146. All type tests shall be carried out for sealing compound
as per IS 3116.
The pole sealing arrangement should be such that no acid particle get entrapped
due to acid creep as a result of capillary action and it should be possible to remove
and refix the sealing to carry out the maintenance.
7.02.02 Vent Plugs
Vent plugs shall be provided in each cells. They shall be antis-plash type, having
more than one exit hole shall allow the gases to escape freely but shall prevent acid
from coming out. The design shall be such that the water loss due to evaporation is
kept to minimum. In addition the ventilator shall be easily removed for topping up the
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
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CLAUSE NO.
cells and of such dimensions that the syringe type hydrometer can be inserted into
the vent to take electrolyte sample.
7.02.03 Plates
The plates shall be designed for maximum durability during all service conditions
including high rate of discharge and rapid fluctuations of load. The construction of
plates shall conform to latest revisions of IS 1652 as applicable.
The separators shall maintain the electrical insulation between the plates and shall
allow the electrolyte to flow freely. Separators should be suitable for continuous
immersion in the electrolyte without distortion. The positive and negative post shall
be clearly marked.
7.02.04 Sediment Space
Sufficient sediment space shall be provided so that cells will not have to be cleaned
during normal life and prevent shorts within the cells.
7.02.05 Cell Insulator
Each cell shall be separately supported on PVC/porcelain/hard rubber insulators

fixed on the racks with adequate clearance between adjacent cells. Minimum
distance between adjacent cells shall be more than the bulge allowed for two cells in
accordance with IS 1146.
7.02.06 Electrolyte
The electrolyte shall be prepared from battery grade sulphuric acid conforming to IS
266 and distilled water conforming to IS 1069. The cells shall be shipped dry
uncharged. The electrolyte shall be supplied separately.
Lead or Lead coated copper connectors shall be used for connecting up adjacent
cells and rows. Bolts, nuts and washers shall be effectively lead coated to prevent
corrosion. The thickness of lead-coating of connectors should not be less than 0.025
mm. The lead coating thickness shall be measured in accordance with APPENDIX F
of IS 6848 (latest edition). All the terminals and cells inter-connectors shall be fully
insulated or have insulation shrouds. End take off connections from positive and
negative poles of batteries shall be made by single core cables having stranded
copper conductors and PVC insulation. Necessary supports and lugs for termination
of these cables on batteries shall also be supplied by the contractor. All connectors
and lugs shall be capable of continuously carrying the 30 minutes discharge current
of the respective Batteries and through fault short circuit current which the battery
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
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CLAUSE NO.
can produce and withstand for the period declared. Contractor shall furnish
necessary sizing calculations to prove compliance to the same.
7.02.08 Battery racks
Wooden racks for all the batteries shall be provided. These racks shall be made of
good quality first class seasoned teak wood in line with CPWD specification. They
shall be free standing type mounted on porcelain/hard rubber/PVC pads
insulators/High impact plastic insulators. Batteries shall preferably be located in the
single tier arrangement. However, batteries having a complete cell weight of lower
than 50 Kg could be located in the double tier arrangement. The batteries rack and
wooden support for cable termination shall be coated with three (3) coats of anti-acid
paint of approved shade. Numbering tags, resistant to acid, for each cell shall be
attached on to the necessary racks. The bottom tier of the stand shall not be less
than 150 mm above the floor. Wherever racks are transported in dismantled
condition, suitable match markings shall be provided to facilitate easy assembly.
7.02.09 Manufacturer’s Identification Systems

(a.) Manufacturer's name and trade marks
(e.) Serial number
8.00.00 TESTS
8.01.00 All equipment to be supplied shall be of type tested design. During detail
date of techno-commercial bid opening. These reports should be for the test
conducted on the equipment similar to those proposed to be supplied under this
contract and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client.
8.02.00 However if the contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of techno-commercial bid opening, or in the case
of type test report(s) are not found to be meeting the specification requirements, the
contractor shall conduct all such tests under this contract at no additional cost to the
owner either at third party lab or in presence of client/owners representative and
submit the reports for approval.
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
SYSTEM
CLAUSE NO.
price.
8.04.00 GENERAL
The Contractor shall submit for Owner’s approval the reports of all the type tests
carried out as per latest IS-1146 (for rubber & plastic containers for lead-acid
storage batteries)/IS 1652 (for lead-acid plante batteries). The complete type test
reports shall be for any rating of battery in a particular group, based on plate
dimensions being manufactured by supplier.
8.05.00 Routine and Acceptance tests shall be as per Quality Assurance & Inspection table
of battery.
8.06.00 Commissioning Checks:

All tests as listed below shall be carried out on sample cell selected at random by the
employer at site after completion of installation.
1) Verification of markings.
2) Verification of dimensions.
3) Test for capacities for 10 hrs discharge rate alongwith the test for voltage
during discharge.
The Contractor shall arrange for all necessary equipment, including the variable
resistor, tools, tackles and instruments.
SUB-SECTION-IIIB-06
BATTERY AND DC PAGE
SYSTEM
BATTERY CHARGER

CLAUSE NO.
BATTERY CHARGER
techno-commercial bid. In case of conflict between this specification and those (IS codes,
standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per
the following standards and codes.
ANSI-C Guide for surge withstand capability tests

37.90a
IS:5 Colours for ready mix paints.
IS : 694 PVC Insulated Cable for working voltages upto and including 1100 V.
IS : 1248 Specification for Direct acting indicating analogue electrical measuring

instruments.
IS:13947 Degree of protection provided by enclosures for low voltage switch gear
Part-1 and control gear.
IS : 13947 Specification for low voltage switch gear and control gear
IS : 3231 Electrical relays for power system protection.
IS : 3842 Application guide for Electrical relays for AC System
IS : 3895 Mono-crystalline semi-conductor Rectifier Cells and Stacks
IS : 4540 Mono crystalline semi-conductor Rectifier assemblies and equipment.
IS:6005 Code of practice for phosphating of Iron and Steel.
IS:6619 Safety Code for Semi-conductor Rectifier Equipment.
IS:6875 Control switches (switching devices for control and auxiliary circuits
including contactor relays) for voltages upto 1000 V AC or 1200 V DC.
IS : 9000 Basic environmental testing procedures for electronic and electrical items.

1 OF 12
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 BATTERY CHARGER
CLAUSE NO.
IS:13703 Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC.
EEUA-45D Performance requirements for electrical Alarm Annunciation System
Indian Electricity Act.
1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, VDE
etc. will also be considered if they ensure performance and constructional features equivalent
or superior to standards listed above. In such a case, the Bidder shall clearly indicate the
standard(s) adopted, furnish a copy in English of the latest revision of the standards along
with copies of all official amendments and revisions in force as on date of opening of techno-
commercial bid and shall clearly bring out the salient features for comparison.
2.00.00 EQUIPMENT DESCRIPTION
2.01.00 PART-I BATTERY CHARGER FOR LEAD ACID PLANTE TYPE BATTERY
(a.) The Battery Chargers as well as their automatic regulators shall be of static type.
Battery chargers shall be capable of continuous operation at the respective rated load
in Trickle mode i.e. Trickle charging the associated DC lead-acid Batteries while
supplying the D.C. loads. The Batteries shall be Trickle charged at 2.25 Volts per cell.
All chargers shall also be capable of Boost Charging the associated D.C. Battery at 2.3
to 2.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as
mentioned above, at an ambient air temperature of 50°C.
(b.) All Battery Chargers shall have provision to receive two input supplies along with
suitable automatic changeover between the sources.
(c.) Battery Chargers shall have a selector switch for selecting the battery charging mode
i.e. whether Trickle or Boost charging.
(d.) All Battery Chargers shall be provided with facility for both automatic and manual
control of output voltage and current. A selector switch shall be provided for selecting
the mode of output voltage/current control, whether automatic or manual. Means shall
be provided to avoid current/voltage surges of harmful magnitude/nature which may
arise during changeover from Auto to Manual mode or vice-versa under normal
operating condition.
(e.) Soft start feature shall be provided to build up the voltage to the set value slowly within
fifteen seconds. The chargers shall have load limiters which shall cause, when the

2 OF 12
CLAUSE NO.
voltage control is in automatic mode, a gradual lowering of the output voltage when the
DC load current exceeds the load limiter setting of the Charger. The load limiter
characteristic shall be such that any sustained overload or short circuit in DC system
shall neither damage the Charger nor shall it cause blowing of any of the charger
fuses. The Charger shall not trip on overload or external short circuit. After clearance of
fault, the Charger voltage shall build up automatically when working in automatic
mode.
(f.) When on automatic control mode during Trickle charging, the Charger output voltage
shall remain within +/-1% of the set value for AC input voltage variation of +/-10%,
frequency variation of +3/-5%, a combined voltage and frequency (absolute sum)
variation of 10% and a continuous DC load variation from zero to full load. Uniform and
step-less adjustments of voltage setting (in both manual and automatic modes) shall
be provided on the front of the Charger panel covering the entire Trickle charging
output range specified & shall be capable of matching the float voltage correction
recommendations(w.r.t. temperature) as suggested by the respective battery
manufacturer. Step-less adjustment of the load limiter setting shall also be possible
from 80% to 100% of the rated output current for Trickle charging mode.
(g.) During Boost charging, the Battery Chargers shall operate on constant current mode
(When automatic regulator is in service). It shall be possible to adjust the Boost
charging current continuously over a range of 50 to 100% of the rated output current
for Boost charging mode. The charger output voltage shall automatically go on rising,
when it is operating on boost mode, as the battery charges up. For limiting the output
voltage of the charger, a potentiometer shall be provided on the front of the panel,
whereby it shall be possible to set the upper limit of this voltage anywhere in the output
range specified for boost charging mode. All voltage and current setting potentiometers
shall be vernier type.
(h.) Energizing the Charger with fully charged battery connected plus 10% load shall not
result in output voltage greater than 110% of the voltage setting. Time taken to
stabilize, to within the specified limits as mentioned elsewhere, shall be less than
fifteen seconds.
(i.) Momentary output voltage of the Charger, without the Battery connected shall be within
94% to 106% of the voltage setting during sudden load Change from 100% to 20% of
full load or vice-versa. Output voltage shall return to, and remain, within the limits
specified as mentioned elsewhere in less than 2 seconds after the above mentioned
change.

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CLAUSE NO.
(j.) The Charger manufacturer may offer an arrangement in which the voltage setting
device for Trickle charging mode is also used as output voltage limit setting device for
Boost charging mode, and the load limiter of the trickle charging mode is also used as
Boost charging current setting device.
(k.) Suitable filter circuits shall be provided in all the Chargers to limit the ripple content
(peak to peak) in the output voltage to 1% irrespective of the DC load, even when they
are not connected to a battery.
(l.) The DC System shall be ungrounded and float with respect to the ground potential
when healthy.
2.02.00 PART-II BATTERY CHARGER FOR NICKEL-CADMIUM TYPE BATTERY
(a.) The Battery Chargers as well as their automatic regulators shall be of static type.
Battery chargers shall be capable of continuous operation at the respective rated load
in Trickle mode i.e. Trickle charging the associated DC Nickel-Cadmium Batteries
while supplying the D.C. loads. The Batteries shall be Trickle charged at 1.4 to 1.42
Volts per cell. All chargers shall be capable of Boost Charging the associated D.C.
Battery at 1.53 to 1.7 Volts per cell at the desired rate. The Chargers shall be designed
to operate, as mentioned above, at an ambient air temperature of 50°C.
(b.) All Battery Chargers shall have provision to receive two input supplies along with
suitable automatic changeover between the sources.
(c.) Battery Chargers shall have a selector switch for selecting the battery charging mode
i.e. whether Trickle or Boost charging.
(d.) All Battery Chargers shall be provided with facility for both automatic and manual
control of output voltage and current. A selector switch shall be provided for selecting
the mode of output voltage/current control, whether automatic or manual. Means shall
be provided to avoid current/voltage surges of harmful magnitude/nature which may
arise during changeover from Auto to Manual mode or vice-versa under normal
operating condition.
(e.) Soft start features shall be provided to build up the voltage to the set value slowly
within fifteen seconds. The chargers shall have load limiters which shall cause, when
the voltage control is in automatic mode, a gradual lowering of the output voltage when
the DC load current exceeds the load limiter setting of the Charger. The load limiter
characteristic shall be such that any sustained overload or short circuit in DC system
shall not damage the Charger, nor shall it cause blowing of any of the charger fuses.

4 OF 12
CLAUSE NO.
The Charger shall not trip on overload or external short circuit. After clearance of fault,
the Charger voltage shall build up automatically when working in automatic mode.
(f.) When on automatic control mode during Trickle charging, the Charger output voltage
shall remain within +/-1% of the set value for AC input voltage variation of +/-10%,
frequency variation of +3 to -5%, a combined voltage and frequency (absolute sum)
variation of 10% and a continuous DC load variation from zero to full load. Uniform and
stepless adjustments of voltage setting (in both manual and automatic modes) shall be
provided on the front of the Charger panel covering the entire Trickle charging output
range specified & shall be capable of matching the float voltage correction
recommendations(w.r.t. temperature) as suggested by the respective battery
manufacturer. Stepless adjustment of the load limiter setting shall also be possible
from 80% to 100% of the rated output current for Trickle charging mode.
(g.) During Boost charging, the Battery Chargers shall operate on constant current mode
(When automatic regulator is in service). It shall be possible to adjust the Boost
charging current continuously over a range of 50 to 100% of the rated output current
for Boost charging mode. The charger output voltage shall automatically go on rising,
when it is operating on boost mode, as the battery charges up. For limiting the output
voltage of the charger, a potentiometer shall be provided on the front of the panel,
whereby it shall be possible to set the upper limit of this voltage anywhere in the output
range specified for boost charging mode. All voltage and current setting potentiometers
shall be vernier type.
(h.) Energising the Charger with fully charged battery connected plus 10% load shall not
result in output voltage greater than 110% of the voltage setting. Time taken to
stabilise, to within the specified limits as mentioned elsewhere shall be less than fifteen
seconds.
(i.) Momentary output voltage of the Charger, without the Battery connected shall be within
94% to 106% of the voltage setting during sudden load Change from 100% to 20% of
full load or vice-versa. Output voltage shall return to, and remain, within the limits
specified as mentioned elsewhere in less than 2 seconds after the above mentioned
change.
(j.) The Charger manufacturer may offer an arrangement in which the voltage setting
device for Trickle charging mode is also used as output voltage limit setting device for
Boost charging mode, and the load limiter of the trickle charging mode is also used as
Boost charging current setting device.

5 OF 12
CLAUSE NO.
(k.) Suitable filter circuits shall be provided in all the Chargers to limit the ripple content
(peak to peak) in the output voltage to 1% irrespective of the DC load, even when they
are not connected to a battery.
(l.) The DC System shall be ungrounded and float with respect to the ground potential
when healthy.
2.03.00 Printed Circuits Boards (PCB)
PCB shall be made of glass epoxy of 1.6 mm thick, fire resistant, bonded with 99.8% pure
copper foil, free of wrinkles, blisters, scratches and pinholes. The contact surface of the edge
connectors of the PCBs shall be plated with hard gold to a minimum thickness of 5 microns.
Component identification shall be printed on PCB by silk screen method. All PCBs shall be
tropicalised and masked.
2.04.00 CONTACTORS
All Battery Chargers shall have an AC contactor on the input side. It shall be of air break type
and suitable for continuous duty. The operating coil shall be rated for 415 Volts AC.
2.05.00 Thermal Overload Relay

A thermal overload relay incorporating a distinct single phasing protection (using differential
movement of bimetal strips) shall also be provided for the AC input. The relay shall trip the
above contactor.
2.06.00 Rectifier-Transformers and Chokes
The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating of the
rectifier-transformers and chokes shall correspond to the rating of the associated rectifier
assembly. The rectifier-transformers and chokes shall have class-F insulation with
temperature rise limited to class-B insulation value.
2.07.00 Rectifier Assembly
The rectifier assembly shall be full wave bridge type and designed to meet the duty as
required by the respective Charger. The rectifier cells shall be provided with their own heat
dissipation arrangement with natural air cooling for up to 400A rating chargers. However, the
rectifier cells shall be provided with their own heat dissipation arrangement along with forced
air cooling for above 400A rating chargers and fan shall be temperature controlled with 100%
standby redundancy. The rectifier shall utilise diodes/thyristors and heat sinks rated to carry
200% of the load current continuously and the temperature of the heat sink shall not be
permitted to exceed 85°C absolute duly considering the maximum charger panel inside
temperature. The Contractor shall submit calculations to show what maximum junction
temperature will be and what the heat sink temperature will be when operating at 200% and

6 OF 12
CLAUSE NO.
100% load current continuously duly considering the maximum surrounding air temperature
for these devices inside the charger panel assuming air ambient temperature of 50°C outside
the panel. Necessary surge protection devices and rectifier type fast acting fuses shall be
provided in each arm of the rectifier connections.
2.08.00 DIGITAL INDICATING INSTRUMENTS
Digital indicating instruments with built in communication port for remote data transfer shall
be provided for all chargers. The instruments shall indicate DC current, DC voltage & AC
voltage and instrument shall be 96 x 96 mm2, with display accuracy 0.5%, 4 digit-7 segment
LED/LCD display and RS 485 Serial Bus port. Ammeters & voltmeters shall have 4-20mA
analog output for current and voltage respectively.
2.09.00 AIR BREAK SWITCHES
All Chargers shall have AC input and DC output switches of air break, single throw, load
break and fault make type. The contacts of the switches shall open and close with a snap
action. Switches shall be rated for 120% of the maximum continuous load. ‘ON’ & ‘OFF’
position of the switch shall be clearly indicated.
2.10.00 CONTROL AND SELECTOR SWITCHES
Control and selector switches shall be of rotary stayput type with escutcheon plates showing
the functions and positions. The switches shall be of sturdy construction and suitable for
mounting on panel front. Switches with shrouding of live parts and sealing of contacts against
dust ingress shall be preferred. The contact ratings shall be atleast the following:
(a.) Make and carry continuously – 10 Amps.
(b.) Breaking current at 220 V DC – 0.5 Amp. (inductive)
(c.) Breaking current at 240 V AC – 5 Amp. At 0.3 p.f.
2.11.00 FUSES
Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse carriers
which are mounted on fuse bases. Wherever it is not possible to mount fuses on fuse
carriers, fuses shall be directly mounted on plug in type bases. In such cases one insulated
fuse pulling handle shall be supplied for each charger. Kick-off fuses (trip fuses) with alarm
contacts shall be provided for all D.C. fuses.
2.12.00 Indicating Lamps
Three (3) indicating lamps shall be provided to indicate A.C. supply availability. The
indicating lamp shall be of panel mounting, filament type low wattage or LEDs and capable of

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CLAUSE NO.
clear status indication under the normal room illumination. The lamps shall be provided with
series resistors (non-hygroscopic) preferably built in the lamp assembly and replaceable from
front. The lamp covers shall be preferably screwed type, unbreakable and moulded from heat
resistant material
2.13.00 Blocking Diode
Blocking diode shall be provided in the output circuit of each Charger to prevent current flow
from the D.C. Battery into the Charger.
2.14.00 Annunciation System
Visual indications through indicating lamps/LEDs or annunciation fascia shall be provided in

all Chargers for the following:
(a.) A.C. supply failure
(b.) Rectifier fuse failure
(c.) Surge circuit fuse failure
(d.) Filter fuse failure
(e.) Load limiter operated
(f.) Charger trip
(g.) Battery on Boost
Potential free NO contacts of all above conditions shall be provided for following remote
alarms in the Employer’s Unit Control Board:
(a) Battery on Boost
(b) Charger trouble (this being a group alarm initiated by any of the faults other than
‘Battery on Boost’)
2.15.00 Name Plates and Marking
The name plates shall be made of non-rusting metal and shall have black back-ground with
white engraved letters and secured by screws. These shall be provided near top edge on the
front as well as on rear side of Charger. Name plates with full and clear inscriptions shall also
be provided on and inside the panels for identification of the various equipments.

8 OF 12
CLAUSE NO.
3.00.00 CONSTRUCTION
3.01.00 The Chargers shall be indoor, floor mounted, self supporting sheet metal enclosed cubicle
type. The Contractor shall supply all necessary base frames, anchor bolts and hardware. The
Charger shall be fabricated using cold rolled sheet steel shall not less than 1.6 mm and shall
have folded type of construction. The panel frame shall be fabricated using cold rolled sheet
steel of thickness not less than 2.0 mm. Removable undrilled gland plates of at least 3.0 mm
sheet steel and lugs for all cables shall be supplied by the Contractor. The lugs for cables
shall be made of electrolytic copper with tin coat. Cable sizes shall be advised to the
Contractor at a later date for provision of suitable lugs and gland plates. The Charger shall be
tropicalised and vermin proof. Ventilation louvers shall be backed with fine brass wire mesh.
All doors and covers shall be fitted with synthetic rubber gaskets. The Chargers shall have
hinged double leaf doors provided on front and/or backside for adequate access to the
Charger internals. All the Charger cubicle doors shall be properly earthed. The degree of
protection of Charger enclosure shall be atleast IP-42.
3.02.00 All indicating instruments, control & selector switches and indicating lamps shall be mounted
on the front side of the Charger. Design of panels shall be based on the following
dimensions.
1) Overall height - Maximum 2350 mm
2) Operating handles - Maximum 1800 mm
(highest and lowest Minimum 350 mm
positions reached by
operator’s hands),
protective mechanical
indicators
3) Doors and panel - Maximum 1800 mm
handles and locks Minimum 300 mm
3.03.00 The layout of Charger components shall be such that their heat losses do not give rise to
excessive temperature within the Charger panel surface. Location of the electronic modules
will be such that temperature rise of the location, in no case, will exceed 15°C over ambient
air temperature outside the Charger.

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CLAUSE NO.
3.04.00 Each Charger panel shall be provided with an illuminating lamp and one 5 Amp. Socket.
Switches and fuses shall be provided separately for each of the above.
3.05.00 Locking facilities shall be provided as following:
1. For locking Trickle/Boost selector switch in the respective position.
2. The Charger enclosure door locking requirements shall be met by the application of
padlocks. Padlocking arrangement shall allow ready insertion of the padlock shackle
but shall not permit excessive movement of the locked parts with the padlock in
position.
3.06.00 Wiring
3.06.01 Each Charger shall be furnished completely wired upto power cable lugs and terminal blocks
ready for external connection. The power wiring shall be carried out with 1.1 KV grade PVC
insulated cables conforming to IS:1554 (Part-I). The control wiring shall be of 1.1KV grade
PVC insulated stranded copper conductors of 2.5 sq.mm. conforming to IS:694. Control
wiring terminating at electronic cards shall not be less than 1.0 sq. mm. Control terminal
shall be suitable for connecting two wires with 2.5 sq.mm. stranded copper conductors. All
terminals shall be numbered for ease of connections and identification. At least 20% spare
terminals shall be provided for circuits.
3.06.02 Power and control wiring within panels shall be kept separate. Any terminal or metal work
which remains alive at greater than 415 V, when panel door is opened, shall be fully
protected by shrouding.
3.06.03 An air clearance of at least ten (10) mm shall be maintained throughout all circuits, except
low voltage electronic circuits, right upto the terminal lugs. Whenever this clearance is not
available, the live parts should be insulated or shrouded.
3.07.00 PAINTING
Treatment as per IS:6005. Two coats of lead oxide primer followed by powder painting with
final shade of RAL9002 for complete panel except end covers & RAL 5012 for end covers.
4.00.00 TESTS
specification and carried out within last ten years from the date of techno-commercial bid
opening. These reports should be for the test conducted on the equipment similar to those
proposed to be supplied under this contract and the test(s) should have been either

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CLAUSE NO.
4.02.00 However if the contractor is not able to submit report of the type test(s) conducted within last
ten years from the date of techno-commercial bid opening, or in the case of type test
report(s) are not found to be meeting the specification requirements, the contractor shall
conduct all such tests under this contract at no additional cost to the owner either at third
party lab or in presence of client/owners representative and submit the reports for approval.
4.04.00 GENERAL
1. For chargers of rating more than 60A, the contractor shall furnish the following type
tests reports for each rating of the equipment to be supplied under this contract.
a) Complete physical examination
b) Temperature rise test at full load. (For chargers of up to 400A rating,

Temperature rise test report for rectifier assembly at 200% of full load shall
also be submitted.)
c) Insulation resistance test.
d) High voltage (power frequency) test on power and control circuits except low
voltage electronic circuits.
e) Ripple content test at
i) No load
ii) Half load
iii) Full load
f) Automatic voltage regulator operation test at specified A.C. supply variations

at
i) No load
ii) Half load
iii) Full load
g) Load limiter operation test
h) Efficiency and power factor measurement.

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CLAUSE NO.
i) Surge withstand capability test at the following points of the Charger:
i) Across each A.C. input phase
ii) Across AC input line to ground.
iii) Across D.C. output terminals.
iv) Across each D.C. output terminal to ground
The Charger shall not exhibit any component damage and there shall be no change
in performance as per (g) and (h).
j) Environmental Tests
Steady state performance tests (f) and (g) shall be carried out before and after
each of the following tests.
i) Soak Test
The electronic modules shall be subjected to continuous operation

for a minimum period of 72 hours. During last 48 hours, the ambient
temperature shall be maintained at 50 deg. C. The 48 hour test
period shall be divided into four equal 12 hour segments. The input
voltage during each 12 hours shall be nominal voltage for 11 hours
followed by 110% of nominal voltage for 30 minutes, followed by
90% of nominal voltage for 30 minutes.
ii) Degree of protection test.
2. Dynamic response test and Temperature rise test at full load shall be carried out on
each charger before dispatch at manufacturer’s works.
5.00.00 COMMISSIONING
5.01.00 The contractor shall carryout the following commissioning tests and checks after installation
of the equipment at site:
a) Complete physical examination.
b) Checking of proper operation of annunciation system.
c) Insulation resistance test.
d) Load limiter operation.

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OUTDOOR TRANSFORMER

CLAUSE NO.
1.00.00 TECHNICAL PARAMETERS
1.01.00 Outdoor Transformers
(a) Rated output As per Requirement
(b) Cooling ONAN
(c) Type Two winding
(d) Voltage Ratio As per Requirement
(e) Frequency 50 Hz
(f) Phase Three (3)
(g) Service Outdoor
(h) Duty Continuous
(i) Overload capacity As per IS: 6600/IEC60076-7 and specified

(j) Permissible Temperature rise over an ambient temp. of 50 deg. C
(1.) Winding (by resistance 55 deg. C (45 deg.C for upto & including
method) 2.5MVA and 33KV rating)
(2.) Top oil (by thermometer) 50 deg. C (40 deg.C for upto & including
2.5MVA and 33KV rating)
(k) Impedance at 75 deg.C As per details of Transformers under "Key

Technical Parameter-Transformers"
Subsection/SLD/ As per sysytem
requirement/specified elsewhere in the
specification.
(l) Noise Level AS PER NEMA TR-1

(m) System fault level As per requirement.

AUXILIARY OUTDOOR 1 OF 29
TRANSFORMERS
CLAUSE NO.
(n) Winding
1. Highest System Voltage(kV) 36 12 7.2 3.6 0.433
2. Lightning impulse withstand 170 75 60 40 -

voltage, kVp
3. One min power frequency 70 28 20 10 3

withstand voltage, kVrms
4. Insulation uniform uniform uniform uniform uniform
5. Method of neutral earthing As per system requirement

and Vector group
(o) Tap changer details:

i) Tap range As per system requirement
ii) Tap Control As per system requirement
(p) Bushing CT Parameters:- As per system requirement
(q) Bushing Parameters
Parameters 36 KV 12 KV 7.2KV 3.6kV 433 V

( 1 .) Rated Voltage(kV) 36 12 7.2 3.6 1.1
( 2 .) Lightning impulse 170 75 60 40 -
withstand voltage, kVp
( 3 .) One min power 77 30 22 11 3.0

frequency withstand
voltage , kV (rms)
( 4 .) Minimum total creepage 25mm/kV x Rated Voltage of Bushing.

distances (mm)
( 5 .) Mounting Tank / Transformer body
( 6 .) Rated Current As per details of Transformers under (r)

Subsection.

TRANSFORMERS
CLAUSE NO.
(r) Bushing Rated Current (in Amperes)

SR. No. LV
HV RATING LV-
KVA RATING RATING HV-Line Neutral
(kV) Line
(kV)
(1.) 16,000 34.5 11 400 1250
(2.) 16,000 11.5 11 1250 1250
HVN =
(3.) 16,000 11 3.45 1250 4000 CURRENT
OF HV
(4.) BUSHING,
12,500 11 3.45 1250 3150
LVN=
CURRENT
(5.) 4,000 11 3.45 400 1250 AS PER LV
BUSHING
(AS
(6.) 2,000 11 0.433 250 3150 APPLICAB
LE)
(7.) 1,600 11 0.433 250 3150
(8.) 1,000 11 0.433 250 2000
(9.) 630 3.3 0.433 250 1250
(s) Termination Details (Indicative only)

(1.) HV Phase Terminal Cable box suitable for XLPE
33kV,11kV, 3.3kV insulated cable.
(2.) LV Phase Terminal Cable box/Busduct suitable for
11.5 KV XLPE insulated cable.
(3.) LV Phase Terminal Busduct (Non-Segregated)
3.45 KV
(4.) LV Phase Terminal Busduct (Non-Segregated) Or Cable
0.433KV Box
(5.) LV Neutral Terminal Grounded through NGR
3.45kV
(6.) LV Neutral Terminal Solidily grounded through Copper
0.433kV flat connection.
(t) XLPE Cable size (as per system requirement)
(u) Minimum Clearance in air (mm)
System voltage 33 kV 11 kV 6.6 kV 3.3 KV 433 V

TRANSFORMERS
CLAUSE NO.
Phase to Phase 350 130 100 70 25
Phase to Earth 320 120 90 60 25
1.02.00 NEUTRAL GROUNDING RESISTORS (AS PER SYSTEM

REQUIREMENT)
1.02.01 3.6 KV NGR
Sr. Parameters 3.6 kV

No
i) Resistance Value at AS PER SYSTEM
50 deg. C. REQUIREMENT
ii) Rated current 600A for 10 seconds
iii) Service Outdoor
iv) Resistor material & Punched stainless steel grid
connection element type
v) Maximum allowable 350 deg. C
temperature rise over
ambient 50 oC
vi) Mounting 3.6 KV grade insulators.
vii) Power frequency test 10 KV (rms)
level
viii) Application Refer "Key Technical
Parameter-Transformers"
Subsection.
Details of Transformers : As per system Requirement
1.02.00 GENERAL
1.03.00 STANDARDS
All equipment provided under the specification shall in general, conform to the latest
issue of the following standards:
Indian Title International &
Standards internationally recognized
No. standards
IS: 2026, Transformers IEC: 60076,
IS 1180

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No. standards
IS: 3639 Fittings & accessories for power
transformers
Insulating oils for transformer and IEC: 60296, BS:148

switchgear
IS: 2099 Bushing for alternating voltages above IEC: 60137, BS: 223
1000 V
IS: 2705 Current transformers IEC: 60185
IS: 325 Three phase induction motors IEC: 60034
IS: 3637 Gas operated relays
IS: 10028 Code of practice for selection

installation & maintenance of
transformers
IS: 4691 Degree of protection provided by

enclosure for rotating electrical
machinery
IS: 13947 Specification for low voltage switchgear IEC: 144

& control gear Part – I
IS : 5 Colours for ready mix paints
IS: 1866 Code of practice for maintenance &

Supervision of mineral insulating oil in
equipment
IS: 6272 Industrial cooling fans
IS: 6600 Guide for Loading of oil immersed IEC: 60076-7

transformers
IS: 3347 Specification for dimensions of

porcelain bushing
IS:8603
IS: 8468 Tap changers IEC: 214
High voltage test technique IEC: 60
Insulation co-ordination IEC: 71
NEMA standard publication for Power NEMA-TR-1

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No. standards
transformers
IS: 10596 Code of practice for selection,

Installation operation & maintenance of
pumps for Industrial applications
IS: 9434 Guide for sampling & analysis of free & IEC: 567
dissolved gas & oil from oil filled
electrical equipment
IS: 2544 Porcelain post insulators for systems

with nominal voltage greater than 1000
V
IS: 5561 Specification for electric power

connectors
IS: 5621 Hollow insulators for use in electrical

equipment
IS: 2633 Methods for testing uniformity of coating

of Zinc coated articles
IS: 12676 Dimensions for OIP insulated

condenser bushings
BEE Guideline & CEA notification
1.04.00 The electrical installation shall meet the requirements of Indian Electricity act 2003.
2.00.00 PERFORMANCE
(a) The maximum flux density in any part of the core & yoke at the rated MVA, voltage
& frequency shall be such that under 110% continuous voltage condition it does
not exceed 1.9 Tesla.
(b) The transformer & all its accessories including CT’s etc, shall be designed to
withstand without injury the thermal & mechanical effects of any external short
circuit to earth & of short circuits at the terminal of any winding for a period of 2
sec.
(c) Transformers shall withstand, without injurious heating, combined voltage &
frequency fluctuations, which produce the following over fluxing condition:
1) 110 %- continuous

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125%- for one minute
140%- for five seconds
2) Bidder shall indicate 150% & 170% over voltage withstand time.
3) Over fluxing characteristics up to 170 % shall be submitted.
(d) The transformers shall be capable of being operated continuously without danger
on any tapping at the rated MVA with voltage variation of ±10% corresponding to
the voltage of tapping.
(e) The transformers shall be capable of being loaded in accordance with IS: 6600 /
IEC: 60076-7 up to load of 150 %. There shall be no limitation imposed by
bushings, tap changers etc. or any other associated equipment.
(f) Auxiliary outdoor transformers up to and including 2500KVA, 33kV shall have
maximum losses of STAR-2 rating or better as per latest BEE guideline. The
outdoor transformer up to 2500KVA, 33kV shall also comply with latest IS:1180.
3.00.00 CONSTRUCTION
The features & construction details of each transformer shall be in accordance with
the requirement stated hereunder.
3.01.00 TANK AND TANK ACCESSORIES
(a) Tank shall be of welded construction & fabricated from tested quality low carbon
steel of adequate thickness. The welding procedure specification (WPS),
procedure qualification record (PQR), shop welding schedule, welder’s
qualification shall be subject to Employer’s approval. After completion of welding,
all joints shall be subjected to visual examination. In case of doubt particular weld
shall be checked by D.P. Test. However weld joints of load bearing member shall
be left unpainted till carrying out of jacking test followed by DP Test during final
inspection of transformer. Details of acceptance norms of welding shall be
submitted for Employer’s approval which shall include permissible undercut,
overlap, surface crack, porosity, out of alignment of plate surface in butt joints,
maximum gap due to incorrect fit up of fillet joint etc.
(b) Each tank shall be provided with :

(i.) Lifting lug suitable for lifting the equipment complete with oil.
(ii.) A minimum of four jacking pads in accessible position to enable the
transformer complete with oil to be raised or lowered using hydraulic or
mechanical screw jacks.
(iii.) Suitable haulage holes shall be provided for transformer wheeling in all four
directions.
(c) For all transformers, suitable bi-directional skids with pre-drilled holes shall be
provided integral with the tank body for fixing the transformer tank on foundation.
These skids shall be such that the bottom of the tank body is at a sufficient height
above foundation for cleaning purposes.

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The transformers (except transformers upto and including 2 MVA) are to be

provided with four no. of bi - directional flat rollers of detachable type & shall be
mounted on wheels on foundation. Suitable locking arrangement shall be provided
for the wheels to prevent accidental movement of transformer.
(d) At least two adequately sized inspection openings one at each end of the tank
shall be provided for easy access to bushing & earth connections. The inspection
covers shall not weight more than 25 Kg. Handles shall be provided on the
inspection cover to facilitate lifting.
(e) All bolted connections shall be fitted with weather proof, hot oil resistant,
rubberized cork gasket in between for complete oil tightness. If gasket is
compressible, metallic stops shall be provided to prevent over compression.
(f) The tank shall be designed in such a way that it can be mounted on the plinth
directly.
(g) Wherever possible the transformer tank & its accessories shall be designed
without pockets wherein gas may collect. Where pockets can not be avoided,
pipes shall be provided to vent the gas into the main expansion pipe.
(h) The main tank body shall be capable of withstanding full vacuum.
3.02.00 Core
(a) The core shall be constructed from cold rolled, super grain oriented (CRGO),
silicon steel laminations of equivalent to M4 or better grade.
(b) The core isolation level shall be 2 kV (rms.) for 1 minute in air.
(c) Adequate lifting lugs will be provided to enable the core & windings to be lifted.
3.03.00 Windings
(a) The contractor shall ensure that windings of all transformers are made in dust
proof & conditioned atmosphere. The bidder shall furnish details of the facilities
available at his works along with the Techno- Commercial bid.
(b) The conductors shall be of electrolytic grade copper free from scales & burrs.
(c) All windings of the transformers having voltage less than 66 kV shall be fully
insulated.
(d) Tapping shall be so arranged as to preserve the magnetic balance of the

transformer at all voltage ratio.
3.04.00 Insulating Oil
No inhibitors shall be used in the transformer oil. The oil supplied with transformers
shall be new and previously unused and must conform to following while tested at
supplier’s premises and shall have following parameters.

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S.No. Property Permissible values
1. Kinematic Viscosity, mm2/s  12 at 40  C

 1800.0 at (-)30  C
2. Flash Point,  C  140 C
3. Pour point,  C  (-)40  C

4. Appearance Clear , free from sediment and
suspended matter
5. Density kg/dm3 at 20  C  0.895
6. Interfacial Tension N/m at 25 C  0.04
7. Neutralisation value, mgKOH/g  0.01

8. Corrosive sulphur Non Corrosive
9. Water content mg/kg  30 in bulk supply
 40 in drum supply
10. Anti oxidants additives Not detectable
11. Oxidation Stability
Neutralization value, mgKOH/g  1.2
Sludge, % by mass  0.8
12. Breakdown voltage

As delivered, kV  30
After treatment, kV  70
Dissipation factor, at 90 C
13.  0.005
And 40 Hz to 60 Hz
14.
PCA content 1%
15.
Impulse withstand Level, kVp  145
16.
Gassing tendency at 50 Hz after 120 5
min, mm3/min
Subsequently oil samples shall be drawn at:
(a) After placement of transformer on foundation, Oil of main tank shall be tested for
i) BDV 60 kV (min) Applicable for all

transformers
ii) Moisture content 10 ppm (max.) including 16 MVA.

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iii)
Tan delta at 90 deg. C 0.002 (max.) Applicable for 16
MVA & above
iv)
Resistivity at 90 deg. C 35 x 1012 ohm-cm Transformers only.
(min)
v)
Interfacial tension 0.040 N/m (min)
(b) Prior to energization at site for following properties & acceptance norms:
i) BDV 60 kV (min) Applicable for all
ii) Moisture content 10 ppm (max.) transformers
including 16 MVA.
iii) Tan delta at 90 deg. C 0.05 (max.) Applicable for 16
iv) Resistivity at 90 deg. C 1 x 1012 ohm-cm (min) MVA & above
v) Interfacial tension 0.035 N/m (min) Transformers only.
3.04.02 Oil Preservations System

(a) The transformers rated below 7.5 MVA shall have the following types of oil
preservation systems:
(i.) Conventional Conservator
The transformer shall be provided with conventional single compartment
conservator with dry air filling the space above the oil. The top of the
conservator shall be connected to the atmosphere through a cobalt free
indicating type silica gel breather with transparent enclosure. The Buchholz
relay shall also be provided.
The conservator shall be fitted with a cobalt free non-carciogenic indicating
type silica gel filter breather of transparent enclosure breather, which shall be
so designed that:
 Passage of air is through a dust filter and silica gel.
 Silica gel is isolated from atmosphere by an oil seal.
 Moisture absorption indicated by a change in colour of the tinted crystal

can be easily observed from a distance.
 Breather is mounted not more than 1400 mm above rail top level.
(b) For transformers rated 7.5 MVA and above, bidder shall offer air cell type oil sealing
in the conservator to prevent oxidation and contamination of oil due to contact with
water. The requirement of air cell type constant oil preservation system are given
below:
i. Contact of the oil with atmosphere is prohibited by using a flexible urethane
or nitrile rubber reinforced with nylon cloth air cell.
ii. The connection of air cell to the top of reservoir is by air proof seal preventing
entrance of air into the conservator.

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iii. The temperature is likely to rise upto 100 Deg C when the transformer is in
operation. As such air cell used shall be suitable for operating continuously at
100 deg. C.
iv. A silica gel breather shall be provided in the air side vent line.
3.05.00 Terminal Arrangements
3.05.01 Bushings
(a) The electrical & mechanical characteristics of bushings shall be in accordance with
IS: 2099, IS: 3347 & IS: 12676.
Bushings of rating below 52 kV shall be solid porcelain/oil
communicating/condenser type. All condenser bushings shall be non-
communicating type.
(b) Condenser type bushings shall be provided with :

(i.) Oil level gauge,
(ii.) Oil filling plug & drain valve ( if not hermetically sealed)
(iii.) Tap for capacitance & tan delta test.
(c) Clamps & fittings shall be of hot dip galvanized steel.
(d) Bushing & fittings shall be provided with vent pipes that shall be connected to route
any gas collection through the Buchholz relay.
(e) No arcing horns shall be provided on the bushings.
(f) Wherever cable termination is specified, bushing terminals shall be provided with
suitable terminal connectors of approved type and size for cable termination.
(g) Where current transformers are specified, the bushings shall be removable without
disturbing the current transformer.
.
3.05.02 Neutral Terminal Arrangement
3.05.03 Neutral Termination
(a) The neutral terminal of 433 V winding shall be brought out on a bushing along with
the 433 V phase terminal to from a 4 wire system for the 433 V. Neutral CT’s shall
be located in the lead coming out of the winding and location of these CT’s shall
not be inside the tank.
(b) The neutral terminal of winding not connected to NGR (as per "Key Technical
Parameter-Transformers" Subsections), shall also be brought out through an
outdoor bushing. Further this neutral terminal shall be connected by a copper flat
of size 50 mm x 8 mm, which shall be brought down upto 100 mm above ground.
The copper flat shall be insulated and supported from the tank body. The

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connection shall be made by using two (2) bolted neutral grounding terminals with
necessary accessories.
(c) The neutral terminal of winding connected to NGR (as per "Key Technical
Parameter-Transformers" Subsections), shall be brought to an outdoor bushing,
away from the busduct termination arrangement (wherever applicable). It shall be
connected to associated neutral grounding resistor by a copper flat, which shall be
supplied & installed by the contractor along with the necessary intermediate
supporting insulators & supporting structure. Also NGR shall be grounded through
copper flat which shall be insulated and properly supported and shall be brought
down upto 100 mm above ground.
3.05.04 Bus Duct Terminations
(a) A flanged throat or equivalent connection shall be provided for termination of

busduct enclosure. The winding termination shall be on outdoor type of bushings.
The Employer would provide necessary flexible connection between the bushing
terminal & the bus duct conductor. The material of the busduct termination shall be
non-magnetic.
(b) The shape of the bus duct conductor shall be informed during detailed
engineering. The bushing pads shall be silver/tin plated. A drain with stopcock
arrangement shall be provided at flange to drain leakage of oil/water at
termination. As bus duct will be pressurized stopcocks shall be airtight.
(c) Tolerance permissible for the height of the terminal connected to busduct over rail
top level is ± 10 mm. Contractor has to ensure that radiator & conservator does not
obstruct the path of the bus ducts in position & during movement of transformer.
The contractor shall co-ordinate final design of terminal arrangement to suit bus
duct arrangement during detailed engineering.
(d) The transformer bushing enclosed in bus duct enclosure shall be designed for
satisfactory operation in the high ambient temperature existing inside the bus duct
enclosure. The temperature inside the bus duct enclosure may be of the order of
90 – 100 deg. C. The bus duct conductor temperature may be as high as 105 deg.
C & temperature in the bus duct enclosure will be of the order of 80 deg. C.
3.05.05 Cable boxes & disconnecting chamber

(a) HV Cable boxes shall be of phase segregated air insulated type & shall be of
sufficient size to accommodate Employer’s cable & termination (as applicable).
Phase segregation shall be achieved by insulating barriers.
(b) Cable boxes shall have bus bars / terminal connectors of adequate size & bolt
holes to receive cable lugs.
(c) A suitable removable gland plate of non-magnetic material drilled as per the
Employer’s instruction shall also be provided in the cable box.
(d) The support from base for the cable box shall be of galvanized iron.

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(e) The contractor shall provide earthing terminals on the cable box, to suit Employer’s
GI flat.
(f) The final cable size & type, number & length of terminating cable (from cable gland
plate to the cable lug) shall be furnished during detailed engg.
(g) Cable boxes shall be designed such that it shall be possible to move away the
transformer without disturbing the cable terminations, leaving the cable box on
external supports.
(h) Cable boxes shall have removable top cover & ample clearance shall be provided
to enable either transformer or each cable to be subjected separately to high
voltage test.
3.05.06 TERMINAL CONNECTOR (If applicable)
(a) Bushing terminal shall be provided with terminal connectors of approved type &
size for connection to external part. Terminal connectors must have been
successfully type tested as per IS: 5561.
(b) Aluminium alloy if used shall conform to designation 4600 M of IS: 617 or of better
quality.
(c) No current carrying part of a clamp shall be less than 10 mm thick.
(d) All ferrous parts shall be hot dip galvanized conforming to IS: 2633.
(e) For bi-metallic clamp, copper alloy liner of minimum 2-mm thickness shall be cast
integral with aluminum body. Alternatively Bidder may offer bimetallic connector
with loose bimetallic sleeve.
(f) Flexible connectors shall be made from tinned copper sheets.
(g) Size of terminal/conductor for which the clamp is suitable & rated current under the
conditions shall be embossed / punched on each component of the clamp, except
hardware.
(h) Rated current of the terminal connectors shall be same as that of corresponding
bushing.
3.06.00 Bushing Current Transformer
(a) Current transformer shall comply with IS: 2705.
(b) It shall be possible to remove turret mounted current transformers from the
transformer tank without removing the tank cover. Necessary precautions shall be
taken to minimize eddy currents & local heat generated in the turret.
(c) All secondary leads shall be brought to a weatherproof terminal box near each
bushing. These terminals shall be wired out to transformer marshalling box using
separate cables for each core.

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3.07.00 Terminal Marking

The terminal marking & their physical position shall be as per IS: 2026 unless specified
otherwise.
3.08.00 Marshalling Box(M. BOX) Unit
(a) Each transformer shall be provided with one Marshalling Box housing all the cooler
control, OTI & WTI etc.
M. Box shall be of stainless steel (SS-316 or better), at least 2.5 mm thick, dust and
vermin proof provided with proper lighting and thermostatically controlled space
heaters. The degree of protection shall be IP 55. Marshalling Box of all transformers
shall be preferably Tank Mounted. The gasket used shall be of neoprene rubber. A
space heater & cubicle lighting with on–off switch shall be provided in each cabinet.
A circuit breaker/contactor with thermal overload device for controlling the AC
auxiliary supply shall be provided.
(b) Terminal Blocks
(1.) The terminal blocks to be provided shall be fully enclosed with removable
covers & made of molded, non-inflammable plastic material with blocks &
barriers molded integrally. The terminal blocks shall be of 650V grade & have
10 A continuous rating. Terminal blocks for current transformer secondary
leads shall be provided with test links & isolating facilities. Also current
transformer secondary leads shall be provided with short circuiting & earthing
facilities. At least 20% spare terminals shall be provided on each panel &
these spare terminals shall be uniformly distributed on all terminal blocks.
(2.) Terminal blocks shall be suitable for connecting the following conductors on
each side :
(i.) Current transformer circuits – minimum of two No. of 2.5 sq. mm
copper wires each side
(ii.) Other circuits— minimum of one No. of 2.5 sq. mm copper wire
each side
(iii.) Terminal blocks numbering shall be made inline with the tender
drawing no. 0000-203-PVE-B-001 (Title: “Standard Terminal
Numbers for Marshalling Box of all Transformers”) enclosed
(c) The temperature indicators shall be so mounted that the dials are not more than
1500 mm from ground level. Glazed door of suitable size shall be provided for
convenience of reading.
(d) All incoming cables shall enter the marshalling box from the bottom. A removable
undrilled gland plate shall be provided at the bottom of the box for accommodating
glands for Employer’s incoming and outgoing cables, which shall not be less than
450 mm from finished floor level.
(e) All devices and terminal blocks inside the marshalling box shall be clearly identified
by symbols corresponding to those used on applicable schematic or wiring
diagram.

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(f) It shall be located in such a way that, the same shall not face towards the
transformer.
(g) The gland plate shall be made into two detachable halves, for facilitating the
termination of Employer’s cable and Contractor’s cables separately. The gland
plate and the associated compartment shall be sealed in a suitable manner to
prevent the ingress to moisture, rodents, insects etc.
(h) One dummy terminal block in between each trip wire terminal shall be provided.
(i) Wiring Scheme shall be engraved in a plate and the same shall be fixed inside the
Marshalling Box door.
3.09.00 Control Wiring & Cabling

Supply, laying & termination of all cables & accessories required of proper termination from
the M. Box except for those stated under next clause below so as to make equipment
complete & functional shall be in scope of supplier. The cable between the M. Box &
transformer shall be laid by the supplier through GI conduits/ pipes. Cable box / sealing end
shall be suitable for following types of cables
1) 415 V power 1100 V grade PVC insulated aluminum conductor cable with
armour.
2) Control 1100 V grade PVC insulated 2.5 sq. mm stranded copper
conductor with armour.
3.10.00 PAINTING
Painting of transformer and its accessories shall be in accordance with the following chart.
PARTS NAME TYPE OF PAINT No.of Total

Coats DFT
(1.) Inside of tank Oil & heat resistant fully glossy white One Atleast
and accessories coat 30
(except M Box) micron
(2.) External surface Chemical resistant epoxy zinc One Atleast

of transformer phosphate primer, MIO (Micaceious coat 100
and accessories iron oxide) as intermediate paint each micron
(except radiator) followed by polyurethane finish paint
of blue colour corresponding to RAL
5012.
(3.) External radiator Anticorrosive primary paint followed Two Atleast

surface by high quality full glossy outer finish coats 100
paint (blue colour corresponding to each micron
RAL 5012.)

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PARTS NAME TYPE OF PAINT No.of Total

Coats DFT
(4.) Internal radiator Hot oil proof, low viscosity varnish and
surface subsequent flushing with transformer oil
3.11.00 Cooling Equipment
The radiators shall be detachable type, mounted on the tank. Each radiator shall be provided
with the following:
(a) A drain plug at the bottom.
(b) An air release plug at the top.
3.12.00 TAP CHANGER DEVICE
3.12.01 Off Circuit Tap change Switch
(a) The tap change switch shall be three phase, hand operated for simultaneous
switching of similar taps on the three phases by operating on external hand wheel.
(b) The tap changing shall be possible without disturbing the transformer in any way
except de-energising.
(c) Arrangement shall be made for securing and pad-locking the tap changer in any of
the working positions, and it shall not be possible for setting or padlocking it in any
intermediate position. An indicating device shall be provided to show the tap in
use.
(d) The Cranking device for manual operation of the off circuit tap changing gear shall
be removable and suitable for operation by a man standing on ground level. The
mechanism shall be complete with the following:-
(i.) Mechanical tap position indicator which shall be clearly visible from near the
transformer.
(ii.) Mechanical stops to prevent over cranking of the mechanism beyond the
extreme tap positions.
(iii.) The manual operating mechanism shall be labeled to show direction of
operation for raising the secondary voltage and vice versa.
(iv.) A warning plate indicating “The switch shall be operated only when the
transformer has been de-energised” shall be fitted.
3.13.00 VALVES
(a) All valves upto and including 50 mm shall be of gun metal or of cast steel. Larger
valves may be of gun metal or may have cast iron bodies with gun metal fittings.

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They shall be of full way type with internal screw and shall open when turned
counter clockwise when facing the hand wheel.
(b) Suitable means shall be provided for locking the valves in the open and close
positions. Provision is not required for locking individual radiator valves.
(c) Each valve shall be provided with the indicator to show clearly the position of the
valve.
(d) Gland packing/gasket material shall be of teflon rope/nitrile rubber. In case of

gate/globe valves, gland packing preferably of teflon rope shall be used to prevent
oil seepage through the gland.
(e) After testing, inside surface of all cast iron valves coming in contact with oil shall
be applied with one coat of oil resisting paint/varnish with two coats of red oxide
zinc chromate primer followed by two coats of fully glossy finishing paint
conforming to IS:2932 and of a shade (Preferably red or yellow) distinct and
different from that of main tank surface. Outside surface except gasket setting
surface of butterfly valves shall be painted with two coats of red oxide zinc
chromate conforming to IS:2074 followed by two coats of fully glossy finishing
paint.
(f) All hardware used shall be cadmium plated/electro galvanised.
(g) Sampling & drain valves should have zero leakage rate.
3.14.00 Neutral Grounding Resistors (If applicable)
The earthing resistors are required for LV neutral point earthing of the various transformers.
(as specified elsewhere in this specification)
(a) Resistor Elements
The resistors shall be of punched stainless steel grid element type. The grids
shall be securely supported at sufficient number of points so that no damage
is caused to the grids due to vibrations and no mechanical stresses are
developed. The resistor element shall be insulated from supporting base by
mica tubes. The insulating material used in the construction shall be heat
resistant such as mica.
(b) Stacking
Various sections comprising the neutral grounding resistor shall be capable

of being stacked one above the other. The insulators supporting the resistor
assemblies shall be of outdoor type. Connecting links shall be provided to
connect adjacent stacks.

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(c) Enclosure
The neutral grounding resistor shall be housed in a 2.5 mm thick sheet steel
enclosure. The enclosure shall be weather proof having IP 33 degree of
protection in accordance with IS: 13947. The resistor neutral side terminal
shall be brought out on the roof and the ground side terminal at the side of
the enclosure through porcelain bushings. The ground side terminal shall be
brought to ground level by a copper flat supported from the mounting
structure by porcelain insulators. The copper bar shall have two (2) bolted
neutral grounding terminals with hole size suitable for M10 bolt size and
necessary accessories for connecting to ground mat through two MS ‘flats’.
The enclosure shall be supported on insulators placed on the mounting
structure.
(d) Mounting Structure
The Contractor shall supply and erect a galvanized structure to support the
NG resistor enclosure so that the base of the enclosure shall be at a
minimum height of 2.4M above ground level. The NG resistor enclosure
mounting and the neutral connection shall be such that it does not obstruct
the busduct routing in any way.
A heating circuit with Thermostat to be provided inside the enclosure to
control humidity.
3.15.00 Bolts & Nuts
All bolts & nuts exposed to weather shall be hot dip galvanised steel /cadmium plated steel.
3.16.00 Gasket
The gaskets shall not deteriorate during the life of transformer if not opened for maintenance
at site. Supplier shall also recommend quality & make of gaskets to be used for replacement
during maintenance if required. All joints flanged or welded associated with oil shall be such
that no oil leakage or sweating occurs during the life of transformer. The quality of these joints
is considered established, only if the joints do not exhibit any oil leakage or sweating for a
continuous period of at least 3 months during the guarantee period. In case any sweating /
leakage is observed, contractor shall rectify the same & establish for a further period of 3
months of the same. If it is not established during the guaranteed period, the guaranteed
period shall be extended until the performance is established.
4.00.00 FITTINGS
4.01.00 The following fittings shall be provided with each transformer covered in this
specification:
1) Conservator for main tank with oil filling hole and cap, isolating valves,
drain valve, magnetic oil level gauge with low level alarm contacts and
dehydrating cobalt free non-carciogenic indicating type silica gel breather
with transparent enclosure. Breather for conservators shall be mounted
not more than 1400 mm above rail top.
2) Oil preservation system: - as specified elsewhere.

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3) Minimum two Nos. of spring operated pressure relief devices with

alarm/trip contacts for transformer of 2 MVA & above rating. Discharge of
PRD shall be properly taken through pipes & directed away from the
transformer /other equipment.
4) Buchholz relay double float type with isolating valves on both sides,
bleeding pipe with Gas collecting device at the end to collect gases and
alarm and trip contacts. Control cable termination at Buchhloz relay shall
be properly sealed to prevent water entry.
5) Air release plug.
6) Inspection openings and covers.
7) Bushing with metal parts and gaskets to suit the termination
arrangement.
8) Cover lifting eyes, transformer lifting lugs, jacking pads, towing holes and
core and winding lifting lugs.
9) Protected type Mercury or alcohol in glass thermometer.
10) Bottom and top filter valves with threaded male adapters, bottom
Sampling valve & drain valve.
11) Rating and diagram plates on transformers (English & Hindi) and auxiliary
apparatus.
12) Radiator as specified.
13) Prismatic/toughened glass oil gauge for transformers.
14) 150 mm dial type oil temp indicator with alarm and trip contacts,
maximum reading pointer & resetting device. Accuracy class shall be ±
1.5 % or better.
15) 150-mm dial type Winding temp indicator with alarm and trip contacts,
maximum reading pointer & resetting device. Accuracy class shall be ±
1.5 % or better.
16) Flanged bi-directional wheels.
17) Marshalling Box.
18) Off load tap changing gear
19) Cooling equipment.
20) Bushing current transformers.
21) Insulating oil.
22) Drain valves/plugs shall be provided in order that each section of pipe
work can be drained independently. Sludge valve at bottom most point of
tank to be provided for easy flush out/removal of sludge during
maintenance.
23) Terminal marking plates.
24) Valves schedule plates.
25) Two (2) earthing terminals on all the equipment mounted separately
suitable for connection to suitable GI flat along with 2 Nos. tapped holes.
M10 bolts etc.
26) Rain hoods to be provided on Buchholz, MOG & PRD. Entry points of
wires shall be suitably sealed.

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4.02.00 The fittings listed above are only indicative and other fittings, which generally are
required for satisfactory operation of the transformer, are deemed to be included.
5.00.00 INSPECTION AND TESTING
(a) The Contractor shall carry out a comprehensive inspection and testing program
during manufacture of the transformer. The owner may waive conduction of any
test subject to availability of test facility. An indication of inspection envisaged by
the Employer is given elsewhere in the specification. This is however not intended
to form a comprehensive program, as it is Contractor’s responsibility to draw up
and carry out such a program in the form of detailed quality plan duly approved by
Employer for necessary implementation.
(b) The Contractor shall carry out all type tests and routine tests on each type/rating
of transformers. The tests are listed elsewhere in the specification.
(c) The bidder shall indicate the charges for each of these type tests separately in the
Techno- Commercial bid and the same shall be considered for the evaluation of
the bids. The type tests charges shall be paid only for the test(s) actually
conducted successfully under this contract and upon certification by the employer’s
engineer.
(d) The equipment checks to be carried out by the Contractor are given elsewhere in
the specification.
(e) The requirements of site tests are given elsewhere in the specification.
(f) The makes of all major bought out items shall be subjected to Employer’s
approval. The contractor shall also prepare a comprehensive inspection and
testing program for all bought out/sub-contracted items and shall submit the same
to Employer.
(g) Each transformer shall be completely assembled with all fittings and accessories
meant for the particular transformer before offering for inspection and testing by
Employer.
(h) The type tests shall be carried out in presence of the employer’s representative, for
which minimum 15 days notice shall be given by the contractor. The contractor
shall obtain the employer’s approval for the type test procedure before conducting
the type test. The type test procedure shall clearly specify the test set–up,
instruments to be used, procedure, acceptance norms, recording of different
parameters, interval of recording, precautions to be taken etc. for the type test(s)
to be carried out.

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(i) In case the contractor has conducted such specified type test(s) not earlier than
ten years as on the date of Techno- Commercial bid opening, he may submit
during detailed engineering the type test reports to the owner for waiver of
conductance of such type test(s). These reports should be for the tests conducted
on the equipment similar to those proposed to be supplied under this contract and
have been witnessed by a client. The owner reserves the right to waive conducting
of any or all the specified type test(s) under this contract. In case type tests are
waived, the type test charges shall not be payable to the contractor.
(j) Following components to be supplied shall be of tested design. During detailed

engineering, the contractor shall submit for employer’s approval the reports of all
the type tests as listed below in specification and carried out within last ten years
from the date of Techno- Commercial bid opening. The reports should be for the
test conducted on the equipment similar to those proposed to be supplied under
laboratory or should have been witness by a client. However if the contractor is not
able to submit report of the type test(s) conducted within last ten years from date of
Techno- Commercial bid opening, or in the case of type test report(s) are not found
to be meeting the specification requirements, the contractor shall conduct all such
tests under this contract at no additional cost to the employer either at third party
lab or in presence of client/employer’s representative and submit the reports for
approval.
(a) Tank Pressure and Vacuum test
(b) Neutral Grounding Resistor (NGR)

(k) All acceptance and routine tests as per the specification and relevant standards
shall be carried out. Charges for these shall be deemed to be included in the
equipment price.
Type and Routine tests
Routine Tests
Sr. OIL FILLED

No. Routine Tests OUTDOOR
TRANSFORMER
1 All routine test in accordance with IEC 60076 shall be carried out in all √
the transformers.
2 Measurement of Voltage Ratio √
3 Measurement of winding resistance on HV & LV on all the taps (as per
√
IEC 60076-1)
4 Vector group and Polarity Check (as per IEC 60076-1) √
5 Magnetic Balance Test √
6 Measurement of no load current with 415 V, 50 Hz AC supply √
7 Measurement of no load losses and current at 90%, 100% & 110% of √
rated voltage (as per IEC 60076-1)
8 Impedance & Load Loss Measurement on principal, Max & Min. Taps √

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Sr. OIL FILLED

No. Routine Tests OUTDOOR
TRANSFORMER
9 IR measurement (As per IEC 60076-1) √
10 Dielectric tests shall be carried out as per IEC 60076-3. √
11 Separate Source Voltage Withstand Test (As per IEC 60076-3) √
12 Induced Over Voltage Withstand test as per IEC 60076-3 √
13 Repeat no load current/loss measurement & IR measurement after √
completion of all dielectric test
14 Measurement of capacitance & tan delta to determine capacitance
√
between winding & earth. (As per IEC 60076-1),also see note (iv)
15 Oil leakage test √
16 Jacking test followed by D.P. test √
17 Marshalling Box/Cable box: It shall not be possible to insert a thin
√
sheet of paper under gaskets and through enclosure joints.
18 IR measurement on wiring of Marshalling Box. √
Type Tests
19 Dynamic Short circuit test (special test) as per IEC 60076-5. √
20 Temp. rise test at a tap corresponding to maximum losses. DGA shall
be conducted on oil sample taken before & immediately after temp. rise
√
test. Gas analysis shall be as per IS: 9434 (based on IEC: 60567),
results will be interpreted as per IS: 10593 (based on IEC: 60599).
21 Lightning impulse (Full & Chopped Wave) test on windings
√
22 Lightning impulse test on Neutral √
(refer note iii)
24 Measurement of acoustic noise level as per
√
NEMA TR-1 (special test)
Note:
i) (√) mark indicates that the test to be carried out.
(x) mark indicates that the test need not be carried out.
ii) All the type tests shall be conducted after short circuit test. If Tank Vacuum &
Pressure Test is to be carried out then it shall be conducted before SC test.
iii) Applicable on transformer neutral connected with NGR.
iv) For outdoor transformer the limiting value of tan delta shall be 1.0% @ 20
deg C.
5.01.02 Type tests on Components

Type test reports shall be submitted for following:
(a) Tank Vacuum & Pressure Test
(b) Neutral Grounding resistors

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5.02.00 TANK TEST
(a) Routine test
(1.) Oil leakage test on assembled transformer

All tank & oil filled compartment shall be tested for oil tightness by being
completely filled with oil of viscosity not greater than that of specified oil at the
ambient temperature & applying pressure equal to the normal pressure plus
35 KN/sq. m measured at the base of the tank. The pressure shall be maintained
for a period of not less than 6 hours during which time no sweating shall occur.
This test shall be done on completely assembled transformer.
(b) Type Tests
(1.) Vacuum Test

Each type of transformer tank shall be subjected to the vacuum test as per CBIP
norms.
(2.) Pressure Test
Transformer tank of each type shall be subjected to a pressure test as per CBIP
norms.
5.03.00 NGR Testing
(a) The following routine tests shall be conducted on each resistor covered in
this package.
(1.) Ohmic resistance value measurement Insulation resistance

measurement before & after HV test
(2.) HV test for 1 min. at a voltage corresponding to the insulation level of

the resistor.
(b) DOP test on enclosure (routine test) as follows.
It shall not be possible to insert a 2.5mm dia. steel wire into the enclosure
from any direction without using force.
Type tests
Type test reports shall be submitted for following:

(a) Short time current test along with temperature rise test.
(b) Degree of protection test for IPX3.
5.04.00 Pre-shipment Checks at Manufacture’s Works
(a) Check for interchangeability of similar transformers for mounting dimensions.

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(b) Check for proper packing and reservation of accessories like radiators, bushings,
dehydrating breather, rollers, Buchhloz relay, fans, control cubicle, connecting
pipes, conservator etc.
(c) Check for proper provision for bracing to arrest the movement of core and winding
assembly inside the tank.
5.05.00 Inspection and Testing at Site
The Contractor shall carry out a detailed inspection and testing program for field activities
covering areas right from the receipt of material stage up to commissioning stage. An
indicative program of inspection as envisaged by the Employer is given below. This is
however not intended to form comprehensive program, as it is contractor’s responsibility to
draw up and carry out such a program duly approved by the Employer. Testing of oil sample
at site shall be carried out as specified elsewhere in this specification.
5.05.01 Receipt and Storage Checks
Following checks as detailed out in finalized/agreed FQP shall be followed.
(a) Check and record condition of each package, visible parts of the transformer etc.
for any damage.
(b) Visual check for wedging of core and coils before filling up with oil and also check
conditions of core and winding in general, if transformer filled with N2/dry air.
5.05.02 Installation Checks
(a) Inspection and performance testing of accessories like tap changers etc.
(b) Check whole assembly for tightness, general appearance etc.
(c) Check oil sample.
(d) Leakage test on bushing before erection, if bushing is transported separately.
(e) Capacitance & tan delta measurement of condenser bushing before fixing /
connecting to the winding, contractor shall furnish these values for site reference.
5.05.03 Commissioning Checks
(a) Check the colour of silica gel in silicagel breather.
(b) Check the oil level in the breather housing, conservator tanks, cooling system,
condenser-bushing etc.
(c) Check the bushing for conformity of connection to the lines etc. and tan delta test
for bushing.
(d) Check for correct operation of protection devices and alarms:

(i.) Buchhloz relay.

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(ii.) Excessive winding temperature
(iii.) Excessive oil temperature
(iv.) Low oil level indication
(v.) Pressure relief valve
(e) Check for the adequate protection on the electric circuit supplying the accessories.
(f) Check resistance of all windings on all steps of the tap changer.
(g) Insulation resistance measurement for the following:

(i.) Control wiring.
(ii.) Main windings
(iii.) Tank & turret mounted CT’s

(h) Check for cleanliness of the transformer and the surroundings.
(i) Check the following

(i.) Buchholz, oil level indicator, pressure gauges, temp indicators etc.
for fitting & operation.
(ii.) Earthing of main tank, marshaling Box, tap changer driving gear,
cable box, fan motor etc.
(iii.) Neutral earthing
(iv.) Calibration of WTI and OTI
(v.) Earthing of bushing test tap
(vi.) Connection of WTI CT with its heater
(vii.) Tightness of CT secondary connection and shorting of unused CTs
(viii.) All valves for their correct opening and close sequence
(j) Phase out and vector group test.
(k) Ratio test on all taps.
(l) Magnetizing current test (HV winding & LV winding).
(m) Capacitance and Tan delta measurement of winding
(n) Oil Dielectric strength test-the various test on oil shall be conducted prior to filling
in main tank at site & prior to energization at site as specified elsewhere in this
specification. Oil samples are to be drawn from top & bottom of main tank &
cooling system.
(o) DGA of oil before commissioning
(p) Magnetic balance test

TRANSFORMERS
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(q) Short circuit impedance measurement
(r) Test on tank/turret mounted CT’s

(i.) IR value between secondary winding & earth and between windings
(ii.) Secondary resistance
(iii.) Polarity
(iv.) Ratio test
(v.) Magnetization current
(s) WTI and OTI setting for alarm/trip, fan start/stop (if applicable) and pump start/stop
(if applicable).
(t) Final IR Value

(i.) HV/E+LV
(ii.) LV/E+HV
(iii.) HV/LV
(u) Continuously observe the transformer operation at no load for 24 hrs. w.r.t.
Voltage, no load current, temperature rise and noise.
(v) Gradually put the transformer on load, check and measure increase in temperature
in relation to the load and check the operation with respect to temperature rise and
noise level etc.
6.00.00 BIDDER MAY REFER ENCLOSED STANDARD TENDER DRAWINGS AS

MENTIONED BELOW FOR LT OUTDOOR TRANSFORMERS UPTO AND
INCLUDING 2 MVA RATING WITH APPROPRIATE PRIMARY AND SECONDARY
VOLTAGE LEVEL (AS MENTIONED IN THE DRAWINGS).
Drawing title Drawing No.

a.) 1.0/1.6/2.0 MVA Transformer (Outdoor) 0000-000-POE-FB-002
b.) 0.5/0.63 MVA Transformer (Outdoor) 0000-000-POE-FB-001
c) Standard Terminal Numbers for Marshalling Box 0000-203-PVE-B-001

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HT POWER CABLES

CLAUSE NO.
bid. In case of conflict between this specification and those (IS: codes, standards, etc.)
referred to herein, the former shall prevail. All the cables shall conform to the requirements of
the following standards and codes :
IS:7098 (Part -II) Specification for Cross linked polyethylene insulated PVC
sheathed cables. Part-II: For working voltages from 3.3 KV upto
and including 33 KV.
IS : 3975 Low Carbon Galvanized steel wires, formed wires and tapes for
IS : 4905 Methods for random sampling.
ASTM-D -2843 Standard test method for density of smoke from the burning or

ground (buried) installation with chances of flooding by water.
2.02.00 All cables including EPR cables shall be flame retardant, low smoke (FRLS) type designed to
withstand all mechanical, electrical and thermal stresses developed under steady state and
transient operating conditions as specified elsewhere in this specification.
2.03.00 Aluminium conductor used in power cables shall have tensile strength of more than 100 N/
sq.mm. Conductors shall be multi stranded.
2.04.00 XLPE insulation shall be suitable for continuous conductor temperature of 90 deg. C and
short circuit conductor temperature of 250 deg C.

1 OF 8
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 HT POWER CABLES
CLAUSE NO.
2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It shall
not stick to insulation and inner sheath. All the cables, other than single core unarmoured
cables, shall have distinct extruded PVC inner sheath of black colour as per IS: 5831.
2.06.00 For single core armoured cables, armouring shall be of aluminium wires. For multicore
armoured cables armouring shall be of galvanised steel as follows : -
Calculated nominal dia of cable under Size and Type of armour

armour
i) Upto 13 mm 1.4mm dia GS wire
ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm dia
GS wire
iii) Above 25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia
GS wire
iv) Above 40 & upto 55mm 1.4 mm thick GS formed wire/2.5mm dia GS
wire
v) Above 55 & upto 70mm 1.4 mm thick GS formed wire/3.15mm dia

GS wire
vi) Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia

GS wire
2.06.01 The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum
resistivity of 0.028264 ohm-sq.mm/mtr at 20 deg.C. The types and sizes of aluminium
armouring shall be same as mentioned for galvanised steel at 2.06.00 above.
2.06.02 The gap between armour wires / formed wires shall not exceed one armour wire / formed
wire space and there shall be no cross over / over-riding of armour wires / formed wires. The
minimum area of coverage of armouring shall be 90%. The breaking load of armour joint
shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be
applied on armour joint surface of GS wires/formed wires.
2.07.00 Distinct extruded PVC inner sheath of black colour as per IS:5831 shall be provided for the
cables as follows:
a). For all multicore cables.
b). For single core armoured cables, where armouring is not being used as metallic
screen.

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CLAUSE NO.
2.08.00 Outer sheath shall be of PVC black in colour. In addition to meeting all the requirements of
Indian standards referred to, outer sheath of all the cables shall have the following FRLS
properties.
(a.) Oxygen index of min. 29 (Test method as per IS 10810 Part-58)
(b.) Acid gas emission of max. 20% as per IEC-754 (Part-I)

(c.) Smoke density rating shall not be more than 60% during Smoke Density Test as per
ASTMD-2843.
2.09.00 Cores of three core cables shall be identified by colouring of insulation or by providing
coloured tapes helically over the cores, with Red, Yellow & Blue colours.
2.10.00 In addition to manufacturer's identification on cables as per IS, following marking shall also
be provided over outer sheath :
(c.) Screen Fault current _ _ _KA for _ _ _ Sec. ( Value of current & time shall
be indicated)
(d.) Sequential marking of length of the cable in metres at every one metre
- To be embossed / printed
The embossing / printing shall be progressive, automatic, in line and marking shall be legible
and indelible. For EPR cables identification shall be printed on outer sheath.
2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC-332 Part-3.
2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum over
the declared value in the technical data sheets.
2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not
acceptable.
2.14.00 The cross-sectional area of the metallic screen strip/tape/wires shall be considered in sizing
calculations.
2.15.00 The eccentricity shall be calculated as

tmax -tmin
------------ x 100
t max
and the ovality shall be calculated as
dmax -dmin
------------ x 100
d max

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CLAUSE NO.
Where t-max/t-min is the maximum/minimum thickness of insulation and d-max/d-min is the

maximum / minimum diameter of the core.
The eccentricity of the core shall not exceed 10% and ovality not to exceed 2% .
2.16.01 HT cables shall be sized based on the following considerations:
a) Rated current of the equipment
b) The voltage drop in the cable, during motor starting condition, shall be limited to 10%
and during full load running condition, shall be limited to 3% of the rated voltage
c) Short circuit withstand capability
2.16.02 Derating Factors
Derating factors for various conditions of installations including the following shall be
considered while selecting the cable sizes:
a) Variation in ambient temperature for cables laid in air
b) Grouping of cables
c) Variation in ground temperature and soil resistivity for buried cables.
2.16.03 Cable lengths shall be considered in such a way that straight through cable joints is avoided.
3.01.00 19/33 KV Grade Power Cables:
3.02.00 Cables shall conform to IS 7098 Part-II. These cables shall be multi-stranded, compacted
circular aluminium conductor, XLPE-insulated, metallic screened PVC outer sheathed. The
conductor screen and insulation screen shall both be of extruded semiconducting compound
and shall be applied along with the XLPE insulation in a single operation of triple extrusion
process so as to obtain continuously smooth interfaces. Method of curing for 19/33 KV
Cables shall be “dry curing / gas curing “. The metallic screen for each core shall be capable
of carrying the system earth fault current and shall consist of copper wires or tape with
minimum overlap of 20%. However, for single core armoured cables, the armouring shall
constitute the metallic part of the screening.
3.03.00 11/11KV, 6.6/6.6KV Grade Power Cables:
Cables shall conform to IS-7098 Part-II. These cables shall be multi-stranded, compacted
circular aluminium conductor, XLPE-insulated, metallic screened, PVC outer sheathed. The
conductor screen and insulation screen shall both be of extruded semiconducting compound
and shall be applied along with the XLPE insulation in a single operation of triple extrusion
process so as to obtain continuously smooth interfaces. Method of curing shall be “dry
curing / gas curing / steam curing “. The metallic screen for each core shall be capable of

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carrying the system earth fault current and shall consist of copper wires or tape with
minimum overlap of 20%. However, for single core armoured cables, the armouring shall
constitute the metallic part of the screening .
3.02.00 3.3/3.3kV Grade Power Cables:
Cables shall conform to IS: 7098 Part - II. These cables shall be multi- stranded, compacted
circular aluminium conductor, XLPE insulated, metallic screened, PVC outer sheathed.
The metallic screen of each core shall consist of copper wires or tape with minimum overlap
of 20%. However, for single core armoured cables, the armouring shall constitute the metallic
part of the screening. The metallic screen of each core shall be capable of carrying the
system earth fault current Method of curing for cables shall be "dry curing / gas curing /
steam curing".
3.03.00 Trailing cables shall have tinned copper (class 5) conductor, insulated with heat resistant
elastomeric compound based on Ethylene Propyline Rubber (EPR) suitable for withstanding
90 deg.C continuous conductor temperature and 250deg C during short circuit, inner-
sheathed with heat resistant elastomeric compound, nylon cord reinforced, outer-sheathed
with heat resistant, oil resistant and flame retardant heavy duty elastomeric compound
conforming to IS 9968.
4.00.00 CABLE DRUMS
4.01.01 Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The
surface of the drum and the outer most cable layer shall be covered with water proof cover.
Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps
secured by 'U' nails so as to eliminate ingress of water during transportation, storage and
erection. Wood preservative anti-termite treatment shall be applied to the entire drum.
Wooden drums shall comply with IS: 10418.
4.01.02 Each drum shall carry manufacturer's name, purchaser’s name, address and contract
number, item number and type, size and length of cable and net gross weight stenciled on
both sides of the drum. A tag containing same information shall be attached to the leading
end of the cable. An arrow and suitable accompanying wording shall be marked on one end
of the reel indicating the direction in which it should be rolled.
4.01.03 The standard drum length for HT power cables with a maximum tolerance of +/- 5%, may be
decided by the bidder subject to condition that there shall not be any joint in cable, where
application length of cable is up to & including 1000 meter for single core cable, and 750
meter for multicore cable.
.5.00.00 TYPE, ROUTINE AND ACCEPTANCE TESTS
a) The contractor shall carry out the type tests as listed in this specification on the
for each of these type tests separately in the relevant schedule of Section - VII-
(Forms & Procedures) and the same shall be considered for the evaluation of the
bids.
The type tests charges shall be paid only for the test(s) actually conducted
successfully under this contract and upon certification by the employer’s engineer.
b) The type tests shall be carried out in presence of the employer’s representative, for
which minimum 15 days notice shall be given by the contractor. The contractor shall

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CLAUSE NO.
obtain the employer’s approval for the type test procedure before conducting the type
test. The type test procedure shall clearly specify the test set–up, instruments to be
used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.
c) In case the contractor has conducted such specified type test(s) within last ten years
as on the date of bid opening, he may submit during detailed engineering the type
test reports to the owner for waival of conductance of such type test(s). These
reports should be for the tests conducted on the equipment similar to those proposed
to be supplied under this contract and test(s) should have been either conducted at
an independent laboratory or should have been witnessed by a client. The owner
reserves the right to waive conducting of any or all the specified type test(s) under
this contract. In case type tests are waived, the type test charges shall not be
payable to the contractor.
d) All acceptance and routine tests as per the specification and relevant standards shall
price
e) The type test reports once approved shall be treated as reference. For subsequent
endorsement sheet.
All types and sizes of cables being supplied shall be subjected to type tests, routine tests and
acceptance tests as specified below and according to relevant standards.
5.01.00 The following type tests shall be carried out on one size each of 19/33kV, 11/11KV,
6.6/6.6KV and 3.3/3.3KV cables. Size shall be decided by the employer during detailed
engineering
S. No Type Test Remarks
Conductor
1. Resistance test
For Armour Wires / Formed Wires
3. Tensile Test
4. Elongation test
5. Torsion test For round wires only
6. Wrapping test
7. Resistance test
8(a) Mass & uniformity of Zinc Coating For GS wires/formed wires only.
tests
8(b) Adhesion test For GS wires/formed wires only

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CLAUSE NO.
S. No Type Test Remarks

For XLPE insulation & PVC Sheath
10. Tensile strength and elongation test

before ageing and after ageing
12. Loss of mass test For PVC outer sheath only.
13. Hot deformation test For PVC outer sheath only.
14. Heat shock test For PVC outer sheath only
15. Shrinkage test
16. Thermal stability test For PVC outer sheath only
17. Hot set test For XLPE insulation only
18. Water absorption test For XLPE insulation only
19. Oxygen index test For PVC outer sheath only
20. Smoke density test For PVC outer sheath only
21. Acid gas generation test For PVC outer sheath only
22 Flammability test as per IEC-332 For completed cable only
Part-3 (Category -B)
5.02.00 The following type tests shall be carried out on each type (voltage grade) & size of the cable:
S. No. Type Test For all cables
1. Insulation resistance test (Volume Resistivity method)

For cables of 19/33kV, 11/11KV & 6.6/6.6KV Grade only.
3. Partial discharge test
4. Bending test
5. Dielectric power factor test
a) As a function of voltage
b) As a function of temperature
6. Heating cycle test

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7. Impulse withstand test
Indicative list of tests/ checks, Routine and Acceptance tests shall be as per Quality
Assurance & Inspection table of H.T. Cables enclosed.

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FIRE PROOF CABLE PENETRATION

SEALING

CLAUSE NO.
1.01.00 The fire proof cable penetration (FPCP) sealing system shall conform to the requirement of
latest edition including amendments of BS:476 Part-20 Fire tests on Building materials and
structures.
1.02.00 Fire penetration seal complying with any other international standards will also be
considered if it ensures performance equivalent or superior to standard listed above.
1.03.00 The Bidder shall clearly indicate the standards adopted and furnish a copy of the English
version of the latest editions of standards along with the bid, and shall clearly bring out the
2.01.00 The fire proof cable penetration sealing system shall be of the following types;
i) Type - A
Type A fire sealing system is either Silicone foam or equivalent foam system or using
individual blocks for each cable along with suitable frame work rated for one hour. Type A
is to be implemented at floor openings below C&I panels, control panels/Boards etc. in CER
& CCR.
ii) Type-B
Type B fire sealing system is any proven fire sealing system rated for one hour. This will
comprise of rest of wall and floor crossings of cables/cable trays, opening below HT/LT
Switchgears/board other than those covered under Type A.
2.02.00 The penetration system, shall be installed immediately after the completion of cable
termination in a particular switchboard/control panel/area after clearance from the Project
Manager.
3.00.00 GENERAL INFORMATION
3.01.00 The cables shall generally be laid in cable trays/racks, conduits, ducts. The fire proof cable
penetration system shall be designed in such a way that the existing supporting
structure/cable is not disturbed.
3.02.00 The penetration system shall be suitable for site condition at 500C ambient temperature and
relative humidity of 100%.
3.03.00 The penetration system of each wall/floor crossing shall be adequately designed/sized such
that 20% addition of cables is possible at any later date without disturbance/wastage of
material in the penetration system.
3.04.00 Contractor shall plan the schedule of supply of the materials in consultation with Project
Manager and use the material within stipulated shelf life of material. After award of work,

FIRE PROOF CABLE 1 OF 7
PENETRATION SEALING
CLAUSE NO.
drawings for each penetration seal shall be prepared by the contractor after verifying the
actual installation of cables at site and approval shall be taken from the Project Manager's
representative before proceeding with the actual work. The requirement of fire sealing
material shall be quantified accordingly.
Fire sealing material to be supplied shall be based on the net area to be sealed, wastage,
thickness, density and other parameters as per the type test report approved under this
contract.
4.01.00 The fire proof cable penetration system shall fully comply with the requirements of BS:476
Part-20 and also to the requirements specified in this specification.
4.02.00 The penetration system shall prevent spreading of fire in cable beyond the seal system in
case of fire and shall have minimum 1 hour fire resistance rating.
4.03.00 The penetration system shall be physically, chemically, thermally stable and shall be
mechanically secure to the masonry/concrete/structural members. The system shall be
mechanically robust and capable of giving satisfactory performance under vibrations
encountered in power stations.
4.04.00 The penetration system shall be capable of withstanding mechanical loads, foot traffic drop
loads, vibrations, wind pressure, etc.
4.05.00 The penetration system shall be completely gas and smoke tight.
4.06.00 The penetration system shall retain integrity and perform satisfactorily even after remaining
in water for long period.
4.07.00 The materials used in FPCP sealing system shall be non-toxic and harmless to the working
personnel.
4.08.00 The penetration materials shall have no reaction with cable sheath/galvanising/painting of
structural steel.
4.09.00 The penetration materials shall have anti-rodent and anti-termite properties.
4.10.00 The penetration materials shall have no shrinkage or cracking after the setting for the
complete life of the power Plant.
4.11.00 Under normal load, short circuit and fire conditions, cables may be subjected to movement
and vibration. The FPCP sealing system shall be designed to withstand and perform
satisfactorily under these conditions.
4.12.00 The penetration system shall not affect the current carrying capacity of cables passing
through it.
4.13.00 Asbestos shall not be used in the construction of fire penetration seal system.

PENETRATION SEALING
CLAUSE NO.
4.14.00 The penetration system shall have life expectancy of 40 years.
4.15.00 The penetration system shall not emit any corrosive or toxic fumes or smoke on the
unexposed face of the barrier.
4.16.00 Any wastage of the compound during the process of mixing for preparing the FPCP sealing
compound shall be to Contractor's account.
4.17.00 For foam type of systems, only the foam shall form the penetration seal of specified rating,
having the damming board removed after curing of the foam.
5.00.00 PACKING AND STORAGE
5.01.00 All materials and components of penetration system shall be supplied in packing to avoid
contamination of materials due to dust/moisture and temperature during transit and storage.
All packing shall be of durable quality and the date of expiry and the date of manufacture
shall be printed on it.
6.01.00 The contractor shall take adequate care to ensure that cables are not damaged in any
manner during penetration system installation.
6.02.00 Wherever the floor/wall opening provided in the vicinity of penetration seals larger or smaller
than that required for the cable fire penetration, these opening size can be reduced or
increased in an approved manner by the contractor using the same materials as provided
around the opening and of the same thickness. Generally the walls in the power station
comprises of brickwork and the floors are made of RCC/steel work.
6.03.00 The work to be carried out under this specification shall be done under the supervision of
Project Manager’s representative.
6.04.00 All work shall be carried out in accordance with the agreed “field quality plan” and approved
drawings. The “field quality plan” shall additionally specify the fire sealing material
thickness, minimum cured density and other related parameters achieved in the approved
type tests for the contract. The work shall be done to the satisfaction of the Project Manager
and the same shall be subject to Project Manager’s approval for acceptance.
6.05.00 The installation shall be carried out in a neat workmen like manner by the skilled,
experienced and competent workmen.
6.06.00 Installation work at site shall be properly coordinated with other services.
6.07.00 All materials being supplied or consumed during installation by the Contractor in the
process of installation shall be of the best quality and according to standards. All materials
shall be inspected and approved by the Project Manager before the same is used for
installation work. Also regarding inspection of work, the engineer shall have the right to
inspect at any stage during installation, testing and commissioning.

PENETRATION SEALING
CLAUSE NO.
6.08.00 The drilling and welding of building-steel or fixing supports etc. shall be carried out by
contractor after taking prior approval of Project Manager.
7.00.00 TYPE TESTS, ROUTINE & ACCEPTANCE TESTS
specification and carried out within last ten years from the date of bid opening. These
reports should be for the test conducted on the equipment similar to those proposed to be
supplied under this contract and the test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client.
7.02.00 However if the contractor is not able to submit report of the type test(s) conducted within last
ten years from the date of bid opening, or in the case of type test report(s) are not found to
be meeting the specification requirements, the contractor shall conduct all such tests under
this contract at no additional cost to the owner either at third party lab or in presence of
client/owners representative and submit the reports for approval.
7.04.00 The type test reports once approved shall be treated as reference. For subsequent
projects, an endorsement sheet will be furnished by the manufacturer confirming similarity
and “No design change”. Minor changes if any shall be highlighted on the endorsement
sheet.
7.05.00 Following Type test reports as per the setup and procedures given in subsequent clauses
for the Fire proof cable penetration sealing system shall be submitted:
a) The accelerated ageing test
b) Water absorption test
c) Fire rating test
d) Hose stream test
e) Vibration test followed by fire rating test
7.05.01 Tests a, b, c and d should have been carried out on same test sample subsequently one
after the other without any touching up/repair/modifications in the same sequence and in
accordance with the clause 9.00.00. The test sample shall be assembled as per clause
8.00.00.
7.05.02 Test indicated in clause 7.05.00 (e) above should have been carried out on a separate
sample and as per the procedure indicated under clause 9.05.00.
7.05.03 Physical, chemical and mechanical properties of various components/ingredients used

should have been also be tested as a part of type tests.

PENETRATION SEALING
CLAUSE NO.
7.05.04 Test reports shall contain the following information:
1. Type of penetration material tested
2. Details of various components/ingredients used alongwith their catalogue.
3. Physical, chemical and mechanical properties of various components/ ingredients

used.
4. Description of the various test assemblies tested.
5. Details of method of conditioning.
6. The observations as called for in BS:476 Part-20 and technical specification.
7.06.00 ROUTINE & ACCEPTANCE TESTS
Routine and acceptance tests to be carried out on Type-A and Type-B cable fire sealing
system shall be mutually agreed based on the type of fire sealing material offered before
placement of award.
8.00.00 TEST SPECIMEN ASSEMBLY
8.01.00 The test specimen shall be assembled as per enclosed drawing and shall resemble typical
floor crossing cable penetration system.
8.02.00 The test specimen shall be designed to seal an opening of adequate size in a concrete slab
of 200 mm thickness. Two lengths of 300/600 mm wide ladder type cable tray shall be
assembled with required layer of XLPE/PVC insulated, PVC sheathed unarmoured cables
in touching formation. Type and number of cables in the cable tray shall be as per enclosed
drawing. Cables shall be adequately clamped with tray at both the sides of the penetration
as shown in the drawings. However, for penetration system with blocks which require
staggered arrangement, cables can be clamped at an adequate distance from the
penetration and the tray need not pass through the penetration seal.
8.03.00 The opening in the test specimen then shall be sealed with fire proof cable penetration
sealing materials.
9.00.00 TEST PROCEDURES
9.01.00 ACCELERATED AGEING TEST
The test specimen assembled as per clause 8.01.00 with damming board removed shall be
subjected to accelerated ageing test by storing in air furnace where the temperature of the
inside air shall be maintained at 85 degree centigrade for 168 hours. The temperature
controlled furnace should have 7 air changes per hour approx.
9.02.00 WATER ABSORPTION TEST
9.02.01 The test specimen shall be immersed in fresh clean water at a temperature of 20 deg. C + 2
deg C. The test specimen must be separated from the bottom and sides of the soak tank by

PENETRATION SEALING
CLAUSE NO.
at least 10 mm and it shall be covered by approximately 25 mm of water. At the end of the

24 hour soak period the specimen shall be removed from water and mopped up with a
damp cloth.
9.03.00 FIRE RATING TEST
9.03.01 The test specimen after withstanding water absorption test shall be subjected to fire rating
test as per BS: 476 part-20.
9.03.02 Oil/Gas fired furnace shall be used for heating. The furnace shall have achieved standard
time/temperature characteristics for fire tests as per BS:476 part-20.
9.03.03 The pressure inside the furnace at the time of test shall be within 1.5 + 0.5 mm water
gauge.
9.03.04 Cables in the test specimen shall be anchored on the hot side to a structure independent of
the barrier and its penetrations. This is to ensure that any differential movement between
the penetration and the cable that could occur during a fire, is produced in the type tests
and the reliability of the integrity of the penetration is checked.
9.03.05 Cables shall be protruding between 1 to 2 metre, from the penetration face on the
unexposed side and protruding into the furnace as far as it is practicable with a minimum
length 750 mm. The ends of the cables shall be capped on the unexposed face to prevent
gases and fumes to escape from the furnace during the fire.
9.03.06 The test specimen shall be subjected to fire test with surface exposed to controlled fire in
the furnace confirming to time/temperature characteristics specified in BS:476(20).
9.03.07 During the test the temperature of both the faces of the fire stop i.e. one which is exposed to
fire and other unexposed shall be measured by calibrated thermo couples after regular
interval of 5 minutes.
9.03.08 Atleast 3 thermo couples shall be provided for temperature measurement of each face. The
results at the end of the test shall be interpreted for failure criteria as under.
1. The system is deemed to have failed to maintain stability if there is a total collapse
of the fire proof seal.
2. In case cracks are seen on the face of the fire stop or cracks through which the
flame/ hot gas can pass the systems deemed to have failed to maintain integrity.
The development of crack is characterised by appearance of black soot on cotton
wool held near the penetration on the unexposed surface at a distance of about
100mm.
3. Failure shall be deemed to have occurred when the mean temperature of the
unexposed surface of the specimen assembly increases by more than 1400C
above the initial temperature or if the temperature of the unexposed surface is
increased at any point by more than 1800C above the initial temperature.
During the test the specimen shall meet all the three criteria simultaneously.

PENETRATION SEALING
CLAUSE NO.
9.03.09 Temperature measurement on the unexposed side of penetration seal shall be measured
by thermocouples at a distance of 25 mm from unexposed side of fire stop.
9.04.00 HOSE STREAM TEST
9.04.01 A hose stream test shall be conducted on the test specimen immediately following a fire
resistance test on that assembly. The specimen must first be removed from the furnace
since the hose stream is to be applied to the exposed face. This must be done quickly since
it is the intention of the test that the stream be applied to the specimen whilst it is hot.
9.04.02 The hose stream shall be long range narrow angle, (200 - 900 set at 300 included angle).
High velocity water spray provided from a 28 mm hose discharging through an appropriate
nozzle. The water pressure shall be 5 bar calculated at the base of the nozzle and the
minimum flow rate shall be 4.7 litres/second. The stream shall be supplied perpendicularly
to the exposed face of the test specimen with nozzle 3 m away from the exposed face.
9.04.03 Application shall be for minimum of two and a half minutes per 9 sq.m. of the test specimen
including the barrier.
9.05.00 VIBRATION TEST
9.05.01 The test assembly is to comprise a single ladder rack penetration in 1 m x 1m high normal
section of fire barrier which is securely supported. The penetration seal shall be formed in
the middle of the barrier around 1 m length of 600 mm ladder rack. The tray shall be fully
loaded with cables in touching formation. The penetration assembly shall be formed
symmetrically through the fire barrier as in service. The penetration sealant material shall
then be allowed to cure for atleast as long as the time required for conditioning to constant
mass. A vibration test shall then be conducted on the sample as set out below.
9.05.02 The vibration shall be of 100 Hz frequency and of 0.5 mm amplitude (1.0 mm peak to peak)
and this shall be applied to one rail of the ladder rack or the centre of a cross member
secured to the two rails at 250 mm from the centre line of the penetration. This vibration
shall be applied to the sample for the minimum period of 3 hrs. Immediately following this
vibration test the barrier/ penetration assembly shall be successfully subjected to a fire test
in accordance with clause no. 9.03.00.

PENETRATION SEALING
STATION LIGHTING

CLAUSE NO.
1.00.00 GENERAL
1.01.00 This specification covers the general description of design, manufacture and construction
features, testing, supply, installation and commissioning of the Station Lighting system
equipment.
2.01.00 All standards and codes of practice referred to herein shall be the latest edition including
all applicable official amendments & revisions as on date of bid opening. In case of
conflict between this specification and those (IS codes, standards etc.) referred to herein,
the former shall prevail. All work shall be carried out as per the following standards &
codes.
2.02.00 Lighting Fixtures and Accessories
IS:1913 General and safety requirements for luminairies.
IS:2148 Flame proof enclosures of electrical apparatus.
IS:418 Tungsten filament general service electric lamps.
IS:1258 Bayonet lamp holders.
IS:1534 Ballast for fluorescent lamps.
IS:1569 Capacitors for use in tubular fluorescent, high pressure mercury

vapour and low pressure sodium vapour discharge lamp circuit.
IS:1777 Industrial luminaire with metal reflectors.
IS:2215 Starters for fluorescent lamps.
IS:2418 Tubular fluorescent lamps for general lighting services.
IS:3323 Bi-pin lamp holders for tubular fluorescent lamps.
IS:3324 Holders for starters for tubular fluorescent lamps.
IS:4013 Dust-tight electric lighting fittings.
IS:8224 Electric Lighting fittings for Division 2 areas.
IS:10276 Edison screw lamp holders.
IS:10322 Luminaires.
IS:13021 AC Supplied Electronic Ballasts for tubular fluorescent lamps.
2.03.00 Lighting Panels, Switch-boxes, Receptacles and Junction Boxes
IS:2147 Degree of protection provided by enclosures for low-voltage

switchgear and control gear.

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WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 STATION LIGHTING
CLAUSE NO.
IS:1293 Plugs & socket outlets of rated voltage upto and Including 250volts &
rated current upto and including 16 Amps.
IS:2551 Danger notice plates.
IS:13947 Low voltage switchgear and controlgear
IS:3854 Switches for domestic and similar purposes.
IS:6875 Control switches (switching devices for control and auxiliary circuits
including contactor relays) for voltages upto and including 1000 V AC
and 1200 V DC.
IS:13703 Low voltage fuses for voltages not exceeding 1000V AC or 1500 V
DC.
2.04.00 Conduits, Pipes and Accessories
IS:2667 Fittings for rigid steel conduit for electrical wiring.
IS:3837 Accessories for rigid steel conduits for electrical wiring.
IS:9537 Conduits for electrical installations.
2.05.00 Lighting Wires/Cables
IS:694 PVC insulated cables for working voltages upto and including
1100 V
IS:3961 Recommended current ratings for cables.(PVC Insulated and PVC

sheathed heavy duty cables and light duty cables).
IS:8130 Conductors for insulated electric cables and flexible cords.
IS:10810 Methods of tests for cables.
2.06.00 LED Luminaries
16101:2012 General Lighting. LEDs and LED modules

Terms and definitions
16102(Part 1):2012 Self Ballasted LED Lamps for General Lighting Services.
Part-1 Safety Requirements.
16102(Part 2):2012 Self Ballasted LED Lamps for General lighting Services.
Part-2 Performance Requirements.
16103(Part I):2012 LED modules for General lighting Safety Requirements.
15885(Part 2/Sec. 13) :2012 Lamp control gear Part 2 particular

Requirements Section 13 d.c. or a.c.
Supplied Electronic control gear for LED modules
16104:2012 d.c. or a.c. Supplied Electronic control gear

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CLAUSE NO.
for LED modules - Performance

Requirements.
16105:2012 Method of Measurement of Lumen

maintenance of Solid-state Light (LED)
Sources.
16106:2012 Method of Electrical and photometric

Measurements of Solid State Lighting (LED)
Products
16107:2012 Luminaires Performance
16108:2012 Photobiological safety of Lamps and Lamp

Systems
IS 513 Cold rolled low carbon steel sheets and strips
IS 12063 Classification of degree of protection provided by

enclosures.
IS 14700 Electro magnetic compatibility (EMC) – Limits

(Part 3/Sec. 2) for Harmonic current
emission – THD < 15% (equipment, input current < 16
Amps. per phase.
IS 9000 (Part 6) Environment testing: Test Z – AD:

composite temperature/humidity cyclic test.
IS 15885 Lamp control gear: particular requirements for

(Part 2/Sec. 13) DC or AC supplied electronic
control gear IS 16004 – 1 and 2) for LED
modules.
IS 4905 Method for random sampling
2.07.00 Electrical Installation Practices & Miscellaneous
IS:1944 Code of practice for lighting of public thorough fare
IS:3646 Code of practice for interior illumination.
IS:5572 Classification of Hazardous areas (other than Mines) having

flammable gases and Vapours for electrical installation
S:6665 Code of practice for industrial lighting.
. National Electrical Code
- Indian Electricity Rules.
Indian Electricity Act

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CLAUSE NO.
IS:5 Colour for ready mixed paints & enamels.
IS:280 Mild steel wires for general engineering purposes.
IS:374 Electric ceiling type fans & regulators.
IS:732 Code of practice for electrical wiring installations.
IS:1255 Code of practice for installation and maintenance of power cables

Upto and including 33KV rating.
IS:2062 Steel for general structural purposes
IS:2629 Recommended practice for hot-dip galvanizing of iron and steel.
IS:2633 Methods for testing uniformity of coating of zinc coated articles.
IS:2713 Tubular steel poles for overhead power lines.
IS:3043 Code of practice for earthing
IS:5216 Guide for safety procedures and practices in electrical work.
IS:5571 Guide for selection of electrical equipments for hazardous areas.
BS:6121 Mechanical cable glands
3.00.00 LIGHTING SYSTEM DESCRIPTION
3.01.00 The illumination of various indoor and outdoor areas in the main plant & offsite area shall
be provided as described here. The lighting system of various areas shall comprise of the
following systems as identified in Annexure-B:
(a) Normal AC Lighting System
(b) Emergency AC Lighting System
(c) DC Lighting System
3.02.01 Normal AC Lighting System
Normal AC lighting system 415V, 3Phase, 4wire, will be fed from lighting panels (LPs)
which in turn will be fed from the lighting distribution boards (LDBs)/Switch board MCC.
3.02.02 Emergency AC Lighting System
This system shall be provided for certain important areas in the main plant. The lighting
fixtures connected to this system shall be normally "ON" along with the normal AC
system. These will be fed from emergency lighting panels (ELPs) which in turn will be fed
3-phase, 4-wire supply from the emergency lighting distribution boards (ELDB'S). These
lights will go off for a few seconds in case of AC supply failure at Emergency Switchgear,

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CLAUSE NO.
but shall be automatically restored when Emergency Switchgear is energised by Diesel

generator set.
3.03.00 DC Lighting System
3.03.01 At strategic locations in the main plant, a few lighting fixtures fed from 220V, DC supply,
shall be provided to enable safe movement of operating personnel and access to
important control points during an emergency, when both the normal AC and Emergency
Lighting system fail. These lighting fixtures will be fed from 220V DC LDBs which in turn
will be fed from DC lighting panels.
3.03.02 The supply to the DC lighting panels shall be automatically switched ON in case of loss of
AC supply at station service switchgear as well as Emergency switch-gear. The DC
supply will be automatically switched OFF after about 3 minutes following the restoration
of supply to normal AC or emergency AC lighting system.
3.03.03 Emergency DC lighting is to be provided, through self-contained DC emergency fixtures

with four hours back-up duration, at strategic locations, in auxiliary/offsite buildings
wherever DC supply system is not available. The fixtures shall be switched 'ON'
automatically in case of failure of AC supply.
3.03.04 For Coal Handling plant.

100W, 220V DC Lighting fixture shall be provided in underground portion of conveyor,
each switchgear room, control room, office room, pump house, each drive floor of TPs,
staircases of various TPs and buildings and each local control area. DC lighting fixtures
shall be fed from 220V DC LDB which in turn will be fed from CHP DC system. The
supply to the DC lighting panels shall be automatically switched ON in case of loss of
normal AC supply.
4.00.00 DESIGN PHILOSOPHY
1. A comprehensive illumination system shall be provided in the entire project areas

under bidder’s scope.
2. All outdoor lighting system shall be automatically controlled by synchronous

timer. Provision to bypass the timer shall be provided in the panel.
3. The system shall include distribution boards, normal/ emergency lighting panels,
lighting fixtures, junction boxes, receptacles, switch boards, lighting pole/masts,
conduits, cables and wires, etc. The system shall cover all interior and exterior
lighting such as area lighting, including Transformer yard & Switch yard area,
aviation obstruction lighting, Street lighting, security lighting, etc. The
constructional features of lighting distribution boards shall be similar to AC/DC
distribution boards described in chapter of LT Switchgear. Outgoing circuits in
LPs shall be provided with MCBs of adequate ratings.
4. The illumination system shall be designed on the basis of best engineering

practice and shall ensure uniform, reliable, aesthetically pleasing and glare free
illumination. The lighting fixtures shall be designed for minimum glare. The design
shall prevent glare/luminous patch seen on VDU/ Large video screens, when
viewed from an angle. The finish of the fixtures shall be such that no bright spots
are produced either by direct light source or by reflection. The diffusers/ louvers
used in fixtures shall be made of impact resistant polystyrene sheet and shall
have no yellowing property over a prolonged period. The Lux levels to be

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CLAUSE NO.
adopted for various area are indicated at Annexure - A. (placed at the end of this
Chapter).
5. Different Lighting Systems envisaged for various plant areas are indicated in
Annexure-B: While finalizing the detailed layout of lighting fixtures, the
position/location and layout of equipments should be taken into account to have
adequate illumination at desired locations.
6. LED Luminaires:
LED Luminaires shall be used for the lighting of all the indoor & outdoor areas in
bidder’s scope. However for DC lighting, hazardous areas & aviation lighting etc.
conventional type luminaires shall be used. However, aviation light in Lighting
Mast shall be of LED type. In false ceiling area LED luminaires shall be recessed
mounting type & in non-false ceiling area the LED luminaires shall be surface
mounting type.
The individual lamp wattage for LED shall be upto 3 watt. Fractional wattage
LEDs are also acceptable. The LED chip efficacy shall be min 120 Lm/W. The
luminaire efficacy shall be not less than 80 Lm/W. Suitable heat sink shall be
designed & provided in the luminaire. The LED used in the luminaires shall have
colour rendering index (CRI) of Min 80. Colour designation of LED shall be “cool
day light” (min 5700K) type for indoor areas. However for outdoor areas, the
colour temperature of LED shall be min. 4000K, including rough & dust prone
areas. LED shall conform to the LM 80 requirements. The LED luminaires shall
have minimum life of 25,000 burning hours with 80% of lumen
maintenance at the end of the life
The max. junction temperature of LED shall be 85 deg C. Further the lumen
maintenance at this temperature shall be min 90%. The THD of LED Luminaires
shall be less than 10%. Further the EMC shall be as per IS 14700. The power
factor of the luminaire shall not be less than 0.9. The marking on luminaire &
safety requirements of luminaire shall be as per IS standards. Suitable heat sink
with proper thermal management shall be designed & provided in the luminaire.
The connecting wires used inside the system, shall be low smoke halogen free,
fire retardant type and fuse protection shall be provided in input side specifically
for LED luminaires.
Care shall be taken in the design that there is no water stagnation anywhere in
the housing of luminaire. The entire housing shall be dust and water proof
protection as per IS 12063.
7. Driver Circuit
LED modules and drivers shall be compatible to each other. The LED module
driver’s ratings and makes shall be as recommended by corresponding LED chip
manufacturer.
LED Drivers shall have following control & protections:-
 Suitable precision current control of LED.
 Open Circuit Protection
 Short Circuit Protection
 Over Temperature Protection
 Overload Protection
 Surge Protection

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CLAUSE NO.
8. Apart from maintenance factor as given below, Temperature correction factor

shall be considered in the lighting design for fixtures located in non air
conditioned area.
(a.) Office area (air conditioned) : 0.8
(b.) Office area (non air conditioned) : 0.7

and other indoor area
(c.) Dust prone indoor and outdoor area : 0.6
(d.) Coal Handling area, Ash Handling : 0.5

Conveyor /Transfer Points etc.
e.) Boiler Area : 0.6
Reflectance Factor:-
Ceiling :0.8
Wall : 0.5
Floor : 0.2
Reflectance factor for CHP areas such as Bunker floor, TPs etc and AHP outdoor
areas :-
Ceiling :0.3
Wall :0.3
Floor :0.1
9. (i) All outdoor fixtures shall be weather proof and of min. IP65 degree
of protection.
(ii) For Indoor type of fixtures:-
(a) Surface/Pendent mounting: - IP 54 class of protection.
(b) Recess Mounting (False ceiling):- IP 20 class of protection .
10. (a) Lighting panels shall be constructed out of 2 mm thick CRCA sheet steel. The
door shall be hinged and the panel shall be gasketted to achieve specified
degree of protection. Lighting panels shall be powder coated with color shade
RAL9002. Lighting panels shall have min. IP55 degree of protection.
(B) All MCBs/Isolators/Switches/Contactors etc. shall be mounted inside the

panel and a fibre glass sheet shall be provided inside the main door such that
the operating knobs of MCBs etc., shall project out of it for safe operation
against accidental contact.
(c) Terminal bocks shall be 1100 V grade, clip-on stud type, made up of
polymide 6.6 or better suitable for terminating multicore 35 or 70 Sq. mm.
stranded aluminium conductor incoming cable and 10 Sq. mm. stranded
aluminium conductor for each outgoing circuits voltage. All terminals shall be
shrouded, numbered and provided with identification strip for the feeders.
(d) MCB’s shall be current limiting type with magnetic and thermal release
suitable for manual closing and automatic tripping under fault condition.
MCB’s shall have short circuit interrupting capacity of 9 KA rms. MCB knob

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CLAUSE NO.
shall be marked with ON/OFF indication. A trip free release shall be provided
to ensure tripping on fault even if the knob is held in ON position. MCB
terminal shall be shrouded to avoid accidental contact.
(e) Contactors of AC lighting panels shall be 3 no’s, 32 A, 3 pole continuous duty
MCB, load make-break type suitable for 415 V, 3 phase 4 wire system. HRC
fuses with suitable mounting base of 125A shall be provided in the incomer of
Contactors in the LP.
(f) DC switches shall be rotary type, 2 pole, continuous duty, load break type,
quick make quick break, suitable for 220 V DC, 2 wire system. Switch knob
shall be provided with ON/OFF indication.
(g) Programmable Digital Timer shall be Electronic Astronomical Almanac Time
switch with battery back up of min. TEN years, 4 Digit LED display, 24 hours
range, manual override facility, 10 Amp 3 relay output, with NO/NC Contacts
suitable for operation on 240V single phase AC supply.
(h) Each lighting panel (LP-3) shall be fed from a 415V/42V, 3 phase-4 wire, 3
KVA transformer. The transformer shall be located inside the lighting panel
itself. Transformers shall be dry type, natural air cooled with class F
insulation or better. Impedance of transformer shall be 5%. Transformers
shall be tested as per IS:11171. Off-circuit tap changer with +/- 5% in steps of
+/- 1.25% tapping shall be provided. One minute power frequency withstands
voltage for lighting transformer shall be 2.5 KV.
(i) Lighting Panels shall be of following types:
TYPE INCOMER FEEDER OUTGOING DETAILOFCONTENTS

FEEDERS
LP-1 3No. 415V, 32 A, TP 18Nos.,20A, 415V, 63A(min.), AC2 duty

MCB 240V MCB contactor and Programmable
Digital Timer of 24 hour range
(31/2Cx70sq.mm cable)
10A, 240V selector switch, fuse,
etc. outdoor type and IP:55
degree of protection
LP-2 3No. 415V, 32 A, TP 9 Nos.,20A, 415V, 63A(min.), AC2 duty

MCB 240V MCB contactor and Programmable
Digital Timer of 24 hour range
(31/2Cx35sq.mm cable)
10A, 240V selector switch, fuse,
etc. outdoor type and IP:55
degree of protection

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CLAUSE NO.
LP-3 1 No., 4A fuse 3 KVA 24 Nos., 16A, IP 55 degree of protection.

transformer,40A TPN 45V MCB Incomer shall be suitable for
MCB receiving 4Cx16 sq. mm cable
and outgoing circuit shall be
suitable for 2Cx16 sq. mm cable.
LP-D1 1No. 220V,32 A, DP 6Nos.,16A, 220V,32A DC Fuse, etc. outdoor

Isolator 220V DP Switch type IP:55 degree of protection.
& Fuse
(2Cx35sq.mm cable)
11. Wires of different phase shall normally run in separate conduit.
12. Power supply shall be fed from 415 / 240 V normal AC supply, emergency AC
supply and 220V DC supply through suitable number of conveniently located
lighting distribution boards (LDB) and lighting panels (LP). AC lighting supply
shall be isolated from main supply by isolation transformers of rating of 50KVA
and fault level restricted to 3 KA at Lighting Panels.
13. Atleast one 6/16A, 240V AC universal socket outlet with switch shall be provided
in offices, cabins, etc. Further 20A, 240V AC industrial receptacle with switch
shall be provided strategically in all industrial areas.
Suitable number of 63A, 3ph, 415V AC industrial receptacles shall be provided
for entire plant for welding purposes, particularly near all major equipment and at
an average distance of 50m. Atleast one 63A, 3ph, 415V AC receptacle shall be
provided in each floor of off-site buildings/ structures.
Receptacles boxes shall be fabricated out of 2 mm thick MS steel hot dip
galvanized or of not less than 2.5 mm thick die-cast aluminium alloy or fabricated
out of 2 mm thick CRCA sheet with electro static powder coating. IP-degree of
protection shall be applicable to receptacles Type ‘RA &’’RC’ only
Receptacles shall be of following types :
Type Switch rating Socket & plug Type & make of plug & Terminal Block size
rating Socket
RA 20 A, SP240V 20A, 3 pin240 V AC EMPLOYER appd. 1-4 way, suitable for loop-
AC(Industrial) make in loop- out of 10 sq.mm.

Al. Conductor

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RB 16A, S.P240V AC 6A+16A6 Pin EMPLOYER 1-4 way, suitable for loop-
decorative Piano- appd.make in loop- out of upto 10
key Type Switch sq.mm. Al. Conductor
RC 20 A, SP24 V 20A, 3 pin24 V AC EMPLOYER appd. 1-4 way, suitable for loop-
AC(Industrial) make in loop- out of 2 core -16
sq.mm. Al. Cable.
14. In the hazardous areas like Hydrogen generation plant, fuel oil handling areas or
any other gas/ liquid fuel storage/ handling areas in bidder’s scope, lighting shall
be flame proof.
15. The type of fixtures, LP, JB, and receptacle used in Hydrogen generation plant
building shall be suitable for group II C as per IS: 2148 or class I, Division II as
per NEC 70-428.
16. All flouresent lamps shall be have "Cool day light" colour designation. The mirror
optics type flouresent fixtures shall have no irridescence effect. Fixtures with
better efficiency and upgraded proven system may also be considered
In candescent lamps may be used only with DC Lighting.
17. Aviation warning lights shall be provided as per the recommendations of ICAO
and Director general of civil aviation, India. The arrangement of light should be
marked such that the object is indicated from every angle in azimuth. The
aviation warning lighting system shall also conform to the latest Indian standard
IS 4998.
18. Contractor shall demonstrate the average lux level achieved for different areas as
per specification requirements, after completion of the lighting work, at site to the
satisfaction of engineer-in-charge.
4.01.00 Ballasts
4.01.01 All fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings (Div-
II/Hazardous Area) shall be provided with electronic ballasts.
4.02.00 All luminaires and their accessories and components shall be of type readily replaceable
by available Indian makes.
4.03.00 Fans & Regulator
4.03.01 Ceiling/Wall Fans, to be provided in non air-conditioned office/control room area. Further
tentatively one (1) no. ceiling fan shall be provided for 10 sq.m area, at suitable mounting
height. The ceiling fans shall be suitable for operation on 240 V +/-10%, 50 Hz, AC supply
comprising of class ‘E’ or better insulated copper wound single phase motor, 1200mm
sweep, aerodynamically designed well balanced AL blades (3 Nos.), down rod, die cast
aluminium housing, capacitor, suspension hook, canopies etc. finished in stove enameled
white or with electro static powder coating. Power factor of fans shall not be less than

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0.9. Fan regulators shall be stepped electronic type suitable for operation on 240V +/-
10% AC supply.
4.04.00 Junction Boxes, Conduits, Fitting & Accessories, Pull Out Boxes:
Junction box for indoor lighting shall be made of fire retardant material. Material of JB
shall be Thermoplastic or thermosetting or FRP type.
Junction boxes for street lighting poles and lighting mast if applicable , shall be deep
drawn or fabricated type made of min. 1.6 mm thick CRCA Sheet. The box shall be hot
dip galvanized. The degree of protection shall be IP55.
All switches and receptacles upto 16A shall be modular type. These shall be provided
with pre-galvanized/galvanized modular switchbox & plate.
Conduits, Pipes and Accessories Galvanised heavy duty steel conduits for normal area
and galvanised heavy duty steel conduits with an additional epoxy coating for corrosive
area shall be offered. Alternatively glass reinforced epoxy conduits with comparable
compressive and impact strength with that of heavy duty steel conduits may be offered.
Conduits in walls and ceilings in buildings with RCC and masonry structure such as
Administrative, Service, Canteen, Time Office, Auditorium, IT building etc shall be
concealed
Rigid steel conduits shall be heavy duty type,hot dip galvanised conforming to IS : 9537
Part-I & II shall be suitable for heavy mechanical stresses, threaded on both sides and
threaded length shall be protected by zinc rich paint. Conduits shall be smooth from
inside and outside.
Flexible conduit shall be water proof and rust proof made of heat resistant TERNE coated
steel.
Pull out boxes shall be provided at suitable interval in a conduit run .Boxes shall be
suitable for mounting on Walls, Columns, Structures, etc.. Pull-out boxes shall have
cover with screw and shall be provided with good quality gasket lining. Pull out boxes
used outdoor shall be weather proof type suitable for IP: 55 degree of protection and
those used indoor shall be suitable for IP: 52 degree of protection. Pull out box & its cover
shall be hot dip galvanized.
4.05.00 Lighting Wires
4.05.01 Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed, stranded
copper/aluminium wire for fixed wiring installation. Colour of the PVC insulation of wires
shall be Red, Yellow, Blue and Black for R, Y, B phases & neutral, respectively and white
& grey for DC positive & DC negative circuits, respectively. Minimum size of wire shall not
be less than 1.5.sq.mm. for copper and 4 sq.mm. for aluminium.
4.06.00 Lighting Poles
4.06.01 The Street Light system and peripheral lighting shall be designed generally in line with
design guidelines. The Poles shall be mounted above ground using base plate and
minimum height of pole shall be 8 mtrs The poles shall be hot-dip galvanized as per

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IS2629/ IS2633/ IS4759. The average coating thickness of galvanizing shall be min. 70
micron. The System shall be capable of withstanding the appropriate wind load etc as per
IS 875 considering prevailing soil/ site condition considering all accessories mounting on
pole.
The street light poles shall have loop in loop out arrangement for cable entry and light
fixture / wiring protected with suitably rated MCB.
4.07.00 Lighting Masts
4.07.01 Lighting Mast shall be of continuously tapered polygonal cross section hot dip galvanised.
The Mast shall be of 30 M or suitable height with lantern carriage to enable
raising/lowering for ease of maintenance, including the Head Frame, Double Drum
Winch, continuous stainless steel wire rope, in built power tool, luminaires, suitable
aviation warning light, lightning alongwith necessary power cables within the mast. The
mast shall be delivered in not more than three sections & shall be joined together by slip
stressed fit method at site. No site welding or bolted joints shall be done on the mast
The Mast together with the fixtures shall be capable of withstanding the appropriate wind
loads as per IS: 875. The Mast shall be fabricated from special steel plates conforming to
BS-EN10-025 and folded to form a polygonal section.
Suitable feeder pillar with TPN MCB, contactors, timer, MCB and other necessary
accessories for operation & protection of the mast and fixtures shall be provided.
4.08.00 Lighting fixtures shall generally be group controlled directly from lighting panel. However,
in office areas, control shall be provided through switch boxes. Each switch shall control a
maximum of three fluorescent fixtures.
4.09.00 A.C. normal, AC emergency and DC system wiring shall run throughout in separate
conduits. Wires of different phase shall run in different conduits.
4.10.00 Lighting panels, etc. shall be earthed by two separate and distinct connections with
earthing system. Switch boxes, junction boxes, lighting fixtures, fans, single phase
receptacles etc. shall be earthed by means of separate earth continuity conductor. The
earth continuity conductor 14 SWG GI wire shall be run alongwith each conduit run.
Cable armours shall be connected to earthing system at both the ends.
4.11.00 Alternately Vendor may offer technically superior and proven product subject to approval
of employer.
4.12.00 Occupancy based Passive Infra-red sensors

The sensors shall be recess mounted, programmable type suitable for lighting load of 6A
with variable off delay settings. The detection area shall be minimum 5 metres for
standard room height of 3mt. All the calibrated settings shall be stored in non-volatile
memory of PIR sensor which shall be unaffected by power supply fluctuations. Necessary
16A contactor shall be supplied alongwith each sensor & shall be located inside the
switch box
5.00.00 TESTS
5.01.00 For LED Fixture
a) The contractor shall carry out the type tests as listed in this specification on the
following types of LED fixtures to be supplied under this contract. The bidder

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shall indicate the charges for each of these type tests separately in the relevant
price schedule of bid document and the same shall be considered for the
evaluation of the bids.
LED fixtures (Type test shall be conducted on one rating each of following type of
LED fixtures. Rating for test conduction shall be decided by the employer during
detailed engineering)
a) High bay fixture.
b) Well glass fixture.
c) Street light fixture
d) Surface mounted type fixture.
e) Recessed mounted type fixture.
The type tests charges shall be paid only for the test(s) actually conducted
successfully under this contract and upon certification by the employer’s
engineer.
b) The type tests shall be carried out in presence of the employer’s representative,
for which minimum 15 days notice shall be given by the contractor. The
contractor shall obtain the employer’s approval for the type test procedure before
conducting the type test. The type test procedure shall clearly specify the test
set–up, instruments to be used, procedure, acceptance norms, recording of
different parameters, interval of recording, precautions to be taken etc. for the
type test(s) to be carried out.
c) In case the contractor has conducted such specified type test(s) within last ten
years as on the date of bid opening, he may submit during detailed engineering
the type test reports to the owner for waival of conductance of such type test(s).
These reports should be for the tests conducted on the equipment similar to
those proposed to be supplied under this contract and test(s) should have been
either conducted at an independent laboratory or should have been witnessed by
a client. The owner reserves the right to waive conducting of any or all the
specified type test(s) under this contract. In case type tests are waived, the type
test charges shall not be payable to the contractor.
5.02.00 For all other Station lighting equipment:
a) All equipment to be supplied shall be of type tested design. During detail

type tests as listed in this specification and carried out within last ten years from
the date of bid opening. These reports should be for the test conducted on the
equipment similar to those proposed to be supplied under this contract and the
have been witnessed by a client.
b) However if the contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in the case of type test
report(s) are not found to be meeting the specification requirements, the
contractor shall conduct all such tests under this contract at no additional cost to
the owner either at third party lab or in presence of client/owners representative
and submit the reports for approval.

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5.04.00 Selection of samples for type test, acceptance test & routine test and acceptance criteria
for all the items shall be as per relevant I.S
5.05.00 Type test reports of the following items as per technical specification requirements/
standards shall be submitted for approval.
SL NO. DESCRIPTION
i. Lighting fixtures of each type
ii. Lighting panel of each type (Degree of Protection)
iii. Junction Box of each type.
Type test reports for LED as per standards for following shall be submitted for approval.
1. Visual and Dimension check
2. Proof of procurement of LEDs
3. Safety tests
a) Marking
b) Construction
c) Provision for Earthing
d) External and Internal wiring
e) Protection against electrical shock
f) Endurance and Thermal
g) Insulation resistance & electrical strength
h) Resistance to heat fire & tracking
i) Resistance to Humidity
4. Fire Retardant test
5. Performance tests (electrical, Photometric color and Life)
6. Burn-in Test
7. Power Cycling

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8. Temperature rise test
9. Emission Tests
a) Radiated & conducted emission
b) Harmonics & flickers
10. Immunity tests
In addition, following test reports to be submitted for LED chip/LED luminaire:

a) LED parameters like Lumen per watt, CRI, Beam angle from manufacturer.
b) LM 80/IS: 16105 report.
c) LM 79/IS: 16106 report.
5.06.00 Acceptance Test and Routine Test
5.06.01 All lighting fixtures, lamps and other items shall be subjected to acceptance and routine
test, as per relevant specified standards.
5.06.02 Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to physical
and dimensional checks also. Switch boxes shall be made of 1.6 mm thick MS sheet with
3 mm thick decorative, Perspex cover. Switch box shall be hot dip galvanized.
Switch boxes shall be of following types :

TYPE No. Switch Fan Regulator* Socket
SWB 1 5 A - 2 Nos. - -
SWB 2 5 A - 3 Nos. - 5A - 1.No.
SWB 3* 5 A - 5 Nos. 1 5A - 1.No
SWB 4* 5 A - 7 Nos 3 5A - 1.No.
SWB 5** 5 A - 5 Nos - 5A - 1.No.
* Space provision shall be kept for fan regulator in switch boxes.
** Shall have the provision for mounting the 16 A contactor.

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5.07.00 Galvanizing Tests
5.07.01 The quality of galvanizing shall be smooth, continuous, free from flux stains and shall be
inspected visually.
5.07.02 In addition following tests shall be conducted as acceptance tests.
(a) Uniformity of coating - The coating of any article shall withstand for one (1)
minute dips in standard copper sulphate solution without the formation of an
adherent red spot of metallic copper upon the basic metal.
(b) The quality of cadmium/zinc plating on items with screw threads shall be free
from visible defects such as unplated areas, blisters and modules and shall be
inspected visually.
(c) In addition, the plating thickness shall be determined microscopically/ chemically

or electronically.
6.00.00 COMMISSIONING CHECKS
1. On completion of installation work, the Contractor shall request the Project

manager for inspection and test with minimum of fourteen (14) days advance
notice.
2. The Project manager shall arrange for joint inspection of the installation for
completeness and correctness of the work. Any defect pointed out during such
inspection shall be promptly rectified by the Contractor.
3. The installation shall be then tested and commissioned in presence of the Project
manager.
4. The contractor shall provide all, men material and equipment required to carry out
the tests.
5. All rectifications, repair or adjustment work found necessary during inspection,

testing and commissioning shall be carried out by the Contractor without any
extra cost. The handing over the lighting installation shall be effected only after
the receipt of written instruction from the Employer/his authorized representative.
6. The testing shall be done in accordance with the applicable Indian Standards and
codes of practices. The following tests shall be specifically carried out for all
lighting installation.
(a) Insulation Resistance.

(b) Testing of earth continuity path.
(c) Polarity test of single phase switches.
(d) Functional checks.

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7. The lighting circuits shall be tested in the following manner:
(a) All switches ON and consuming devices in circuit, both poles connected
together to obtain resistance to earth.
(b) Insulation resistance between poles with lamps and other consuming
devices removed and switches ON.

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ANNEXURE-A
Sl No. Location** Average Type of Fixture

Illumination
Level (Lux)
(a) Turbine Hall operating floor 200 High/medium bay LED luminaire
(b) Turbine Hall Other Platforms 200 LED high/medium bay,

LED well glass fixtures
(c) Switchgear rooms, Charger, 200 Industrial type LED Luminaire

Rectifier room
(d) Control room, computer 350 LED luminaire equivalent to

room, control equipment room Mirror optics with anti-glare
features or downlighter.
(e) Offices, conference rooms, etc. 300 Decorative mirror optics

Type LED luminaire or
LED downlighter
(f) Battery rooms 100 Totally enclosed corrosion

Proof LED Luminaire
(g) Transformer yard 20 (general) LED Luminaire

50 (on equipment)
(h) Boiler platforms 100 LED well glass fixtures,
(i) Diesel generating room

/enclosure, Compressor room, 150 LED medium bay/
pump house etc. Industrial type LED Luminaire
(j) Fuel oil pump house 150 Flame proof fluorescent

fixtures suitable for division-
2 hazardous area
(k) Cable galleries/vault 50 Industrial type LED Luminaire
(l) Street lighting- LED street lights

primary roads 20
secondary roads 10
(m) Outdoor storage handling and 20 LED Luminaire

unloading area
(n) Cement stores 150 Industrial dust proof type

LED Luminaire

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CLAUSE NO.
(o) Chemical stores/House 150 Corrosion proof LED Luminaire
(p) Permanent stores 150 LED high/medium bay /

Industrial trough LED
Luminaire
(q) Workshop. Building 150 LED high/medium bay /

Industrial trough LED
Luminaire
(r) Laboratory
General 150 Corrosion proof LED Luminaire
Analysis area 300
(s) Garage/Car Parking 50 Industrial type LED Luminaire
(u) AIS Switchyard and 20(general LED Luminaire

Substation 50(on strategic
equipment)
(v) Transfer points, 100 LED Dust tight/Well glass

Sheds, tunnels, bunker house, type Luminaire
Crusher house,
Conveyor Gallery etc.
in bidders scope
(w) Facility building, canteen etc 150 Industrial type LED Luminaire
(x) Hydrogen Plant Building 150 Explosion proof HPMV/

Flourcent fittings suitable
for class-I and Division –IIC
(y) DC Lighting- Control room - In candescent down light

fixtures, Decorative recessed
type with cylindrical reflector
(z) DC Lighting- Other Area - Incandescent Industrial

Bulkhead
(aa) Corridors, Walkways 50 LED Luminaire
(ab) Building Periphery Lighting 10 LED Street Light fixture/

LED Luminaire
(ac) Security Lighting along 10 LED Street Light fixture/

Boundary LED Luminaire
(ad) ESP platform 150 LED well glass fixtures

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(ae) Gate complex/Time Office 150 LED Luminaire
(af) GIS Hall 150 LED medium bay/ Luminaire
(n) DM plant, water treatment plant 150 LED high/medium bay /

CW Pump house, Raw water PH, Industrial trough LED
Fire Water PH Luminaire
ANNEXURE-B
Sl. Plant Areas Normal AC Emergency AC 220 V DC Portable

Lighting Lighting Lighting DC
System System System Fixtures
1 TG Building( turbine 80% 20% √

hall, switchgear room __
etc)
2. Boiler Platform 80% 20% √
3 DG Area/ Room 80% 20%
4 Compressor Room √
5 ESP Control Room 80% 20% √
6 Unit Control Room 70% 30%
7 Switchyard Control 80% 20%
Room
8 Battery Room 80% 20%
9 Cable Spreader Room/ 80% 20% √
Vault
10 Make Up Water Pump 100% √
House
11 Chemical House 100% √
12 Fuel Oil Pump House 100% √
13 Ash Handling Plant 100% √
14 Water Treatment Plant 100% √
15 CT Switchgear Room 100% √
16 Cooling Towers 100%
17 Workshop 100% √
18 Service Building 100%
19 Area Lighting 100%

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20 Street Lighting 100%

21 Transformer Yard and 100%
Storage Yard
22 Coal Handling Plant 100% √
23 GIS Hall 80% 20%
24 AIS Switchyard 80% 20%
DC Emergency Lighting:
Area Average Lux Level

1 Unit Control Room 100
2 Control Equipment Room 100
3 Switchyard Control Room 20
4 Strategic Control Points 20

( In TG Building & Boiler Area, Switchgear
room, SWAS, Battery Room, UPS Area,
TG Hall, Luboil Room etc
5 Cable Vault & Galleries 1 fixture at every 20 metres

spacing along walkways
6 Boiler Stair Case 1 fixture at every 20 metres

spacing along walkways
7 Exit/ Entry of Main Plant Building 1 fixture
8 Fire Exit Sign 1 fixture

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VARIABLE FREQUENCY DRIVES

CLAUSE NO.
1.00.00 GENERAL
The Design, manufacture, erection, testing and performance of items and services
provided under this specification shall comply with the latest edition including all
applicable official amendments and revisions as on date of award of the following
standards. In case of conflict between this specification and code (IS Code,
standards, etc.) referred herein, the former shall prevail. All work shall be carried out
as per the following codes and standards.
HT breaker IEC:60056
DC reactor IEC 60289
Transformers IS:2026, IEC: 60076
IEC 61378
Bushing IS: 2099, IEC 60137
Adjustable Speed Electrical Power Drive Systems IEC 61800
Semiconductor converters–General requirements IEC 60146
IEEE Recommended practices and requirements
for harmonic control in electrical power systems IEEE 519
Degrees of protection provided by enclosures (IP Code) IEC 60529
Electrostatic immunity test IEC1000-4-2
Fast transient immunity test IEC1000-4-4
Surge immunity test IEC1000-4-5
High-voltage switchgear and controlgear; Pt.102: Alternating current
disconnectors and earthing switches IEC
62271-102
High-voltage switchgear and controlgear; Pt.200: AC metal-enclosed switchgear
and controlgear for rated voltages above 1 kV and up to and including 52 KV
IS/IEC: 62271-200
AC electricity meters IS: 722

Metal oxide surge arrestor without gap for AC system IEC: 60099-4
Terminal blocks for copper conductors IEC: 60947-7-1
Dry transformer IS: 11171
Motor IEC 60034-18-41 &42,
IEC60034 / NEMA 30 &
31,
Contactor/Switches/Fuses etc. IEC:60947, IS: 13947
Harmonics & EM compatibility IEEE:519/IEC: 61000
VFD IEC: 60034/ IEC: 61800
Equipment complying with other internationally accepted standards will also be

considered if they ensure performance and constructional features equivalent or
superior to standards listed above. In such a case, the Bidder shall clearly indicate

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WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 VFD
CLAUSE NO.
the standard(s) adopted, furnish a copy in English of the latest revision amendments
and revision in force as on date of opening of bid and shall clearly bring out the
3.00.00 OPERATING CONDITIONS
Centigrade and also relative humidity of 95% at 40 deg. Celsius shall be considered.
3.02.00 All equipment shall be suitable for rated frequency of 50 Hz with a variation of +3% &
-5%, and 10% combined variation of voltage and frequency unless specifically
brought out in the specification.
3.03.00 The auxiliary AC voltage supply arrangement shall have 11/6.6/3.3kV and 415V
systems (as applicable). It shall be designed to limit voltage variations as given
below under worst operating condition:
1. 11kV/ 3.3 kV/ 6.6 KV : +/- 6%
2. 415V : +/- 10%
Note: The Voltage level mentioned above is the Nominal Voltage available at the
input of the VFD System from the MCC/ Switchgear/transformer, based on the
system requirement/Availability.
The voltage level for the VFD output to be fed to motor shall be as follows:-
1. Upto 400 kW : 415V/690V, Low Voltage, Three Phase
AC
2. Above 400kW and upto 700 KW : 690V, Low Voltage, Three Phase AC
3. Above 700KW : Medium Voltage
From here onwards in the specifications all the VFD Systems consisting of either
415 V or 690 V may be termed as LV VFD while the higher rated VFD System shall
be termed as MV VFD. If nothing is mentioned than the Clause is applicable for both
the LV and the MV VFD until deliberated otherwise.
Type of drive 3-Phase Diode / Thyristor / Multi Stage IGBT / IGCT /

SGCT/ IEGT
Type of Cooling of VFD Naturally air cooled/forced air cooled/Liquid cooled
Converter Type Full wave diode rectifier/active front end type
Inverter Type Thyristor/IGBT/IGCT/SGCT/IEGT

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CLAUSE NO.
5.01.00 Medium Voltage VFD: The Variable frequency drive (VFD) system shall be of a
modern proven design for similar applications in power plants/industry. The system
shall be either Current Source Inverter (CSI) or Voltage Source Inverter (VSI) type
with minimum eighteen (18) pulse design.
5.02.00 415 V/690 V LV VFD: The Variable frequency drive (VFD) system shall be of a
modern proven design for similar applications in power plants/industry. The system
shall be either Current Source Inverter (CSI) or Voltage Source Inverter (VSI) type
with minimum Twelve (12) pulse design. For drives less than 100 KW Six (6) pulse
can be offered meeting all other requirements.
5.03.00 The system shall be fully digital, PLC/Microprocessor based, energy efficient, and
shall provide very high reliability, high power factor, low harmonic distortion and low
vibration and wear and noise. It shall be easy to install in minimum time and
expense and no special tools shall be required for routine maintenance.
5.04.00 The offered equipment shall be with state of art technology and proven field track
record. No prototype equipment shall be offered.
5.05.00 The VFD manufacturer shall ensure the proper coordination of their VFD with the
Driven Motor and the supply system. All the Motors which are to be driven by VFDs
will be of Inverter duty type. The VFD operation shall have no inherent detrimental
impact on the Motors/ cables & supply system.
6.00.00 TECHNICAL AND OPERATIONAL REQUIREMENTS
6.01.00 The system shall be designed to deliver the motor input current and torque for the
complete speed torque characteristics of the driven equipment, with worst input
supply voltage and frequency variation. The system shall be suitable for the load
characteristics and the operational duty of the driven equipment.
6.02.00 The overload capacity of the controller shall be 150% of the rated current of the
motor for one minute for constant torque applications and 110% of rated current for
one minute for variable torque applications at rated voltage. If the motor load
exceeds the limit, the drive shall automatically reduce the frequency and voltage to
the motor to guard against overload.
6.03.00 The drive system shall be designed to operate in one or more of the following
operating modes as to suit characteristics of the driven equipment or specified by
the load:
a. Variable torque changing as a function of speed.
b. Constant torque over a specific speed range.
c. Constant power over a specific speed range.

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CLAUSE NO.
d. Any other as specified in data-sheet
6.04.00 VFDs shall comply with the latest edition of IEEE 519 & IEC 61000 for both
individual as well as total harmonic voltage and current distortion limits. The Voltage
and Current limits shall be applicable at the Point of Common Coupling (PCC),
which shall be the MCC/ Switchgear/ from which the VFD system is fed.
6.05.00 The above compliance shall be verified by the field measurements of harmonics at
the PCC with and without VFDs operation.
6.06.00 VFD shall be capable of withstanding the thermal and dynamic stresses and the
transient mechanical torque, resulting from short circuit. Any damage resulting from
such a short circuit or internal fault shall be limited to the component concerned.
6.07.00 The system shall be suitable to maintain speed variation within range 10-110% or
as per the requirement of driven equipment with speed set accuracy of +1% of rated
maximum speed and steady state regulation of +0.5% of rated speed as per system
requirement.
6.08.00 The VFD System shall maintain a power factor of 0.95 (minimum) (for LV VFD
system) and 0.9 (minimum) (for MV VFD system) in the entire operating range.
6.09.00 Maximum allowable audible noise from the VFD system will be 85 dB (A) at a
distance of one meter under rated loaded with all cooling fan operating conditions.
6.10.00 All the circuit components shall be suitably protected against over voltages, surges,
lightning etc.
6.11.00 The panels shall be designed to provide easy access to hardware, to facilitate
replacement of cards in case of any failure.
6.12.00 All the VFDs for particular application shall be of same design so as to ensure 100 %
interchangeability of components.
6.13.00 For each programmed warning and fault protection function, the VFD shall display a
message in complete English words or Standard English abbreviations. At least 30
time tagged fault messages shall be stored in the drive’s fault history.
6.14.00 The VFD cubicles shall be placed in air conditioned environment. However if VFDs
of less than 100 kW are designed to operate in non-air condition environment the
same shall also be acceptable.
6.15.00 The 3-Phase Thyristor/IGCT/SGCT/ multistage IGBT/IEGT based VFD system shall
have minimum number of components to ensure very high reliability. The input side
converter shall have 3-Phase Diode/Thyristor bridge configuration modular type and
inverter shall be of 3-Phase Thyristor/IGCT/SGCT/multi stage IGBT/IEGT type,
using Pulse Width Modulation or better technique for generating near sine wave
output to motor.
6.16.00 Fiber optic cable connection shall be provided preferably to ensure high network
reliability.

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CLAUSE NO.
7.00.00 VFD COMPATIBILITY WITH THE MOTOR
7.01.00 MV VFD output current waveform, as measured at the motor, shall be inherently
sinusoidal at nominal loads, with a total harmonic current and voltage distortion
within acceptable/standard limits. VFD with transformers on output side are not
acceptable.
7.02.00 The system design shall not have any inherent output harmonic resonance in the
operating speed range.
7.03.00 VFD shall provide stable operation of motor from high-voltage dv/dt stress,
regardless of cable length to motor. The vendor shall clearly state the limitations in
the motor cable distance in his proposal. However, due to system requirements &
constraints if the cable length becomes critical, filters/ chokes etc. shall be provided
by the VFD manufacturers as an integral part of the VFD to mitigate the reflected
wave effect of harmonics.
8.00.00 BYPASS ARRANGEMENT (OPTIONAL, IF SPECIFIED)
8.01.00 The VFD System shall have an optional feature to run the motor under bypass
arrangement for operation of Motor with VFD bypassed. During starting (under rated
conditions) the motor will be switched on in VFD Mode to limit the starting current
and after gaining speed, the load would be switched over to bypass mode.
8.02.00 Comprehensive motor protection scheme for protection and control for operation
VFD during bypass mode shall be finalized during detailed engineering.
9.00.00 STANDBY VFD ARRANGEMENT (OPTIONAL, IF SPECIFIED)
9.01.00 A Common standby arrangement with auto/manual switchover shall be provided in

case of failure of any VFD in a group of drives. Complete protection, interlocks &
control required shall be provided in the changeover module.
10.00.00 EFFICIENCY
10.01.00 Efficiency (Drive only) shall be minimum 98% for both MV VFD and LV VFD. Overall
efficiency shall be minimum 96.5% for LV VFD and minimum 94 % for MV VFD at
rated load and speed. Overall Efficiency evaluation shall include input transformer,
harmonic filters and power factor correction (if applicable), VFD converters, cooling
fans and output filter, as applicable in the system. Auxiliary controls, such as internal
VFD control boards, cooling fans/pumps.
10.02.00 In absence of valid test report, a factory test shall be performed at the VFD
manufacturer’s facility verifying the efficiencies. Manufactures who are supplying
Drive and transformer from different locations, efficiency test will be conducted
separately for Drive and transformer.
11.00.00 COOLING SYSTEM
11.01.00 The VFD shall be designed to operate indoor under temperature range of 0 deg C to
50 deg C and relative humidity of 95 %( at 40 deg C).

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CLAUSE NO.
11.02.00 VFD manufacturer to primarily offer Air cooled Design. However in case of large
ratings, liquid cooled drives may be accepted subject to employer’s approval. In
case of liquid cooled system, there shall be no necessity of continuous water supply
system (Closed Loop System).
11.03.00 In case of Air cooled design, the VFD Cooling system shall be such that it puts
minimum heat load inside the room and preferably throw the hot air outside the room
with ventilation ducts. The Cooling system shall be designed in such a way that the
Air Conditioning & Ventilation Air requirements are kept to minimum. The VFD
Manufacturer shall furnish the data regarding heat load, air flow requirements during
the detailed engineering.
11.04.00 Air cooled VFDs shall be provided with cooling fans mounted integral to the VFD/
enclosure. The VFD shall include air-flow pressure switches and temperature
detectors to monitor proper operation of the air cooling system. If the fan fails, the
system must generate the alarm/trip for the fan failure.
12.00.00 TRANSFORMER:
12.01.00 Type: Outdoor Mineral oil filled ONAN type or Indoor natural air-cooled Dry type,
Three phase unit, rectifier/converter duty type transformer.
12.02.00 All other components, technical parameters shall be as per applicable IEC/IS.
12.03.00 Enclosure for Dry Type Transformer (as applicable)
Enclosure shall be of a tested quality sheet steel of minimum thickness 2 mm & shall
also accommodate cable terminations. The housing door shall be interlocked such
that it should be possible to open the door only when transformer is off. The
enclosure shall be provided with lifting lugs and other hardware for floor mounting.
12.04.00 Core Shall be High grade non-ageing cold rolled grain

oriented silicon steel
Laminations.
12.05.00 Winding conductor Shall be electrolytic grade copper.

Windings shall be of class F insulation.
12.06.00 Winding temperature Shall be Platinum resistance type temperature

Indicator (WTI) detector in each limb.
12.07.00 Thermistors Shall be embedded in each limb with alarm and trip
contacts for remote annunciation.
12.08.00 Temperature rise: Winding temperature rise shall be as per applicable IEC.

6 OF 13
CLAUSE NO.
13.00.00 POWER CONVERTER:

13.01.00 The static power converter shall consist of a line side converter for operation as a
rectifier and a load side power converter for operation as a fully controller inverter.
Power converter shall be fast switching, most efficient and low loss type.
13.02.00 The converter shall be coordinated with the transformers. The converter shall be
able to withstand a three phase short circuit current until interrupted by normal
breaker operation.
13.03.00 Adequate short circuit and over voltage protection shall be provided for the converter
and inverter system.
13.04.00 All power converter devices shall include protective devices, snubber networks and
dv/dt networks as required.
13.05.00 The current rating of the converter’s semi-conductor components shall not be less
than 120% of the nominal current flowing through the elements at full load of the
VFD through the whole speed range. If the parallel connection of semiconductor is
applied, the above current rating shall not be less than 140% of the above values.
13.06.00 All power diodes shall be of silicon type with minimum VBO rating at 2.5 times the
rated operating voltage.
13.07.00 The power converter circuit shall be designed so that motor can be powered at its
full nameplate rating continuously without exceeding its rated temperature rise nor
reducing its service factor due to harmonic currents generated by the inverter
operation. The conversion devices and associated heat sinks shall be assembled
such that individual devices can be replaced without requiring the use of any special
precautions / tools.
13.08.00 The cooling system of the electronic components, if provided, shall be monitored
and necessary alarms shall be provided to prevent any consequential damage to the
power control devices.
14.00.00 OUTPUT FILTER (AS APPLICABLE):
14.01.00 Output/ dv/dt filter shall be provided, if required. It shall be an integral part of the
VFD system and included within the VFD enclosure. It shall inherently protect motor
from high voltage dv/dt stress.
15.00.00 DC LINK CAPACITOR (AS APPLICABLE):
15.01.00 Capacitor shall be of self-healing film or electrolytic type having high life time. The
capacitor shall be an integral part of VFD system. DC link Capacitors shall have
discharge resistors which shall be capable of reducing the residual charges to zero
just after the capacitor is disconnected from the supply source. The capacitor shall
be suitable for high ripple currents.
16.00.00 DC Reactor (As applicable)
1) Type: Dry type, air cored, self cooled, indoor type. Suitable for withstanding
earth fault continuously.

7 OF 13
CLAUSE NO.
2) Insulation: Thermal Class 155(F), temperature rise is limited to thermal class

130 (B).
3) Noise level shall not exceed value specified in NEMA TR-1.
17.00.00 VFD PANEL REQUIREMENTS
17.01.00 Enclosure frames and load bearing members shall be fabricated using suitable mild
steel structural sections or pressed and shaped cold-rolled sheet steel of thickness
2.0 mm. Frames shall be enclosed in cold-rolled sheet steel of thickness 1.6 mm.
Doors and covers shall also be of cold rolled sheet steel of thickness 1.6 mm.
Stiffeners shall be provided wherever necessary. The gland plate thickness shall be
3.0 mm for hot / cold-rolled sheet steel and 4.0 mm for non-magnetic material. In
case dry type transformer is provided inside VFD panels, the enclosure and in its
frame thickness shall be same as indicated in this para.
17.02.00 The cable entry shall be from the bottom of the panel and a removable bolted un-
drilled gland plate.
17.03.00 All Panels shall be of dust-proof and vermin-proof construction and shall be provided
with a degree of protection of IP: 4X as per IS/IEC 60947.
17.04.00 Enclosures must be designed to avoid harmonic and inductive heating effects and to
shield any outside equipment from interference, enclosing and shielding the
complete to eliminate any radio frequency interference. The construction of the
panel shall provide effective protection against electromagnetic emissions.
17.05.00 Each panel shall be provided with illuminating lamp, space heater with switch fuse
and variable setting thermostat.
17.06.00 Proper ventilation using air filters and fans/pumps shall be provided in the
panels to ensure that maximum temperature inside the cubicle is within
permissible limits for reliable and continuous operation of the system.
18.00.00 PAINTING
Paint shade shall be as follows
a) VFD transformer : RAL 5012 (Blue), legend in black letter
reactor enclosure
b) Motors : RAL 5012 (Blue)
c) VFD Panels : Front and rear panels in Grey (RAL9002). End panel
sides in blue (RAL 5012)
19.00.00 HT SWITCHGEAR
19.01.00 The technical requirements of HT switchgear shall be as per chapter of HT
switchgear in Part-B of Technical specifications.
20.00.00 MOTORS
20.01.00 VFD shall be used to drive three (3) phase squirrel cage inverter duty Induction
motor with VPI insulation (Resin poor) suitable for VFD application. These motors
shall be provided with insulated bearing on at least one side.

8 OF 13
CLAUSE NO.
20.02.00 Motors shall also meet the requirements mentioned in subsection for motors and
relevant IS/IEC.
20.03.00 Motor shall be suitable for operation with a solid state power supply consisting of an
adjustable frequency inverter for speed control & shall be suitable for the current
waveforms produced by the power supply including the harmonics generated by the
drive.
20.04.00 Motor insulation shall be designed to accept the applied voltage waveform, within the
Vpeak and dv/dt limits as per IEC-61800.
20.05.00 Drive manufacturer shall coordinate with the motor manufacturer for proper selection
of the motor for the given load application and the output characteristics of the drive.
20.06.00 Other requirements of motor shall be as stipulated in technical chapter of Motors in
Part-B of technical specifications.
21.00.00 LT & HT CABLES
.
21.01.00 Contractor’s scope shall also include LT and HT cables suitable for VFD system and
Motors.
22.00.00 CONTROL AND PERFORMANCE REQUIREMENTS
22.01.00 The VFD to provide an automatic current limiting feature to control motor currents
during startup and provide a “soft start” torque profile for the motor load combination.
Current and torque limit adjustments shall be provided to limit the maximum VFD
output current and the maximum torque produced by the motor.
22.02.00 It shall be possible to vary the speed of the drive and control it in either Local or
Remote mode. Local / Remote selection shall be done from VFD panel unless
otherwise specified.
22.03.00 Provision shall be kept for exchange of information between different VFD control
system parameters thru PLC/DDCMIS.
Man machine interface for (MV) VFD shall have one flat TFT monitor with keyboard
(password protected) in the VFD room and a color laser printer for system alarm and
monitoring located in control room.
Parameter Monitoring: -Input and output voltage of Drive

- Input and output current of Drive
- Motor speed
- Input and output power frequency of Drive
- Torque
-Input and Output power of Drive system (covering
transformer if applicable)
- Output kWhr of Drive
- Transformer (if applicable) temperature for alarm & trip.
- Ambient temperature
- Run/stop and local/remote status displayed
22.04.00 Drive shall be equipped with a front mounted operator console panel consisting of a
backlit alphanumeric display and a keypad with keys for parameterization and

9 OF 13
CLAUSE NO.
adjusting parameter. Control panel shall be operable with password for changing the
protection setting, safety interlock etc.
22.05.00 Operator console/Main Control Card shall have facility / port to connect external
hardware such as Lap-Top etc. Console shall have facility for upload and download
of all parameter settings from one drive to another drive for start up and operation.
22.06.00 User-friendly licensed software for operation and fault diagnostic shall be loaded in
the drive system panel before commissioning.
23.00.00 PROTECTION FEATURES
23.01.00 The system offered shall incorporate adequate protection features as per IEC 61800-
4: 2002 Table-8, properly coordinated for the drive control and for motor including
following:
i) Converter transformer: short circuit, over current, earth fault & winding temperature
high protection.
ii) Incoming and outgoing line surge protection.
iii) Under / over voltage protection
iv) Phase loss, phase reversal, overload, negative phase sequence, locked rotor
protection.
v) Instantaneous Over current & Earth fault protection
vi) Converter/Inverter module failure indication.
vii) Over frequency/speed protection.
viii) Ventilation failure indication & alarm.
ix) Over temperature of VFD
x) Bearing temperature protection.
xi) System earth fault protection.
xii) Speed reference loss protection.
23.02.00 Under VFD Bypass Mode (if applicable) all the electrical protections related to the
Motor shall remain applicable.
24.00.00 CONTROL FEATURES
24.01.00 Following controls shall be provided as a part of the Operator Control Panel or
through separate switches on the front panel door.
i) Start / stop (in local/remote mode)

10 OF 13
CLAUSE NO.
ii) Speed control (Raise / lower)
iii) Acknowledge/Accept/ Test Push Button for annunciation
iv) Auto / Manual / Test Mode select
v) Emergency stop
vi) Trip-Remote Breaker
25.00.00 DIAGNOSTIC FEATURES
25.01.00 The VFD shall include a microprocessor/PLC based digital diagnostic system which
monitors its own control functions and displays faults and operating conditions.
25.02.00 Fault diagnostic shall be built into the system to supervise the operation and failure
of the system. The information regarding failure of any of the system including shut
down of the system shall be available. It shall be possible to retrieve the record of
events prior to tripping of the system or de-energization. Auxiliary supply to the
system components or to the electronics (firmware) for the diagnostics / display shall
be taken care of by the manufacturer for this purpose.
26.00.00 SERVICEABILITY / MAINTAINABILITY
26.01.00 Front Access: VFD system should be designed for front access only. Manufacturer
shall state in his proposal if rear access is provided.
26.02.00 Power Component Accessibility: All power components in the converter sections
shall be designed for rack-out accessibility for ease of maintenance and to minimize
repair downtime.
26.03.00 Marking / Labeling: Sleeve type wire marker tags or other acceptable means of
permanent identification shall be applied to power and control wiring. Individual
labels shall be provided for all major components of the VFD system.
27.00.00 STORAGE AND PRESERVATION
27.01.00 The Contractor shall be responsible for the storage and preservation of all the
equipments to be supplied under the VFD System, till the time of successful
installation and commissioning. The equipment should be suitable for storage for
long periods before installation. Contractor should take adequate measures to
ensure that no damage happens to the VFD System due to storage and
preservation.
28.00.00 TESTS
28.01.00 ROUTINE TESTS
All acceptance and routine tests as envisaged in QA section shall be carried out.
Charges for these shall be deemed to be included in the equipment price.

11 OF 13
CLAUSE NO.
28.02.00 TYPE TESTS

28.02.01 The Contractor shall carry out the type tests as listed in this specification on the
for each of these type tests separately in the relevant schedule and the same shall
be considered for the evaluation of the bids. The type tests charges shall be paid
only for the test(s) actually conducted successfully under this contract and upon
certification by the employer’s engineer.
28.02.02 The type tests shall be carried out in presence of the employer’s representative, for
which minimum 15 days’ notice shall be given by the Contractor. The Contractor
shall obtain the employer’s approval for the type test procedure before conducting
the type test. The type test procedure shall clearly specify the test set–up,
instruments to be used, procedure, acceptance norms, recording of different
parameters, interval of recording, precautions to be taken etc. for the type test(s) to
be carried out.
28.02.03 In case the Contractor has conducted such specified type test(s) within last ten
years as on the date of bid opening, he may submit during detailed engineering the
type test reports to the Employer for waival of conductance of such test(s). These
reports should be for the tests conducted on the equipment similar to those
proposed to be supplied under this contract and test(s) should have been either
The Employer reserves the right to waive conducting of any or all the specified type
test(s) under this contract. In case type tests are waived, the type test charges shall
not be payable to the Contractor.
28.02.04 Further the Contractor shall only submit the reports of the type tests as listed in
"LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED" and carried
out within last ten years from the date of bid opening. These reports should be for
the test conducted on the equipment similar to those proposed to be supplied under
laboratory or should have been witnessed by a client. However if the Contractor is
not able to submit report of the type test(s) conducted within last ten years from the
date of bid opening, or in the case of type test report(s) are not found to be meeting
the specification requirements, the Contractor shall conduct all such tests under this
contract at no additional cost to the Employer either at third party lab or in presence
of client/Employers representative and submit the reports for approval.
28.03.00 LIST OF TYPE TESTS TO BE CONDUCTED
The following type tests shall be conducted under this contract for MV VFD
i) Overall efficiency determination of VFD system including transformer/ Harmonic
filters etc at motor full load
ii) Temperature rise test
iii) Noise level
iv) Harmonics of No load current.(Input/Output)

The following type test reports shall be submitted for VFD Panels’

12 OF 13
CLAUSE NO.
1) VFD panels (For LV VFD)

i. Rated Current/ Output
ii. Temperature rise test
iii. Noise level test
iv. Power Loss Determination Test
v. Power factor measurement.
vi. Degree of Protection Test
vii. EMC Test
viii. The Fast transient SWC tests as per ANSI / IEEE C37.901-2002 / IEC
60255-22-04-2008 / IEC 61800
2) VFD panels (For MV VFD)

i. Rated Current/ Output
ii. Current Sharing
iii. Voltage Division
iv. Power Loss Determination Test
v. Power factor measurement.
vi. Degree of Protection Test
vii. The Fast transient SWC tests as per ANSI / IEEE C37.901-2002 / IEC
60255-22-04-2008 / IEC 61800
3) AC/DC Reactor
i. Lightning impulse test(If applicable)
ii. Heat run test
iii. Short time current test(If applicable)
iv. Noise level test
4) Transformers (In case of non integrated type)
i. As per requirements mentioned in subsection for Transformer chapter in
technical specifications.

13 OF 13
CONSTRUCTION POWER

CLAUSE NO.
1.00.00 GENERAL
1.01.00 Power shall be made available to the bidder, at 11kV level from owners construction power
ring mains. Bidder shall be fully responsible to make all his arrangement beyond these
points for receiving & further distribution to meet all construction power requirements for the
entire scope including the owner’s construction power requirements indicated in Section-VI,
Part-A Sub section –IIB of the technical specification.
1.02.00 The power shall be extended by the bidder to different areas by armoured cables or
overhead lines. All the equipments used in construction power shall ensure full safety to the
working personnel and no live parts which are accessible shall be exposed.
2.00.00 LT DISTRIBUTION BOARDS
2.01.00 In general, these shall meet the requirements covered in LT switchgear chapter. However,
the board shall be provided with outer enclosure so that access to individual compartments,
busbar and cable alley shall be available only after the outer door is opened.
2.02.00 The distribution boards shall be provided with the following:
Pad locking arrangement with hinged door
Sloped canopy to prevent ingress of rain water
Caution notice
Earthing
3.00.00 CABLES
Cables shall be armoured and suitable for direct underground buried installation. Cable
armour shall be suitable for carrying system earth fault current. HT cables shall be XLPE
insulated type.
4.00.00 EARTHING SYSTEM
4.01.00 Earthing of all substation equipment and overhead line shall be carried out as per IS:3043.
Earthing system shall consist of number of earth electrodes interconnected. Earth
electrodes shall be of 40mm dia. galvanised steel pipe, buried in earth pit.
4.02.00 Number of earth electrodes for LT substation shall be decided considering soil resistivity.
However, each LT substation shall have minimum two earth electrodes for neutral earthing,
two earth electrodes for body earthing and two earth electrodes for lightning arrestor
earthing.
4.03.00 All non-current carrying metal parts shall be connected to earth system at two points, each
of 100% rating. Metallic supports, fencing, etc. shall also be connected to earth system.
4.04.00 Size of earthing conductor shall be selected considering fault current, duration of fault and
corrosion rate. Earthing conductor shall be of galvanised steel strip/wires.
4.05.01 Overhead lines shall be earthed by continuous galvanised steel overhead earth wire
fastened to each pole and connected with earth at minimum three points in every km length.
Cross section of earth wire shall not be less than 25 sq.mm.
KHURJA SUPER THERMAL POWER TECHNICAL SPECIFICATION SUB-SECTION-IIIB-13 PAGE

PROJECT (2X660 MW) SECTION – VI, PART-B Construction Power 1 OF 2
CLAUSE NO.
5.01.00 The electrical installation shall generally be carried out as per Indian electricity rules and
acts.
5.02.00 For road crossing, protective guarding shall be provided. The clearance for the lowest
conductor from ground shall be decided keeping in view the vertical clearance required for
movement of vehicles/cranes etc.
5.03.00 The LT substation area shall be graded and sloped to prevent any stagnation of rain water.
5.04.00 The LT substation shall be enclosed by barbed wire fencing on mild steel angle iron posts to
a height of not less than 2500 mm with suitable gates for entrance.
5.05.00 All cable connection parts within the switchgear shall be shrouded with insulating materials.
5.06.00 The extension boards provided for hand held equipments shall have 3 wire system i.e.
phase, neutral & earth as per IE rules. The plug & socket arrangement provided shall be of
industrial type with switch provided for proper isolation at the time of insertion or withdrawal
of plugs.
5.07.00 The flexible cable used shall have heavy duty insulation.
5.08.00 All equipment used for construction activities shall be fed from separate switching/isolating
devices.
5.09.00 All the working areas shall be adequately illuminated for safe working with proper
fittings/fixtures. The wire shall be laid with proper fixing without any hindrance to personnel
or vehicular movement.
6.00.00 WORKING PROCEDURES
6.01.00 Adequate safety equipments shall be provided to all the workers, like hand gloves, head
gear etc. Meggers & testers shall be provided in sufficient quantity.
6.02.00 Only ITI qualified workers shall be allowed to handle the electrical or electrically operated
equipments.
7.00.00 Quality Assurance: All equipments to be tested for routine tests as per relevant standards.
The charges for the same will be deemed to be included in the price of the equipment.
KHURJA SUPER THERMAL POWER TECHNICAL SPECIFICATION SUB-SECTION-IIIB-13 PAGE

PROJECT (2X660 MW) SECTION – VI, PART-B Construction Power 2 OF 2
PART – B
CONTROL & INSTRUMENTATION
KHURJA SUPER THERMAL POWER PROJECT (2X660 MW) SECTION-VI
BID DOC. NO.: THDC/RKSH/CC-9915-373
PART – B (CONTROL AND INSTRUMENTATION SYSTEM)
III C – 01 BASIC DESIGN CRITERIA
III C – 02 DISTRIBUTED DIGITAL CONTROL, MONITORING & INFORMATION SYSTEM
(DDCMIS)
ANNEXURE TO DDCMIS
IIIC – 02A NOT USED
IIIC – 02B NOT USED
IIIC – 02C NOT USED
IIIC – 02D NOT USED
IIIC – 02E NOT USED
IIIC – 02F NOT USED
IIIC – 02G HMI HARDWARE
IIIC – 02H SPECIAL REQUIREMENTS
IIIC – 02J SECURITY POLICIES AND PROCEDURES
IIIC - 02K GENEREAL REQUIREMENTS FOR FIELDBUS INSTRUMENTS
AND ACTUATORS
III C - 03 NOT USED

III C – 04 MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)
III C – 05 ELECTRICAL POWER SUPPLY SYSTEM
III C – 06 PROCESS CONNECTION AND PIPING
III C – 07 INSTRUMENTATION AND POWER SUPPLY CABLES
III C – 08 CONTROL VALVES AND ACTUATORS
III C – 09 NOT USED
III C – 10 TYPE TEST REQUIREMENTS
III C – 12 CONTROL DESK , PANELS AND FURNITURE
IIIC- 16 NOT USED
IIIC- 17 NOT USED
IIIC- 18 FIELDBUS INSTRUMENTS
IIIC-19 ELECTRIC ACTUATORS
IIIC-20 NOT USED
SUB – SECTION – IIIC - 01
BASIC DESIGN CRITERIA
CLAUSE NO.
BASIC DESIGN CRITERIA

1.01.00 The Contractor shall provide Independent Control & Instrumentation system consisting of
Distributed Digital Control, Monitoring and Information System (DDCMIS), associated
Measuring Instruments, Process Connection and Piping & LIE/LIRs, Electrical Power
Supply System, , Control Desk (CD), associated Instrumentation and Power Supply Cables,
Control valves and Actuators etc. as identified in the specification.
1.02.00 In addition to requirements specified under this Section-VI, Part-B, all C&I systems/ sub-
systems/ equipment/ devices shall also meet other requirements stipulated under other Sub-
sections/ parts/ sections of specification.
2.00.00 PROVENNESS CRITERIA
2.01.00 Bidder shall either provide his own DDCMIS or from his approved suppliers meeting all
provenness, parametric, technical and other requirement specified under various sections of
this specification.
2.02.00 All equipment, systems and accessories furnished under this specification shall be from the
latest proven product range of a reputed experienced manufacturer whose successful
performance has been established by a considerable record of satisfactory operation in coal
fired utility power stations as specified in Section IFB and/or Section-VI. Bidder shall furnish
satisfactory evidence regarding successful operation and high reliability of the proposed
equipment/systems in coal fired utility stations for similar applications for meeting this
requirement as specified in Section IFB and/or Section-VI.
2.03.00 The Bidder shall furnish a complete list of bought out items (i.e., items not from
manufacturing range) which the Bidder has included in his proposal along with the names of
proposed suppliers as a part of his proposal. However the make and model of all bought out
items to be supplied by the Contractor shall be as approved by Employer during detailed
engineering stage.
3.00.00 RELIABILITY AND AVAILABILITY
3.01.00 Each component and system offered by the Bidder shall be of established reliability. The
minimum target reliability of each piece of equipment like each electronic module/card,
Power supply, Peripheral etc. shall be established by the Bidder, considering its failure
rate/mean time between failures (MTBF), meantime to repair (MTTR), such that the
availability of the complete DDCMIS is assured for 99.7%.
3.02.00 When more than one device uses the same measurement or control signal, the transmitter
and other components/ module shall be fully equipped to provide all signal requirements. All
the 4-20 mA output signals from transmitters/other control system shall be able to drive
minimum 500 Ohms load resistance. The system shall be arranged so that the failure of any
monitoring device or control components or spurious intermediate grounding in the signal
path shall not open the signal loop nor cause the loss or malfunction of signal to other
devices using the same signal.
3.03.00 To ensure availability, adequate redundancy in system design shall be provided at hardware,
software and sensor level to satisfy the availability criterion mentioned above. For the

TECHNICAL SPECIFICATION PAGE
(2X660 MW) SUB-SECTION-IIIC-01
SECTION – VI, PART-B 1 OF 4
WATER SYSTEM PACKAGE BASIC DESIGN CRITERIA
BID DOC NO.:THDC/RKSH/CC-9915-373
CLAUSE NO.
protection system, independent sensing devices shall be provided to ensure adequate safety
of plant equipment.
4.00.00 STANDARDISATION AND UNIFORMITY OF HARDWARE
4.01.00 Bidder shall ensure that various C&I instruments /equipment like vibration monitoring system,
4-20mA electronic transmitters / transducers, Temperature elements and other instruments/
local devices etc. that are being furnished by the Bidder, are of the same make, series and
family of hardware to the extent possible so as to ensure smooth and optimal maintenance,
easy interchangeability and efficient spare parts management.
4.02.00 Bidder to ensure that the depth of all the cabinets (both DDCMIS and Non-DDCMIS) shall be
800mm except in few cases like Feeder Cabinets, Power Supply Cabinets.
5.00.00 OPERABILITY & MAINTAINABILITY
5.01.00 The design of the control systems and related equipment shall adhere to the principle of ‘Fail
Safe’ Operation wherever safety of personnel / plant equipment is involved. ‘Fail Safe’
operation signifies that the loss of signal, loss of excitation or failure of any component shall
not cause a hazardous condition. However, it shall also be ensured that occurrence of false
trips are avoided / minimized.
5.02.00 The types of failure that shall be taken into account for ensuring operability of the plant shall
include but not be limited to:
— Failure of sensor or transmitter.
— Failure of main and/or redundant controller/other modules.
— Loss of motive power to final control element.
— Loss of control power.
— Loss of instrument air.
5.03.00 The choice of hardware shall also take into account sound maintainability principles and
techniques. The same shall include but shall not be limited to the following:
— Standardization of parts.
— Minimum use of special tools.
— Grouping of functions.
— Interchangeability.
— Malfunction identification facility/self-surveillance facility.
— Easy modular replacement.
— Fool proof design providing proper identification and other features to preclude
improper mounting and installation.
— Appropriate de-rating of electronic components and parts.

CLAUSE NO.
5.04.00 The equipment shall employ latest state of the art technology to guard against obsolescence.
In any case, Contractor shall be required to ensure supply of spare parts in line with relevant
clause of GCC for spares. In case, the Bidder feels that certain equipment/component
(barring HMI hardware and networking components) is likely to become obsolete, the Bidder
shall clearly bring out the same in his Bid and indicate steps proposed to deal with such
obsolescence. For HMI hardware and networking components, Bidder need not bring out the
same in the bid; but shall inform the Employer in case of obsolesce so that Employer can
take appropriate actions as necessary ( both during the tenure and outside the tenure of the
contract ).
6.00.00 CONTROL & MONITORING PHILOSOPHY
6.01.00 Control & Monitoring philosophy to be adopted for this project irrespective of the scope of
supply (i.e. under this package or in any of Employer's other Packages) is explained in
Appendix-III to Part-A.
6.02.00 Back-Up Instrumentation
As per Employer’s practice, certain back-up instrumentation and Secondary instruments are
to be provided. The exact quantity of the back-up instrumentation shall be as finalized during
detailed engineering in consultation with the Contractor.
7.00.00 ENVIRONMENTAL CONDITIONS
7.01.00 Instruments, devices and equipment for location in outdoors/indoor/air-conditioned areas
shall be designed to suit the environmental conditions indicated below and shall be suitable
for continuous operation in the operating environment of a coal fired utility station and also
during periods of air conditioning failure without any loss of function, or departure from the
specification requirements covered under this specification.
Ambient Pressure Relative Atmosphere Required

Temperature(o humidity# protection Class of
utside panels/ cabinets /
cabinets) desks to be
provided by
contractor.
Outdoor Location
55 degree C max. / Atmosphere 100 % Max./5 Air (dirty) IP 55

5 % min.
4 degree C min.
Indoor Location
55 degree C max. / Atmosphere 95 % Air IP 54**

Max./5 %
4 degree C min.
min.
Air Conditioned Areas
24 +/- 5 degree C Atmosphere 90% Max. / Air IP 22***

normal/50 degree C
10%min.
max.*

CLAUSE NO.
* During air conditioning failure for a short period of time.
**For non-ventilated equipment/ control system enclosures. For ventilated equipment/

control system enclosures, protection class shall be IP 42.
***With a suitable canopy at the top to prevent ingress of dripping water.
# For instruments: as per OEM standard for intended application.
For Hazardous areas the protection class shall be in accordance with the requirements of
the relevant NEC code for the location.
PCs, OWS, EWS, Servers, Network Switches, Printers, mini UPS and other peripherals,
maximum temperature limit shall be 35 Deg. C. For LVS the same shall be around 25 Deg.
C
For the remote I/O cabinets mounted in non-AC areas, panel AC shall be provided.
7.02.00 All equipment / instruments envisaged for sea water applications, shall be provided with
wetted parts made of Monel/ Hastelloy C or any other material (if provenness experience of
the proposed material for such applications is established by contractor).
7.03.00 For coastal areas, all equipment / instruments/ accessories shall be provided with durable
epoxy coating for housings and all exposed surfaces of the equipment / instruments/
accessories.
7.04.00 For coastal areas, all impulse piping / air supply piping / local instrument enclosures and
racks/ accessories shall be provided with durable epoxy coating fo rall exposed surfaces.
7.05.00 For coastal areas, all conduits / cable sub trays / cabling accessories shall be provided with
durable epoxy coating for all exposed surfaces.
8.00.00 GROUNDING SYSTEM
All panels, desks, cabinets shall be provided with a continuous bare copper (or chromated
steel for DDCMIS panels, as per OEM Standard practice)ground bus. The ground bus shall
be bolted to the panel structure on bottom on both sides. The bolts shall face inside of
panels.
The system ground shall be isolated from the panel ground with suitable isolators. All
internal component grounds or common shall be connected to the system ground, which
shall be fabricated of copper flat (size 25mm x 6mm min., length as applicable).
Shield on instrumentation cables shall be grounded on panel side. Suitable shielding

terminals shall be furnished on Copper flat forming system ground.
Alternatively, Manufacturer’s standard & proven solution, which is functionally equivalent
shall also be acceptable subject to employer’s approval.
The Bidder shall submit with the offer recommended grounding scheme required for his
system. The exact grounding scheme shall be finalized during detailed engineering.

SUB–SECTION – IIIC - 02
DISTRIBUTED DIGITAL CONTROL,
MONITORING & INFORMATON SYSTEM
(DDCMIS)
CLAUSE NO.
1.00.00 DISTRIBUTED DIGITAL CONTROL, MONITORING AND INFORMATION SYSTEM

(DDCMIS)
1.01.01 The requirements for Distributed Digital Control Monitoring and Information System
(DDCMIS) are indicated on functional basis in this specification. Contractor shall be
responsible for engineering, selection and connection of all components and sub-systems to
form a complete system whose performance is in accordance with functional, hardware,
parametric and other requirements of this specifications. It is not the intent or purpose of this
specification to specify all individual system components since the Contractor has full
responsibility for engineering and furnishing of a complete system.
1.02.00 System Configuration
DDCMIS shall basically consist of the following :
1.02.01 Control System (including its Measurement system).
1.02.02 Human-Machine Interface and Plant Information System (HMIPIS)
1.02.03 System Programming & Documentation Facility
1.02.04 Data Communication System
1.02.05 Integrated LVS based Annunciation functions
1.02.06 Time synchronization with Master clock
The basic configuration of DDCMIS shall be as indicated in the DDCMIS configuration

drawing No. 0000-999-POI-A-001.
Contract Quantities of the C&I System shall be as per Part-A.
1.03.00 System Expandability
1.03.01 Modular System design shall be adopted to facilitate easy system expansion. The system
shall have the capability and facility for expansion through the addition of controller modules,
I/O cards, peripherals like Large Video Screen (LVS), operator workstations (OWS), printers
etc. The system shall have the capability to add any new control loops, groups/subgroups
logics in control system..
1.04.00 On-Line Maintenance
1.04.01 It shall be possible to remove/replace various modules online (like I/O module, interface
module etc.) from its slot for maintenance purpose without switching off power supply to the
corresponding rack. System design shall ensure that while doing so, undefined signaling and
releases do not occur and controller operation in any way is not affected . Further, it shall
also be possible to remove/replace any of the redundant controller module without switching
off the power to the corresponding rack and this will not result in system disturbance or loss
of any controller functions for the other controller. The on-line removal/insertion of controller,
I/O modules etc. shall in no way jeopardize safety of plant and personnel.

SUB-SECTION-IIIC-02 PAGE
1 OF 23
WATER SYSTEM PACKAGE BID DOC NO.:THDC/RKSH/CC-9915-373 DDCMIS
CLAUSE NO.
1.05.00 Fault Diagnostics
1.05.01 The DDCMIS shall include on-line self-surveillance, monitoring and diagnostic facility so that
a failure/malfunction can be diagnosed automatically and reported/indicated remotely on
OWS/LVS/Programmer station. The failure/ malfunctions to be reported shall include:
(a) Module level faults of control system.

(b) Failure of HMIPIS bus/unit LAN, system bus, Local/Remote comm. Bus.
(c) Power supply faults (Over voltage, under voltage, loss of input) for each feeder of
power supply for system / marshalling/ relay and HMIPIS cabinets.
(d) Software faults.
These faults shall typically be reported as color change on system status display and
messages on programmer station/ LVS/ OWS as well as through local indication. The
diagnostic system shall ensure that the faults are detected before any significant change in
any controller output has taken place. Failure of any I/O modules, Controller etc. shall be
annunciated to LVS/OWS. For I/O modules, these alarms shall be grouped, while for
controller, comm. controller, power supply, these shall be individual. In case the faults are not
acknowledged / rectified within certain interval, then the same shall be reported to predefined
users through messaging system described subsequently in this subsection. The exact
strategy of the messaging system shall be elaborated and finalised during detailed
engineering.
HMIPIS shall include on-line self surveillance, monitoring and diagnostic facility so that a
failure/malfunction in any of the nodes, networking device as well as communication medium
can be diagnosed on the programmer/engg. Work station/OWS.
1.06.00 Fault Tolerance & Controllability
1.06.01 The DDCMIS shall provide safe operation under all plant disturbances and on component
failure so that under no condition the safety of plant, personnel or equipment is jeopardised.
Control System shall be designed to prevent abnormal swings due to loss of Control System
power supply, failure of any Control System component, open circuits/short circuits,
instrument air supply failure etc. On any of these failures the control system output shall
either remain in last position before failure or shall come to fully open/close or on/off state as
required for the safety of plant/personnel/equipment and as finalised during detailed
engineering. System shall be designed such that there will be no upset when Power is
restored.
1.06.02 I/O modules shall have protection so that any fault in sensor & its wiring upto I/O module like
open/short circuit, earth fault affects only that channel of I/O module. Other channels of that
I/O module or other modules or other parts of system shall not be affected in any way.
1.06.03 No single failure either of equipment or power source shall be capable of rendering any
part/system/sub-system of DDCMIS inoperative to any degree. No single failure in HMIPIS
shall lead to non-availability of more than one OWS or one LVS. In such an event i.e., single
failure leading to non-availability of any OWS/LVS, it shall be possible to operate the entire
plant in all regimes of operation including emergency conditions from each of the other
available OWS/LVS.

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CLAUSE NO.
1.06.04 In order to achieve above, following shall be redundant with automatic change-over
(including the associated software), as a minimum:
Controller, Comm. Controllers, HMIPIS bus/Unit LAN, System bus,

Local/Remote communication bus.
Power supply arrangement (feeders/modules)
Output modules. (for which redundancy is specified in part-A-Contract

quantities for DDCMIS).
 Servers/information work stations
However, following need not be redundant:
I/O bus, (if it is a backplane bus & extension/joining of such backplane buses
cabinet/adjacent cabinet) and input modules.
1.06.05 The system design shall ensure that no single failure, whatsoever in any part of DDCMIS
result in loss of communication except communication between HMI and control system, for
which loss of communication upto a maximum of five seconds is acceptable. However,
during this period, the control system shall remain fully functional and this event shall not
create any disturbance/malfunction whatsoever (e.g., accumulation of control commands,
issue of spurious commands/signals etc.).
1.06.06 DDCMIS shall meet all requirements stipulated under other Sub-sections/sections of the
specification including Sub-Section-IV, Part-A, (including the requirement Authorisation to
shipment test ATST) Quality assurance (sub-section-III-E Part B, Section VI of technical
specifications) & General Technical Requirements (Part C Section VI of Technical
Specifications).
1.07.00 Signal Exchange
All the signal exchange between various functional groups of each control systems shall be
implemented through redundant system bus.
1.08.00 System Spare Capacity
1.08.01 For Control system spare capacity, refer Contract Quantities of DDCMIS, Appendix I to Part
A, Section VI of technical specification.
1.08.02 For HMIPIS spare capacity, refer Annexure-II, Contract Quantities of DDCMIS, Appendix-I to
part A, Section VI of technical specification.
1.08.03 NOT USED.
1.08.04 NOT USED.
1.08.05 NOT USED

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CLAUSE NO.
1.09.00 NOT USED.
1.10.00 NOT USED.
1.11.00 DDCMIS shall meet system performance and parametric requirements as stipulated under
Performance Guarantees under Part-A, Section-VI, Sub-Section-IV of specifications. Also the
Authorisation to shipment tests shall be performed in line with the Chapter-III-E, Part-B,
Section-VI.
2.01.00 The DDCMIS shall include following main constituents. (Also refer DDCMIS configuration
drg.no. 0000-999-POI-A-001). The DDCMIS shall work in full integration and conjunction with
field equipment/drives like pumps, motors, valves, actuators, dampers, hydraulic control
systems and field instruments.
2.02.00 Control System
2.02.01 The Control system along with its measurement system shall perform functions of closed
loop control, sequence control, interlock & protection of the Plant and auxiliaries in all
regimes of its operation.
2.02.02 The measurement system of control system shall perform the functions of signal acquisition,
conditioning and signal distribution of various types of inputs/outputs like analog, (4-20 mA
DC- either from pressure / DP/ flow / level transmitters, analysers etc. as well as from
temperature transmitters for all temperature) measurements from thermocouple, RTD to be
connected to this system), binary, pulse, digital transmission through serial port, bus
connection etc. (from remote I/O etc., Through various industry standard protect including
MODBUS/FIELDBUS/PROFIBUS, prefabs freed and Ethernet etc. The inputs, which are
required for only information & monitoring purposes, shall be distributed suitably in various
groups plant area-wise.
2.02.03 The control system shall also perform logic & computation for annunciation functions.
2.02.04 The control system hardware (controllers, modules/cards etc.) shall be housed in cabinets
located in respective control equipment room (CER) unitised and offsite except for the
remote I/O cubicles (as specified in Part-A) which shall be located in respective areas.
2.03.00 Human-Machine Interface and Plant Information System (HMIPIS)
2.03.01 Functionality/features mentioned for HMIPIS in this specification are also applicable for
unified HMIPIS. The HMIPIS shall perform control, monitoring and operation of the Plant and
auxiliaries in all regimes of its operation, interacting with the Control System. For this,
HMIPIS shall primarily perform following functions:
2.03.02 Operator interface for Control System
2.03.03 Plant Supervisory functions like displays, alarm monitoring & reporting, reports & logs,
calculations, trend recording, historical and long term data storage & retrieval, etc.
2.04.00 System Programming & Documentation Facility

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CLAUSE NO.
2.04.01 The programmer stations shall be provided for On-line configuration & tuning of Control
System and On-line program development/modifications in HMIPIS.
2.04.02 A work-station based system documentation facility shall be provided to generate retrieve
store & all system documentation, logic, control loops, cable interconnection, etc. to achieve
paperless documentation for the complete plant.
2.05.00 Data Communication System (DCS)
2.05.01 The Data Communication System shall be provided for communication between Control
System and HMIPIS, communication & signal exchange between various functional groups
as well as communication between various units & off site / off line systems.
2.06.00 Annunciation System
The annunciation logic will be implemented as a part of DDCMIS and annunciation shall be
made available on all OWS/LVS.
2.07.00 Power supply:
2.07.01 Power supply of control system shall be based on 24V DC. The Power supply along with its
associated circuitry is intended to provide the following functionalities
(a) Isolation between input & output side and distribution.
(b) Multiple voltages as required by various modules as well as integration/supply

voltage to field devices.
(c) Auctioneering of dual voltages.
(d) Providing stabilized/regulated power to Control System, taking care of input power
supply variations.
2.07.02 The Control System shall be fed from 24V DC power supply system (please refer power
supply section of specification). The complete Control System, including power supply for
various modules & field interrogation, shall be through regulated power supply using power
supply modules/packs. Further, the monitoring of individual feeders of input power supply
shall be done as specified at clause 1.05.01 (c) of IIIC-02.
3.00.00 MEASUREMENT FUNCTIONS OF CONTROL SYSTEM
3.01.00 The input / output modules employed in the Control System shall be separate from controller
hardware.
3.01.01 The functions listed below shall generally be performed in I/O modules. However, some of
the functions can be implemented in the controllers .
3.01.02 FIELDBUS ((Foundation Fieldbus/ Profibus) Interface

For interfacing fieldbus compatible field devices/ actuators, Foundation Fieldbus/Profibus
interface modules, power supply, field cables(armoured) and other accessories shall be
provided. The design of fieldbus interfacing scheme, from field to Controller shall comply with
all requirements of latest version of standards for Foundation Fieldbus/Profibus viz. IEC

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CLAUSE NO.
61158. All required libraries to execute various tasks like data acquisition, control/protection
etc shall be provided. Redundant host/ master card and redundant power supply along with
diagnostic module shall be provided. For detailed fieldbus design guidelines, refer Annexure-
IIIC-02K, Part-B, Section-VI.
The Contractor shall present complete implementation scheme, including wiring scheme
during detailed engineering stage for review & approval by Employer.
3.02.00 Analog signal conditioning & processing
3.02.01 The conditioning and processing functions to be performed as a minimum for the analog
inputs coming for control and information purposes are:
1. : Galvanic isolation of input and output signals for which power supply source is
other than the measurement system of the control system.
2. : Transmitter power supply with per point fuse protection or current limiting and
power supply monitoring.
3. : Monitor sensor wire break/open circuit/short circuit and take suitable actions in
logic/loop. (This will include blocking of trip signals in case of RTD failure).
3.02.02 All analog signals for control purpose shall be acquired, validated, processed and their
respective Controller data base updated at a maximum interval of 250 milli seconds except
for some fast-acting control loops for which the above-referred time shall be as per process
requirement. For signals required for information only, the above functions shall be
performed at an interval of 1 seconds. The HMI database updation shall not take more than
one (1) second. The validated analog inputs shall be converted into engineering units on a
per point basis. Analog input processing (scanning to alarm checking) shall be performed
once every scan cycle. It shall be possible to manually disable any analog input either
through deleting from scan or substitution from HMI.
3.02.03 For Unit DDCMIS, the analog 4-20 mA input cards shall have input resistance >= 250 ohm inside
the card/FTA (as applicable) for interfacing transmitters/analysers/temp. signals (through temp
transmitters) giving 4-20mA analog signal along with superimposed HART interface signals. 4-20
mA DC signal will only be used for control purpose and superimposed HART signal will be used
for configuration, maintenance, diagnostic and record keeping facility for electronic transmitters
and Analysers etc
3.03.00 Binary signal conditioning & processing
3.03.01 The binary inputs shall be wired either in form of changeover type contacts (i.e. 'NC' + 'NO'
together) or non-changeover type Contact ('NC' or 'NO') depending on the requirement, as
defined in Part-A of specification.
3.03.02 The conditioning and processing functions to be performed as a minimum for the binary
inputs coming for control and information purposes are:
1. : 24 VDC power supply for contact interrogation for all potential free contacts with
per point fuse protection or suitable current limit feature/ isolation through opto-
coupler.
2. : Contact bounce filtering. (The field contact which is changing state must remain in

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CLAUSE NO.
the new state for the filter delay time to be reported as one event). The filter delay
time should be suitable for the field input & its scan rate.
3. : Facility for automatic pegging the binary signal to logic one/zero or last correct
value in case of failure of binary input module.
4. : All binary signals shall be acquired validated, processed, alarm checked and their
data base updated within one second.
5. : It shall be possible to manually disable any binary input either through deleting
from scan or substitution from HMI.
6. : The non-coincidence monitoring shall be provided for binary inputs for all
changeover signals.
3.04.00 Multiple Measurement Scheme
3.04.01 Triple / Dual measurement schemes shall be provided for triple / dual redundant sensors
used in closed loop and open loop controls.
3.04.02 The triple / dual measurement schemes for closed loop control shall provide median /
average outputs. The operator shall be able to select any of the transmitters or the
median/average value from the LVS/OWS.
3.04.03 The sensors for multiple measurement schemes for open loop controls shall always be in
service (except when gone Bad) and operator shall not be able to select / deselect any of the
sensors. Further, measurement scheme shall be implemented considering safety / availability
aspects.
3.04.04 Individual transmitter signals, their status and selected value for control/ measurement and
shall be available on LVS/OWS in the CLCS displays and the popups
3.05.00 Wiring Scheme for inputs to control system
3.05.01 Each of the triple redundant binary & analog inputs shall be wired to separate input modules.
Similarly each of the dual redundant binary & analog inputs shall be wired to separate input
modules. Implementation of multiple measurement schemes of these inputs will be
performed in the redundant hardware. Loss of one input module shall not affect the signal to
other modules. Other channels of these modules can be used by other inputs of the same
functional group.
No single failure in any component of the control system shall lead to unavailability of more
than one of dual/triple redundant input signals to control system. Similarly, no single failure in
any component of the control system shall lead to unavailability of more than one of
dual/triple redundant Output signals from the control system.
3.05.02 The single (i.e. non-redundant) binary & analog signal required for control purposes shall be
wired as follows:
1. The on-off status of HT drives and synch type breakers shall be wired to two input
modules in parallel.

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CLAUSE NO.
2. Triple/dual analog sensors are required both in CLCS and OLCS for control purpose,
then all of these triple/dual sensors shall be wired to the controller where CLCS loop
is configured. If based on the same set of sensors, any protection action is required
in OLCS (e.g., protection stop of drive) in another controller(s), then CLCS Controller
shall provide three digital outputs for each such controller from three separate output
modules (at defined LVM-Limit Value Monitor blocks inside Controller). The three
such digital outputs of CLCS controller shall be acquired in each of the OLCS
controllers in three separate digital input modules. Similar philosophy will be used
when triple/dual analog sensors are required in OLCS in multiple controllers for
protection function.
3. If triple/dual/single binary sensors are required in OLCS in multiple controllers for

protection function in these controllers, each of these sensors shall be shared among
these controllers. Each of these sensors shall be directly shared from marshalling
TBs without any ‘active’ multiplying hardware (‘active’ defined as hardware which
requires a separate power supply for its functioning). Further, removal/insertion of
any of such multiple modules shall not affect availability of such signal(s) to other
modules.
4. The input sharing scheme shall be subject to Employer’s approval during detailed
engineering. The inputs/outputs for such sharing is already included in he Contract
quantities in Part-A).
3.06.00 Remote Input output modules and cubicles
It is envisaged to use remote I/O modules in various plant areas. The remote I/O signals
shall be connected to the respective functional groups through redundant extended I/O bus
as indicated in the Contract quantities for DDCMIS. The hardware independence of
functional groups mentioned elsewhere in specification shall be applicable for remote I/O as
well.
The remote input/output modules shall be located in cubicles in respective areas. Remote
input/output modules may be located in harsh environment, the modules shall be designed in
such a way to work continuously under the harsh environment expected to be encountered in
these areas (high temp, dust level, humidity etc.). It shall be ensured that extending of I/O
bus of functional group in field does not result in false signaling /noise pickups. Further, it
shall in no way deteriorate the performance of that functional group and Control System.
3.06.01 Power supply arrangement for these cubicles shall be similar to DDCMIS system cabinets.
3.07.00 The maximum number of inputs/outputs to be connected to each type of module shall be as
follows:
1 : Analog input module 16
2 : Analog output module 16
3 : Binary input module 32
4 : Binary output module 32

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CLAUSE NO.
5 : Analog input & output (combined) module 16
6 : Binary input and output (combined) module 32
Note: For binary inputs, one changeover contact is counted as 2 inputs.
3.08.00 The following requirements shall be met for analog/binary input/output modules as
applicable.
3.08.01 Input filters to attenuate noise shall be provided.
3.08.02 All analog outputs shall be short circuit proof.
3.09.00 The Control Desk mounted hardwired devices & stations shall be interfaced through the I/O
modules. No signal multiplication shall be done at marshalling end input termination end.
4.00.00 CONTROL SYSTEM REQUIREMENTS
4.01.00 The control system shall be broadly divided into the followings:-
4.01.01 (i) Close Loop Control System (CLCS) - Modulating control functions for various
applications including individual control and operation of modulating drives.
(ii) Open Loop Control System (OLCS) - Binary control functions pertaining to
sequence / interlock / protection of plant auxiliaries for various applications including
individual control and operation of binary drives.
(iii) Other functions as per various requirements specified in Part-A of specification.
(iv) Performing logic & computation for annunciation functions & other miscellaneous
Controls, signal processing etc.
4.01.02 The number of Functional Groups (FGs) which are derived from the above mentioned
guideline are the minimum required. For each of the FGs, separate sets of controllers, I/O
modules, communication controllers, power packs/ modules etc. shall be provided. Mixing of
hardware of two or more FGs shall not be acceptable. However, splitting of any functional
group in more than one FGs due to any limitation in Contractor's system (e.g. limitation in
handling number of inputs/outputs including spare capacity, limitation in implementation of
number of functional blocks including spare blocks etc.) shall be acceptable, subject to
Employer's approval. It may be noted that after splitting of the functional groups, each FG
must have its own set of controllers, I/O modules, etc. It shall be ensured that failure of any
set(s) of hardware of any FG does not affect other FG(s) and data communication between
other FG(s) and HMIPIS. Each FG can have one or more set of controllers, if supported by
standard design of the offered system.
4.01.03 The Contractor shall provide all hardware/software, whether or not specifically indicated in
this specification to fully meet operational/maintenance/ safety requirement as well as
statutory/international standard and proven practices.

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CLAUSE NO.
4.01.04 The Control System shall function reliably under the environmental conditions as specified in
Sub-Section:- Basic Design Criteria of this specification. It shall be immune from the
interference resulting from disturbances in power supply feeders, signals lines, inputs,
outputs etc. as experienced in a coal fired power station. It shall be able to withstand power
line disturbances.
4.01.05 The Control System shall have on-line simulation & testing facility.
4.01.06 The system shall have the flexibility to easily reconfigure any controller at any time without
requiring additional hardware or system wiring changes and without disabling other devices
from their normal operation mode. Modifications shall not require switching off power to any
part of the system.
4.01.07 Power supply to individual functional group shall be from redundant 24V feeders with diode
auctioneering and further sub-distribution.
4.01.08 The assignment of I/O channels for Inputs/Outputs, arrangement of modules within cabinet
etc. shall be identical for all units except those inputs/outputs which are common for all units.
Further uniformity should be maintained for redundant stream of process equipment within a
unit.
4.01.09 The application programs for the functional controllers shall be software based which shall be
maintained even through power supply failure.
4.01.10 Independent and dedicated controllers (main and its 100% standby) shall be provided for
each of the functional group (FG) of Control System except for the cases where triple
redundant controllers are to be used as per this specifications. All the 100% hot redundant
backup controllers shall be identical in hardware and software implementation to their
corresponding main controllers and shall be able to perform all its tasks. The backup
controller shall track its corresponding main controller. There shall be an automatic and
bumpless switchover from the main controller to its corresponding backup controller in case
of main controller failure and vice versa without resulting in any change in control status. In
case of switchover from main controller to the 100% hot backup controller, the back-up
controller shall work as the main controller. Further, when only one controller is working and
other controller is inserted on line (for example after repair/replacement), there should not be
any degradation in the function of the working controller & control operation.
4.01.11 The loop/logic reaction time (from change of input to input module to the corresponding
control command output) shall be suitable to match actual process requirements, subject to
minimum requirement wherever specified.
4.02.00 Binary Controls/Open Loop Control System (OLCS) Functions
4.02.01 These clauses are applicable for all the Binary controls of DDCMIS included in Contractor’s
Scope.
4.02.02 The OLCS shall include sequence control, interlock & protection for various plant
auxiliaries/valves/dampers/drives etc. The sequence control shall provide safe and automatic
startup and shutdown of plant and of plant items associated with a plant group. The interlock

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CLAUSE NO.
and protection system shall ensure safe operation of plant/plant items at all times and shall
automatically shut down plant/plant items when unsafe conditions arise.
4.02.03 The OLCS shall be arranged in the hierarchical control structure consisting of unit level,
group level, subgroup level & drive level (as applicable).
4.02.04 The group level shall control a set of functional sub-groups of drives. Appropriate start-up
and shut down commands shall be issued to the sub-group control and various check-backs
shall be received from sub-groups or drives. Each sub-group shall execute the sequential
start-up and shut down programs of a set of inter-related drives along with system interlocks
and protections associated with that sub-group as well as basic interlocks and protections
related to individual drive falling under that sub-group. The drive level shall accept
commands from the sub-groups, push buttons (wherever provided), etc., and transmit them
to the respective drive, after taking into account various per missives and protections of that
particular drive. For HT and other critical drives, first-up logic shall be incorporated to indicate
the cause of protection/trip.
4.02.05 Sequence Control
(a.) A sequence shall be used to move a set of groups, sub-groups from an initial steady
state (for instance 'OFF') to a final steady state (for instance 'ON'). The sequence
initiating command for the unit & group level shall be issued from LVS/OWS.
(b.) A sequence shall be made of steps. The steps shall be executed in predetermined order
according to logic criteria and monitoring time consisting of the interlock & protection
requirements and check back of previous step which shall act as preconditions before
the sequence control can execute the command for that step.
(c.) Each step shall have a "waiting time" implying that the subsequent step would not be
executed unless the specified time elapses. A monitoring time shall also be defined as
the maximum time required in executing the commands of any step and the time
required for appearance of check back signals. In case, this is not completed within the
specified time, a message shall be displayed and program will not proceed further.
(d.) Manual intervention shall be possible at any stage of operation and the sequence
control shall be able to continue at the correct point in the program on return to
automatic control. Protection commands shall have priority over manual commands,
and manual commands shall prevail over auto commands.
(e.) Open or close priority shall be selectable for each drive.
(f.) The sequence startup mode shall be of the following types.
i) Automatic Mode
ii) Semi-Automatic Mode
iii) Operator Guide Mode/Test Mode
4.02.06 For the drives, the command shall be provided through O/P module to the coupling relays in
MCC/SWGR/Actuator/Relay Cabinets as applicable and inputs (status, SWGR & process)

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shall be acquired through input modules. Redundancy in drive outputs shall be provided for
drives, as quantified in Part-A). The failure of one of the redundant, output module shall in no
way affect the function of the other output module, wherever redundancy is provided.
4.02.07 The output modules shall have the feature that ensures that in case of failure, all the outputs
are driven to zero. The 24V DC command outputs to drives for ON/OPEN, OFF/CLOSE
shall be separate and independent and inverted outputs shall not be employed. Live +24V
DC outputs shall be provided to MCC/SWGR/ actuator as applicable when command is to be
issued. Keeping +24V DC extended to the relays for these outputs continuously & extending
ground/negative when command is to be issued, is not acceptable except some of the
auxiliary plants as to be decided during detailed Engineering.
4.02.08 For inching type of drives, position transmitter power supply and monitoring of position
transmitter signal shall be provided.
4.02.09 The sequence interlock & protection requirements shall be finalised during detailed
engineering and the same shall be subject to Employer's approval.
4.02.10 The drive function i.e. basic interlock & protection logic of the drive shall be implemented in
redundant controllers. The drive function shall ensure that protection signals for the safety of
the drive shall be effective under all conditions and under all modes of operation. The
different commands shall be performed according to the priority of protection 'Off', Protection
'On', manual and automatic. The standard functions like running time monitoring, status
signaling, alarm/drive annunciation, etc. shall be performed in drive function. The drive
function shall prevent hunting of the actuator in the presence of both open & close
commands for actuators of the valves & dampers. The drive function shall be implemented
in dedicated standard software functional block (drive macros).
4.02.11 It shall be possible to control all common system drives (i.e. common for more than one
units), from all or some of the units.
4.03.00 Modulating Controls/Closed Loop Control System (CLCS) Functions
4.03.01 This Clause is applicable for all analog controls of DDCMIS.
4.03.02 The CLCS shall continuously act on valves, dampers or other mechanical modulating
devices such as hydraulic couplings etc., which alter the plant operation conditions. The
system shall be designed to give stable control action in steady state condition and for load
changes in step/ramp over the load range of 60% to 100% MCR. The system shall have the
following minimum features :
4.03.03 The controller capability shall, as a minimum, include (i) P, PI, PD and PID control functions
and their variations (ii) cascade control (iii) feed forward control (iv) On-Off control, (v) Ratio
and bias control, (vi) Logical operation. Other advanced control strategy like adaptive &
predictive control etc. can be considered for important loops like Furnace Draft, combustion
control, FW flow control etc. in addition to SH/RH temperature control.
4.03.04 The control loop shall have enough flexibility and various features to perform feed forward,
balancing of controller, increasing the response to achieve the desired process parameter
within prescribed time frame.

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4.03.05 The control system shall be bumplessly transferred to manual on the conditions of Control
power supply failure, Failure of redundant controllers, Field input signal not available, Analog
input and / or deviation exceeding preset value, etc. as a minimum and as finalised during
4.03.06 Any switch over from auto to manual, manual to auto and switchover from LVS / OWS
operation to H/A station operation and vice versa shall be bumpless and without resulting in
any change in the plant regulations and the same shall be reported to the operator and
recorded automatically.
4.03.07 Analog output (positioning signal) of 4-20mADC shall be provided from CLCS to the
respective microprocessor based positioner E/P converters / electrical actuators as
applicable. Redundancy in drive outputs shall be provided for drives as quantified in Part-A.
The failure of one of the redundant, output module shall in no way affect the function of the
other output module, wherever redundancy is provided. CLCS shall also provide all the
necessary outputs for indicators and other devices as specified in Part-A with output loop
resistance of 500 ohms for each channel of the output module.
4.03.08 The System being supplied shall be such that when permissible limits are exceeded, an
automatic switchover from an operation governed by maximum efficiency, to an operation
governed by safety and availability is affected.
4.03.09 For safety reasons, switchover logics associated with the modulating control loops shall be
performed within the same controller. Modulating control loops shall be provided with
standard features to interface overriding commands from OLCS/SG/TG Protection System
like open, protection open etc.
4.03.10 All controllers shall be freely configurable with respect to requisite control algorithms.
5.00.00 HUMAN-MACHINE INTERFACE AND PLANT INFORMATION SYSTEM (HMIPIS)

REQUIREMENTS
5.01.00 Operator interface to the Control System
5.01.01 The following functions shall be provided as a minimum:
All OWS/LVS of the HMIPIS shall be fully interchangeable i.e. all operator functions including
control, monitoring and operation of any plant area or drive shall be possible from any of the
OWS/LVS at any point of time without the necessity of any action like downloading of
additional files.
5.01.02 Further, simultaneous operation ( availability of popup window/faceplate) of multiple drives of

control system shall be possible from a single display.
5.01.03 The system shall have built-in safety features that will allow/disallow certain functions and
entry fields within a function to be under password control to protect against inadvertent and
unauthorised use of these functions. Assignment of allowable functions and entry fields shall
be on the basis of user profile. The system security shall contain various user levels with
specific rights which shall be as finalized by the Employer during detailed engineering.
However, no. of user levels, no. of users in a level and rights for each level shall be
changeable by the programmer (Administrator). The users created for a particular user level
shall be specific to a DDCMIS. Hence, a user of one DDCMIS shall not be able to exercise

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the same privileges in other DDCMIS(s). The rights of each user shall contain two types of
privileges as follows :-
a) Privileges for the DDCMIS
b) Privileges for the Operating System features.
5.01.04 Typically following user levels shall be available:
a) Operator
b) Supervisor
c) Maintenance Engineer
d) Programmer
e) Shift Incharge/Station Incharge/other Monitoring Users.
5.01.05 The system shall have functionality to configure view only privilege of any sub-system from
HMI of any other sub-system. In case Cross HMI operation is applicable as per Part-A, it
shall be possible to enable/disable operation of any valve or drive or area belonging to any
sub-system from the HMI of any other sub-systems by a supervisory command through
station LAN. Such control shall be based on a pre-engineered list and as per pre-predefined
priority hierarchy. In case, cross HMI operation privilege is not available for a particular
drive/area and still an operation is attempted for the drive/area then a suitable regret
message should be displayed in HMI to the operator. It shall be possible to modify the list at
site under Maintenance Engineers/ Administrator’s right.
The Contractor shall implement all necessary logics & selection facility in Control
System/HMIPIS for the same with safeguard to prevent multiple operations simultaneously.
Status & other signals related to the drive and the selection by any other user shall be made
available to other users.
5.02.00 The following functions shall be provided:
a) Calculations: Basic calculations like time of max./min., number of transgression of a

point in a band etc. shall be provided. Same can be implemented in control system
also. These calculated points shall be capable of being assigned to any functions like
any other scanned point.
b) Displays such as mimics, bar chart displays, X-t plots with various update rates using
the data from historian, X-Y plots (with superimposed operating curves).
c) Control related displays like faceplates for different types of drives, sequence
displays, drive level displays (pop-ups giving details of auto/ protection/ permissive
condition/ faults), control type display (giving details of A/M selection, tagout /
maintenance mode, process value, set point, deviation, command output, position
feedback etc). Further, CLCS displays giving the single line diagram of the control
loop shall be provided.
d) System status displays: This will provide an indication of the faults in a graphical
form.

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5.02.01 LVS/OWS Annunciation Display
The LVS/OWS annunciation will replicate in software the salient features of conventional
hardware annunciations facia (for permanent viewing i.e., not operator changeable) while
presenting more flexibility. This annunciation shall include both the process alarms as well as
system alarms. The top area of the OWS and LVS (around 20-25%), shall be reserved for
these display.
The annunciation system shall be implemented as an in-built function of DDCMIS. The field
contacts shall be acquired through DDCMIS only. The annunciation points will be presented
on topmost area of mimics display. The annunciation area will be divided in three (3) “alarm
bands”. The annunciation sequence shall be as discussed and finalized during detailed
engineering.
Bidder shall implement the annunciation functionality as described below as a minimum.
There will be one alarm for each alarm window. Grouped alarms shall be provided only for
pre-defined system / field faults like non-coincidence, monitoring etc. The alarm text is to be
displayed only when that alarm is present. A “tool-tip” will be associated with each alarm
window, which will show tag no. of alarm point when cursor is brought over alarm window.
Hooters/Speakers of different audio types shall be available for reporting new alarms and
resetting of alarms (corresponding to slow flash) etc shall be available. All flashing windows
shall flash together (synchronized) in any screen. Suitable means shall be provided to
distinguish new alarms and return to normal messages.
Annunciation points shall be distributed on various stations based on process area. That is,
each annunciation point will be assigned screen no.(s) and an alarm band no. A particular
point can be assigned more than one station also.
No fixed space will be reserved for any alarm on any of the band. Once a particular alarm
band is full, the new alarm in that band will be reported by automatic shifting of the older
alarm(s) on left side of band one by one in FIFO fashion. Scroll buttons shall be provided on
both the sides to view the alarms in a particular band after the particular band is full.
The scroll button will fast flash when scrolled alarms are fast flashing, will slow flash when
alarms are slow flashing and will be steady when alarms are steady. When scrolled alarms
are of mixed type, the scroll bar will flash with highest flashing rate of scrolled alarms.
When operator right clicks on LVS alarm area, he will get a menu with following options (i)
acknowledge all- to acknowledge all new alarm(s) (ii) reset all- to reset all alarm(s) returning
to normal (iii) acknowledge point- to acknowledge the particular point in alarm (iv) reset- to
reset the particular point in alarm (v) Root Cause – To link to Alarm Analysis result for that
particular tag (vi) “configuration utility”- to view and edit alarm list, tag nos., etc of all points in
all stations (vii) closing the annunciation display. This menu can be dragged & placed
anywhere on station screen. The actions (i), (ii), (iii), (iv) and (v) can be done by operator but
action (vi) & (vii) will be permitted only to Programmer. The hooter sounds will be different for
each of the Unit of power plant, when there is common control room for multiple Units.
Bidder shall provide suitable “configuration utility” for viewing and modifying list of all alarms
(process and system) to be displayed on all annunciation area, band color, text color,
flashing color and frequency, font, etc.

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5.02.02 Displays On large Video Screen
LVS based overview displays shall be provided, which shall be overlaid across all the LVS for
viewing as video wall.
5.02.03 Facility of separate individual pop-up window for 30 critical alarms (to be decided during
detail engineering) over the active mimic display, other than LVS annunciation band, in OWS/
LVS OWS is to be provided. The pop-up window should require operator intervention to
close. Pop-up window of one critical alarm should not overlap with any other critical alarm
pop-up. The size of the pop-up window, colour of description and size of font shall be
decided during detail engineering.
5.03.00 Facility of time activated logs ( Daily & Shift logs), event activated logs ( Post trip log) shall be
provided. At any point of time, log/ report can be demanded by operator. Maintenance data
log shall be provided for total running timer & other maintenance related statistics. This shall
also include standby running hours.
5.04.00 Historical storage and retrieval system (HSRS)
Complete HSRS functionality shall be implemented in server/information work station (Please

refer Part-A for redundancy requirements). The data shall be saved online on hard disk and
transferred to the portable storage device like DVD periodically for long term storage.
Provision shall be made to notify the operator when the portable disk is required to be
replaced with a fresh disk. The Hard disk capacity shall be sufficient to store at least One(1)
year data Suitable facility for retrieval of data shall also be provided.
The data to be stored in the above system shall include alarm and event list, periodic plant
data (tags computed in control system as well as computed in HMIPIS) including data
required for Residual life assessment, logs/reports etc. The data/information to be stored &
frequency of storage and retrieval shall be as finalized during detailed engineering.
6.00.00 PROGRAMMER'S STATION (PROGRAM DEVELOPMENT/ MODIFICATION, SYSTEM

MAINTENANCE AND DOCUMENTATION FACILITY)
6.01.01 The structuring/configuration/modification of Control loops/logics in Control system and

program development/modification in HMIPIS shall be possible from fully graphic displays
using familiar & conventional functional blocks.
6.01.02 Any modification done in Control System and HMIPIS shall be suitably logged so that it can
be traced to the user log-in ID and time of change.
6.02.00 Control system structuring/configuration/tuning facilities
6.02.01 Structuring/configuring and tuning facilities shall be provided for structuring/ modification,
storing/loading, testing, tuning, monitoring, etc. of all the microprocessor-based controllers of
the control system.
6.02.02 It shall be possible to configure the system with ease without any special knowledge of
programming or high level languages.

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6.02.03 On-line tuning of the control loops shall be possible without causing any disturbance in the
execution of the control loops. Provision to store and retrieve on immediate and long term
basis the system configuration, data base etc. on some device such as floppy disk shall be
included. Facility shall be provided to reload/down-load the system or controller module from
the already stored data, on-line.
6.02.04 Facility for modification shall be user-friendly. For example, modification of logics/loops etc.,
zooming for better display, stretching etc. should be possible. It shall be possible to
add/modify, delete blocks in logics/loops on-line
6.03.00 System Documentation Facility
6.03.01 The system shall have the facility to generate the associated documentation for both the
Control System & HMIPIS with all required software and hardware tools for viewing and
printing drawings and documents..
7.00.00 DATA COMMUNICATION SYSTEM (DCS)
7.01.00 The Data Communication System shall include a redundant System Bus for major
subsystems with hot back-up. Other applicable bus systems like cubicle bus, local bus, I/O
bus etc shall be redundant except for backplane buses which can be non-redundant. The
system shall have the following minimum features:
7.01.01 Redundant communication controllers shall be provided to handle the communication

between each functional group of controllers of Control System and the System Bus.
7.01.02 Failure of one bus and changeover to the standby system bus shall be automatic and
completely bumpless.
7.01.03 The following buses shall be fiber-optic only.
(a) System bus from locally mounted control system cabinets/OWS to central location.
(b) I/O Bus from remote I/Os to centrally located system cabinets.
7.01.04 The redundant buses shall be physically separate and shall be routed separately.
8.00.00 POWER SUPPLY, GROUNDING, CABINET/PANELS, ETC.
8.01.01 Power Supply
8.01.02 Contractor shall provide totally reliable & quality power supply for DDCMIS.
8.01.03 Wherever hot backup or redundant equipment likes controllers, processors, I/O modules, etc.
have been specified and provided, the same shall be powered through separate power
supply feeders.
8.02.00 Grounding

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All panels, desks, cabinets shall be provided with a continuous bare copper ground bus,
bolted to the panel structure on bottom on both sides. The bolts shall face inside of panels.
Further, for connection of shields of the field instrumentation cables, a separate shield bus
independent of the ground bus shall be provided, which shall be connected to the earth risers
by means of independent cables.
8.03.00 System Cabinets/Panels
8.03.01 All DDCMIS system modules, power supply components, other control devices (except field
mounted sensors/transmitters) which are required for completeness of the system shall be
housed in cabinets furnished by the Contractor. All equipment and dedicated cabinets
required for termination, marshalling and proper interface within Contractor’s system and also
with other systems shall also be provided by the Contractor.
8.03.02 The cabinet mounted equipments shall be fully assembled, installed in mounting racks, wired
and fully tested as per specification requirements and Employer approved drawings in the
manufacturing works of a qualified manufacturer prior to shipment to the project site. The
Contractor shall ensure that the cabinets are complete and ready for installation before
dispatch from manufacturing works. The installation work at project site for these cabinets
should only involve connections through multi pair cables from marshalling cabinets
(wherever provided) to system cabinets and inter-cabinet/cabinet to Control Desk/UCP.
8.03.03 The DDCMIS cabinets shall be grouped into physically separate cabinets as follows:
(a.) Control System Cabinets
(b.) Marshalling cabinets
(c.) Relay cabinets
(d.) HMIPIS cabinets
However, in case Bidder’s system design requires the termination cabinet independent from
system cabinet, the marshalling cabinets can be combined with the termination cabinet. In
case, the termination arrangement is part of the system cabinet, independent marshalling
cabinets shall be provided. The HMIPIS cabinets can be clubbed with Control System
Cabinets for small areas where only 24V dc power supply is used.
Contractor may make a special note that termination of field cables directly to control system
cabinet is not acceptable.
8.03.04 Hardware like network components, power supply distribution etc. shall be suitably housed in
cabinets/enclosures. In network cabinets suitable arrangements shall be provided to ensure
that the network components are visible in door closed condition (e.g. Glass doors etc), as
approved by Employer
8.03.05 Relay cabinets (or marshalling / termination cabinet cum relay cabinets, as the case may be)
shall house all the interfacing relays in the system.

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8.03.06 Marshalling
All the incoming / outgoing signals shall be grouped as per their origin / destination and will
be terminated in the marshalling cabinets (or marshalling cum termination cabinet as the
case may be). The grouping of these signals shall be subject to Employer's approval. The
Contractor may make a special note that termination of field cables directly to the system
cabinet (whether on TBs or on the pins on I/O modules) is not at all acceptable.
System cabinet(s) and corresponding marshalling and termination cabinet(s) shall be a single
shipping section, so that the internal wiring from field terminal to the module is done
completely at the factory itself.
The system cabinets shall be furnished with side panels even within a shipping section.
8.03.07 Contractor shall design the cabinet internal arrangement, floor cutout and cable gland plate
such that all the cables entering or leaving the cabinet can be properly glanded in the gland
plate. In case, glanding is not possible Contractor shall indicate in his proposal his suggested
procedure for cable entry and securing the cable at place.
8.03.08 The type of termination and terminal blocks to be used in the relay cum termination/ Field
Termination cabinets shall be as per requirements specified under Sub-Section-Inst. Cable.
The terminals used for terminating the spare cores/ pairs of field cables shall not be
employed for terminating the spare channels of I/O modules/ FTMs. The following are the
guidelines for termination:
a. 8 level cage clamp type of termination block shall be used in marshalling/ termination
panel
b. Minimum 4 pair Instrumentation Cables shall be used for connection between field/JB
and DDCMIS marshalling cabinet and all the cores of 4 pairs or its multiples to be
terminated in the marshalling panel (including spare cores) sequentially as per color
coding philosophy indicated in the corresponding Tender Drawing. When more than 4
pair cable is used, the same is to be terminated in consecutive marshalling posts. No
core/ bundle shall be left un terminated in the marshalling panel.
c. In MFT and Turbine protection and governing system, Contractor’s standard and proven
practice for cable type and cable termination scheme shall also be acceptable.
8.03.09 The protection class of cabinets and environmental rating shall be as defined in Basic Design
Criteria. The Contractor shall ensure that the packaging density of equipment in these
cabinets is not excessive and abnormal temperature rise, above the cabinet temperature
during normal operation or air-conditioning failure, is prevented by careful design.
Temperature rise inside cabinet shall not be more than 10 deg C with respect to ambient
temperature in any condition. Dual blowers/fan with blower/fan failure alarm shall be provided
in each cabinet with proper enclosure. Suitable louvers with wire mesh shall be provided on
the cabinet. Contractor shall furnish detailed calculation of heat dissipation of various
components housed in the cabinet like power supply, controller, I/O cards etc., cooling fans/
blower capacity and component density in cabinets, during detailed engineering to ensure
that temperature rise is limited as specified above. Further, temperature sensor (RTD) shall
be provided in each system cabinet to monitor temperature inside cabinet and suitable
alarms shall be configured to indicate high temperature inside the cabinet.

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8.03.10 The cabinets shall be totally enclosed, free standing type and shall be constructed with
minimum 2 mm thick steel plate frame and 1.6 mm thick CRCA steel sheet or as per
supplier's standard practice for similar applications, preferred height of the cabinet is 2200
mm. The cabinets shall be equipped with full height front and rear doors. The floor mounting
arrangement for other cabinets shall be as required by the Employer and shall be furnished
by the Contractor during detailed engineering.
8.03.11 Front and rear doors shall be provided with locking arrangements with a master key for all
cabinets. If width of a cabinet is 600 mm or above, double doors shall be provided.
8.03.12 Two spray coats of inhibitive epoxy primer-surface shall be applied to all exterior and interior
surfaces. A minimum of 2 spray coats of final finish color shall be applied to all surfaces.
The final finished thickness of paint film on steel shall not be less than 65-75 micron for sheet
thickness of 2 mm and 50 microns for sheet thickness of 1.6 mm. As an alternative, single
coat of anodic dip coat primer along with single textured powder coating with epoxy polyester
meeting the thickness requirement is also acceptable.
The Bidder shall furnish sufficient touch-up paint for one complete finish coat on all exterior
factory applied painted surface of each item of equipment.
The finish colors for exterior and interior surfaces shall conform to following shades:
Front & Rear-RAL 9002; End panel side- RAL 5012. Internal color shall be same as external
color.
Paint films which show sags, checks or other imperfections shall not be acceptable.
8.03.13 Cabinets shall be designed for a grounded installation on the building structure. Any isolation
from the building ground which is required by equipment design shall be provided internal to
the cabinet.
8.03.14 All alarm contacts located within cabinets as well as inputs/outputs from other related system
shall be suitably terminated in the cabinets.
8.03.15 The Contractor may submit details of his standard wiring practice for similar application for
consideration and approval of Employer.
8.04.00 Relays
8.04.01 All the relays provided by Contractor shall be suitable for control supply of 24V DC. Each
relay shall have 2 changeover type contacts & the rating of contacts shall be 5 Amp at 240V
AC & 0.2A at 220V DC. The VA burden of relays shall be suitable to match the capacity of
output modules (however, it shall not be more than 2.5 VA). Each relay shall be provided with
a freewheeling diode. The relays shall be mounted in relay cabinets except for cases where
number of relays is vey less . In the cases where the number of relays is very less, the same
can be mounted in termination / marshalling cabinets. All the contacts of relays shall be wired
upto the cabinet terminal blocks.

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9.00.00 SYSTEM SOFTWARE REQUIREMENTS
9.01.00 The Contractor shall provide all licensed software packages required by the system for
meeting the intent, functional and parametric and performance requirements of the specifica-
tion.
9.02.00 All licenses shall be valid for the continuous service life of the plant. The software licenses
shall be provided for the project (e.g. organisation or site license) and shall not be
hardware/machine-specific, except the operating system licenses, in the event of non-
machine specific license not being supported by the operating system supplier. Necessary
documentary evidence to establish the same shall be submitted by the DDCMIS supplier
9.03.00 As a customer support, the Contractor shall periodically inform and upgrade the Anti-Virus /
IPS/IDS software of the workstations/servers/switches/firewall till completion of the warranty
period and also till the completion of the AMC period.
9.04.00 DDCMIS supplier to periodically provide list of qualified operating system patches/ service
packs and software patches of other third party software (like Office, Adobe etc as
applicable, except antivirus and IPS/IDS) for use on its system during the continuous service
life of the plant, subject to availability of the same by the manufacturer of the software.
9.05.00 As a customer support the DDCMIS supplier should periodically inform and provide
software/firmware fixes/patches for bugs, deficiencies, security vulnerability (including those
reported in US-CERT, CERT of the country of origin of DDCMIS OEM, CERT of respective
DDCMIS OEM) for DDCMIS, till continuous service life of the plant.
10.00.00 SYSTEM DOCUMENTATION
The Contractor shall furnish detailed system and equipment documentation. It shall include
detailed system and components description covering the installation, operation, care and
maintenance of all system components. All final system documentation for DDCMIS
hardware and related software shall be furnished. The same shall be complete, accurate and
fully representative of the supplied system and its elements. All documentation/catalogues
etc., shall be furnished in English language. In addition to the hard copies, CD ROM based
documentation system shall also be provided. The same should be compatible to the On-line
document generation facility indicated above.
10.01.00 Hardware documentation
10.01.01 Detailed technical literature, reference manuals, user’s guide/manuals for the complete
hardware like control system hardware, HMIPIS hardware, I/O hardware, bulk memory units,
peripherals and their controllers, communication hardware including controllers, man-
machine interfaces programmers unit, power supply modules etc., shall be furnished by the
Bidder.
10.01.02 Operation and Maintenance manuals
The operation and maintenance manuals shall include all information required for trouble
shooting, repair and maintenance information regarding all equipments furnished for the
completeness of the system. For details refer Part-C, General Technical Requirements.

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10.02.00 Software Documentation And Software Listings
10.02.01 All technical manuals, reference manuals, user’s guide etc., in English required for
modification/editing/addition/deletion of features in the software of the DDCMIS shall be
furnished. The Bidder shall furnish a comprehensive list of all system/application software
documentation after system finalisation for Employer’s review and approval.
10.02.02 The software listings shall be submitted by the Bidder for source code of project specific
application software and all special-to-project data files
11.00.00 NOT USED
12.00.00 WARRANTY
12.01.00 The Bidder shall provide an unlimited warranty on all equipment and software during the
Defect liability period. This warranty shall include repair, replacement or correction of
identified software or hardware discrepancies at no cost to Employer.
12.02.00 NOT USED.
12.03.00 The Bidder shall provide warranty spares and an exhaustive list of warranty spares including
components for system hardware and instrumentation and peripherals based on (and
keeping adequate margin over) normally experienced failure rate shall be submitted by the
Bidder for Employer's review regarding adequacy of the same. The warranty spares as per
the list mentioned above will be dispatched by the Bidder along with the main equipment
consignment. The Bidder shall also provide expandable items for the warranty period. This
shall include printer ribbon, ink/tonner cartridge print head etc. Excluding floppy disk, M.O.
Disk, tape cartridge and paper. Unused spare/consumable shall be contractor’s property and
taken back.
12.04.00 In case of any hardware failure which hampers normal operation, the Bidder during the
warranty period must provide on-site technical expertise to repair/rectify the problem within a
week and if any component is not available at site, the Bidder must arrange to supply these
components at site within additional 48 hours. If a software problem is identified, this problem
shall be corrected within two weeks.
12.05.00 After six months of DDCMIS operation the Bidder shall provide the list of parts and
expendables utilized for the period. The same information will be provided at the conclusion
of the warranty.
12.06.00 In order to discharge the warranty responsibility, the bidder shall include in his proposal
lumpsum price for the provisions of a team of service personnel at Site who will be fully
qualified to perform the required duties throughout the warranty period of one year. The
Bidder shall deploy at least one engineer, one supervisor and two technicians in the team.
The Employer shall approve the exact nos. & composition of team members. In case, the
team is unable to rectify hardware or software problems, the Bidder shall depute and/or
station additional specialist to rectify the problem to ensure 99.7% availability of system. The
availability of system shall be calculated as per Sub-section-IV, Part-A, Section-VI of
specifications.

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CLAUSE NO.
13.00.00 ANNUAL MAINTENANCE CONTRACT (AMC)
13.01.00 The Bidder shall provide maintenance services of complete DDCMIS System under a
comprehensive Annual Maintenance Contract (AMC) for period of Three years after Warranty
period.
13.02.00 The AMC shall cover total maintenance of all hardware & software coming under the scope
of DDCMIS and shall include free repair/replacement of all cards/ modules/ peripherals/
cables/ components etc., correction of software problems and supply of expendable items.
The Bidder shall ensure 99.7% availability of the system with the AMC. For that purpose,
contractor may maintain adequate no. of staff at site as per his own assessment if
considered necessary to ensure availability.
13.03.00 Further, Bidder may note that during the AMC he will be allowed to use Employer's
mandatory spares and has to replenish the same within three months time or before
completion of AMC period whichever is earlier. However, if in the opinion of the Bidder, more
spares than those included in the mandatory spare list are required to meet the availability
requirement, then Bidder shall stock the same.
13.04.00 The Bidder shall prepare detailed list of faults corrected and parts, expendables utilised
during AMC period and shall furnish the same to Employer, properly documented at the end
of AMC period. Further, during AMC period the details as required by Employer/ Project
Manager shall be made available by Bidder's personnel.
14.00.00 REMOTE SERVICE CENTRE
Bidder shall provide the necessary hardware & software required for connecting the DDCMIS
system to Bidder's remote service centre, through which the diagnostics & fault analysis of
the DDCMIS system can be carried out. This shall include the control system and unit HMI,
however the diagnostic of bought out items like LVS, LAN switches, Master & Slave Clock
etc are excluded. The method of connection shall be as per Bidder's standard practice with
Two-Factor Authentication (2FA). However, it is preferred to have the connection through a
single point in the plant's DDCMIS system. The fixed charges & running cost till warranty
period shall be included in the Quoted Price. The running cost thereafter shall be included in
the AMC price. Refer Clause (4) of Annexure C-02E for the method of connection.
15.00.00 TESTING AND COMMISSIONING TOOL
The testing and commissioning tool is intended to be used for test operation of any drive in
absence of DDCMIS during initial commissioning (e.g. fan trial run, etc.) While the tool shall
be used for all type of drives envisaged in the specification, it is designed to be operated for
one drive at a time. Portable trolley mounted system completed with necessary hardware for
operating the drives and monitoring its parameter shall be supplied.

23 OF 23
CLAUSE NO.
TECHNICAL REQUIREMENTS Annexure IIIC-02G
1.00.00 Requirements for HMI Hardware (Refer sub section- scope of supply & services for
applicability of this annexure)
1.01.00 HMIPIS Hardware
1.01.01 All the peripherals shall conform to the following minimum requirement but the exact make &
model shall be as approved by Employer during detailed engineering.
1.01.02 The Servers/Worstations/PCs/Laptop to be provided by the Contractor should be latest

available in the market at the time of supply to prevent early obsolescence and shall be
subject to Employer’s approval. The software packages to be included with the PCs shall
also be the latest version available at the time of supply.
1.01.03 The actual size of the Main and Bulk Memory shall be sufficient to meet the functional and
parametric requirements as specified with 25% additional working memory and 50%
additional bulk memory over and above the memory capacity required for system
implementation.
1.01.04 Power Fail Auto Restart (PFAR) facility with automatic time update shall be provided.
1.01.05 For Servers and Historians / Station LAN Server/ Programming station/NMS Server the
hardware shall conform to the following minimum requirements:
HARDWARE REQUIREMENTS
1. Min three no. redundant; hot swappable; Hard Disk with RAID 5 implementation.
Usable Hard disk capacity shall be sufficient for the application and to store at least
one (1) year historical data, wherever required.
2. Redundant Hot swappable Power supply
3. Quantity of Monitor, Keyboard and Mouse (as indicated in Part-A, appendix) has to
be supplied in total for the stations placed in Programmer room of Unit Area. For all
other stations Monitor Keyboard and mouse are provided as per Bidder’s standard
Practice.
4. One intelligent SNMP manageable mini-UPS (online) for 30 minutes backup shall
be provided, with all accessories and software for remote monitoring facility, with
each station.
5. Additional external graphics card with dual output ports (apart from onboard
graphics card) suitable to display full HD resolution in Programmer room.
SOFTWARE REQUIREMENTS
1. Application software as per the functional requirement.
2. Anti-Virus Software with IPS#

TECHNICAL SPECIFICATION SUB-SECTION - IIIC-02 PAGE
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CLAUSE NO.
# if anti-virus software cannot be provided as per standard practice of the DCS OEM
suitable mitigating controls like whitelisting to be provided.
1.01.06 For Operator workstations/ Other workstations/ Documentation station (in case not part of
prog. Stn.)
1. Standard Hardware as recommended by the Bidder shall be acceptable.
2. Individual Monitors shall be supplied for all stations (except LVS OWS)
3. Additional external graphics card with dual output ports (apart from onboard
graphics card) suitable to display full HD resolution in control room.
1. Application software as per the functional requirement.
# if anti-virus software cannot be provided as per standard practice of the DCS

OEM suitable mitigating controls like whitelisting to be provided.
1.01.07 For PC Station
1. Standard Hardware as recommended by the Contractor shall be acceptable.
2. One intelligent SNMP manageable mini-UPS (online) for 30 minutes backup shall
be provided, with all accessories and software for remote monitoring facility, with
each PC Station.
1. Application software as per functional requirement
2. Latest MS OFFICE (Word, Excel, PowerPoint, Outlook)
3. Microsoft Visual Studio (only for Programmer PC)
4. Adobe Acrobat
# if anti-virus software cannot be provided as per standard practice of the DCS

OEM suitable mitigating controls like whitelisting to be provided.

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1.01.08 Specification for Lap-Top (Note-Book) PC

The screen size of the laptops should be 15 – 17 inches.
All the Laptop will also be used as pluggable temporary programmer’s station and operator
station functionalities of the programming stations mentioned in the specifications shall be
provided (including requisite license).
1.01.09 Large Video Screen (LVS)
Large video screens, complete with projectors, screens, control units (graphical generators),
Master controller, Matrix switcher & associated accessories shall be supplied as per the
following specifications.
1. Size (diagonal) 65 inch – 70 inch
2. Type LED illuminated Digital Light Processing (DLP)

technology with rear projection configuration.
3. Resolution of each Minimum 1400 x 1050 pixels

screen
4. . Configuration of LVS Double tier with screens seamlessly combined with

provision of expansion of one screen on each side.
5. . Control Unit / LVS Same as operator work station without the TFT LCD
Workstation monitor.
Facility of projecting a particular display on a selectable

area of the screen upon activation of a predefined event
shall be provided.
6. . Input signal interface Interfacing with Video signals, to receive & project
pictures from CCTV, Employer’s Live camera, VCP,
Flame Camera
Signal types : PAL, NTSC or SECAM in S-VHS/VHS,

Composite, Component , S-Video
DVI, VGA
Each cube should be capable of taking two inputs.

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Video Switcher (applicable for only Unit DDCMIS)
No. of input channels : 16
No. of output channels
:4
The output of the video switcher will be connected to

video wall through Master controller.
Matrix Switcher (for Unit Control room LVS)
A matrix switcher shall be provided used for connecting

the control unit to the video wall.
No of Inputs: 12
No. of Outputs: 12
Remote unit for switching between video signal & HMI

signal, selecting the video signal channel (live camera
no./location typically) shall be provided.
7. . Illumination level To be finalised during detailed engineering.
8. . Degree of viewing in To be finalised during detailed engineering.

horizontal & vertical
9. . LVS shall be designed for continuous viewing (24 hours in a day) under normal
room ambient lighting without any need to darken the room. Suitable darkening of
the projection screen for light absorption shall be provided for this purpose.
10. The LVS and its accessories shall be designed in such a way that the brightness in
the centre of the screen and the edges of the screen is uniform and there is no
perceivable difference in the quality of the picture on the centre and on the edges of
the screen. If any extra hardware has to be provided for achieving the above
feature, same shall be provided by the contractor at no extra cost.
11. The screen should be flicker free and there shall not be any screen burn in due to
display of same information for a long time.
12. Auto brightness & color adjustment between each screen.
13. . The hardware/software of the control unit shall be such that the command execution
time of any control command from the LVS shall be same or better than the
execution time from the OWS as stipulated under 'Guarantee under category-III,
Sub-section-IV, Part-A, Section-VI of specifications. If during any stage of the
contract, the command response times as stated in specifications are not achieved,
the contractor shall upgrade the hardware/software of the control unit in order to
achieve the same at no extra cost to the Employer.

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14. Master controller unit shall be provided for controlling the entire video wall in Unit
Control Room LVS. It shall be capable of projecting HMI displays over a part of
screen to multiple screens. Any configuration of windows shall be possible. Facility
for overlays shall be provided.
1.01.10 Graphical Interface Unit
Minimum specifications of Graphical Interface unit shall be as follows:-
Sl no. Features Description
1. Power supply 230 V AC
2. Display Size 10-11”
3. Display Type Color,TFT screens
4. Protection class IP-65 for extremely dust prone area,

otherwise IP-55.
5 Keys Function keys and numeric
keys
Interface with respective DDCMIS
6 Interfacing requirements
7 Functional requirements Ability to do programming.
Graphics display including alarms and

operator guidance messages.
8. Mounting/Enclosure The GIU unit shall be installed inside

suitable enclosure with lock and key
arrangement so as to guard against
pilferage.
Enclosure shall be IP 65 for extremely dust

prone area, otherwise IP-55
1.01.11 Printers
Sr. Features Colour Laser Colour Laser Line Impact Dot Matrix Printer
No Printer Printer
1 Paper Size A3 A4 132 column continuous fan
fold type
2 Printing 6 ppm 4 ppm (color) 1000 LPM
Speed (Color)

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(min.)- in 24 ppm 16 ppm

normal mode (B&W) (B&W)
for A4 size
paper
3 Type Heavy duty, Heavy duty, Heavy duty, at least 50000
at least at least pages/month
50000 30000
pages/month pages/month
4 Resolution 600 dpi 600 dpi -
(black) (min.)
5 First page =<1 min for =<1 min for
out time (with color, color,
full graphic
<45 sec for <45 sec for
display)
BW BW
6 Paper input 500 sheets 500 sheets Continuous paper feed
capacity
(min.)
7 Additional Automatic With printer Stand & sound
features Duplex proof enclosure (<60 dB)
Printing
8 Additional 1 1 100
Cartridge/ton
er/ ribbon of
each type as
used in
printer with
each printer
1.01.12 Switches :
Layer-3 switches shall have the following features:
Minimum 15 nos. Fiber Gigabit Ethernet Port. 20% spare ports are to be provided
over and above the total ports used
10/100/1000 Base TX ports (STP) as per requirement with 20% spare
SNMP v1, v2, v3, RMON, VLAN, Multi link Trunk support (IEEE 802.3ad – Link
Aggregation)
Broadcast/multicast storm control
Non-Blocking wire speed

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Hot swappable dual redundant Power Supply
RIP, OSPF, BGP
VRRP
PIM and DVMRP Multicast Routing
IPV4and IPV6 ready
Support MACsec in hardware (IEEE 802.1AE)
10 GB module support for future upgradeability
Expandability/stackability through a dedicated high speed expansion port.

Routable, remotely manageable, configurable.
One intelligent SNMP manageable mini-UPS for 30 minutes backup shall be provided with all
accessories and software.
Secondary switches shall have the following features:
10/100/1000 Base TX ports (STP) as per requirement with 20% spare
Gigabit Ethernet Port as per requirement with 20% spare
SNMP, RMON, VLAN, Multi link Trunk support.
Support for stacking with high throughput
Broadcast/multicast storm control
1.01.13 Firewall :
Firewall appliance should facilitate multi-vendor, multi-application environment and should

support third-party products on open alliance. It should support Active-Active configuration.
The firewall should contain following features:
(a) Stateful inspection of packets.
(b) NAT functionality, including dynamic and static NAT translations
(c) Latest version of SNMP
The firewall must send log information to a separate log server via an encrypted
connection. Firewall logging must not impact firewall performance.
Remote network access to the firewall should only be possible through the
administration interface.
Firewall should also meet the following requirements.
The firewall must not support any unencrypted means of access to the firewall.

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 It should Monitors ALL network traffic-traffic at Firewalls (Internet and external

networks), in the DMZ and detect known threat through deep packet inspection.
 Detects unknown threats via anomaly scanning.
 Detect unknown threats via behavior pattern to protect from zero day attacks.
 Keeps up-to-date on new threats and vulnerabilities.
1.01.14 IPS/ IDS Features :
In order to inspect all inbound and outbound network activity and identify suspicious patterns
that may indicate a network or system attack from someone attempting to break into or
compromise a system on the EMPLOYER Station LAN Network, the IDS/IPS will be provided
as per the Station LAN configuration.
1.01.15 Network Management Software (NMS) :
The network management software should contain the below mentioned features.
 Graphical user interface (GUI) management.
 Automated discovery and display of Ethernet topology and devices.
 Monitor traffic flow through the device
 View a device image indicating which ports are active and which modules are
installed. It a particular network device is down, it should give the tools like
ping/telnet options in the same screen to further diagnose the problem.
 Real-time activity and utilization statistics and graphical trends.
 Facility of providing pre-defined actions like e-mail, SMS etc. upon any event
generated in the network.
 Facility of viewing logical graphs of devices like routers, web servers, according to
the needs.
 The following parameters should be monitored.
 Device status
 Port Status
 CPU utilization
 Memory Utilization
 All port utilization including uplink ports.
For monitoring the parameters mentioned above, the NMS workstation should be
connected to all HMIPIS switches/firewalls through management LAN which is a
separate LAN from the redundant Station LAN.

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1.01.16 KVM Switch
Necessary KVM switches for controlling multiple operator work stations/LVS workstations
(upto four nos.) from single key board/mouse/video placed at UCD in Control Room shall be
supplied. For quantity of switches refer Appendix-I. These switches are intended to be used
only for keyboard multiplexing.
For extension of keyboard & mouse cables from PC rack to control desk, necessary
converters shall also be provided, if required. These shall be supplied on as required basis
within the quoted price.
1.01.17 Matrix KVM Switch

A matrix KVM switch for accessing multiple Servers, Gateway, Workstations etc, via multiple
user consoles placed in the Programmer Room in Server Rack. User consoles shall also be
located in the same room. These switches will be used for Keyboard, Video and Mouse
multiplexing. The KVM switch sizing should consider 20% spare capacity and associated
spare server & user consoles. Refer Part-E drg no 0000-999-POI-A-006. For quantity of
switches refer Appendix-I to Part-A.
Specifications
The requirement of each Matrix KVM switch shall be as follows:
1. Minimum Connections 16 Servers and 4 user consoles
2. System Cable Cat 5/Cat6
3. Port Selection Hot keys, User Interface
4. Power Supply 230 V AC
5. Mounting Rack Mountable in server rack.
6. Keyboard, Mouse PS/2 , USB

Support (with/without
convertor)
7. Video The video shall be displayed at the user stations without

any distortion/skew etc.
8. Resolution Full HD
9. Security Password/ Multiple user profiles
Allowing/disallowing access of particular machines to a

user profile.
10. User to Switch Distance 30 Meters or less
11. Servers to Switch 15 Meters or less

Distance
Computer connections (CPU End)

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1 Video Type DVI or VGA as required
2 Keyboard and Mouse PS/2 or USB as required

Type
3. Mounting The device shall be fixed with proper fixtures in the

server rack.
User consoles
1 Video Type DVI or VGA as required
2 Keyboard and Mouse PS/2 or USB as required

Type
3 Mounting Suitable mounting arrangement shall be provided.
The types of Video, keyboard and Mouse connectivity of each shall be finalized during
detailed Engg. All the converters and cables required for completeness of the system shall
be in scope of this package.

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CLAUSE NO.
TECHNICAL REQUIREMENTS Annexure IIIC-02H
Special Requirements (Refer sub section- scope of supply & services for applicability
of this annexure)
1.00.00 Software for determination of optimum Controller parameters
The programming station shall be equipped with a system/software to calculate the tuning
constants i.e. P, I and D values of control loops automatically. Facility shall be provided to
conduct open loop test (i.e. controller in manual mode) and closed loop (i.e. controller in auto
mode) tests on control loops through GUI based user interface. It shall be possible for the
user to adjust the step size of disturbance, sample time, duration of test. Facility shall be
provided to choose the type of process being tuned i.e. PI, PID etc, controller type i.e.
regulating or tracking, and the type of process being controlled i.e. integrating, non
integrating. Further it shall also be possible to calculate the tuning constants by capturing
process changes during normal process disturbance (without conducting any test). The
calculation of tuning constants shall follow internationally accepted tuning procedures. The
system shall be provided with facility to monitor the performance of control loops during
normal operation of the plant and display important statistics and performance indices about
the loops e.g. average absolute error, peak overshoot, no. of set point crossings, controller
output saturation etc. and recommend retuning of the loop based on these parameters.
2.00.00 (A) PERFORMANCE CALCULATIONS (CLASS I)
The Class I calculations are generally for the purpose of detecting & alarming unit
malfunctions. These shall be executed at the scan cycle of the inputs, for the calculation.
These shall include cold reheat steam approach to saturation temp, super heater spray outlet
approach to saturation temp., turbine steam-metal temp. differences, turbine metal temp.
rates of change, feed water heater terminal temp. difference, feed water heater drain cooler
approach, excess air deviation from standard, feed water heater temp. deviation from
standard, any saturation temp. rate of change, metal temp. difference for SH ‘Y’ and RH ‘Y’
piece etc.
(B) PERFORMANCE CALCULATIONS (CLASS II)
Class-II Performance Calculations (which is the Plant / equipment efficiency calculation) for
various equipment along with heat rate deviation & revenue calculation, availability tariff, etc.
shall be provided as per list given below:-
Boiler efficiency
Gross turbine-generator heat rate
Gross unit heat rate
Net unit heat rate
H.P. turbine enthalpy drop efficiency
I.P. Turbine enthalpy drop efficiency
L.P. turbine enthalpy drop efficiency (using dry exhaust)
Feed water heater performance terminal temperature difference.

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Feed water heater performance drain cooler approach
Condenser performance
Deaerator performance
Economiser performance
BFP performance
Air Preheater performance
Fan efficiency
Unit availability calculations
Deviation from expected values from each calculation.
In addition to the above, the net unit heat rate vs. load profile shall be calculated using the
last values of heat rates at different load interpolating the results. Facility shall be provided
for entering unit constraints like a particular mill not available by the operator.
3.00.00 MESSAGING SYSTEM
It shall be possible to send pre defined messages either periodically or on occurrence of

certain events in the form of
a) operator guidance message to LVS/OWS
b) e-mail messages to various clients on the station LAN
c) messages to pre selected mobile nos (around twenty numbers)
In case the faults as per Clause 1.05.00 of IIIC-02 are not acknowledged/rectified within a
certain interval, then the same shall also be reported to users through messaging system.
A configuration utility shall also be provided for the above providing facilities of configuring
the events, grouping of events areas wise, priority of events within a group and configuring
user groups for to which the event/event group can be assigned etc.
Adequate security in the system shall be built in the system to avoid any unauthorized
access to DDCMIS system.
4.00.00 TREND ALARMS
Facility of Trend alarms shall be provided in DDCMIS for slowly varying process parameters,
so that appropriate corrective actions are taken in time. These alarms shall be suitably
provided in OWS/LVS, which will be decided during detailed Engg. Stage.

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5.00.00 Alarm Analysis
DDCMIS shall provide fault alarm analysis guiding the operator to the most likely cause of
fault. The alarm system shall be designed in such a manner that main auxiliaries tripping can
be traced to the originating cause.
6.00.00 Software package for Merit order rating programme
Merit order rating calculation for this package shall be provided by the contractor. The units
shall be grouped on the basis of regional grid being fed by them, and MOR programme shall
be capable of running separately for each such group. The grouping of units shall be
customizable allowing regrouping, at any point of time, as per requirements.
The contractor however shall develop his own algorithms, which shall be finalized during
detail engineering with approval from Employer.
Necessary signal exchange between this package and other sub-system covered under this
package shall be provided, as defined in Part-A.
7.00.00 Automatic Unit Startup & Shutdown
It shall be possible to perform automatic unit startup & shutdown by issuing minimum number
of command from the LVS/OWS. Thus, the unit level shall control all the Control System
Blocks and issue appropriate startup & shutdown commands to various blocks of this Control
System and SG/TG C&I and receive corresponding check backs / feedbacks. All
signals/points to HMIPIS for implementation of sequence, drive & other displays shall be
made available from Control System.
8.00.00 Replay Software for Trip/Disturbance analysis
A software based trip/disturbance analysis utility shall be provided. The utility shall have the
capability to acquire point information of last 48 hrs. from the Station LAN server or Unit
historians on a continuous basis (FIFO) and using the acquired data, replay the actual plant
mimics with auto updation every second. It shall be possible to select the time interval for
which the data is to be replayed. Process alarms, commands from OWS/LVS, UCD
commands, GIU commands etc. during the selected time interval shall also be suitably
displayed for ease of analysis. Actual no. of points which is to be configured shall be decided
9.00.00 Other functions of Control System
9.01.00 The major auxiliaries / logics to be controlled from control system have been indicated in
Part-A of specification. The exact implementation of the logics, drive functions, monitoring etc
will be to meet actual process requirements and as finalised during detail engineering stage.
If control of electrical system is included (refer part-A) then functions such as open/close or
on/off etc. of various electrical systems such as breakers and isolators, Raise/ lower for
equipment like transformers tap changer, synchronization of electrical breakers, etc. shall be
provided. Control and all the operation, in case of electrical system, shall be performed
through LVS/OWS.

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9.02.00 The major control loops to be controlled from Control System have been indicated in Part-A
of specification. However, exact implementation of these control loops shall be finalised
during detailed engg. Stage in consultation with main equipment supplier. The Contractor
shall furnish his standard & proven implementation practices for similar control loops in
power stations. The Contractors shall be responsible for final implementation of control loops
which shall meet all specification requirements. Employer shall only be responsible for
furnishing inputs such as range, function curves, tags etc
9.03.00 The measurement system of control system should be capable of acquiring data from various
equipment & system in digital form through serial port, field bus / profibus, Ethernet
connection using industry standard protocols. The control system shall include requisite
modules for accepting such signals. Examples of such signals will be from remote I/O signals
(through extended I/O bus), field bus/profibus type temperature transmitters, fault/diagnostic
signals from vibration monitoring system, UPS/DC system etc. Requirement of such ports is
indicated at appendix-I to Part-A.

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TECHNICAL REQUIREMENTS Annexure IIIC-02J
Security Policies/Procedures and Security Audits :
In order to enforce network security in the Station LAN & the HMI of all DDCMIS, security
policies and procedures are to be followed by the Contractor during the tenure of the
Contract & by Employer’s site personnel thereafter.
For checking compliance to the above security policies & procedures ,periodic security audit
by a certified auditor (as per CERT-IN panel or CERT of country of origin of DDCMIS
supplier)) is to be arranged by the Contractor during ATST, at the time of trial operation/PG
test of C&I package and every year during AMC period. This shall include vulnerability
assessment of the workstations/ servers and penetration testing of the Station LAN through
the firewall from a node outside the network. Suitable actions based on the findings of the
security audit shall be carried out by the Contractor.
These security policies/procedures envisages formation of an Information Security team

which shall comprise of vendor’s personnel deputed at site during tenure of the contract and
EMPLOYER personnel thereafter. All the responsibilities of information security team have
to be discharged by vendor’s team during tenure of the contract and EMPLOYER team
thereafter. Even though different roles have been identified for the individual members of the
information security team more than one role can be performed by the same person. It may
be noted that following policies/procedures are only the operation guidelines and advisory
steps to ensure maximum data security.
The following security policies shall be followed. Details of the same shall be provided during
detailed engg.
1. Information Security Policy

a) Information Security Team Policy
b) Firewall Policy
c) Information Identification and Classification Policy
d) Security Policy Review Policy
e) Information Labeling and Handling Policy
f) System Planning and Acceptance Policy
g) Capacity Management Policy
h) Media Handling Policy
i) Information Security Awareness Policy
j) Third Party Access Policy
k) Change Control Policy
l) Anti Virus Policy
m) System Access Policy
n) Monitoring Policy
o) Incident Handling Policy
p) Information Backup and Restoration Policy
q) Network Access Policy
r) User Access Management Policy

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TECHNICAL REQUIREMENT Annexure IIIC-02K
1.00.00 GENEREAL REQUIREMENTS FOR FIELDBUS INSTRUMENTS AND

ACTUATORS
This section provides the basic guidelines for the design and implementation
of Fieldbus (Foundation Field Bus/ Profibus) based control system.
1.01.00 The requirements given herein are minimum requirements to be considered

by Contractor to ensure uniformity in basic design and shall not be
considered as final requirements. The Fieldbus design shall be further
validated by contractor and approved by Employer during detailed
engineering and any variation/ changes required based on DDCMIS system
requirements and actual field installation, operational philosophy etc. shall be
considered by contractor without any implications.
1.02.00 The fieldbus segment design shall be finalized and validated based on
functional requirements as per:
 Process requirements (P&IDs/ operational requirements).

 Loop response time of different loops device communication time i.e.
cycle time for fast and slow loops with scheduled and unscheduled
organization as per project.
 Area classification requirements (e.g. hazardous or safe).
 Fieldbus devices specifications (maximum current drawn from bus, block
execution speeds, power conditioner suitable for field barrier, etc.)
 Length of segments.
 Instrument location plans with elevation details.
 Host-system documentation showing configuration rules or restrictions.
 For Foundation Fieldbus & Profibus PA chicken foot/ branch/ or combination of
both topology shall be provided. For Profibus DP, Bus/ Line topology in
Redundant mode shall be provided. That is, for Profibus DP redundant cables
connected to redundant ports of devices shall be provided.
Suitable field bus segment design shall be considered keeping the safety &
integrity of the system intact so that the cabling, marshalling, junction boxes
and system performance shall be optimized.
However, all such segment device allocation, topology shall be decided

1.03.00 Contractor to provide all standard functional blocks for all Foundation
Fieldbus/ Profibus devices as per latest FF/ Profibus version and standard
guidelines. Fieldbus components including power supply, terminators,
isolators, etc. provided by Contractor shall comply to IEC 61158 and other
standard Fieldbus guidelines.
1.04.01 Redundant host/ master card and redundant power supply along with
advance diagnostic module shall be provided. All required libraries to execute
various tasks like data acquisition, control/protection etc. shall be provided.

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1.04.02 In fieldbus system following spare capacity in each FG shall be provided :
Item Sub Item Spare capacity

Controller Software Blocks 30%
Host 30%
Host/ Power Installed spare capacity 10%
supply
Host/ Power Only spare space 20%
supply space
Segment spare 40%
capacity
If in a FG, conventional and fieldbus system both are implemented then

above spare capacity shall be in proportion to fieldbus/ conventional system
implementation.
1.04.03 The contractor shall present complete implementation scheme, including

wiring scheme during detailed engineering stage for review and approval by
Employer.
1.05.00 Fieldbus cable (specifically used for Foundation Fieldbus/ Profibus PA and
Profibus DP) shall be Individually shielded twisted pair, with round steel
wired armour (SWA) complying to IEC 61158, Type A. The cable
construction shall meet EN 50288-7 standard for physical properties and the
outer sheath shall be of PVC-TM53 as per EN 50290-2-22. Continuous
operating temperature of Fieldbus cable shall be minimum 90 Deg C.
For laying of fieldbus cables, cable trays envisaged for instrumentation cable
with all the accessories shall be used by the contractor. Minimum 300 mm
spacing to be kept between the fieldbus trays and other high voltage cables
to avoid any interference.
SS Junction boxes specially designed for fieldbus application shall be

provided on as required basis. These SS JBs shall house field mounted
fieldbus components like distributers, tee, etc. These SS JBs shall have
suitable cover and gasket and shall have protection class of IP-66 or better.
SS Cable glands and blind plugs shall be provided by the Contractor.
1.06.00 Comprehensive Fieldbus Maintenance and Diagnostic software shall be

provided. This software shall be capable of collecting complete diagnostic
information from fieldbus network and all fieldbus devices and presenting in
user friendly interface for detailed diagnostic and troubleshooting of the
system. It shall be possible to completely configure parameters of fieldbus
network and fieldbus devices from centralized system through this software.
This software shall have feature of providing data related to maintenance of
fieldbus devices as available through fieldbus system. This system/ software
shall have provision to get updated to latest version/ release of various
fieldbus devices.

(2X660 MW) DDCMIS
CLAUSE NO.
1.07.00 During FAT suitable arrangement shall be made by Contractor to test

Fieldbus modules including field devices as per approved FAT procedure.
1.08.00 The contractor shall use fieldbus segment design tool / software to design
complete network verifying various design parameters like device voltage,
total cable length, spur length, system power requirements etc. the
contractor shall provide device voltage calculations for all segments, based
on calculation in software package. All these calculations shall be handed
over during detailed engineering in electronic format in a way that Employer
can thoroughly verify design basis/ calculations carried out by Contractor.
1.09.00 Suitable short circuit protection, surge protection, grounding requirements

shall be provided for all devices, so that fault in one device shall not impact
the availability of other devices in the segment.
1.10.00 All required diagnostic and configuration tools/ hand held devices shall be
provided for configuration and troubleshooting of devices and network.

(2X660 MW) DDCMIS
SUB–SECTION – IIIC – 03
NOT USED
MEASURING INSTRUMENTS
(PRIMARY & SECONDARY)
CLAUSE NO.
1.00.00 MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)
1.01.00 Measuring instruments/equipment and subsystems offered by the Bidder shall be from
reputed experienced manufacturers of specified type and range of equipment, whose
guaranteed and trouble free operation has been proven. Refer Sub-section Basic Design
Criteria. Further, all instruments shall be of proven reliability, accuracy, and repeatability
requiring a minimum of maintenance and shall comply with the acceptable international
standards and shall be subject to Employer's approval.
1.02.00 Every panel-mounted instrument requiring power supply shall be provided with easily
replaceable glass cartridge fuses of suitable rating. Every instrument shall be provided with a
grounding terminal and shall be suitably connected to the panel grounding bus.
1.03.00 All transmitters, sensors, switches and gauges for parameters like pressure, temperature,
level, flow etc. as required for the safe and efficient operation and maintenance as well as for
operator and management information (including all computation) of equipment in the system
under the scope of specification shall be provided on as required basis with in quoted lump
sum price. The Contractor shall furnish all Instrumentation / Control equipment & accessories
under this specification as per technical specification, ranges, makes & model as approved
by the Employer during detailed engineering.
1.04.00 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve
manifolds and all the other accessories required for mounting/erection of these local
instruments shall be furnished, even if not specifically asked for, on as required basis. The
contacts of equipment mounted instruments, sensors, switches etc. for external connection
including spare contacts shall be wired out in flexible/rigid conduits, independently to suitably
located common junction boxes. The proposal shall include the necessary cables, flexible
conduits, junction boxes and accessories for the above purpose. Double root valves shall be
provided for all pressure tapping where the pressure exceeds 40 Kg./sq.cm.
1.05.00 All instruments envisaged for sea water applications, shall be provided with wetted parts
made of Monel/ Hastelloy C or any other material (if provenness experience of the proposed
material for such applications is established by contractor).
For Chlorine application: Instruments shall be provided with wetted parts (e.g. diaphragm
seal, etc.) made of Hastelloy C. Also, filled liquid shall be Fluorolube oil/ Inert Hydrocarbon /
CTFE etc., for these applications.
For applications of FECL3 solution: Instruments shall be provided with wetted parts (e.g.
diaphragm seal, etc.) made of Tantalum.
1.06.00 For coastal areas, all instruments shall be provided with durable epoxy/ polyurethane coating
for housings and all exposed surfaces of the instruments.
KHURJA SUPER THERMAL POWER PROJECT SUB-SECTION-IIIC-04

(2X660 MW) MEASURING
WATER SYSTEM PACKAGE INSTRUMENTS (PRIMARY
& SECONDARY)
CLAUSE NO.
2.00.00 SPECIFICATION FOR ELECTRONIC TRANSMITTERS
2.01.00 SPECIFICATION FOR ELECTRONIC TRANSMITTER FOR PRESSURE, DIFF PRESS

AND DP BASED FLOW / LEVEL MEASUREMENTS
Sl.No. Features Essential/Minimum Requirements
1. Type of Transmitter Microprocessor based 2 wire type (loop powered), Hart

protocol compatible.
2 Output signal 4-20 mA DC (Analog) along with superimposed digital

signal based on HART protocol
3 Accuracy ± 0.060 % of calibrated range (minimum) for calibrated

range greater than 400 mmwc.
+0.065% of calibrated range (minimum) for calibrated
range greater than 250 kg/cm2.
± 0.10 % of calibrated range (minimum) for calibrated
range less than 400 mmwc
4. Turn down 50:1 for greater than or equal to span of 400mmwcl.
(minimum) 20:1 for span below 400mmwcl.
10:1 for span greater than 250 kg/cm2
5. Stability 0.25 % of calibrated range for 10 years for calibrated
range greater than equal to 400 mmwc on standard
conditions of manufacturer.
0.2 % of calibrated range for 1 years for calibrated range
less than 400 mmwc on standard conditions of
manufacturer.
0.15% of calibrated range for 5 years for static pressure
greater than 250 kg/cm2.
(Above mentioned (3,4,5 ) parameters/features of offered models shall be strictly as

defined in standard published catalogue of the manufacturer only).
6. Zero and span drift +/- 0.015 per degC at max span
+/-0.11% per degC at min. Span
Power Supply 24V DC ± 10%.
7. Load impedance 500 ohm (minimum)
8. Housing Weather proof as per IP-67, metallic housing with durable
corrosion resistant coating

& SECONDARY)
CLAUSE NO.
9. Over Pressure 150% of max. Operating pressure

10. Electrical Plug and socket type except in hazardous area
Connection
11. Process connection 1/2 inch NPT (F)
12. Span and Zero Continuous, tamper proof, Remote as well as manual
adjustability from instrument with zero suppression and
elevation facility.
13. Accessories -Diaphragm seal, pulsation dampeners, syphon etc. as
required by service and operating condition.
Diagnostics and Self-Indicating feature and digital display
Display
14. Accessories 2 valve manifold for absolute & Gauge pressure
transmitters,
3-valve manifold for Differential Pressure and 5 valve
manifold for Level /Flow applications.
The valve manifold shall be non integral type (except
Fuel Oil area).
-For hazardous area, enclosure as described in NEC
article 500
-2 inch pipe for mounting with Enclosure /Rack/Canopy
15. Certification SIL 2 or Better

16. Adjustment/calibratio From hand held HART calibrator
n/maintenance
Notes
LVDT type is not acceptable.
For primary air/ secondary air/flue gas applications, DP type transmitters shall be provided
for pressure measurement below range of 2000 mmwc
Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm
seals shall be provided. Parts below the diaphragm shall be removable for cleaning. The
entire volume above the diaphragm shall be completely filled with an inert liquid suitable for
the application.

& SECONDARY)
CLAUSE NO.
2.02.00 GUIDED WAVE RADAR TYPE LEVEL TRANSMITTER
Type Microprocessor based 2 wire type (loop powered), HART protocol

compatible Guided wave radar transmitter.
Principle TDR (Time domain reflectometry)
Probe Type & (i) Coaxial probe of SS316/316L. If required, probe shall be suitable
Material for overfill prevention.
(ii) Rod probe, cable probe of SS316/SS316L can be used for

applications wherever coaxial probe is not suitable.
Output signal 4-20 mA DC along with superimposed digital signal (based on HART
protocol), suitable for over fill prevention.
Accuracy +/- 0.5% of calibrated span or minimum 5mm.
Power supply 24 VDC +/- 10%.
Housing Weather proof as per IP-65, metallic housing with durable corrosion
resistance coating.
Adjustment/ Using hand held HART calibrator/ centralized PC based system (as
applicable).
calibration
Zero & span Continuous, temper proof, remote as well as manual adjustability
adjustment from instrument. It should be possible to calibrate the instrument
without any level in the tank/sump etc.
Display Integral digital display.
Load Impedance 500 ohms (minimum).
Electromagnetic Shall meet EN 61326-1 (1997) and AmdtA1, class A equipment/EN

compatibility 50081-2 & EN 5008 1-2 & EN 50082-2
Mounting (i) External cage shall be provided where ever side mounting is
required. External cage and other mounting accessories to be
provided by the contractor.

& SECONDARY)
CLAUSE NO.
(ii) Where ever top mounting is required, all mounting accessories,

stilling well (as required) etc., shall be provided by the contractor.
(iii) All weather canopy shall be provided for protection from direct
sunlight and direct rain for open locations.
Note: Four wire type transmitters can also be provided for applications where 2- wire
transmitter has some technical limitations, subject to employer’s approval during
detailed engineering stage. However, in such cases isolated 4-20 mA DC (analog)
output shall be provided. Power supply required for such transmitters shall be 240V
AC / 24V DC.
2.03.00 Ultrasonic Type level Transmitter
S.No. Features Essential/Minimum requirement
1. Type of Transmitter Non-contact Microprocessor based 2 wire type

(loop powered), HART protocol compatible
Ultrasonic transmitter.
2. Output signal 4-20 mA DC (Analog) along with superimposed

digital signal (based on HART protocol).
3. Accuracy +/- 0.5% of calibrated span or minimum 5mm.
4. Power supply 24 V DC +/- 10%.
5. Temperature compensation To be provided within transducer.
6. Housing Weather proof as per IP-65, metallic housing

with durable corrosion resistance coating.
7. Adjustment/calibration/ Using hand held HART calibrator/ centralized PC

based system (as applicable).
maintenance
.
8. Zero and Span adjustment Continuous, tamper proof, remote as well as

manual adjustability from instrument. It should
be possible to calibrate the instrument without
any level in the tank/sump etc.

& SECONDARY)
CLAUSE NO.
9. Sensor Material Corrosion resistant material to suit individual

application requirement.
10. False signal tolerance Transmitter shall be capable of ignoring false

echoes from internal tank/sumps obstructions
such as pipes, heating coils or agitator blades.
Also transmitter shall have adjustable damping
circuitry.
11. Range Range of transmitter shall be capable of

covering the complete level span of tank taking
care of blocking distance, frequency attenuation
due to surface, obstructions, vapors etc.
12. Display Integral digital display
13. Diagnostics Loss of echo alarm etc.
14. Load Impedance 500 ohms (minimum).
15. Electrical Connection Plug and socket
16. Accessories  All weather canopy shall be provided for

protection from direct sunlight and direct
rain for open locations.
 All mounting accessories required for

erection and commissioning shall be
provided.
 For hazardous area, explosion proof

enclosure as described in NEC article
500
Note:
1) Contractor can also provide Radar type transmitter as per above specification in
place of ultrasonic transmitter subject to approval by Employer during detailed

& SECONDARY)
CLAUSE NO.
Engineering. Sonic frequency based transmitters can also be provided under

“ultrasonic transmitters” category for fly ash silo level.
2) Four wire type transmitters can also be provided for applications where 2- wire
transmitter has some technical limitations, subject to employer’s approval during
detailed engineering stage. However, in such cases isolated 4-20 mA DC (analog)
output shall be provided. Power supply required for such transmitters shall be 240V
AC / 24V DC.
3) For applications where transmitter location is not accessible, the transmitter shall
have separate sensor unit and electronic unit for such applications. It shall be
possible to mount the electronic unit at accessible location.
2.04.00 HART Hand Held calibrator

Hand held calibrator shall be provided for adjustment/calibration/maintenance of the HART
compatible transmitters. The hand held calibrator shall be suitable for all types of transmitters
supplied in the package. If one type of hand held type calibrator is not suitable for
communicating with all types of transmitters then separate hand held calibrator will be
provided for that specific type of transmitter.
3.00.00 Temperature Elements and accessories
3.01.00 Thermocouple
Sr. Features Essential/Minimum Requirements

No.
1 Type of Thermocouple. : 16 AWG wire of Chromel-Alumel (Type K)

or 24 AWG wire Pt-Rhodium Pt (Type R)
depending on operating temperature Range
(ungrounded separate junction type).
2 No. of element : Duplex
3 Housing/Head : IP-65/Diecast Aluminium. Head of TE to be

provided with sufficient space and
arrangement to mount head mounted
temperature transmitter (as applicable).
Plug in connectors are to be provided for
external signal cable connection. TE
terminal head shall be spring loaded for
positive contacts with the thermo well.
4 Insulation and Sheathing of : Swaged type mineral (magnesium oxide)

Thermocouple insulation and SS316 sheath.

& SECONDARY)
CLAUSE NO.
5 Calibration and accuracy : As per IEC-584/ ANSI-MC-96.1 (special

limits of errors/ class1) for T/C.
6 Accessories : Thermo well and associated fittings
7 Standard : IEC-584/ ANSI MC 96.1 for Thermocouple

and ASME PTC-19.3 for Thermo-well
3.02.00 Resistance Temperature Detector ( RTD )
Sr. Features Essential/Minimum Requirements

No.
1 Type of RTD. : Four wire, Pt-100 (100 Ohms resistance at zero

degree Centigrade).
2 No. of element : Duplex
3 Housing/Head : IP-65/Diecast Aluminium. Head of TE to be

provided with sufficient space and arrangement
to mount head mounted temperature transmitter
(as applicable). Plug in connectors are to be
provided for external signal cable connection.
TE terminal head shall be spring loaded for
positive contacts with the thermo well
4 Insulation and sheathing : Mineral (magnesium oxide) insulation and

of RTD SS316 sheath,
5 Calibration and accuracy : As per As per IEC-751/ DIN-43760 Class-A for

RTD
6 Accessories : Thermo well and associated fittings
7 Standard : IEC-751/ DIN-43760 for RTD and ASME PTC-

19.3 for Thermo-well.
NOTES :
1) The specifications for RTDs of winding/ bearings of motor/pump, can be as per their
manufacturer standards. The manufacturer shall submit the adequate supporting
documents for establishing their standard practice. However the type of RTD shall be
Pt100.
2) The specifications of temp elements for air conditioning & ventilation system /
process can be as per system manufacturer’s standards. The manufacturer shall
submit the adequate supporting documents for establishing their standard practice.

& SECONDARY)
CLAUSE NO.
3.03.00 Metal Temperature Thermocouples
Measuring Medium Metal Temperature
Material of Chromel Alumel Type K

Thermocouple.
Type of Thermocouple Duplex with ungrounded separate hot junctions
Insulation Mineral Insulation (Magnesium Oxide).
Thermocouple wire 16 AWG

gauge
Protective sheath SS 321
Protective sheath dia 8 mm OD
Calibration & accuracy As per IEC-584/ ANSI-MC-96.1 (special limits of error) for T/C
Mounting accessories 1/2" BSP SS sliding end connector, weld pad, clamps of heat
resistant steel SS310. Adjustable gland fitting for connection at
the junction box end as per manufacturer’s standard.
Cold end sealing SS pot seal with colour coded PTFE Insulated flexible tails.
Sealing compound- Epoxy resin. Length of PTFE insulated
flying leads shall be minimum 750 mm.
Minimum bending 30 mm
radius
Length of T/C On as required basis considering location of measurement

point and the JB/TTJB location.
Notes :
1) The specification for thermocouples of bearings metal temp measurements can be

as per their manufacturer standards. The manufacturer shall submit the adequate
supporting documents for establishing their standard practice. However type of
thermocouples shall be K-type.
2) For boiler metal temperature applications, considering the location of installations
and response time, manufacturer’s standard and proven specification for metal
temperature measurement can also be accepted subject to employer’s approval. The
manufacturer shall submit adequate supporting documents for establishing their
standard and proven practice.
3.04.00 Thermo well (for all process temp. elements)
(a) Shall be one piece solid bored type of 316 SS of step-less tapered design. (As per
ASME PTC 19.3, 1974)

& SECONDARY)
CLAUSE NO.
(b) For Mill classifier outlet long life solid sintered tungsten carbide material of high
abrasion resistance shall be provided.
(c) For Air & Flue gas 316 SS protecting tube with welded cap. (However contractor
shall provide better material for Flue gas service if required based on the specified
boiler design parameters).
(d) For furnace zone, impervious ceramic protecting tube of suitable material along
with Incoloy supporting tubes and adjustable flanges.
3.05.00 Not Used
3.06.00 TEMPERATURE TRANSMITTER
Following specifications are applicable for Dual input/ Single input temperature transmitter.
Temperature transmitter shall be 2-wire (loop powered) directly powered from 4-20mA
input cards of DDCMIS. TT shall be fully compatible with thermocouples and RTDs being
provided by the contractor. Temperature compensation for thermocouples shall be
performed in the temperature transmitter itself.
S Features Essential/Minimum Requirements

No.
1. Output 2-wire (power supply from input card of control system)

with 4-20mA output with superimposed HART protocol
signal
2. Input Same transmitter shall be capable to handle Pt-100 RTD,
Thermocouples –K, R & ,S types ( Selectable through
HART terminal/calibrator)
Isolation Min 500 VAC

EMC compatibility As per EN 61326
Power supply 24 V C +/- 10%
3. Housing Weather proof as per IP-67, metallic housing with durable
corrosion resistant coating
4. Electrical Plug and Socket connector except hazardous area
connection
5. Diagnostics & Self-Indicating feature and digital display on transmitter
display
6. Operating Ambient 85 deg C without display.
temperature
70 deg C with display.
7. Mounting 2 inch pipe mounting with Canopy.

& SECONDARY)
CLAUSE NO.
8. Accessories As required by service and operating condition.
9. Composite (Refer note 2 )

Accuracy
RTD =<0.25% of 0-250 deg C span
T/C-K type =<0.2% of 0-600 deg C span
CJC accuracy (for thermocouples) shall be =< 1 deg C
Notes:
1.In case of failure (open or burn-out) of RTD/thermocouple, transmitter shall provide
low temperature output.
2. Dual input temperature transmitter shall have bump less changeover facility to
second sensor in case first sensor fails. This changeover is to be alarmed in
control system.
3. Composite accuracy is to be calculated as summation of all applicable accuracies of
temperature transmitter for converting sensor input to output (e.g., A/D accuracy,
basic accuracy, digital accuracy, etc.) and temperature effect on these accuracies
at ambient temperature of 50 deg C, based on the figure/ formula given in the
standard product catalogue for span as specified above for various types of
temperature elements specified. All such accuracy/ temperature effect figures in
catalogue shall be first converted to deg C, and then percentage of this converted
accuracy in specified span shall be calculated to compare with the specified
composite accuracy figures. All temperature transmitters shall be interchangeable
(i.e. can be used for either RTD or thermocouple) and composite accuracy shall be
met for each type of input as specified above.
3. Above mentioned parameters/features of offered models shall be strictly as defined
in standard published catalogue of the manufacturer only.
4. Dual input temperature transmitters can also be accepted in place of single input
TT.
4.00.00 ELECTRICAL METERING INSTRUMENTS
Electrical metering instruments shall be furnished in accordance with the following general
specifications. However, the scope shall be governed by the Contract quantity given in
appendix-1 to part-A. Application standard for electrical metering instruments shall be as per
IS: 1248- 2003 (Revised). The size of each instrument shall be as approved by Employer
during detailed engg. All metering instruments shall be flush panel mounting type.
4.01.00 (a) Frequency meters for Synchronization purposes: Accuracy: ± 1.5% of full scale.
(b) Synchroscope: Accuracy class: 0.5 or better.

(c) Voltmeters: Accuracy: ± 2.0% of full scale or better.

& SECONDARY)
CLAUSE NO.
4.02.00 Synchronizing Relays
Synchronizing check relay with necessary ancillary equipment shall be provided which shall
permit breakers to close after checking the requirements of synchronizing of incoming and
running supply. The phase angle setting shall not exceed 10 Degree and this angle shall be
adjustable and shall take the account the circuit breaker closing period. This relay shall have
a response time of less than 200 milliseconds when the two system conditions are met within
preset limits and with the timer disconnected. The relay shall have a frequency difference
setting not exceeding 0.45% at rated value and at the minimum time setting. The relay shall
have a continuously adjustable time setting range of 0.5-3 secs. Additionally, a guard relay
shall be provided to prevent the closing attempt by means of synchronizing check relay when
control switch is kept in closed position long before the two systems are in synchronism. The
Control Voltage shall be 220V DC and PT input Voltage shall be 110 V AC.
4.03.00 Auxiliary PTs for Measurement & Synchronization
Applicable Standard IS : 3156
Rated Voltage 110V

Insulation Level 660V grade
Frequency 50 Hz
Mounting Panel Mounting
Test Voltage (Power frequency) 2.5 KV for 1 min.
Operating temperature (-) 40 Deg C to (+) 85 Deg C
Primary Voltage 63.5 V to 115V
Secondary Voltage 63.5 V to 115V
Class of accuracy 1
Burden 25 VA
Class of Insulation E or better
5.00.00 IMPACT HEAD TYPE FLOW ELEMENT
The impact head type element shall be tubular insert type with four impact ports facing
upstream direction, located precisely for determination of average flow velocity and shall
be of SS 316 L.
Accuracy shall be 1.0% of actual value or better. Repeatability shall be + 0.1% of actual
value or better.
The elements shall be supplied complete with mounting hardware; end support plugs and
CS valve manifold (1/2" NPT connection) for instrument connections. All pertinent data
including Employer's instrument tag no. for the flow element shall be punched on a
stainless steel plate and affixed to the element.

& SECONDARY)
CLAUSE NO.
Flushing arrangement shall be provided.

For quantity and line size etc., refer Appendix-I to Part-A.
Dual path transit time clamp-on Ultrasonic Flow meter may also be used for measurement of
CW flow.
6.00.00 CONTINUOUS EMISSION MONITORING SYSTEM (CEMS):-
Continuous Emission Monitoring system consisting of the following equipments

(Analysers/monitors) shall be provided for measurement of emissions in stack of each unit:-
1. SO2/NOx Analyser
2. CO analyser
3. CO2 analyser
4. Flue gas Flow Meter
5. Flue gas temperature measurement( As defined under Particulate Emission
Analyser)
6. Particulate Emission (Stack Opacity) Analyser
7. Mercury Analyser
Additionally, low temp and high temp Oxygen analysers (independent of CEMS) shall also be
provided at locations as indicated in the table below
The common requirements to be met for all types of analysers are as below. The specific
requirements to be met by each type of analyser are detailed in the subsequent clauses.
6.01.00 Common Requirements for all Analysers
1 Output signals
Analog 4-20 mA DC galvanically isolated.
2 Zero & span To be provided for all selectable ranges.

Adjustment
3 Ambient temp. 0-50°C unless defined otherwise.
4 Indication Digital Alphanumeric Display. Display of reading in engineering
units shall be provided.
5 Analyser Die cast Aluminium/SS. Weather protection for analyser mounted
enclosure inside analyser panel shall be IP-22 or better. For all other
Type/Material analysers, weather protection class shall be IP-55.
6 Type of Microprocessor based with self diagnostic.
Electronics
7 Digital Signal RS232/ RS485 Modbus Protocol/ Ethernet TCP/IP protocol for
transmission bidirectional communication of stack emission data to Employer’s cloud

& SECONDARY)
CLAUSE NO.
server
8 Calibration Auto & Manual (from Remote)

9 Power Supply To be arranged by Contractor subject to Employer’s approval.
10. Others i) All interconnection tubing and cabling between probe and
analyser / analyser panel and cabling from analyser/ analyser
panel to DCS (in respective unit control room) are to be provided
by Contractor.
ii) All the calibration gases required for one year continuous
operation shall be provided. The calibration gas container
material shall not contaminate the calibration gas.
11 Location of SO2/NOx/CO/CO2-On stack at approximate elevation of 35 Mtrs.
probe
Particulate Emission (Stack Opacity) & Flow measurement -On
stack at approximate elevation of 88 Mtrs
High temp O2 –SH zone
Low temp O2:- ECO outlet, AH outlet and ID inlet.
Mercury Analyser:- on stack at 35 Mtrs.
12 Location of the AT 0’ Mtrs near stack for CEMS
analysers (other
than insitu
type)/Analyser
Panel.
13 Compliance to USEPA, TUV, MCERTS or equivalent standards
standards
14 Type of SO2/NOx :- Hot-extractive sampling type/ Dilution Extractive/ In-
Technology situ (Path) type
CO :- Hot-extractive sampling type/ Dilution Extractive/ In-situ
(Cross-duct) type. (can be combined with SO2/NOx)
CO2 :- Hot-extractive sampling type/ Dilution Extractive/ In-situ
(Cross-duct) type (can be combined with CO or SO2/NOx above).
Stack Opacity :- In-situ (Path)type
Low temp O2 & High temp O2 :- In-situ type
Note:- For Hot extractive sampling type and Dilution extractive

sampling type system – The components involved in sample
handling system shall be imported & further, Sample handling
system design shall be vetted by Original Analyzer Manufacturer
(OAM). Necessary documents shall be furnished during detailed
engineering in order to establish the above requirement.
Technical expert of OAM shall witness testing of sample handling
system and validate it. Alternatively sampling handling system
assembled at Original Analyzer manufacturer (OAM) works shall

& SECONDARY)
CLAUSE NO.
also be accepted.
15 Contractual Warranty:- As defined elsewhere in the Contract.
Comprehensive Annual Maintenance Contract:-. Refer sub-
conditions for
section-IIC-C& I/ Section-VI/ Part-A. This shall cover total
CEMS system maintenance of all hardware and software related to CEMS and
shall include free repair/replacement of all
components/cables/equipment etc and
supply of expendable items.
Availability of valid data:-AT least 90% of time during warranty
and CAMC period. For this purpose, contractor may take
necessary steps to ensure availability.
Services to be provided during Warranty and CAMC period shall
be as per clause no. 19.03.00,19.04.00 and 19.05.00, Sub-
Section-II-C, SECTION-VI, PART-A
6.02.00 Specific requirements for Hot-extractive sampling type SO2/NOx, CO2 & CO analysers
Specification SO2 Analyser and Nox CO2 ANALYZER CO Analyser

Requirements Analyser cum monitor
(combined)
Type of Instrument Sampling type - Hot Hot-Extractive Hot-extractive type

Extractive type
Principle of Radiation absorption NDIR absorption NDIR absorption

Measurement
Measurement 0-300 ppm/ 0-1500 ppm 0 to 40% (selectable) 0-200 ppm to 0-
Range (selectable) 1000 ppm
(selectable)
Accuracy +/- 1% of FS +/-2% of measured +/- 2% of FS
value
Linearity +/- 1% of FS +/- 1% of FS +/- 1% of FS
Repeatability < 1% of Span < 0.5% of Span < 1% of Span
Response time(up < 5 secs < 5 secs < 5 secs
to 90% of full
scale)
a) Temperature +/- 2% / 10 deg.C +/-1% in 24 hrs +/- 2% / 10 deg.C
Drift
b) Zero Drift < 1% span/week < 1% span/week < 2% span/week
c) Span Drift < 1% measured < 1% measured < 1% measured
value/week value/week value/week
Operating 0-300 deg.C 0-300 deg.C 0-300 deg.C
Temperature
Range for probe
Filter Ceramic 3.5 Micron Ceramic 3.5 Micron Ceramic 3.5
Micron

& SECONDARY)
CLAUSE NO.
Accessories for Purging system including Purging system Purging system

purging system Auto Scavenging facility including Auto including Auto
shall be provided Scavenging Scavenging facility
facilityshall be shall be provided
provided
Sample gas inlet Temperature of the Temperature of the Temperature of the

temperature to sample gas inlet to sample gas inlet to sample gas inlet to
analyser analyser shall be analyser shall be analyser shall be
controlled before controlled before controlled before
analyser as per analyser as per analyser as per
manufacturer standards. manufacturer manufacturer
standards. standards.
6.03.00 Specific requirements for Dilution Extractive type SOx/NOx/CO2 & CO Analsyers
The design of the Dilution Extractive type system shall be satisfying the following
requirements. The sampling system shall consist of In-situ dilution probe, dilution probe
controller, sample conditioning system like air drier and filters etc and other accessories
meeting the following requirements as a minimum. All system components and accessories
required for completion of this system shall be furnished although these may not be
individually specified herein. Following are the minimum requirements:

& SECONDARY)
CLAUSE NO.
a) Modular Electronic Design.
b) Heatless Air dryer with inlet filter, chemical scrubbers to remove traces of
NOx/CO2/SO2 from air and accumulator
c) Self test facility with screen display
d) Protection of instrument in case ambient or surrounding temp going high beyond

stipulated limit
e) The following are the minimum requirement for the probe:-
 Flange and counter flange for inserting probe
 Coarse and Fine filters
 Critical orifice
 Automatic blow back or purging facility
 SS316L probe material
f) Further dilution probe controller shall be provided with the ability to control dilution ratio
(g) Unheated umbilical chord to be provided for transportation of the diluted sample, zero
air, vacuum pressure, and calibration gas. This chord has to be a single bundle in
FRLS PVC outer sheath. The sample line has to be of PTFE.

& SECONDARY)
CLAUSE NO.
Specification CO Analsyer
SO2 Analsyer NOx Analsyer CO2 Analsyer
Requirements
Principle of Pulsed/UV Chemiluminesc Gas Filter Gas Filter

measurement Fluorescence ence correlation Correlation
technology. technology. technology
Measurement 0-1500 ppm 0-500 ppm 0 to 40% 0-200 ppm to

Range (selectable) (selectable) (selectable)
0-1000 ppm
(selectable)
Probe operating 0-300 deg C 0-300 deg C 0-300 deg C 0-300 deg.C
temp
Zero drift <1 ppb/day < 0.5 ppb/day <=1 ppm/day <0.1 ppm/day
span drift +/-1% FS/day +/-1% FS/ day +/-2% FS/day +/-1%FS/day
Lower detection <=1.0 ppb <=0.4 ppb <=1 ppm 0.05 ppm
limit.
Response time(up 100 sec 60 sec 90 sec 60 sec
to 95% of full scale)
Accuracy/Precision. +/- 1% +/- 1% +/- 1% +/- 1%
Linearity +/- 1% Full +/- 1% Full +/- 1.5% Full +/- 1% of Full
scale scale scale scale
Sample gas inlet 5 deg.C - 40 5 deg.C - 40 5 deg.C - 40 5 deg.- 40
temperature to deg.C deg.C deg.C deg.C
analyser
6.04.00 Specific requirements for In-situ (Path) type SO2/NOx, CO2 & CO analysers
Specification CO Analyser cum SO2/NOx CO2 Analyser

Requirements monitor Analyser cum cum monitor
monitor
Principle of Measurement IR absorption Differential Optical Differential Optical

Absorption Absorption
Spectroscopy Spectroscopy
Measurement Range 0-200, 0-1000 ppm, 0-300 ppm/ 0- 0-40% (selectable)
(selectable) 1500 ppm
(selectable)
Accuracy +/- 5% of FS <= 2% of
measured value
for SO2 and +/-
5% for NO2
Linearity +/-2% of FS +/-1% of +/-1% of

& SECONDARY)
CLAUSE NO.
measurement measurement
span span
Repeatability < 0.5% of Span
Response time(up to 90% < 5 sec
of full scale)
a) Temperature Drift Automatic temp

compensation
b) Zero Drift <1% span/week
c) Span Drift < 1% measured
value / week
Probe Operating 0 to 300 deg C 0 to 300 deg C 0 to 300 deg C
Temperature Range
Accessories for purging Purging system to Purging system to Purging system to
system be provided with be provided with be provided with
heavy duty blowers heavy duty heavy duty
and shutter blowers and blowers and
mechanism for shutter shutter
automatic isolation mechanism for mechanism for
of lens during purge automatic isolation automatic isolation
air failure. of lens during of lens during
purge air failure. purge air failure.
Temperature Automatic Automatic Automatic
compensation temperature temperature temperature
compensation to be compensation to compensation to
provided be provided be provided
6.05.00 Specific requirements for Particulate Emission (Dust density Stack Opacity)
monitor
Specification Requirements PARTICULATE EMISSION (Dust density
Stack Opacity) monitor
Type of Instrument * In-Situ dry type visible light (through LED)

stack
Principle of Measurement Transmission and absorption
Measurement Range 0 to 999mg/m2, (Programmable)
Accuracy 2% of FS
Linearity +/- 1% of FS
Repeatability < 1% of Span
Response time(up to 90% of full scale) < 5 sec
a) Temperature Drift +/-1% in 24 hrs

& SECONDARY)
CLAUSE NO.
b) Zero Drift < 1% span/week

c) Span Drift < 1% measured value/week
Operating Temperature Range for probe 0-300 deg.C
Filter To be provided
Accessories purging system Purging system to be provided with heavy duty

blowers and shutter mechanism for automatic
isolation of lens during purge air failure.
Temperature compensation/measurement Temperature compensation to be provided.
Further, additional 4-20 ma signal for stack
temperature through temperature transmitter
shall be provided and connected to DDCMIS.
Note: * For stack dust density measurement - In case specified type of instrument is not
suitable for the actual flue gas parameters at chimney, the contractor can provide suitable
instrument based on other proven technology for the intended application & meeting the
other technical requirements specified above, subject to Employer’s approval during detailed
engineering. Contractor shall furnish necessary documents in support of suitability and
provenness of instruments for envisaged application.
6.06.00 Specific requirements for Continuous On-line Mercury Analyser
S.NO. PARAMETER DETAILS
1 Measurement Atomic Absorption Spectrometry/ Atomic Fluorescence

Principle spectrometry.
2 Range 0-100 microgram/Nm3
6.07.00 Specific requirements for Low temp O2 and High temp O2 Analyser cum monitor
Specification Oxygen Analyser cum Low Temp. O2 Analyser cum

Requirements monitor (High temp.) monitor
Type of Instrument Non-heated In-situ dry type Heated In-situ type
Principle of Measurement Partial-pressure using Partial-pressure using
Zirconium Oxide Cell Zirconium Oxide Cell
Measurement Range 0.01% to 10% oxygen 0 to 25% oxygen programmable
up to min 0.5% of O2
Accuracy +/-1% of FS +/-1% of Full scale
Linearity +/- 1% of FS +/- 1% of FS
Repeatability < 0.5% of Span < 0.5% of Span
Response time(up to 90% < 5 sec < 5 sec
of full scale)
a) Stability 1% deviation through out life -

& SECONDARY)
CLAUSE NO.
of sensor
b) Zero Drift - < 1% span/week

c) Span Drift - < 1% measured value/week
Process Temperature 600-1600 deg.C 0-450 deg.C
Range
Filter/protection Cell shall be protected using Suitable filter to be provided
ceramic boot
Accessories purging Not applicable Not applicable
system
Temperature Yes With R/B type Automatic temperature control
thermocouples. of heating circuit through
thermostat.
Probe Length Approx. 900mm or 3 feet Approx. 2000 mm or 6 feet
6.08.00 ULTRASONIC FLOW METER FOR FLUE GAS FLOW IN STACK
Type Transit time Ultrasonic meter

Mounting Style Transducers on the duct/stack
Transducer type and material Single pair of Corrosion resistant material to be
provided
Zero and Span adjustment To be provided
Flow measurement Instantaneous Flow rate as well as totalized flow
Power supply Distribution to be arranged by the Contractor from Employer’s
terminal point.
Outputs :
Analog 4-20 mA DC galvanically isolated.
Datalink RS 232/RS485/Modbus protocol/ Ethernet TCP/IP

protocol for bidirectional communication link with
Employer’s cloud server
Display/Indication Flow meter with LCD screen backlight based local

display and keypad . If required, transmitter shall
be suitably located away from the sensor for
better access and visibility.
Recording / Totalizing/Logging To be provided
Facilities
Diagnostics False signal tolerance , power supply failure etc
Protection class IP-65 or better

& SECONDARY)
CLAUSE NO.
Ambient temperature -20 deg to +60 deg C

Accuracy <+/- 2%
Electrical connection Plug and socket
Accessories All mounting hardware required like clamping
fixtures, mechanism to remove the transducers
online, interconnecting cables to DDCMIS, cables,
flexible conduits, junction boxes etc
Purging arrangement for Cleaning sensors to be

provided. Material of all fittings shall be SS 316.
Software features Compensation for temperature and pressure and
any cross path errors.
Programming, configuration, shall be possible
from front panel.
NOTES:-
01. Hot extractive sampling type/ Dilution extractive type systems shall be provided with
dual sample probes along with all required accessories such as redundant heavy
duty pumps with continuous rated motors, moisture detection facility, pre-fabricated
heated (for sampling type only) sample lines from probes to analyser panel, solenoid
valves, filters, coolers along with level switch in gas coolers for auto draining purpose
and flow meter etc as applicable.
02. Not used

03. If the SOx, NOx, CO2 & CO ( if sampling/dilution type) analyzers do not meet the
environmental conditions specified at cl. 7.00.00 of Sub Sec IIIC-01, Section-VI, Part-
B, panel AC shall be provided in analyzer cabinets to meet the requirement.
04. For O2 Analyser, the construction of the sensor shall be such that joints between
dissimilar materials are avoided to prevent formation of cracks.
6.09.00 Connectivity with DDCMIS and provision for bidirectional communication with Employer’s
Cloud Server
1. 4-20mA signals from all the above analysers/flow meters/temperature transmitter to

DCS of respective unit.
2. RS232/ RS485 Modbus protocol/ Ethernet TCIP/IP protocol for bidirectional

communication with Employer’s Cloud Server as defined in Sub-section-IIC-C&I/
Section-VI/ Part-A.
All the accessories and cables required for connecting Analysers outputs to DCS and
provision of bidirectional communication as defined above shall be provided by Contractor on
as required basis.
7.00.00 VIBRATION MONITORING SYSTEM :

& SECONDARY)
CLAUSE NO.
Microprocessor based vibration monitoring system shall be provided for fan/pumps/motors

etc. qty. of which shall be as indicated in Appendix I to Part A.
The Vibration Monitoring System shall be furnished on a system basis including, vibration
transducers, phase marker sensor with low noise flexible cables in flexible conduit,
terminated in local terminal boxes, necessary pre-amplifier/electronics mounted in local
weather proof boxes, vibration monitors, mounting racks and cabinets etc. The vibration
monitoring system shall include all power supplies, interconnecting cabling, calibration
equipment, indicators, integrating units, signal conditioning devices and all other
accessories, erection hardware required for monitoring of Vibration at each point. The
contractor shall provide the vibration pads.
Contractor can offer up to Four Channel Vibration monitors. The allocation of channels
shall be such that loss of one monitor shall not affect more than one side of the bearing of
one machine. In the case of more than two channel Vibration monitors being provided by
the Contractor, then one spare monitor shall be provided mounted in the panel to take
care of immediate replacement of any failed monitors. Offered vibration monitors shall be
modular in construction, plug in type.
Eddy current / piezoelectric type transducers shall be used. The sensors shall be either
proximity or velocity or accelerometer type. However, the finally selected sensor type shall
also depend on recommendation of the equipment manufacturer & suitable for application
requirement which shall be finalised during detail engineering and without any extra price.
Transducers shall be furnished in weatherproof housing suitable for field conditions.
Cables/cabling from transducers local JB to Vibration Monitoring system in Control
Room/Control Equipment Room shall be provided by the Contractor.
Vibration monitoring system shall give one no. buffered output of 4-20 mA DC and two no.
of buffered raw signal for each point monitored and one no. of buffered raw signal for
each phase marker sensor. The 4-20mA signal shall be suitable for use as an input to
DDCMIS, linear in proportion to vibration velocity or displacement. Raw buffered signal(s)
shall be suitable for archiving and analysis. Monitor shall provide vibration indication
calibrated in velocity units along with provisions of changing to displacement unit (field-
programmable) for each measurement point in both horizontal & vertical planes. The
generation of alarm and trip signals is not envisaged in vibration monitoring system , the
same shall be derived in DDCMIS . However in case of vibration initiated protection of
equipments , OEM standard and proven practices shall also be considered.
The Vibration monitor with power supplies shall be mounted in a separate self standing
cabinet to be located in Control Equipment Room for the main plant auxiliaries and in
respective offsite area control rooms for offsite auxiliaries as applicable. Contractor shall
feed the vibration monitoring cabinet from redundant 24 V DC feeders from the respective
24 VDC chargers in the contractor’s scope.
The power supply arrangement for monitors shall ensure that failure of one power supply shall
not affect any monitoring function in the system. Also any power supply failure /earth fault in
any of the monitors will be isolated without affecting other monitors/ common power supply. If
230 V AC UPS power supply is required for panel PC/ desktop PC, UPS/Mini UPS for the
same shall be provided by the contractor.
The functional requirement for vibration monitoring system shall include but not be limited
to the following:
- Vibration monitor front face status indications shall be available for indications of
healthy conditions of pick up circuit, monitor circuit and power supply. On sensor

& SECONDARY)
CLAUSE NO.
fault/wire break in the sensor circuit, the system shall have the feature of identifying the
same through suitable means like the signal forced to a value less than 4 mA. In case,
such a feature is not available then suitable contact shall be provided from the monitor
for sensor fault.
- The facility shall be available for online functional checking of monitors.
- All vibration monitoring equipment shall be functionally tested for circuit continuity and
output response. All the components & interconnection cables shall be tested to ensure
compliance with the specification requirements & all other applicable codes &
standards.
In case it is the proven standard practice of a Contractor to provide vibration monitoring PC

with TFT LCD monitor, instead of dedicated monitors with the signal conditioning equipment
in control equipment room, the same shall also be acceptable. However, all relevant
functional requirements detailed above shall be met and the system shall be subject to
Employer’s approval.
8.00.00 E-P Converter

E-P converters and associated accessories shall be furnished in accordance with the
specifications given below :
A. Fail Freeze Type E/P convertes

:
1 Air supply Pressure 2 kg/sq. cm.
:
2 Input signal 4-20mA DC
:
3 Output signal 0.2 to 1.0 kg/sq. cm
:
4 Linearity 0.5% of span or better.
:
5 Span/Zero Adjustment To be provided
:
6 Hysteresis 0.5% of span or better.
: Stay put at last position on failure of 4 –20mA
7 Fail Freeze Feature signal.
:
8 Allowable drift rate Maximum 2% set point/ hour.
Ambient Temperature :
9 Effect less than 0.02% of span per deg C between -
:
10 Mounting Surface/Pipe/Bracket Mounting.
:
11 Protection class IP 65.
:
12 Connection Port Sizes ¼ inch NPT (F)
:
13 Electrical Cable Entry ½ inch NPT
Output Pressure :
14 Gauge 1/4 inch NPT connection, 2 inch dial.

& SECONDARY)
CLAUSE NO.
: All accessories like mounting brackets, fittings

15 Accessories etc. required for installation is to be supplied.
B. FaiL Safe type E/P converters
1 Air supply Pressure : 2 kg/sq. cm.
2 Input signal : 4-20mA DC
3 Output signal : 0.2 to 1.0 kg/sq. cm
4 Linearity : 0.5% of span or better.

5 Span/Zero Adjustment : To be provided.
6 Hysteresis : 0.5% of span or better.
Output shall drive to minimum on failure of
7 Fail Safe Feature : either 4-20mA signal or air supply.
8 Mounting : Surface/Pipe/Bracket Mounting.

Ambient Temperature less than 0.02% of span per deg C between
9 Effect : -20 to +60 deg C.
10 Protection class : IP 65.
11 Connection Port Sizes : ¼ inch NPT (F)
12 Electrical Cable Entry : ½ inch NPT
13 Output Pressure Gauge : 1/4 inch NPT connection, 2 inch dial.

All accessories like mounting brackets,
fittings etc. required for installation is to be
14 Accessories : supplied.
9.00.00 NOT USED
10.00.00 AMBIENT AIR QUALITY MONITORING STATION (AAQMS) (Not Applicable)
10.01.00 General Specifications for AAQMS
10.01.01 The Analysers / Monitors should be 19" Rack Mounted with the ON / OFF switch and display
of all important status signals including Lamps, etc should be preferably on the front panel.
10.01.02 The system must function properly in the weather and atmospheric conditions mentioned in
Sub-Section-IIIC-01, in view of ambient temperature, relative humidity and high dust levels
for instruments / equipments housed in an enclosure.
10.01.03 The system should function without frequent servicing / maintenance. The parts requiring
regular service / maintenance must be easily accessible.

& SECONDARY)
CLAUSE NO.
10.01.04 All ambient Gas Analysers and Dust Monitor shall conform to the US EPA reference or
equivalent method. A proof of approvals and certificates of the above compliance along with
copy of the Test Report (in English) from internationally reputed agencies such as US EPA,
TUV / UAB of Germany, Envt Canada, Envt. Japan, EEC etc shall be furnished.
10.01.05 All Analysers shall be micro-processor controlled with automatic calibration. All Analysers,
Monitors and Sensors should be fully integrated in the 19” Rack Cabinet, fully calibrated and
tested before supply.
10.01.06 The vendor shall provide warranty and Comprehensive Annual Maintenance Contract for the
entire system as defined elsewhere in the Contract. Services to be provided during Warranty
and CAMC period shall be as per clause no. 19.03.00,19.04.00 and 19.05.00, Sub-Section-II-
C, SECTION-VI, PART-A.
10.01.07 NOT USED.
10.01.08 Vendor shall give complete list of spares, consumables etc. along with their costs required for
trouble-free operation.
10.01.09 The system shall be supplied with all ancillaries and consumables necessary for trouble free
operation during the Warranty period. In case self-life of any consumable is shorter, such
supplies to be done in suitable phases. Vendor shall give details of self-life, quantity of
consumables required etc. to last the warranty period.
10.01.10 O&M Manuals shall be supplied in line with the general requirement indicated in sub-section
GTR indicating details of installation, operation and calibration; preventive, routine &
corrective maintenance.
10.01.11 A Sampling System compatible with the Analysers / Monitors for Total Suspended
Particulates (TSP), PM10 PM2.5, NOx, SOx, CO, Mercury and Ozone shall be provided by
the vendor. The system, wherever applicable, shall also be compatible with Analysers for Pb
(which the Employer may procure in future). The system, wherever applicable, shall have
the facility for moisture removal.
10.01.12 Minimum requirements like power supply, space, building, ventilation & approach road
required for installation and commissioning of the AAQMS shall be specified by the vendor in
the offer. Vendor shall obtain statutory and other clearances for purchase, commissioning
and operation & maintenance of the AAQMS.
10.01.13 Vendor shall furnish, along with the bid documents, the details of calibration system provided
with each Analyzer / Monitor.
10.01.14 In addition to connection with respective local data logger and central data logger as defined
in subsequent clauses, AAQMS analysers shall have provision for bidirectional connectivity
with Employer’s central cloud server as defined in Sub-section-IIC-C&I/ Section-VI/Part-A.
10.02.00 SPECIFICATIONS OF CONTINUOUS MONITORING AMBIENT AIR ANALYSERS
10.02.01 Oxides of Nitrogen (NO-NO2-NOX) Analyser
1. Principle Chemi-luminescence

& SECONDARY)
CLAUSE NO.
2. Measurement NO, NO2, NOx in Ambient Air
3. Display LCD
4. Ranges 0-1000 PPB in multi-ranges (minimum four

selectable ranges) Preferably as below:
0-100 PPB, 0-200 PPB, 0-500 PPB and 0-1000

PPB
5. Minimum Detectable Limit 1 PPB
6 Noise Level 0.5 PPB or less
7 Zero Drift at Lowest Range <1PPB in 24 hours
8 Span Drift at Lowest + 2% in 7 days of full scale

Range
9 Response Time at Lowest 2 minutes or less

Range
10 Linearity + 1% of full scale
11 Calibration Built-in Calibration Facility
12 Consumables and spares Recommended requirements of 3 years of

continuous operation
13 Digital Signal RS 232 link. Analyser shall be capable to

Transmission transfer all the data through RS 232 link to a
PC based data logger.
10.02.02 Sulphur Dioxide (SO2) Analyser
1. Principle UV Fluorescence
2. Measurement Sulphur Dioxide in Ambient Air
3. Display LCD
4. Ranges 0-1000 PPB in multi-ranges (Minimum four

selectable ranges) Preferably as below:
5. 0-100 PPB, 0-200 PPB, 0-500 PPB and 0-1000

PPB

& SECONDARY)
CLAUSE NO.
6. Minimum Detectable Limit 1 PPB
7. Noise Level 0.5 PPB or less
8. Zero Drift at Lowest <1PPB in 24 hours with automatic zero

Range Compensation.
9. Span Drift at Lowest + 2% in 7 days of full scale

Range
10. Response Time at Lowest 2 minutes or less

Range
11. Linearity + 1% of full scale
12. Calibration Built-in Calibration Facility
13. Consumables and spares Recommended requirements of 3 years

Continuous operation
14. Digital Signal RS 232 link. Analyser shall be capable to

10.02.03 NOT USED
10.02.04 Continuous ambient air measurement of TSP, PM 10 & PM 2.5
Principle The suspended Particulate Matter (SPM)

Monitor for monitoring ambient air shall be
based on the principle of beta attenuation by
particulates sampled through the instrument
and collected on movable filter tape. Before
and after sampling, beta radiation shall be
measured by appropriate counter. An internal
microprocessor shall handle all sequences and
automatically calculate the concentration of the
particulate matter being measured. Contractor
shall provide two nos SPM analysers in each
AAQMS station for continuous measurement of
suspended particulate matter. Each analyzer
shall be designed for measurement of TSP,
PM 10 & PM 2.5 so that any analyzer can be
freely configurable at site for either TSP, PM
10 & PM 2.5. These analysers shall be
provided with sampling heads suitable for
continuous measuring of TSP and PM10.

& SECONDARY)
CLAUSE NO.
Additional sampling arrangement for PM 2.5

shall also be provided and it shall be possible
to easily connect it to the Analyser normally
measuring TSP.
Measurement Continuous ambient air measurement of TSP,

PM10 & PM 2.5.
Sampling System System for sampling of particulates of following

sizes
(a) Total Suspended Particulates (TSP)
(b) 10 microns or less.
(c) 2.5 microns or less.
The system shall have provision for removal of

moisture from the sample, wherever
applicable.
Measurement Range 0-2000 microgram per cubic meter

(microgram/m3) in programmable multi-ranges
Display LCD
Resolution 1% of the concentration
Minimum Detectable Limit 2 micrograms/m3
Filter material glass fiber filter
Roll length Approximately 30 meters
Measurement result 1 hour average of or shorter
Digital Signal RS 232 link. Analyser shall be capable to


& SECONDARY)
CLAUSE NO.
10.02.05 Multi-Gas Calibration System
To cross check the built-in-calibration facility of the Analysers/Monitors, a standard Multi-

Gas Calibration System for each AAQMS station with fast response time shall be offered by
the Vendor for SO2 and NOx (Vendor to give complete details thereof) which can be used
as manual or remote multi-point generation of gas concentrations from one to several high
concentration Span Gas Cylinders. The Multi-Gas Calibration System shall meet the US
EPA or TUV/UAB of Germany, Envt Canada, Envt Japan, EEC etc. requirements.
10.02.06 Mercury Analyser

1.
Principle Atomic Absorption/Atomic Fluorescence
2.
Measurement Elemental Mercury in ambient air
3
Display LCD
4
Range 0.5-2000ng/m3 / 5-10000 ng/m3 (selectable)
5
Calibration Built-in calibration facility
6
Digital Signal Transmission RS232 link. Analyser shall be capable to transfer
all the data through RS 232 link to a PC based
data logger.
7
Accessories To be provided
10.02.07 Ozone Analyser
1 Principle UV Photometric / Chemiluminescence
2 Measurement O3
3 Display LCD
4 Ranges 0-100 ppb to 0-10 ppm.
5 Minimum detectable limit 0.6 ppb (RMS)
6 Zero drift < 1.0 ppb
7 Span drift +/-1% of measured value /week
8 Response time (upto 95% 20 Seconds.

of full scale)
9 Linearity 1% of Full-Scale

& SECONDARY)
CLAUSE NO.
10 Calibration Built-in Calibration facility
11 Consumable and Spares Recommended requirement of 3 year continuous

operation
12 Digital signal transmission RS 232 link. Analyser shall be capable to transfer

all the data through RS 232 link to PC based Data
logger.
13 Accessories To be provided.
10.02.08 Carbon Monoxide (CO) Analyser
1 Principle NDIR spectroscopy
Measurement CO
Display LCD
Ranges 0-1 PPM to 0-1,000 PPM selectable.
Minimum detectable limit 0.05 ppm
Zero drift at lowest range < 0.1 ppm/day
Span drift at lowest range < 1% of reading per day
Response time at lowest <60 sec.

range
Linearity 1% of Full-Scale
Precision 0.5% of reading
Calibration Built-in Calibration facility
Consumable and Spares Recommended requirement of 3 year continuous

operation
Digital signal transmission RS 232 link. Analyser shall be capable to

transfer all the data through RS 232 link to PC
based Data logger.

& SECONDARY)
CLAUSE NO.
10.03.00 SPECIFICATIONS OF METEOROLOGICAL SENSORS
10.03.01 Specifications of Wind Speed Sensor
1. Principle Frequency proportional to wind speed
2. Range 0-60 m/ sec
3. Accuracy 2 % of full scale
4. Threshold 0.3 m/ sec
5. Operating Temperature 0 to 50 deg C
10.03.02 Specifications of Wind Direction Sensor
1. Principle Potentiometric type Sensor (Resistance

proportional to Wind direction)
2. Range 0-360 deg
3. Accuracy 2 % of full scale
4. Threshold 0.3 m/ sec
10.03.03 Specifications of Air Temperature Sensor
1. Principle RTD (Platinum) Resistance proportional to

temperature
2. Range 0-50 deg C
3. Accuracy + 0.2 deg C
5. Radiation Shield Non-aspirated Radiation Shield

& SECONDARY)
CLAUSE NO.
10.03.04 Specifications of Relative Humidity (Rh) Sensor
1. Principle Thin film capacitance type sensor
2. Range 0-100% RH
3. Accuracy 3 % for range 10% to 90%
4. Sensitivity 0.2% RH
6. Radiation Shield Non-aspirated Radiation Shield
10.03.05 Specifications of Solar Radiation Sensor (Solarimeter)
1. Principle Thermopile/Thermo couple based with

Appropriate Wind Shield
2. Range 0.3 to 60 microns
3. Measurement Range 0-1500 watt/m2
4. Accuracy + 3.5 %
10.03.06 Specifications of Rain Gauge
Rain Gauge shall be of Self Recording Type and of reputed make & recording facility shall be
provided in Electronics. The Gauge shall be rugged having material of construction resistant
to atmospheric corrosion. The Instrument shall have automatic functions for computing
rainfall for pre set time periods.
1. Accuracy + 1 % to + 5% for rainfall rates Ranging from

the lowest to 125 mm/hr or more
2. Sensitivity 0.5 mm
10.03.07 Meteorological Mast
One Meteorological Mast of telescopic type and of specified height to be placed on an

existing structure (such as Buildings etc) so that height of the Meteorological Sensors from
the Ground Level (GL) is 10 meters. The Mast is required for mounting the Meteorological
Sensors. Necessary Hangers and Holders along with electrical Grounding Set shall be

& SECONDARY)
CLAUSE NO.
provided by the vendor for installation of the Sensors. Material of Construction of the Mast
shall be metallic and robust and shall be resistant to atmospheric corrosion.
11.00.00 DATA LOGGER AT AAQMS & METEOROLOGICAL STATION (Not Applicable)
a) There shall be one PC based Data Logger for each AAQMS and Meteorological
Station. The entire data capture and mean value calculation as well as control of
Analyzers should be through user-.friendly software and operate on the latest
Windows software system. Connection of Analyzers with serial Interface should be
done through standard Connectors. Diagnostic features should be clearly indicated
by the system and any unauthorized access should be protected by a pass word.
PPB to micrograms per cubic meter (ug/m3) conversion factors should be part of the
system.
b) The Data Logger shall be provided with at least 8 Analog and 24 Digital Inputs and
internal memory for all collected parameters. The Data Logger shall have ability to
log Channels at different intervals and should have capability of averaging and
displaying real time data and averaged data over selectable periods (minutes, hours,
days, months and years) such as 1 min, 10 min, ½ hr, 1 hr., 4 hrs., 8hrs., 24 hrs., 1
month, 3 months, 6 months, year etc. It shall have adequate capability of connecting
to all Analysers/ Monitors including the optional Analysers and Sensors for
meteorological parameters.
11.01.00 Functional Requirements of Data Logger
1. Calculate vector mean of wind direction and wind speed
2. Graphic & tabular display of the current air quality monitoring data.
3. Generation of Wind Roses, Pollution Roses etc.
4. Data reports, calibration reports and status reports for user selectable time period
(instantaneous or averaged over a period of ½ hr, 1 hr, 4 hrs, 8 hrs, 24 hrs, weekly,
monthly or yearly).
5. Control panel window for controls of each Analyser, including calibration.
6. Alarm for all parameters.
7. Real time multi-curves/graphs over user selectable time period.
8. Historic multi-curves/graphs over user selectable time period.
9. Real time status and diagnostics for maintenance people.
10. Programmable down loading of data.
11. Diurnal variation, standard deviation, regression and other statistical parameter
reporting possibilities with various available models.
12. Possibility to export the data files in other formats.

& SECONDARY)
CLAUSE NO.
11.02.00 Central Station for AAQMS
There shall be separate Data Logger for the Central Station having configuration similar to
the individual AAQMS. Location of central station shall be in one of the unit control room.
11.03.00 Data Communication System for The Central Station
11.03.01 Data Communication system shall handle the data transmission of an ambient air quality
network and receive incoming messages/ signals from remote Stations. The following
additional features should be part of the system:
1. To collect all the data from the remote Stations at prescribed time or on request.
2. Manage at least 3 or more remote air quality-monitoring Stations.
3. Should have the remote control facilities for calibrations (Zero & Span) and
Measuring Range.
4. Should display multiple Stations on-line data (momentary values) in tabular text
and graphic format.
5. Should connect the remote stations through Wireless Communication link.
11.03.02 Additional features of the Data Logger at Central Station
1. Data Management, analysis and reporting
2. Latest Microsoft Windows operating System
3. 32 bit application
4. Data collection from remote stations via Data communication Server
5. Inter-comparison of data between monitoring stations
6. Comparison of data of various parameters for the same monitoring station.
7. Integrates charts, tables and graphics.
8. Should support primary and secondary mean values of user defined time interval.
9. Should have data backup facilities
10. Should have the facilities for calculation of Arithmetic mean values, average ½ hr, 1
hr, 2 hrs, 3 hrs, 4 hrs, 8 hrs, 12 hrs, 24 hrs, weekly monthly and yearly
11. Minimum, Median, percentile, Maximum, standard deviation frequency analysis and
cumulative frequency analysis
12. Calculation of pollution load and Wind Roses

& SECONDARY)
CLAUSE NO.
13. Reports of daily, weekly, annual and user defined period
14. Reports of Pollution load and Wind Roses, frequency analysis, and calibration
15. Should have the facilities of the following chart types:
 Line & column chart
 Simple 3 D, line & column chart
 Polar diagram and 3 D perspective column chart
11.03.03 Data Communication System
Each AAQMS station shall be connected to Central data Acquisition station through a two
way wireless communication link. This shall allow for wireless transmission of data
periodically to individual and central DAS & do the necessary communication between
stations. Bidders shall determine the optimal antenna type required to achieve data transfer
rate between all wireless access points. Contractor shall use for this purpose, approved and
standard equipment like antennas and/or amplification devices etc required to achieve the
above and shall provide agreement of technical support and support availability.
Contractor shall obtain necessary approval for Licenses authorizing the use of
communication equipment specified frequencies.
12.00.00 SPECIFICATION FOR CORIOLIS FLOW TRANSMITTER
Type Coriolis
Material of Wetted Parts 316 SS
Material of Housing 304L SS
Accuracy ± 0.2% of Rate
Repeatability ± 0.1% of Rate
Output 4-20 mA DC, HART Compatible
Power Supply 230 VAC or 24VDC operated
Process Temperature range 0-200 degree Celsius
Others Drain / purging arrangement shall be

provided as per standard practice.
Viscosity range of Fluid 0-500cst for HFO
The offered Coriolis type flow transmitter shall be suitable for intended application. Contractor
shall submit flow and sizing calculation for Employer’s approval. For each type of Coriolis

& SECONDARY)
CLAUSE NO.
type flow transmitter general arrangement and assembly drawing and cable wiring diagram
shall be submitted for Employer’s approval.
13.00.00 SPECIFICATION FOR FLOW ELEMENTS
13.01.00 Orifice Plate

Features Essential/Minimum Requirements
Type Concentric as per ASME PTC-19.5 (Part-II), ISA RP-
3.2, 1960 or BS-1042, ISO 5167
Material 316 SS
Thickness 3 mm for main pipe diameter up to 300 mm and6 mm
for main pipe dia above300 mm.
Material of branch pipe Same as main pipe
Root valve type Globe
Root valve material Same as pipe material
Root valve size 1 / 2 inch or 1 inch (as applicable)
Impulse pipe of same material up Required
to root valve
Tappings Flanged weld neck or D & D/2 with 3 pairs of tapping (
as applicable ). Root valves to be provided in all the
tappings. However for flow elements in CPU, DM & PT
plant- 2 Pairs of Tappings shall be provided as
minimum.
Beta Ratio 0.34 to 0.7
Beta Ratio calculation to be Yes
submitted
Assembly drg. and flow Vs DP Yes
Curves
Accessories Root valves, flanges, Vent/drain hole(As required)
Contractor shall submit certified flow calculation and differential pressure vs. flow curves for
each element for Employer's approval. Sizing calculation, precise flow calculation for all the
flow elements, fabrication and assembly drawings and installation drawings shall be
submitted for Employer's approval.
13.02.00 Flow Nozzle
Type Long radius, welded type as per ASME PTC-

19.5 (Part-III) or BS-1042
Material 316 SS
Thickness Suitable for intended application.

& SECONDARY)
CLAUSE NO.
Material of branch pipe Same as main pipe
Root valve type Globe
Root valve material Same as pipe material
Root valve size 1 inch
Impulse pipe of same material up to root Required

valve
Tapping Flanged weld neck or D & D/2 with 3 pairs of

tapping ( as applicable ). Root valves to be
provided in all the tappings. However for flow
elements in CPU, DM & PT plant- 2 Pairs of
Tappings shall be provided as minimum.
Beta Ratio Around 0.7
Beta Ratio calculation to be submitted Yes
Assembly drg. and flow Vs DP Curves Yes
Accessories Root valves, vent and drain hole.
Contractor shall submit certified flow calculation and differential pressure vs. flow curves for
each element for Employer's approval. Sizing calculation, precise flow calculation for all the
submitted for Employer's approval.
13.03.00 Venturi (For Liquid applications)
---------------------------------------------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------------------------------------------
Type Rough Welded (for Pipe dia between 200mm to
1200mm) or Machined (for Pipe dia 50mm to
250mm) as per ISO 5167-4:2003,
Material Same as Main Pipe
Thickness Same as Main Pipe.
Root valve type Globe Type
Root valve material Same as Pipe material
Root valve size 1 inch
Impulse pipe of same material Required

up to root valve
Tapping 3 pairs of tappings for each Venturi as per ISO

5167-4:2003, However for some areas like CPU,

& SECONDARY)
CLAUSE NO.
DM & PT plant- 2 Pairs of Tappings shall be

provided as minimum.
Beta Ratio 0.4 to 0.7
Beta Ratio calculation to be Yes

Submitted
Assembly drg. and flow Yes

Vs DP Curves
Accessories Root valves, vent and drain hole.

---------------------------------------------------------------------------------------------------------------------------
Contractor shall submit certified flow calculation and differential pressure vs. Flow curves for
each element for employer's approval. Sizing calculation, precise flow calculation for all the
submitted for employer's approval.
13.04.00 ROTAMETERS
Sr. Features Essential / minimum requirements

No.
1. Type Variable Area Metal Tube
2. Fluid media Water/oil
3. Tube body SS316
4. Material of float 316 SS

5. Indicator Linear scale
6. Accessories Flange, orifice in case of bypass Rota meter (for line size
above 100 mm)
7. Housing protection IP-55
class
8. Accuracy + 2% of measured value.
14.00.00 NOT USED

& SECONDARY)
CLAUSE NO.
15.00.00 PROCESS ACTUATED SWITCHES
FEATURES ESSENTIAL / MINIMUM REQUIREMENTS

Pressure/ Draft Temperature Level switches
Switches/ DP switches
Switches
Sensing Piston actuated Vapor pressure Capacitance types, float type,
Element for high pressure sensing, liquid conductivity type, RF type,
and diaphragm or filled bellow Ultrasonic type as per suitability to
bellows for low type with SS the application. .
pr./ vacuum bulb and
capillary (5 m
minimum, to
suit application)
Material 316 SS Bulb 316 SS/ 316 SS

capillary 304 SS
End ½ inch NPT (F) ½ inch NPT (F) Manufacturer standard
connection
Over range/ 150% of - 150% of maximum operating pr.
proof pressure maximum
operating pr.
Repeatability +/- 0.5% of full range
No. of contacts 2 No.+2NC. SPDT snap action dry contact
Rating of 60 V DC, 6 VA (or more if required by DDCMIS)

contacts
Elect. Plug in socket.
Connection
Set point Provided over full range.
adjustment
Dead band Adjustable/ fixed as per requirement of application.
adjustment
Enclosure Weather and dust proof as per IP-55, metallic housing.
Accessories Siphon, snubber, Thermo well of All mounting accessories

chemical seal, 316 SS and
pulsation packing glands
dampeners as
required by
process
Mounting Suitable for Suitable for rack -
enclosure/ rack mounting or
mounting or direct mounting
direct mounting

& SECONDARY)
CLAUSE NO.
Power Supply As per Contractor’s Standard practice.

(wherever
required)
Notes :-
1) Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be removable
for cleaning. The entire volume above the diaphragm shall be completely filled with
an inert liquid suitable for the application.
2) Pressure/ Diff pressure switches for very low press/ DP measurements can have
sensor material other than SS316 in case of any technical limitation and the offered
product is standard product of the manufacture for very low pressure applications.
3) Repeatability can be upto +/-1% of full range in case of switches with diaphragm
seals or very low pressure/DP range.
4) The specifications of switches for air conditioning & ventilation system / process can
be as per system manufacturer’s standards. The manufacturer shall submit the
adequate supporting documents for establishing their standard practice.
16.00.00 NOT USED
17.00.00 SOLENOID VALVES

Solenoid valves shall fulfil the following requirements:
a. Type 2/3/4 way SS 316/Forged Brass (depending on the application subject to

Employer’s approval during detailed Engg.)
b. Power supply : 24 V DC + 10%.
c. Plug and socket electrical connection.
d. Insulation : Class ‘H’

e. IP Class : IP65
18.00.00 REVERSE ROTATION INDICATOR (RRI)

Reverse rotation indicator comprising of proximity sensors, processing electronics with
output of 4-20mA (corresponding to speed) interconnecting cables, speed display in rpm,
normal, reverse indication and required channel alarm contact shall be provided. The contact
rating shall be 60VDC, 6VA (or more if required by Control system). The exact details of the
RRI shall be strictly as approved by Employer during detailed engineering. The power supply
of RRI is to be arranged by the Bidder.

& SECONDARY)
CLAUSE NO.
19.00.00 WATER SYSTEM RELATED SPECIAL INSTRUMENTS (DM PLANT, CPU PLANT, PT
PLANT, ETC)
19.01.00 ANALYSER INSTRUMENTS:

For Technical specification of Cation/Specific Conductivity, pH, Sodium, Silica, Turbidity,
Total Dissolved Solids (TDS. please refer Specification of Analysers, Part-B, Sub-section
IIIC-13, SWAS chapter of this specification. Specification of concentration analyser shall be
similar to Conductivity analyser except range which shall be as per process requirements.
19.02.00 Residual Chlorine Analyser
a An automatic chlorine residual analyser of amperometric type shall be provided

alongwith the chlorinating plant for monitoring the residual chlorine content of cooling
water. The analyser shall be suitable for accurate residual measurement in
open/closed systems. The measurement accuracy shall not be affected by presence
of treatment chemicals as chromates, phosphates, de-former highly polluted water,
change in temperature etc.
b The analyser shall comply with the following specification requirements, as a
minimum
(i) Indicator : Provision of LC display in the panel of analyser.
(ii) Range : 0 to 20.0 mg/L (ppm)
(iii) Accuracy : 2% or better
(iv) Sensitivity : 0.01 mg/1
(v) Output signal : 4-20mA DC isolated output,
(vi) Alarm : High and low alarms to be provided on panel and
annunciation shall be field adjustable.
(vii) Calibration : Zero and span adjustment facility to be provided.
Final calibration adjustments of the analyser to be
done at site and duly verified by titration.
Temperature compensation range 0 to 50degC.
(x) Mounting : The analyser shall be suitable for field mounting
conform to protection class IP-55.
(xii) Electrodes : Platinum/Gold and copper electrodes shall be
provided with cell cleaning system.
(c) Circulating water as sample to residual chlorine analyser shall be taken from hot
circulating water pipe work before entry to cooling towers. Exact location and layout of
sampling arrangement shall be finalised during detailed engg. stage. Bidder shall
provide necessary pumping system (with 100% standby) for meeting the analyser
requirements, if needed. All the drains shall be terminated up to the nearest plant
drainage system.
19.03.00 All the outdoor field instruments such as analysers/transmitters/meters etc. shall be provided
with suitable Free standing cabinet(s)/panel/rack so that the equipments are protected
against rain/ sunlight etc.

& SECONDARY)
CLAUSE NO.
19.04.00 Parshall Flume
The Bidder shall provide all the control and Instrument devices including primary sensors,
transmitters, flow indicator cum integrator / totaliser and shall include all required
accessories for the flow measurement of raw water through the clarifier. The system shall
be of reputed make and acceptable to the owner.
Level measurement shall be based on ultrasonic/radon technology. The flow compensation
is to be implemented in the transmitter itself. The transmitter shall provide 4-20 mA DC in
direct proportion to flow and shall be able to drive a load impedance of 500 ohms minimum
Accuracy shall be +/- 1 % or better.
All the mounting hardware and accessories required for erection and commissioning of the
same are to be provided by the contractor. Mounting fittings material shall be SS316. All
weather canopy is to be provided for electronics/sensor to protect the same from rain/
sunlight etc.
The Type makes and models no. shall be subject to Owner’s approval.
19.05.00 Electronic Flow-Meter
The electronic flow meter shall include flow sensor and flow indicator cum integrator /
totaliser and shall include all required accessories for satisfactory operation. The flow
meter shall be based on full bore electromagnetic principle and shall be electronic type of
proven design, make and model acceptable to the owner.
The Bidder shall submit all necessary technical literature and details of selection criteria of
the instrument offered to substantiate the model selected. The Bidder shall also furnish list
of similar installation along with feed back on satisfactory performance of the instruments.
The flow meter shall meet or exceed the following requirement :
(a) Output : 4-20 mA DC Isolated output
(b) Accuracy : ± 0.5% of calibrated span or better *
(c) Repeatability : ± 0.2% of calibrated span or better
(d) Power Supply : 240V AC ± 10%, 50 HZ ± 5%/ 24 V DC, to be arranged
by the contractor.
(f) Protection class : IP-55
(e) Flow tube SS304
(f) liner Hard Rubber
The flow meter shall provide local indication for instantaneous flow. It should also be
possible to get local display for daily and monthly discharge. The flow meter shall indicate
totaliser/ integrator to get the daily and monthly discharge as stated above.
20.00.00 AC PLANT RELATED SPECIAL INSTRUNMENTS
20.01.00 HUMIDITY SENSOR
Sensor : Capacitance type

Accuracy : +/-3% R.H
Range : 0-100% R.H
Output : 4-20 ma

& SECONDARY)
CLAUSE NO.
Time constant : 2 mins.

Output from the sensor is to be connected to respective control system. Contractor can also
provide combined instrument for measurement of humidity and temperature subject to
Employer’s approval during detailed engineering. In all such cases, 4-20 ma outputs, each
for temperature and humidity measurements are to be provided.
20.02.00 TEMPERATURE/ HUMIDITY INDICATOR
Sensor : RTD for( Pt 100 ) for temperature

: Capacitance Type for Humidity (specs for humidity and temperature shall
be as mentioned above)
Display : Combined enclosure with two three digit seven segments LED display
with decimal point after two digits. LED height shall be 4 inches, clearly
legible from a distance of at least 10 meters.
Range : 0-60 Deg C for temperature.
: 0-95.0 % for Relative Humidity.
Accuracy : Better than +/_0.5 % for Temperature
: Better than +/_2.5 % for Relative Humidity
Mounting : Table Top/ wall mounting.
Power : 240 V AC, 50 Hz.

supply
Output : 4-20 mA signal each for temperature.
Qty. : 15 nos. each of temperature & Humidity indicators ( combined indicators
for Humidity and temperature is also applicable).
One Set of output signal is to be connected to respective control system. Apart from
displaying the temperature/humidity values on indicator.
21.00.00 Limit switches
For offsite plant (except PT, DM, Chlorination, chemical treatment, Liquid effluent treatment)
application Limit switches shall be silver plated with high conductivity and non corrosive type.
Contact rating shall be sufficient to meet the requirement of DDCMIS subject to a minimum of
60 V, 6 VA rating. Protection class shall be IP 55.
For main plant application limit switches are to be provided as per contractor standard and
proven practice.
For PT, DM, Chlorination system , chemical treatment, Liquid effluent treatment plant , limit
switches of manual valves and solenoid operated on-off valves shall be of inductive
proximity type and shall be mounted inside the enclosure: pl. refer the minimum specification
requirement below .
Operating voltage Range 10‐40 V DC
Sensing system Inductive Proximity type , 2 Wire

& SECONDARY)
CLAUSE NO.
Sensor Contact Type NO
Reverse polarity and short circuit protection Yes
IP Class‐Sensor IP67
IP Class‐Enclosure(Switch box) IP67
Cable entry‐Enclosure(Switch box) 2no‐1/2" NPT
Casing material‐Sensor Brass /SS
Enclosure(Switch box) Housing material FRP or SS
Operating Ambient temp(sensors) ‐5 to 70 deg C
Max allowed Voltage Drop across sensor 5 V
Standard applicable EN 60947‐5‐2 or equivalent.
22.00.00 NOT USED.
23.00.00 Monitoring System for Coal Bunker, Fly Ash Silo and ESP Hopper (First Field)
Complete Level Monitoring System comprising of Acoustic Frequency Based 3D Level

Scanners, PC, electronic modules, splitters, modems, junction boxes, mounting kit,
enclosures, interconnecting cables, software and all other accessories required to make the
system complete and fully functional, shall be provided on as required basis for continuous
level measurement and monitoring of level of each coal bunker, each Fly Ash Silo and each
ESP Hopper (First Field of ESP Only) complying with following requirements:
S. No. Feature Requirements

One Set of Non-Contact Acoustic Frequency Waves
1 Type Based 3D Level Scanner for each Coal Bunker, each
Fly Ash Silo and each ESP Hopper (First Field)
2 Protection Class IP-65 or Better
3 Housing and Antenna Die-Cast Aluminium
4 Accuracy 1% or Better
Empty to Full (Coal Bunker, Fly Ash Silo and ESP
5 Measurement Range
Hopper as applicable)
6 Power Supply 24V DC For 3D Level Scanner, 230V AC for LMS PC
For Each Bunker Bay, One Set of Local Indicators
mounted at Tripper Floor for respective coal bunkers
in that Bay.
Local Indicator One Set of Local Indicators for Fly Ash Silos.
7 (Applicable for Coal Above Local Indicators shall display Average Level of
Bunker and Fly Ash Silo) each Coal Bunker/Fly Ash Silo.
Local Indicator shall be mounted inside an Enclosure
with Transparent Window for Viewing.
Degree of Protection of Enclosure – IP55 or Better
8 LMS PC 1 No. PC Per Unit (in Programmer Room in Main

& SECONDARY)
CLAUSE NO.
Plant CCR/CR) for Coal Bunkers.

1 No. PC Per Unit (in ESP Control Room) for ESP
Hoppers.
1 No. PC (in AHP Control Room) for Fly Ash Silos.
Above PCs shall display Average Level, Maximum
Level, Minimum Level, Volume, Mass and Real Time
Complete 3D Profile of each Coal Bunker/Fly Ash
Silo/ESP Hopper (First Field).
The minimum specifications of LMS PC shall be as
specified in Sub-Section-DDCMIS, Section-VI, Part-B.
4-20 mA signal shall be hardwired to corresponding DDCMIS for displaying
Average Level of each Coal Bunker, each Fly Ash Silo and each ESP Hopper in
the First Field of ESP. In addition to the information available in LMS PC, the
9 Contractor shall provide all required hardware and software to display the
respective information on OWS located at Main Plant CCR/CR, AHP CR and ESP
CR. Further, information available in LMS PC for Coal Bunkers shall also be
made available in CHP DDCMIS OWS.
24.00.00 DEPOSIT MONITOR

Sno Feature Details
1 Standard AS per NACE
standard RP0189‐
2002

2 Type Online, Annular flow
, scale deposition
3 Measurement Deposit weight and
average weight per
unit surface area
4 Observation 1. Online‐
Visual
Offline‐ Quantitative
by weighing heat
transfer surface
5 Accessories:‐
Qty
(i) Flow Switch 1 Nos
(ii) Flow meter ( Rota meter) 1 Nos
(iii) Manual Flow Control valve 1 Nos

& SECONDARY)
CLAUSE NO.
(iv) Skin temperature Sensor 2 Nos
(v) Temperature Controller 1 Nos
(vi) Digital Temperature Indicator 2 channel
(vii) Electric heater(Electrical resistance heating 2 Nos
element)
6 Power Supply 230VAc
7 Electric heater protection (a). No water Flow
(b).Outlet
temperature more
than set point.
25.00.00 BIO-FOULING MONITOR

Sno Feature Details
1 Standard AS per NACE standard RP0189‐2002
2 Type Online, Loss In static pressure due to
friction in the direction of flow
3 Cooling water Sample Bypass Stainless Steel
tube/pipe for DP measurement
Measurement Differential pressure
4 Accessories:‐ Qty
(i) Flow Meter 1 Nos
(ii) Manual Flow Control valve 2 Nos
(iii) Differential pressure 1 Nos
transmitter ( Across the tube)
(iv) Pressure gauge ( At Inlet) 1 Nos
(v) Strainer ( To Eliminate
suspended solids)
Eliminate suspended solids

& SECONDARY)
CLAUSE NO.
26.00.00 CORROSION METER
Sno Feature Details

1. Type of electronics Microprocessor based
2. Zero & span Adjustment To be provided
3. Ambient temp. 50°C
4. Display LCD
5. Range
Corrosion rate : 0.01 to 150MPY
Imbalance ( Pitting Index) : 0.01 to 100 pitting units
6. Accuracy : < ± 2% of reading
7. Enclosure Type / Material Weather and Dust proof (IP 65)
8. Mounting All weather Local Panel fitted with
integral Air Conditioner are to be

provided by the Contractor.

Sensor Probe Specification Requirement

Sno Feature Details
a) Type : Linear Polarization Resistance Probe ( LPR)
b) Electrodes : 2 electrode/3 electrode
c) Spares Three sets of spare electrodes for LPR probes
27.00.00 ONLINE ORP MONITOR / ANALYSER

Orp Sensor

Sno Feature Details
a) Type : Cell ‐ flow through
b) Accuracy : < ± 1mv
c) Range : ‐1400mv to +1400mv
d) Electrode : Platinum


& SECONDARY)
CLAUSE NO.

Monitor / Analyzer Specification:‐
Sno Feature Details
2. Zero & span To be provided
Adjustment
4. Display LCD
5. Enclosure Type / Weather and Dust proof (IP 65)
Material
6. Output signals Analog 4‐20 mA DC
7. Error / fault Diagnostic To be provided.
8. Power supply For power supply and distribution, refer scope /
and terminal point part of the specification.
Conversion / distribution from the terminal point
shall be done by contractor.
9. Load 500 Ohms minimum
10. Mounting All weather Local Panel fitted with integral
Air Conditioner are to be provided by the
Contractor.
28.00.00 ORP/PH PORTABLE METER

Sensor Probe Specification Requirement
Sno Feature pH ORP

b) Electrode : Glass : Platinum
c) Accuracy :< ± 1% of reading : < ± 1mv
d) Range : 0‐14 pH : ‐1400mv to +1400mv
e) Temperature Automatic
Compensation

Portable meter
Sno Feature Details
2. Measurement Ph & ORP
4. Display LCD
5. Enclosure Type / Material IP 67
6. Power source Batteries
7. Battery life >=200 hrs

& SECONDARY)
CLAUSE NO.
29.00.00 SPECIFICATIONS OF EFFLUENT QUALITY MONITORING SYSTEM (EQMS)
29.01.00 COMMON REQUIREMENTS FOR ALL ANALYSERS
Sno Features Minimum Requirement

1. Output signals Analog 4-20 mA DC galvanically isolated.
2. Zero & span Adjustment To be provided with range selection facility
3. Ambient temp 50 degC
4. Sample Temperature 40 degC
5. Indication Digital Alphanumeric Display of reading in
engineering units shall be provided.
6. Type of Electronics Microprocessor based with self-diagnostic
7. Others All interconnection tubing and cabling between
sensor and analyzer / analyzer panel etc to be
provided.
All chemical reagents required for EQMS
analyzers for entire AMC period is to be supplied
in phased manner depending on shelf life.
8. Location of the Temp & flow Effluent Treatment plant outlet (Exact location to
measurement be decided by contractor in consultation with site )
9. Location of the Analyser
cabinet/enclosure
10. Accessories All the accessories required for mounting the
sensor/analyser are to be provided
11. Digital Signal Transmission Each analyser shall have a provision for
bidirectional soft connectivity over
Modbus/RS232/RS485 with employer’s central
cloud server in addition to 4-20 ma connectivity to
DDCMIS.
12. Compliance to standards Latest regulatory requirements of
CPCB/SPCB/other regulatory/statutory body
prevailing at the time of award of the
contract.
29.02.00 CONDUCTIVITY ANALYSER
Type Continuous flow through type
Measuring Range 0 – 60000 µS/cm for sea water application

0-5000 µS/cm for other application
Response Time <= 5 sec (90% of full scale)

Temperature Compensation Automatic
Power To be arranged by the contractor

& SECONDARY)
CLAUSE NO.
Accuracy <= +/- 1 %
29.03.00 PH ANALYSER
Type Cell flow through sample
Measuring Range 0-14 units of pH

Temperature Compensation Automatic
Power To be arranged by the contractor.
Accuracy <= +/- 1 %
29.04.00 BOD BIOLOGICAL OXYGEN DEMAND / COD CHEMICAL OXYGEN DEMAND

ANALYSER
Principle COD/BOD measurement by:
Option A. Total Organic Carbon (TOC) measurement

complying to US EPA 415.1 / 415.2 or equivalent standard
for effluent/sewage/waste water.
Option B. UV-VIS spectrometer measuring absorption in

UV-VIS spectrum.
Measuring Range 0-50 mg/L for BOD, 0-500 mg/L for COD
Response Time <= 15 min
Power To be arranged by contractor
Cleaning Self-cleaning (Automatic)
Accuracy +/- 3%
29.05.00 OIL IN WATER ANALYSER
Principle UV Fluorescence
Measuring Range 0 to 30 mg/l

Response Time <= 60 sec
Power To be arranged by the contractor.
Accuracy +/- 5 % of full scale

& SECONDARY)
CLAUSE NO.
29.06.00 TOTAL SUSPENDED SOLIDS – TSS ANALYSER
Principle Light reflection principle
Measuring Range 0-500 mg/l
Response Time <= 5 min

Power To be arranged by bidder
Accuracy +/- 5%
30.0.00 ENCLOSURE/CABINETS / PANELS FOR EQMS AND ANALYSERS OF PT, LET,

CHLORINATION, DM/RO, CWT AND CPU PLANT
The enclosure shall accommodate all EQMS Analyzers. The enclosure of all analyzers shall
provide protection from dust, humidity, precipitations, sunlight and environmental pollution.
The material for the enclosure shall be of steel plate (SS304) with minimum 2 mm thick frame
and minimum 2 mm thick steel (SS-304) sheet of protection IP 65 or better with safety lock of
good quality. The lighting provision in the cabinet is to be provided. The cabinets shall be
designed such that the wet section and dry section are separate, the exact details shall be
finalized during detailed engineering. The panel shall be free standing type constructed of
suitable 3 mm thick channel frame of SS and shall be provided with a canopy to protect the
equipment mounted in racks from falling objects, water etc. The canopy shall not be less than
3 mm thick steel, and extended beyond the ends of the rack.
In order to ensure the healthy operation of the installed electronic modules, cards, analyzers,
etc inside the enclosure during continuous operation, the EQMS enclosure shall be provided
with Air conditioner unit .

& SECONDARY)
ELECTRICAL POWER SUPPLY SYSTEM
CLAUSE NO.
ELECTRICAL POWER SUPPLY SYSTEM
1.00.00 ELECTRICAL POWER SUPPLY
1.01.00 The requirements of Electrical Power Supply system are specified herein on system basis.
The Contractor shall be responsible for engineering and furnishing a complete and
operational system fully meeting the intent and requirements of this specification including
tender drawings and Employer approved drawings during detailed engineering. All equipment
and accessories required for completeness of this system shall be furnished by the
Contractor whether these are specifically mentioned herein or not. All the equipments and
sub systems offered shall be from reputed experienced manufacturers. All system cabinets,
enclosures, & distribution boards shall be manufactured, assembled, wired and fully tested
as a complete assembly as per the requirements of this specification at the manufacturer’s
works.
The Contractor shall furnish all required equipment cubicles and wiring required for
conversion and/or stabilization of the power sources provided by the Employer to all other
levels which may be necessary for meeting the individual requirement of equipment/system
furnished by him including the panel/desk mounted equipment.
1.02.00 The power supply system shall be designed to meet the electrical power requirements of
various C&I systems including DDCMIS. The Power Supply System shall be designed to give
the voltage at approximate mid level of the tolerance band of the power supply
modules/packs of Control System, when the charger is feeding the load. This shall also take
in consideration the voltage drop in cables from DCDB to the control panels. In case the
Power Supply Output of a charger exceeds the voltage band tolerated by the power supply
modules/packs of Control System, provision for safe tripping of that charger is to be ensured.
1.03.00 The DC Power Supply for various sub-systems shall consist of one or more of the following
configurations. The applicable configurations are as indicated in Appendix-1 to Part-A of
contract quantities: -
(A) NOT USED.
(B1) DC power supply system for UNIT (BOP) Area: DC power supply system shall
comprise of two sets. Each set shall consist of 1 x 100% microprocessor controlled,
intelligent, modular rectifier banks, Controller –one for each rectifier bank, 1 x 100%
batteries for one (1) hour duty, 1 X 100% DC distribution board. 1x100%
Microprocessor controlled Battery Health Monitoring System (BHMS)–common for
both the sets.
Contractor has the option of supplying either Nickel Cadmium type batteries or
Lead Acid Plante type batteries for this configuration.
The specifications for this DC Power Supply System shall be as per Cl.No.2.01.00 to
2.03.00 and specifications for Battery shall be as per Cl. No 4.00.00 for Ni-Cd type
Batteries & 5.00.00 for Lead Acid Plante type Batteries.
(B2) DC power supply system for areas other than Unit (BOP) : DC power supply system
shall comprise of two sets. Each set shall consist of 1 x 100% microprocessor
controlled, intelligent, modular rectifier banks, Controller –one for each rectifier bank,
1 x 100% Nickel - Cadmium batteries for one (1) hour duty, 1 X 100% DC
distribution board. 1x100% Microprocessor controlled Battery Health Monitoring
System (BHMS)–common for both the sets.

WATER SYSTEM PACKAGE POWER SUPPLY
CLAUSE NO.
The specifications for this DC Power Supply System shall be as per Cl.No.2.01.00 to
2.03.00 and specifications for Battery shall be as per Cl. No 4.00.00 for Ni-Cd type
Batteries
(C) DC power supply system shall comprise of 2 x100% power supply unit along with
1x100% sealed maintenance free lead Acid batteries for 30 Min back up and DC
Distribution Board. DC power supply unit along with batteries shall be housed in a
single panel. The power supply unit shall be capable of charging the batteries and
feeding the load simultaneously. The DC distribution board shall have redundant
feeders for critical loads.
The specifications for this configuration shall be as per Cl.No.2.04.00.
(D) DC power supply system shall consist of one set of 24 VDC redundant power
supply system with battery back up as per the process requirement. In case power
supply module/power packs with 24 VDC output are used, the input power supply to
the same can be either of 24 VDC/110 VAC/230 VAC/220 VDC, to be finalized
during detailed engineering. The specifications for this configuration shall be as per
manufacturer’s standard
Bidder shall clearly bring out in the proposal the redundancy features along with configuration
diagram, single line diagram & data sheets etc. and this shall be finalized and subject to
Employer’s approval during detailed engineering.
1.04.00 NOT USED.
1.05.00 The UPS Power Supply for various sub-systems shall consist of one or more of the following
configurations. The applicable configurations are as indicated in Appendix-1 to Part-A of
contract quantities.
Bidder shall clearly bring out in the proposal the redundancy feature along with configuration
diagram, single line diagram and data sheets etc. & this shall be finalized subject to
employer’s approval during detailed engineering.
(A) UPS System shall consist of 2 x 100% parallel redundant chargers and inverters with
input isolation transformers, 1 x 100% battery bank for one (1) hour, Bypass line
transformers & voltage stabilizer, static switch manual bypass switch, 2 x 100% ACDB,
1x100% Microprocessor controlled Battery Health Monitoring System (BHMS) and other
necessary protective devices and accessories.
Contractor has the option of supplying either Nickel Cadmium type batteries or
Lead Acid Plante type batteries for this configuration.
The specifications for this UPS configuration shall be as per Cl.No.3.00.00 to 3.05.00
and specifications for Battery shall be as per Cl. No 4.00.00 for Ni-Cd type Batteries &
5.00.00 for Lead Acid Plante type Batteries.
(B) UPS system shall consist of 1 x 100% charger and inverter with input isolation
transformer, 1 x 100% Ni Cd Battery Bank for 1 hour, Bypass Line Transformers and
Voltage Stabilizer, static switch, manual bypass switch, 2 x 100% ACDB, 1x100%
Microprocessor controlled Battery Health Monitoring System (BHMS) and other
necessary protective devices and accessories.
The specifications for this UPS configuration shall be as per Cl.No. 3.00.00 to 3.05.00
and specifications for Battery shall be as per Cl. No 4.00.00 for Ni-Cd type Batteries.

CLAUSE NO.
(C) On line UPS with remote monitoring having a battery backup of 30 min. The batteries for
UPS System shall be Sealed Maintenance Free type and shall be as per Control System
Vendor’s standards.
1.06.00 For distribution of UPS Supply in Main Plant Area, Contractor shall provide PDBs. The
number of PDB’s shall be as per Appendix-1 to Part-A of contract quantities.
PDBs which are to be used for the distribution of UPS Supply for HMI peripherals shall have
Static Switches mounted inside the PDB for change over. PDBs which are to be used for the
distribution of UPS Supply for all other loads shall have Auto Change over circuitry without
static switches implemented inside the PDBs. For distribution of UPS Supply in the offsite
areas, separate PDBs are not envisaged.
Each PDB shall be provided with input feeder monitoring through potential free contact wired
to DDCMIS.
The output feeders from the PDB shall be provided with separate fuse & MCB’s. 10% spare
feeders (min. 1 no.) with MCB & fuses for each rating shall be provided in Bidder’s each
PDB.
The PDBs provided for distribution of UPS loads shall be as per following guidelines.
(a) For Main Plant HMI Loads, half of the HMI load shall be distributed through one set of
static switches with input from both the ACDB’s while the other half of the HMI load shall
be distributed through other identical set of static switches.
(b) For offsite Area HMI & other loads which accept redundant inputs shall be fed directly
from redundant ACDB feeders. The loads which accept only single input feeder shall be
divided between the two ACDB’s such that even in event of unavailability of one ACDB,
half of the devices/peripherals are available.
2.00.00 DC POWER SUPPLY SYSTEM (24 V),
2.01.00 Microprocessor based, Intelligent, Modular Power Supply
The minimum capacity of the modular power supply inclusive of 10% design margin shall be
as indicated in Appendix-I to Part A of the specification.
2.01.01 Microprocessor based, Intelligent, Modular Power Supply shall be sized for continuous duty
to meet 100% load requirements and keep the connected battery fully charged in float mode.
The minimum capacity inclusive of 10% design margin shall be as indicated in Appendix-1 to
contract quantity Part-A of the specification. Either of the bank of rectifier modules shall be
able to re-charge the fully discharged battery within 8 hours. It shall also be possible to
discharge batteries periodically manually. Each rectifier bank shall be provided with N+1
rectifier modules and the maximum numbers of rectifier modules shall not be more than 25
Nos. However, the exact number of rectifier modules shall be as finalized by the Employer
during Detailed Engineering. The exact sizing of the rectifiers in one bank shall be subject to
Employer approval during detailed engineering. It shall be ensured that all rectifier modules
in one rectifier bank shall be of same rating and not more than three ratings of rectifier
modules shall be used in various rectifier banks. Provision for manual boost charging with
isolation of loads shall be provided.. While sizing, the temperature derating factor as
applicable, is to be considered for arriving at the rating of the modules as per Bidder’s
manufacturing standard if the modules are rated for lower than the 50 deg. C ambient. For
the rectifier bank, matching controller along with applicable software shall be provided to
meet system requirements under all modes of operation.”

CLAUSE NO.
2.01.02 The rectifier module shall be microprocessor controlled, IGBT/ Power MOSFET based, high
frequency with active load sharing, designed for single and parallel operation with battery and
shall have automatic voltage regulators for a close voltage stability even when AC supply
voltage and DC load fluctuates, effective current limiting features, front access design,
programmable temperature compensation feature for battery charging and filters on both
input and output to minimise harmonics. The rectifier module output regulation shall be ± 1%
or better from no load to full load with an input power supply variation of ± 10% in voltage and
± 5% in frequency. In addition to indications/display on charger panel, alarms shall also be
provided by employing RS 485 Port Modbus Protocol / Ethernet TCP/IP protocol for use in
DDCMIS. Further isolated 4-20 mA signals shall be provided for important parameters like
rectifier bank voltage, rectifier bank current, battery voltage, battery current, DCDB Voltage,
DCDB current etc. The list of alarm output & 4-20 mA signals shall be as approved by
Employer during detailed engineering. Necessary provision shall be done in DDCMIS end
also.
2.01.03 The rectifier module shall be fed from 415V AC, 50 HZ, 3 phase, 3 wire system.
2.01.04 "Float/Boost" charge functions shall be provided with alarm/indications.
2.01.05 The rectifier module circuitry shall be of fail-safe design and failure of any component should
not result in any rectifier bank output voltage to increase beyond acceptable limits of the C&I
system being fed from it.
2.01.06 The rectifier module shall be current limited for circuit protection and protection of battery
from overcharge. The current limit shall be continuously programmable.
2.01.07 The rectifier module shall have a slow walk-in circuit which shall prevent application of full
load DC current in less than 10 seconds after AC power is energised.
2.01.08 The full load efficiency of rectifier module at nominal input and output shall be at least 90%.
The ripple content shall be limited to +/- 0.5 % of output voltage.
2.01.09 The Controller shall be microprocessor controlled for monitoring & control of rectifier
modules with features viz. Auto/Manual battery discharge test, battery reserve time
prediction, energy management, float/boost mode control etc.
2.01.10 All Software as required for smooth operation and monitoring of rectifier modules in
conjunction with Controller & BHMS shall be provided by the Contractor.
2.01.11 Contractor shall furnish the equipment complete in all respects along with rectifier module
rating & voltage drop calculations, supporting curves/data etc.
2.02.00 DC Distribution Board (DCDB)
Redundant DC feeders (one from each DCDB) shall supply each of the connected loads. The
exact design, rating & number of feeders of the each redundant DCDB shall be as finalised
during detailed engineering and as approved by Employer. However, 25% spare feeders
(min. 1 no.) with MCB and fuses for each rating shall be provided in each DCDB.
2.03.00 Battery Health Monitoring System (BHMS)
BHMS, wherever applicable, shall include microprocessor based hardware and software to
monitor the condition of each battery cell of 24 V DC systems & UPS battery banks on-line.

CLAUSE NO.
With BHMS it shall be possible to measure & analyse the minimum and maximum voltage
values of each battery-cell so that any damage to battery shall be prevented by pro-active
maintenance. BHMS shall communicate with the DDCMIS and provide alarms as finalized by
Employer during detailed engineering. Contractor to ensure that the configuration of the
BHMS system being supplied along with the batteries of 24 V DC Charger System and UPS
System shall meet the technical requirements of the type of batteries supplied along with
these power supply systems.
2.04.00 Power Supply shall be sized to meet connected load requirements and keep the connected
battery full charged in Float/ Boost mode. The rectifier module output regulation shall be ±
1% or better from no load to full load with an input power supply variation of ± 10% in voltage
and ± 5% in frequency. In addition to indications/display on the panel, potential free contacts
for alarms like O/P voltage high & low, AC Input supply failure, battery feeding the load etc
shall also be provided for use in respective control system i.e., PLC/Remote IO etc . Further
isolated 4-20 mA signals shall be provided for important parameters like rectifier module
voltage, rectifier bank current, battery voltage etc. The list of alarm output & 4-20 mA signals
shall be as approved by Employer during detailed engineering. The exact design, rating &
number of feeders of the DCDB shall be as finalised during detailed engineering and as
approved by Employer. However, 25% spare feeder (min. 1 no.) with fuses for each rating
shall be provided in each DCDB.
3.00.00 UNINTERRUPTIBLE POWER SUPPLY (UPS) SYSTEM
The minimum capacity of the UPS at load factor of 0.8 lagging inclusive of 10% design
margin at 50 deg c shall be as indicated in Appendix-I to Part-A of the specification.
The UPS system shall meet the following requirements as a minimum.
If UPS KVA rating is applicable at a lower ambient temperature than specified 50 deg.c, the
bidder shall consider a derating factor of at least 1.5%/deg.c for arriving at the specified UPS
capacity at 50 deg.c ambient. The UPS shall have an overload capacity of 125 % rated
capacity for 10 minutes and 150 % rated capacity for 10 seconds. The inverter shall have
sufficient capability to clear fault in the maximum rated branch circuit, limited to 8 percent of
finally selected ups capacity.
3.01.00 Chargers
3.01.01 The chargers shall be self regulating, solid state silicon controlled, full-wave rectifier type
designed for single and parallel operation with battery and shall have automatic voltage
regulators for close voltage stability even when AC supply voltage fluctuates, effective
current limiting features and filters to minimise harmonics. The Battery should be directly
connected to the Controlled Rectifier and no intermediate component between Battery and
controlled rectifier is allowed. In event of mains failure, Battery should feed the inverter
directly without any intermediate component. The charger should be capable to fully charge
the required batteries as well as supply the full rated load through inverter. Furthermore the
charger should be able to re-charge the fully discharged battery within 8 hours. The charger
output regulation shall be ± 1% from no load to full load with an input power supply variation
of ± 10% in voltage and ± 5% in frequency. In addition to indications/display on charger
panel, alarms along with relevant analog measurements shall also be provided by employing
RS 485 Port Modbus Protocol / Ethernet TCP/IP protocol for use in DDCMIS. The list of
alarm output & 4-20 mA signals shall be as approved by Employer during detailed
engineering.
3.01.02 The charger shall be current limited for charger circuit protection and protection of battery
from overcharge shall also be provided. The current limit shall be continuously adjustable.

CLAUSE NO.
The chargers shall have a slow walk-in circuit which shall prevent application of full load DC
current in less than 10 seconds after AC power is energised.
3.01.03 The chargers shall be fed from 415V AC, 50 HZ, 3 phase, 3 wire system. Charger design
shall ensure that there is no component failure due to fluctuations of input supply or loss of
supply and restoration.
3.01.04 The minimum full load efficiency at nominal input and output shall be 90%. The ripple content
shall be limited to +/- 2 % of Charger output voltage.
3.01.05 The UPS battery shall have sufficient amp-hour capacity to supply the steady state KVA
rating of the UPS specified for 60 minute, irrespective of the actual load on UPS.
3.01.06 The UPS system shall be capable of operating without D.C. battery in circuit under all
conditions of load and the performance of various components of UPS like inverter, charger,
static switch etc. shall be guaranteed without the battery in circuit.
3.01.07 The UPS system design shall ensure that in case of failure of mains input power supply to
one of the chargers, the other charger whose mains input power supply is healthy, shall feed
to one or both the inverters as the case may be as per manufacturer's standard practice &
continue to charge the D.C. battery at all load conditions. The Bidder should note that this
situation should not in any way lead to the discharge of the D.C. Battery.
3.02.00 Static Inverters
The static inverter shall be of continuous duty, solid state type using proven Pulse Width
Modulation (PWM)/Quasi square wave/step wave technique. Ferro-resonant types Inverters
are not acceptable. The nominal voltage output shall be 230 Volts. single phase ,50 Hz. The
inverter equipment shall include all necessary circuitry and devices to conform to
requirements like voltage regulation, current limiting, wave shaping, transient recovery,
automatic synchronization etc. The steady state voltage regulation shall be +/-2% and
transient voltage regulation (on application/removal of 100% load) shall be +/-20%. Time to
recover from transient to normal voltage shall not be more than 50 mSec. Frequency
regulation for all conditions of input supplies, loads and temperature occurring simultaneously
or in any combination shall be better than ± 0.5% (automatically controlled). The total
harmonic content shall be 5% maximum and content of any single harmonic shall be 3%
maximum. The inverter efficiency shall be at least 85% on full load and 80% on 50% load.
The synchronisation limit for maintenance of synchronisation between the inverter and stand
by AC source shall be 48-52Hz, field adjustable in steps of 1 Hz.
3.03.00 Static Switch and Manual Bypass Switch
The static switch shall be provided to perform the function of transferring UPS loads
automatically without any break from (i) faulty inverter to healthy inverter in case of failure
of one of the two inverters and (ii) from faulty inverter to standby AC source in case of
failure of both the inverters. The transfer time shall be ¼ cycle maximum in synchronous
mode.
Manual bypass switch shall be employed for isolating the UPS during maintenance.
Continuous and overload capacity of the switches shall be equal to 100% of the
continuous and overload rating of each inverter. Peak Capacity shall be 1000% of
continuous rating for 5 cycles.

CLAUSE NO.
3.04.00 Step Down Transformer and Voltage Stabiliser
One 415V three phase to 230V, single phase transformer along with associated voltage
stablizer shall be furnished with each UPS system. The transformer and stablizer
combination shall convert Employer furnished 415V ± 10% three phase plant auxiliary AC
supply to 230 V ± 2%, single phase standby AC Power Supply source.
The transformer shall be of low impedance air-cooled type and its KVA rating and
percentage impedance should be selected so that extremely fast fault clearance is
achieved.
The overload capacity of the transformer and voltage stabilizer shall not be less than 300%
for 200 millisecond duration. The voltage stabilizer shall employ servo-controlled circuitry
and shall maintain the specified output voltage for 0-100% load with maximum input
voltage variations as indicated above. The efficiency of the stabiliser shall be 95% or
better.
The type and other details shall be subject to Employer’s approval.
3.05.00 AC Distribution Board (ACDB)
The details of the AC distribution board, i.e. exact, rating and number of feeders etc. of the
2x100% ACDB shall be as indicated in Appendix-1 to contract quantity, Part-A of the
specification and as approved by Employer during detailed engineering . ACDB shall be
designed to cater to the requirements of both Employer’s System and Contractors systems.
4.00.00 Batteries
4.01.00 Nickel Cadmium Batteries
4.01.01 The batteries shall be heavy duty Nickel-cadmium type and shall be sized for one hour of full
load operation during non-availability of AC supply / chargers. The Ni-Cd batteries shall
strictly conform to the latest edition of IS: 10918 including all applicable official amendments
and revisions as on date of opening of techno-commercial bid. For sizing calculation, an
aging factor of 0.8 and a temperature correction factor as per manufacturer’s standard at 4
deg. C electrolyte temperature (Based on temperature characteristics curve to be submitted
by the Contractor at a temperature of 4 deg. C), Capacity factor, float correction (if
applicable) shall be taken into consideration. The sizing of the battery shall be as approved
by Employer during detailed engineering. The Contractor shall typically consider a voltage
drop of 2.5V from battery room to DCDB and DCDB to load, while sizing the battery for 24 V
DC Charger System and 4V from battery room to the inverter input while sizing the battery for
UPS System.
Nickel plated copper connectors shall be used for connecting adjacent cells and PVC
insulated flexible copper cables shall be used for inter-row / inter-tier / inter-bank
connections. Bolts, nuts and washers shall be Stainless Steel / Nickel coated steel to prevent
corrosion. All the terminals and cells inter-connectors shall be fully insulated or have
insulation shrouds. Necessary supports and lugs for termination of these cables on batteries
shall also be supplied by the contractor. All connectors and lugs shall be capable of
continuously carrying the 60 minutes discharge current of the respective batteries and fault
short circuit current which the battery can produce and withstand for the period declared.

CLAUSE NO.
4.01.03 Manufacturer’s Identification Systems
(a.) Manufacturer's name and trade marks
(e.) Serial number
4.02.00 Lead Acid Plante Batteries
4.02.02 All standards, specification and codes of practice, referred to herein, shall be the latest
edition including all applicable official amendments and revisions as on date of opening of
techno-commercial bid.
In case of conflict between this specification and those (IS Codes Standards etc.) referred to
herein, the former shall prevail. All works shall be carried out as per the following standards
and codes:
IS : 266 Specification for sulphuric acid
IS : 1069 Specification for water for storage batteries
IS : 1146 Specification for rubber & plastic containers for lead acid storage batteries.
IS : 1652 Specification for stationary cells and batteries, lead acid type (with plante
positive plates).
IS : 3116 Specification for sealing compound for lead acid batteries.
IS : 8320 General requirements and methods of tests for lead acid storage batteries.
IS : 6071 Specification for synthetic separators for lead acid batteries.
4.02.03 Equipment complying with other internationally accepted standards such as IEC, BS, VDE
etc. will also be considered if they ensure performance and constructional features equivalent

CLAUSE NO.
or superior to standards listed above. In such a case, the Bidder shall clearly indicate the
standard(s) adopted, furnish a copy in English of the latest revision of the standards
alongwith copies of all official amendments and revisions in force as on date of opening of
techno-commercial bid and shall clearly bring out the salient features for comparison.
4.02.04 GENERAL TECHNICAL REQUIREMENTS
4.02.04.01 Equipments
DC Batteries shall be stationary lead acid Plante positive plate type conforming to IS:1652.
The battery shall be high discharge performance type shall be sized for one hour of full load
operation during non-availability of AC supply / chargers. For the purpose of sizing
Temperature Correction Factor as per manufacturer’s standard at 4 Deg C electrolyte
temperature, relative humidity of 95%, aging factor of 0.8 and Capacity Factor shall be
considered. The Contractor shall furnish relevant charts, curves, tables etc. in support of the
various factors considered during battery sizing.
DC Batteries shall be suitable for standby duty. The Batteries shall normally be permanently
connected to the load in parallel with a charger and shall supply the load during emergency
conditions when AC supplies are lost. Batteries shall be suitable for a long life under
continuous float operations and occasional discharges. The batteries shall be boost charged
at about 2.7 volts per cell maximum and float charged at about 2.25 V/cell:
The number of cells for the 24 V DC Charger System and UPS System shall be decided
4.02.04.02 Connectors and Fasteners
Lead or Lead coated copper connectors shall be used for connecting up adjacent cells and
rows. Bolts, nuts and washers shall be effectively lead coated to prevent corrosion. All the
terminals and cells inter-connectors shall be fully insulated or have insulation shrouds.
Necessary supports and lugs for termination of these cables on batteries shall also be
supplied by the contractor. All connectors and lugs shall be capable of continuously carrying
the 60 minutes discharge current of the respective Batteries and fault short circuit current
which the battery can produce and withstand for the period declared.
4.02.04.03 Manufacturer’s Identification Systems
(f.) Manufacturer's name and trade marks
(g.) Country and year of manufacture.
(h.) Manufacturer type designation.
(i.) AH capacity at 10 hour discharge rate.
(j.) Serial number

CLAUSE NO.
5.00.00 AUXILIARY EQUIPMENTS
5.01.00 All required auxiliary equipment/materials as finalised during detailed engineering shall be
furnished with each rectifier bank, UPS & battery bank and shall include as a minimum
various meters (AC/DC voltage/current, kVA, power factor, frequency meters etc), circuit
breakers, selector switches, push buttons indicating lights, ground detector system, battery
accessories like (inter cell connectors, inter step connectors, battery racks etc.) isolated 4-20
mA signals for important parameters and potential free contacts for important alarms shall be
provided for use in DDCMIS.
5.02.00 Manual Discharge Resistance bank of adequate capacity for UPS & 24 V DC Power
Supply System batteries as indicated in Appendix-1 to Part-A of contract quantities
shall be provided by the Contractor.
5.03.00 Accessories and devices required for maintenance and testing of batteries shall be supplied
as per Appendix-1 to Part-A of Contract Quantities.
6.00.00 Battery Racks
The battery racks shall be constructed from high strength good quality mild steel sections.
Battery Racks should either be epoxy painted or epoxy powder coated with three (3) coats,
with acid resistant grade of pigment as per approved coating process to provide a non-peel
able protective coat. The racks shall be of single tier/ two tier construction depending on the
final layout based on space availability.
7.00.00 DRAWINGS/DOCUMENTS REQUIREMENTS
Bidder shall furnish the power supply distribution scheme, single line diagram, all calculations
such as Rectifier Modules / UPS Charger / Inverter rating calculations, battery sizing
calculation etc. for DC system as well as for UPS during detailed engineering for Employer’s
review and approval.
8.00.00 CABINETS / ENCLOSURES / POWER DISTRIBUTION BOXES
The Construction details for Power Supply System Cabinets/ Enclosure/Racks shall conform
to the requirements of the following paragraphs.
(1) Equipment enclosures shall match and line up in assemblies of freestanding floor
mounted cabinets designed for indoor service.
(2) Individual enclosure shall be ventilated switchboard type fabricated from not less
than 1.6-mm thick sheet steel. Enclosures shall be furnished with concealed hinges.
Front and rear doors shall be designed to permit easy access to all components for
maintenance or replacement. The enclosures shall be reinforced with formed steel
members as required to form a rigid self-supporting structure. Doors shall have three
point latches.
(3) Each assembly may be shipped in sections for ease of handling and field assembly.
Terminal blocks shall be furnished as required adjacent to each shipping split to
facilitate field assembly. Cable bundles cut to the required length and furnished with
terminal lugs tagged for identification shall be provided for the wiring between
shipping sections.
(4) Adequate ventilating louvers and enclosure top panels shall be included. All vent
openings shall be covered with corrosion resistant fine screen coverings.
(5) The temperature rise inside all the cabinets/enclosures shall not exceed 10 deg.C
above ambient temperature. The cabinets shall be IP-22 protection class .

CLAUSE NO.
(6) The Colour shade of Panels exterior/interior shall be as per RAL 9002, end panel
Colour shall be as per RAL 5012.
9.00.00 COOLING SYSTEM
If the equipment supplied requires forced air cooling, the cooling system furnished shall meet
the following requirements:
(1) Reserve cooling equipment shall be furnished for each assembly. Reserve fan(s)
capacity shall be equal to 100 percent of cooling fan requirements for full load
operation with only one bank of rectifier/inverter in service at the specified maximum
ambient temperature.
(2) Completely independent duplicable wiring and control systems shall be provided for
the normal cooling fan system and the reserve cooling fan system.
(3) Each cooling fan shall normally run continuously and shall be powered from the
output of the inverter whose enclosure it serves (for cubicles housing inverters). For
other cubicles, fan power supply shall be as finalised during detailed engineering.
Each cooling fan supply circuit shall be separately fused.
(4) Each cooling fan shall be equipped with a switch having an alarm contact that closes
upon failure of airflow or rise of temperature.
11.00.00 SITE TESTS
The Contractor shall also carry out the site tests on equipments/systems as specified
below..However, these shall not be limited to this specification only and in case any other site
test is required to be conducted as a standard practice of the Contractor or deemed
necessary by the Employer and mutually agreed between the Contractor and the Employer,
the same shall also be carried out.
11.01.00 Uninterruptible Power Supply System
11.01.01 Functional Test
On completion of installation and commissioning of the equipment the following tests/checks

shall be carried out with the max. available load, which does not exceed the rated continuous
load. These tests/checks shall include but not limited to the tests as indicated below.
The details of the tests are as indicated below:
1. Light Load Test
This test is carried out to verify that the UPS is correctly connected and all functions
operate properly. The load applied is limited to some percent of rated value. The
following points should be checked:
(a) Output voltage, frequency and the correct operation of meters;
(b) Operation of all control switches and other means to put units into
operation.
(c) Functioning of protective and warning devices.
(d) Operation of remote signaling and remote control devices.

CLAUSE NO.
2. Checking of Auxiliary Devices
The functioning of auxiliary devices, such as lighting, cooling, pumps, fans,

annunciation, etc., should be checked, if convenient, in conjunction with the
preliminary light load test.
3. Synchronisation Test
If possible, frequency variation limits should be tested by use of a variable frequency

generator, otherwise, by simulation of control circuit conditions. If applicable the rate
of change of frequency during synchronization shall be measured.
4. A. C. Input Failure Test
The test is performed with a fully charged battery and is carried out by tripping input
circuit breakers or may be simulated by switching off all UPS rectifiers and bypass
feeder as at the same time. Output voltage variations are to be checked for specified
limits with an oscilloscope or equivalent. Frequency variation is defined as the steady
state frequency of the UPS with and without AC input. The rate of change of
frequency is measured by the time it takes to reach steady-state values.
5. A. C Input Return Test
AC input return test is performed by closing AC input circuit breakers, or is simulated

by energizing rectifiers and bypass feeders.
Proper operation of rectifier starting and voltage and frequency variations are to be
observed.
Note: This test is normally performed with a fully of partially charged battery.
6. Simulation of Parallel Redundant UPS Fault
This test is applicable for UPS with parallel redundant connections. Faults of rectifier
or inverter units may be carried out by simulation. Output transients are to be
observed.
7. Transfer Test
This test is applicable for UPS with bypass, particularly in the case of an electronic
bypass switch. Transients shall be measured during load transfer to bypass caused
by a simulated fault and load retransfer after clearing of the fault.
8. Full load test
Load tests are performed by connecting the actual load to the UPS output.
Large UPS in parallel connection may be load tested by testing the individual UPS
units separately. Load tests are necessary for testing output voltage and frequency,
rated stored energy, recharge time, ventilation, temperature rise and determination of
efficiency. Load tests are performed to prove transient voltage deviations specified
under step load conditions.
9. Efficiency
Efficiency should be determined by the measurement of the active power at input

and output.

CLAUSE NO.
10. Actual Load Test
Conditions under actual load may differ from those with a dummy load. Steady-state
generation of current and voltage harmonics and transients at load switching
conditions should be observed
11. Current Division in Parallel
Load sharing between the Modular DC power supply rectifier banks & UPS units
shall be measured with actual load under conditions of parallel operation.
12. Rated Stored Energy Time (Battery Test)
This test is a load test to prove the actual possible time of battery operation.
If rated load is not available in the case of large UPS, it is possible to apply a partial
load to check the actual battery discharge characteristics and compare these with
characteristics specified by the battery manufacturer. Discharge time with rated load
shall then be calculated. The test shall be performed with a fully charged battery and
also may be done under other battery conditions to be specified, if so agreed. Active
power output of the UPS and the battery voltage shall be recorded during the test.
Since new batteries often do not provide full capacity during a starting up period, the
discharge test may be repeated after a reasonable recharge time if the original test
has failed.
13. Rated Restored Energy Time
Restored energy depends on the charging capacity of the rectifiers and the battery
characteristics. If a certain recharging rate is specified, it shall be provided by
repeating the discharge test after the specified charging period.
14. Battery Ripple Current
If battery ripple currents are specified, then the ripple current which depends on UPS
operation shall be checked under normal operating conditions. Rough measuring
methods are sufficient.
15. On site Ventilation Test
The test is performed with the actual load. Temperature conditions of all Modular DC
power supply rectifiers & UPS cubicles are to be observed.
16. Overload Capability Test
Overload capability test is a load test. Specified values of short time overload or
starting up sequences of actual load are to be applied for the time interval specified.
Specified values of voltage and current are to be recorded.
17. Short Circuit Current Capability
If short-circuit current capability is specified, it may be tested by applicable of a short

circuit to UPS output if necessary, via a suitable fuse, Short-circuit current is to be
recorded.
18. Short Circuit Fuse Test
Fuse tripping capability of a UPS shall be tested, by short-circuiting the UPS output
via a fuse of specified type.

CLAUSE NO.
The test shall be repeated to ensure against fuse non-uniformity and switching time
during the cycle. The test is carried out at an appropriate UPS load, under normal
operation, if not otherwise specified by Employer.
19. Restart
Automatic or other restart means are to be tested after a completed shut-down as

specified.
20. Output Over voltage
Output over voltage protection is to be checked.
21. Periodic output voltage modulation
When this test is specified, it may be checked by voltage recording at different loads
and operating conditions.
22. Harmonic Components
Harmonic components of output voltage shall be checked with the actual load.
Methods of specification and checking shall be subject to Employer’s approval.
23. Earth Fault Test
If the DC Power Supply/ UPS output is isolated from earth, then an earth fault can be
applied to any output terminal. DC Power Supply/ UPS output transients (if any) shall
be measured.
If the battery is isolated from earth, then an earth fault can be applied to any output
terminals. DC Power Supply/ UPS output transient (if any) shall be measured.
11.02.00 24V DC Power Supply System
The functional tests to be carried out for 24V DC Power Supply system shall be the same as
specified under clause no. 11.01.01 above excepting the Sl. Nos. 2,3,6,7,17,18 and 22.
12.00.00 CONTRACT QUANTITIES
Refer Appendix-I to part A, Section VI of technical specifications.
13.00.00 TRAINING
Contractor shall provide training on UPS & 24V DC Power Supply system for Employer's
personnel. Please also refer Part-C, Section-VI of technical specifications.

PROCESS CONNECTION
AND PIPING
CLAUSE NO.
PROCESS CONNECTION AND PIPING
1.00.00 PROCESS CONNECTION PIPING
1.01.00 The Contractor shall provide, install and test all required material for completeness of
Impulse Piping System and Air Piping System as per the requirements of this Sub-Section on
as required basis for the connection of all instruments and control equipments of entire plant.
1.01.01 IMPULSE PIPING, TUBING, FITTINGS, VALVES AND VALVE MANIFOLDS
1.01.02 All impulse pipes shall be of seamless type conforming to ANSI B36.10 for schedule
numbers. The material of the impulse pipe shall be same as that of main process pipe or
equivalent. The size of impulse pipe shall be ½” for Steam & Water Application and ¾” for Air
& Flue Gas applications. The rating of material of impulse pipes, tubes, fittings, valves and
their installation thereof shall conform to the latest edition of standards as per following table:
Impulse Pipes, Tubes (Material, Rating) ANSI B31.1, ANSI B31.1a, ANSI/ISA 77.70
Valves (Material, Pr. Class, Size) ASTM A182/ASTM A105 as per ASME 16.34
Fittings (Size, Rating, Material) ANSI B31.1, ANSI B31.1a, ASME B16.11-2009
Installation Schemes BS 6739-2009, ANSI/ISA 77.70
Stainless steel tube shall be provided inside enclosures & racks from tee connection to valve
manifold and then to instrument. The source shut-off (primary process root valve) and blow
down valve shall be of 1/2 inch size globe valve type for all applications except for air and
flue gas service wherein no source shut-off valves are to be provided. Two root valves are to
be used wherever pressure is more than 40 Kg/cm2 or Temp>280 oC. The end connections
of valves shall be of socket welded type. Typical installation scheme of DP Transmitter
(inside LIE/LIR) mounted below instrument source point is indicated in Drg. No. 0000-999-
POI-A-036. Same scheme with necessary changes shall be applied for other instruments.
1.01.03 The valve manifolds of 316 SS with pressure rating suitable for intended application shall be
provided as given below:
Manifold Application/Measurement
2 Valve Pressure measurements using pressure transmitters/pressure switches
3 Valve Pressure measurements using differential pressure transmitter/ switches
5 Valve Differential Pressure, Flow and Level Measurements
For Pr./D.P gauges, two-way globe/gate valve shall be provided on each impulse line to the
instrument in Fluid/Air & Flue Gas applications respectively .
2.00.00 AIR SUPPLY PIPING
2.01.01 All pneumatic piping, fittings, valves, air filter cum regulator, purge rotameter and other
accessories required for instrument air for the various pneumatic devices/ instruments shall
be provided. This will include as a minimum air supply to pneumatically operated control
valves, actuators, instruments, continuous and intermittent purging requirements etc.
2.02.00 Instrument air and Service air supply shall be provided for continuous and intermittent
purging respectively for all transmitters of mill, dirty air and flue gas applications. Purging
Scheme shall be as per Drg. No. 0000-999-POI-A-036.

TECHNICAL SPECIFICATION SUB-SECTION-IIIC-06 PAGE
(2X660 MW)
SECTION – VI, PART-B PROCESS CONNECTION 1 OF 4
BID DOC NO.:THDC/RKSH/CC-9915-373 AND PIPING
CLAUSE NO.
2.03.00 The Contractor shall also provide SS Tubing and associated fittings (screwed type) of
suitable sizes for all pneumatic equipments/actuators (including supply air, signal air and
output to actuators) conforming to ANSI 31.1 and 31.3 standard. All other air supply lines
shall be of mild steel hot dipped galvanized inside and outside as per IS-1239, heavy duty
with threaded ends. Fittings for air supply line shall be of forged carbon steel A234 Gr. WPB
galvanized inside and outside, screwed as per ASA B2.1. Dimensions of fittings shall be as
per ASA B16.11 of rating 3000 lbs. Air supply piping shall be adequately sloped to prevent
accumulation of condensed water within the pipe. The air supply headers, sub-headers and
branch pipes shall be supported properly by clamps or supports.
2.04.00 The instrument/service air supply to each equipment/devices requiring air supply shall be
provided by a well designed air distribution scheme comprising of 2” GI Pipe Header feeding
1” GI Pipe sub-header feeding ½” pipe at each equipment/device. Instrument air filters cum
regulator set with mounting accessories shall be provided for each pneumatic device
requiring air supply except for Ash Handling System wherein it shall be provided on
instrument air header at each location.
2.05.00 All the isolation valves in the air supply line shall be gate valves as per ASTM B62 inside
screw rising stem, screwed female ends as per ASA B2.1. Valve bonnet shall be union type
& trim material shall be stainless steel, body rating 150 pounds ASA. The valve sizes shall be
½ inch to 2 inch.
2.06.00 Instrument air filters cum regulator set with mounting accessories shall be provided for
pneumatic device requiring air supply. The filter regulators shall be suitable for 10-kg/ sq.cm
max. Inlet pressure. The filter shall be of size 5 microns and of material sintered bronze. The
air set shall have 2-inch size pressure gauge and built in filter housing blowdown valve. The
end connection shall be as per the requirement to be finalized during detailed engineering.
3.00.00 INSTALLATION AND ROUTING
3.01.01 All instrument piping, tubing and its accessories shall be supported in a safe manner to
prevent excessive vibrations and anchored sufficiently to prevent undue strain on connected
equipment. Impulse piping shall be supported at an interval not exceeding 1.5 meters. The
slope of the impulse pipe form the process connection to the instrument shall be as per
ANSI/ISA 77.70 latest edition and BS 6739-2009. All impulse piping shall be installed to
permit free movement due to thermal expansion. Wherever required expansion loops shall
be provided.
Condensate pots shall be provided for all level measurements in steam and water services,
all flow measurement in steam services and for flow measurements in water services above
120 Deg. C. Colour coding of all impulse pipes shall be done by the Contractor in line with
the colour coding being followed for the parent pipes.
4.00.00 SHOP AND SITE TESTS

4.01.01 The equipment and work performed as per this Sub-section shall be subject to shop and site
test as per requirements of Sub-section-IIIE-04 (Quality Assurance & Inspection) other
applicable clauses of this Sub-section and Employer approved quality assurance plan.
4.01.02 Hydrostatic and Pneumatic leakage tests shall be performed on all pipes, tubing and systems
and shall conform to ANSI B31.1.

(2X660 MW)
CLAUSE NO.
5.00.00 LOCAL INSTRUMENT ENCLOSURE AND RACKS
All transmitters, switches etc. in Boiler Turbine Generator measurements (except for all
fuel oil applications) shall be suitably grouped together and mounted inside (i) local
instruments enclosures in case of open areas of the plant like boiler area, etc. and (ii) In
local instrument racks in case of covered areas like Turbine/Generator area. The GA of LIE
with purging indicated in the Drg. No. 0000-999-POI-A-036 is to be followed by contractor.
The GA of LIR shall be similar to LIE except for front/rear doors and side panels.
.
The internal layout shall be such that the impulse piping/ blow down lines are accessible
from back side of the enclosure / rack and the transmitters etc. are accessible from front
side for easy maintenance. Bulkheads, especially designed to provide isolation from
process line vibration shall be installed on instrument enclosures/racks to meet the process
sensing line connection requirement. Vibration dampeners shall be installed for each
enclosure / rack. The Degree of Protection of LIE and JB of LIE/LIR shall be IP-55.
The instrument racks shall be constructed from 1.6 mm sheet plate and shall be free
standing type constructed of suitable 3 mm thick channel frame of steel and shall be
provided with a canopy to protect the equipment mounted in racks from falling objects,
water etc. The canopy shall not be less than 3 mm thick steel, and extended beyond the
ends of the rack.
Enclosures/Racks shall be reinforced as required to ensure true surface and to provide

adequate support for instruments and equipment mounted therein. Centre posts or any
member which would reduce access shall not be provided.
Contractor shall provide not more than three variants for LIE/LIR with respect to max. no.
transmitters mounted in each LIE/LIR.
5.01.00 ENCLOSURE / RACKS FOR DUAL/SINGLE I/P TEMPERATURE TRANSMITTERS
All Dual/Single Input temperature transmitters in Boiler Turbine Generator measurements

shall be suitably grouped together and mounted inside (i) Enclosures in case of open areas
of the plant like boiler area, etc. and (ii) Racks in case of covered areas like
Turbine/Generator area. Integral JB shall be provided with each Enclosure and Rack.
The internal layout shall be such that the transmitters are accessible from both front and
back side of the enclosure / rack for easy maintenance.
Enclosure/ Racks shall be of robust and rugged design. Vibration dampeners shall be
installed for each enclosure / rack. The Degree of Protection of Enclosure and JB shall be
IP-55.
Enclosure and Racks shall be free standing type.
Enclosures/Racks shall be reinforced as required to ensure true surface and to provide

adequate support for instruments and equipment mounted therein.
Contractor shall provide not more than five variants for Enclosure/ Rack with respect to
max. no. transmitters mounted in each Enclosure/ Rack. However, the maximum number of
Transmitters that can be grouped in one Enclosure/ Rack shall be decided during detail
Engineering.

(2X660 MW)
CLAUSE NO.
5.02.00 Local Control Panels:
Local control panels shall be designed as per IP class 65 or better. These local panels shall
be suitably placed taking care of safety of the operating personnel and Instruments. For Hot
and dusty environment / process (e.g. Mill reject, Ash hoppers etc), panels shall be placed at
least 5mtrs away from the process.
6.00.00 INSTALLATION OF OTHER INSTRUMENTS:
For installation and routing of other field mounted instruments which are not covered in Cl.
No. 5.00.00, please refer Cl. No 52.04.00(f) of Section-VI, Part-D, Erection Conditions of
Contract (ECC) of Technical Specifications.
7.00.00 Painting Color scheme for Impulse Piping:
Sl. Area / Impulse Pipe Ground Color Identification Tag/Band

No. Equipment
Color RAL Color ISC No. RAL
1. Air Grey 9002 Sky Blue 101
2. Water Grey 9002 Sea Green 217
3. Steam Aluminium Signal Red 537 3001

4. Air Steam Aluminium Sky Blue 101
Mixture
5. Gas Grey 9002 Canary Yellow 309
6. Oils Grey 9002 Light Brown 410
7. Pulverized Fuel Grey 9002 Silver Grey 628
8. Fire Fire Red 536 (ISC) 3001 White 9010

Installations (RAL)
9. HP Dosing Grey 9002 Dark Admiralty 632
Grey
10. LP Dosing / Grey 9002 Signal Red 537
acid / alkali
Piping
11. Ash Piping Grey 9002 French Blue 166
Note: Ground color indicated against each piping shall be followed in case
piping is not insulated /cladded.

(2X660 MW)
SUB–SECTION – IIIC-07
INSTRUMENTATION AND POWER
SUPPLY CABLES
CLAUSE NO.
1.00.00 INSTRUMENTATION CABLE, CONTROL & POWER SUPPLY CABLE, INTERNAL

WIRING AND ELECTRICAL FIELD CONSTRUCTION MATERIAL (CABLE SUB-TRAYs
ETC)
1.01.00 General requirements

1.01.01 All cables including special cables, internal wiring and electrical field construction material
shall conform to this specification, Employer approved detail engineering drawings &
documents and the latest edition of the relevant standards & guidelines. The Bidder shall
furnish all material and services required for the completeness of the work identified in his
scope as per this specification.
1.01.02 The Contractor shall supply, erect, terminate and test all instrumentation cables for control
and instrumentation equipment/devices/systems included under Contractor's scope and
ensuring completeness of the control system.
1.01.03 Any other application where it is felt that instrumentation cables are required due to
system/operating condition requirements, are also to be provided by Contractor.
1.01.04 Other type of cables like fiber optic/co-axial cables for system bus, cables for connection of
peripherals etc. (under Contractor's scope) are also to be furnished by the Contractor.
1.01.05 Contractor shall supply all cable erection and laying hardware from the main trunk routes like
branch cable trays/sub-trays, supports, flexible conduits, cable glands, lugs, pull boxes etc.
on as required basis for all the systems covered under this specification.
1.01.06 Wherever the quantity has been defined as on as required basis, the same are to be
furnished by contractor on as required basis within his quoted lump sum price without any
further cost implication to the Employer.
2.00.00 SPECIFICATION OF INSTRUMENTATION CABLE
2.01.00 Common Requirements
S. No. Property Requirement
1 Operating Voltage 225 V (peak value)
2. Codes and standard All instrumentation cables shall comply with VDE
0815, VDE 0207, Part 4, Part 5, Part 6, VDE 0816,
VDE 0472, SEN 4241475, ANSI MC 96.1, IS-8784,
IS-10810 (latest editions) and their amendments
read along with this specification.
3. Continuous operation At 205 Deg C for Type-C cables & heat resistant
suitability cables, at 70 Deg C for all other type of cables.

(2X660 MW)
SECTION – VI, PART-B INSTRUMENTATION 1 OF 14
WATER SYSTEM PACKAGE CABLES
CLAUSE NO.
S. No. Property Requirement
4. Marking :- a.Progressive automatic on-line sequential marking of length in

meters to be provided at every one meter on outer sheath.
b.Marking to read ‘FRLS’ to be provided at every 5 meters on outer sheath

except for Type-C cable
c.Durable marking at intervals not exceeding 625 mm shall include

manufacturer’s name, insulation material, conductor’s size, number of pairs,
voltage rating, type of cable, year of manufacturer to be provided on outer
sheath.
5. Allowable Tolerance on +/- 2 mm (maximum) over the declared value in data

overall diameter sheet
6. Variation in diameter Not more than 1.0 mm throughout the length of

cable.
7. Ovality at any cross- Not more than 1.0 mm

section
8. CAGE-CLAMP suitability To be provided
9. Color The outer sheath shall be of blue color.
10. Others Repaired cables shall not be acceptable.
2.02.00 Specific Requirements
Specification Type-A Type-B Type F & G Type-C cable

Requirements cable cable cable
A. CONDUCTORS
Cross section area 0.5 sq. mm
Conductor material ANSI type ANSI type Annealed bare ANSI type KX
KX SX copper
Colour code Yellow-Red Black-Red As per VDE-815 Yellow-Red
Conductor Grade As per ANSI MC 96.1 Electrolytic As per ANSI MC

96.1
No & dia of strands 7x0.3 mm (nom)
No. of Pairs 2 2 2/4/8/12/16/24 2

/ 48

(2X660 MW)
CLAUSE NO.

Max. conductor loop As per ANSI MC 96.1 73.4 As per ANSI MC

resistance per Km (in 96.1
ohm) at 20 deg. C
Reference Standard As per ANSI MC 96.1 VDE : 0815 As per ANSI MC

96.1
B. INSULATION
Material Extruded PVC type YI 3 Teflon (i.e.

extruded FEP)
Thickness in mm 0.25/0.35 0.4 / 0.50

(Min/Max) (nominal)
Volume Resistivity 1 x 1014 at 20 deg. C & 1x1011 at 70 deg. C. 2.8x 1014 at 20

(Min) in ohm-cm deg. C & 2x1011 at
205 deg. C.
C. PAIRING & TWISTING
Max. lay of pairs (mm) 50
Single layer of binder Each core printed with Yes Each core printed
tape on each pair number or Numbered with number or
provided binder tape to be Numbered binder
provided on each pair tape to be
provided on each
pair
Bunch ( Unit N.A To be provided N.A

Formation) for more
than 4P
Conductor /pair N.A. To be provided N.A.

identification as per
VDE0815
D. SHIELDING
Type of shielding Al-Mylar tape
Individual pair No To be provided No

shielding for F-type cable
Minimum thickness of No 0.028mm (28 No

Individual pair micron)
shielding

(2X660 MW)
CLAUSE NO.

Overall cable To be provided

assembly shielding
Minimum thickness of 0.055 mm (55 micron)

Overall cable
assembly shielding
Coverage / 100% / 20%

Overlapping
Drain wire provided for N.A. Yes (for F-type) N.A.

individual shield
Size- 0.5 sqmm
No of strands-7
Dia of strands- 0.3mm
Annealed Tin coated copper
Drain wire provided for Yes, Size- 0.5 sqmm,No of strands-7,Dia of strands-
overall shield 0.3mm,Annealed Tin coated copper
E. FILLERS (if applicable)
Non-hygroscopic, To be provided
flame retardant
F. OUTER SHEATH
Material Extruded PVC compound YM1 with FRLS Teflon (i.e.

properties extruded FRP)
Minimum Thickness at 1.8 mm 0.4 mm

any point
Nominal Thickness at >1.8 mm 0.5 mm

any point
Resistant to water, Required

fungus, termite &
rodent attack
Minimum Oxygen 29 % N.A.

index as per ASTMD-
2863
Minimum Temperature 250 deg.C N.A.

index as per ASTMD-

(2X660 MW)
CLAUSE NO.

2863
Maximum Acid gas 20% N.A.

generation by weight
as per IEC-60754-1
Maximum Smoke 60% N.A.

Density Rating as per
ASTMD-2843 (defined as the average area under the curve
when the results of smoke density test
plotted on a curve indicating light absorption
vs. time as per ASTMD-2843)
Reference standard VDE207 Part 5,VDE-816 VDE207 Part 6

ASTM D2116
G. Electrical
Parameters
Mutual Capacitance 200 nF/km 120 nF/km for F 200 nF/km

Between Conductors type
At 0.8 Khz (Max.)
100 nF/km for G-
type
Insulation Resistance 100 M Ohm/Km

(Min.)
Cross Talk Figure 60 dB 60 dB 60dB

(Min.) At 0.8 Khz
Characteristic N.A. 320 OHM FOR N.A.

Impedance (Max) At 1 F-TYPE 340
Khz OHM FOR G-
TYPE
Attenuation Figure At 1 N.A. 1.2 db/km N.A.

Khz (Max)
H. COMPLETE
CABLE
Complete Cable Shall pass Swedish Chimney test as per N.A.

assembly SEN-SS 4241475 class F3.

(2X660 MW)
CLAUSE NO.

Flammability Shall pass flammability as per IEEE-383 read As per

in conjunction to this specification manufacturer’s
standard subject
to employer’s
approval
I. CABLE DRUM
Type Non-returnable wooden drum (wooden drum to be constructed

from seasoned wood free from defects with wood preservative
applied to entire drum) or steel drum.
Length 1000 m + 5% for up to & including 12 pairs
500 m + 5% for above12 pairs
Note: Heat resistant instrumentation cable shall have same specification as of G/F type
instrumentation cable as specified above, except that insulation and outer sheath material
shall be Teflon and cable shall be suitable for continuous operation at 205 Deg. C
3.00.00 SPECIFICATION OF OPTICAL FIBER CABLES (OFC)
3.01.00 Optic Fiber cable shall be 4/8/12 core, Electrolytically chrome plated corrugated steel taped
(ECCST), fully water blocked with dielectric central member for outdoor/indoor application so
as to prevent any physical damage. The cable shall have multiple single-mode or multi mode
fibers on as required basis so as to avoid the usage of any repeaters. The outer sheath shall
have Flame Retardant, UV resistant properties and are to be identified with the
manufacturer’s name, year of manufacturer, progressive automatic sequential on-line
marking of length in meters at every meter.
3.02.00 The cable core shall have suitable characteristics and strengthening for prevention of
damage during pulling viz. Dielectric central member, Loose buffer tube design, 4 fibers per
buffer tube (minimum), Interstices and buffer tubes duly filled with Thixotropic jelly etc. The
cable shall be suitable for a maximum tensile force of 2000 N during installation, and once
installed, a tensile force of 1000 N minimum. The compressive strength of cable shall be
3000 N minimum& crush resistance 4000 N minimum. The operating temperature shall be –
20 deg. C to 70 deg.C
3.03.00 All testing of the fiber optic cable being supplied shall be as per the relevant IEC, EIA and
other international standards.
3.04.00 Bidder to ensure that minimum 100% cores are kept as spares in all types of optical fibre
cables.
3.05.00 Cables shall be suitable for laying in conduits, ducts, trenches, racks and under ground
buried installation.
3.06.00 Spliced / Repaired cables are not acceptable.

(2X660 MW)
CLAUSE NO.
3.07.00 Penetration of water resistance and impact resistance shall be as per IEC standard.
4.00.00 SPCIFICATION OF CONTROL & POWER SUPPLY CABLES
Refer Electrical sub-sections
5.00.00 INSTRUMENTATION CABLE INTERCONNECTION AND TERMINATION PHILOSOPHY
The cable interconnection philosophy to be adopted shall be such that extensive grouping of
signals by large scale use of field mounted Group Junction Boxes (JBs) at strategic locations
(where large concentration of signals are available, e.g. valves limit & torque switches,
switchgear) is done and consequently cable with higher number of pairs are extensively
used. The details of termination to be followed are mentioned in the given Table A.
TABLE A: CABLE TERMINATION TO BE FOLLOWED
Application Type Of Termination Type Of

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

drives (Integral Marshalling – cum connector cage clamp
Junction box) Termination Cubicle type.
/ local group JB
Transmitters, Integral Junction box Plug in Cage clamp F,G

Process Actuated of LIE/LIR connector (Rail mount)
switches mounted type.
in LIE/LIR
RTD heads Local junction box Plug in Cage clamp F

connector (Rail mount)
type.
Thermocouple Local junction box / Plug in Cage clamp A, B, C*

CJC box (if connector (Rail mount)
applicable) type.
Other Field Local JB / Group JB Plug in Cage clamp F,G

mounted Instrument connector (Rail mount)
type.
RTD Temperature Plug in Screwed, F

transmitter connector Cage clamp
type
Thermocouple Temperature Plug in Screwed, A, B, C*

transmitter connector Cage clamp
type

(2X660 MW)
CLAUSE NO.

Cable
Local Junction box, Group JB Cage clamp Cage clamp F,G

Temperature (Rail mount) (Rail mount)
Transmitter, Int. type. type.
Junction box of LIE/
LIR/ MCC/SWGR
Local Junction box, Marshalling / Cage clamp Cage clamp F,G

Temperature Marshalling – cum (Rail mount) (Post
Transmitter, Int. Termination Cubicle type. mounted)
Junction box of LIE/ type.
LIR/ Group JB /
MCC/SWGR
Marshalling cubicle/ Electronic system Cage clamp Plug-in Internal

Termination Cabinet cabinet (Post mounted) connector / wiring
type. other
system as
per Mfr.’s
Standard
Marshalling/ UCD mounted Cage clamp Plug in F,G

Termination System equipments (Post mounted) connector / (with
Cabinets type. Cage clamp plug-in
type (rail connect
mounted). or at
one
end)
DDCMIS/PLC PC, Printers etc. Plug in Plug in Mfr.’s

cabinets connector connector Standar
d
Notes 1 Normally 10% spare cores shall be provided when the numbers of pairs of
cables are more than four pairs, except for pre-fabricated cables which shall
be as per manufacturer’s standard.
2 For analog signals, individual pair shielding & overall shielding & for Binary
signals, only overall shielding of instrumentation cables shall be provided.
* For high temperature applications only.

3
4 Not used.
5 Not used.

(2X660 MW)
CLAUSE NO.

Cable
6 For Cable type and cable termination scheme for the instruments/
equipment that are connected to Steam Turbine and Generator (STG)
control system defined at Part A, sub section IIC, clause no. 2.03.01 (a) (ii)
above and hydrogen generation plant auxiliaries system, Contractor’s
standard and proven practice is also acceptable. However, for termination
of instrumentation cable at marshalling cabinets/DCS panel end, cage-
clamp termination shall be offered. For power and control cable
termination, Contractor’s standard and proven practice would be
acceptable.
5.01.00 Following general guidelines are to be followed for terminating the signal cables at
DCS marshalling panel:
1. Between a) field and DCS (for ungrouped signals) and b) field JB and DCS (for
grouped signals), cables of 4 pair or its multiples shall be used.
2. 2 pair cables can be used between instrument/field devices to field JB only.
However, use of 2P cable from integral JB of LIE/LIR upto group JB in field is
acceptable.
3. All the cores of a cable shall be terminated in the marshalling panel sequentially as
per the color coding philosophy indicated in tender drawing no. 0000-999-POI-A-065.
Number of marshalling posts required shall depend on number of pairs in the cable
e.g. 8 pair cable shall be terminated on 2 consecutive marshalling posts and a 12
pair cable shall be terminated on 3 consecutive marshalling posts. Further, splitting
of one bundle of a cable on posts located in separate rows should be avoided.
4. Preferably similar sequence of termination of binary & analog signals to be followed
in all marshalling panels e.g a sequence like all binary signals are terminated first
and then analog signals are terminated in every marshalling panel may be followed.
5. Signals of Redundant drives shall not be assigned in one cable.
6. If both analog & binary signals are required to be taken through one cable, then F
type cable shall be used.
7. It should be ensured that all the cables in the marshalling cabinet are laid through
suitable glands on the gland plate. Contractor to substantiate the compliance of the
above through details of the number and types of cables engineered per panel
during Factory Acceptance Test.
Above points are to be read in conjunction with tender drawing no. 0000-999-POI-A-065.
6.00.00 TERMINAL BLOCKS
6.01.00 All terminal blocks shall be rail mounted/post mounted, cage clamp type with high quality
non-flammable insulating material of melamine suitable for working temperature of 105 deg.
C. The terminal blocks in field mounted junction boxes, temperature transmitters, instrument
enclosures/racks, etc., shall be suitable for cage clamp connections. The terminal blocks in
Control Equipment Room logic/termination/marshalling cubicles shall be suitable for post
mounted cage clamp connection at the field input end. The exact type of terminal blocks to

(2X660 MW)
CLAUSE NO.
be provided by the Bidder and the technical details of the same including width etc. shall be
subject to Employer’s approval.
6.02.00 All the terminal blocks shall be provided complete with all required accessories including
assembly rail, locking pin and section, end brackets, partitions, small partitions, transparent
covers, support brackets, distance sleeves, warning label, marking, etc.
6.03.00 The marking on terminal strips shall correspond to the terminal numbering on wiring
diagrams. At least 20% spare unused terminals shall be provided everywhere including local
junction boxes, instrument racks/enclosures, termination/marshalling cabinets, etc. All
terminal blocks shall be numbered for identification and grouped according to the function.
Engraved labels shall be provided on the terminal blocks.
6.04.00 For terminating each process actuated switches, drive actuators, control valves,
Thermocouple, RTD, etc. in Local Junction Boxes, etc, refer Drg no. 0000-999-POI-A-065.
6.05.00 The terminal blocks shall be arranged with at least 100 mm clearance between two sets of
terminal blocks and between terminal blocks and junction box walls.
7.00.00 INTERNAL PANELS/ SYSTEM CABINETS WIRING
7.01.00 Internal panel/cabinet wiring shall be of multi-stranded copper conductor with FRLS PVC
insulation without shield and outer sheath meeting the requirements of VDE 0815.
7.02.00 All internal wires shall be provided with tag and identification nos. etched on tightly fitted
ferules at both ends. All wires directly connected to trip devices shall be distinguished by one
additional red colour ferrule.
7.03.00 All external connection shall be made with one wire per termination point. Wires shall not be
tapped or spliced between terminal points.
7.04.00 All floor slots of desk/panels/cabinets used for cable entrance shall be provided with
removable gasketed gland plates and sealing material. Split type grommets shall be used for
prefabricated cables.
7.05.00 All the special tools as may be required for solder less connections shall be provided by
Bidder.
7.06.00 Wire sizes to be utilised for internal wiring.
(i) Current (4-20 mA), low voltage signals (48V); 0.5 Sq.mm.
Ammeter/Voltmeter circuit, control switches etc.
for electrical system.
(ii) Power supply and internal illumination. 2.5Sq.mm. minimum (shall be as

per load requirement.)
8.00.00 INSTRUMENTATION CABLE INSTALLATION AND ROUTING
8.01.00 All cables assigned to a particular duct/conduit shall be grouped and pulled in simultaneously
using cable grips and suitable lubricants. Cables removed from one duct/conduit shall not be
reused without approval of Employer.

(2X660 MW)
CLAUSE NO.
8.02.00 Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the higher
voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of
the tray stack. The distance between instrumentation cables and those of other system shall
be as follows:
From 11 kV/6.6 kV/3.3 kV tray system - 914 mm
From 415V tray system - 610 mm
From control cable tray system - 305 mm
8.03.00 Cables shall terminate in the enclosure through cable glands. All cable glands shall be
properly gasketed. Sealing (to prevent ingress of dust entry and propagation of fire) shall be
provided for all floor slots used for cable entrance. Compression cable glands (double for
armoured and single for other cables) shall be provided.
8.04.00 Not in use
8.05.00 The cables emanating from redundant equipment/devices shall be routed through different
paths. The above segregation of cables & wiring for redundant equipments/devices shall be
in accordance with IEEE-Std-422.
9.00.00 CABLE LAYING AND ACCESSORIES
9.01.00 CABLE LAYING
1 Cables shall be laid strictly in line with cable schedule.
2 Identification tags for cables.
Indelible tags to be provided at all terminations, on both sides of wall or floor

crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in cable
trench/tray.
3 Cable tray numbering and marking.
To be provided at every 10m and at each end of cable way & branch connection.
4 No jointing is permissible for Instrumentation cables. For other cables Jointing for
more than 250 Meters run of cable shall be permitted.
5 Buried cable protection
With concrete slabs; Route markers at every 20 Meters along the route & at every
bend.
6 Road Crossings
Cables to pass through buried high density PE pipes encased in PCC. At least 300
mm clearance shall be provided between
- HT power & LT power cables,
- LT power & LT control/instrumentation cables,

(2X660 MW)
CLAUSE NO.
Spacing between cables of same voltage grade shall be in accordance with the
derating criteria adopted for cable sizing.
7 Segregation (physical isolation to prevent fire jumping)
a All cable associated with the unit shall be segregated from cables of other
Units.
b Interplant cables of station auxiliaries and unit critical drives shall be

segregated in such a way that not more than half of the drives are lost in case
of single incident of fire.
8 Cable clamping
All cables laid on trays shall be neatly dressed up & suitably clamped/tied to the
tray. For cables in trefoil formation, trefoil clamps shall be provided.
9 Optical fiber cables ( OFCs) :
Outside Building Area - to be laid necessarily inside covered cable tray of 100
mm with support from Trestle structure.
Inside Building Area – to be laid on separate cable sub-trays
While buried- in separate burried trench approx.1.0 meter depth, to be laid in 2”

rodent proof HDPE conduits covered with sand, brick, laid breadth-wise and soil
along the pipe line route by contractor;
While crossing roads - to be laid in rodent proof HDPE conduits with sand filling at
bottom and sand, soil filling at top with cement concrete;
While crossing canals/river- to be laid in rodent proof HDPE conduits within hume
pipe.
10 Laying of Network Cable (UTP/STP) :

Out side Building Area- to be laid necessarily inside covered cable tray of 100
mm with support from Trestle structure.
Inside Building Area- to be laid necessarily inside separate covered cable sub-
trays.
9.02.00 Bidder shall supply and install all cable accessories and fittings like Light Interface Units,
Surge suppressors, Opto isolators, Interface Converters, Fibre Optic Card Cage, Fibre Optic
Line Driver, Repeater / Modem (for Optical Fibre Cables), cable glands, grommets, lugs,
termination kits etc. on as required basis.
9.03.00 Cables, which terminate in cabinets of draw out sections shall have sufficient cable coiled in
the bottom of the cabinet to permit full withdrawal of draw out sections without disconnecting
the cables. When prefabricated cables with factory connectors on both ends are longer than
required, the excess cable shall be coiled in the bottom of one or both termination cabinets.
9.04.00 The Bidder shall be responsible for proper grounding of all equipment under this package.
Further, proper termination of cable shields shall be verified and the grounding of the same
shall be coordinated so as to achieve grounding of all instrumentation cable shields at same
potential. This shall be completed prior to system tests.

(2X660 MW)
CLAUSE NO.
9.05.00 The Contractor shall take full care while laying / installing cables as recommended by cable
manufacturers regarding pulling tensions and cable bends. Cables damaged in any way
during installation shall be replaced at the expense of the Contractor.
10.00.00 FIELD MOUNTED LOCAL JUNCTION BOXES
(i) No. of ways 12/24/36/48/64/72/96/128 with 20% spares terminals.
(ii) Material and 4mm thick Fiberglass Reinforced Polyester (FRP).

Thickness
(iii) Type Screwed at all four corners for door. Door gasket shall be of
synthetic rubber.
(iv) Mounting clamps Suitable for mounting on walls, columns, structures etc. The
and accessories brackets, bolts, nuts, screws, glands required for erection shall
be of SS, included in Bidders scope of supply.
(v) Type of terminal Rail mounted cage-clamp type suitable for conductor size upto
blocks 2.5 mm2. A M6 earthing stud shall be provided.
(vi) Protection Class IP: 55 minimum for indoor & IP-65 minimum for outdoor
applications.
(vii) Grounding To be provided.
(viii) Color RAL 7035
Note : For solenoid valve box, the material for the enclosure shall be of steel plate
(SS304) with minimum 2 mm thick frame and minimum 2 mm thick steel (SS-304) sheet.
Provision of individual isolation for each solenoid shall be provided inside the box.
Minimum 100 mm space between the solenoids shall be ensured for ease of access
and maintenance. All other specifications shall be as per above.
11.00.00 CONDUITS
11.01.00 Conduits shall be generally used for interconnecting cables from field instruments to Local
JB’s. All rigid conduits, couplings and elbows shall be hot dipped galvanised rigid mild steel
in accordance with IS: 9537 Part-I (1980) and Part-II (1981). The conduit interior and exterior
surfaces shall have continuous zinc coating with an overcoat of transparent enamel lacker or
zinc chromate. Flexible conduit shall be heat resistant terne coated steel with , water leak,
fire and rust proof protected for the areas of Mills,Drum, Main Steam, RH steam Air Heaters
and Furnace, BFPDT’s .
And for remaining applications, water leak, fire and rust proof flexible GI conduits shall be
provided. The temperature rating of flexible conduit shall be suitable for actual application.
11.02.00 All rigid conduit fittings shall conform to the requirements of IS: 2667, 1976. Galvanized steel
fitting shall be used with steel conduit. All flexible conduit fittings shall be liquid tight,
galvanized steel. The end fittings shall be compatible with the flexible conduit supplied.

(2X660 MW)
CLAUSE NO.
11.03.00 Conduit sealing, explosion proof, dust proof and other types of special fittings shall be
provided as required by these specifications and shall be consistent with the area and
equipment with which they are installed. Fittings installed outdoors and in damp locations
shall be sealed and gasketed. Hazardous area fittings and conduits sealing shall conform
with NEC requirements for the area classification.
11.04.00 Contractor shall provide double locknuts on all conduit terminations not provided with
threaded hubs and couplings. Water tight conduit unions and rain tight conduit hubs shall be
utilised for all the application which shall be exposed to weather. Moisture pockets shall be
eliminated from conduits.
11.05.00 Conduits shall be securely fastened to all boxes and cabinets.
12.00.00 CABLE SUB-TRAY & SUPPORT
12.01.00 The cable sub-trays and the supporting system, to be generally used between Local/Group
JBs and the main cable trays and the same shall be furnished and installed by the
Contractor. It is the assembly of sections and associated fittings forming a rigid structural
system used to support the cable from the equipment or instrument enclosure upto the main
cable trays (trunk route).
12.02.00 The covers on the cable sub-trays shall be used for protection of cables in areas where
damage may occur from falling objects, welding spark, corrosive environment, etc. & shall be
electrically continuous and solidly grounded.

(2X660 MW)
CONTROL VALVES AND ACTUATORS
CLAUSE NO.
CONTROL VALVES, ACTUATORS & ACCESSORIES
1.00.00 CONTROL VALVES, ACTUATORS & ACCESSORIES

1.01.01 The control valves and accessories equipment furnished by the Bidder shall be designed,
constructed and tested in accordance with the latest applicable requirements of code for
pressure piping ANSI B 31.1, the ASME Boiler & pressure vessel code, Indian Boiler
Regulation (IBR), ISA, and other standards specified elsewhere as well as in accordance
with all applicable requirements of the “Federal Occupational Safety and Health Standards,
USA” or acceptable equal standards. All the Control Valves, their actuators and accessories
to be furnished under this Sub-section will be fully suitable and compatible with the
modulating loops covered under the Specification.
1.01.02 All the control valves and accessories offered by the Bidder shall be from reputed,
experienced manufacturers of specified type and range of valves.
1.01.03 For special type of control valves such as combined pressure and temperature control
valves for Aux PRDS application, separator drain control valves, refer to the corresponding
mechanical sections.
1.01.04 Specification for control valves in this Sub-section has to be read in conjunction with other
relevant Sub-sections of this specification.
1.02.00 CONTROL VALVE SIZING & CONSTRUCTION
1.02.01 The design of all valve bodies shall meet the specification requirements and shall conform to
the requirements of ANSI (USA) for dimensions, material thickness and material specification
for their respective pressure classes.
1.02.02 The valve sizing shall be suitable for obtaining maximum flow conditions with valve opening
at approximately 80% of total valve stem travel and minimum flow conditions with valve stem
travel not less than 10% of total valve stem travel. All the valves shall be capable of handling
at least 120% of the required maximum flow. Further, the valve stem travel range from
minimum flow condition to maximum flow condition shall not be less than 50% of the total
valve stem travel. The sizing shall be in accordance with the latest edition of ISA handbook
on control valves. While deciding the size of valves, Bidder shall ensure that valves outlet
velocity as defined in ISA handbook does not exceed 8 m/sec for liquid services, 150 m/sec.
for steam services and 50% of sonic velocity for flashing services. Bidder shall furnish the
sizing calculations clearly indicating the outlet velocity achieved with the valve size selected
by him as well as noise calculations, which will be subject to Employer’s approval during
1.02.03 Control valves for steam and water applications shall be designed to prevent cavitation, wire
drawing, flashing on the downstream side of valve and down stream piping. Thus for
cavitation/flashing service, only valve with anti cavitation trim shall be provided. Detailed
calculations to establish whether cavitation will occur or not for any given application shall be
furnished.
1.02.04 Control valves for application such as SH Spray Control, RH spray Control, Heavy Oil
Heating, pressurizing and Control system, HP/LP heater Emergency level control,
Emergency Make-up to condenser hotwell, GSC minimum flow, Deaerator Drain to
Condenser Hotwell, Condensate spill to condensate reserve tank, condenser normal make-
up and valve gland sealing supplying pressure control, CEPS minimum flow control, BFP
circulation control valve shall have permissible leakage rate as per leakage Class V. All other
control valves shall have leakage rate as per leakage Class-IV as per ANSI / FCI /70.2,2006
or equivalent.
1.02.05 The control valve induced noise shall be limited to 85 dBA at 1 meter from the valve surface
under actual operating conditions. The noise abatement shall be achieved by valve body and

(2X660 MW) CONTROL VALVES,
WATER SYSTEM PACKAGE ACTUATORS &
BID DOC NO.:THDC/RKSH/CC-9915-373 ACCESSORIES
CLAUSE NO.
trim design and not by use of silencers except for few cases as per contractor’s standard and
proven practice subject to employer’s approval.
1.02.06 Control valves for steam and water application shall be provided with rangability of 30:1 for
all services except for applications wherein control valves are envisaged to be operated in
lower range like Reheater spray and superheater spray system wherein control valve with
rangability of 50:1 shall be provided
2.00.00 VALVE CONSTRUCTION
2.01.00 All valves shall be of globe body design & straightaway pattern with single or double port,
unless other wise specified or recommended by the manufacturer to be of angle body type.
Rotary valve may alternatively be offered when pressure and pressure drops permit.
2.02.00 Valves with high lift cage guided plugs & quick-change trims shall be supplied.
2.03.00 Cast Iron valves are not acceptable.
2.04.00 Bonnet joints for all control valves shall be of the flanged and bolted type or other
construction acceptable to the Employer. Bonnet joints of the internal threaded or union type
will not be acceptable.
2.05.00 Plug shall be of one-piece construction cast, forged or machined from solid bar stock. Plug
shall be screwed and pinned to valve stems or shall be integral with the valve stems.
2.06.00 All valves connected to vacuum on down stream side shall be provided with packing suitable
for vacuum applications (e.g. double vee type chevron packing)
2.07.00 Valve characteristic shall match with the process characteristics.
2.08.00 Extension bonnets shall be provided when the maximum temperature of flowing fluid is
greater than 280 deg. C.
2.09.00 Flanged valves shall be rated at no less then ANSI press class of 300 lbs.
3.00.00 VALVE MATERIALS
Sr. Service Body material Trim Material

No.
1 Non-corrosive, Carbon steel ASTM-A216 Gr. 316SS stellited with stellited

non-flashing WCB for design fluid faced guide posts and
and non- temperature below 275 Deg. C bushings.
cavitation
service except Alloy steel ASTM-A217Gr. WC6
DM water for design fluid temperature
above 275 Deg. C and upto 400
Deg. C
Alloy steel ASTM-A217Gr. WC9
for design fluid temperature
above 400 Deg. C
2. Severe Alloy steel ASTM-A217 Gr. WC9 440 C

flashing/cavitati
on services
3. Low Alloy steel ASTM-A217 Gr. WC6 17-4 PH SS

flashing/cavitati
on service
4. DM water 316 SS 316 SS

service

CLAUSE NO.
NOTE: (a) Valve body rating shall meet the process pressure and temperature
requirement as per ANSI B16.34.
(b) Severe flashing / cavitation services includes as a minimum all control
valves whose downstream piping is connected to condenser or flash tank.
However, Bidder may offer valves with body and trim materials better than specified
materials and in such cases Bidder shall furnish the comparison of properties including
cavitation resistance, hardness, tensile strength, strain energy, corrosion resistance and
erosion resistance etc. of the offered material vis-a-vis the specified material for Employer’s
consideration and approval.
Contractor shall ensure that all required measures like proper selection of anti-
corrosive/erosive material along with durable epoxy coating with polyurethane finish shall be
provided for all the C&I equipment/ devices being supplied in this contract, which are
mounted in non-AC areas (prone to sea water environment corrosion / erosion) like
measuring instruments, control valves & actuators, JBs, LIEs / LIRs, impulse pipes, sample
pipes, fittings, conduits, cable trays and accessories, local control panels, erection hardware
items etc. Contractor shall furnish their comprehensive proposal regarding the anti-corrosion/
erosion measures for protection against sea water environment which shall be finalized
during detailed engineering subject to Employer’s approval.
4.00.00 END PREPARATION

Valve body ends shall be either butt welded/socket welded, flanged (Rubber lined for
condensate service) or screwed as finalized during detailed engineering and as per
Employer’s approval. The welded ends wherever required shall be butt welded type as per
ANSI B 16.25 for control valves of sizes 65 mm and above. For valves size 50 mm and
below welded ends shall be socket welded as per ANSI B 16.11. Flanged ends wherever
required shall be of ANSI pressure-temperature class equal to or greater than that of the
control valve body.
5.00.00 VALVE ACTUATORS
All control valves shall be furnished with pneumatic actuators except for pressure and
temperature control valve for auxiliary PRDS application (electro-hydraulic / pneumatically
operated) and separator drain control valve (electro-hydraulic type).The Bidder shall be
responsible for proper selection and sizing of valve actuators in accordance with the pressure
drop and maximum shut off pressure and leakage class requirements. The valve actuators
shall be capable of operating at 60 deg.C continuously.
Valve actuators and stems shall be adequate to handle the unbalanced forces occurring
under the specified flow conditions or the maximum differential pressure specified. An
adequate allowance for stem force, at least 0.15 Kg/sq.cm. per linear millimeter of seating
surface, shall be provided in the selection of the actuator to ensure tight seating unless
otherwise specified.
The travel time of the pneumatic actuators shall not exceed 10 seconds.
6.00.00 CONTROL VALVE ACCESSORY DEVICES

6.01.00 All pneumatic actuated control valve accessories such as air locks, hand wheels/hand-jacks,
limit switches, microprocessor based electronic Positioner, diffusers, external volume
chambers, position transmitters (capacitance or resistance type only), reversible pilot for
Positioner, tubing and air sets, solenoid valves and junction boxes etc. shall be provided as
per the requirements.

CLAUSE NO.
7.00.00 SPECIFICATIONS FOR MICROPROCESSOR BASED ELECTRONIC POSITIONER
(i) 4-20mA for conventional positioners.

1 Electrical a) Input Demand
Signal (ii) Demand signal would be received
through fieldbus network for fieldbus
based positioners.
i) Loop powered from the output card of
b) Power Supply
Control System for conventional
positioners.
(ii) Fieldbus based positioners shall be
powered from the fieldbus network.
(i) Conventional positioners shall be
c) Protocol
compatible to HART Protocol
(ii) Fieldbus based positioners shall be
compatible to Foundation fieldbus/
Profibus depending on the Protocol which
is finalized for DDCMIS.
(i) Position sensing 4-20 mA output signal
d. Valve position
to be provided for Control System for
sensing
conventional positioners.
(ii) Valve position feedback shall be
available to Control system through
fieldbus network for Fieldbus based
positioners.
2 Environment a) Operating temp. (-)30 To 80 Deg. C
b) Humidity 0-95 %
c) Protection class IP-65 Minimum
3 Software for Software Software shall meet the requirements for

Configuration Configuration, Diagnostics, Calibration
and and Testing of the actuator.
Diagnostics
Diagnostic/Test Advanced diagnostic features like Stroke
features counter or Travel counter, Leakage in
actuators, Valve Signature analysis, Step
Response test, Valve friction /Jamming
detection etc to be provided.
4 Test reports/ Factory Valve Signature Tests Reports (Pr Vs Valve travel and
Certificates Travel Vs I/P signal) are to be provided.
Test certificates as per Manufacture Standard/Relevant

Standard are to be submitted.
5 Configuration/ Remote & Local Calibration, Auto & Manual Calibration shall be
Calibration. possible.
6 Operating Full range/ Split range.

Range

CLAUSE NO.
7 Modes Valve Action Direct / Reverse Valve

Action
Flow Characterization Possible to fit Valve

Characteristic Curves-
Linear , Equal
percentage etc.
8 Fail Safe/Fail Fail Safe/Fail Freeze feature is to be provided. (In case the fail
Freeze freeze feature is not intrinsic to the positioner, Bidder shall
achieve the same externally through solenoid valve connected
in the pneumatic circuit).
9 Pneumatic Air capacity Sufficient to handle the

valves & actuators
selected/ Boosters to be
supplied, if required.
Air pressure To suit the air supply

pressure/quality
available.
Process connection ¼” NPT
10 Performance Characteristic deviation <=0.5 % of span.
Ambient temp effect <=0.01 %/ deg C or

better.
10 EMC & CE Required to International Standard EN50081-2 & EN50082

Compliance like EN/IEC. or equivalent.
11 Accessories In-built Operator Panel Display with push buttons

for configuration and
display on the positioner
itself (Password
protected/Hardware lock).
(i) Universal HART
Hand Held Calibrator
Calibrator to be provided
for conventional
positioners. (for quantity,
refer Part-A. Contract
quantities of the
specification).
(ii) Fieldbus compatible
calibrator to be provided
for fieldbus based
positioners. (for quantity,
refer Part-A)
Press Gauge Block For supply & output
pressures, Air Filter
Regulator and other
accessories shall be

CLAUSE NO.
provided on as required
basis for making system
complete.
Electrical Cable Entry 1/2'”NPT, side or bottom

entry to avoid water
ingress.
Valves Mounting Assembly For Sliding

Stem/Rotary/Single
acting/Double acting
actuators on as required
basis
* Note:
The HART signals shall be picked up from marshalling terminals of DDCMIS (SG/TG
DDCMIS as well as BOP DDCMIS), as applicable. The details of the above mentioned
HART management system specification are mentioned in HART system (Annexure IIIC-02C
to DDCMIS).
The conventional positioners shall be monitored from this HART management system . The
fieldbus based positioners shall be monitored directly through fieldbus based DDCMIS
network. To achieve this, Bidder shall provide the necessary software to achieve the
functionalities described above under ” Software for Configuration and Diagnostics”, and this
software shall be loaded in the HART management system.
8.00.00 TEST AND EXAMINATION
All valves shall be tested in accordance with the quality assurance programme agreed
between the Employer and Contractor, which shall meet the requirements of IBR and other
applicable codes mentioned elsewhere in the specifications. The tests shall include but not
be limited to the following:
8.01.00 Non Destructive Test as per ANSI B-16.34.
8.02.00 Hydrostatic shell test in accordance with ANSI B 16.34 prior to seat leakage test.
8.03.00 Valve closure test and seat leakage test in accordance with ANSI-B 16.34/ FCI 70.2 standard
and as per the leakage class indicated above
8.04.00 Functional Test: The fully assembled valves including actuators control devices and accesso-
ries shall be functionally tested to demonstrate times from open to close position.
8.05.00 CV Test: Please refer Cl No. 1.00.00 & 3.00.00 OF Sub-section- IIIC-10 (Type test
requirements), Control Valves.
Bidder shall furnish all the control valves under this main plant package as finalized during
detailed engineering stage without any price repercussions whatsoever depending on the
process requirements. All the control valves provided by the Bidder for this project shall
meet the specifications requirements specified herein. Specification for control valves in this
Sub-section has to be read in conjunction with other relevant Sub-sections of this speci-
fication.

NOT USED
TYPE TEST REQUIREMENTS
CLAUSE NO.
1.00.00 TYPE TEST REQUIREMENTS
1.01.01 The Contractor shall furnish the type test reports of all type tests as per relevant standards
and codes as well as other specific tests indicated in this specification. If the bidder proposes
a different standard/code from that indicated at table 3.00.00, same is acceptable provided
the equivalence of the proposed standard is established by the bidder. A list of such tests
are given for various equipment in table titled 'TYPE TEST REQUIREMENT FOR C&I
SYSTEMS' at the end of this chapter and under the item Special Requirement for Solid State
Equipments/Systems. For the balance equipment instrument, type tests may be conducted
as per manufactures standard or if required by relevant standard.
(a) Out of the tests listed, the Bidder/ sub-vendor/ manufacturer is required to conduct
certain type tests specifically for this contract (and witnessed by Employer or his
authorized representative) even if the same had been conducted earlier, as clearly
indicated subsequently against such tests.
(b) For the rest, submission of type test results and certificate shall be acceptable
provided.
i. The same has been carried out by the Bidder/ sub-vendor on exactly the same
model /rating of equipment.
ii. There has been no change in the components from the offered equipment &
tested equipment.
iii. The test has been carried out as per the latest standards alongwith
amendments as on the date of Bid opening.
(c) In case the approved equipment is different from the one on which the type test had
been conducted earlier or any of the above grounds, then the tests have to be
repeated and the cost of such tests shall be borne by the Bidder/ sub-vendor within
the quoted price and no extra cost will be payable by the Employer on this account.
1.01.02 As mentioned against certain items, the test certificates for some of the items shall be
reviewed and approved by the main Bidder or his authorized representative and the balance
have to be approved by the Employer.
1.01.03 The schedule of conduction of type tests/ submission of reports shall be submitted and
finalized during pre-award discussion.
1.01.04 For the type tests to be conducted, Contractor shall submit detailed test procedure for
approval by Employer. This shall clearly specify test setup, instruments to be used,
procedure, acceptance norms (wherever applicable), recording of different parameters,
interval of recording precautions to be taken etc. for the tests to be carried out.
1.01.05 The Bidder shall indicate in the relevant BPS schedule, the cost of the type test for each item
only for which type tests are to be conducted specifically for this project. The cost shall only
be payable after conduction of the respective type test in presence of authorize
representative of Employer. If a test is waived off, then the cost shall not be payable.

(2X660 MW)
SECTION – VI, PART-B TYPE TEST 1 OF 9
WATER SYSTEM PACKAGE REQUIREMENTS
CLAUSE NO.
2.00.00 SPECIAL REQUIREMENT FOR SOLID STATE EQUIPMENTS/ SYSTEMS
2.01.00 The minimum type test reports, over and above the requirements of above clause, which are
to be submitted for each of the major C&I systems shall be as indicated below:
i) Surge Withstand Capability ( SWC) for Solid State Equipments/ Systems
All solid state systems/ equipments shall be able to withstand the electrical noise
and surges as encountered in actual service conditions and inherent in a power
plant. All the solid state systems/ equipments shall be provided with all required
protections that needs the surge withstand capability as defined in ANSI 37.90.1/
IEEE-472. Hence, all front end cards which receive external signals like Analog
input & output modules, Binary input & output modules etc. including power supply,
data highway, data links shall be provided with protections that meets the surge
withstand capability as defined in ANSI 37.90.1/ IEEE-472. Complete details of the
features incorporated in electronics systems to meet this requirement, the relevant
tests carried out, the test certificates etc. shall be submitted along with the proposal.
As an alternative to above, suitable class of EN 61000-4-12 which is equivalent to
ANSI 37.90.1/ IEEE-472 may also be adopted for SWC test.
ii) Dry Heat test as per IEC-68-2-2 or equivalent.
iii) Damp Heat test as per IEC-68-2-3 or equivalent.
iv) Vibration test as per IEC-68-2-6 or equivalent.
v) Electrostatic discharge tests as per EN 61000-4-2 or equivalent.
vi) Radio frequency immunity test as per EN 61000-4-6 or equivalent.
vii) Electromagnetic Field immunity as per EN 61000-4-3 or equivalent.
Test listed at item no. v, vi, vii, above are applicable for electronic cards only as defined
under item (i) above.

(2X660 MW)
CLAUSE NO.
3.00.00 TYPE TEST REQUIREMENT FOR C&I SYSTEMS
Sl. Item Test Standard Test To Be EMPLOYER’s

No Requirement Specifically Approval Req. On
Conducted Test Certificate
Col 1 Col 2 Col 3 Col 4 Col 5 Col 6
1 Elect. Metering As per IS-1248 No No

instruments standard
(col 4)
2 Transducers As per IEC- No No

standard 60688,IS127
(col 4) 84
3 Thermocouple Degree of IS-13947 No No

protection
test
4 RTD As per IEC-60751 No No

standard
(col 4)
5 Electronic As per BS-6447 / No No

transmitter standard IEC-60770
(col 4)
6 E/P converter As per Mfr. standard No No

standard
(col 4)
7 Dust emission Degree of IS-13947 No No

monitor protection
test
8 Instrumentation Cables Twisted & Shielded*
-Conductor Resistance VDE-0815 No No

test
Diameter test IS-10810 No No
Tin Coating IS-8130 No No

test (Persul-
phate test)
-Insulation Loss of mass VDE 0472 No No
Ageing in air VDE 0472 No No

ovens**

(2X660 MW)
CLAUSE NO.
Tensile VDE 0472 No No

strength and
elongation
test before
and after
ageing**
Heat shock VDE 0472 No No
Hot VDE 0472 No No

deformation
Shrinkage VDE 0472 No No
Bleeding & IS-10810 No No

blooming
-Inner sheath*** Loss of mass VDE 0472 No No
Cold bend/ VDE 0472 No No

cold impact
test
Hot VDE 0472 No No

deformation
-Outer sheath Loss of mass VDE 0472 No No
Ageing in air VDE 0472 No No

ovens**
Tensile VDE 0472 No No

strength and
elongation
test before
and after
ageing**
Hot VDE 0472 No No

deformation
Bleeding & IS-10810 No No

blooming
Colour IS-5831 No No
fastness to
water
Cold bend/ VDE-0472 No No

(2X660 MW)
CLAUSE NO.
cold impact
test
Oxygen index ASTMD-2863 No No

test
Smoke ASTMD-2843 No No
Density Test
Acid gas IEC-60754-1 No No

generation
test
-fillers Oxygen index ASTMD-2863 No No

test
Acid gas IEC-60754-1 No No

generation
test
-AL-MYLAR Continuity No No
shield test
Shield No No
thickness
Overlap test No No
-Over all cable Flammability IEEE 383 No No

Test
Swedish SEN No No
Chimney Test 4241475
Noise IEEE Trans- No No

interference actions
Dimensional IS 10810 No No
checks
Cross talk VDE-0472 No No
Mutual VDE-0472 No No
capacitance
HV test VDE-0815 No No
Drain wire No No
continuity

(2X660 MW)
CLAUSE NO.
* 1.0 All cables to be supplied shall be of type tested quality. The Contractor shall
submit for Owner's approval the reports of all the type tests as listed in this
specification and carried out within last Ten years from the date of bid opening. These
reports should be for the tests conducted on the equipment similar to those proposed
to be supplied under this contract and the test(s) should have been either conducted
at an independent laboratory or should have been witnessed by a client.
2.0 In case the Contractor is not able to submit report of the type test(s)
conducted within last Ten years from the date of bid opening, or in case the type test
report(s) are not found to be meeting the specification requirements, the Contractor
shall conduct all such tests either in an independent laboratory or at manufacturer’s
works in presence of Owner’s representative under this contract free of cost to the
Owner and submit the reports for approval.
**These tests shall be carried out as per VDE0207 Part 6 & ASTMD-2116 for
TEFLON insulated & outer sheathed cables
***Applicable for armoured cables only
9 DC Power Supply System (Applicable for each model and rating)
1)The Type Test reports for offered rectifier module and the controller module
irrespective of the rectifier bank shall be acceptable
Surge ANSI 37.90.1/ No No

Withstand IEEE-472,EN
Capability( 61000-4-12
SWC)
Dry Heat Test IEC-68-2-2 orr No No

equivalent
Damp Heat test IEC-68-2-3 orr No No

equivalent
Vibration test IEC68-2-6 orr No No

equivalent
Electrostatic EN 61000-4-2 No No
discharge test orr equivalent
Radio EN-61000-4-3 No No
frequency orr equivalent
immunity test
Electromagneti EN 61000-4-3 No No
c field immunity orr
equivalent
Degree of IS-13947 or No No
Protection equivalent

(2X660 MW)
CLAUSE NO.
10 Battery ## As per IS-10918 (Ni- No No

standard Cd Batteries)
(col 4)
IS-1652
(Lead Acid No No
Plante
Batteries)
11 NOT
APPLICABLE
12 UPS ( Applicable for each model and rating )
1) Type Test reports of same series of UPS with similar PCB’s cards and controllers
as the target UPS system shall be acceptable.
2) For Dry heat, Damp heat and vibration, the tests conducted on individual PCB’s
shall be acceptable.
Surge Withstand ANSI 37.90.1/ No No

Capability( SWC) IEEE-472,EN
61000-4-12
Dry Heat Test IEC-68-2-2 orr No No

equivalent
Damp Heat test IEC-68-2-3 orr No No

equivalent
Vibration test IEC68-2-6 orr No No

equivalent
Electrostatic EN 61000-4-2 No No
discharge test orr equivalent
Radio frequency EN-61000-4-3 No No

immunity test orr equivalent
Electromagnetic EN 61000-4-3 No No
field immunity orr
equivalent
Degree of IS-13947 No No
protection test
Fuse Clearing Approved No No

Capability procedure

(2X660 MW)
CLAUSE NO.
Short Circuit IEC 60146-2 No No

current capability
13 Voltage Over Load Test Approved No No

Stabilisers procedure
Temp rise test Approved No No

without redundant procedure
fans
14 Public Address System
IP based PA As per IEC 60268- No Yes

system Standard 16
components
15 LIE / LIR Degree of IS-13947 No No

protection
test
16 Flue gas Degree of IS-13947 No No

analyzers protection
test
17 Master Functional As per No No

Clock test
approved
procedure
18 CJC Box Degree Of IS-13947 No No

protection
test
19 Junction Degree Of IS-13947 No No

Box protection
Test
20 OPC Data OPC No No

Access Server, Compliance (Self
Data Exchange Testing certification is
Server & also
Historical Data acceptable)
Access Server
21 Conductivity Degree of IS-2147 No No

Type Level protection
Switch test
22 Local Gauges Degree of IS-2147 No No
protection
test

(2X660 MW)
CLAUSE NO.
23 Process actuated Degree of IS-2147 No No

Switches protection
test
24 Control Valves CV test ISA 75.02& No No

75.11
25 PLCs As per IEC 1131 No No

standard (Col
4)
26 Flow Nozzle Calibration ASME PTC No No

Orifice plates
BS 1042
## The contractor shall submit for Employers approval the reports of all the type test as per
latest IS-10918 carried out within last ten years from the date of Bid opening and the test(s)
should have been either conducted at an independent laboratory or in presence / owners
representative. The complete type test reports shall be for any rating of Battery in a particular
group based on plate dimensions being manufactured by supplier.
Note:
Type Tests are to be conducted only for the items, which are being supplied as a part of this
Package.

(2X660 MW)
NOT USED
CONTROL DESK & PANELS
CLAUSE NO.
1.00.00 CONTROL DESK & PANELS
1.01.00 GENERAL
1.01.01 All control desk, panels, LVS panel etc. shall be furnished fully wired with necessary
provision for convenience outlets, internal lighting, grounding, ventilation, space heating, anti-
vibration pads, internal piping & accessories as required for completeness of the system.
1.01.02 All panels, desks, cabinets shall be free standing type & have bottom / top entry for cables to
be finalised application wise during detailed engineering stage. The bottom of desk &
cabinets shall be sealed with bottom plate, compression cable glands (double for field and
single for inside rooms) and fire proof sealing material to prevent ingress of dust and
propagation of fire. Sufficient number of power receptacles with disconnect switches shall be
installed within all panels/desk.
1.01.03 Exterior steel surface shall be sand blasted, ground smooth, filled, primed, sanded and
smooth enamel painted to give a good finish subject to minimum paint thickness of 65-75
microns for sheet thickness of 3 mm and 50 microns for sheet thickness of 2mm. The exact
color shall be finalised during detailed engineering.
1.01.04 The design shall conform to the EN ISO 11064 (Ergonomical design of control room), Part-
1,2 and 3.
2.00.00 CONTROL DESK & PANEL
2.01.00 GENERAL
2.01.01 The exact dimensions, material, construction details, grounding, general arrangement etc. of
Control Desk etc. shall be as per the actual requirement and shall be finalised during detailed
engineering and subjected to Employer’s Approval. For bidding purpose, the length of the
desk/ panel and CD mounted devices are given in Appendix-I to Part-A, Section-VI.
2.01.02 For control desk mounted instruments/ devices etc., which are to be powered from UPS, all
required conversion of interface equipments / accessories to make such devices compatible
with UPS supply shall be provided. All necessary hardware like Input switches/ fuse unit for
each feeder as well as switch fuse unit for each instrument/ device on the power supply line
shall be provided. From UPS, redundant feeders shall be provided with suitably rated MCB
and provision of fast auto changeover of UPS feeders.
2.02.00 Control Desk (CD)

Control desk shall be Modular, non-welded construction free standing table top type with front &
back cover constructed of 1.6 mm thick CRCA steel plates. The tabletop of the control desk shall be
arc-shaped for mounting TFT monitors & mice for SG, TG, BOP (irrespective of scope of supply)
and synchroscope. TFT monitors and synchroscope shall be provided with adjustable mounting
arrangement. The work surface of control desk shall be 30mm thick with the top 12mm of Acrylic Solid
Surface (ASS) and the remaining 18mm of laminated medium density fiber board. Work surface shall
be made of two different colors at same level and seamlessly joined in each section. The
structure frame shall consist of extruded aluminum top and bottom horizontal beams and
vertical support tensioned together to form an integrated, finished curvilinear shaped frame.
Vertical & Horizontal supports, minimum 2.5mm and 2mm thick respectively, have to be
provided for the structure frame. Extreme side legs shall be illuminated type and should

(2X660 MW)
SECTION – VI, PART-B CONTROL DESK & 1 OF 4
WATER SYSTEM PACKAGE PANELS
CLAUSE NO.
complete the overall form and aesthetics of the desk. It shall have concealed cable & wire way
management system. PA system hand sets, telephone sets, very few PB stations and lamps
shall be mounted on the control desk on mosaic grid structure as per attached list. Sliding
keyboard trays shall be provided on the CD. The exact profile of the desk, dimension and the
radius of curvature shall be finalised during detailed engineering stage.
2.02.01 All operator monitors & mice for SG, TG, BOP shall be mounted on this CD.
2.02.02 The cabling / wiring between OWS & CPU’s, power supply cables etc. shall be aesthetically
routed and concealed from view.
2.03.00 Hardwired devices on Control Desk (CD) (draw out section)
2.03.01 CD shall be provided with a draw out section where hardwired devices shall be mounted on a
mosaic grid mosaic portion for mounting backup.. The mosaic grid tiles shall be of 24 mm x
48 mm (or 25 mm x 50 mm) size, made of heat and flame retardant, self extinguishing and
non-hygroscopic material with flat matt finish without glare and non reflecting type.
2.04.00 Control Desk Devices
"Release" & Lamp Test push buttons shall be provided for a set of push
buttons/Auto/Manual stations. Depending on the type of control/function and required number
of push buttons and indicating LEDs & their color, push button stations shall be selected. The
size of the push button stations & A/M stations shall be 24 x 48 mm or 25x 50 mm and shall
have service inscription details at the front.
Emergency push buttons(with cover) shall be mounted on top of CD, as per quantity
indicated in Part-A of specification.
2.05.00 Unit-Incharge Desk
Profile and construction of the Unit Incharge Desk shall be same as that of CD. Provision for
Operator Work Station and PA system/ telephone handset etc. shall be provided similar to
the Control Desk..
2.05.01 Internal Panel/Desk Items
2.06.00 Equipment and devices mounted within the panels/desk shall be mounted on suitable
racks/brackets and shall be arranged for convenient access for adjustment and maintenance
work.
2.07.00 Furniture
2.08.00 Bidder shall provide following industrial grade furniture items as a minimum from reputed
manufacturers/suppliers meeting International Standards. The furniture shall be modular and
latest with ease of operational features. The furniture shall be modern, aesthetically
designed, modular, flexible, space saving and future safe. Each module shall have
transparent cover and adjustable partition. It shall have locking provision for security. The
components shall be suitable for integration/fabrication without any welding technology.

(2X660 MW)
CLAUSE NO.
1.
Work Station furniture
Modular work station furniture, suitable for mounting servers & historians,
programmer stations, PC based systems, printers (inkjet or A4 laser) etc. is to be
provided..
2.
Server Rack
Server rack shall be provided to mount programmer stations, PC based

systems (of rack type and tower type), Matrix KVM switcher, Mini UPS etc. in
Programmer room. Suitable arrangement for Ventillation and cooling shall be
built in.
3.
PC rack
PC rack shall be provided to mount CPUs of work stations/PCs of OWS/LVS etc in

Control Room.
4.
Chairs
Industry standard revolving chairs with wheels and with provision for adjustment of
height (hydraulically/gas lift) shall be provided for the operators, unit-in-charge &
other personnel in control room area. These shall be designed for sitting for long
duration such that these are comfortable for the back.
5.
Tables
a Industry standard computer tables shall be provided & shall be as approved

by Employer during detailed Engineering.
b Conference Room standard tables shall be provided with acrylic coat for
good finish. Details shall be finalised & approved by Employer during
detailed engg.
6.
Almirahs
Steel Almirahs shall be provided for keeping documents in the documentation

room.
7.
Keypad
Keypads shall be provided for the storing of keys of relevant areas in the
respective control rooms
8.
Lockers
Suitable lockers shall be provided in the room adjacent to the control room for
storing of personal articles of control room personnel & also for documents.
3.00.00 LVS PANEL
3.01.00 An arc shaped Large Video Screen (LVS) panel shall be supplied for mounting large video
screens in number of tiers in various Control rooms as specified at Part-A of specification. An

(2X660 MW)
CLAUSE NO.
indicative typical sketch of Control Room Concept showing LVS & OWS is given in drawing
no. 0000-999-POI-A-061Rev.B.
3.02.00 The profile, dimensions and the general arrangement shall be finalised & approved by
Employer during detailed engineering. Recommendations, if any, for the control room lighting
in order to ensure continuous proper viewing of the LVS screen by the operator & shift
incharge (without any fatigue) shall be clearly brought out by the Contractor in his offer, along
with all relevant details/basis.
3.03.00 Any other requirement for proper LVS mounting & functioning & viewing shall also be
specifically brought out by the Contractor in his offer, along with all relevant details.
4.00.00 CONTRACT QUANTITIES
Refer Appendix-I to Part-A, Section-VI of Technical Specifications.

(2X660 MW)
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
FIELDBUS INSTRUMENTS
CLAUSE NO.
1.00.00 FIELD INSTRUMENTS BASED ON FIELDBUS

The following instruments shall be connected to DDCMIS through fieldbus i.e.
FOUNDATION Fieldbus/PROFIBUS PA protocol complying to IEC 61158 directly
from transmitter.
1.01.00 Electronic Transmitter for Pressure, Differential Pressure and DP based Flow
/ Level measurements.

S No. Features Essential/Minimum Requirements
1. Type of FOUNDATION Fieldbus/PROFIBUS PA based

Transmitter output
2 Accuracy ± 0.060 % of calibrated range (minimum) for

calibrated range greater than 400 mmwc.
+0.065% of calibrated range (minimum) for
calibrated range greater than 250 kg/cm2.
± 0.10 % of calibrated range (minimum) for
calibrated range less than 400 mmwc.
3. Stability 0.25 % of calibrated range for 10 years for

calibrated range greater than equal to 400 mmwc
on standard conditions of manufacturer.
0.2 % of calibrated range for 1 years for calibrated
range less than 400 mmwc on standard conditions
of manufacturer.
0.15% of calibrated range for 5 years for DPT with
static pressure greater than 250 kg/cm2.
4 Turn down
50:1 for greater than or equal to span of 400mmwcl.
20:1 for span below 400mmwcl.
10:1 for span greater than 250 kg/cm2
(Above mentioned (2,3,4) parameters/features of offered models shall be
strictly as defined in standard published catalogue of the manufacturer
only).
5 Housing Weather proof as per IP-67, metallic housing with
durable corrosion resistant coating
6. Electrical ½” NPT(F) FOUNDATION Fieldbus/PROFIBUS PA
connection compatible

PAGE
(2X660 MW) SECTION – VI, PART-B SUB-SECTION-IIIC-18
1 OF 4
WATER SYSTEM PACKAGE BID DOC NO.:THDC/RKSH/CC-9915-373 FIELDBUS INSTRUMENTS
CLAUSE NO.
7. Process ½” NPT (F)

connection
8. Operating Ambient 85 deg C without display.

temperature
Overpressure 150% of max operating pressure
9 Accessories -Diaphragm seal, pulsation dampeners, syphon etc.
as required by service and operating condition.
-2 valve manifold for absolute & gauge pressure
transmitters, -3-valve for DP and 5 valve manifold
for level/flow applications.
-The valve manifold shall be non-integral type.
-For hazardous area, enclosure as described in
NEC article 5.
10. Mounting 2 inch pipe mounting with Enclosure/Rack/Canopy.
11. Diagnostics & Self-Indicating feature and digital display on

display transmitter
Notes
- For primary air/ secondary air/flue gas/ furnace pressure applications, DP type
transmitters shall be provided for pressure measurement below 2000 mmwc.
- LVDT type is not acceptable.
- Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be
removable for cleaning. The entire volume above the diaphragm shall be
completely filled with an inert liquid suitable for the application.
1.02.00 Temperature Transmitter
1.02.01 Single Input /Dual Input Temperature transmitter
Temperature transmitter shall be provided which shall be fully compatible with

thermocouples and RTDs being provided by the contractor. Temperature
compensation for thermocouples shall be performed in the temperature
transmitter itself. Transmitters shall be capable of withstanding ambient
temperature up to 85 deg C.

Following specifications are applicable for dual input/single input temperature
transmitter.

PAGE
2 OF 4
CLAUSE NO.

S No. Features Essential/Minimum Requirements
1. Output FOUNDATION fieldbus /PROFIBUS PA
2. Input Same transmitter shall be capable to handle Pt-100
RTD, Thermocouples –K, R & ,S types
3. Housing Weather proof as per IP-67, metallic housing with
durable corrosion resistant coating
4. Electrical ½” NPT(F) FOUNDATION Fieldbus/PROFIBUS PA
connection compatible
5. Diagnostics & Self-Indicating feature and digital display on
display transmitter
6. Operating 85 deg C without display.
Ambient
temperature
7. Mounting 2 inch pipe mounting with Canopy.
8. Accessories As required by service and operating condition.
9. Composite (Refer note 2 )

Accuracy
RTD =<0.25% of 0-250 deg C span
T/C-K type =<0.2% of 0-600 deg C span
CJC accuracy (for thermocouples) shall be =< 1 deg
C
Notes:
1. In case of failure (open or burn-out) of RTD/thermocouple, transmitter shall
provide low temperature output.
2. Dual input temperature transmitter shall have bump less changeover
facility to second sensor in case first sensor fails. This changeover is to be
alarmed.
3. Composite accuracy is to be calculated as summation of all applicable
accuracies of temperature transmitter for converting sensor input to output
(e.g., basic accuracy, digital accuracy, etc.) and temperature effect on
these accuracies at ambient temperature of 50 deg C, based on the figure/
formula given in the standard product catalogue for span as specified
above for various types of temperature elements specified. All such
accuracy/ temperature effect figures in catalogue shall be first converted to
deg C, and then percentage of this converted accuracy in specified span
shall be calculated to compare with the specified composite accuracy
figures. All temperature transmitters shall be interchangeable (i.e. can be
used for either RTD or thermocouple) and composite accuracy shall be met
for each type of input as specified above.

PAGE
3 OF 4
CLAUSE NO.
3. Above mentioned parameters/features of offered models shall be strictly as

defined in standard published catalogue of the manufacturer only.
4. Dual input temperature transmitters can also be accepted in place of single
input TT.

1.02.02 Multi Input Temperature transmitter (Temperature Multiplexer)
For only information related temperature inputs fieldbus based Multi input
temperature transmitters can be provided. Transmitters shall be capable of
withstanding ambient temperature upto 85 deg C. Maximum number of inputs per
such temperature transmitter shall be eight. These shall be mounted in standard
enclosures available along with manufacturer of such TTs, with minimum IP-67
protection class. Exact applications shall be as defined in PART-A of
specifications.

PAGE
4 OF 4
ELECTRIC ACTUATORS
`
CLAUSE NO.
1.00.00 GENERAL:
1.01.00 Actuators shall be designed for valve operation to ensure proper function in accordance with
specifications given below and complying to EN15714-2 or equivalent. All standards,
specifications and codes of practice referred to herein shall be the latest editions including all
applicable official amendments and revisions.
1.02.00 This sub-section of specification is applicable for following types of electric actuators:
1.02.01 Modulating duty electric actuators:
These shall be provided as per standard practice of OEM of equipment, meeting other
requirements of specifications. The examples of such applications are Blade pitch actuators
of ID/FD/PA Fans, Scoop tube actuator of BFPs etc. For specifications of Blade pitch actuators
of ID/FD/PA Fans, refer clause no. 5.00.00 of this chapter.
1.02.02 Electric actuators for valves/ dampers/ gates (other than covered in 1.02.01):
These actuators shall be Non-Intrusive type electric actuators. The interface of these actuators
with DDCMIS shall be of two types viz. with Hardwired interface and with Fieldbus interface.
The common requirements of both these type of actuators are specified at clause 2.00.00,
specific requirements of Non-Intrusive hardwired actuators are specified at clause 3.00.00 and
specific requirements of Non-Intrusive fieldbus actuators are specified at clause 4.00.00. The
applications where these two types of actuators are to be provided is specified in Part-A of
Technical Specifications.
2.00.00 COMMON REQUIREMENTS FOR NON INTRUSIVE ELECTRIC ACTUATORS
2.01.00 TYPE:
2.01.01 The actuators shall have integral starters with built in SPP (Single Phasing Preventer). 415 V,
3 phase 3 wire power supply shall be given to the actuator from switch board as applicable
through a switch fuse unit. Control voltage of the motor starter shall be 110 V AC / 24 V DC,
derived suitably from 415V power supply.
2.01.02 The actuators shall be Non- Intrusive electric actuator. All actuator settings including torque,
limit shall be possible without opening the actuator cover and LCD indication shall be available
integral to actuator body.
2.02.00 RATING:
(a) Supply Voltage & frequency: 415V +/- 10%, 3 Phase, 3 Wire & 50HZ +/-5%.
(b) Sizing:
Open/Close at rated speed against designed differential pressure at 90% of rated

voltage.
For ON/OFF type: Three successive open-close operations or 15 minutes, whichever

is higher.
For inching type: 150 starts per hour or required cycles, whichever is higher.
2.03.00 CONSTRUCTION:
(a) Enclosure:
Totally enclosed weatherproof, minimum IP-68 degree of protection.
(b) Manual Wheel:
Shall disengage automatically during motor operation.

TECHNICAL SPECIFICATION SUB-SECTION IIIC-19 PAGE
(2X660 MW) ELECTRIC ACTUATORS
`
CLAUSE NO.
2.04.00 MOTOR:
(a) Type :
Squirrel cage induction motor suitable for Direct On Line ( DOL )starting.
(b) Enclosure:
Totally enclosed, self-ventilated.
(c) Insulation
Class F. Temperature rise 70 Deg C. over 50 Deg C ambient.

Bearings:
(d)
Double shielded, grease lubricated antifriction.
(e) Earth Terminals:
Two
(f) Protection:
Single Phasing Protection, Over heating protection through Thermostat (as

applicable) and wrong phase sequence protection shall be provided over and above
other protection features standard to bidder's design. Suitable means shall be
provided to diagnose the type of fault locally.
2.05.00 POSITION/TORQUE TRANSMITTER:

The Position/ Limit measurement shall be done using absolute encoders which will give
information of position/ limit in both the directions. Electronic measurement of torque shall be
provided.
2.06.00 LOCAL OPERATION:
It shall be possible to operate the actuator locally also. Lockable local/remote selection shall
be provided on the actuator.
2.07.00 LCD DISPLAY:
A local LCD display shall be provided to give information regarding actuator alarms, status
and valve position indications as a minimum in local.
2.08.00 WIRING:
Suitable voltage grade copper wire.
2.09.00 TERMINAL BLOCK:
For power cables, the grade of TBs shall be minimum 650V.

2.10.00 ACCESSORIES:
All required accessories (if applicable) for calibration / settings/ configuration of various
parameters of actuator shall be provided. For quantities, please refer Part A of technical
specifications.

`
CLAUSE NO.
2.11.00 SIL CERTIFICATION:

All actuators shall be certified for SIL 2 or better.
3.00.00 SPECIFIC REQUREMENTS FOR NON INTRUSIVE HARDWIRED ACTUATORS

3.01.00 INTERFACES:
For ON-OFF and INCHING type actuators interface with the control system shall be through
hardwired signal only.
(a) Open/Close command, open/ close status and disturbance monitoring signal (common
contact for Overload, Thermostat, control supply failure, L/R selector switch at local &
other protections operated) shall be provided hardwired.
(b) The actuator shall be able to accept open/close command at 24V DC with max. 2.5VA
load from control system. Accordingly suitable isolated interface in the actuator shall
be provided.
(c) Open/close command termination logic shall be suitably built inside actuator.
(d) For typical wiring diagram Refer Tender Drawing No. 0000-999-POI-A-063 (Except
plug & socket connector, if not applicable)
3.02.00 TERMINAL BOX:

Suitable terminals/ connectors, integral to actuator, for terminating instrumentation & power
cables shall be provided. Necessary glands for power cables and instrumentation cables shall
be provided.
3.03.00 TRAINING:
Contractor shall provide training on Non-Intrusive hardwired Electric Actuator for Employer’s
personnel. The duration of the training shall be as elaborated in Part-C, Section-VI of technical
specifications.
4.00.00 SPECIFIC REQUIREMENTS FOR NON INTRUSIVE FIELDBUS ACTUATORS

4.01.00 INTERFACES:
For ON-OFF and INCHING type actuators interface with the control system shall be through
fieldbus network.
(a)
Open/ close commands, open/ close feedback status, disturbance signal etc. shall be
available to the Control System through the fieldbus network along with diagnostics.
The detailed diagnostics including the actuator operating data shall be available to the
DDCMIS through the fieldbus network.
(b) All actuators shall be Foundation Fieldbus/ Profibus compatible. However the exact
protocol shall be based on finalized protocol of DDCMIS. If Profibus DP protocol is
envisaged then actuator shall have two (redundant) Profibus DP ports for connecting
the redundant Profibus DP cables. That is if one profibus cable is cut or not working/
not available, then complete actuator functionality shall be available through the
second redundant cable without any manual intervention.

`
CLAUSE NO.
(c) Open/close command termination logic shall be suitably built inside actuator.
4.02.00 TERMINAL BOX:
Suitable terminals/ connectors, integral to actuator, for terminating fieldbus cables and power
cables shall be provided. Necessary glands for power cables and armored fieldbus cables
shall be provided.
4.03.00 TRAINING:
Contractor shall provide training on Non-Intrusive Fieldbus Electric Actuator along with detail
training on Foundation Fieldbus/ Profibus interface used in actuator for Employer’s personnel.
The duration of the training shall be as elaborated in Part-C, Section-VI of technical
specifications.
5.00.00 SPECIFIC REQUIREMENTS FOR BLADE PITCH ACTUATORS OF ID/FD/PA FANS
Sl Description Requirement
No.
1. Duty Continuous duty / Modulation,
2. Operating Ambient Temperature -20 to +60 Deg C or better
3. Enclosure Protection IP 68
4. Resolution/ Precision 0.1%- 0.2% or better of total travel
5. Supply Voltage & frequency 415V +/- 10%, 3 Phase, 50HZ +/-5%
or
230V +/- 10%, Single Phase, 50Hz +/- 5%
6. Motor Suitable for Continuous Duty
7. Motor insulation Class F
8. Analog Control 4-20mA, (24VDC)
9. Position Transmitter 4-20mA (24VDC)
10. Integral Starter Yes
11. Terminal Block For power cables, the grade of TBs shall be
minimum 600V
12. Accessories (if applicable) for calibration / settings/ configuration of
various parameters of actuator shall be
provided
13. Hand wheel Yes
14. Standard Compliance EN 15714-2 Class D or equivalent

NOT USED
PART-B
SUB-SECTION – IIID-01
CIVIL WORKS

CLAUSE NO.
1.00.00 GENERAL
1.01.00 This specification is to cover, survey works, design, preparation of general arrangement
drawings, construction and fabrication drawings, supply of labour & materials and
construction of all civil, structural and architectural works by the Bidder.
Description of various items of work under this specification and nature of work in detail are
given hereinafter. The complete work under this scope is referred to as civil works. Various
buildings, structures, plant and systems, facilities, etc., covered under the scope is given in
Part-A and herein.
The work to be performed under this specification consists of design, engineering,
construction, erection and providing all labour, materials, consumables, equipment,
temporary works, temporary storage sheds, temporary colony for labour and staff, temporary
site offices, constructional plants, fuel supply, transportation and all incidental items not
shown or specified but reasonably implied or necessary for the completion and proper
functioning of the plant, all in strict accordance with the specifications including revisions and
amendments thereto as may be required during the execution of work.
All construction materials including cement, reinforcement steel, coarse & fine aggregate,
structural steel and construction water etc., shall be arranged by the Bidder.
The scope shall also include setting up by the Bidder a complete testing laboratory in the
field to carry out all relevant tests for structural steel, reinforcement steel & reinforced
concrete (RCC) works.
Preliminary geotechnical investigation in the proposed area has been carried out by the
Owner and the bore-log data is furnished in Annexure ‘C’. Detailed Geotechnical
Investigation shall be carried out by the bidder. The foundation system shall be evaluated by
the bidder based on the above mentioned detailed geotechnical investigation.
The work shall be carried out according to the design/drawings to be developed by the
Bidder and approved by the Employer. For all buildings, facilities, systems, structures, etc.,
necessary layout and details are to be developed by the Bidder keeping in view the statutory
and functional requirements and providing enough space and access for operation, use and
maintenance. The Bidder’s work shall cover the complete requirements as per IS codes, fire
safety norms, requirements of various statutory bodies, International Standards, best
prevailing practices and to the complete satisfaction of the Employer.
The Bidder shall make the layout and levels of all structures from the general grid of the plot
and the nearest GSI benchmark or other acceptable benchmark of Government. department.
As per the directions of the Engineer. The Bidder shall be solely responsible for the
correctness of the layout and levels and shall also provide necessary instruments, materials,
access to works, etc., to the Engineer for general checking of the correctness of the civil
works.
All the quality standards, tolerances, welding standards and other technical requirements
shall be strictly adhered to.
The Bidder shall fully apprise himself of the prevailing conditions at the proposed site,
climatic conditions including monsoon pattern, soil conditions, local conditions and site
specific parameters and shall include for all such conditions and contingent measures in the
bid, including those which may not have been specifically brought out in the specifications.
In case of any conflict between stipulations in various portions of the specification, most
stringent stipulation would be applicable for implementation by the Bidder without any extra
cost to the Employer.
Wherever there is an anomaly in the design concept between the data furnished in the
General Design Criteria & Design Concept of Buildings, the data furnished in the design
concept of buildings shall be treated as final.
Bidder or his agencies engaged as detailer for fabrication drawings should have the
experience of detailing for power house structures or steel plant or Industrial structures like
Petro/Chemical/Refinery/Cement etc.

SUB-SECTION-IIID-01 PAGE
CIVIL WORKS 1 OF 126
CLAUSE NO.
Bidder shall obtain the approval of detailing agency for making fabrication drawings before
engaging them.
2.00.00 SCOPE OF WORK

2.01.01 The scope of work for the EPC contractor shall include the analysis, design, construction,
erection of all civil, structural & architectural works and all other items mentioned in Part-A of
this Specification.
2.02.00 Construction Facilities
For details of construction facilities refer to Part-A of this specification.
2.03.00 Exclusions:
The details of exclusions and terminal points, refer to Part-A of this specification.
3.00.00 SUBMISSIONS
3.01.00 The documents and drawings as listed below are to be submitted for the approval of the
Employer unless specified otherwise. The list given below is not exhaustive but indicative
only.
3.02.00 Project design intent document giving the basis of design, which shall cover all the aspects,
parameters, assumptions, references, structural idealization / mathematical model, loading
cases, load combinations, basis of analysis and design of all buildings, facilities, systems and
structures etc. shall be furnished and got approved before commencement of detailed
engineering.
a) Structural analysis, design calculations and drawings of substructure and super
structures for all buildings, structures, facilities, and systems. Analysis, design
calculations and drawings for all services like roads, culverts, bridges, road/rail
crossings, drainage pump houses (if required), drains, sewers, sewage pump house,
water supply, water tank, coal conveyor galleries, trestles, transfer points, trenches,
ducts, etc.
b) Survey drawings indicating spot levels for the area under the scope of work and L-
section along pipe corridors outside plant boundary.
c) Plant 'General Layout Plan' drawing with coordinates of roads, boundary wall, buildings
and facilities, piping/cable corridors, railway lines, green belt, etc.
d) Drawings showing underground facilities with co-ordinates and invert levels of the
facilities like buried pipes, buried cables, trenches, ducts, sewers, drains, sumps, pits,
culverts, manholes, etc.
e) Bidder shall engage a specialized architect consultants with experience in different
design aspects like architecture, interior design & landscape design. The consultant
shall be involved in the overall architectural design and character of the buildings.
However detailing work of the individual buildings may be done by In-house architects
having adequate experience. The consultant shall evolve the design based on
employer's guidelines and shall present it in the form of presentation drawings, detail
drawings, perspective view& 3D model/ walk through. All drawing and document shall
be duly stamped by the registered architect.
f) All architectural drawings required for execution of construction work such as detail
floor plans, detail elevations, detail sections and other miscellaneous architectural
details such as finish schedule(internal & external), colour schemes (both internal and
external), doors and windows, flooring details & pattern,Atrium Vault/ Dome in
polycarbonate sheet in the roof, false flooring, false ceiling, etc., architectural fascia
and projections, miscellaneous stair details &architectural details like, coping, flashing,
khurras, water proofing, fillet, roof decking, wall cladding, surface drains, rain water
down comers, sanitary, plumbing, etc.

CLAUSE NO.
i) Design criteria and design calculations including dynamic analysis and drawings for all
foundations subjected to dynamic loadings.
j) All statutory clearance and permits from concerned local bodies/authorities, write-up on
various statutory requirements and their compliance for various buildings, facilities,
structures and systems, etc.
k) As-Built final architectural drawings andAs-Built final shop drawings/fabrication
drawings of all structural steel works(only for reference)and design calculations for
important joints/connections
l) In case of piling, scheme for initial pile load tests in vertical, lateral and uplift modes
along with supporting design calculations, scheme of routine load test of piles, High
Strain Dynamic Load Test, Pile Integrity Tests and methodology for installation of
working piles.
m) In case of piling, the design of piles in terms of type, rated capacity, length, diameter
and termination criteria to locate the founding level.
n) Material test certificates.
o) As-built drawings with quantities of various items of work system wise, building wise,
structure wise, etc. duly certified by Site after execution of work for information/record.
p) Details of corrosion protection measures for all structures.
q) One complete set of applicable standards, references, specifications, code of practice
along with soft copy (wherever required with minimum 2 years license fee) to the
Engineer for use at site.
r) Wherever applicable, scheme for dewatering, shoring, strutting/sheet piling.
s) All other design details/drawings or any other submission as indicated elsewhere in
this specification and as required by the Employer.
t) Commencement of fabrication and erection and construction shall be done after
approval of the relevant documents and drawings. All drawings shall be of standard
sizes (Metric System) and shall be made on AutoCAD. All documents shall be made
using MS office. Bidder shall submit all documents and drawings as specified in Part–C
(General technical requirement) of the bidding document.
u) In general 3D modeling and structural frame analysis and design for the plant
structures shall be submitted by the bidder for Employer’s review and approval. Soft
copy of 3D modeling (including input and output files shall be submitted.
v) All construction drawings shall include total quantity of concrete (grade wise),
reinforcement (diameter wise) and structural steel (section wise).
4.00.00 GENERAL LAYOUT PLAN
4.01.00 The preliminary layout plan proposed for the project is shown in the drawing titled "General
layout plan". It shall form the basis for further elaboration by the Bidder for the plant facilities,
which are in his scope. Area identified for facilities remain same as indicated in GLP,
however, minor modification of location of building may be done to optimize layout.
Bidder shall prepare the detailed layout of the plant facilities which are in his scope and shall
submit the same for Owner's approval.
While preparing the detailed layout, planning his facilities and deciding upon the
transportation and erection strategy he shall ensure the following aspects.
a) All Statutory requirements including safe distances between various facilities as per
applicable rules/acts/laws including local bye-laws are met.
b) Face of the buildings and facilities are located in such a way so as to have an offset
of minimum 20m with respect to centre line of double lane road and 15 metre with
respect to centre line of single lane road.

CLAUSE NO.
c) The entire construction activity shall take into account the commissioning of the units
in phases matching with the phased commissioning of the plant.
d) The interface requirements with the plant construction/erection activities of other
contracting agencies engaged by Owner. These agencies engaged will be working
simultaneously with the Bidder within the plant premises.
e) The area for construction/erection facilities like lay-down, pre-assembly, offices and
stores have been earmarked on the General Layout Plan.
f) No permanent facility shall be located within the safety zone limit around the fuel Oil
storage tanks etc., except those permitted by Owner.
g) Transportation of all equipment and materials shall be by road as envisaged. Any
other mode envisaged by the bidder may be proposed. However the same may be
adopted subject to approval of the Employer.
h) All the buildings and facilities shall be approachable by fire tenders.
5.00.00 SALIENT FEATURES & DESIGN CONCEPT
This section of specification covers salient features and design concepts of Civil, Structural
and architectural works pertaining, CW system and Raw Water System, Cooling Towers,
Water treatment plant system, Station piping, FDPS.
5.01.00 Architectural Concepts &Design
a) All the Architectural design works shall be carried out by professionally qualified
architects having adequate experience in the design and detailing of architectural work
of power plant buildings. Bidder may have in-house Architects with the required
experience for the above or engage Architect Consultant having similar experience.
Bidder shall submit adequate documentary proof in support of the qualification &
experience of Architects and Landscape designers.
b) Power plant buildings shall be architecturally treated, based on functional requirements,

in such a way that they retain the desired scale, and present a pleasing composition of
mass and void. The overall impact of the buildings shall be one of aesthetically unified
architectural treatment having a comprehendible scale, blending colour scheme with the
surroundings.
c) All buildings and structures shall be architecturally treated in such a way so as to be in

complete harmony with the main plant building, surrounding structures and environment.
Due considerations shall be given to orientation, landscape design, and interior design.
All finishes for floors, walls, ceiling, structural elements, partitions for offices and
industrial areas shall be suitable for their aesthetics, durability and functional
requirements and shall include the latest building material & technology. Consideration
shall be given for achieving standardization & fast track construction.
d) Overall colour scheme of the Main plant building and other buildings shall be designed
judiciously and in a comprehensive manner taking into a account the mass and void of
buildings, its facade, equipment, exposed structural elements, piping, trestles, bus
ducts, and other service elements.
e) For adequate light and ventilation, National Building Code recommendations shall be
followed. All buildings having height more than 4.0 m shall have glazed ventilators.

CLAUSE NO.
f) All the buildings shall be architecturally designed to meet the National Building Code
requirement & Fire Safety Regulations &incorporating sustainable building design
features like energy efficiency, solid waste management, water conservation and
recycling, use of local material etc.
g) All public buildings shall be designed incorporating the provision of barrier free
environment for physically disabled persons.
h) All the buildings and site development including landscaping shall be designed to take
care of rain water harvesting &ground water recharging. Development of rain water
harvesting scheme for the project and obtaining approval of the scheme from Central
Ground Water Board is in Bidder’s Scope.
i) Overall emphasis shall be on developing eco-friendly architecture, merging with the

nature with its own sustainable energy management systems. Ecofriendly architecture
means design and constructions that are eco-friendly and helps to save the natural
resources of the earth. . The above definition is only indicative and the bidder shall
incorporate the above features into design and construction to achieve a sustainable,
ecofriendly architectural design for the whole project.
j) Landscape Development
There shall be comprehensive landscape development in entire plant area to create a

pleasant and healthy environment. The scope of work for landscape and horticulture
work shall include supply and planting of trees, shrubs, hedges/edges/borders, grass
lawn around different areas, buffer and peripheral plantation etc. The scope shall also
include supply and installation of all landscape furniture i.e. Park-Benches, &gazebos,
landscape fountain & water bodies, landscape pavers/ tiles etc and all associated
electrical works/ items, mechanical works/items and civil works and all other work
required for completion of landscape development. The landscape design and drawing
shall be developed by competent and signed by landscape architect. The landscape
shall use the suitable plants and trees preferably local trees, plants, and shrubs. There
shall be provision of pathways in and around the landscaped area. Around the pathways
and roads, trees shall be planted. There shall be provision of drip/sprinkler irrigation
system for irrigation of landscaped area. There shall be intense landscape with water
body development one each near Service building. Minimum size of water bodies shall
be 5.5m diameter and 1.0m depth.
The landscape (including water body) around Service Building shall meet the GRIHA
requirement for 3 STAR rating.
k) The development of green belt is not in bidder scope. However, bidder has to plan the
facilities leaving the space for peripheral green belt of average width of 100m around the
main facilities of power plant. In addition to that laydown areas and other vacant land of
the plant will be used by owner for the development of green belt.
l) All floor areas indicated in subsequent pages shall be total floor area required.

CLAUSE NO.
Cooling Towers
5.02.01 Induced Draught Cooling Towers
The civil works for cooling towers are related mainly to following areas, but not limited to:
5.02.01.01 Cooling Tower Basin
The basin of the cooling tower for collection of cold water shall be made of Reinforced
Cement Concrete (RCC M - 30 grade as per IS: 456). The floor of the basin shall be sloped
to minimum 1 in 80 towards the sludge drains. The required slope shall be achieved by
screed concrete of grade M-15 as per IS:456 having minimum thickness at edge as 25 mm.
Drainage arrangement of basin shall be as specified elsewhere in the Technical
Specifications. If the cooling tower basin and sludge sump is below ground level, FRP hand
railing shall be provided all around the cooling tower basin and sludge sump pit. The bottom
500 mm of hand railing shall also have FRP/PVC wire mesh with opening size of 50mm grid
to avoid ingress of leaves, vegetation, and debris into the basin. The basin shall be tested for
water tightness as per IS:3370.
Bottom of the lowest level beam shall be at least at free board level. In case, the beams are
provided into the water, the same shall be designed for un-cracked section as per IS:3370.
Hot water duct around cooling towers, if placed below ground shall be encased with min.
500mm thick PCC (M20 grade).
a) Foundation of Cooling Tower
The foundation of the Cooling Tower shall be as detailed out elsewhere in the
specifications.
b) Super Structure of Cooling Tower (applicable in case of RCC cooling tower)
Columns, beams and other structures like tie beams, slabs etc. shall be of reinforced
cement concrete of grade M-30 (minimum) as per IS : 456. Uniform concrete grade
shall be used for the entire cast-in-situ reinforced concrete superstructure.
The fan deck slab shall be properly sloped so that rain water does not accumulate
over the deck slab. The slope shall be 1 : 120 (min.). The slope shall be provided
with screed concrete of grade M-15 (minimum) as per IS : 456.. Fan Deck slab and
all other over ground platforms shall be provided with FRP handrailing. Suitable
arrangement for drainage of rain water to be provided. However, there is no specific
requirement of Rain Water down comers.
c) Cells, Distribution System and Stack (applicable in case of RCC cooling tower)
Cooling tower cells shall consist of RCC columns, beams and walls. The spacing of
columns shall be minimum 4000 mm c/c. Inclined bracings shall not be provided
between the columns. Hot water distribution channel shall also be of RCC. Cell
division partition walls shall be of precast solid concrete blocks with provision of
pilasters for walls, if required. The peripheral wall shall be Cast-in-Situ RCC wall and
shall have two layers of reinforcement on either faces in both directions with
minimum dia of reinforcement bars as 8 mm and maximum spacing as 150 mm c/c.
Minimum thickness of Cast-in-Situ RCC peripheral walls shall be 200 mm.
Hot water channel shall be covered with suitably designed precast / cast - in - situ
concrete slab. Wherever flow control valves are located over hot water basin, these
shall be placed over precast concrete covers / concrete slab and designed for
specified load. The minimum thickness of RCC fan stack shall be 150 mm. The
fanstack shall have two layers of reinforcement on either faces in both directions with
minimum dia of reinforcement bars as 8mm and maximum spacing as 200mm c/c.

CLAUSE NO.
d) Stairs
RCC staircase for approach to fan deck for each cooling tower shall be provided.
The stairs shall have 1000 mm clear width and FRP hand railing. The riser shall be
maximum 175 mm & treads 250 mm (minimum). Edge protection angle (min
35X35X6, made of aluminum) shall be provided to the treads with the lugs.
e) Steel Structures
All mild steel parts of structures used in cooling towers shall be hot dip galvanized or
seal spray zinc coated as per BS:5493 (for a very long period of maintenance of
more than 20 years). The minimum coating for galvanization shall be 610 gm/sq.m
and shall comply with relevant IS Codes. Galvanizing shall be checked and tested in
accordance with IS: 2629. All welding shall be done before galvanizing. Any site
joints required to be carried out after galvanizing shall be either flanged or screwed
joints. Nails, nuts, bolts and all components coming in direct contact with water shall
be of stainless steel of SS 316.
f) Water proofing of structures and construction joints

For water proofing of underground structures including basin slab and hot water
distribution channel, water proofing cum plasticizer compound shall be mixed with
the concrete. In addition Chemical injection treatment shall be provided for the
construction joints of all underground structures.
g) Expansion Joints
PVC sealing strips shall be used for all expansion joints where water is retained. The
minimum thickness of PVC sealing strip will be 6 mm (minimum) and minimum width
225 mm. The expansion joint shall be as per IS: 3370. At expansion joints, joints filler
material with sealing compound on both sides shall be provided throughout the
length of the joint.
h) Grade of concrete
All RCC associated with induced draught cooling towers including switchgear and
control room, unless specified otherwise, shall be design mix (controlled) concrete of
grade M 30 of IS: 456. Water - cement ratio shall not exceed 0.45.
Minimum 75 mm thick PCC of grade M-7.5 as per IS: 456 shall be provided as mud
mat below foundation unless specified otherwise. The PCC shall extend 75 mm
beyond the outer edge of structural concrete.
For water retaining structure minimum 100 mm thick PCC of grade M-10 as per
IS:456 shall be provided as mud mat below the bottom slab / raft. The PCC shall
extend 100 mm beyond the outer edge of the structural concrete.
i) Form-Work
Plywood Form-work shall be used for basin, basin walls, outlet channel and super
structures.
j) Doors
FRP door shall be provided in each fan stack at fan deck level. Door height & width
as per requirement for equipment movement (clear) shall be provided. However,
door size shall be minimum 2100 mm high (clear) & 1200 mm wide (clear). Door
shall have locking facility.

CLAUSE NO.
k) Coating
All concrete surfaces in direct contact with water/ water spray/moist air shall be
applied with Moisture Compatible Corrosion Resistant Coating System or its
equivalent as specified in Annexure-G. All concrete surfaces subject to water/ water
spray/moist air upto and including Fan Deck slab level including basin slab, inner
faces of peripheral walls, all faces of cell partition wall, all faces of columns, all faces
of beams (both cast in situ and precast), bottom surface of fandeck slab for counter
flow tower and both surface of fandeck slab for cross flow tower, inner face of
fanstack, all faces of hot water basin (for cross flow tower), etc as applicable shall
receive the said coating after cleaning and drying of the concrete surface. The
detailed specification of the coating system on concrete surfaces is given in
Annexure-G.
External surfaces of Cooling tower peripheral walls and fanstack shall be painted
with two or more coats of waterproof cement paint of approved shade, make and
color.
l) Paving
Paving shall be provided for a minimum clear width of 5.0 m from the outer face of
the HW pipes all around the cooling tower basin. Paving shall also be provided in
between the hot water pipes and space available between HW pipes and CT basin
wall spray catcher. The minimum total width of paving around CT basin shall be
atleast 8.5 m from outer edge of the spray catcher or basin wall. Paving shall consist
of reinforced concrete base slab laid over 75 mm thick PCC of grade M-10 as per
IS:456 sub-base and 200 mm thick stone soling. The sub-base shall be laid on the
compacted and suitably prepared sub-grade. The degree of compaction of sub-grade
shall be as specified elsewhere in the specification. The thickness of the RCC base
slab of grade M - 25 shall be suitably designed considering a superimposed load
intensity of 5T / Sq.m. However the minimum thickness of base slab shall be not less
than 150 mm having double layered reinforcement in both directions both top and
bottom. The maximum spacing of the reinforcement bars shall be 150mm c/c and
minimum dia of reinforcement bars shall be 8mm.
RCC peripheral drain of minimum cross sectional dimensions 300mm X 300mm to
dispose storm water shall be provided around area paving and shall be connected to
nearest Owner’s storm water drain.
m) Walkways
Permanent walkways at least 1000mm clear width shall be provided at hot water
distribution level and at drift eliminator level for counter flow type cooling towers. The
clear working height available above these walkways shall be at least 2.0 meters.
The walkway and its supporting structure shall be of RCC M - 30 grade. Suitable
RCC guards rails 300 mm high shall also be provided on both sides of these
walkways. Over the guard rails FRP hand railing shall be provided. The vertical post
of handrail shall be 700 mm high and at an interval of 1500mm c/c. There shall be
two levels of horizontal pipes for hand railing spaced equally in vertical plane.
Permanent walkways at least 1000 mm clear width shall also be provided for access
to fan and around gear box with FRP gratings of clear opening size not more than 50
MM x 50 mm and grating thickness of 50 mm on RCC supports at fan deck Level.
5.02.01.02 Design Criteria
R.C.C. Structures
(a) The design of all liquid retaining/conveying structures of cooling tower like C.W. basin,
sump, hot water distribution channel/basin, sludge drain and pits shall be designed by

CLAUSE NO.
working stress method as outlined in Clause 4.5 of IS 3370 (Part 2) : 2009. These
structures shall be designed for following conditions :-
1. Water filled inside upto the designed level and no earth outside.
2. Earth pressure plus 2.0 T / M2 surcharge (Vertical direction) plus ground
water table at Finished Graded ground Level (FGL) outside and no water
inside.
(b) The design of all structures other than liquid retaining/conveying structures of cooling
tower above CW basin slab such as columns, beams, fins, walkways, slabs,
cladding/partition wall, fan stack, precast beams etc. as applicable shall be carried out
by limit state method as outlined in Clause 4.4 of IS: 3370 (Part 2): 2009. Further, for
limiting the crack width, the stress for the reinforcement steel shall be limited to 130
MPa (on all faces) as per clause 4.4.3.1 of IS: 3370 (Part 2): 2009 using the partial
safety factor for serviceability condition as per clause 4.4.1.3.
Wherever, the foundation raft of cooling tower is same as CW basin slab, the
foundation shall be designed by working stress method as outlined in Clause 4.5 of IS
3370 (Part 2): 2009 (all faces). However, if the cooling tower foundation is not the
same as the CW basin slab and a separate foundation for the cooling tower is provided
below the CW basin slab due to founding level requirements, the basin slab shall be
designed as a structural slab resting on grid of beams taking support from columns or
as a flat slab taking support from columns. Arrangement with providing walls between
the columns and the periphery to support the structural basin slab is not permitted. The
CW basin slab (both faces, including beams at CW basin slab level) shall be designed
as structural slab by working stress method as outlined in Clause 4.5 of IS 3370 (Part
2): 2009 and the structures below CW basin slab shall be designed as per IS:456
(2000). However, the size of the column below CW basin slab upto foundation shall be
maintained same as the size of the columns just above CW basin slab.
(c) The design of staircase, switchgear building, control room/RIO room, transformer and
trestle foundation, storm water drain shall be as per IS: 456 (2000).
(d) The Cold Water basin shall be checked against uplift for basin empty condition with
ground water table at FGL. Stability against uplift shall be ensured both for construction
& operating stage with no water inside. The provision of flap valve / pressure release
valves is not permitted. The factor of safety against uplift shall be as per IS: 3370.
(e) Fan deck shall also be designed for rolling loads due to movement of equipment during
Installation / maintenance operation.
Minimum Clear cover for all RCC structures/elements of cooling towers to meet
durability requirements shall conform to severe exposure condition as per IS: 456
(2000).
Fan Supporting Structures (applicable in case of RCC cooling tower)
Static Analysis & Design
The following load conditions and load combinations shall be considered for the design of the
Fan supporting structures.
(a) Machine Load
(b) Load case (a) + unbalance load for the balance of the fan corresponding to G16 as per
ISO 1940-1: 2003
(c) Load case (a) + unbalance load corresponding to one blade failure load condition.
The strength design of the Fan supporting structure shall be done for worst loading
combinations as stated above.

CLAUSE NO.
Dynamic Analysis
(a) Free vibration analysis
A free vibration analysis of the fan supporting structure including the intermediate
supporting structure for motor, gear box and pillow block (if applicable) shall be
carried out to calculate the natural frequency of the fan supporting structure and its
fundamental natural frequency shall be at least + 20% away from the operating
speed of the fan and motor.
(b) Forced vibration analysis
Forced response analysis shall be carried out on the fan supporting structure
including the intermediate structure supporting the motor, gear box and pillow block
to calculate the vibration amplitudes for the following unbalance condition: -
1. For unbalance load corresponding to G16 as per ISO 1940-1: 2003
2. For unbalance load corresponding to one blade failure condition.
The amplitude derived shall be within the permissible values as specified by the fan
manufacturer or IS: 2974 (Part - IV), whichever is more stringent.
Mid Bearing Supporting Structure
The intermediate supporting structure for motor, gear box and pillow block if provided shall
be so arranged that it does not cause any torsional moments on the beams / pedestals on
which the intermediate support rests. The intermediate supporting structure shall be
orthogonal to the grid of beams on which it rests. The motor shall be supported on a base
frame. The concrete block supporting the fan/gear reducer shall be connected to immediate
lower level of beam column junctions by means of at least four diagonal columns.
Fan Stack
The fan stack shall be made of RCC with minimum 150 mm thickness. With reinforcement
provided on both faces in either direction. Design of the fan stack shall be made on the basis
of relevant stipulations of IS : 11504 for Natural Draught Cooling Towers. The fanstack shall
have two layers of reinforcement on either surfaces in both directions with minimum dia of
reinforcement bars as 10mm and maximum spacing as 150mm c/c.
Steel Structure
All mild steel parts or structural steel works used in the cooling towers shall be hot dip -
galvanised as per IS: 4759 with 610gm/sq.m. coating or seal spray zinc coated as per
BS:5493 (for a very long period of maintenance of more than 20 years). Nails and all
components coming in direct contact with water shall be of stainless steel of SS 316 or
equivalent.
For all steel structures, other than hot water pipes, sludge pipes and hot water distribution
pipes, which are outside cooling tower painting shall be as specified in corrosion protection
clause. However, for painting of hot water pipes, sludge pipes and hot water distribution
pipes, relevant clause for painting specified elsewhere in the technical specification shall be
referred.
The minimum cement content as specified in subsequent clauses of this specification shall be
applicable for all structures of cooling towers.
Test for water tightness
The water tightness of C.W. basin, outlet channel, hot water channel and all other water
retaining structures shall be tested for water tightness as per the provisions of IS : 3370.

CLAUSE NO.
5.02.01.03 LOADING
For consideration of loads on structures and load combinations IS : 875 (Part -1 to 5) Code
of Practice for design loads (other than Earthquake) for Buildings and Structures shall be
followed.
Site specific seismic data and wind data shall be followed for design of cooling towers.
Live Loads
The following live loads (minimum) shall be adopted for the design of buildings and structures
associated with Cooling Towers:
a) Roof / Fan deck 500 Kg / Sq. M.
b) RCC Floors 500 Kg / Sq. M.
c) Stair, landings 500 Kg / Sq. M.
d) Chequered & Grating floor 400 Kg / Sq. M.
e) Basin, sump and duct Earth pressure; water pressure as

applicable and additional surcharge
load of 2.0 T/Sq. M.
f) Covers for H.W. channels / H.W. distribution 300 Kg / Sq. M.

basin
g) Walkways inside cooling towers 300 Kg / Sq. M.
h) Underground pipes and ducts Earth pressure and surcharge load of

2.0 T / Sq. M.
5.02.02 STOPLOG GATES AND TRASH RACK FOR COOLING TOWER

Stoplog gates
The stoplog gate shall cover the clear opening of the cold water channel and effectively
stop the water leakage. Clear size of the stoplog gates shall be equal to the clear opening
size (freeboard of minimum 300mm over the maximum water level in stop log depth shall
be ensured.). The capacity of the hoist (Min 2 ton capacity) shall be decided to match with
provided size units of the stoplog gate. Structural design of stoplog gate shall conform to
IS : 5620 and IS : 4622 (latest). Maximum water level for designing the stoplog gates shall
be taken as maximum water level in the CT basin.
Stoplog gate and its lifting arrangement shall designed for a condition when basin is empty
and water upto full level on the other side. Proper rubbers seal shall be provided in the
stoplog to avoid any leakage of water.
Painting Specification for Structural Steel parts for stoplog gates and trash racks:
(i) All structural steel surfaces shall be cleaned by shot blasting.
(ii) All MS structural parts shall be galvanised to minimum coating of Sealed Zinc spray
(250 Micron) as per BS:5493.

CLAUSE NO.
(iii) Over zinc coating one coat of zinc Phosphate Epoxy primer having minimum 30
micron DFT and three coats of coal tar Epoxy paint having minimum 75 micron DFT /
coat shall be provided. Total DFT of epoxy paint including primer shall be minimum
250 microns.
Leakage Tests of Stoplog Gates

Leakage tests shall be carried out with the stoplog gates lowered onto the sill. Before
observation for leakage, the stoplog gate shall be raised and lowered about one meter
several times in order to dislodge any debris that might have lodged in the side and
bottom seals, The leakage shall then be measured and it should not be more than 5 Liters
/ Minute / Meter length of seal under maximum head.
Material Specifications of stop log gate
All material used in the fabrication of stoplog gate shall be of high grade, free from defects
and imperfections and shall be of the highest standard commercial quality suitable for the
intended use. Radiographic examination or magnetic particle testing or other comparable
tests shall be carried out for determining the soundness of steel castings and shall be
conducted by the Contractor, if asked for by the Employer.
Materials for the various components of Stoplog gates
Sl. Component Parts Recommended Reference

No. Materials
1. Stoplog Gate Leaf Structural steel IS : 2062
2. Stoplog Gate Frames and 1st Structural steel IS : 2062

stage embedded parts
3. 2nd stage embedment Stainless steel SS 316L or IS :

1570 (Part 5).
4. Wheels (the hardness of wheel Cast steel IS : 1030

track surface shall be kept 50
points higher than that of wheel
tread)
5. Wheel axles, wheel track Corrosion resistant IS : 1570

steel.
6. Seals Rubber IS : 11855
7. Bearings SKF of equivalent 04 Cr 19 Ni
8. Seal seats Stainless steel SS 316 L or IS

1570 (Part -5)
9. Lifting pin Stainless steel IS 1570 (04 Cr, 19

CLAUSE NO.
Sl. Component Parts Recommended Reference

No. Materials
Ni)
10. Guide Corrosion resistant IS : 6603

steel
11. Guide shoe Structural steel IS : 2062
12. Counter sunk bolts Stainless steel IS:1570 (Part 5)
TRASH RACKS
Materials, Manufacture and Design
Material Specifications:
All materials used in the fabrication of equipment required shall be new and shall conform to
the requirements of specifications and codes as applicable referred herein. If a material is
specifically not referred to in these specifications/specification drawings, Contractor shall
furnish material of the highest standard commercial quality suitable for the intended use.
The material referred to in the design and drawings mostly conform the Indian Standard
Specifications unless otherwise stated:
Materials for Trash Racks
--------------------------------------------------------------------------------------------------------------------------
S.No. Component/Part Recommended Reference
material
--------------------------------------------------------------------------------------------------------------------------
1. Trash rack Structural Steel IS-2062

and embedded
parts
2. Slide block Structural Steel IS-2062

with bronze and IS:305
padding
3. Track base Stainless Steel SS 316L or IS : 1570 (Part 5)
4. Track Stainless Steel SS 316L or IS : 1570 (Part 5)
5. Guides Corrosion resistant IS : 6603

Steel
6. 2nd stage embedment Stainless steel SS 316L or IS : 1570 (Part 5)
----------------------------------------------------------------------------------------------------------------------
Design
Trash rack should be designed for 2.0m differential head as per IS:800 and also conform to
IS:11388 (latest). Each unit of trash rack shall be consisting of vertical flats and horizontal

CLAUSE NO.
flats. The grating shall be pressure locked. Size of opening shall be 100 mm x 100 mm for all
trash racks.
All trash rack should be capable of being lowered in the associated stoplog gate grooves to
enable drawl of clean water while a particular track rash is raised for cleaning purposes.
Trash racks shall be hot dip galvanized as per IS:4759 with 610 gm/sqm coating.
Alternatively, trash racks shall be painted with sealed spray zinc coating conforming to
BS:5493 (Table – 3, Part-8) for very long (20 or more) years of maintenance interval.
5.02.03 Switch Gear / Control Room for Cooling Tower
It shall be single storied building, framed RCC structure with beams, columns, floor and roof.
It shall have non-load bearing brick wall cladding. It shall house the switch gear and MCC of
cooling tower & associated cable trenches. It shall have toilet block with drinking water
facility. The architectural features shall be as specified elsewhere in the specification.
The RCC roof of this building shall be of minimum 150 mm thickness. With reinforcement
provided on both faces in either direction. The roof shall have two layers of reinforcement on
either surfaces in both directions with minimum dia of reinforcement bars as 10mm and
maximum spacing as 150mm c/c.

CLAUSE NO.
5.03.00 CW SYSTEM & RAW WATER SYSTEM CIVIL WORKS

5.03.01 Circulating Water Pump House (CWPH) & Raw Water Pump House (RWPH)
5.03.01.01 An open circulating water pump house (CWPH) for housing circulating water pumps and
Raw water pump house (RWPH) for housing raw water pumps shall be provided. Separate
bays shall be provided for each pump by providing intermediate dividing piers of RCC
between the pumps.
a) The pump house shall be provided with minimum two sets of stop-logs along
with electrically operated hoisting arrangements. Steel embedments required
for stop-logs shall be provided for all the bays.
b) All bays of pump house shall be provided with a removable trash rack
including electrically operated hoisting arrangements and cleaning
arrangements. Moreover, one spare trash rack shall also be supplied. Steel
embedments required for trash-racks shall be provided for all the bays.
c) Stop-logs, trash-racks and hoists shall be supplied in accordance with the
specifications covered elsewhere.
5.03.01.02 The pump house including its forebay shall be of RCC with M-30 grade of concrete
conforming to IS 456. The pump house shall be structurally separated from forebay by
providing an expansion joint. The pump house shall be provided with separate maintenance
bay.
5.03.01.03 Sump model study for CWPH
Sump model study for circulating water pump house shall be carried out as specified
5.03.01.04 Design requirement for for CWPH & RWPH
Design of substructure shall be divided into two parts, namely,
(a) Stability analysis, and
(b) Structural analysis and design.
For the design of substructure, a surcharge load of 2.0 T / Sq.m shall be assumed at the
finished ground level.
(a) Stability Analysis
The Pump House substructure shall be analyzed and designed for following load
combinations: -
1. Under Operation Stages
Maximum load from super structure + equipment load + load from sub structure + no
water in the pump chambers + earth pressure at rest from outside with surcharge and
maximum ground water pressure.
2. Condition ( 1 ) + earthquake/ wind
3. Under Construction Stages
No load from super structure and deck slab, load from sub structure with no water in
the pump chambers, pump units not installed, earth pressure at rest from sides with
surcharge and maximum ground water pressure.
4. Condition ( 3 ) + earthquake
Following stability checks will be made for the above load combinations:
i) Check for overturning

CLAUSE NO.
Factor of safety against overturning, i.e, the ratio of stabilizing moment to overturning
moment shall be as per IS: 456.
For the above condition, uplift due to maximum Ground water table (GWT) acting on
the base slab and side pressures on the walls due to earth and ground water shall be
considered as destabilizing forces. In order to have no tension condition at tip of the
base slab, resultant of all the forces acting on the pump house under different
conditions of loading as listed above shall fall within middle one third of the base width
provided. Maximum compressive stress at other end of the base slab shall be within
the safe bearing capacity of soil / rock.
Under earthquake condition, resultant of all the forces including earthquake force shall
fall within middle three fourth of the base width provided. An increase of 25% shall be
allowed in the safe bearing capacity of soil when earthquake forces are considered.
ii) Check for Sliding
Factor of safety against sliding under static condition, i.e. ratio of horizontal frictional
resistance to horizontal sliding force shall be as per IS 456. For this condition, earth
pressure at rest and the maximum GWT pressure from sides shall be taken as de -
stabilizing forces. Keys shall be provided, if found necessary, to increase the factor of
safety against sliding.
To ensure an adequate factor of safety under earthquake condition, the factor of
safety against sliding shall not be less than 1.2.
iii) Check for Uplift
Right from construction to operating stage, minimum factor of safety against uplift due
to ground water shall be 1.2. Installation of pressure release valves shall not be
permitted in the base slab (raft) of the pump house to counter the uplift due to ground
water.
(b) Structural Analysis
1) Base Slab
Base slab of the pump house shall be designed as a raft foundation supported at
locations of piers. Following load cases shall be considered:
i. Maximum water level in the sumps with maximum GWT.
ii. No water in the sumps and maximum GWT.
iii. Alternate bays of sumps filled with water with maximum GWT.
iv. Same as in (iii) above but with minimum water level.
2) Intermediate Piers
Intermediate piers shall be designed by working stress method as per IS: 456 ( latest),
with limiting crack width of 0.2mm for the worst combination of maximum water
pressure on one side and no water in the adjacent sump. These shall be designed as
RC walls fixed at base and supported (hinged) at top by the deck slab. Since a breast
wall may be provided for stop logs and back wall is provided connecting all the piers
at the rear end, additional restraints for the pier due to breast walls and back wall may
also be accounted for.
Intermediate piers are also to be checked for the combined action of direct load due to
superstructure and bending due to water pressure from one side.
3) End Piers
Design of end piers will be similar to the intermediate piers. The end piers shall be
designed for the following conditions:

CLAUSE NO.
i. Soil pressure + maximum GWT + surcharge of 2 Ton / Sq.m. at FGL from

outside or design surcharge load at floor level with no water in the sumps.
ii. Only maximum water level in the sump.
End piers shall be designed by working stress method as per IS: 456 (latest),
with limited crack width of 0.2mm on water face and the outside, i.e., earth side
shall be designed as cracked section as per IS : 456. Since end piers are fixed at
base and supported (hinged) at top by deck slab, there will be negligible yielding
of the wall at top. This will give rise to earth pressure at rest and therefore an
earth pressure at rest, Ko = (1 - Sin ) is considered where  =angle of internal
friction of soil.
End piers shall also be checked for the combined action of direct load due to
super structure and bending due to earth pressure with surcharge and ground
water pressure.
4) Back Wall
Back walls shall be designed as fixed at bottom of the base slab and on two vertical
sides by the piers and supported at top by the deck slab. Since back walls are also of
the unyielding type, earth pressure at rest, Ko, shall be considered for design.
Back walls shall be designed by working stress method as per IS: 456, with crack
width limited to 0.2 mm on water face and as cracked section on outer face as
cracked section as per IS : 456.
Following load combinations shall be considered:
i. Soil pressure + maximum GWT + surcharge of 2 T / Sq.m. at FGL from
outside with no water inside the sump.
ii. Only maximum water level inside the sump.
5) Operating Floor Slab
Operating floor slab or deck slab shall be designed for loads of the pumps and other
equipment, which may be placed on it. A live load of 1.5 ton / Sq.m. shall be
considered on the deck slab. The deck / slab shall have monolithic construction with
the piers and shall be designed as a continuous RC slab supported on piers. Design
of slab shall be by working stress method as per IS: 456, with crack width limited to
be 0.2 mm. Floor slab of maintenance bay may be designed as slab on grade. A live
load of 3 T / Sq. m. may be considered for the maintenance bay floor slab. Dynamic
analysis shall be carried out to ensure proper separation of natural frequency of the
structure and pump operating frequency.
5.03.02 C.W. Ducts
CW ducts shall be concrete encased steel lined ducts. The concrete encasement shall be of
minimum 500mm thick with square shape outside. Generally, M20 grade PCC encasement
shall be provided. At locations of duct crossing road, rail in transformer yard or any other
facility, RCC encasement of grade M25 shall be provided. Minimum two layers of
reinforcement (On both faces) of 12 mm diameter bars @ 200 mm c/c shall be provided for
RCC encasement of CW Duct. Top of CW duct encasement shall be minimum 1.5 m below
finished ground level.
The minimum thickness of steel pipes shall be as follows including corrosion tolerance of 2
mm:
a. For pipes above 1800 mm upto and including - 12 mm
2300 mm dia.
b. For pipes above 2300 mm upto and including - 14 mm

3200 mm dia.

CLAUSE NO.
c. For pipes above 3200 mm upto and including - 16 mm

3750 mm dia.
d. For pipes above 3750 mm upto and including - 20 mm

4000 mm dia.
However, for ducts running below rail line in transformer yard/road, minimum thickness of
CW liner shall be 20 mm.
RCC bridge/culvert shall be provided at location of CW duct crossing rail track of railway
siding. Design and construction of the bridge/culvert across rail track shall be as stipulated in
clause 8.04.00 of technical specification.
Suitable tap-offs shall be provided in the duct to connect CW blow down, ACW tapping etc.
Based on the transient analysis, sufficient number of stub connection shall be provided in the
duct to fix air release valves.
All duct installation & jointing shall be strictly in accordance with the stipulation given
elsewhere in the specification for structural steel work. All the joints of liners shall be butt
welded joints. The circular deformation of liner shall be less than 1% of diameter of liner
while handling, transportation, erection & construction. If required, temporary bracings may
be provided, during handling, transportation & concreting to reduce the deformation.
The completed duct shall be tested for water tightness, for the pressure equal to twice the
working pressure or 1.5 times the design pressure whichever is higher and shall be generally
water tight to Engineer's satisfaction. The testing pressure shall be held for minimum period
of 30 minutes without any signs of leakage or failure of weld. Any in flow / leakage of water
from the duct shall be sealed / repaired at Contractor's cost. However, tests in part of length
of duct may be permitted with prior approval only.
Wherever required anchor / thrust blocks shall be provided with RCC M25 grade concrete.
Suitable RCC chambers shall be provided with precast covers to install flow measurement
devices and valves in the duct.
Manholes of minimum 1000mm clear opening shall be provided in each CW duct at a
spacing of 200M (approx.) to facilitate maintenance / dewatering of CW ducts. At least one
manhole shall be provided at the deepest point for both intake & discharge duct.
Following shall be considered for design of C.W. ducts:
a. Maximum design water pressure
b. Surge or water hammer pressure of 5.0 Kg / Sq.cm.
c. Expected vacuum conditions as arrived from transient analysis
d. Soil overburden
e. Surcharge Pressure of 2T/Sq.m
f. The effect of concrete encasement shall not be considered in the design of CW
duct
Painting as per Cl. 6.04.03 shall be carried out on machined faces, flanges and external
exposed surfaces of CW ducts. For external surfaces of CW ducts encased in concrete,
painting shall be as specified in Cl. 6.04.02(a).
5.03.03 CW Channel
5.03.03.01 The channel shall be of RCC section with vertical wall projecting minimum 300mm above
finished ground level. Hand rails with 32 NB (medium) pipe shall be provided on both walls of
the channel where height of channel wall is less than 1200 mm above finished ground level.
5.03.03.02 The channel shall be designed to carry the required discharge with minimum water level in
cooling tower basin and considering minimum value of rugosity coefficient (n) of 0.018 for

CLAUSE NO.
concrete surface. However, the maximum velocity in CW channel shall be restricted to

1.8m/sec.
5.03.03.03 The channel shall be designed by working stress method with crack width limited to 0.2 mm
on water face and as cracked section on outer face as per IS: 456 considering (i) no water
inside the channel, with earth pressure of soil upto FGL, ground water table upto FGL and
surcharge load of 2.0 ton / Sq.m from outside, and (ii) with water inside the channel upto
maximum level in the forebay / channel and no earth pressure, ground water pressure and
surcharge load from outside. Right from construction to operating stage, minimum factor of
safety against uplift due to ground water shall be 1.2.The channel shall be checked against
uplift due to 50% of the total water head considering ground water table upto FGL. In addition
pressure relief valves with under drainage arrangement in the channel shall be provided to
prevent uplift of the channel as per relevant IS Codes. Minimum wall thickness shall be 250
mm.
5.03.03.04 Forebay Structure
Forebay consists of retaining wall and forebay slab. The walls shall be analysed as a
retaining wall for stability against overturning and sliding, similar to end piers of the pump
house. Pressure relief valves and under drainage arrangements shall be provided below the
forebay slab to prevent uplift of the forebay slab. Size and spacing of pressure relief valves
shall be designed by the Bidder to take care of the uplift due to ground water table. However,
centre to centre spacing of PRV shall not exceed 5000mm.The forebay slab shall be
designed against uplift due to 50% of the total water head considering ground water table
upto FGL.The forebay slab shall be minimum 250 mm thick. The forebay slab shall be
structurally separated from the retaining walls and water stops shall be provided at the
junction of slab and retaining wall. Minimum thickness of retaining wall at top shall be 250
mm. Hand rails with 32NB (medium) pipe shall be provided on both walls of the forebay.
5.03.04.00 Stop-logs and Trash Racks for CWPH
5.03.04.01 Stop-log gates
Clear size of the stop logs shall be equal to the clear opening size of water inlet opening
below breast wall. Number of segments of the stop log shall be decided to match the
capacity of the electrically operated monorail hoist provided to handle it. Structural design of
stop log shall conform to IS: 5620 and IS: 4622. Maximum water level for designing the stop
logs shall be taken as maximum water level of the forebay. Top and bottom unit of stop log
gates shall be designed for their respective water head, whereas the remaining
interchangeable units shall be designed for the water head corresponding to the lower most
interchangeable unit. The stop logs shall be operated under balanced water head and they
are not to be designed for operating under flowing water. Filling valves shall be provided in
the stop logs to balance the water pressure before lifting the stop log. These stop logs are
used only during maintenance / inspection of pumps. The stop logs shall be operated by
means of an electrically operated hoist. Suitable lifting beam shall be provided to operate the
stop logs.
5.03.04.02 Trash Racks
Bar screen trash rack is to be provided at inlet of the sump of the pump house in order to
prevent ingress of timber & other floating particles which could damage the Pumps.
Each bay of pump sump shall be provided with Type - 1 trash rack (removable section rack),
conforming to IS: 11388. Centre to centre spacing of trash rack bars shall be 100mm (max).
The trash racks shall be provided with number of interchangeable segments, to facilitate
easier handling by means of a lifting beam and electrically operated hoist. Trash rack bars
shall be designed for a differential water head of 2.0m and other structural members shall be
designed for a differential water head of 1.0m. Minimum thickness of trash rack bars shall be
10mm. Suitable size of horizontal members and end members shall be provided as per
design requirements, for efficient operation of trash rack.

CLAUSE NO.
All trash racks should be capable of being lowered in the associated stop log groove to
enable drawal of clean water while a particular trash rack is raised for cleaning purpose.
Suitable arrangement for storing all the stop logs and spare trash rack shall be provided by
the Bidder, to keep them in good working condition.
5.03.04.03 Lifting Beams
Separate lifting beams (automatic) shall be designed & fabricated with guide shoes, hooks,
links and counter weights etc. complete for automatic operation to engage and disengage the
stop logs and trash racks in the required position.
5.03.04.04 Leakage Tests of Stop logs
Leakage tests shall be carried out with the stop logs lowered onto the sill. Before observation
for leakage, the stop log shall be raised and lowered about one meter several times in order
to dislodge any debris that might have lodged in the side and bottom seals, The leakage shall
then be measured and it should not be more than 5 litre / minute / meter of length of seal
under maximum head.
5.03.04.05 Material Specifications of Stop logs & Trash racks
All material used in the fabrication of stop log or trash rack shall be of high grade, free from
defects and imperfections and shall be of the highest standard commercial quality suitable for
the intended use. Radiographic examination or magnetic particle testing or other comparable
tests shall be carried out for determining the soundness of steel castings and shall be
conducted by the Bidder, if asked for by the Employer.
5.03.04.06 Materials for the various components of Stop logs
Sl. No. Component Parts Recommended materials Reference
1. Stop log Leaf Structural steel IS 2062
2. Stop log Frames, 1st stage Structural steel IS 2062

embedded parts and
structural steel members
3. 2nd stage embedment Stainless steel SS316L or IS:1570

(part-5)
4. Wheels (the hardness of Cast steel IS 1030

wheel track surface shall
be kept 50 points higher
than that of wheel tread)
IS 1570
5. Wheel axles, wheel track Corrosion resistant steel.
IS 11855
6. Seals Rubber
04Cr19Ni
7. Bearings SKF or equivalent
SS316L or IS 1570
8. Seal seats Stainless steel
(part-5)
SS316L or IS 1570
9. Lifting pin Stainless steel
(part-5)
IS 6603
10. Guide Corrosion resistant steel
11. Guide shoe Structural steel IS 2062

CLAUSE NO.
5.03.04.07 Materials for various components of Trash Rack:
Sl. No. Component Parts Recommended Reference Materials
1. Trash rack and 1st Structural steel IS 2062

stage embedded parts
2. 2nd stage embedment Stainless steel SS 316L or IS 1570 (Part–5 )
3. Slide Block Structural steel with IS 2062 & IS 305

bronze padding
4. Track base Stainless steel SS 316L or IS 1570 (Part–5 )
5. Track Stainless steel SS 316L or IS 1570 (Part–5)
6. Guides Corrosion resistant IS 6603

steel.
5.03.04.08 Painting Specification for Structural Steel parts for Stoplog Gates and Trash Racks
(i) All structural steel surfaces shall be cleaned by shot blasting.
(ii) All MS structural parts shall be galvanised to minimum coating of Sealed Zinc spray
(250 Micron) as per BS 5493.
(iii) Over zinc coating one coat of zinc Phosphate Epoxy primer having minimum 30
micron DFT and three coats of coal tar Epoxy paint having minimum 75 micron DFT /
coat shall be provided. Total DFT of epoxy paint including primer shall be minimum
250 microns.
5.03.04.09 Construction Requirement and Access to Work Areas
Contractor shall notify to the Engineer before start of work well in advance about the method
of construction for crossing road, pipeline, cable, railway, canals, utility lines and other
existing obstacles.
Contractor shall not commence work on such crossings before having obtained approval
from the authorities and land owners concerned to the satisfaction of the Engineer. The work
at crossings shall meet at all times requirements and conditions of the permit issued by the
authorities concerned. In the absence of any specific requirements by authorities, Bidder
shall comply with Engineers' instructions.
Where the work areas come within the area of influence of high voltage electrical
installations, contractor shall propose and provide adequate safety measures for all
personnel working. He shall obtain necessary permission/permit from the concern authority.
No work is allowed in such areas without Engineer's prior approval.
5.03.04.10 Switch Gear / Control Room/ Remote IO room for CWPH & RWPH
It shall be single storied building, framed RCC structure with beams, columns, floor and roof.
It shall have non-load bearing brick wall cladding. It shall house the switch gear and MCC of
respective Pump house & associated cable trenches. The architectural features shall be as
specified elsewhere in the specification.

CLAUSE NO.
5.04.00 DM Plant, PT Plant, ETP, CW Chemical Treatment and CPU Civil Works
5.04.01 Design Concepts for Buildings/ Shed
i.All buildings shall have framed super structure.
ii.Equipment/facilities with shed shall have structural steel superstructure with
permanently colour coated metal sheeting at roof and side open. However, kerb wall
shall be provided all around the plinth/ floor area above the Finished Floor Level
(FFL). For other buildings brick wall cladding on exterior face shall be provided.
iii.Unless specified, the wall cladding for buildings shall be with minimum one brick
thick on exterior face. However, brick wall for buildings adjacent to transformers shall
be minimum 345mm thick.
5.04.01.01 Individual members of the frame shall be designed for the worst combination of forces such
as bending moment, axial force, shear force, torsion, etc.
5.04.01.02 The load and load combinations and design criteria shall be as specified elsewhere in the
specification.
5.04.01.03 All liquid retaining structures shall be designed for following load conditions.
Underground structures:
a. Water filled inside up to design level and no earth outside.
b. Earth pressure with surcharge of 2.0 T/m2 and ground water table up to FGL
outside and no water inside.
c. Stability against uplift shall be checked for completed structure and under
construction stage with no water inside and ground water table up to FGL,
with a minimum factor of safety of 1.20 against uplift. Installation of pressure
relief valves shall not be permitted in the base slab of any liquid retaining /
conveying structure.
d. The structure shall also be checked for normal working condition with water
filled inside up to design level and earth pressure outside with no effect of
surcharge and ground water table.
For design of over - ground liquid retaining structures appropriate load cases shall be
considered.
5.04.01.04 All liquid retaining and conveying structures shall be designed by working stress method as
given in clause 4.5 of IS 3370(Part2):2009.
5.04.01.05 In the wall of liquid retaining structures with cylindrical shape such as clarifiers, vertical
reinforcement shall be checked assuming the walls were fully fixed at the base, and the
horizontal reinforcement shall be provided to resist horizontal (hoop) tension assuming
hinged condition at the junction of the base slab & wall.
5.04.01.06 Wherever sandwich slabs are provided in liquid retaining structures to take care of stability
against uplift, only well graded sand of approved quality shall be used as fill material. The
sand compaction shall be done with plate / disc compactors in such a manner that the bottom
slab is not structurally damaged.
5.04.01.07 Clear free board of at least 300 mm above design (total) water level shall be provided in all
liquid retaining / conveying structures.
5.04.01.08 Coefficient of active earth pressure shall be considered for design of free standing retaining
walls and coefficient of earth pressure at rest shall be considered for design of top propped
retaining walls.
5.04.01.09 The minimum grade of concrete for all RCC structures associated with DM plant, PT plant,
ETP, CW chemical treatment and CPU shall be of grade M30.The minimum concrete clear
cover to reinforcement bars in all RCC structures shall be as per IS:456(2000) and

CLAUSE NO.
IS:3370(Part II) for water retaining structures. Durability of concrete shall conform to
moderate exposure conditions as per Table-3 of IS 456 except noted specifically otherwise.
5.04.01.10 Factor of safety against overturning and sliding
The structure shall be checked for minimum factor of safety of 1.5 against overturning
conditions (ratio of stabilizing moment to overturning moment) and 1.4 against sliding
conditions as per IS: 456.
5.04.01.11 For detailing of Reinforcement IS 5525, IS 13920, IS 4326 and SP 34 shall be followed.
5.04.01.12 Two layers of reinforcement (on both faces) shall be provided for RCC sections having
thickness of 150 mm and above.
5.04.01.13 Minimum diameter of main and distribution Reinforcement bars in different structural
elements shall be as follows:
Sl. No. Structural Element Main Distribution

Reinforcement Reinforcement /
Stirrups/ ties/
Anchor Bars
a) Foundation 12 mm 12 mm
b) Beams 12 mm 8 mm
c) Columns 12 mm 8mm
5.04.01.14 Spacing of reinforcement bars in walls and slabs of liquid retaining / conveying structures
shall not be more than 200 mm.
5.04.01.15 Suitable shrinkage reinforcement shall be provided at top face of foundations. Minimum
shrinkage reinforcement shall be 10 mm dia. @ 200mm c / c.
5.04.01.16 Minimum Reinforcement in all elements of liquid retaining / conveying structures shall be
0.24 % of cross sectional area.
5.04.01.17 Minimum tensile Reinforcement in each direction for all foundation slabs / rafts shall be 0.2%
of cross sectional area.
5.04.01.18 Minimum thickness of foundation slab / raft and base slab of all liquid retaining tanks / pits
shall not be less than 250 mm.
5.04.01.19 Minimum thickness of all elements of RCC liquid retaining / conveying structures (except
effluent drains, launders and aerator waste slab) shall be 200mm. Effluent drains (depth
more than 500mm), aerator waste slab and launders shall have minimum element thickness
of 150mm.
5.04.01.20 All Insert plates (except edge protection angles) provided in liquid retaining structures shall
be 12 mm thick GI with lugs not less than 12 mm diameter. Edge protection angles shall be
provided as specified elsewhere.
5.04.01.21 All water retaining structures shall be tested for water tightness as per provisions of IS: 3370
and IS: 6494.
5.04.01.22 2.0m wide walkway with concrete paving shall be provided connecting all structures,
buildings and facilities. The top of walkway shall be minimum 200mm above FGL.
5.04.01.23 Architectural Concepts and Finishing Schedule

Architectural concepts and finishing schedule shall be as specified elsewhere in architectural
specification.

CLAUSE NO.
5.04.02 Acid / Alkali Resistant Treatment:

Acid / alkali resistant lining treatment shall be provided in different areas as follows:
Neutralization Pit: The walls shall be provided with one coat of bitumen primer, followed by
18 mm thick bitumastic layer, 115 mm thick A.R. bricks, 6 mm thick under bed of potassium
silicate mortar, pointing the joints of bricks with acid / alkali resistant epoxy / furane mortar
upto a depth of 20 mm and bitumastic end sealing. Suitable pilasters shall be provided with
A.R. bricks at regular intervals depending upon the height of lining, as per the specification.
The floor of neutralization pit shall be provided with acid / alkali resistant lining treatment as
given in the above para, except that the 115 mm thick A.R.bricks layer shall be replaced by
75 mm thick A.R. tile layer and pilasters shall be omitted.
The ceiling of neutralization pit shall be provided with one coat of epoxy primer followed by 2
coats of epoxy paint (150 micron).
Acid / Alkali storage area / projections above the floor, pedestals projecting from the floor /
saddles. The floor shall be provided with one coat of bitumen primer followed by 12 mm thick
bitumastic layer, 20 mm thick A.R. tiles, 6 mm thick under - bed by potassium silicate mortar,
6mm thick pointing of joints of tiles with acid / alkali resistant epoxy / furane mortar up to a
depth of 20 mm and bitumastic end sealing. Dado of 1.0M high with above treatment shall
also be provided if applicable in case of walls nearby.
Alum/Lime Storage area and first floor of Chemical House : One coat of bitumen primer
followed by 12mm thick bitumastic layer, 20 mm thick A.R. tiles, 6 mm thick underbed of
potassium silicate mortar, 6mm thick pointing of joints of tiles with acid /alkali resistant
epoxy /furane mortar up to a depth of 20 mm and bitumastic end sealing.
Alum solution preparation tank: The wall shall be provided with one coat of bitumen primer
followed by 12 mm thick bitumastic layer, 75 mm thick A.R. tiles, 6 mm thick underbed by
potassium silicate mortar, pointing of joints of tiles with acid / alkali resistant epoxy / furane
mortar upto a depth of 20 mm and bitumastic end sealing.
The floor shall be provided with acid / alkali resistant lining treatment as given in the above
para except that the 75 mm thick A.R. tile layer shall be replaced by 12 mm thick A.R. tile
layer.
Basket of Alum Solution Preparation tank: 5mm thick epoxy lining over a coat of epoxy
primer.
Curved surfaces of saddles shall have minimum 12 MM thick bitumastic layer to support the
vessel / tanks.
Effluent Drains: Acid Resistant lining treatment indicated for the storage area shall be
provided on the bed as well as walls of the drains with 38 MM AR tiles. The underside of the
pre-cast slab cover shall be applied with one coat of epoxy primer and two coats of epoxy
coating, total DFT 150 microns.
Lime tank: Two coats of bitumen paint conforming to IS : 9862, with total DFT 150 microns.
Guarantee
The Contractor shall give a guarantee for satisfactory functioning of the lining for a period of
36 months from the date of completion of the work or date of handing over the site to the
Engineer, whichever is later.
The Contractor shall replace / rectify defects is any, observed in the lining to the satisfaction
of the Engineer without any extra cost during this period.
5.04.03 Foundation Of Over Ground Steel Circular Water Storage Tanks /DM TANK
The tank foundation shall be as per IS:803 and as specified in relevant clause of foundation
chapter.

CLAUSE NO.
5.04.03.02 Sub Grade Preparation
The surface of natural soil shall be thoroughly compacted by rolling or other means, as
directed by Engineer, to obtain 95% of max. laboratory dry density for the soil, as per IS:2720
(Part-VII).
5.04.03.03 Anti Corrosive Layer

Anti-corrosive layer shall consist of screened coarse sand, mixed with 80/100 bitumen or
equivalent 8% to 10% by volume.
Bitumen shall be heated to a temperature 1750 C to 1900 C, with 3% kerosene, if required.
Sand shall be thoroughly mixed with it in a mixing drum to obtain uniform mixture and shall
be laid over the compacted surface, laid in line, grade and levels and as directed by the
Engineer. Bitumen shall not be heated beyond the temperature limits given above.
The premix carpet shall be laid in two layers of 3 cm and 2 cm respectively. After compacting
and laying the first layer of 3cm, a tack coat of hot bitumen at the rate of 1 Kg. per Sq.m.
shall be uniformly applied to the surface, by means of Sprayer and the Second layer of 2cm
thick shall be laid, tamped and compacted to the satisfaction of the Engineer.
Sand shall be spread on the final surface at the rate of 0.5 Cu. m per 100Sq.m.
5.04.03.04 Premix
Materials
Sand
Sand shall be clean, dry, coarse, hard angular, free from coatings of clay, dust and mix of
vegetable and organic matters and shall conform to IS 383 (Grade -III).
Stone Chippings
Stone chippings shall be hard black trap or granite or approved locally available stone and
shall conform to IS 383. The grading shall be of normally 12mm down size and 6mm down
size, in the ratio of 3:2 respectively.
Bitumen
Bitumen required for the work shall be 80/100 grade or its equivalent quality.
Laying
Areas on which the premix is to be laid shall be thoroughly cleaned of all dust and loose
materials. On the cleaned surface, a tack coat at the rate of 1.0 Kg. per Sq.M. of hot Bitumen
shall be uniformly applied by Sprayers. The applied Binder shall be evenly brushed.
The Binder bitumen 80/100 shall be heated to the temperature of about 1900 C with 3%
kerosene, if required and mixed with stone chippings of size, as mentioned above, at the rate
of 400 KG, with Six (6) Cu. M. of stone chips, for 100 Sq.M. of surface. The total mixed
quantity, as mentioned above, is the quantity required for the total 50mm thick for 100 Sq. m.
of area. Mixing shall continue until the aggregate is well coated.
5.04.00 SEWERAGE SYSTEM

Complete sewerage system including package type sewage treatment plant for facilities in
Bidder's scope within the plant is in bidder's scope. The bidder shall provide De-centralised
sewage treatment plant units. The capacity of the Decentralized Sewage Treatment units
shall be as per the design requirements, subject to minimum capacity of 5 cum/day. Minimum
2 nos of minimum capacity 5 cum/day capacity shall be provided. De-centralized Treatment

(2X660 MW) SUB-SECTION-IIID-01 PAGE
SECTION-VI, PART-B
CLAUSE NO.
Units shall be of Sintex (PWTS-STBF or NBF) or Ion-exchange (NGPSTP) make or

equivalent.
Cement concrete pipes of class NP-3 as per IS 458 shall be used below ground level for
sewage disposal in all areas other than main plant area. However, for pressure pipes and in
main plant areas, and under roads spun Cast Iron pipes conforming to IS 1536 of required
class shall be used.
RCC manholes with CI cover shall be provided at every 30m along the length, at connection
points, and at every change of alignment, gradient or diameter of a sewer pipeline. This shall
be as per IS 4111.
Sewage pump house shall be provided as per IS 4111.
Sewage treatment plant is to be provided by the owner in South East corner of the site.
Bidder shall have to provide complete arrangement for sewage disposal up to the sewage
treatment plant including pumping facilities.
5.05.00 PLANT STORM WATER DRAINAGE SYSTEM
Complete storm water drainage system for facilities in Bidder’s scope within the plant is in
bidder’s scope. Storm water drain shall be designed taking into account the finished ground
levels of the plant/township area, drainage pattern, intensity of rainfall, etcwith a return period
of 50 years. These values shall be based on minimum rainfall intensity of 75mm/hr. All RCC
drains shall be either RCC Cast-in-Situ or RCC Pre-cast drains. The minimum grade of
concrete shall be M25 for RCC Cast-In-Situ drains and M30 for RCC Pre-cast drains. The
maximum velocity for RCC open drains shall be limited to 1.8 metre per second. However,
minimum velocity of 0.6 metre per second for self - cleansing shall be ensured. Bed slope not
milder than 1 in 1000 shall be provided. The inside drain dimension at any point should not
be less than 0 .75m (height) x 0.75m (breadth).
Open RCC rectangular section, unless required otherwise due to functioned requirement,
shall be provided for all drains. The thickness of side walls and bottom slab of RCC drains
shall be minimum 150mm or as per design considerations whichever is higher for drains upto
depth of 1m from formation level. For depth of drain more than 1m from formation level, the
thickness of side walls and bottom slab of RCC drains shall be minimum 200mm or as per
design considerations whichever is higher.
The drains shall be provided on both sides of the double lane roads and single lane roads.
The drains shall be provided on one side of the patrol roads along boundary wall. These shall
be designed to drain the road surface as well as all the free and covered areas, etc. Box
culverts shall be provided at all rail, road and other crossings.
All plinth drains along the periphery of all buildings other than BTG area shall have perforated
precast RCC cover of minimum 50 mm thickness. The drain in BTG areas shall be covered
with cast-in situ/ precast RCC cover with minimum 200mm thickness designed for all crane
/vehicular loads. All drains in the area shall also be provided with heavy duty galvanized MS
gratings with opening of 1mx 1m at 7.5m interval.
All drains inside the building shall have minimum 40 mm thick grating covers. In areas where
heavy equipment loads would be coming, precast RCC covers shall be provided in place of
steel grating.
The invert levels of the in-plant and plant peripheral drains shall be kept such that water can
be discharged by gravity to the main / trunk drains under all conditions.The invert levels of
the drains shall be decided in such a way that the water can easily be discharged to the
natural water bodies above the high flood level.

SECTION-VI, PART-B
CLAUSE NO.
5.06.00 ROADS
All roads shall be of rigid pavements unless otherwise specified. The design of rigid
pavement shall be carried out as per IRC: 58. The effects of design wheel load, maximum
tyre inflation pressures, tyre contact area for the vehicle, traffic loads, environmental factors
such as temperature changes in the pavement, other factors, like impact, load repetitions,
etc., are to be taken. Detailed plate load tests to determine the modulus of sub grade
reaction “K” shall be carried out as per the procedure outlined in IS: 1888. The design traffic
load shall be a minimum value of 4 million standard axles. The road shall be designed for 30
years of life and considering a minimum traffic growth rate of 1 per cent per annum. The
concrete pavement for roads shall be minimum 250 mm thick slab.
The road construction including its shoulders, base, sub base and concrete pavement shall
be as per IRC standards. IRC: 58 shall be followed for the pavement design and MORTH
specification (latest) shall be followed for the construction of the concrete pavement road.
The road base shall be with minimum 150 mm thick dry lean concrete over granular sub
base. Dry lean concrete shall be laid by a mechanical paver and compacted by vibratory
rollers. Concrete pavement of the road shall be done with fully mechanized paver fitted with
electronic sensors for construction techniques. Dry lean concrete shall be minimum M10
grade and concrete pavement slab shall be minimum M35 grade concrete pavement shall be
provided with 125 micron polythene sheet below it concrete pavement shall also be provided
with contraction and expansion joint with MS dowel bars as per MORTH specification.
The finished top (crest) of all roads shall be 350 mm above the surrounding finished ground
level.
The sub grade under all roads and its shoulders shall be compacted to achieve 95 per cent
or more of Standard Proctor’s Density MDD using mechanical means.
Cutting / extending / rerouting / remaking of existing roads including associated works to

maintain continuity of road system / network shall also be carried out.
All culverts and RCC bridges at crossings of all roads / rail tracks / facilities with drains /
nallahs / channels / roads / rail tracks / pipes / other facilities, etc. are to be designed and
constructed.
Unless otherwise specified, all roads (excluding access roads to all buildings / facilities /
structures, patrol road along boundary wall and road inside the switchyard) shall be double
lane roads.
5.06.01 Double Lane Roads

The double lane roads shall be (12 metre wide) with 7.5 metre wide concrete pavement and
2.25 metre wide raised shoulders on both sides of the roads.
The raised shoulders (on both sides of the road) shall comprise of 75mm thick inter locking
precast designer concrete blocks (M35 grade) at the top, over 20 mm thick sand layer. A
200mm diameter NP3 pipes shall carry the surface water from the road through a PCC drain
trench (M20) on both sides of the roads to the drain. The pipes shall run over PCC (M 20)
continuous cradle bedding. The pipes shall be laid at 10 metre centre to centre. A layer of
100 mm (average) thick PCC (M15) shall be laid over the pipes and below the sand layer. All
roads shall be provided with edge protection on both sides of the road using pre - cast kerb
blocks (450 mm long x 250 mm wide x 500 mm deep) (M25) laid in 1 (cement) : 6 (coarse
sand) cement mortar.

CLAUSE NO.
5.06.02 Single Lane Roads

All access roads to all buildings / facilities / structures, road approaches / connections,
access roads to liquid fuel storage areas and other equipment areas where access is
necessary from inspection, operation and maintenance point of view and all roads inside the
switchyard shall be single lane roads. These shall be single lane roads (5.75 metre wide)
with 3.75 metre wide concrete pavement and 1 metre wide shoulders on both sides of the
roads. The shoulders shall also have 150 mm thick dry lean concrete and 75 mm thick inter
locking blocks over compacted granular sub base of two layers of 75mm thick WBM grade III
53-22.4mm. All roads shall be provided with edge protection on both sides of the road using
PCC blocks (300 mm long x 250 mm wide x 150 mm deep) (M25) laid in 1 (cement) : 6
(coarse sand) cement mortar.
5.06.03 Patrol Roads

All patrol roads along the boundary wall shall be single lane roads with 3.75 metre wide
concrete pavement and 1 metre wide shoulders on one side of the road. The shoulders shall
also have 150 mm thick dry lean concrete and 75 mm thick inter locking blocks over
compacted granular sub base of two layers of 75mm thick WBM grade III 53-22.4mm. All
roads shall be provided with edge protection on both sides of the road using PCC blocks
(300 mm long x 250 mm wide x 150 mm deep) (M25) laid in 1 (cement) : 6 (coarse sand)
cement mortar. The road shall slope towards the inner drain. The centre line of the black top
of the road shall run at a distance not less than 2625 mm from the centre line of the boundary
wall.
5.07.00 FIRE WATER PUMP HOUSE, FIRE WATER BOOSTER PUMP HOUSE& FOAM SYSTEM
Salient Features:
The scope of the Bidder shall be design and construction of Civil, Structural, Architectural,
Water Supply, Plumbing and Sanitary Works of Fire Water Pump House, Fire Water Booster
Pump House and foam system including supply of all materials.
The fire water Pump House shall be single storeyed and single bay RCC superstructure
provision for a structural steel monorail. MCC /switchgear rooms, control room etc. shall have
RCC framed structure with cast-in-situ RCC roof slabs with brick cladding. The building shall
be fully covered with external brick wall with provision for doors, windows, rolling shutters and
exhaust fans.
The Fire Water Booster Pump House shall be structural Steel Shed superstructure with
provision for a structural steel monorail. Control room shall have RCC framed structure with
cast-in-situ RCC roof slabs with brick cladding. . The shed and building shall be fully covered
with external brick wall with provision for doors, windows, rolling shutters and exhaust fans.
Steel shed with roof covering with provision for a structural steel monorail shall be provided
for foam system including associated civil works for foam bladder tank foundations, grade
slab, pipe pedestals etc. Control room shall have RCC framed structure with cast-in-situ
RCC roof slabs with brick cladding. The shed and building shall be fully covered with external
brick wall with provision for doors, windows, rolling shutters and exhaust fans. Fire water
storage tank foundation shall be provided as detailed in clause 5.05.03 above.
5.08.00 AREA PAVING
RCC paving of minimum 150 mm thick with M25 grade concrete, over an under bed as
specified herein shall be provided for areas mentioned below. RCC paving shall be designed
as rigid reinforced concrete pavement for the crane/ vehicular/ equipment movement loads
which the paving has to bear. The under bed for paving shall consist of preparation and
consolidation of sub-grade to the required level, laying of stone soling of 200mm compacted
thickness for normal duty paving and 400mm compacted thickness for heavy duty paving
with 63 mm and down aggregate with interstices filled with selected moorum/ non-expansive

CLAUSE NO.
soil followed by 75 mm thick 1:4:8 PCC (1 part cement, 4 parts sand and 8 parts stone
aggregate) with 40 mm nominal size aggregate. For normal duty paving, reinforcement of
the RCC paving shall consist of minimum 8mm diameter bars @ 200 mm c / c in both
directions at the centre of the slab. For heavy duty paving/ passage, reinforcement of the
RCC paving shall consist of minimum 10mm diameter bars @ 200 mm c / c in both directions
at the centre of the slab.
Paving areas shall be provided with the metallic hardener floor finish as specified elsewhere
in the specification.
Entire area as defined in Part-A (Sub section-IID) shall be provided with RCC paving.
Passages shall be provided inside the main plant block connecting to the outer periphery
road to have access to the various facilities/buildings. These passage areas shall be
provided with heavy duty paving for movement of heavy vehicles. The top surface of the
passages shall be finished with 50 mm thick metallic hardener topping. Heavy duty paving
shall also be provided for the areas in the complete Mill bunker building and handling areas
for PA/FD/ID fans with 50 mm thick metallic hardener topping.
Ground floor area in the boiler shall be provided with normal duty paving and shall be
finished with 50 mm thick metallic hardener topping.
Lightly loaded areas such as corridors below trestle and other areas in the main plant block
outside Mill Bunker Building, Boiler area, ESP area where no heavy traffic movement is
envisaged shall be provided with interlocking concrete block paving with RCC concrete
blocks of minimum M35 grade and minimum 80 mm thickness underlain by 200mm thick with
63 mm and down aggregate with interstices filled with selected moorum/ non-expansive soil.
All other areas inside the Main plant block shall be provided with normal duty paving without
metallic hardener topping.
Suitable open RCC drains shall be provided to dispose off storm water drain. Separate open
RCC drains shall be provided to dispose off floor wash and plant effluents into RCC sump
pits. Separate RCC sump pits shall be provided for different types of effluents. The paving
shall be provided with slope of 1:500 to dispose the surface water/wash water to the nearest
drain. All drains/pits shall be provided with electro forged GI grating cover.
Sewer lines (Cast Iron), interconnected by sewer manholes (RCC) at regular intervals (not
exceeding 30 meter centre to centre) shall be provided to dispose off sewage from main
plant block.
5.08.01 Ground Floor Slab of Buildings
In all buildings including main plant building, the ground floor slab shall consist of minimum
150mm thick RCC M25 grade base slab over an under bed as specified below. The under
bed for ground floor slab shall consist of 75mm thick 1:4:8 PCC on stone soling of 200mm
compacted thick with 63 mm and down aggregate with interstices filled with well graded
selected sand/ moorum/ non-expansive soil on compacted and dressed sub - grade.
Reinforcement for the slab shall consist of minimum 8mm diameter bars @ 200 mm c/c at
top & bottom of the slab in both directions. However, at passages, unloading & maintenance
bays, stone soiling of minimum 400mm thick and minimum 10mm diameter bars @ 200 mm
c/c at top and bottom in both directions shall be provided.
Further, top surface of ground floor slabs shall be finished with 50mm thick metallic hardener
topping.
5.08.02 Civil Works for Fire Detection & Protection System in Ground Floor/ Paving
Fire water pipes shall be provided with either RCC trench or buried underground as per
requirement. Tender drawings shall also be referred.
Fire water trenches shall be open RCC type trench with removable RCC cover.
Interlocking concrete block paving shall be provided over the buried fire water pipes as
specified elsewhere in the specification.

CLAUSE NO.
At road/rail/ drain crossings of fire water pipes, the fire water pipes shall be provided with
minimum 200mm thick PCC encasement all around the pipe.
5.09.00 TRANSFORMER FOUNDATION
Foundations of transformers shall be designed for seismic and wind loads in addition to other
applicable loads. RCC block foundations shall be provided for the main transformer.
The oil soak pit, if provided, shall be filled with gravel of size 40mm. The volume of the soak
pit shall be sufficient to store complete oil of the transformer/reactor along with 10 minutes of
fire water considering only 40% of the volume as available voids between gravel filling.
However, in case a separate oil collection tank is provided for the transformer/reactor, oil
soak pit of volume equivalent to one-third (1/3) the oil volume of transformer/reactor shall be
provided around transformer/reactor. The oil collection tank, in such cases, shall be designed
for an effective capacity of complete oil of the transformer along with 10 minutes of fire water.
The oil soak pit shall also be provided with a sump at the corner to allow drainage of water/oil
from the soak pit.
Arrangement for moving the transformer into place using rail cum road, jacking pads and
pulling blocks including inserts, as required, shall be provided along with the
transformer/reactor foundations.
RCC Firewall shall also be provided between the transformers wherever required.
300 mm thick PCC M20 encasement all around the Pylon supports inside soak pit for
firefighting system shall be provided up to top of gravel filling. However, the supply and
erection of Pylon supports with anchor fasteners for HVW spray system are not under the
scope of this package. Coarse aggregate filling inside the transformer oil soak pit shall be
carried out only after construction/erection of Pylon supports and PCC encasement.
5.10.00 OTHER BUILDINGS

For all other buildings mentioned in the scope of work but requirement not furnished in this
chapter, the Bidder shall develop the details of such buildings based on the functional and
statutory requirements.

CLAUSE NO.

6.01.01 General
The design criteria given herein is applicable for all sub-structure, super-structure works/
buildings/ facilities and various other works included in the scope of the Bidder.
6.01.02 Structures shall be designed for the most critical combinations of dead loads, imposed loads,
equipment loads, crane loads, piping loads (static, friction and dynamic), earth pressure &
surcharge loads, hydrostatic &hydrodynamic loads, wind loads, seismic loads and
temperature loads. In addition, Erection loads, loads and forces developed due to differential
settlement shall also be considered.
6.01.03 i) All the buildings shall have framed super structure. If the superstructure of building is
a steel structure, the framed superstructure shall be moment resisting sway frame in
the lateral direction and axially braced in the orthogonal direction. Columns having
depth of 400mm & less shall have bracing in single plane and at the centerline of
column. For columns having depth of 500mm & above, the longitudinal bracings shall
comprise a pair of members (spaced) with spacing equal to the column depth. Only
where axial bracing to one vertical plane is to be waived due to functional
requirement, columns in that vertical plane may be allowed to undergo biaxial
bending. Beam column joints shall be detailed as per seismic resistant joint with
adequate ductility.
All 2-legged structural steel trestles shall be completely braced in the vertical plane.
All 4-legged structural steel trestles shall be completely braced in all four vertical
planes. In addition, specified horizontal planes shall be completely braced to provide
stiffness against torsional sway.
If the superstructure is RCC structure, the superstructure shall be moment resisting
sway frame in both orthogonal direction and all the members shall be designed for
biaxial bending. Design of RCC structures shall be done as per IS 456 Detailing for
ductility shall be followed as per guidelines of IS13920 to be effective against seismic
load. Design of liquid retaining structures shall be done as per IS 3370
ii) The Main Plant building, Bunker building, transfer towers, conveyor galleries and
trestles, crusher house, boiler, ESP Control Building, ESP supporting structures,
including inlet and exhaust duct support structures, Compressor House, Pipe cable
Gallery shall have structural steel framed super structure.
iii) All other buildings may have either RCC or structural steel framework.
iv) All buildings having RCC framing shall have masonry cladding of minimum one
masonry unit thickness (not less than 225 mm.) on exterior face.
v) Cladding detail for specific building shall be provided by the bidder as per final
recommendation for type of buildings furnished to the bidder.
6.02.00 Loading
6.02.01 Dead loads
Dead loads shall include the weight of structure complete with finishes, fixtures and partitions
and shall be taken as per IS: 875 (Part-I)
6.02.02 Imposed loads
Imposed loads in different areas shall include live loads, erection, operation and maintenance
loads. Equipment loads (which constitute all loads of equipment to be supported on the
building frame) are not included in the imposed loads furnished below and shall be
considered in addition to imposed loads.
For consideration of imposed loads on structures, IS:875 (Part-2) “Code of practice for
design loads (other than earthquake) for buildings and structures” shall be followed. The
following minimum imposed loads as indicated for some of the important areas shall however

CLAUSE NO.
be considered for the design. If actual expected load is more than the specified minimum
load, then actual load is to be considered.
Sl.No. Location Imposed Loads
(T/Sq.m.)
A) Pump Houses
Operating floor 1.50
B) Maintenance bay (CWPH & RWPH) 3.0

C) Underground Structures such as Channels, Sumps, Underground Pump House,
Tanks, Trenches, Reservoirs, C.W. ducts etc.
In addition to earth pressure and ground water pressure, the surcharge load of
2T/sq.m. shall also be considered for design of all underground structures.
D) Road Culverts/Bridges and its allied structures including RCC Pipe Crossings and
Road Crossing of Trenches.
Design for class ‘AA’ loading (wheeled and tracked both) and checked for class ‘A’
loading as per IRC Standard.
E) Covers for Channels/trenches 0.40 (General) or central point load
of 75 kg whichever is higher
As per IRC Standard
(at road crossings
for vehicular traffic)
F) Railway Supporting Structures, As per Railway ‘Bridge

Rail Culverts Rules’
G) Conveyor Galleries In addition to the live loads, loads

due to cable trays, firefighting /
service water pipes shall also be
considered @125kg/m(minimum) on
each of the longitudinal girder.
Roof-truss members are to be
checked for supporting firefighting
pipes/ Service water pipes. Tentative
locations and diameter for pipes
H) General (Unless Specified Otherwise)
i) Stairs, Landings and Balconies 0.50
ii) Toilets 0.20
iii) Chequered plates, grating floors, etc., 0.50
iv) RCC floors (General) 0.50
a) Flat Roofs (where no equipment

are located) 0.15
b) Flat Roofs (where equipment 0.50

are located)

CLAUSE NO.
c) Inaccessible roof 0.075
vi) Inclined Roofs As per IS : 875

(Part-II)
vii) Dust load on roof Equivalent to 0.30 M of ash

deposit
viii) Walkways (General) 0.50
ix) Walkways of conveyor

galleries, DM & PT 0.30
x) Floor of control room of 1.00

switchyard control building
xi) Cable and pipe trestles 0.40 for walkway and in

addition, friction loads as applicable
Notes:
a) If erection load is higher than the specified imposed loads on any floor or part
thereof, then the erection loads are to be considered for the design.
b) Additional load for cable, piping/ducting, shall be considered as applicable. For any
other structures, the loads specified for those structures elsewhere in the
specification shall be followed.
6.02.03 Equipment, piping and associated loads
Equipment loads shall be considered over and above the imposed loads. Equipment loads
shall be considered as given by equipment supplier.
6.02.04 Crane load
For crane loads, an impact factor of 25% and lateral crane surge of 10% (of lifted weight +
trolley weight) shall be considered in the analysis of frame according to the provisions of
IS:875. The longitudinal crane surge shall be 5% of the static wheel load. Longitudinal surge
and lateral surge shall not be considered to act simultaneously.
6.02.05 Seismic load
For design of all structures, the site specific seismic spectrum as attached in Annexure-(e)
shall be followed.
6.02.06 Wind load
For design of all structures, the wind loads shall be taken as per the site specific wind data
specified in Annexure–(d) of this specification.
6.02.07 Temperature Load
For temperature loading, the total temperature variation shall be considered as 2/3 of the
average maximum annual variation in temperature. The average maximum annual variation
in temperature for this purpose shall be taken as the difference between the mean of the
daily minimum ambient temperature during the coldest month of the year and mean of daily
maximum ambient temperature during the hottest month of the year. The structure shall be
designed to withstand stresses due to 50% of the total temperature variation.
Suitable expansion joints shall be provided in the longitudinal direction wherever necessary
with provision of twin columns. The maximum distance of the expansion joint shall be as per
the provisions of IS 800 and IS 456 for steel and concrete structures respectively.

CLAUSE NO.
6.03.00 Civil Design Concepts

6.03.01 Individual members of the frame shall be designed for the worst combination of forces such
as bending moment, axial force, shear force, torsion, etc.,
6.03.02 The different load combinations shall be taken as per IS: 875 (Part-5) and other relevant IS
Codes.
a) Wind and seismic forces shall not be considered to act simultaneously.
b) For the design of main plant structures during seismic condition, the deaerator feed
water tank shall be considered full upto operating level. However, for other load
combinations, deaerator feed water tank in flooded condition shall be considered.
c) ‘Lifted load’ of crane shall not be considered during seismic condition.
d) In case two cranes are provided and tandem operation is not envisaged, the load
shall be taken as one crane fully loaded and second crane without lifted load but
standing idle adjacent to first crane.
e) In case two cranes are provided and tandem operation is envisaged then the crane
wheel loads shall be taken as both the cranes fully loaded to capacity and travelling
side by side although the main power house building length.
f) Permissible stresses for different load combinations shall be taken as per relevant IS
and IRS codes.
g) For the design of pipe/cable supporting structure, the soil weight shall be considered
as backfilled up to grade level for the condition of pipe running full/cables in position.
h) Frictional forces between the pipes and supporting structure in longitudinal direction
need not be considered along with seismic or wind forces.
i) Paving in crane corridor shall be designed for the maximum load due to movement of
crane.
k) For checking against uplift / tension case, 90% of Dead Loads with no Imposed
Loads shall be considered along with other Loads.
l) The Structures shall be Designed for most unfavorable Combination of Dead Loads,
Imposed Loads, Equipment Loads, Piping / Cables / Ducts Loads, Wind / Seismic
Loads, Temperature Loads, Ash Loads, and other applicable Loads without
exceeding the Permissible Stresses
m) In all Loading Combinations, the Loads that have reduction effect on design
condition shall not be taken into account in the Combination concerned.
n) Where Wind is the main Load acting on the Structure, no increase in Stresses is to
be considered for Design of Structures and Foundation Bolts.
o) In all Load Combinations, differential settlement loads (with reversible effects) are to
be considered.
6.03.03 Design of steel structures shall be done by the Working stress method. Design shall be as
per provisions of IS:800 :1984 and other relevant IS standards.
6.03.04 Shop connections will be welded type and all field connections will be bolted. Field permanent
bolts wherever provided will be high tensile bolts of property class 8.8(min) as per 1367 for all
major connections. However, nominal connections in the field like purlins, stairs, wall beams
will be done by means of M.S. black bolts of grade 4.6 conforming to IS-1367. The bolted
joints will be designed for friction grip or bearing type. For friction grip type connections, bolts
will be tightened to develop the required pretension during their installation.
For bolted Connection, IS 4000, IS: 3757, IS: 6623 and IS: 6649 shall be followed. IS 814, IS
816, IS: 1024, IS 4353 and IS: 9595 shall be followed for welding of structures.
6.03.05 Nil

CLAUSE NO.
6.03.06 Nil
6.03.07 Horizontal Deflection criteria
The maximum Horizontal Deflection for various structures shall not exceed and be limited to
the following:
----------------------------------------------------------------------------------------------------------------
Sl. No. Description Maximum value of
----------------------------------------------------------------------------------------------------------------
1. For Trestles and transfer points Height/1000

(Transverse deflection at Conveyor (For Wind load by Peak Wind
gallery supporting level) Speed Method / Seismic Load)
2. For all buildings Height/325

envisaged in this specification
3. Vertical Metal Sheeting in Cladding Span/250

---------------------------------------------------------------------------------------------------------------------
However, the maximum deflection of Grating / Chequered Plate Shall be limited to 6mm.
Note: Stresses under wind load condition for all structures shall be checked for the higher of
forces obtained from Gust Factor Method and Peak Wind Speed Method.
For deflection check on TP’s/ Trestles Wind Load by Peak Wind Speed Method along
with load due to Belt Tension and Dead Loads shall be considered.
6.03.08 a) Dispersion of load in any direction through soil shall be as per IS 8009 (relevant
part).
b) Dispersion of load through concrete shall be considered at an angle of 45 degrees
with horizontal from the edge of contact area.
6.03.09 a) Permissible deflection (unless specified otherwise in this specification) for latticed
framework and beams of floors other than drive floor shall be span/325.
b) The allowable deflection for beams directly supporting drive machinery and
equipmentshall be restricted to span/500 unless specified otherwise in this
specification.
c) The deflection for manually operated cranes & monorail supporting beams shall not
exceed span/500.
For electric overhead cranes :
1) upto 50 Tonne capacity : span/750
2) over 50 Tonne capacity : span/1000
d) The vertical deflection of metal deck sheet for floor shall be limited to span/250.
e) Permissible deflection for all purlins, cladding runners, roofing/cladding sheets and
grating / chequered plates shall be span/250. However, the maximum vertical
deflection of Grating/ Chequered plate shall be limited to 6 mm.
6.03.10 a) The design and construction of RCC structures shall be carried out as per IS: 456.
Working stress method shall be adopted for the design wherever specifically
mentioned in this specification.

CLAUSE NO.
b) For design and construction of steel-concrete composite members, IS: 11384 shall
be followed.
c) For reinforcement detailing, IS: 5525 and SP: 34 shall be followed.
d) Two layers of reinforcement (on both inner and outer faces) shall be provided for RCC
wall sections having thickness 150 mm or more
6.03.11
a) All RCC liquid retaining/conveying shall be designed by working stress method as
outlined in clause no. 4.5 of IS 3370 (Part-2) 2009 unless specified other wise.
b) Water proofing treatment shall be provided for liquid retaining/ carrying structures
and basement type structures (requiring dry working condition). Dense and durable
concrete with water cement ratio not more than 0.45 shall be used. Plasticiser
/super-plasticiser cum water proofing compound shall be added to the concrete.
c) All liquid retaining/carrying structures shall be tested for water tightness as per the
provisions of IS: 3370 and IS: 6494 and in case of leakage, the same shall be
rectified by chemical injection grouting through nozzles.
6.03.12
For design of all underground structures, foundations, C.W. ducts, etc. ground water
table shall be assumed at the finished ground level unless specified otherwise.
6.03.13 Earth pressure for all underground structures shall be calculated using coefficient of earth
pressure at rest or co-efficient of active earth pressure, whichever is applicable, depending
upon the structural configuration. However, for the design of substructure of pump houses,
earth pressure at rest shall be considered. Co-efficient of passive earth pressure shall be
used only in design of shear keys for stability against sliding.
6.03.14 a) Following loading conditions shall be considered in addition to the loading from super
structure for the design of substructure of pump house, channels, sumps, tanks,
trenches and other underground structures containing liquid
i) Water pressure from inside and no outside pressure, like earth pressure,
ground water and surcharge pressure (applicable only to structures, which
are liable to be filled up with water or any other liquid.)
ii) Earth pressure, surcharge pressure and ground water pressure from outside
and no water pressure from inside.
iii) Design shall also be checked against buoyancy due to the ground water
during construction as well as after construction stages. Minimum factor of
safety of 1.2 against buoyancy shall be ensured considering empty condition
inside and ignoring the superimposed loadings. Provision of pressure relief
valves/flap valves, etc., shall not be permitted to counter the buoyancy
unless specified otherwise.
iv) Base slab and piers of the pump houses shall also be designed for the
condition of different combination of pump sumps being empty during
maintenance stages with maximum ground water level.
b) Intermediate dividing pier of pump sumps and partition wall (if applicable) in channel
shall be designed considering water on one side only and other side being empty for
maintenance.
c) All pump houses and other substructures (wherever applicable) shall be checked for
stability against sliding and overturning during construction as well as operating
conditions for various combinations of loads.
6.03.15 If RCC floor/roof is assumed to act as diaphragm, transmitting lateral loads to braced bays, it
shall be provided with shear connectors. However, whenever large / more number of cut-outs
are provided in the floor slab, horizontal floor bracings shall be provided below slab to
transfer horizontal force to columns without considering diaphragm action from slab.

CLAUSE NO.
6.03.16 All roads shall be rigid pavements specified elsewhere in this specification. The design traffic
load shall be a minimum 4 million cumulative standard axle. The design of concrete
pavement shall be carried out as per IRC-58.
6.03.17 a) No cable/pipe trench is envisaged in the plant area. However, if required, pipe/cable
trench can be provided inside the buildings and inside switchyard or some other
localised areas.
b) All pipes and cable shall generally be routed above ground.
c) A minimum clearance (clear headroom) of 8 m shall be kept for all over-ground
pipe/cable trestles for all road/rail crossings. For other areas, the requirement of
trestle height is specified elsewhere in the specifications. All trestles shall be
provided with continuous walkway of minimum 600mm width with hand-rails and toe-
guards all along the length of the trestle along with approach ladders near roads,
passageways, etc. Before and after the road/rail crossings, a barrier of suitable
height shall be constructed so as to prevent the approach of cranes (having height
more than 8 m) etc, upto the pipe/cable racks/trestles.
d) Within AB bay in Main plant area, generally grating shall be provided for Mezzanine
floor except for valve room area, cable spreader floor, etc. where the floor shall be of
RCC. Oil equipment room shall also have RCC floor below the grating floor.
6.03.18 The maximum velocity for pipe drains and open drains shall be limited to 2.4m/sec and 1.8
m/sec. respectively. However, minimum velocity of 0.6m/sec. for self-cleansing shall be
ensured. Bed slope not milder than 1 in 1000 shall be provided. The open drains shall be
open rectangular drains of RCC unless required otherwise due to functional requirement. RC
box culverts shall be provided at rail, road or other crossings.
6.03.19 Sewers shall be designed for a minimum self-cleansing velocity of 0.75m/sec and the
maximum velocity shall not exceed 2.4m/sec.
Manual on sewerage and sewage treatment (published by Central Public Health Environment
Engineering Organisation, Government of India) shall be followed for design purpose
6.03.20 Roof decking sheets shall be designed as per IS: 801 to carry the self load, dead load due
to RCC slab and finishes and imposed load. The deflection of metal deck shall be limited as
per BS: 5950. In case composite action is considered in the design, suitable shear studs
shall be provided as per BS: 5950.
6.03.21 Foundations for all tanks shall be designed for as per IS: 803.
6.03.22 Footings shall be so proportioned to as to minimise the differential settlement.
6.03.23 Plinth level of all buildings shall be kept at least 500 mm above the finished grade/formation
level.
6.03.24 Joints/Connections in steel structures:
Steel structures shall be detailed and connection and joints provided as per the provisions of
IS 800, IS 816, IS 9595, IS 1367, and IS 9178 and as per following requirements.
a) Connection of vertical bracings with connection members and diagonals of truss
members shall be designed for full tensile capacity of the bracings unless actual
loads are indicated on the drawings.
b) Size of fillet weld for flange to web connection for built up section
i) For box section weld size shall be designed for full shear capacity or actual
shear whichever is more. Where fillet weld is not possible, full penetration butt
weld shall be provided.

CLAUSE NO.
ii) For built up I section, weld size shall be designed for 80% of full shear capacity
or actual shear, (if indicated, in drawings) whichever is more. However, weld
size shall not be less than 0.5 times the web thickness. Weld shall be double
fillet.
iii) All welds shall be continuous unless otherwise specifically approved. The
minimum size of the fillet weld shall be 6mm.
c) Shear connections shall be designed for 60% of section strength for rolled sections
and 80% of section strength for built up section or rolled section with cover plates.
However, if load is more than above, the connection shall be designed for actual
load.
d) Moment connections between beam and column shall be designed for 100% of
moment capacity of the beam section.
e) All butt welds shall be full penetration butt welds.
f) The connection between top flange and web of crane girder shall be full penetration
butt weld. Bottom flange, connection with web can be fillet weld or butt weld as
directed by Engineer.
g) Connection of base plate and associated stiffeners with the columns shall be
designed considering the total load transferred through welds. However, minimum
weld size (double fillet) shall not be less than 0.6 times the thickness of stiffeners.
h) Splicing: All work shall be full strength. Field splicing shall be done with web and
flange cover plates for full strength. Shop splicing for all sections other than rolled
shall be carried out by full penetration butt welds with no cover plates. Splicing for all
rolled sections shall be carried out using web and flange cover plate.
6.03.18 Design Criteria of RCC Floors
a) For structural steel framed buildings:
These buildings being steel framed structure, all RCC floors shall comprise RCC slab
supported on troughed, profiled metal deck sheet of minimum thickness 0.80mm (to
be used as permanent shuttering). The RCC slab shall be minimum 150mm thick
above the top surface (crest) of the metal deck sheet. The spacing of structural steel
secondary beams shall be based on the bending capacity of the metal deck sheet for
self-weight of green concrete and additional construction load of 100 kg/m2.
The permanent metal deck sheets shall be fixed to the top flange of secondary
beams by means of drawn arc welding of headed shear anchor studs directly
through the metal sheet. The details of shear anchor studs are specified elsewhere
in this specification.
The RCC slab shall be designed without considering any composite action effect of
metal deck sheet (i.e. the structural strength of metal deck sheet shall not be
considered for RCC slab design).
(b) For RCC buildings.
These buildings being complete RCC framed structures, conventional RCC slabs of
minimum thickness 125mm shall be provided. The RCC slabs shall be monolithic
with RCC beams and RCC columns
6.03.33 Design Criteria of RCC roofs
a) For Steel framed Buildings:
The roof system shall comprise minimum 40mm thick RCC slab on top of profiled
permanent metal deck sheet. The permanent metal deck sheets shall be fixed to the
top flange of secondary beams by means of arc welding of headed shear anchor
studs to the purlins directly through the metal sheet. The details of shear anchor

CLAUSE NO.
studs are specified elsewhere in this specification. Water proofing treatment to roof
slab shall be provided as per details specified elsewhere in this specification).
The RCC slab shall be designed without considering any composite action effect of
metal deck sheet (i.e. the structural strength of metal deck sheet shall not be
considered for RCC slab design.
b) For RCC Buildings.
Cast-in-Situ RCC slab shall be provided using removable plywood shuttering. Water
proofing treatment to roof slab shall be provided as per details specified elsewhere in
this specification).
6.03.34 Design Criteria for Foundation
The founding depth / cut off level of piles shall be decided based on functional requirement.
Where structural steel columns are envisaged, the bottom of the base plate shall be kept
suitably below the paving level such that the top level of the gusset plate and foundation bolt
remain at least 200 mm below the top level of paving except for Main power House Building
columns, Boiler Structure, Bunker Building Columns, TP & Trestle Columns, ESP Control
Building Columns for which the requirement of levels for bottom of base plates is specified
elsewhere in this specification. Further the gusset plate and foundation bolts are to be
encased in concrete up to the top of the paving level. For outdoor structural steel columns,
about 300 mm height of steel columns above the top of paving level shall be provided with at
least 125 mm thick encasement with minimum reinforcement to prevent corrosion of the steel
columns from surface water
a) OPEN Foundations
For all major foundations, the minimum founding depth and the minimum size of foundation
shall be as per foundation system and geotechnical data specified in the foundation chapter
include hereafter in this specification.
For open foundations, the total permissible settlement shall be as per the criteria furnished
under the foundation system specified elsewhere in this specification.
The sizing of foundation, design criteria & clear cover shall conform to IS:1904, IS:456 and
other relevant Indian codes. However minimum 0.12% of reinforcement shall be provided on
the top face of the foundation concrete on either direction and minimum percentage of
reinforcement at bottom face of foundation shall be same as that stipulated for beam as per
IS:456.
No major foundation shall rest on filled up soil. Loose soil if any below foundation is to be
removed and replaced with PCC of grade M7.5.
b) PILE Foundations
Minimum centre to centre spacing of the piles shall be 3 times the diameter of pile. Incase
single piles are used, these piles are to be interconnected with tie beams along both
orthogonal directions perpendicular to each other.
Minimum penetration of piles into Pilecap shall be 75 mm and clear cover to the main
reinforcement at the bottom face of the pile cap shall be 100 mm. Structural design of pile
cap and reinforcement shall conform to IS:2911 and IS:456. However minimum 0.12% of
cross section of the pile cap shall be provided on the top face of the pile cap along two
orthogonal directions and minimum percentage of reinforcement at bottom face of pile cap
shall be same as that stipulated for beam as per IS:456.
Detailed requirement of pile foundation have been presented in the foundation chapter
specified hereafter in this specification.

CLAUSE NO.
6.04.00 CORROSION PROTECTION

6.04.01 General
(a) All Steel structures shall be provided with painting as given in the specification.
Further, painting system shall also meet the requirements of Corrosivity category C3
(durability High) as per ISO 12944.
Painting system for steel surfaces embedded in Concrete is given separately.
(b) All Painting shall be done as per Technical Specification Painting scheme shall
submitted by the Bidder for approval of Employer / Manufacturers, which shall be
submitted by the Bidder and as approved by the Employer.
(c) All steel structures shall be designed by following basic design criteria in ISO 12944
Part 3. However, where it is not feasible to follow the design criteria given in ISO
12944 Part 3 where the steel surface are inaccessible for application of protective
coating, corrosion allowance of 1.5 mm shall be kept in thickness(over the design
thickness) of structural steel members for Talcher Thermal Power Project.
6.04.02 Painting Of Steel Surfaces Embedded In Concrete
a) For the portion of Steel surfaces embedded in Concrete, the surface shall be prepared
by Manual Cleaning and provided with Primer Coat of Chlorinated Rubber based Zinc
Phosphate Primer of Minimum 50 Micron Dry Film Thickness (DFT).
b) All threaded and other surfaces of foundation bolts and its materials, insulation pins,
Anchor channels, sleeves, etc. shall be coated with temporary rust preventive fluid and
during execution of civil works, the dried film of coating shall be removed using organic
solvents.
6.04.03 Painting Of Steel Surfaces (Other Than Those Embedded In Concrete)
a) All steel surfaces shall be provided with two component moisture curing zinc (ethyl)
silicate primer coat (having minimum 80% of metallic Zinc content in dry film, solid by
volume minimum 60% ±2%) of minimum 70 micron DFT to be applied over blast cleaned
surface conforming to Sa 2 ½ finish of ISO 8501-1 with surface profile 40-60 Micron. The
primer coat shall be applied in shop immediately after blast cleaning by airless spray
technique. Zinc dust composition and properties shall be Type-II as per ASTM D520-00.
b) Primer coat shall be followed with the application of Intermediate coat of two component
polyamide cured epoxy with MIO Content (containing lamellar MIO minimum 30% on
pigment, solid by volume minimum 80% ±2%) of minimum 100 micron DFT. This coat
shall be applied in shop after an interval of minimum 24 hours (from the application of
primer coat) by airless spray technique.
c) Intermediate coat shall be followed with the application of finish coat of two-pack aliphatic
Isocyanate cured acrylic finish paint (solid by volume minimum 55% ±2%) with Gloss
retention (SSPC Paint Spec No 36, ASTM D 4587, D 2244, D 523) of Level 2 (after
minimum 1000 hours exposure, Gloss loss less than 30 and colour change less than 2.0
∆E) and minimum 70 micron DFT. This coat shall be applied shop after an interval of
minimum 10 hours and within six (6) months (from the completion of Intermediate coat),
Colour and shade of the coat shall be as approved by the Employer.
Notes:
1. For Primer, high quality surface preparation is necessary and good amount of moisture
is required for proper curing. Below 70 % relative humidity, curing time may go up to 7
days or more. In such a case additional water sprinkling may be ensured for
completion of curing. Additionally Inorganic zinc silicate cannot be recoated; even
with itself. Typically it should be used when coating bare steel surface for first time.
2. The most frequent problem associated when top coating Primer is bubbling/pinholing
especially with non-weathered zinc silicate coatings. To a great extent, this bubbling of
finish paint can be eliminated by applying a mist coat of intermediate/topcoat as the

CLAUSE NO.
first pass of the product, allow the bubbles to subside and then apply a full coat, as
required.
3. In case topcoating of zinc silicate with epoxy/polyurethane coatings, is expected to be
delayed, it is advisable to use a suitable tie coat to avoid formation of white
rust. However, if white rust forms then clean the surface with high pressure water, dry
and apply the subsequent coats as required.
4. Touch up paintings on damaged areas: Surface preparation by manual tools, wire
brush/ emery paper etc. Minimum 6 inches peripheral area, adjoining to damaged area
to be covered. If metal surface is exposed, it is to be painted with Zinc rich epoxy (70
micron) or suitable primer with existing paint scheme. If primer is intact, intermediate &
top coat to be done with specified DFT in scheme.
6.04.04 Coating for Mild Steel parts in contact with Water.

a) All mild Steel parts coming in contact with water or water vapour shall be hot dip
galvanised. The Minimum Coating of Zinc shall be 610 g/ Sq.m. for galvanised
Structures and shall comply with IS: 4759 and other relevant Codes. Galvanising shall
be checked and tested in accordance with IS: 2629.
b) The galvanising shall be followed by the application of an etching Primer and dipping in
black bitumen in accordance with BS: 3416, unless otherwise specified.
6.04.05 Gratings
All gratings shall be blast cleaned to Sa 2 ½ finish or cleaned by acid pickling as per ISO
8501-1 and shall be hot dip galvanized at the rate of 610 g/Sq.m.
6.04.06 Hand Railings and Ladders
All Mild steel handrails and ladders shall be galvanised at the rate of 610 g/Sq.m as per IS
4736. However, Stainless steel handrails shall be provided as specified in General
Architectural Specification clause 9.0.0.
6.04.07 Sea Worthiness
All Steel Sections and fabricated Structures, which are required to be transported on sea,
shall be provided with anti corrosive Paint before shipment to take care of sea worthiness.
6.04.08 All structural steel members in switchyard (excluding fencing and gate) shall be hot dip
galvanised as specified elsewhere.
6.04.09 For reinforced concrete work.
i) The protection for concrete sub-structure shall be provided based on aggressiveness
of the soil, chemical analysis of soil/sub-soil water and presence of harmful
chemicals/salts.
ii) The protection to super structure shall depend on exposure condition and degree of
atmospheric corrosion.
This shall require use of dense and durable concrete, control of water cement ratio,
increase in clear cover, use of special type of cement and reinforcement, etc.,
coating of concrete surface, etc.,
Bidder shall furnish the details of corrosion protection measures.

CLAUSE NO.
GEOTECHNICAL DATA AND FOUNDATION SYSTEM
7.00.0 SOIL DATA AND FOUNDATION SYSTEM

Bearing capacity for design of foundations and Borelogs data are given at Annexure - I of this
specification.
7.01.01 Soil Data
Employer has carried out geotechnical investigation in the areas pertaining to this package.
The geotechnical investigation report comprising of Boreholes, Laboratory tests, Chemical
analysis, etc. in respect of the sub-strata prevailing at site will be made available for the
Bidder's study at the Employer's office, if required.
Based on the available bore logs, the soil stratum consists of sandy silt/clayey silt of low
plasticity layer varying from 1.5m to 5m depth from ground level followed by silty sand/fine
sand layer of thickness varying from 20m to 30m. This layer is underlain by about 5m layer of
sandy silt followed by silty sand/fine sand layer up to the depth of investigation. The ground
water table is encountered at about 4m depth at the time of investigation and may fluctuate
with seasonal variation.
Based upon the initial assessment, soil up to a depth of 5m to 6m (below existing

ground level) is prone to liquefaction hazard. For heavily loaded structures, pile
foundations may be considered and for lightly loaded structures, open foundation
after suitable ground improvement as per clause 1.02.04 & 1.02.05 may be considered.
Minimum cut off level of piles below NGL is 5m.
Onus of correct assessment/ interpretation and understanding of the existing subsoil

condition / data is on the Bidder. Bidder may refer topographical survey drawing for variation
in existing ground level (EGL) and FGL. As per topographical survey drawing, EGL is varying
from RL(+) 191.5m to RL(+) 193.5m and FGL is RL(+) 194.0 i.e. there may be filling of 0.5m
to 2.5m.
7.01.02 Tank Foundations:
a) The tanks shall rest on flexible tank pad foundation, resting on sand with concrete
ring wall to retain sand. Base of the concrete ring wall shall not rest on the expansive
soil, if any.
b) Entire loose/ soft soil inside the concrete ring wall shall be removed and shall be
filled with sand. Sand for filling shall be clean and well graded conforming to IS 383
with grading Zone I to III.
c) Sand shall be spread in layers not exceeding 30cm compacted thickness over the
area. Each layer shall be uniformly compacted by mechanical means like plate
vibrators, small vibratory rollers, etc to achieve a relative density of not less than
80%.
d) Other requirements of tank foundations shall be as per IS 803 and as specified

elsewhere in the specifications.
7.01.03 Foundation System

The requirements for the foundation system to be adopted are as given in subsequent
clauses. Depending upon the depth of competent strata/stratum, type of structures, functional
requirement of facility, extent of cutting / filling, suitable foundation, open or pile shall be
adopted with approval of owner. For heavily loaded structures, pile foundations may be
considered and for lightly loaded structures, open foundation after suitable ground
improvement may be considered.

CLAUSE NO.

a) All structures/equipment shall be supported either on suitable open foundations
(isolated, combined, raft) or on pile foundation depending on type of
structures/facilities, sub-strata, topography etc.
b) The roads, ground floor slabs, trenches, pipe pedestals except thrust blocks,
channels/drains and staircase foundation with foundation loading intensity less than 4
T / M2 may be supported on open / shallow foundations resting on virgin / controlled
compacted filled up soil. If the encountered sub-strata is black cotton soil, the same
shall be either replaced upto the full depth or black cotton soil shall be stabilized by
suitable treatment. For mitigation of liquefaction separate clause may be referred.
c) No other foundation (other than as mentioned in (b) above) shall rest on the filled up
ground / soil.
d) All foundations shall be designed in accordance with relevant parts of the latest
revisions of Indian Standards.
e) The water table for design purpose shall be considered at Finished Ground Level.
f) A combination of open and pile foundations shall not be permitted under the same
equipment / structure / building.
g) Foundation for miscellaneous equipment’s on ground floor with sand backfilling.
For equipments of static weight upto 1.5 T, the equipment may be supported on the
ground floor slab by locally thickening the slab. Thickening of the ground floor slab
shall be done upto an extent of about 0.6 m beyond the plan area of the equipment on
all the sides. Further, the load intensity below the equipment shall be limited to 4T/m2.
Other requirements of floor slab and compaction below the floor slab shall be adhered,
as specified elsewhere in the specifications.
For equipment’s of static weight between 1.5 T and 20 T, the equipment may be
supported on compacted sand filling with the load intensity below the equipment limited
to 4T/m2. The minimum depth of foundation is 1.0m below FFL. Other requirements of
sand compaction below the foundation shall be adhered, as specified elsewhere in the
specifications.
For equipment of static weight more than 20 T, the equipment foundation shall be
taken to the founding level or shall be built up with PCC from the level as mentioned in
the Table 1. The pedestal of equipment foundation or the foundation Block shall be
isolated from the adjoining floor slab by providing bitumen impregnated fiber board of
minimum 50 mm thick, conforming to IS: 1838 all around the equipment pedestal for
the full depth of the floor slab.
7.01.05 Open Foundations

Structures which are not founded on pile foundation are to be placed on open foundation and
if the depth of foundation is less than 5.0m below the EGL than the ground improvement shall
be done using stone columns as per clause 1.02.04 & 1.02.05.
In case open foundations are adopted, following shall be adhered to.
7.01.05.1 The minimum width of foundation shall be 1.0 m.

CLAUSE NO.
7.01.05.2 Minimum founding level, bearing capacity and permissible settlements shall be as given in
the Annexure - 1 to this specification.
7.01.05.3 It shall be ensured that all foundations of a particular structure/ buildings/ facility shall rest on
one bearing stratum.
7.01.05.4 Incase pile foundations are to be adopted the requirements under para "pile foundations"
shall be adhered to.
7.01.06 Pile Foundations

In case piles are adopted, following shall be adhered to :
i) The pile foundation shall be of RCC, Cast-in-situ bored piles as per IS:2911. Pile
boring shall be done using Rotary Hydraulic Rigs. Two stage flushing of pile bore
shall be ensured by airlift technique duly approved by the Employer. Due to
presence of sandy strata air flushing shall be done cautiously with controlled
pressure. If required, temporary or permanent casing shall be provided for piling
work.
ii) The minimum diameter of pile shall be 600 mm. The allowable load carrying
capacities of the pile in various modes shall be limited to the values given at
Annexure - I. However, the pile capacities to be adopted shall be the least of the
estimated design values and that obtained from the initial pile load tests.
iii) Only straight shaft piles shall be used. Minimum cast length of pile above cutoff
level shall be 1.0 m.
iv) The contractor shall furnish design of piles (in terms of rated capacity, length,
diameter, termination criteria to locate the founding level for construction of pile in
terms of measurable parameter, reinforcement for job as well as test piles, pile load
test arrangement, locations of initial test piles etc.) for Engineer’s approval.
v) The piling work shall be carried out in accordance with IS:2911 (Relevant part) and
accepted construction methodology. The construction methodology shall be
submitted by the Contractor for Engineer's approval.
vi) Number of initial load tests to be performed for each diameter and rated capacity of
pile shall be subject to minimum as under.
Vertical
Lateral Minimum of 2 nos in each mode
Uplift
vii) The initial pile load test shall be conducted with test load upto three times the pile
capacity mentioned in Annexure-1. In case of vertical compression test (initial test)
the method of loading shall be cyclic as per IS:2911 (relevant part).
viii) Load test shall be conducted at pile Cut-off Level (COL). If the water table is above
the COL the test pit shall be kept dry throughout the test period by suitable de-
watering methods. Alternatively the vertical load test may be conducted at a level
higher than COL. In such a case, an annular space shall be created to remove the
effect of skin friction above COL by providing an outer casing of suitable diameter

CLAUSE NO.
larger than the pile diameter.

ix) Number of routine pile load tests to be performed for each diameter/allowable
capacity of pile shall be as under :
Vertical : 0.5% of the total number of piles provided
Lateral : 0.5% of the total number of piles provided
x) The routine tests on piles shall be conducted upto test load of one and half times
the allowable pile capacity. Piles for routine load tests shall be approved by the
Employer.
xi)
In case, routine pile load test shows that the pile has not achieved the desired
capacity or pile(s) have been rejected due to any other reason, then the Contractor
shall install additional pile(s) as required and the pile cap design shall accordingly
be reviewed and modified, if required.
xii) Testing of piles and interpretation of pile load test results shall be carried out as per
IS:2911 (Part-4). Contractor shall ensure that all the measuring equipment and
instruments are properly calibrated at a reputed laboratory / institute prior to their
use. Settlement / movement of the pile top shall be made by Linear Variable
Differential Transducers (LVDT) having a least count of 0.01mm.
xiii) The test load on initial test piles shall be applied by means of reaction from anchor
piles / rock anchors alone or combination of anchor piles / rock anchors and
kentledge with concrete blocks.
xiv) Low Strain Pile Integrity test shall be conducted on all test piles and job piles. This
test shall be used to identify the routine load test and not intended to replace the
use of static load test. This test is limited to assess the imperfection of the pile shaft
and shall be undertaken by an independent specialist agency to be approved by
Engineering department of Owner. The test equipment shall be of TNO or PDI
make or equivalent. The process shall confirm to ASTM.
High Strain Dynamic Load Test may be carried out for routine load testing of
working piles. However, at least two numbers of static routine vertical load tests
shall be carried out on pile on which high strain dynamic load test has already been
carried out for establishing the correlation between the two tests. In case of
discrepancy if any between dynamic and static vertical load tests, then additional
static routine vertical load tests shall be conducted as decided by the Engineer and
the results of static routine vertical load shall prevail. Number of routine vertical pile
load tests as per clause 7.02.03 (ix) shall be total of static routine vertical load test
and high strain dynamic load tests.
The procedure to carry out the test shall be submitted to the Engineer. The test and
equipment shall conform to ASTM D4945-00. The test shall be conducted by an
experienced independent test agency approved by the owner. Field data shall be
submitted to the site engineer and shall include force velocity curves, pile capacity,

CLAUSE NO.
simulated static load test curve, net and total pile displacement, pile integrity. A
(Case pile wave analysis) CAPWAP or equivalent software analysis shall be
conducted on the field data for correct capacity estimation and to evaluate end
bearing and skin friction components of the pile.
xv) From load considerations, single pile may be used under a column/tower. In that
case, pile shall be connected with tie beams at pile cut off level in both directions.
xvi) Contribution of frictional resistance of filled up soil if any, shall not be considered for
computation of frictional resistance of piles.
xvii) Reinforcement for job piles shall be designed as following:
i. Compression + bending piles: For these piles, the allowable safe pile
capacities in compression and bending shall be considered.
ii. Tension + bending piles: For these piles, the actual pile forces to be
considered. However, maximum 3 types of combinations for varying
percentage of tension capacity + bending case may be designed & adopted by
contractor for the entire scope of work under this package.
7.02.01 Ground Improvement below structures/facilities using stone columns:
i) The work broadly involves installation of stone columns for mitigation of liquefaction
hazard, improvement in bearing capacity of the soil and to bring down the residual
settlements so that the facilities that may be constructed over the stone column area
shall stand safely and perform satisfactorily throughout their lifetime.
The stone columns shall be installed using bottom/top feed Vibroflotation techniques without
water jetting i.e. dry method (displacement method) in accordance with these specifications.
Installation of stone column by rammed/driven technique without water jetting may also be
permitted/used subject to conforming to the specification and meeting to the construction
schedule.
In case of vibro replacement method, the bidder shall submit the construction methodology
giving information regarding details of equipment, type and energy rating of vibratory probe,
details of power output, compaction criteria etc.
In case of rammed stone column methodology, the bidder shall submit the construction
methodology giving information regarding type of equipment, weight of rammer, height of fall,
compaction criteria, stages of casing withdrawal etc. Use of bentonite slurry for formation of
stone columns shall not be permitted. A casing pipe shall be provided by the bidder upto to
full depth of stone column.
In either of the above techniques adopted, the parameters shall be so chosen to give stone
column of specified diameter and load carrying capacity.
In either of the above techniques adopted, the quantity of stones shall be placed in such that
the column is filled in stages of height not exceeding 1m. Each stage shall be compacted to
ensure uniform consumption of stones throughout the depth.
The method of placement of stone shall be such that it is possible to measure the total
consumption of stones in a column.
Stone column installation procedure submitted by the bidder shall be approved by the
Engineer.

CLAUSE NO.
ii) All materials and workmanship shall be in accordance with this specification and IS:
15284: Part 1: 2003.“Design and Construction for Ground Improvement – Guidelines, Part 1
Stone Columns”.
iii) Case:1 Ground improvement without piling provision after it
Dia of column (D) = 900mm
Spacing = 3D (Triangular pattern)
Depth of ground improvement (d) = 6m
Case:2 Ground improvement with piling provision after it
Dia of column (D) = 900mm
Spacing = 4D (Rectangular pattern)
Depth of ground improvement (d) = 6m
iv) Ground improvement with stone column shall be carried out minimum d/2 distance beyond
the footprint of buildings(minimum 2 rows beyong the building footprint), where d is the depth
of improvement. The ground improvement shall be carried out below the entire
building/structure rather than restricting it to just below the foundations.
v) Initial load tests shall be performed at the trial site as identified by Engineer to evaluate
load settlement behaviour of the stone columns. These tests shall be conducted on a single
as well as on a group of three columns. Load testing procedure, equipment and interpretation
shall confirm to IS 15284 (Part-I).
vi) Boreholes shall be drilled prior and after the installation of stone columns and frequency
shall be minimum 1 borehole under each structure/facility or 2000 Sqm whichever is less.
The performance of the stone column(s) shall be considered acceptable and approved by the
Engineer based on the SPT ‘N’ values of the improved ground.
The installation of stone column is considered acceptable if it achieve SPT ‘N’ value more
than 15 from the natural ground level upto depth of improvement. The minimum net safe
bearing pressure after ground improvement shall be as mentioned in table-1 of this
specification.
7.02.02 Ground Improvement below roads & drains:
In order to mitigate liquefaction below roads & drains, ground improvement by dynamic
compaction or any other method can be done. The improvement shall be done along the
alignment & additional d/2 distance on both sides away from the road/drain footprint, where d
is depth of treatment. Boreholes shall be drilled prior and after the ground improvement and
frequency shall be minimum 1 borehole under each structure/facility or 2000 Sqm whichever
is less. The ground improvement is considered acceptable if it achieve SPT ‘N’ value more
than 15 from the natural ground level upto depth of improvement. The minimum load intensity
after ground improvement shall be 7T/m2. In case alignment of roads/drains changes at a
later stage then the ground improvement using stone columns shall be done as per clause
7.02.04.
7.03.0 Excavation, Filling and Dewatering
7.03.01 For excavation works, comprehensive dewatering with well point or deep wells arrangement
wherever required shall be adopted. Scheme for dewatering and design with all computations

CLAUSE NO.
and backup data for dewatering shall be submitted for the owner’s information. The water
table shall be maintained at 0.5m below the founding depth during complete construction
time.
7.03.02 Excavation for shallow foundations shall be covered with PCC immediately after reaching the
founding level. In case of any local loosening of soil or loose pockets are encountered at
founding level during excavation the same shall be removed and compensated by PCC M
7.5. The final layer of about 300 mm thickness above the founding level shall be excavated
by suitable means, so as to avoid disturbance to founding stratum.
7.03.03 Backfilling around foundations, pipes, trenches, sumps, pits, plinths, etc. shall be carried out
with approved material in layers not exceeding 300 mm compacted thickness (higher
thickness of layers upto 500mm with heavy mechanical compacting equipment) and each
layer shall be compacted to 90% of standard proctor density for cohesive soils and to 80% of
relative density for non cohesive soils. In any case, black cotton soil shall not be used in back
filling without providing cusion of 1m of non expansive cohesive soil/moorum around the
footings. In case of roads in the area of black cotton soil, minimum 0.4m moorum shall be
provided.
7.03.04 The founding level for trenches/channels shall be decided as per functional requirement. The
bottom of excavation shall be properly compacted prior to casting of bottom slab of trenches /
channels.
7.03.05 CBR tests for pavement/road design shall be carried out by the Contractor after earth filling (if
applicable) has been completed upto the formation level.
1.03.06 The contractor shall take all necessary measures during excavation to prevent the hazards of
falling or sliding of material or article from any bank or side of such excavation which is more
than one and a half meter above the footing by providing adequate piling, shoring, bracing
etc. against such bank or sides.
Adequate and suitable warning signs shall be put up at conspicuous places at the excavation
work to prevent any persons or vehicles falling into the excavation trench. No worker should
be allowed to work where he may be stuck or endangered by excavation machinery or
collapse of excavations or trenches.
1.03.07 Following details shall be submitted by the Bidder before start of work at site.
Scheme for initial pile load tests in vertical, lateral and uplift modes along with supporting
design calculations and methodology for installation of working piles.
1.04.00 Sheeting & Shoring

The contractor shall ascertain himself the nature of materials to be excavated and difficulties,
if any, likely to be encountered in excavation, while executing the work. Sheet piling, sheeting
and shoring, bracing and maintaining suitable slopes, dewatering, draining etc. shall be
provided and installed by the Contractor, to the satisfaction of the Engineer.

CLAUSE NO.
1.05.00 SOIL DATA AND FOUNDATION SYSTEM

a) Logs of representative boreholes and laboratory test results from this area are enclosed at
Annexure-C.
b) The foundation system to be adopted for different structures shall be as given in Table – 1
below
Table – 1: Net Allowable Bearing Pressure

STRUCTURE TYPE OF
FOUNDATION TO BE
ADOPTED
Water System Package Structures Open/Piles
c) The minimum founding level and the corresponding net allowable bearing pressure shall be
as given in Table – 2 below.
Table – 2: Net Allowable Bearing Pressure

Founding Depth/ Stratum Net Allowable Bearing Pressure
T/m2
Isolated Isolated Rafts
and and (width >
combined combined 6m) for
footings footings for 75mm
including raft 40mm permissible
for 25mm permissible settlement
permissible settlement in case of
settlement in in case of soil
case of soil soil
Width upto 6.0m
1.0m to 5.0m below NGL (After 10 12 15

ground improvement using stone
columns)
5.5m below NGL without Ground 10 14 18
improvement
improvement
improvement
For NGL of the proposed area GLP along with topographical survey drawing along with
borelog data may be referred. In case any loose/soft pockets is encountered at founding
level, the same shall be removed completely upto the hard strata and filled up with PCC
(1:4:8).
The net allowable bearing pressure higher than above mentioned values shall not be
permitted. At intermediate levels the bearing capacity shall be same as the net allowable
bearing pressure corresponding to the immediate shallower level mentioned above.

CLAUSE NO.
d) Permissible Settlement of Foundations:

For open foundations, the total permissible settlement and differential settlement shall be
governed by IS: 1904 and from functional requirements whichever is more stringent.
However, total settlement shall be restricted to the following:
Isolated & Strip 40 mm
Raft (widths greater than 6 m) 75 mm
In case the total permissible settlement is to be restricted to less than as above specified
from functional requirements, then the net allowable bearing pressure shall be reduced after
review in consultation with Engineer.
e) The diameter of pile, minimum length and maximum allowable capacity of piles shall be as
given below:
Area/ Pile Minimum Length of Bored Safe Load Capacity in
Location Diameter Pile Below Cut-off Level
Vertical Lateral
(mm) (m)
Comp. Pullout (MT)
(MT) (MT)
600 25 100.0 30 7.0
Misc Buildings
Structures 600 35 140 45 7.0
760 35 250 75 12.5
- Cut off Level (COL) is assumed at 5.0 m below FGL.
f) The criteria for Pile Termination (founding level) shall be as given below:
The termination level of the pile shall be decided based on the following criterion:
i) Minimum length of the pile below COL (cut off level) shall be as specified above
ii) The minimum pile length for each group of piles shall be determined based on the
nearest borelog. A minimum embedment of 4.0m into the dense to very dense sand
strata with SPT ‘N’ value greater than 40 for 100 T vertical capacity pile and a minimum
embedment of 4.0m into very dense sand strata with SPT ‘N’ value greater than 70 for
140 T & 250 T vertical capacity pile as observed in such borelog shall be ensured, while
deciding the minimum length of pile.
iii) For pile termination, SPT shall be conducted in a separate borehole of 100mm dia as
per IS 1892. In this borehole, SPT shall be conducted at 3.0m interval upto 20m below
ground level and 1.0m interval beyond 20m to at least 5.0m below the pile termination
level. One borehole shall be done for 50-70 piles or in a pile group and one borehole for
each test pile group. The SPT N value at pile termination level shall not be less than 50
for 100 T vertical capacity pile and 100 for 140 & 250 T vertical capacity piles.

CLAUSE NO.
iv) However, in no case the length of pile shall be less than the minimum length determined
as in (i) or (ii) above whichever is longer, for that pile group
g) Special Requirements:
1) Chemicals in ground water and subsoil, as observed during investigation are:
Chemical SO3 Chlorides pH

Ground Water 336 ppm 90 ppm 7.8
Sub-soil 0.12 - 0.13 % 0.02 - 0.03 % 7.7 - 7.8
2) In view of the above, the site can be classified in class-2 category as per IS:456 and
following shall be adopted.
Cement Type As specified elsewhere in the specifications
Concrete Grade M25 for piles
Minimum cement content for piles shall be 400 kg/cum
of concrete. Concrete shall be dense and durable.
Admixtures in concrete are not permitted
Type of Reinforcement As specified elsewhere in the specifications
Cover to Reinforcement As specified elsewhere in the specifications

CLAUSE NO.
8.00.00 GENERAL SPECIFICATION
8.01.01 JOINTS IN CONCRETE STRUCTURES
Construction Joints
All horizontal construction joints shall be provided with a groove (shear key) for transfer of
shear force.
For construction joint in concrete wall, the maximum height of any lift should not exceed 2
meters. However, the time interval between the successive lifts should be as small possible
and the wall should be built to its full height in the least possible time.
Expansion joints for all underground structures shall be made watertight by using ribbed PVC
water stops with central bulb or of kicker type. The thickness and width of PVC water stops
shall be as per the requirement of design. However, the minimum thickness and width shall
be 6mm and 225mm respectively.
Expansions Joints
In case of expansion joints, preformed bitumen impregnated fibre board conforming to IS

1838 shall be used as joint filler. The joints shall be sealed with bitumen sealing compound
conforming to IS 1834, however in case of liquid retaining/carrying structures, two parts
polysulphide sealant conforming to IS 12118 or silicon sealing compound shall be used.
IS 3414 shall be followed for details of joints in buildings. 3 mm thick stainless steel strip in
matt or buff finish shall be provided over building expansion joints.
8.01.02 Miscellaneous General Requirements
8.01.02.1 All steel sections and fabricated structures, which are required to be transported on sea, shall
be provided with anti-corrosive paint before shipment to take care of sea worthiness.
8.01.02.2 Monorails, monorail girders and fixtures shall be provided, wherever required to facilitate
erection / maintenance of equipment.
8.01.02.3 Wherever possible all floor openings shall be provided with 100 mm thick 150 mm high RCC
kerb all around.
8.01.02.4 Angles 75 x 75 x 6 mm (minimum) with 8mm diameter and 150mm long MS lugs @ 150 c/c
shall be provided for edge protection all around cut outs/openings in floor slabs. Angles 50 x
50 x 6mm with effective anchor lugs shall be provided for edges of concrete drains
supporting grating/covers, edges of RCC cable / pipe trenches supporting covers/chequered
plates/ grating, edges of manholes supporting covers, supporting edges of precast RCC
covers and any other place where breakage of corners of concrete is expected.
8.01.02.5 Floor of switchgear room shall be provided with embedded M.S. channel suitable for easy
movement of breaker panels.
8.01.02.6 Anti-termite constructional measures and chemical treatment measures shall be given to all
vulnerable areas susceptible to termite including column pits, wall trenches, foundations of
buildings, filling below the floors, etc., as per IS 6313 and other relevant Indian Standards.
KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION PAGE

(2X660 MW) SUB-SECTION-IIID-01
WATER SYSTEM PACKAGE CIVIL WORKS
CLAUSE NO.
8.01.02.7 All cable & pipe routing shall be done as per system requirement and as stipulated elsewhere
in the specification and shall run above ground on elevated trestles or other supporting
structures except in some localized area (as approved by Employer) where the same can run
in trenches. In case, pipes are to be routed on RCC pedestals, the height should not be less
than 500mm above formation level/paving level. All trenches shall be of RCC with removable
RCC covers.
All cable trenches located inside buildings shall have minimum 6mm thick (o/p) chequered
plate covers.
Cable trenches, where allowed, located outside the buildings shall project at least 200mm
above the finished formation level unless noted otherwise elsewhere in this specification so
that no storm water shall enter the trench. The bottom of the trench shall be provided with a
longitudinal slope of 1:500.The downstream end of trenches shall be connected through pipe
drains to the nearby RCC manholes (to convey water from trenches) of storm water drainage
system, but avoiding back flow of storm water. In general, the precast covers shall not be
more than 300 mm in width and shall not weigh more than 65 kg. Lifting hooks shall be
provided in the precast covers.
All cable trenches, wherever required, shall be provided with suitable insert plates for fixing
support angles of cable trays.
In Main plant area wherever fire water pipe trenches are envisaged, these trenches shall be
of RCC and provided with precast RCC cover flush with finished level of paving in that area.
R. C. C. cable slits shall be filled with sand after erection of cables, up to top level and
covered with 75mm thick PCC cover of minimum M15 grade.
8.01.02.8 All steel platforms above grade shall be provided with 100 x 6 thick kick plates at edge of
platform.
8.01.02.9 Duct banks consisting of PVC conduits conforming to IS 4985 for cables shall be provided
with proper sealing arrangement consisting of fire retardant sealing compound.
8.01.02.10 Independent network of lines for sewerage and drainage shall be provided. Plant effluent
shall not be mixed with either storm water or sewage.
8.01.02.11 The sub-grade for the roads and embankment filling shall be compacted to minimum 95% of
the Standard Proctor density at Optimum moisture content (OMC.)
8.01.02.12 Detailed scheme for dewatering shall be prepared, wherever required, before starting of deep
excavation work. IS 9758 shall be followed as general guidance for dewatering.
8.01.02.13 Structural steel column base plates and bolts, gussets, etc., shall not project above the floor
level unless and noted otherwise. These shall be encased by concrete cover up to floor level
with concrete grade M 25.
8.01.02.14 Non-shrink flow able grout shall be used for under-pinning work below base plate of columns.
Nominal thickness of grout shall be 50 mm. Non-shrink cum plasticizer admixture shall be
added in the grout. Crushing strength of the grout shall generally be one grade higher than
that of the base concrete. Minimum grade of grout shall be M-30.
Grouting of all pockets, blockouts, sleeves and the openings around the embedment, inserts,
bolts etc. and under pinning below the base / sole plate shall be with non - shrink flow able
grout. Grade of grout shall be one grade higher than concrete. However minimum grade of
grout shall be M - 30.

CLAUSE NO.
However, for equipment foundations, high strength (minimum characteristic compressive
strength of 60 N/sq.mm at 28 days) ready mixed non-shrink, chloride free, cement based,
free flowing, non-metallic grout as recommended by equipment manufacturer shall be used.
8.01.02.15 All building shall be design to take care of Rain Water harvesting & ground water recharging.
8.01.02.16 As required suitable steel frames shall be provided around openings in the roof and external
walls for mounting exhaust fans.
8.01.02.17 750mm wide x 100 mm thick plinth protection in PCC (M-15) shall be provided around all
buildings, pits / sumps, clarifiers, tanks, etc.
8.01.02.18 All masonry walls shall be provided with Damp Proof Course at plinth level.
8.01.02.19 All monorail openings in the walls shall be provided with double plate flush steel door
shutters with suitable access platform and ladder as required.
8.01.02.20 Hand rail (of minimum 1m height), size and material to be adopted shall be as per general
architectural specification.
8.01.02.21 In all buildings, suitable arrangement for draining out water collected from equipment blow
downs, leakages, floor washings, firefighting etc. shall be provided for each floor with suitable
floor drains.
8.01.02.22 Unless specified all sand filling shall be compacted to minimum 80% of the relative density
and backfilled earth shall be compacted to minimum 90% of the Standard proctor density at
OMC.
8.01.02.23 All buildings shall be provided with peripheral drains by the side of plinth protection for
catering to the rain water from roofs and storm water from adjacent area. Plinth protection
drains shall be provided all around the building and to be connected with nearest storm water
drain. Minimum size of plinth protection drain will be 300mmx300mm.
8.01.02.24 Minimum 2.0m wide walkway with plain cement concrete (nominal mix M15 grade) paving
150 mm thick laid over 75 mm thick bed of dry aggregate shall be provided connecting all
buildings and facilities. The top of walkway shall be minimum 200mm above FGL, unless
specified otherwise.
8.01.02.25 For all buildings, finished floor level (FFL) shall be minimum 500mm above finished ground
level (FGL).
8.01.02.26 40mm Diameter MS rods as earthing mat, placed at a distance of 1.0m away and at depths
between 0.60m and 1.00m shall be supplied and laid all around the periphery of buildings,
structures, and outdoor equipment, as per approved drawings. Riser of 40mm Dia. MS rods
and connecting to the above Earthing mat shall also be supplied and laid in position by the
Contractor, as per the approved drawings. Raiser shall be laid up to a height of 300 mm
above the local Ground level, at each of the columns of the buildings on the outside of the
buildings, and minimum 2 (two) numbers for each structures and equipment. The contractor
shall also supply and lay necessary number of 3.0 m deep 40 mm diameter MS rods Earthing
electrodes and connect electrodes to the Earthing mat, as per the approved drawings and
supplying and laying of 40 mm Dia. MS rods for connecting the Contractor’s earthing mat
with the Employer’s earthing mat separately.
8.01.03 Acid/ Alkali Resistant Lining
All structures receiving acid / alkali resistant lining shall be tested for water tightness and
made leak proof before lining work.

CLAUSE NO.
The acid / alkali resistant lining shall be provided broadly in the areas identified. The Bidder
shall give a guarantee for satisfactory functioning of the lining for a period of 36 months from
the date of completion of the work or date of handing over the site to the Engineer, whichever
is later. The Bidder shall replace / rectify defects is any, observed in the lining to the
satisfaction of the Engineer without any extra cost during this period.
The material for Acid/ Alkali Resistant Lining shall conform to the following:
i) Bitumen primer shall conform to IS: 158.
ii) Bitumastic compound shall conform to IS: 9510. Where the height of bitumastic layer
on vertical surface is more than 2.0 m, the bitumastic layer shall be reinforced with
diamond pattern expanded metal steel sheets conforming to IS: 412.
iii) A.R. Bricks/ Tiles shall conform to class II of IS: 4860 & IS: 4457 respectively.
iv) Mortar: Potassium silicate & resin type mortars shall conform to IS: 4832 Part-I&II
respectively.
8.02.00 CONCRETE
8.02.01 GENERAL
a) Concrete work shall be carried out as per IS 456. Mix design concrete shall be used
for all areas other than lean concrete work and plain cement concrete where
nominal/volume mix can be permitted. Design mix shall be carried out as per
IS10262. Specific approval of the Engineer shall be obtained regarding degree of
quality control to be adopted for design mix.
b) Minimum grade of reinforced cement concrete for all foundations shall be M25
unless noted otherwise. Minimum grade of concrete for other structures/areas (other
than machine foundations) shall be M25 for all superstructure and substructure
unless noted otherwise elsewhere in this specification.
N/A
d) Higher grade of concrete than specified above may be used at the discretion of the
Bidder.
e) Unless otherwise specified, 20mm and down aggregates shall be used for all
structural concrete works. However, 40mm and down aggregates may also be used
under special conditions for mass concreting in foundation.
f) For thin concrete sections such as roof slab over profiled metal deck sheets, 12mm
and down coarse aggregates shall be used for coarse aggregates.
g) Minimum 75mm thick lean concrete M-7.5 shall be provided below all other
underground structures, foundations, trenches, etc., to provide a base for
construction.
h)

CLAUSE NO.
8.02.02 Reinforcement Couplers

Reinforcement couplers (mechanical splicing systems with upset parallel threaded couplers)
may be used in reinforced concrete works, subject to following conditions:
a. Couplers shall meet the performance requirements of IS 16172 for class H.

i. It shall have minimum tensile strength corresponding to Fe550D which is 600
N/mm2 and failure shall take place outside the length of splice as per clause no
9.2.1 of IS 16172.
ii. Percentage elongation at maximum force in the reinforcing bar outside the length
of mechanical splice shall be minimum 3 % before the failure of test piece as per
clause no. 9.2.2 of IS:16172.
iii. Slip test value shall not exceed 0.10 mm. as per clause no 9.3 of IS 16172.
iv. Cyclic tensile test corresponding to Fe550D reinforcement bar as per clause no
9.4 of IS 16172.
v. Low cycle fatigue test as per clause no 9.5.1 of IS 16172.
vi. High Cycle Fatigue test as per clause no 9.5.2 of IS 16172.
b. The manufacturer shall mark the coupler in such a way that all finished reinforcement
couplers can be traced to the original cast from which they were made along with
date of manufacture.
c. Sampling and other requirements of IS 16172 shall be complied with.
d. Each lot shall be supplied with manufacturer’s test certificate (MTC) indicating values
of tests in line with IS 16172.
e. The minimum clear cover requirements are to be ensured for reinforcement couplers
also.
f. The couplers shall be used only at the locations where joint is required as per
standard lapping purpose and couplers shall not be used for joining of several cut
pieces of reinforcement in a single bar. As a general guideline, the length of the bars
in which coupler is to be provided should not be less than 4m.
Vendors for the reinforcement couplers shall be subject to the approval of

Engineer-In-Charge
8.02.03 Special requirements for concreting of major equipment foundations shall be as given below.
a) Admixture
Plasticizer /super plasticizer admixture shall generally be added to the concrete for
promoting workability. In addition, plasticizer/super plasticizer-cum-retarder shall be
added to retard the setting time for mass concreting work as required. In case of
pumping, suitable pumping additive shall also be added to avoid segregation and
increase flowability. The slump shall generally be in the range given below:
Block foundations - 100 mm to 150 mm
b) Form work
Plywood with film face form work shall be used for the top decks of all machine
foundations
c) Placing of Concrete

CLAUSE NO.
Base Raft and top deck of machine foundations shall be cast in a single pour.
d) Scheme for Concreting
Weigh Batching Plants, transit mixer, concrete pump shall be mobilized.

Arrangements for standby Plant and Equipment shall also be made.
8.02.04 Anchor Fasteners
Anchor Fasteners for use in concrete shall conform to the following:
a. The safe tensile load carrying capacity of the anchors shall be arrived by providing
the minimum factor of safety of 2.5 on the characteristic load of the anchor. Minimum
size of the anchors shall be M8.
b. All anchors shall be from established and approved makes/ manufacturers.
c. Anchors shall be fixed in position as recommended by the manufacturer and as

approved by the engineer.
d. Anchor fastener can be of mechanical type based on working principles such as
keying, friction, combined friction- keying or chemical bonding type.
1) Mechanical type: The anchors shall be cold formed stud type torque controlled
mechanical expansion fasteners having 3-way expansion sleeve of SS 316 grade
with nut and washer and galvanized to minimum 5 microns. For coastal/ corrosive
environments, the anchors shall be of Stainless Steel (min grade SS 304) or HCR
(High Corrosion Resistance). The anchors shall conform to a minimum grade of
5.8 as per IS: 1367.
2) Chemical type: The anchor shall be adhesive type consisting of slow curing
chemical adhesive with a proportion of resin and hardener as per manufacturer’s
recommendation in a soft foil pack, threaded rod of carbon steel conforming to a
minimum grade of 5.8 as per IS: 1367 and minimum galvanization of 5 microns
with associated nut and washer. The chemical shall be dispensed through
mechanical dispenser and shall be self-curing type.
e. Capacity of the anchors shall be established after considering the effect of concrete
grade, embedded depth, concrete thickness, anchor spacing and edge distance from
the concrete.
f. The selection for particular type of the anchors shall be made after considering the
concrete grade, available embedment depth, load to be transferred, space available
for installing anchors.
8.03.00 FORMWORK
Formwork for building RCC Slabs/ Beams & Columns shall be of 2 different types.
Type 1 Formwork: (For RCC slab of Structural Steel Framed Buildings Only)
Troughed colour coated metal deck sheets shall be used as permanent shuttering having
minimum thickness of 0.80mm. These profiled metal deck sheets shall be fixed to the

CLAUSE NO.
structural steel secondary beams/ Purlins using Headed shear anchor studs. The detailed
material property requirement of metal deck sheet is specified elsewhere in this specification.
The shear anchor studs for fixing metal deck sheet to floor structural beams shall conform to
Type-B studs specified in AWS D1.1/D1.1M or equivalent as shear connector of 19mm
diameter and 100mm length manufactured from cold drawn round steel bars conforming to
the requirement of ASTM A 29, of grade designation 1010 through 1020, of standard quality
with either semi-killed or killed, welded by Drawn Arc Stud Welding through metal deck
sheet.
The shear anchor studs for fixing metal deck sheet to roof structural purlins shall conform to
Type-B studs specified in AWS D1.1/D1.1M or equivalent as shear connector of 16mm
diameter and 65mm length manufactured from cold drawn round steel bars conforming to the
requirement of ASTM A 29, of grade designation 1010 through 1020, of standard quality with
either semi-killed or killed, welded by Drawn Arc Stud Welding through metal deck sheet.
Type 2 Formwork: (For RCC Buildings)
Plywood with film face formwork shall be used for floor & roof slabs, Columns & Beams of all
RCC buildings.
8.04.00 CULVERTS /RACKS ACROSS RAIL TRACKS

Design of bridges/ culverts or any other structure crossing the Railway tracks shall be as per
Railways/ RDSO guidelines/specifications for Dedicated Freight Corridor (DFC) 32.5 T loads.
The Bidder shall obtain necessary approvals from Railways before start of construction work.
Construction of these structures is to be done as per Railways guidelines. Any statutory and
codal charges payable to Railways/ RDSO for approval & execution of the above crossings
shall be borne by the Bidder. Engagement of approved Railway Consultant for the above
work by the bidder would be at his own cost.
The levels/clearances of the above crossings are to be finalized by the bidder as per Railway
standards and shall be subject to approval of Owner/Owner’s Consultant.
However, for design of the above crossings above rail track, the following minimum
clearance from Rail track shall be maintained:
A. Horizontal clearance: A minimum clearance of 3.5m shall be maintained between

centre line of the Railway track to face of the crossing structure.
B. Vertical clearance: A min vertical clearance of 8.5m shall be maintained between
Rail top level and bottom of structure.
Bidder has to submit to the Owner two sets of railway approved drawings and two sets of
(hard & soft copies) as built drawings.
The construction of rail network inside the plant for transportation of coal, fly ash & POL is in
the scope of Owner. The bidder should plan to complete the construction work of all roads/
drainage/ pipe line/ cable crossings etc which are crossing below the rail track well in
advance to facilitate owner to undertake the construction work of siding.
8.05.00 FENCING AND GATE
8.05.01 FENCING
Fencing with gate shall be provided around fuel oil area, and other areas wherever
necessary due to security, safety, and statutory requirements as per following specifications.

CLAUSE NO.
However for isolation between existing station/township and the project, the total height of
fence may be reduced to 2.4m with 450mm barbed wire on top, while other details being
same as given below.
The fencing, with gate (unless specified otherwise) shall comprise of PVC coated G.I. welded
wire mesh fencing of minimum 4 mm diameter (including PVC coating) of mesh size
75mmX75mm of height 2.4m above the toe wall with a 600mm high galvanised concertina at
the top, such that total fence height of 3.0m above the toe wall is achieved. The diameter of
the steel wire for chain link fence (excluding PVC coating) shall not be less than 2.5 mm.
The PVC coated chain link will be stretched by the clips at 0.5m intervals to three strands of
galvanised high tensile spring steel wire (HTSSW) of 2.5 mm diameter interwoven with chain
link wire mesh and kept under tension which in turn are attached to the fence post with
security nuts and bolts. On every fourth post a clamping strip will be threaded through the
links of chain link and bolted to the fence post with the help of security nuts and bolts.
Above the chain link a 600mm high tensile serrated galvanised wire (HTSW) concertina
made with wire diameter of 2.5mm will be stretched to 6m and attached to two strands of
galvanised HTSSW of 2.5 mm diameter by means of clips at 1m intervals. These two
HTSSW strands will be attached to the fence posts with 12 mm security fasteners.
All nuts, bolts, fasteners, clamping strips, clamps, clips, etc., shall be galvanised.
All fence posts shall be of 75 x 75 x 6 MS angles spaced at 2.5m c/c distance. All corner
posts will have two stay posts and every tenth post will have transverse stay post. Suitable
R.C.C. foundations for the post and stays shall be provided based on the prevailing soil
conditions. All posts of fencing shall be painted with chlorinated rubber paint over a suitable
primer.
Toe walls either of brick masonry with bricks of minimum 50 kg./sq.cm. Crushing strength or
of hollow concrete block masonry shall be provided between the fence posts all along the run
of the fence with suitable foundation. Toe wall shall be minimum 200mm above the
formation level with 50mm thick P.C.C. coping (1:2:4) and shall extend minimum 300mm
below the formation level. Toe wall shall be plastered with cement sand mortar (1:6) on both
sides and shall be painted with two coats of textured cement point (Sandtax Matt or
equivalent) of approved colour and shade. Toe wall shall be provided with weep holes at
appropriate spacing.
8.05.02 Gate along Fencing
All gates shall be of structural steel of minimum 3.75 metre width for single lane access road
and 8.00 m width for double lane access roads. The height of gate shall be same as that of
the fence unless noted otherwise. Each gate shall have provision for wicket gate of size 1.0
m x 2.1 m.
The gate frame and post shall be fabricated from medium class MS pipe of nominal diameter
not less than 75 mm. The panel plate shall be of minimum thickness 2.5 mm conforming to
IS: 513.
The gate shall be complete with fabricated hinges, MS aldrops with locking arrangement,
tempered steel pivot, guide track of MS tee, bronze aluminium ball bearing arrangement,
castor wheel, etc.
8.06.00 GRATING
All gratings shall be electroforged types. Minimum thickness of the grating shall be 40 mm
for indoor installation and 32 mm for outdoor installation. The opening size shall not be more

CLAUSE NO.
than 30mmx100mm. The minimum thickness of the main bearing bar shall be 5 mm or as per
design requirement whichever is higher. All gratings shall be hot dip galvanised at the rate of
610 g. per sq.m. after surface preparation by means of shot blasting or cleaned by acid
pickling.
8.07.00 FABRICATION & ERECTION OF STEEL STRUCTURES
The fabrication shall be done as per fabrication drawing which would clearly indicate various
details of joints to be welded, type of weld, length and size of weld.
All steel structures shall be fabricated in factory, transported and erected at site. All factory
fabricated structures shall have bolted field connections.
Coal bunkers with hoppers and chimney flue liners can either be fabricated at factory in
segments, transported and welded at site before erection or fabricated at site. For coal
bunkers, hoppers and chimney flue liners, to prevent coal dust/flue gas leakages, the
applicable field joints shall necessarily be welded.
Note: Steel structures shall mean Plant and Non-Plant building structures, boiler & ESP
support structures, CHP structures (boiler area), AHP structures, chimney flue liners
support platforms & stairs, pipe and cable support structures.
Site welding can be permitted in special cases where final inputs are not available
before release of fabrication drawings.
Before dispatching the fabricated structural members to site, it shall be ensured that
all parts in the assembly fit accurately together by carrying out pre-assembly of
fabricated structural members having bolted field joints, in the factory.
All steelwork before and after manufacturing shall be smooth, straight and free of
deformations, cracks, twists and burrs. All steelwork shall be cut and fabricated to a
tolerance of ± 1.5 mm in its length and location of matching bolt holes for field
connections.
8.07.01 Welding
a) Welding of Structural steel shall be done by an electric arc process and shall
conform generally to relevant acceptable standards viz. IS:816, IS:9595, IS:814,
IS:2014, IS:4354 and Indian Standard Hand Book for metal arc welding, and other
standards, codes of practice internationally accepted. For welding of any particular
type of joint, Bidder shall give appropriate tests as described in any of the Indian
Standards - IS: 817, IS: 7307 and international standards as relevant.
b) Submerged arc-welding shall be used for welding longitudinal fillet welds (connecting
flange with web) and longitudinal / transverse butt joints for fabrication of columns,
framing beams and crane girders and all other built-up members, unless manual arc
welding is specifically approved by the Engineer. Necessary jigs and fixtures and
rotation of structures shall be so arranged that vertically down-hand position of
welding becomes possible. ‘Open-Arc-Welding’ process employing coated
electrodes shall be employed for fabrication of other welded connections and field
welding.
c) Wherever welding is done for assembling the components of structures, the job shall
so positioned that down hand welding is possible.
d) Any structural joint shall be welded only by those welders who are qualified for all
welding procedures and positions in such type of joint that is welded.

CLAUSE NO.
e) All records for entire welding operations such as welders identification marks, the
joints welded by the each welder, the welding procedures adopted, welding machine
employed, pre and post heating done and any non-destructive test done and stress
relieving /heat treatment performed on such joints shall be accessible to the
Engineer for scrutiny.
f) In a fabrication of plated columns/beams and built up members all shop splices in

each component part shall be done before such component part is welded to other
parts of the member. Wherever weld reinforcement interferes with proper fitting
between components to be assembled by welding, these welds shall be ground flush
prior to assembly.
g) The members to be joined by fillet welding shall be brought and held as close
together as possible and in no event shall be separated locally by more than 3mm. If
the local separation is 1.5mm or greater, the fillet weld size shall be increased by the
amount of separation.
Edge preparation for welding as per weld joint detail shall be prepared either by machines or
by automatic gas cutting. All edges cut by flame shall be ground before they are welded.
8.07.01.1 Electrodes
a) The electrodes used for welding shall be of suitable type and size depending upon
specification of the parent materials, the method of welding, the position of welding
and quality of welds desired e.g. normal penetration welds or deep penetration
welds. However, only low Hydrogen electrodes shall be used for plate thickness
above 20 mm.
b) All low hydrogen electrodes shall be baked and stored before use as per
manufacturer recommendation. The electrodes shall be rebaked at 2500°C - 3000°C
for one hour and later on cooled in the same oven to 1000C. It shall be transferred to
an holding oven maintained at 600°C - 700°C. The electrodes shall be drawn from
this oven for use.
c) Where coated electrodes are used they shall meet the requirements of IS: 814 and
relevant ASME-Sec. Covering shall be heavy to withstand normal conditions of
handling and storage.
d) Only those electrodes which give radiographic quality welds shall be used for welds
which are subjected to radiographic testing
e) Where bare electrodes are used, these shall correspond to specification of the
parent material. The type of flux-wire combination for submerged arc welding shall
conform to the requirements of F-60 Class of AWSA-5-17-69 and IS: 3613. The
electrodes shall be stored properly and the flux shall be baked before use in an oven
in accordance with the manufacturer’s requirements as stipulated.
f) 308L and 309L electrodes / fillers shall be used for welding of stainless steel to
stainless steel and stainless steel to mild steel respectively.
g) Specific approval of the Engineer shall be taken by Bidder for the various electrodes
proposed to be used on the work before any welding is started.
8.07.01.2 Preheating inter-pass Temperature and Post Weld Heat Treatment.
a) Mild steel plates conforming to IS: 2062 and thicker than 20mm, may require
preheating of the parent plate prior to welding as mentioned in Table-I.

CLAUSE NO.
However, higher preheat and inter-pass temperatures required due to joint restraint
etc. and will be followed as per approved welding procedure. In welding materials of
unequal thickness, the thicker part shall be taken for this purpose.
c) Base metal shall be preheated, notwithstanding provisions of IS: 9595, to the

temperature given in Table-1 prior to welding or tack welding. Preheating shall bring
the surface of the base metal to the specified preheat temperature and this
temperature shall be maintained as minimum temperature while welding is in
progress.
TABLE – 1
MINIMUM PREHEAT and INTER PASS TEMPERATURE FOR WELDING
Thickness of thicker part Welding using Low hydrogen

at point of Welding electrodes or Submerged
arc welding
Upto and including 20mm None

o
Over 20mm and upto and 20 C
including 40m
o
Over 40mm and upto and 66 C
including 63mm
o
Over 63mm 110 C
c) Preheating may be applied by external flame which is non-carbonising like LPG, by
electric resistance or electric induction process such that uniform heating of the
surface extending up to a distance of four times the thickness of the plate on either
side of the welding joint is obtained.
d) Thermo-chalk, thermo-couple or other approved methods, shall be used for

measuring the plate temperature.
e) All butt welds with plates thicker than 50mm and all site butts weld of main framing
beam shall require post weld heat treatment as per procedure given in AWS D-1.1.
Post heating shall be done up to 600oC and rate of application shall be 200oC per
hour. The post heat temperature shall be maintained for 60 minutes per 2.5cm.
thickness. For maintaining slow and uniform cooling, asbestos pads shall be used
for covering the heated areas.
8.07.01.3 Sequence of Welding
a) The sequence of welding shall be carefully chosen to ensure that the components
assembled by welding are free from distortion and large residual stresses are not
developed. The distortion should be effectively controlled either by a counter effect
or by a counter distortion. The direction of welding should be away from the point of
restraint and towards the point of maximum freedom.
b) Each case shall be carefully studied before finally following a particular sequence of
welding.
c) Butt weld in flange plates and/or web plates shall be completed before the flanges
and webs are welded together.

CLAUSE NO.
d) The beam and column stiffeners shall preferably be welded to the webs before the
web and flanges are assembled unless the web and flanges to the beam or column
are assembled by automatic welding process.
e) All welds shall be finished full and made with correct number of runs, the weld being
kept free from slag and other inclusions, all adhering slag being removed.
f) Current shall be appropriate for the type of electrode used. To ensure complete
fusion, the weaving procedure should go proper and rate of arc advancement should
not be so rapid as to leave the edges unmelted.
g) Pudding shall be sufficient to enable the gases to escape from the molten metal
before it solidifies.
h) Non-uniform heating and cooling should be avoided to ensure that excessive

stresses are not locked up resulting ultimately in cracks.
i) The ends of butt welds shall have full throat thickness. This shall be obtained on all
main butt welds by the use of run off and run on pieces adequately secured on either
side of main plates. The width of these pieces shall not be less than the thickness of
the thicker part joined. Additional metal remaining after the removal of extension
pieces shall be removed by grinding or by other approval means and the ends and
surface of the welds shall be smoothly finished. Where the abutting parts are thinner
than 20mm the extension pieces may be omitted but the end be welded to provide
the ends with the required reinforcement.
j) The fusion faces shall be carefully aligned. Angle shrinkage shall be controlled by
presetting. Correct gap and alignment shall be maintained during the welding
operation.
k) All main butt welds shall have complete penetration and back surface of the weld
being gouged out clean before first run of the weld is given from the back. However,
partial penetration butt weld shall be permitted, when specifically shown in the design
drawings.
l) Intermittent welds shall be permitted only when shown in the design drawings.
m) The welding shrinkage shall be minimised by adopting the correct welding procedure
and method. In long and slender member extra length should be provided at the
time of fabrication for shrinkage.
8.07.01.4 Testing of Welders
All the welders to be employed for the job shall have to qualify the appropriate tests laid
down in IS: 817 and IS: 1181 and ASME IX/AWS D1.1. All the necessary arrangements
required for the testing of welders are to be provided by the Bidder.
8.07.01.5 Inspection of Welds
a) Visual Inspection
100 percent of the welds shall be inspected visually for external defects.
Dimensions of welds shall be checked. The lengths and size of weld shall be as per
fabrication drawings. It may be slightly oversized but should not be undersized. The
profile of weld is affected by the position of the joint but it should be uniform. The
welds should have regular height and width of beads. The height and spacing of
ripples shall be uniform. The joints in the welds run shall as far as possible be

CLAUSE NO.
smooth and should not show any humps or craters in the weld surface. Welds shall
be free from unfilled craters on the surface, under-cuts, stages on the surface and
visible cracks.
Such inspection shall be done after cleaning the weld surface with steel wire
brushes and chisel to remove the spatter metal, scales, slag, etc., If external defects
mentioned above are noticed, there is every possibility of internal defects and further
radiographic/ultrasonic examination shall be undertaken.
b) Production Test Plate
Test plates shall be incorporated on either side of at least one main butt welds of
each flange plate and web plate of every main frame columns and crane girder. The
weld shall be continuous over the test plate. The test plate extensions of the main
plates and shall be fixed so that metal lies in the same direction as that of the main
plate. Test plates shall be prepared and tested in accordance with the accepted
Standards, in the presence of the Engineer or his authorised representative. Should
any of these tests fail, further radiographic examination of the welds shall be done.
These tests for test plates and radiographic examination are additional to those
contemplated under inspection and testing.
c) Non-destructive and special testing
Radiographic / ultrasonic or other non-destructive examination shall be carried out.

All tests of welds shall be carried out by the Bidder at his own cost. The cordoning of
radiation zone, while Radiography testing is going on, shall be done.
In case of failure of any of the tests, re-testing of the joints shall also be carried out
after rectification is done.
d) Rectification of defective welding work
Wherever defects like improper penetration, extensive presence of blow holes,

undercuts, cracking, slag inclusion, etc., are noticed by visual inspection/other tests,
the welds, in such location shall be removed by gouging process. The joints shall be
prepared again by cleaning the burrs and residual matters with wire brushes and
grinding, if necessary, and rewelded. The gouging shall as far as possible be done
using gouging electrodes.
8.07.01.6 Inspection and Testing
a) Fillet Welds
i) All fillet welds shall be checked for size and visual defects.
ii) Macroetch examination on production test coupons for main fillet weld with
minimum one joint per built up beam, column and crane girder, etc.
iii) 25% weld length of tension members of crane girder shall be subjected to dye-
penetration test.
iv) On all other welds, dye-penetration test on 5% of weld length with minimum
300mm at each location shall be carried out.
b) Butt Welds
i) 100% visual examination.

CLAUSE NO.
ii) Dye penetration test on all butt welds after back gouging shall be carried out.
iii) Mechanical testing of production test coupons - minimum one joint/built up

beam, column and crane girder. The engineer may reduce the frequency of
the test, after getting consistently satisfactory results of initial 10 tests.
iv) 100% radiography test on butt welds of tension flange (bottom flange) of
crane girder and bunker supporting girders. All other butt welds shall be
subjected to radiography test on 10% of weld length of each welder.
c) Dimensional Tolerance and Acceptance Criteria of Welds
i) Every first and further every 10th set of identical structure shall be checked
for control assembly at shop before erection.
ii) All structures, components/members shall be checked for dimensional

tolerance during fabrication and erection as per IS:7215 and IS:12843
respectively.
iii) Dry film thickness after painting shall be checked by using elchometer.
iv) Acceptance criteria of NDTs on welds shall be as per AWS D-1.1

(Dynamically loaded structures - Tension welds).
8.07.01.7 Correction of Defective Welds
Correction of defective welds shall be carried out without damaging the parent metal. When
a crack in the weld is removed magnetic particles inspection or any other equally positive
means shall be used to ensure that the whole of the crack and material up to 25mm beyond
each end of the crack has been removed.
8.07.02 Painting
a) Surface treatment and painting before and after delivery to site shall be in
accordance with Clause no. 6.4.0 above. All steel structures shall be designed by
following basic design criteria in ISO 12944 Part 3. However, where it is not feasible
to follow the design criteria given in ISO 12944 Part 3 where the steel surface are
inaccessible for application of protective coating, corrosion allowance in
thickness(over the design thickness) of structural steel members shall be kept.
b) For parts to be bolted, the surfaces in contact shall be provided with ethyl Zinc
silicate primer as specified in clause 6.4.3 (a) and shall be free of oil, dirt, loose rust,
burrs and other defects, which would prevent proper seating of the parts. For design
of friction type bolted joints slip factor for surfaces with ethyl zinc silicate primer as
given in IS 4000 shall be considered.
c) Surfaces inaccessible after shop assembly shall receive the full-specified protective
treatment before assembly. However, interior surfaces of Box-sections, which are
effectively sealed from all ends, need not be painted.
8.07.03 Bolting
The threaded portion of each bolt shall project through the nut by at least one thread.
Approved high strength friction grip bolts, preferably the type with indicated load, shall be
used where specified and shall be tightened strictly in accordance with the manufacturer's

CLAUSE NO.
instructions and the relevant regulations.
When connections are made using high strength friction grip bolts the relevant standards
shall be observed.
8.07.04 Erection of Structures
All erection work shall be done with the help of cranes, use of derrick is not envisaged.
Erection Marks
a) Erection marks in accordance with fabrication drawing shall be clearly painted on the
fabricated steelwork. Each piece shall be marked in at least on two places. Each
piece shall also have its weight marked thereon.
d) The centre lines of all columns, elevations and girder bearings shall be marked on
the sections to ensure proper alignment and assembly of the pieces at site.
Erection Scheme
a) The Erection Scheme for the erection of all major structures shall be furnished. The
erectability of the structure shall be checked by the Bidder before commencement of
fabrication work to avoid future modification. The erection scheme shall indicate the
approximate weight of the structural members, position of lifting hook, crane boom
length, crane capacity at different boom length and at different boom inclination, etc.,
Bidder shall take up the erection work only after he has obtained the approval of the
erection scheme from the Engineer.
b) The erection scheme shall also give details of the method of handling, transport,
hoisting, including false work/staging, temporary, bracing, guying, temporary
strengthening, etc., It will also give the complete details of the number and capacity
of the various erection equipment that will be used such as cranes, winches, etc.,
along with disposition at the time of erection of columns, trusses, etc.
c) The erection of columns, trusses, trestles, portals, etc., shall be carried out in one
single piece as far as practicable. No column shall be fabricated and erected in
more than 3 pieces. Galleries shall generally be erected as box i.e. the bottom chord
and bracings, top chord and bracings, side vertical posts and bracings, end portals
and roof-trusses shall be completely welded prior to erection and if required
temporary strengthening during erection shall be made. The inside sheeting runners
and roof sheeting purlins may be erected individually. When erection joints are
provided in columns, their location shall generally be just above a floor level.

CLAUSE NO.
9.00.00 Architectural Concepts and Design
9.01.00 For Architectural Concepts and Design refer to 5.00.01 in this specification.
9.02.00 General Architectural Specifications
9.02.01 General
a) Minimum 1000 mm high (from floor/ roof level) hand railing shall be provided around
all floor/roof openings, projections/balconies, walkways, platforms, steel stairs, etc.,
wherever the height of the building is more than 12m, railing ht to be 1.2m. All
handrails and ladder pipes (except at operating floors) shall be 32 mm nominal bore
MS pipes (medium class) conforming to IS: 1161 and shall be galvanised as per IS:
4736 and finished with suitable paint. All rungs and ladders shall also be galvanised.
Minimum weight of galvanising shall be 610 g/sqm. The spacing of vertical posts
shall be maximum 1500mm. Two number of horizontal rails shall be provided
including the top member. In addition, toe guard/ kick plate of min size 100x6th shall
be provided above the floor level.
For RCC stairs, passages &, around all floor openings at operating floors, 1000 mm
/1200mm high hand railing with 32 NB (polished) stainless steel pipe shall be
provided. The spacing of vertical posts shall be 1500mm. Two number of horizontal
rails shall be provided including the top member. Toe guard and kick plate shall be
provided above the floor level.
b) All stairs shall have a maximum riser height of 180mm and a minimum tread width of
275 mm. Minimum clear width of stair shall be 1200 mm unless specified otherwise..
c) All buildings having metal cladding shall be provided with 1M high brick wall at
ground floor level. All buildings having metal cladding shall be provided with a 150
mm high RCC toe kerb (on upper floor) at the edge of the floor along the metal
cladding. 1000 mm high hand railing shall be provided on this RCC kerb, wherever
required from the safety point of view.
d) In all buildings, structures, suitable arrangement for draining out water collected from
equipment blowdowns, leakages, floor washings, fire fighting, etc., shall be provided
for each floor. All the drains shall be suitably covered with grating or precast RCC
panels.
e) RCC staircase shall be provided for main entrance of all RCC construction buildings.
f) Parapet, Chajjas 450mm over window and 600mm door heads, 900mm over rolling
shutters, architectural facia, projections, etc., shall be provided with drip course in
cement sand mortar 1:3.
g) All fire exits shall be painted with fire resistant paint P.O red/signal red colour shade
which shall not be used anywhere except to indicate emergency or safety measure.
Fire safety norms shall be followed as per National Building Codes and fire safety
requirements for providing fire exits, escape stairs and fire fighting equipment. In
detailing of all buildings, fire safety requirements conforming to IS: 1641 and IS:1642
shall be followed.

CLAUSE NO.
9.03.00 Water Supply and Sanitation
9.03.01 Roof water tanks of adequate capacities depending on the number of users and 8 hours
requirement shall be provided for each building and pump house. Polyethylene water
storage tanks conforming to IS:12701 shall be used. The tanks shall be complete with all
fittings including lid, float valve, stop cock, vent pipe, etc. Service water tank shall be of RCC
construction.
Galvanised MS pipe of medium class conforming to IS:1239 shall be used for internal piping
works for service water and potable water supply. The pipes shall be concealed, and painted
with anti-corrosive bituminous paint (as per IS: 158) wherever required.
UPVC (conforming to IS:13592) shall be used for sanitary works above ground level. All
Buildings shall be designed with Toilets as per NBC norms.
. Toilets for physically handicapped shall be provided as mentioned. Attached toilets shall be
provided for all senior executive rooms and conference rooms. All buildings shall have
minimum one toilet block each. The facilities provided in the toilet block shall depend on the
number of users. However, minimum facilities to be provided shall be as stipulated in
subsequent clause. IS:1172 shall be followed for working out the basic requirements for
water supply, drainage and sanitation.
In addition, IS:2064 and IS:2065 shall also be followed.
9.03.02 Each Toilet block shall have the following minimum facilities. Unless specified all the fittings
shall be of Chromium plated brass (fancy type)..
a) One number wall mounted coloured glazed vitreous China European water closet and
flushing valve system, water faucet, toilet paper holder as per IS:2556
b) One number colour glazed ceramic oval shaped wash basin 450x 550 mm (approx.)
mounted over 18mm thick granite beveled edge counter fitted with photo-voltaic control
system for water controls, bottle trap as per IS:2556. For common toilets, number of
washbasins shall be as per requirement. However for Pump Houses the same shall be
provided without photo voltaic control system for water control.
c) For Male Toilets Urinal as per requirements, with all fittings with photovoltaic control
flushing system as per IS: 2556.
d) One number looking mirror 600 x 900 x 6 mm, edge mounted with teak beading and
minimum 12 mm thick plywood backing, one number stainless towel rail 600 x 20 mm,
one number liquid soap dispenser
e) One toilet with required facilities shall be provided for physically challenged persons as
per National Building Code requirements
f) Janitor Space & space for drinking water cooler.
g) Electric operated hand dryer with photo voltaic control.
h) The pantry shall consist of one number stainless steel pantry sink, as per IS : 13983, of
size 610 x 510 mm, bowl depth 200 mm with drain board of at least 450 mm length with
trap, hot and cold water mixer, one number geyser of 25 liters capacity, with inlet and
outlet connections, one number HDPE loft type / over head water storage tank, as per IS
: 12701 and of 500 liters capacity, complete with float valve, overflow drainage pipe
arrangement, GI concealed water supply pipe of minimum 12 mm diameter of medium

CLAUSE NO.
class, cast iron sanitary pipe (with lead joints) of minimum 75 mm diameter, floor trap
with Stainless
Steel grating, inlet and outlet connections for supply and drainage, with all bends, tees,
junctions, sockets, etc., as are necessary for the commissioning and efficient functioning
of the pantry (all sanitary fittings shall be heavy duty chrome plated brass, unless noted
otherwise)
One number of pantry shall be provided on each floor of ESP control room building.
i) Laboratory sink shall be of white vitreous china of size 600x400x200 mm conforming to

IS: 2556 (Part-5).
j) In addition, adequate number of portable toilet units with adequate plumbing and
sanitary arrangement, shall be provided during construction stage for workers.
k) Adequate number of toilet units with adequate plumbing and sanitary arrangement, shall
be provided for workers (O&M workers).
l) One number of toilet block with drinking water facility shall be provided in each building
having control room.
9.04.00 Flooring
Floor finishes of approved shade and colour (non - premium colours), over under bed of
cement mortar / concrete, at all levels and for all kind of works, elevations, on horizontal and
vertical surfaces for all types of work (like flooring, skirting, dado, wall lining & facing, tread
and risers etc.), including topping, spreading white cement slurry at an average rate of 2.5
kg/Sq. M., (unless noted otherwise), jointing and joint filling with white cement (unless noted
otherwise) slurry mixed with colour pigment, to match the shade of the finishing material,
laying to plumb and water level in desired pattern, line and flush butt square jointing, curing,
rubbing, grinding, polishing, edge moulding, finishing and cleaning, testing, providing opening
of required size and shape, casting in panels wherever specified.
9.04.01 The nominal total thickness of floor finish shall be 50/70 mm i.e. underbed and topping. The
floor shall be laid on an already laid and matured concrete base. The underbed for floors and
similar horizontal surfaces shall consist of cement concrete M20 grade. Stone chips shall be
12.5 mm down well graded & proper filling shall be done with brick bats/cinders. Flooring
like Tiles/ Stones shall be laid with 1:4 cement sand mortar and Tile/ Stone Cladding on wall
shall be laid with 1:3 cement sand mortar.
9.04.02 All toilets shall have sunken slab to accommodate sanitary pipes and the finish level of floor
shall match with general floor finish level. Sunken slabs shall be made watertight by suitable
water proofing treatment.
9.04.03 Metallic hardener topping -with ordinary grey cement shall be- 12 mm thick (insitu) or
finishing the concrete / mortar surfaces topping shall be furnished with neat cement slurry
(with ordinary grey cement)
9.04.04 Heavy duty cement concrete tiles 300 mm x 300 mm shall be in using white cement with
pigment, with hard and abrasion resistant carborundum / quartz chips for wearing course as
per IS:1237. Laying of tiles shall be as per IS: 1443.
9.04.05 Digitally glazed ceramic tiles shall be as per IS: 15622. Designer digitally glazed ceramic
floor and wall tiles
a) 300x300mm in white colour of Kajaria/ Nitco/ Somany/ Orient/ Johnson or equivalent

CLAUSE NO.
b) 300x450mm in DIGITAL series of Kajaria/ Nitco/ Somany/ Orient/ Johnson or equivalent
c) 300x600mm in DIGITAL series of Kajaria/ Nitco/ Somany/ Orient/ Johnson or equivalent
9.04.06 12mm/20mm / 38mm / 75 mm/ 115mm thick acid resistant tile on horizontal and vertical
surfaces, at all levels for all type of works shall include one coat of bitumen primer followed
by 12 mm thick bituminastic layer, 20mm / 38mm/ 75 mm / 115mm thick A.R. tiles, 6 mm
thick under-bed by potassium silicate mortar conforming to IS:4832 (Part-I), pointing of joints
of tiles with acid/alkali resistant epoxy/furane mortar conforming to IS:4832 (Part-I), up to a
depth of 20 mm and bituminastic end sealing.
Requirements for acid/ alkali resistant flooring and lining for different areas shall be as given
Table-A enclosed at the end of this specification. Battery Room in all buildings shall be
provided with acid/ alkali resistant tiles on flooring & dado 1200mm high.
9.04.07 Mirror polished Digitally glazed vitrified & Matt Finish Digitally glazed Vitrified ceramic tiles
(minimum 9.0mm thick) with 3mm groove joints as per approved pattern pointed neatly with
3x4mm stainless epoxy grout mix of 0.70kg of organic coated filter of desired shade (0.10kg
of hardener and 0.20kg of resin per kg) with sizes of the tiles shall be as under:
a) Size of tile 600x600/605x605 of Premium Series Kajaria/ Royale Series Somany/

OMA00025 Series Johnson or equivalent
b) Size of tile 800x800 of Polished and Lapatto Series Kajaria/Diamond Series Somany/
Polished and Lapatto Series Johnson or equivalent
9.04.08 For pathway, chequered and designed concrete tiles minimum 22 mm thick, 200x200 mm
size conforming to IS: 13801 of approved shade and colour shall be used. 1000 wide
pathways shall be provided for maintenance on rooftops of all buildings.
9.04.09 Epoxy Flooring
Epoxy Flooring shall be provided with surface preparation of concrete substrate with Captive
Shot Blasting Machine OR Light Grinding to form the required anchor profile on the floor
substrate followed by application of epoxy resin based moisture barrier underlay of 2 mm
thickness including filling of saw cut joints with epoxy cementitious resin based moisture
barrier underlay as per manufacturer specification. Application of self smoothing epoxy floor
topping of epoxy based resin of 2 mm thickness over epoxy resin based moisture barrier
underlay including application of solvent free epoxy resin based two component primer.
It shall include application of PU Sealant at Expansion and Isolation Joint respectively

including surface preparation of the joint, fixing of backup strip and application of sealant.
9.04.10 Wherever required, carpet flooring shall be provided over cement concrete floor. The carpet
shall be of tile/roll form, machine/handmade tupled un-cut loop pile and lay with under lay of
10mm thick and shall be laid as per manufacturer’s recommendations, in matching grains. It
shall be treated with anti fungus and anti-termite before laying.
9.04.11 Mirror polished (6 layers of polish) Granite stone (slab) - 18 mm thick (minimum) / Flame
finish/ (making top surface rough by burning)/ honed finish granite stone (slab) - 18 mm thick
(minimum) shall be provided.
9.04.12 Decorative/designer prepolished, plain and pigmented, high wearing resistance concrete tiles
of 20mm thickness (minimum) in various non-standard interlocking patterns.
9.04.13 Skirting in general shall be 150 mm high. Dado in toilets & pantries, shall be upto false ceiling
level from finished floor level. Skirting and Dado shall match with the floor finish.

CLAUSE NO.
9.04.14 Interlocking concrete blocks shall be of various sizes and thickness having M 35 grade of
concrete and pigmented to specified colours, in different pattern (in different textures
chequered or other patterns in indentation for guiding band/s for visually impaired persons)
including the preparation of sub base with 20mm thick sand and filling of joints with sand.
9.04.15 24 mm x 24 mm x 3.8 mm thick (minimum) glass mosaic tiles shall be provided in decorative
murals and pattern.
Laminated wooden flooring (11mm thick) shall be provided in VIP area, conference rooms.
9.04.16 Rubber Flooring

Rubber flooring shall conform to IS 809. The minimum thickness shall be 4 mm with sheet
size of 602mm x 602mm. Rubber flooring shall consist of 100% virgin elastomer reinforcing
agents, resins, curing agents, anti-oxidants and pigments. It shall have excellent abrasion
resistance and shall have class-I fire rating. It shall be acid & alkali resistant and shall be of
anti static grade. In general, BS code shall apply for their technical characteristics.
9.05.00
Paving
a) Ground floor of all buildings shall be provided with normal duty paving with 50mm
thick metallic hardener floor finish. For details of normal duty paving refer to
description elsewhere in this specification.
b) PCC paving of nominal mix 1:2:4 (1 part cement: 2 parts sand: 4 parts aggregate),
100 mm thick laid over 75 mm thick bed of dry brick aggregate shall be provided for
following areas:
i) 750 mm wide plinth protection around all buildings other than those covered
under paved area.
ii) 2.0 m wide pathway all along pipe/ cable corridor and all around each
cooling tower. 2.0 mm wide ways inter connecting all cooling towers with
each other.
Acid /Alkali 9.05.00 Acid/ Alkali Resistant Lining
9.05.01 The material shall conform to the following:

i) Bitumen primer shall conform to IS: 158.
ii) Bitumastic compound shall conform to IS: 9510. Where the height of bitumastic layer
on vertical surface is more than 2.0 m, the bitumastic layer shall be reinforced with
diamond pattern expanded metal steel sheets conforming to IS: 412.
iii) A.R. Bricks/ Tiles shall conform to class II of IS: 4860 & IS: 4457 respectively.
iv) Mortar: Potassium silicate & resin type mortars shall conform to IS: 4832 Part-I&II
respectively.
9.05.02 Requirements for acid/ alkali resistant flooring and lining for different areas are specified at
Cl. 5.05.02. Battery Room in all buildings shall be provided with acid/ alkali resistant tiles on
flooring & dado 1200mm high.
9.06.00 Roof
9.06.01 Except for the roofs subjected to heavy loads, roof of all buildings having structural steel
frame work shall consist of permanently colour coated (on exposed face) troughed metal
sheet decking of approved profile as specified in clause 9.08.00. Silicon modified polyester
paint having DFT of minimum 20 microns shall be used for permanent coating. The sheeting
shall be fixed by means of concealed fixing system or any other compatible method approved
by the Engineer. RCC slab of minimum 40 mm clear thickness in excess of trough depth
shall be provided over the metal decking. Water proofing cum plasticiser compound shall be
added to concrete over the metal decking. Bidder shall demonstrate that the roof is leak

CLAUSE NO.
proof by carrying out the water-retaining test by maintaining the minimum water depth of
50mm over the roof surface for a period of 48 hours. Water Proofing Treatment as given
below for RCC roof slabs shall be provided to ensure that the roof is watertight.
9.06.02 Roof of all buildings having RCC framework shall have cast-in-situ RCC slab. Such roof shall
be provided with roof water proofing treatment using high solid content liquid applied
elastomeric water proofing membrane with separate wearing course as per ASTM - C-836 &
898. Thickness of the membrane shall be 1.5mm (min.). This treatment shall include
application of polymerised mastic over the roof to achieve smooth surface and primer coat.
Wearing course on the top of membrane shall consist of 25mm thick PCC (1:2:4) cast in
panels of maximum 1.2 x 1.2m size and reinforced with 0.56mm dia galvanised chicken wire
mesh and sealing of joints using sealing compound/elastomeric water proofing membrane.
However, chequered concrete tile flooring 22 mm (min.) thick of approved colour and shade
conforming to IS: 13801 shall be provided for path way of 1 m. width for access of personnel
and handling of equipment and for the entire area of the roof where equipment like AC /
Ventilation plant, cooling towers, etc. are provided in place of PCC wearing course.
Equipment shall be installed on raised pedestal of minimum 30 cm height from the finished
roof to facilitate maintenance of roof treatment in future.
9.06.03 For efficient disposal of rainwater, the run off gradient for the roof shall not be less than 1:100
and the roof shall be provided with RCC water gutter, wherever required. Gutter shall be
made water tight using suitable watertight treatment. This gradient can be provided either in
structure or subsequently by screed concrete 1:2:4 (using 12.5 mm coarse aggregate) and/or
cement mortar (1:4). However, minimum 25 mm thick cement mortar (1:4) shall be provided
on top to achieve smooth surface.
9.06.04 Medium class galvanised mild steel pipes conforming to IS 1239/IS 3589 with welded joints
shall be provided to drain off rain water from the roof. These shall be suitably concealed with
masonry work, cement concrete / or sheeting work to match with the exterior finish. The
number and size of down comers shall be governed by IS 1742 and IS 2527. Roof drain level
of all RCC framed buildings having cast-in-situ RCC roof shall be provided with Rain water
gutter and/or 45 x 45 cm size Khurras having minimum thickness of 30 mm with 1:2:4
concrete over PVC sheet of 1 m x 1 m x 400 micron and finished with 12 mm thick cement
sand plaster 1:3. All the pipes shall be provided with suitable fittings and fixtures.
9.06.05 DELETED
9.06.06 Roof Water Proofing
Roof water proofing treatment shall be as follows:
a) For roofs having structural slope:
Top surface of sloped R.C.C. slab shall be finished with 15mm thick cement plaster
(1:4). Over the finished surface elastomeric membrane shall be laid. The elastomeric
shall comprise of high solid content liquid applied urethane laid over reinforcing layer
of polyscrim cloth or non woven geo-textile. The top of the elastomeric membrane
shall be finished with 20 mm thick cement: sand (1:4) mortar with chicken wire mesh
and pressed precast concrete tiles of 20 mm thickness where applicable shall be laid
over mortar at green stage. Provision for thermal expansion of roofing tiles shall be
kept by providing an expansion gap in both directions filled up with polysulphide joint
sealant. The expansion gap shall be provided in the cement sand mortar underbed
layer also.

CLAUSE NO.
b) For roofs having no structural slope:
Screed concrete mix (1:2:4) grading having minimum 25mm thickness at the lowest
point of the slope shall be laid over R.C.C. slab and shall be laid as per the slope
specified elsewhere in the specification. Top surface of grading underbed shall be
finished with 15mm thick cement plaster (1:4). Over the finished surface elastomeric
membrane shall be laid and top of the elastomeric membrane shall be finished with
20 mm thick cement: sand (1:4) mortar with chicken wire mesh and pressed precast
concrete tiles of 20 mm thickness where applicable shall be laid over mortar at green
stage. Provision for thermal expansion of roofing tiles shall be kept by providing an
expansion gap in both directions filled up with polysulphide joint sealant. The
expansion gap shall be provided in the cement sand mortar underbed layer also
9.06.07 Roof of all buildings shall be provided with access/approach through staircase or ladder.
Roof where equipment are mounted shall be provided with access through staircase.
9.06.08 RCC parapet wall of minimum 1000 mm height (above top of slab) for all accessible roofs
and 600 mm height for all non-accessible roofs shall be provided. Alternatively parapet wall
comprising structural steel post, runner and sheeting may be provided for buildings with
metal sheet cladding.
9.06.09 Fillets at junction of roof and vertical walls shall be provided with cast-in-situ cement concrete
(1:1.5:3) nominal mix followed by 12mm thick 1:4 cement sand plaster.
9.06.10 Pathways for handling of materials and movement of personals shall be provided with 22mm
thick chequered cement concrete tiles as per IS:13801 for a width of 1000mm .
9.07.00 Walls
9.07.01 All walls shall be non-load bearing infill panel walls.
9.07.02 For initial height up to 1 metre in buildings one brick thick masonry wall shall be provided
wherever metal cladding is specified.
9.07.03 All internal walls shall be with one brick thick in cement mortar (1:6). However, internal
partition walls for toilets shall be with half brick masonry thick with cement mortar (1:4).
9.07.04 DELETED
9.07.05 External face of Toilets, Air-conditioned and pressurised areas shall be provided with
masonry wall as per functional / aesthetic requirements. (Inside the metal cladding wherever
provided).
9.07.06 50 mm thick DPC in Cement concrete (1:1.5:3) with water proofing compound followed by
two layers of bitumen coating 85/25 grade as per IS: 702 @ 1.7 kg./sq.m. shall be provided
at plinth level before starting the masonry work.
9.08.00 COLOUR COATED AND OTHER SHEETING WORK
9.08.01 Material
a) Wall Cladding & Roofing Material
Troughed permanently colour coated sheet of approved shade and colour shall be
i) either of steel with minimum 0.6mm bare metal thickness (i.e. excluding the
thickness of galvanizing/aluminium-zinc coating and painting) of grade G250 as

CLAUSE NO.
per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per EN
10326 with zinc coating to class Z275 / aluminium-zinc alloy coating to class
AZ150
ii) or of minimum 0.5mm BMT (i.e. excluding the thickness of galvanizing/aluminium-

zinc coating and painting) of grade G350 as per AS1397 / grade SS340 class 4 as
per ASTM A792M / grade S350GD as per EN 10326 with zinc coating to class
Z275 / aluminium-zinc alloy coating to class AZ150.
iii) or of steel of minimum 0.4mm BMT (i.e. excluding the thickness of

galvanizing/aluminium-zinc coating and painting) of grade G550 as per AS1397 /
grade SS550 as per ASTM A792M / grade S550GD as per EN 10326 with zinc
coating to class Z275 / aluminium-zinc alloy coating to class AZ150
Alternatively aluminium feed material of minimum bare metal thickness of 0.7 mm of

aluminium alloy of Series 31000 and above as per IS 737 and IS: 1254.
Bidder to ensure that same profile is to be used throughout the package for all facilities
to maintain uniformity.
b) Metal Deck Roof Material
Troughed permanently colour coated metal decking sheets shall be
thickness of galvanizing/aluminium-zinc coating and painting) of grade G250 as
per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per EN
10326 with zinc coating to class Z275.

per ASTM A792M / grade S350GD as per EN 10326 with zinc coating to class
Z275.

coating to class Z275.

aluminium alloy of Series 31000 and above as per IS 737 and IS 1254 can also be used
for metal decking.
Thickness tolerance of (+/-) 0.04mm is permissible. However, all design calculations

shall be carried out on the basis of lowest value of sheet thickness provided.
Bidder to ensure that same profile is to be used throughout the package for all facilities
to maintain uniformity. In addition, the depth of the profile shall be restricted to 60 mm
(maximum) to reduce the overall thickness of floor slab and thus minimizing the dead
load of the floor slab. If the bidder proposes to use two different metal deck sheets
(same profile but different grades or thicknesses), the unexposed (concrete) side of the
metal deck sheets shall be painted with clearly distinct colours to facilitate identification.

CLAUSE NO.
9.08.02 Colour Coating
Steel shall be colour coated with total coating thickness of at least 40 microns (nominal)
comprising of silicon modified polyester (SMP with silicon content of 30% to 50%) paint or
Super Polyester paint, of minimum 20 microns (nominal) dry film thickness (DFT) on external
face over primer coat of minimum 5 microns (nominal) and minimum 10 microns (nominal)
SMP or super polyester paint over primer coat of minimum 5 microns (nominal) on internal
face. SMP and Super polyester paint systems shall be of industrial finish of product type 4 of
AS/NZ2728.
For wall cladding insulated / uninsulated and conveyor gallery sides and roof, permanently
colour coated sheet of troughed profile shall be used. However alternative profile meeting the
strength, deflection and other functional requirements such as section modulus and moment
of inertia shall be provided.
Sheet shall be of approved profile, sectional properties, colour and shade.
For profiled metal decking sheets (to be used for RCC floor slab or roof slab) the sectional
modulus and moment of inertia of troughed profile per meter width shall be so as to limit the
deflection of sheets to span/250 under total super imposed loading (DL +LL) comprising the
self-weight of metal deck sheet, dead weight of green concrete and an additional
construction load 100kg per sq.m for two span condition. The section modulus and moment
of inertia of troughed profile shall be computed as per the provisions of IS 801 for satisfying
the deflection and strength requirements.
For metal deck sheets used for roofing (with or without RCC) and side cladding, the sectional
modulus and moment of inertia of troughed profile per metre width shall be such that the
deflection of sheets is limited to span/250 under design wind pressure for two span condition.
The sectional modulus and moment of inertia of troughed profile shall be computed as per
the provisions of IS 801 for satisfying the deflection and strength requirements. No increase
in allowable stress is permissible under wind load condition.
9.08.04 Fasteners
Side cladding/roofing/decking sheets shall be fixed to the runner/purlins using self-drilling

special coated fasteners confirming to corrosion resistant class 3 of AS3566 and tested for
1000 hours salt spray test. Spacing of Self-drilling fasteners in transverse direction (along
runners/purlin) shall be equal to the pitch of trough or 250(+/-100) mm, whichever is lesser
and in longitudinal direction at every runner/purlin location.
Shear anchor studs shall also be provided through metal deck, which are to be used as
permanent shuttering, at regular interval on all top flange / flange plate of structural beams as
specified in Clause no. 8.03.00.
Alternatively, J/U type hooks shall be used in roofing which shall be provided in transverse
direction (along runners/purlin) at a spacing equal to the pitch of trough or 250(+/-100) mm,
whichever is lesser and in longitudinal direction at every runner/purlin location.
9.08.05 Miscellaneous Details
To minimize the number of joints, the length of the sheet shall preferably be not less than
4.5m, cut pieces shall not be used, unless specifically approved by the Engineer. However,
the actual length shall be such so as to suit the purlin / runner spacing.

CLAUSE NO.
Lap between the sheets shall be at least 150mm in the longitudinal direction and at least one
crest wide in the transverse direction which shall be properly anchored / fixed with fasteners.
Z spacers if required shall be made of at least 2 mm thick galvanised steel sheet of grade
350 as per IS 277
Sealant used for cladding shall be butyl based, two parts poly sulphide or equivalent
approved, non stainless material and be flexible enough not to interface with fit of the sheets
. Filler blocks as a trough filler shall be used to seal cavities formed between the profiled sheet
and the support or flashing. The filler blocks shall be manufactured from black synthetic
rubber or any other material approved by the Engineer.
For insulation of cladding and other areas, mineral wool conforming to IS 8183 shall be used.
The density shall be 32 or 48 kg. /cu.m for glass or rock wool respectively. The nominal
thickness of insulation shall be 50mm.
All flashings, trim closures, caps etc. required for the metal cladding system shall be made
out of plain sheets having same material and any weather/moisture sealants with appropriate
material and coating specification as mentioned above for the outer face of the metal
cladding. Overlap shall be min. 150 mm or as specified by manufacturer.
The contractor shall prepare working drawings of sheeting system including end and side
laps, flashing, fixing details etc. before starting sheeting work at site.
9.08.06 Pre-Fabricated Insulated Metal Sandwich Panels
For buildings where Pre-Fabricated Insulated Metal Sandwich Panels shall be used for
Roofing, the sandwich panels shall comprise top sheet as troughed permanently colour
coated sheet & bottom sheet as plain permanently colour coated with 50mm thick insulation
sandwiched between the two sheets. Each sheet shall be
thickness of galvanizing/aluminium-zinc coating and painting) of grade G250 as per
AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per EN 10326 with
zinc coating to class Z275 / aluminium-zinc alloy coating to class AZ150.

per ASTM A792M / grade S350GD as per EN 10326 with zinc coating to class Z275 /
aluminium-zinc alloy coating to class AZ150

coating to class Z275 / aluminium-zinc alloy coating to class AZ150.

aluminium alloy of Series 31000 and above as per IS 737 and IS 1254.
Metal sheets (steel or aluminium) shall be colour coated with total coating thickness of at
least 40 microns (nominal) dry film thickness (DFT) comprising of Silicon Modified Polyester
(SMP with silicon content of 30% to 50%) paint or Polyester paint, of minimum 20 microns
(nominal) SMP or polyester paint on one side (exposed face), over minimum 5 micron
(nominal) primer coat and minimum 10 micron (nominal) SMP or Polyester paint over
minimum 5 micron (nominal) primer coat on other side. SMP and Super Polyester paint shall
conform to product type 4 of AS/NZS 2728. Troughed sheet shall be of approved profile,

CLAUSE NO.
sectional properties, (suitable for the specified loading / deflection and purlins / runners
spacing), colour and shade.
Special coated fastener conforming to corrosion resistant Class 3 of AS3566 and tested for
1000 hours salt spray test shall be used for fixing Pre-Fabricated Insulated Metal Sandwich
Panels with the structural members below.
The contractor shall prepare working drawings of sheeting system including end and side
laps, fixing details etc. before starting sheeting work at site.
9.08.07
9.09.00 Plastering
9.09.01 Outer face (i.e. rough side) of all brick walls shall have 18 mm thick and inner face (i.e.
smooth side) of all walls shall have 12 mm thick cement sand plaster 1:6.
9.09.02 Acrylic wall putty in two coats shall be applied over cement plastered surfaces in interior of
building. The finish surface shall be smooth and shall be of 2 mm nominal thickness.
9.09.03 All R.C.C. walls shall have minimum 12mm thick cement sand plaster 1:6.
9.09.04 All RCC ceilings (except areas provided with false ceiling, cable vault ceiling and metal
decking) shall be provided with 6mm thick cement sand plaster 1:4.
9.09.05 Groove of uniform size 12 x 12 mm up to 20 x 15 mm in plastered surface as per approved

pattern, shall be provided as per approved drawing.
9.09.06 All plastering work shall conform to IS: 1661.
9.10.00 Painting & Aluminium Composite Panel Cladding
9.10.01 All painting on masonry or concrete surface shall preferably be applied by roller. If applied by
brush then same shall be finished off with roller.
9.10.02 All paints shall be of approved make including chemical resistant paint.
9.10.03 Minimum 2 finishing coats of paint shall be applied over a coat of primer.
9.10.04 Stone work for wall lining etc. (Veneer work) over 20 mm thick bed of cement mortar 1:3
(1 cement: 3 coarse sand) and jointed with grey cement slurry @3.3kg/sq.m, including
rubbing and polishing in complete. (Black polished granite stone slab, 18 mm thick / polished
Sadarhally grey granite slab 18 mm thick).
The final, finished coating shall be fungus resistant, UV resistant, water repellant, alkali
resistant, and extremely durable with colour fastness.
9.10.05 Acrylic emulsion paint shall be as per IS: 15489. Acrylic distemper shall be as per IS: 428.
Cement paint shall conform to IS: 5410, white wash/colour wash shall conform to IS: 627.
9.10.06 All fire exits shall be painted in post office red/signal red colour shade, which shall not be
used anywhere else except to indicate emergency or safety measure.
9.10.07 For painting on concrete, masonry and plastered surface IS: 2395 shall be followed. For
painting on wood work IS: 2338 shall be followed.

CLAUSE NO.
9.10.08 For painting on steel work and ferrous metals, BS: 5493 and IS: 1477 shall be followed. The
type of surface preparation, thickness and type of primer, intermediate and finishing paint
shall be according to the painting system adopted.
9.10.09 Bitumen primer used in acid/alkali resistant treatment shall conform to IS: 158.
9.10.10 All internal paints shall be of low VOC content conforming to GRIHA rating for reduction of
VOC content.
9.10.11 DELETED
Exterior Painting on Wall (Premium Acrylic Smooth Exterior Paint with Silicone
Additives)
The paint shall be (premium acrylic smooth exterior paint with silicone additives) of approved
brand and manufacture. This paint shall be brought to the site of work by the contractor in its
original containers in sealed condition. The material shall be brought in at a time in adequate
quantities to suffice for the whole work or at least a fortnight’s work. The materials shall be
kept in the joint custody of the contractor and the Engineer-in-Charge. The empty containers
shall not be removed from the site of work till the relevant item of work has been completed
and permission obtained from the Engineer-in-Charge.
Preparation of Surface
For new work, the surface shall be thoroughly cleaned off all mortar dropping, dirt dust,
algae, fungus or moth, grease and other foreign matter of brushing and washing, pitting in
plaster shall make good, surface imperfections such as cracks, holes etc. should be repaired
using white cement. The prepared surface shall have received the approval of the Engineer
in charge after inspection before painting is commenced.
Application of Base Coat
Base coat shall be of water proofing cement paint.
Preparation of Mix for Base Coat
Cement Paint shall be mixed in such quantities as can be used up within an hour of its mixing
as otherwise the mixture will set and thicken, affecting flow and finish. Cement Paint shall be
mixed with water in two stages. The first stage shall comprise of 2 parts of cement Paint and
one part of water stirred thoroughly and allowed to stand for 5 minutes. Care shall be taken
to add the cement Paint gradually to the water and not vice versa. The second stage shall
comprise of adding further one part of water to the mix and stirring thoroughly to obtain a
liquid of workable and uniform consistency. In all cases the manufacturer’s instructions shall
be followed meticulously.
The lids of cement Paint drums shall be kept tightly closed when not in use, as by exposure
to atmosphere the cement Paint rapidly becomes air set due to its hygroscopic qualities. In
case of cement Paint brought in gunny bags, once the bag is opened, the contents should be
consumed in full on the day of its opening. If the same is not likely to be consumed in full, the
balance quantity should be transferred and preserved in an airtight container to avoid its
exposure to atmosphere.
Application of Base Coat
The solution shall be applied on the clean and wetted surface with brushes or spraying
machine. The solution shall be kept well stirred during the period of application. It shall be
applied on the surface which is on the shady side of the building so that the direct heat of the

CLAUSE NO.
sun on the surface is avoided. The method of application of cement Paint shall be as per
manufacturer’s specification. The completed surface shall be watered after the day’s work.
The second coat shall be applied after the first coat has been set for at least 24 hours. Before
application of the second or subsequent coats, the surface of the previous coat shall not be
wetted.
For new work, the surface shall be treated with three or more coats of water proof cement
Paint as found necessary to get a uniform shade.
Precaution
Water proof cement Paint shall not be applied on surfaces already treated with white wash,
colour wash, distemper dry or oil bound, varnishes, Paints etc. It shall not be applied on
gypsums, wood and metal surfaces. If water proofing cement is required to be applied on
existing surface, previously treated with white wash, colour wash etc., the surface shall be
thoroughly cleaned by scrapping off all the white wash, colour wash etc. completely.
Thereafter, a coat of cement primer shall be applied followed by two or more coat of water
proof cement.
Application of exterior paint
Before pouring into smaller containers for use, the paint shall be stirred thoroughly in its
container, when applying also the paint shall be continuously stirred in the smaller containers
so that its consistency is kept uniform. Dilution ratio of paint with potable water can be altered
taking into consideration the nature of surface climate and as per recommended dilution
given by manufacturer. In all cases, the manufacturer’s instructions & directions of the
Engineer-in-charge shall be followed meticulously.
The lids of paint drums shall be kept tightly closed when not in use as by exposure to
atmosphere the paint may thicken and also be kept safe from dust. Paint shall be applied
with a brush on the cleaned and smooth surface. Horizontal strokes shall be given, First and
vertical strokes shall be applied immediately afterwards. This entire operation will constitute
one coat. The surface shall be finished as uniformly as possible leaving no brush marks.
9.11.00 Doors & Windows
9.11.01 Doors, windows and ventilators of air-conditioned areas, entrance lobby of all buildings
(where ever provided), and all windows and ventilators of all buildings (unless otherwise
mentioned) shall have aluminium framework with glazing. The aluminium section shall have
minimum 2 mm thickness. The aluminium frame shall be electro colour dyed (anodised with
15 micron coating thickness) when used on outer side of the building and it shall be powder
coated( 50 microns coating thickness) when used in interior of the building. All doors of toilet
areas shall be of steel framed solid core flush shutter. For Mill Bunker Building, transfer
points, crusher house, conveyor gallery, steel louvered windows shall be provided.
9.11.02 DELETED Control Rooms of all buildings shall be provided with Aluminium Glazed door.
9.11.03 Single glazed panels with aluminium framework shall be provided as partition between two
air-conditioned areas wherever clear view is necessary.
9.11.04 a) The doors frames shall be fabricated from 1.6 mm thick MS sheets and shall meet
the general requirements of IS: 4351.
b) All steel doors shall consist of double plate flush door shutters. The door shutter shall
be 35 mm (min.) thick with two outer sheets of 1.2 mm rigidly connected with
continuous vertical 1.0 mm stiffeners at the rate of 150 mm centre to centre. Side,
top and bottom edges of shutters shall be reinforced by continuous pressed steel
channel with minimum 1.2 mm. The door shall be sound deadened by filling the

CLAUSE NO.
inside void with mineral wool. Doors shall be complete with all hardware and fixtures
like door closer, tower bolts, handles, stoppers, aldrops, locks etc.
9.11.05 Steel windows and ventilators shall be as per IS: 1361 and IS: 1038.
9.11.06 Wherever functionally required Rolling shutter (fully closed/partly grilled) with suitable
operating arrangement (manual/Electric) shall be provided to facilitate smooth operations.
Rolling shutters shall conform to IS: 6248. M.S sliding doors with suitable mechanical and
electrical operations fixtures as per requirement for bigger openings shall be used.
9.11.07 All windows and ventilators on ground floor of all buildings shall be provided with suitable
Aluminium grill.
9.11.08 Fire-Proof doors with panic devices shall be provided at all fire exit points as per
requirements. These doors shall generally be as per IS 3614 (Part 2). Fire rating of the doors
shall be of minimum 2 hours. These doors shall be double cover plated type with mineral
wool insulation.
9.11.09 Hollow extruded section of minimum 2 mm wall thickness as per IS: 1285 shall be used for
all aluminium doors, windows and ventilators.
9.11.10 Minimum size of door provided shall be 2.1 m high and 1.2 m wide. However for toilets
minimum width shall be 0.75 m and office areas minimum width shall be 1.20m.
9.11.11 Electrically operated, self operable/closing, aluminium framed with tinted glass, sliding doors
shall be provided at the entrance of all common control rooms, entrance lobby of facility
building.
9.11.12 Minimum area of windows in building on each floor level shall be 10% of floor area.
9.12.00 Glazing
9.12.01 All windows and ventilators (not specified elsewhere) shall be provided with minimum 6 mm
thick toughened glass conforming to IS: 5437.
9.12.02 For single glazed aluminium partitions and doors, 8mm thick clear toughened glass shall be
used.
9.12.03 Toughned tinted glass of 6 mm thickness shall be used for all windows and ventilators in
toilets.
9.12.04 All glazing work shall conform to IS: 1083 and IS: 3548.
9.12.05 For glazings of Air Conditioned Buildings Composite double glazing shall be 24mm thick
consisting of 6mm thick clear float glass on inner side and 6mm thick reflective toughened
glass on outer side. The two glasses shall be separated by 12mm air-gap and hermetically
sealed by beading of anodized aluminium with outer edge sealed with silicon sealant. Outer
glass of 6mm thickness shall have following technical characteristics: Solar factor 25% or
less, Maximum U-value 3.3 W/ SQMK, VLT min 30%: Light reflection internal 10 to 15%,
light reflection external 10 to 20 %, shading coefficient (0.25- 0.28)
The glass to be used should be from the manufacturers of glass like Saint Gobain (India) or
Asahi (India) or equivalent. The glass should be free from distortion and thermal stress. The
fire glass panels shall be min 11mm thick clear, toughened, interlayered 120 minute fire
rated for both integrity & radiation control (EW120) with min 15 minute full insulation (EI15) ,
non wired toughened glass complying to BS476 Part22 or (EN-1634-1 :1999). The glass
shall be complied to Class 2B2 Category of Impact Resistance to as per EN 12600 safety

CLAUSE NO.
Glazing Material. The Glass shall have a light transmission ratio of approx. 86% according to
EN410 standards and sound reduction of >=37 dB.. The partition frame frame shall be
manufactured of 1.6mm thick galvanized steel sheet (zinc coating not less than 120 gm/sqm)
pressed to form a profile of section 35 mm x 60 mm on the vertical sides and 50 x 60 mm
on the horizontal side suitable for mounting 120 min Fire Rated Glazed Door Shutter. The
Frame shall be filled with mineral wool insulation having density min 96kg/m3. The door
frame will have a provision of GI anchor fasteners 14 nos (5 each on vertical side and 4 on
horizontal side of size M10x80) suitable for fixing in the opening with Factory made template
for SS Ball Bearing Hinges of size 100x89x 3 mm for the fixing of fire rated glazed shutter.
The frame shall be finished with a approved fire resistant primer or Powder coating of not
less than 30 micron in desired shade.
9.12.06 For internal glazed partition, 8mm thick clear toughened glass shall be provided.
9.13.00 False ceiling
9.13.01 False ceiling of 12.5 mm thick tapered/square edge glass fibre reinforced gypsum board
conforming to IS : 2095 having fine texture finish, including providing and fixing of frame work
at all levels, for all kind of work, consisting of light weight galvanised steel member (minimum
0.8 mm thick and galvanised as per IS: 277) having maximum grid size of 1200 mm x 600
mm for supporting panels of specified size, suspended from RCC structural steel or
catwalkway grid above, with 4 mm (minimum) galvanised wires (rods), with special height
adjustment clips, providing angle section of minimum 25 mm width along the perimeter of
ceiling, supporting grid system (minimum 0.8 mm thick and galvanised as per IS: 277 ),
expansion fasteners for suspension arrangement from RCC, providing openings for AC
ducts, return air grills, light fixtures, etc., all complete. (concealed grid and finished flat
seamless and curve shape (dome etc.), finished smooth(seamless) along with the
galvanised light gauge steel supporting system laid in profile to suit the profile of dome).
9.13.02 False ceiling of 15 mm thick mineral fibre board, in tile form of size 600mm x 600mm, along
with galvanised light gauge rolled form supporting system in double web construction pre
painted with steel capping, of approved shade and colour, to give grid of maximum
size of 1200x600. as per manufacturers details including supporting grid system, expansion
fasteners for suspension arrangement from RCC, providing openings for AC ducts, return air
grills, light fixtures, etc., all complete.
9.13.03 False ceiling of 12 mm thk calcium silicate board of 'HILUX' or equivalent with suspension
system as per manufacturers details including supporting grid system, expansion fasteners
for suspension arrangement from RCC, providing openings for AC ducts, return air grills, light
fixtures, etc., all complete. (With concealed grid and finished flat seamless).
9.13.04 Providing and fixing GI Clip in Metal Ceiling System of 600x600 mm module (of Armstrong/
Hunter Douglas/ Durlam make) which includes providing and fixing ‘C’ wall angle of size
20x30x20mm made of 0.5mm thick pre painted steel along the perimeter of the room with
help of nylon sleeves and wooden screws at 300mm center to centre, suspending the main C
carrier of size 10x38x10mm made of G.I steel 0.7 mm thick from the soffit with help of soffit
cleat 37x27x25x1.6 mm, rawl plugs of size 38x12 mm and C carrier suspension clip and
main carrier bracket at 1000mm c/c. Inverted triangle shaped Spring Tee having height of 24
mm and width of 34mm made of GI steel 0.45 mm thick is then fixed to the main C carrier
and in direction perpendicular to it at 600mm centers with help of suspension brackets.
Wherever the main C carrier and spring T have to join, C carrier and spring T connectors
have to be used. All sections to be galvanized @ 120 gms/sqm (both side inclusive) Fixing
with clip in tiles into spring 'T' with GI Metal Ceiling Clip in plain Beveled edge global white
color tiles of size 600x600 and 0.5mm thick with 25mm height, made of G I sheet having
galvanizing of 100 gms/sqm (both sides inclusive) and 20% perforation area with 1.8mm dia
holes and having NRC of 0.5, electro statically polyester powder coated of thickness 60
microns (minimum), including factory painted after bending and perforation and backed with
a black Glass fiber acoustical fleece.

CLAUSE NO.
9.13.05 Pre-Painted Coil coated Steel false ceiling system, at all level, for all kind of works, consisting
of 0.5 mm thick galvanised as per IS: 277, along with galvanised supporting steel members
exposed faces of galvanised member to be prepainted with regular modified polyester
coating / super polyester coating minimum 20 DFT, to form panels of specified size for tile
type panels and roll formed stove enamelled 0.6 mm thick steel carrier, for fixing of lineal
type panels by clip on arrangement, suspended from RCC slab / structural steel or catwalk
way steel channel grid above with 4 mm (minimum) galvanised wires (rods), with special
height adjustment clips, providing angle section of minimum 25 mm leg width along the
perimeter of ceiling, including all labour, material, supporting grid system (members minimum
0.8 mm thick and galvanised as per IS: 277) anchor fasteners for making suspension
arrangement from RCC, providing openings for AC ducts, return air grills, insulation light
fixtures, etc., all complete.
9.13.06 Tile type steel false ceiling system in square pattern panels of 600 mm x 600 mm size along
with galvanised light gauge rolled form. supporting system in double web ‘T’ construction with
pre-painted steel, with Tee support.
9.13.07 Lineal pattern (closed type) of 100 mm nominal width, with carrier support. Metal ceiling as
above in lineal/tile shape in stainless steel, bright finish instead of pre-painted coil coated
finish.
9.13.08 Additional hangers and height adjustment clips shall be provided for return air grills, light
fixtures, A.C. ducts etc.
9.13.09 Suitable M.S. channel (Minimum MC75 with maximum spacing of 1.2 m C/C both ways) grid
shall be provided above the false ceiling level for movement of personnel and to facilitate
maintenance of lighting fixtures, AC ducts etc.
9.13.10 Underdeck insulation shall be provided on the ceiling (underside of roof slab) and underside
of floor slab of air-conditioned area depending upon the functional requirements. This
underdeck insulation shall consist of 50mm thick mineral wool insulation with 0.05 mm thick
aluminium foil & 0.6 mm x 25mm mesh wire netting and shall be fixed to the ceiling with 2
mm wire ties.
9.13.11 Suitable cut-outs shall be provided in false ceiling to facilitate fixing of lighting fixtures, AC
grills, smoke detectors, etc.
9.14.00 Interior Design
A comprehensive interior design scheme shall be conceived with the intention of projecting a
definite theme and aesthetic appearance to inside working environment. It shall take into
account the multidisciplinary engineering activities involving power plant technology, and
architectural & civil engineering for a smooth control hierarchy and man machine interface.
All the design aspects such as flooring, false ceiling, furniture, colour scheme equipment
design & layout, illumination, fire fighting, acoustics and ergonomics requirements shall be
detailed out so as to present an overall unified aesthetic spatial appearance.
The areas to be undertaken for this interior design process shall be control room complex
including common control room, computer room, conference rooms and office areas in the
buildings and the following aspects shall be reviewed and evaluated for design. Furniture to
be supplied by Bidder for the control room complex shall be as specified under C&I
specification.
a) Layout, keeping in view the man-machine interface and suitable ergonomic

practices.
b) Integration of civil engineering with architecture and interior design.

CLAUSE NO.
c) Illumination levels, noise levels, electromagnetic interference levels, taking into
account the equipment and furniture.
d) Comfort and safety requirements such as air conditioning, fire fighting, fire escapes,
etc.
e) Microprocessors based control system to control the functional requirements.
The above design philosophy put into practice shall be detailed out through presentation
drawings, perspective views, scale models, detail drawings, etc.
9.15.00 DELETED
9.16.00 Finishing Schedule

Interior and Exterior Finishes shall be as given in Tables-B & C respectively attached at the
end of these specification.

CLAUSE NO. TECHNICAL REQUIREMENTS
TABLE – A
PROPOSED ACID /ALKALI RESISTANT TREATMENT
S.NO. AREA PRIMER TYPE OF LINING AND THICKNESS EPOXY

(ONE COATING (TWO
COAT) COATS)
EFFLUENT A.R. A.R. EPOXY BITUMASTIC
TREATMENT PLANT BRICKS TILES MORTAR
1 CPU:
a) Neutralisation Pit
i) Floors Bitumen 75 mm thick 18 mm thick
ii) Walls Bitumen 115 mm 18 mm thick

thick
iii) Ceiling Epoxy 150 micron
iv) Pillasters 115 mm

thick
b) Effluent Drains Bitumen 38 mm 12 mm thick

thick
c) Floor around Bitumen 38 mm 12 mm thick

equipment & dado thick
d) Regeneration area Bitumen 38 mm 12 mm thick

floor & dado thick

e) Acid / Alkali storage Bitumen 75 mm 12 mm thick

area thick
f) Degasser area floor Bitumen 38 mm 12 mm thick

thick
g) Pedestals for Bitumen 38 mm 12 mm thick

supporting thick
equipment
h) M.S. Grating / Epoxy 150 micron

Chequered plate
Note : -
1. The above table is for general guidance only, however, actual areas/ facilities to be covered shall be as per Scope of work.
2. Suitable end sealing shall be provided.
3. Structures shall be tested for waterproofing before application of Acid / Alkali Resistant Treatment.
4. This treatment shall be applied on dry surface.
5. For laying of AR bricks / tiles, the bedding mortar shall be of potassium silicate 6 mm thickness and the pointing mortar shall
be of Epoxy / furane 20 mm deep and 6 mm thickness.

TABLE –A
INTERIOR FINISHING SCHEDULE
S.NO. DESCRIPTION OF AREA FLOORING WALLING CEILING
1 CW Pump house, Raw awter Pump

House , Switch gear , control room/Any
othe building.
a) Operating/Maintenance areas/ Cement concrete with Acrylic distemper Acrylic distemper (except metal
MCC room Metallic hardener topping deck area)
b) Office Room, Staff Room Digitally glazed Vitrified Acrylic emulsion paint Acrylic distemper.
ceramic tiles.
c) Control room Matt finish Vitrified Ceramic Acrylic emulsion paint Mineral fiber board false ceiling.
Tiles
d) RCC Stair case Marble stone / Granite stone. Marble stone / Granite Acrylic Distemper.
stone up to 1.2m.ht. &
Acrylic emulsion paint
e)Toilet area Ceramic tiles and Granite Digitally glazed ceramic Acrylic distemper.
stone in one piece for wash wall tiles up to 2.1m /
basin platform. ceiling ht. and Acrylic
distemper over plaster of
Paris for balance height.

TABLE –A

Fire water pump house
2
a). Maintenance /Pump floor/PLC Cement concrete with Acrylic distemper Acrylic distemper (except metal
Metallic hardener topping deck area)
Vitrified ceramic tiles Mineral fiber board false ceiling.
b). Control room /PLC. Acrylic emulsion paint.
Epoxy flooring
Calcium silicate false ceiling

c). Toilet area Heavy Duty Dust pressed Designer ceramic wall tiles
ceramic tiles. dado up to false ceiling
level.
Fire water booster water pump house
a). Maintenance /Pump floor/PLC Cement concrete with Acrylic distemper Acrylic distemper (except metal
Metallic hardener topping deck area)
Mineral fiber board false ceiling.
b). Control room /PLC. Control room /PLC Acrylic emulsion paint.
Calcium silicate false ceiling

c). Toilet area Heavy Duty Dust pressed Designer ceramic wall tiles
ceramic tiles. dado up to false ceiling
level.

TABLE –A
3. a)Water & Effluent treatment plant

buildings/Switch yard Control Building &
Other auxiliary building.
b)Workshop/ Operating/Maintenance Cement concrete with Acrylic distemper Acrylic distemper (except metal
areas/MCC areas Metallic hardener topping deck area)
c) Office Room, Staff Room Vitrified ceramic tiles. Acrylic emulsion paint Mineral fiber board false ceiling.
d) Control room Vitrified Ceramic Tiles Acrylic emulsion paint Mineral fiber board false ceiling.
e) Acid/Alkali storage area/ CW Acid, Alkali resistant tile as Acid/Alkali resistant tile as Chemical resistant paint.
treatment area/DM plant area/ per requirement. per requirement and
Regeneration area/ Neutralization pit etc. chemical resistant paint
above dado.
e) RCC Stair case Marble stone / granite stone. Marble stone up to1.2 m.ht. Acrylic Distemper
& Acrylic Distemper paint.
Acrylic distemper
f) Toilet area Heavy Duty Dust pressed Designer ceramic wall tiles
ceramic tiles. up to false ceiling level
Note : 1. All wall and roof areas above false ceiling shall be plastered.
2. The colour and pattern of finish shall be as per approved details.
3. All materials shall be of reputed and established brand approved by Engineer-in-charge.

4. Wherever alternative materials are specified, the final selection rests with Engineer-in-charge.
5. This finishing schedule shall also be applicable to similar functional areas for all other buildings and facilities.
6. All the finishing materials shall be applied/provided as per manufacturer specification and guidelines under the supervision & guidelines of
manufacturer.
7. Requirement given above are suggestive and minimum. Bidder is welcome to suggest alternative scheme conforming to design functional
requirement subject to approval of the Engineer-in-charge.

TABLE –C
EXTERIOR FINISHES SCHEDULE
Sl.No. DESCRIPTION OF AREA WALL AND PROJECTIONS SOFFIT OF PROJECTIONS
1. Auxiliary building in steel framed Premium Acrylic Smooth Premium Acrylic Smooth exterior paint with silicon additives
structure. exterior paint with silicon over suitable primer of Water Proof Cement Paint over plastered
additives over suitable primer surface
of Water Proof Cement Paint
over plastered surface/ Approved colour/ colour combination of colour coated metal
Aluminuim Composite Panel cladding
Approved colour/ colour

combination of colour coated
metal cladding
2. Building with concrete frame work, etc. Premium Acrylic Smooth Premium Acrylic Smooth exterior paint with silicon additives
exterior paint with silicon over suitable primer of Water Proof Cement Paint over plastered
additives over suitable primer surface
of Water Proof Cement Paint
over plastered surface
3. Steel Structure, trestles, etc. High performance Paint of

approved specification and
shade.
NOTE : 1. The colour and pattern of finish shall be as finalized by Engineer.
2. All materials shall be of reputed and established brand approved by Engineer.

CLAUSE NO.
10.00.00 MATERIAL SPECIFICATION
10.01.00 Cement
Fly ash based portland pozzolana cement conforming to IS: 1489 (Part-1) shall be used for
all areas other than for the critical structures identified below. Other properties shall be as per
IS code.
Ordinary Portland Cement (OPC) shall necessarily be used for RCC for Chimney shell..
The grade of cement shall be Grade 43 for OPC conforming to IS: 8112.
In place of fly ash based portland pozzolana cement, OPC mixed with Fly Ash can be used.
Batching plant shall have facility for mixing fly ash. Fly ash shall conform to IS: 3812(Part I &
Part II). Percentage of fly ash to be mixed in concrete shall be based on trial mix. Mix design
shall be done with varying percentage of fly ash mix with cement
10.02.00 Aggregates
a) Coarse Aggregate
Coarse aggregate for concrete shall be crushed stones chemically inert, hard,
strong, durable against weathering of limited porosity and free from deleterious
materials. It shall be properly graded. It shall meet the requirements of IS: 383.
b) Fine Aggregate
Fine aggregate shall be hard, durable, clean and free from adherent coatings of
organic matter and clay balls or pellets. Fine aggregate in concrete shall conform to
IS: 383. For plaster, it shall conform to IS: 1542 and for masonry work to IS: 2116.
c) Petrographic examination of aggregate shall be carried out by the contractor at

National Council for Cement and Building Materials (NCB), Ballabgarh, or any other
approved laboratory to ascertain the structure and rock type including presence of
strained quartz and other reactive minerals for machine foundations, etc. In case, the
coarse aggregate sample is of composite nature, the proportions (by weight) of
different rock types in the composite sample and petrographic evaluation of each
rock should also be ascertained. While determining the rock type, special emphasis
should be given on identification of known reactive rocks like chalcedony, opal etc.
The procedure laid down in IS 2430 for sampling of aggregates may be followed.
The laboratory shall determine potential reactivity of the aggregate, which may lead
to reaction of silica in aggregate with the alkalis of cement and / or potential of some
aggregates like limestone to cause residual expansion due to repeated temperature
cycle. If the same is established, the contractor shall further carry out alkali
aggregates reactivity test as per IS 2386 (Pt.VII) and / or repeated temperature cycle
test to establish the suitability of the aggregates for the concrete work. The test
results, with the final recommendations of the laboratory, as to a suitability of the
aggregate, for use in the concrete work for various structures and suggested
measures, in case of results are not satisfactory, shall be submitted to the Engineer
for his review, in a report form.
In case in the report, it is established, that the aggregates contain reactive silica,
which would react with alkalis of the cement, the contractor shall change the source

SECTION – VI, PART-B
WATYER SYSTEM PACKAGE CIVIL WORKS 91 OF 126
CLAUSE NO.
of supply of the aggregate or use low alkali cement as per recommendation or take
measures as recommended in the report as instructed by Engineer. In case
aggregates indicate residual expansion, under repeated temperature cycle test (from
10o Celsius to 65o Celsius and for 60 temperature cycles) the material shall not be
used for concreting of TGs', BFPs', Mills', Fans' and other equipment foundations
which are likely to be subjected to repeated temperature cycle. The contractor shall
use aggregates free from residual expansion under repeated temperatures cycle
test.
10.03.00 Reinforcement Steel
Reinforcement steel shall be of high strength deformed TMT steel bars of grade Fe-500/Fe
500D and shall conform to IS 1786. However, minimum elongation shall be 14.5%.
Mild steel & medium tensile steel bars and hard drawn steel wire shall conform to grade A of
IS 2062. Welded wire fabric shall conform to IS 1566.
10.04.00 Structural Steel
Structural Steel (including embedded Steel) shall be straight, sound, free from twists, cracks,
flaw, laminations and all other defects. Structural steel shall comprise of mild steel, medium
strength steel and high tensile steel as specified below.
10.04.01 Mild Steel
a) Rolled sections shall be of grade designation E250, Quality A/BR, Semi-killed/ killed
conforming to IS 2062. All steel plates shall be of Grade designation E250, Quality
BR (fully killed), conforming to IS 2062 and shall be tested for impact resistance at
room temperature. Plates beyond 12mm thickness and up to 40mm thickness shall
be normalized rolled. Plates beyond 40mm thickness shall be vacuum degassed &
furnace normalised and shall also be 100% ultrasonically tested as per ASTM –A578
level B-S2.
b) Pipes shall conform to IS: 1161.
c) Hollow (square and rectangular) steel sections shall be hot formed conforming to IS:
4923 and shall be of minimum Grade Yst 240.
d) Chequered plate shall conform to IS 3502 and shall be minimum 6 mm thick

excluding projection. Steel for chequered plate shall conform to grade E250A semi
killed of IS: 2062 or equivalent grade conforming to ASTM & BS standards only.
10.04.02 Medium and High Tensile Steel
Rolled Sections and plates shall be of grade designation E350 or higher, Quality B0 (Fully
killed), conforming to IS: 2062. Plates beyond 12mm thickness and up to 40mm thickness
shall be normalized rolled. Plates beyond 40mm thickness shall be vacuum degassed &
furnace normalised and shall also be 100% ultrasonically tested as per ASTM –A578 level B-
S2.
10.05.00 Bricks
Only fly ash bricks shall be used in all construction, except for elevator shafts, which can be
either of burnt clay bricks or RCC construction as per functional / codal provisions. Bricks
shall be table moulded/ machine made of uniform size, shape and sharp edges and shall
have minimum compressive strength of 75kg/cm2. Burnt clay fly ash bricks and fly ash lime
bricks shall conform to IS: 13757 and IS: 12894 respectively. Minimum fly ash content in fly

CLAUSE NO.
ash based bricks shall be 25%.
10.06.00 Foundation Bolts
Material and details of foundation bolts shall conform to IS: 5624. Mild steel bars used for the
fabrication of bolt assembly shall conform to grade 1of IS: 432 and/ or grade A of IS: 2062.
Hexagonal nuts and lock nuts shall conform to IS: 1363 & IS: 1364 upto M36 diameter and
IS: 5624 for M42 to M150 diameter.
10.07.00 Stainless steel
The material specification for stainless steel plates are mentioned in the design concept area
of Mill Bunker building.
10.08.00 Water
Water used for cement concrete, mortar, plaster, grout, curing, washing of coarse aggregate,
soaking of bricks, etc. shall be clean and free from oil, acids, alkalis, organic matters or other
harmful substances in such amounts that may impair the strength or durability of the
structure. Potable water shall generally be considered satisfactory for all masonry and
concrete works, including curing. When water from the proposed source is used for making
the concrete, the maximum permissible impurities, development of strength and initial setting
time of concrete shall meet the requirements of IS: 456.
All materials brought for incorporation in works shall be of best quality as per IS unless
specified otherwise.
10.08.00 Statutory Requirements
Bidder shall comply with all the applicable statutory rules pertaining to Factories Act, Fire
Safety Rules at Tariff Advisory Committee. Water Act for pollution control, Explosives Act,
etc.
Provisions of safety, health and welfare according to Factories Act shall be complied with.
These shall include provision of continuous walkways along the crane - girder level on both
sides of building, comfortable approach to EOT crane cabin, railing, fire escape, locker room
for workmen, pantry, toilets, rest room etc.
Provisions for fire proof doors, number of staircases, fire separation wall, lath
plastering/encasing the structural members (in fire prone areas), type of glazing etc. shall be
made according to the recommendations of Tarrif Advisory Committee.
Statutory clearances and norms of State Pollution Control Board shall be followed.
Bidder shall obtain approval of Civil/Architectural drawings from concerned authorities before
taking up the construction work.

CLAUSE NO.
11.00.00 Inspection, Testing and Quality Control
11.01.00 Sampling and testing of major items of civil works viz. earthwork, concreting, structural steel
work (including welding), piling, sheeting, etc. shall be carried out in accordance with the
requirements of this specification. Wherever nothing is specified relevant Indian Standards
shall be followed. In absence of Indian Standard equivalent International Standards may be
used.
The Bidder shall submit and finalise a detailed field Quality Assurance Programme before
starting of the construction work according to the requirement of this specification. This shall
include frequency of sampling and testing, nature/type of test, method of test, setting of a
testing laboratory, arrangement of testing apparatus/equipment, deployment of
qualified/experienced manpower, preparation of format for record, Field Quality Plan, etc.
Tests shall be done in the field and/or at a laboratory approved by the Engineer. The Bidder
shall furnish the test certificate from the manufacturer’s of various materials to be used in the
construction.
11.02.00 Workmanship and dimensional shall be checked as stipulated below.

CLAUSE NO.
12.00.00 ANNEXURES
(a) List of Codes and Standards
All applicable standards, references, specifications, codes of practice, etc., shall be the latest
edition including all applicable official amendments and revisions. A complete set of all these
documents shall be available at site with Bidder. List of some of the applicable Standards, in
original Codes and references is as following:
Where provisions are not covered in Indian Standards, reference shall be made to ACI,
AISC, EN, CICIND and other International Standards. Annexure-(A)
LIST OF CODES AND STANDARDS
Excavation and Filling
IS :2720 Methods of test for soils(relevant parts)
IS:4701 Code of practice for earth work on canals.
IS:9759 Guide lines for dewatering during construction.
IS:10379 Code of practice for field control of moisture and compaction of soils for
embankment and sub-grade.
Properties, Storage and Handling of Common Building Materials
IS:269 33 grade for ordinary Portland cement.
IS:383 Coarse and fine aggregates from natural sources for concrete.
IS:432 Specification for mild steel and medium tensile steel bars and
(Part 1&2) hard drawn steel wires for concrete reinforcement.
IS:455 Portland slag cement.
IS:702 Industrial bitumen.
IS:712 Specification for building limes.
IS:1077 Common burnt clay buidling bricks.
IS:1161 Steel tubes for structural purposes.
IS:1239 Mild steel tubes, tubulars and other wronght steel fillting - MS tubes.
IS:1363 Hexagon head bolts, screws and nuts of productions
(Part 1-3) grade - C.
IS:1364 Hexagon head bolts, screws and nuts of productions
(Part 1-5) grade-A & B.

CLAUSE NO.
IS:1367 Technical supply condition for threaded fasteners.

(Part 1-18)
IS:1489 Portland-pozzolana cement.

(Part-I) Fly ash based
IS:1542 Sand for Plaster.
IS:1566 Hard drawn steel wire fabric for concrete reinforcement.
IS:1786 High strength deformed steel bars & wires for concrete reinforcement.
IS:2062 Hot Rolled Low, Medium and High Tensile Structural Steel
IS:2116 Sand for masonry mortars.
IS : 2185 Hollow & solid concrete blocks.

(Part 1)
(Part 2) Hollow & solid light weight concrete blocks.
IS:2386 Testing of aggregates for concrete.

(Part I-VIII)
IS:3812 Specification for fly ash for use as pozzolona and admixture.
IS:4082 Recommendation on stacking and storage of construction materiel and

components at site
IS:8112 43 grade ordinary portland cement.
IS:8500 Structural steel-Microalloyed (Medium and high strength qualities).
IS:12269 53 grade ordinary portland cement.
IS:12894 Specification for fly ash lime bricks.
IS:13757 Burnt clay fly ash building bricks.
Cast in-situ Concrete and Allied Works
IS:280 Mild steel wire for general engineering purpose.
IS:456 Code of practice for plain and reinforcement concrete.
IS:457 Code of practice for general construction of plain and reinforced concrete for
dams and other massive structures.
IS:516 Method of test for strength of concrete.

IS:1199 Methods of sampling and analysis of concrete.
IS:1791 General requirement for batch type concrete mixers.
IS:1834 Hot applied sealing compound for joints in concrete.

IS:1838 Preformed fillers for expansion joints in concrete pavement and structures.

CLAUSE NO.
IS:2438 Specification for roller pan mixers.
IS:2502 Code of practice for bending and fixing of bars for concrete reinforcement.
IS:2505 Concrete vibrators - immersion type.
IS:2506 General requirements for screed board concrete vibrators.
IS:2722 Specification for Portable Swing weigh batchers for concrete (single and
double bucket type).
IS:2750 Steel scaffoldings
IS:2751 Recommended practice for welding of mild steel plain and deformed bars for
reinforced construction.
IS:3150 Hexagonal wire netting for general purposes.
IS:3366 Specification for pan vibrators.
IS:3370 Code of practice for concrete structures for the

(Part 1-4) storage of liquids.
IS:3558 Code of practice for use of immersion vibrators for consolidating concrete.
IS:4014 Code of practice for steel tubular scaffolding.

(Part-1&2)
IS:4326 Code of practice for earth quake resistant design and construction of
buildings.
IS:4656 Form vibrators for concrete.
IS:4925 Concrete batching and mixing plant.

IS:4990 Plywood for concrete shuttering work.
IS:5256 Code of practice for sealing expansion joints in concrete lining on canals.
IS:5525 Recommendations for detailing of reinforcement in reinforced concrete

works.
IS:6461 Glossary of terms relating to cement concrete.
IS:6494 Code of practice for water proofing of underground reservoir and swimming
pools.
IS:6509 Code of practice for installation of joints in concrete pavements.
IS:7861 Code of practice for extreme weather concreting.

(Part -1&2)
IS:9012 Recommended practice for shotcreting.

IS:9103 Admixtures for concrete.
IS:9417 Recommendations for welding cold worked bars for reinforced concrete
construction.

CLAUSE NO.
IS:10262 Recommended guidelines for concrete mix design.
IS:11384 Code of practice for composite construction in structural steel and concrete.
IS:12118 Two parts polysulphide based sealants.
IS:12200 Code of practice for provision of water stops at transverse construction joints
in masonry and concrete dams.
IS:13311 Non destructive testing of concrete - methods of test.
(Part 1) Ultrasonic pulse velocity.
(Part 2) Rebound hammer.
SP-16 Design codes for reinforced concrete to IS:456-1978.
SP-23 Hand book of concrete mixes.
SP-24 Explanatory handbook on Indian standards code for plain and reinforced
concrete. (IS : 456)
SP-34 Hand book on concrete reinforcement and detailing.
ACI-318 American Concrete Institute code for structural concrete.
Precast Concrete Works
SP:7 National Building Code - Structural Design

(Part 6/Sec.7) Prefabrication and system building and mixed / composite construction.
IS:10297 Code of practice for design and construction of floors and roofs using
precast reinforced/prestressed concrete ribbed or cored slab units.
IS:10505 Code of practice for construction of floors and roofs using pre-cast reinforced
concrete waffle units.
IS:15658 Pre-cast concrete block for paving.
Masonry & Allied Works
IS:1905 Code of practice for structural use of unreinforced masonry.
IS: 2185 Part-1 Concrete Masonry Units - Specification Part 1 Hollow and Solid
Concrete Blocks
Part-3 Specification for concrete masonry units: Part 2 Hollow and solid light
weight concrete blocks
IS:2212 Code of practice for brick work.
IS:2250 Code of practice for preparation and use of masonry mortars.
IS:2572 Code of practice for construction of hollow concrete block masonry.
SP:20 Hand book on masonry design and construction.
Sheeting Works

CLAUSE NO.
IS:277 Galvanised steel sheets (Plan & corrugated).
IS:513 Cold-rolled low carbon steel sheets & strips.
IS:730 Hook bolts for corrugated sheet roofing.
IS:801 Code of practice for use of cold formed light gauge steel structural members
in general building construction.
IS:2527 Code of practice for fixing rain water gutters and down pipe for roof drainage.
IS:7178 Technical supply condition for tapping screw.
IS:8183 Bonded mineral wool.
IS:8869 Washers for corrugated sheet roofing.
IS:12093 Code of practice for laying and fixing of sloped roof covering using plain and
corrugated galvanised steel sheets.
IS:12436 Preformed rigid Polyurethane (PUR) and isocyanurate (PIR) foams for
thermal insulation.
IS:12866 Plastic translucent sheets made from thermosetting polyester resin (glass
fibre reinforced).
IS:14246 Continuously pre-painted galvanised steel sheets and coils.
BS:5950 Code of practice for design of light gauge profiled
(Part-6) steel sheeting
Fabrication and Erection of Structural Steel Works
IS:800 Code of practice for General Construction of steel.
IS:813 Scheme for symbols for welding.
IS:814 Covered electrodes for manual metal arc welding of carbon & carbon
manganese steel.
IS:816 Code of practice for use of metal arc welding for general construction in mild
steel.
IS:817 Code of practice for training and testing of metal arc welders.
IS:1024 Welding in bridges and substructured subject to dynamic.

IS:1181 Qualifying tests for Metal Arc welders (engaged in welding structures other
than pipes).
IS:1182 Recommended practice for Radiographic examination of fusion welded butt

joints in steel plates
IS:1608 Mechanical testing of metals - tensile testing

CLAUSE NO.
IS:1852 Rolling and Cutting Tolerances for Hot rolled steel products.
IS:2016 Specification for Plain washers.
IS:2595 Code of practice for Radiographic testing
IS:2629 Hot dip galvanising of iron and steel
IS:3502 Steel chequred plate.
IS:3613 Acceptance tests for wire flux combination for submerged arc welding.
IS:3658 Code of practice for liquid penetrant flaw detection.
IS:3664 Code of practice for ultra sonic pulse echo testing contact and immersion
method
IS:3757 High strength structural bolts.
IS:4000 High strength bolts in steel structure - code of practice.
IS:4353 Sub merged arc welding of mild steel and low alloy steel Recommendation
IS:4759 Hot dip zinc coating on structural steel and other allied products.
IS:5334 Code of practice for magnetic particle flaw detection of welds.
IS:5369 General requirements for plain washers and lock washer
IS : 6623 High strength structural nuts.
IS:6649 Hardened and tampered washers for high strength structural bolts & nuts.
IS:6911 Stainless steel plate, sheet and strip.
IS:7205 Safety code for erection of structural steel.
IS:7215 Tolerances for fabrication of structural steel.
IS:7307 Approved test for welding procedures
(Part - I) Fusion welding of steel.
IS:7310 Approval test for welders working to approval welding procedure.

(Part-I) Fusion welding of steel
IS:9178 Criteria for design of steel bins for storage of bulk material.
(Part-1to 3)
IS:9595 Recommendations for metal arc welding of carbon & carbon manganese
steel.
IS:12843 Tolerances for erection of steel structures.
SP:6 ISI Hand book for structural Engineers.

(Part 1 to 7)

CLAUSE NO.
Plastering and Allied Works
IS:1661 Code of practice for application of cement and cement lime plaster finishes.
IS:2402 Code of practice for external rendered finishes.
IS:2547 Gypsum building plaster.

(Parts 1&2)
Acid and Alkali Resistant Lining
IS:158 Ready mixed paint, brushing, bituminous, black, lead free, acid, alkali & heat
resisting.
IS:412 Expanded metal steel sheets for general purpose.
IS:4441 Code of practice for use of silica type chemical resistant mortars.
IS:4443 Code of practice for use of resin type chemical resistant mortars.
IS:4456 Method of Test for chemical resistant tiles.

(Part I & II)
IS:4457 Ceramic unglazed vitreous acid resisting tiles.
IS:4832 Specification for chemical resistant mortars.
(Part - 1) Silicate type
(Part - 2) Resin type
(Part - 3) Sulfur type
IS:4860 Acid resistant bricks.
IS:9510 Bitumastic acid resisting grade.
Water Supply, Drainage and Sanitation
IS:458 Precast concrete pipes (with & without reinforcement).
IS:554 Pipe threads where pressure tight joints are made on the threads –
dimensions, tolerances and designation.
IS:651 Salt glazed stoneware pipes and fittings.
IS:774 Flushing cisterns for water closets and urinals.
IS:775 Cast iron brackets and supports for wash basins and sinks.
IS:778 Copper alloy gate, globe and check valves for water works purposes.
IS:781 Cast copper alloy screw down bib taps & stop valves for water services.
IS:782 Caulking lead.

CLAUSE NO.
IS:783 Code of practice for laying of concrete pipes.
IS:1172 Code of basic requirements of water supply, drainage and sanitation.
IS:1230 Cast iron rain water pipes and fittings.
IS:1239 Mild Steel tubes, tubulars and other wrought steel fittings
(Part 1&2)
IS:1536 Centrifugally cast (Spun) iron pressure pipes for water.
IS:1537 Vertically cast iron pressure pipes for water, gas and sewage.
IS:1538 Cast iron fittings for pressure pipe for water, gas and sewage.
IS:1703 Copper alloy float valve for water supply fitting.
IS:1726 Cast iron manhole covers and frames.
IS:1729 Cast iron / Ductile iron drainage pipes and pipe/fittings for over ground non
pressure pipeline socket and spigot series.
IS:1742 Code of practice for building drainage.
IS:2064 Selection, installation and maintenance of sanitary appliances.
IS:2065 Code of practice for water supply in buildings.
IS:2326 Automatic flushing cisterns for urinals.
IS:2548 Plastic seats and covers for water closets.
IS:2556 Vitreous sanitary appliances (vitreous china).
IS:3114 Code of practice for laying of cast iron pipes.
IS:3311 Waste plug and its accessories for sinks and wash basins.
IS:3438 Silvered glass mirrors for general purposes.
IS:3486 Cast iron spigot and socket drain pipes.
IS:3589 steel pipe for water and sewage (168.3 to 2540mm outside diameter)
IS:3989 Centrifugally cast (Spun) iron spigot and socket soil, waste and ventilating
pipes, fittings and accessories.
IS:4111 Code of practice for ancillary structure in sewerage system.
(Part 1 to 5)
IS:4127 Code of practice for laying of glazed stone ware pipes.
IS : 4733 Methods of sampling and testing sewage effluents.
IS:4764 Tolerance limits for sewage effluents discharged into inland surface waters.
IS:1068 Electroplated coating of nickel plus chromium and copper plus nickel plus
chromium.

CLAUSE NO.
IS:5329 Code of practice for sanitary pipe work above ground for buildings.
IS:5382 Rubber sealing rings for gas mains, water mains and sewers.
IS:5822 Code of practice for laying of electrically welded steel pipes for water supply.
IS:5961 Specification for cast iron grating for drainage purpose.
IS:7740 Code of practice for construction and maintenance of road gullies.
IS:8931 Copper alloy fancy single taps combination tap assembly and stop valves
for water services.
IS:9762 Polyethylene floats for float valves.
IS:10592 Industrial emergency showers, eye and face fountains and combination
units.
IS:12592 Specification for precast concrete manhole covers and frames.
IS:12701 Rotational moulded polyethylene water storage tanks.
IS:13983 Stainless steel sinks for domestic purposes.
SP:35 Hand book on water supply and drainage with special emphasis on
plumbing.
CPH&EEO Manual on sewage and sewage treatment
Publication - as updated.
Doors Windows and Allied Works
IS:204 Tower Bolts.
(Part 1) Ferrous metals
(Part 2) Non - ferrous metals
IS:208 Door Handles.
IS:281 Mild steel sliding door bolts for use with padlocks.
IS:362 Parliament Hinges.
IS:419 Putty, for use on window frames.
IS:451 Technical supply conditions for wood screws
IS:733 Wrought aluminium and aluminium alloy bars, rods and sections for general
engineering purposes.
IS:1003 Timber panelled and glazed shutters (doors shutters).

(Part I)
IS:1003 Timber panelled and glazed shutters

CLAUSE NO.
(Part-1) door shutters.
IS:1038 Steel doors, windows and ventilators.
IS:1081 Code of practice for fixing and glazing of metal (steel and aluminium) doors,
windows and ventilators.
IS:1285 Wrought aluminium and aluminium alloy extruded round tube & hollow
section (for general engineering purposes).
IS:1341 Steel butt hinges.
IS:1361 Steel windows for Industrial buildings.
IS:1823 Floor door stoppers.
IS:1868 Anodic coatings on Aluminium and its alloys.
IS:2202 Wooden flush door shutters (solid core type) particle
(Part-2) board face panels and hard board face panels.
IS:2209 Mortice locks (vertical type)
IS:2553 Safety glass.
(Part-1) General purposes
IS:2835 Flat transparent sheet glass.
IS:3548 Code of practice for glazing in buildings.
IS:3564 Door closers (Hydraulically regulated)
IS:3614 Specification for fire check doors :
(Part-1) plate, metal covered and rolling type.
(Part-2) Resistance test and performance criteria.

IS:4351 Specification for steel door frames.
IS:5187 Flush bolts.
IS:5437 Figured, rolled and wired glass.
IS:6248 Specification for metal rolling shutters and rolling grills.
IS:6315 Specification for floor springs (Hydraulically regulated) for heavy doors.
IS:7196 Hold fast.
IS:7452 Hot rolled steel sections for doors, windows and ventilators.
IS:10019 Mild steel stays and fasteners.
IS:10451 Steel sliding shutters (top hung type)

CLAUSE NO.
IS:12823 Prelaminated particle boards.
Roof Water Proofing and Allied Works
IS:3067 code of practice for general design details and preparatory work for damp
proofing and water proofing of buildings.
ASTM Standard specification for high solid content cold
C836-89a liquid applied elastomeric water proofing membrane for use with separate
wearing course.
ASTM Standard guide for high solid content cold
C898-89 liquid applied elastomeric water proofing membrane for use with separate
wearing course.
Floor Finishes and Allied Works
IS:5318 Code of practice for laying of flexible PVC sheet and tile flooring.
IS:8042 White portland cement.
IS:13755 Dust pressed ceramic tiles with water absorption of 3%, E 6% (Group B11a).
IS:13801 Chequered cement concrete tiles.
Painting and Allied Works
IS:162 Ready mixed paint, brushing fire resisting, silicate type for use on wood,
colour as required.
IS:428 Distemper, oil, emulsion, colour as required.
IS:1477 Code of practice for painting of terrous metals in buildings.
(Part -1) Pretreatment.

(Part -2) Painting.
IS:1650 Specification for colours for building and decorative materials.
IS:2074 Ready mixed paint, air drying, red oxide-zinc chrome, priming.
IS:2338 Code of practice for finishing of wood and wood based materials.
(Part -1) Operations and Workmanship.
(Part -2) Schedule.
IS:2395 Code of pratice for painting concrete, masonry and plaster surfaces.
(Part-1) Operations and Workmanship.
(Part -2) Schedule.
IS:2524 Code of practice for painting of nonferrous metals in buildings.

CLAUSE NO.
(Part -1) Pretreatment
(Part -2) Painting.
IS:2932 Enamel, synthetic, exterior, (a) under coating and (b) finishing.
IS:2933 Enamel exterior, (a) under coating, (b) finishing.
IS:4759 Hot dip zinc coatings on structural steel and other allied products.
IS:5410 Specification for cement paint.
IS:15489 Plastic emulsion paint.
IS:6278 Code of practice for white washing and Colour washing.
IS:10403 Glossary of term related to building finish.
IS:12027 Silicone based water repellent
IS:13238 Epoxy based zinc phosphate primer (2 pack)
IS:13239 Epoxy surfacer (2 pack)
IS:13467 Chlorinated rubber for paints
IS:14209 Epoxy enamel, two component glossy.
BS:5493 Code of practice for protective coating of iron and steel structures against
corrosion.
Piling and Foundation
IS:1080 Code of practice for design and construction of shallow foundations on soils.
IS:1904 Code of practice for design and construction of foundation in Soils : General
Requirements.
IS:2314 Steel sheet piling sections.
IS:2911 Code of practice for design and construction of pile foundations.

(Relevant Parts)
IS:2950 Code of practice for designs and construction of Raft foundation.
(Part-1) Design
IS:2974 Code of practice for design and construction of machine

(Part-1 to 5) foundation.
IS:4091 Code of practice for design and construction foundations for transmission
line towers and poles.
IS:6403 Code of practice for determination of Bearing capacity of Shallow

foundations.

CLAUSE NO.
IS:8009 Code of practice for calculation of settlement of foundation.
(Part -1) Shallow foundations.
(Part -2) Deep foundations.
IS:12070 Code of practice for design and construction of shallow foundations on

rocks.
ISO 10816 Criteria for assessing mechanical vibrations of machines.
ISO 1940 Criteria for assessing the st of balance of rotating rigid bodies.
DIN : EN 13906-1 Helical compression spring made of round wire and rod : calculation and
design of compression .
DIN:2096 Helical compression spring out of round wire and rod : Quality requirements
for hot formed compression spring.
DIN:4024 Flexible supporting structures for machine with rotating machines.
Roads
IRC:5 Standard specifications and Code of practice for road bridges,

(Section-1) General Features of Design.
IRC:14 Recommended practice for 2cm thick bitumen and tar carpets.
IRC:15 Standard specifications and code of practice for construction of concrete

roads.
IRC:16 Specification for priming of base course with bituminous primers.
IRC:19 Standard specifications and Code of practice for water bound macadam.
IRC:21 Standard specifications and Code of practice for road bridges.

(Section-III) Cement concrete (plain and reinforced).
IRC:34 Recommendations for road construction in water logged areas.
IRC:36 Recommended practice for the construction of earth embankments for road
works.
IRC:37 Guidelines for the Design of flexible pavements.
IRC:56 Recommended practice for treatment of embankment slopes for erosion

control.
IRC:58 Guidelines for the design of rigid pavements for highways.
IRC:73 Geometric Design standards for rural (non-urban) highways.
IRC : 86 Geometric Design standards for urban roads in plains.
IRC:SP:13 Guidelines for the design of small bridges & culverts.

CLAUSE NO.
IRC - Ministry of Surface Transport (Road wing),

Publication specifications for road and bridge works.
IS:73 Paving bitumen.
Loading
IS:875 Code of practice for design loads (other than earthquake) for
(Relevant parts) buildings and structures.
IS:1893 Criteria for earthquake resistant design of structures.
IS:4091 Code of practice for design and construction of foundation for transmission
line towers and poles.
IRC:6 Standard specifications & Code of practice for road bridges.

(Section-II) loads and stresses
Safety
IS:1641 Code of practice for fire safety of buildings - General principles of fire grading
and classification.
IS:1642 Code of practice for fire safety of buildings - Details of construction.
IS:3696 Safety code for scaffolds and ladders.

(Part-1&2)
IS:3764 Excavation work - code of safety.
IS:4081 Safety code for blasting and related drilling operations.

IS:4130 Demolition of buildings - code of safety.
IS:5121 Safety code for piling and other deep foundations.
IS:5916 Safety code for construction involving use of hot bituminous materials.
IS:7205 Safety code for erection of structural steel work.
IS:7293 Safety code for working with construction machinery.
IS:7969 Safety code for handling and storage of building materials.

Indian Explosives (As updated)
Act 1940)
Architectural Design of Buildings
SP:7 National Building Code of India
SP:41 Hand book on functional requirements of buildings (other than industrial

buildings)
ECBC Energy Conservation Building Code
GRIHA Green Rating For Integrated Habitat Assessment.

CLAUSE NO.
Chimney
IS:4998 Criteria for design of reinforced chimneys
IS:6533 Code of practice for design and construction of steel chimneys
ICAO International Civil Aviation Organisation (ICAO)
DGCA Instruction of Director General of Civil Aviation , India
ACI:307 Specification for the design and construction of reinforced concrete

chimneys
BS:4076 Specification for steel chimneys
CICIND Model Code for concrete chimneys

Model code for steel chimneys
ASCE Code Design and construction of steel chimney liners prepared by Task committee
on steel chimney liners. Fossil power committee, Power division published
by ASCE - 1975.
IS:1554 PVC insulated (heavy duty) electric cables
IS:2606 Alloy lead anodes for chromium plating
IS:3043 Code of Practice for Earthing
IS:9537 Conduits for electrical installations.

The Indian Electricity Rules
The Indian Electricity Act
The Indian Electricity (Supply) Act
The Indian Factories Act
IS:2309 Practice for protection of buildings and allied structures against lightning
Miscellaneous
IS:802 Code of practice for use of structural steel in overhead trans-

(Relevant parts) mission line towers.
IS:803 Code of practice for design, fabrication and erection of vertical mild
steel cylindrically welded in storage tanks.
IS:10430 Criteria for design of lined canals and guidance for selection of type
of lining.
IS:11592 Code of practice for selection and design of belt conveyors.
IS:12867 PVC handrails covers.
IS 11504 Criteria for structural design of reinforced concrete natural draught

cooling towers
BS:4485 (IV) British Standard : Code of design for water cooling towers

CLAUSE NO.
CIRIA Design and construction of buried thin-wall pipes.

Publication
IS 4671 Expanded polystyrene for thermal insulation purposes.

CLAUSE NO.
ANNEXURE (B)
CONSTRUCTION METHODOLOGY
Construction and erection activities shall be fully mechanized from the start of the work.
All excavation and backfilling work shall be done using excavators, loaders, dumpers,
dozers, poclains, excavator mounted rock breakers, rollers, sprinklers, water tankers, etc.
Manual excavation can be done only on isolated places with specific approval of engineer.
For controlled rock blasting specialized agency, equipped with sensors to assess the impact
of the blast on the adjoining existing structures, shall be employed.
Dewatering shall be done using the combination of electrical and standby diesel pumps.
Pile installation equipment suitable for flushing with air lift technique shall be used for
construction of bored piles.
For concreting, weigh batching plants, transit mixers, concrete pumps, hoists, etc. shall be
used.
All fabrication and erection activities of structural steel shall be carried out using automatic
submerged arc welding machines, cutting machines, gantry cranes, crawler mounted heavy
cranes and other equipment like heavy plate bending machines, shearing machines, lathe,
milling machines, etc. Use of derricks shall not be permitted. Special enclosures, for blast
cleaning of steel structure surface preparation, shall be used.
All handling of materials shall be with cranes. Heavy trailers shall be used for transportation.
Mechanized modular units of scaffolding and shuttering shall be used.
Grouting shall be carried out using hydraulically controlled grouting equipment.
Roadwork shall be done using pavers, rollers and premix plant.
All finishing items shall be installed using appropriate modern mechanical tools. Manual
punching etc. shall not be permitted.
Heavy duty hoists for lifting of construction materials shall be deployed. Compressors for
cleaning of foundations and other surfaces shall be used.
Field laboratory shall be provided with all modern equipment for survey, testing of soil,
aggregates, concrete, welding, etc. For testing of steel works, ultrasonic testing machines,
radiographic testing machines, dye penetration test equipment, destruction testing
equipment, etc. shall be deployed.
All persons working at site shall be provided with necessary safety equipment and all safety
aspects shall be duly considered for each construction/ erection activity. Moreover, only the
persons who are trained in the respective trade shall be employed for executing that
particular work.

CLAUSE NO.
BORE HOLE DATA ANNEXURE-C

(2X660 MW) SECTION – VI, PART-B SUB-SECTION-IIID-01 PAGE
BID DOC NO.: THDC/RKSH/CC-9915-373
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ANEEXURE-D
CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND

EQUIPMENT
All structures shall be designed for wind forces in accordance with IS: 875 (Part-3) and as
specified in this document. See Annexure – B for site specific information.
Along wind forces shall generally be computed by the Peak (i.e. 3 second gust) Wind
Speed method as defined in the standard.
Along wind forces on slender and wind sensitive structures and structural elements shall
also be computed, for dynamic effects, using the Gust Factor or Gust Effectiveness Factor
Method as defined in the standard. The structures shall be designed for the higher of the
forces obtained from Gust Factor method and the Peak Wind Speed method.
Analysis for dynamic effects of wind must be undertaken for any structure which has a
height to minimum lateral dimension ratio greater than “5” and/or if the fundamental
frequency of the structure is less than 1 Hz.
Susceptibility of structures to across-wind forces, galloping, flutter, ovalling etc. should be

examined and designed/detailed accordingly following the recommendations of
IS:875(Part-3) and other relevant Indian standards.
It should be estimated if size and relative position of other structures are likely to enhance
the wind loading on the structure under consideration. Enhancement factor, if necessary,
shall suitably be estimated and applied to the wind loading to account for the interference
effects.
Damping in Structures
The damping factor (as a percentage of critical damping) to be adopted shall not be more
than as indicated below for:
a) Welded steel structures : 1.0%
b) Bolted steel structures : 2.0%
c) Reinforced concrete structures :1.6%
d) Steel stacks : As per IS: 6533 & CICIND Model

Code whichever is more critical.

CLAUSE NO.
Appendix-I
SITE SPECIFIC DESIGN PARAMETERS
The various design parameters, as defined in IS: 875 (Part-3), to be adopted

for the project site shall be as follows:
a) The basic wind speed “Vb” at ten

metre above the mean ground level : 47 metre/second
b) The risk coefficient “K1” : 1.07
c) Category of terrain : Category-2

CLAUSE NO.
Annexure-E
CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND

EQUIPMENT FOR KHURJA STPP
All structures and equipment shall be designed for seismic forces adopting the site specific
seismic information provided in this document and using the other provisions in accordance
with IS: 1893 (Part 1 to Part 4). Pending finalization of Part 5 of IS: 1893, provisions of part 1
shall be read along with the relevant clauses of IS: 1893:1984, for embankments
A site specific seismic study has been conducted for the project site. The peak ground
horizontal acceleration for the project site, the site specific acceleration spectral coefficients
(in units of gravity acceleration ‘g’) in the horizontal direction for the various damping values
and the multiplying factor (to be used over the spectral coefficients) for evaluating the design
acceleration spectra are as given at Appendix-I.
Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding horizontal
values.
The site specific design acceleration spectra shall be used in place of the response
acceleration spectra, given at figure-2 in IS: 1893 (Part 1) and Annex B of IS: 1893 (Part 4).
The site specific acceleration spectra along with multiplying factors specified in Appendix-I
includes the effect of the seismic environment of the site, the importance factor related to the
structures and the response reduction factor. Hence, the design spectra do not require any
further consideration of the zone factor (Z), the importance factor (I) and response reduction
factor (R) as used in the IS: 1893 (Part 1 to Part 4).
Damping in Structures
The damping factor (as a percentage of critical damping) to be adopted shall not be more
than as indicated below for:
a) Steel structures : 2%
b) Reinforced Concrete structures : 5%
c) Reinforced Concrete Stacks : 3%
d) Steel stacks : 2%
Method of Analysis
Since most structures in a power plant are irregular in shape and have irregular distribution of
mass and stiffness, dynamic analysis for obtaining the design seismic forces shall be carried
out using the response spectrum method. The number of vibration modes used in the
analysis should be such that the sum total of modal masses of all modes considered is at
least 90 percent of the total seismic mass and shall also meet requirements of IS: 1893 (Part
1). Modal combination of the peak response quantities shall be performed as per Complete
Quadratic Combination (CQC) method or by an acceptable alternative as per IS: 1893 (Part
1).

CLAUSE NO.
In general, seismic analysis shall be performed for the three orthogonal (two principal
horizontal and one vertical) components of earthquake motion. The seismic response from
the three components shall be combined as specified in IS: 1893 (Part 1).
The spectral acceleration coefficient shall get restricted to the peak spectral value if the
fundamental natural period of the structure falls to the left of the peak in the spectral
acceleration curve.
For buildings, if the design base shear (VB) obtained from modal combination is less than the
base shear (VB) computed using the approximate fundamental period (Ta) given in IS:
1893: Part 1 and using site specific acceleration spectra with appropriate multiplying factor,
the response quantities (e.g. member forces, displacements, storey forces, storey shears
and base reactions) shall be enhanced in the ratio of VB/ VB. However, no reduction is
permitted if VB is less than VB.
Design/Detailing for Ductility for Structures

The site specific design acceleration spectra is a reduced spectra and has an in-built
allowance for ductility. Structures shall be engineered and detailed in accordance with
relevant Indian/International standards to achieve ductility.

CLAUSE NO.
APPENDIX-I
SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES AND

EQUIPMENT
The various site specific seismic parameters for the project site shall be as follows:
1) Peak ground horizontal acceleration (MCE) : 0.32 g
2) Multiplying factor to be applied to the site specific horizontal

acceleration spectral coefficients (in units of gravity acceleration ‘g’)
to obtain the design acceleration spectra
a) for special moment resisting steel frames designed and detailed

as per IS:800 : 0.08
b) for special concentrically braced steel frames designed and : 0.06

detailed as per IS:800
c) For special moment resisting RC frames designed and detailed as

per IS:456 and IS:13920 : 0.048
d) for RCC chimney, RCC Natural Draft Cooling Tower : 0.16
e) for Liquid retaining tanks : 0.096
f) for Steel chimney, Absorber Tower, Vessels : 0.12
g) for design of structures not covered under 2 (a) to 2 (f) above and
under 3 below, in general(excluding special structure/ : 0.08
configuration/ materials)
3) Multiplying factor to be applied to the site specific horizontal

acceleration spectral coefficients (in units of gravity acceleration
‘g’) for design of equipment and structures where inelastic action is
not relevant or not permitted : 0.16
Note:
g = Acceleration due to gravity
The horizontal seismic acceleration spectral coefficients are furnished in subsequent pages.

CLAUSE NO.
APPENDIX – II
HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS for Khurja TPP

(In units of ‘g’)
Time Damping Factor (as a percentage of critical damping)

Period
(Sec) 2% 3% 5%
0.000 1.000 1.000 1.000
0.030 1.000 1.000 1.000
0.040 2.240 2.032 1.600
0.050 2.450 2.222 1.750
0.060 2.660 2.413 1.900
0.070 2.870 2.604 2.050
0.080 3.080 2.794 2.200
0.090 3.290 2.985 2.350
0.100 3.500 3.175 2.500
0.105 3.500 3.175 2.500
0.110 3.500 3.175 2.500
0.115 3.500 3.175 2.500
0.120 3.500 3.175 2.500
0.125 3.500 3.175 2.500
0.130 3.500 3.175 2.500
0.135 3.500 3.175 2.500
0.140 3.500 3.175 2.500
0.145 3.500 3.175 2.500
0.150 3.500 3.175 2.500
0.200 3.500 3.175 2.500
0.220 3.500 3.175 2.500
0.230 3.500 3.175 2.500
0.240 3.500 3.175 2.500
0.300 3.500 3.175 2.500
0.350 3.500 3.175 2.500
0.400 3.500 3.175 2.500
0.450 3.500 3.175 2.500
0.500 3.500 3.175 2.500
0.550 3.500 3.175 2.500
0.600 3.173 2.879 2.267
0.650 2.929 2.657 2.092
0.700 2.720 2.467 1.943
0.750 2.539 2.303 1.813
0.800 2.380 2.159 1.700
0.850 2.240 2.032 1.600
0.900 2.116 1.919 1.511
0.950 2.004 1.818 1.432

CLAUSE NO.

Period
(Sec) 2% 3% 5%
1.000 1.904 1.727 1.360
1.050 1.813 1.645 1.295
1.100 1.731 1.570 1.236
1.150 1.656 1.502 1.183
1.200 1.587 1.439 1.133
1.250 1.523 1.382 1.088
1.300 1.465 1.329 1.046
1.350 1.410 1.279 1.007
1.400 1.360 1.234 0.971
1.450 1.313 1.191 0.938
1.500 1.269 1.151 0.907
1.550 1.228 1.114 0.877
1.600 1.190 1.080 0.850
1.650 1.154 1.047 0.824
1.700 1.120 1.016 0.800
1.750 1.088 0.987 0.777
1.800 1.058 0.960 0.756
1.850 1.029 0.934 0.735
1.900 1.002 0.909 0.716
1.950 0.976 0.886 0.697
2.000 0.952 0.864 0.680
2.050 0.929 0.843 0.663
2.100 0.907 0.822 0.648
2.150 0.886 0.803 0.633
2.200 0.865 0.785 0.618
2.250 0.846 0.768 0.604
2.300 0.828 0.751 0.591
2.350 0.810 0.735 0.579
2.400 0.793 0.720 0.567
2.450 0.777 0.705 0.555
2.500 0.762 0.691 0.544
2.550 0.747 0.677 0.533
2.600 0.732 0.664 0.523
2.650 0.718 0.652 0.513
2.700 0.705 0.640 0.504
2.800 0.680 0.617 0.486
2.850 0.668 0.606 0.477
2.900 0.657 0.596 0.469
2.950 0.645 0.585 0.461
3.000 0.635 0.576 0.453
3.050 0.624 0.566 0.446
3.100 0.614 0.557 0.439

CLAUSE NO.

Period
(Sec) 2% 3% 5%
3.150 0.604 0.548 0.432
3.200 0.595 0.540 0.425
3.250 0.586 0.531 0.418
3.300 0.577 0.523 0.412
3.350 0.568 0.516 0.406
3.400 0.560 0.508 0.400
3.450 0.552 0.501 0.394
3.500 0.544 0.493 0.389
3.550 0.536 0.487 0.383
3.600 0.529 0.480 0.378
3.650 0.522 0.473 0.373
3.700 0.515 0.467 0.368
3.750 0.508 0.461 0.363
3.800 0.501 0.455 0.358
3.850 0.495 0.449 0.353
3.900 0.488 0.443 0.349
3.950 0.482 0.437 0.344
4.000 0.476 0.432 0.340

PART-B (QA-MECHANICAL)

SUB-SECTION TITLE
PART – B (QA-MECHANICAL)
IIIE – 01 PT & LET PLANT, DM PLANT & CWT SYSTEM
IIIE – 02 INDUCED DRAFT COOLING TOWERS
IIIE – 03 CW AND RAW WATER SYSTEM
IIIE – 04 CHLORINE DI-OXIDE PLANT
IIIE – 05 LOW PRESSURE PIPING
IIIE – 06 AIR CONDITIONING & VENTILATION SYSTEM
IIIE – 07 FIRE DETECTION & PROTECTION SYSTEM

SUB-SECTION – IIIE-01
PT & LET PLANT, DM PLANT &

CWT SYSTEM

CLAUSE NO.
QUALITY ASSURANCE
Hydraulic test / Pneumatic test

Test/Check
Test as per relevant Std /

Appd. Data Sheets
WPS/PQR/Welder
Performance Test
Assembly Fit up
/ Vacuum test
Material Test
Other Tests
Dimension
DPT/MPI
Remarks
Items / Components
COMMON ITEMS: RT
1. Horizontal Centrifugal Y Y Y1 Y LEGENDS: Applicable tests are identified by ‘Y’.
Pumps Ya : One per Heat / Heat Treatment batch / Lot.
1.1. Casing Ya Yb Y Y Yb : On machined surfaces only. Also 100% on Butt Welds & 10% on Fillet
1.2. Impeller Ya Yb Y Yd Welds.
1.3. Shaft Ya Y Y Yc Yc : UT shall be done for shafts with Dia 50 mm or above & Plates of
2. Vertical Pumps Y Y Y1 Y Thickness 25 mm or above.
2.1. Casing Ya Yb Y Y Yd :Dynamic Balancing per ISO: 1940, Grade 6.3 minimum shall be
2.2. Impeller Ya Yb Y Yd conducted for rotating assy.
2.3. Shaft Ya Y Y Yc Y1 : As per Pump governing standard. Tolerences as per HIS, USA.
2.4. Fabricated Parts Ya Y Yb Y Y2 Y Y2 : Random 10% RT to be conducted on butt welds for Thk >10 mm.
3. Dosing/ Metering Pumps Ya Y Y Y1 Y Y3 : Seat Leakage Test for actuator operated valves shall be done by
operating the valve with job actuator.
4. Gate/ Globe/ Check Valves Ya Yb Y Y Y Y Y3, Y6
Y4 : Tests on Rubber Diaphragms shall be conducted per batch of Rubber mix
5. Dual Plate Check Valves Ya Yb Y Y Y Y Y6,
for Tensile, Elongation, Hardness, Thickness, Bleed Resistance. In
Y12
addition, Type Test for 50,000 cycles for each type of diaphragm shall
6. Diaphragm Valves Ya Y Y Y Y4, Y3
also be conducted.
7. Butterfly Valves (Low Pr.) Y Y Y Y Y Y3
7.1 Body & Disc (Cast Ya Yb Y Y6 : Blue Matching, Wear Travel for Gate Valves and reduced pressure test
7.2 Body and Disc (Fabricated) Ya Y Yb Y Y Y2 for check valves shall be conducted as per relevant standards.
7.3 Shaft Ya Yb Y Yc
TECHNICAL SPECIFICATION SUB-SECTION-IIIE-01

KHURJA SUPER THERMAL POWER PROJECT (2X660 MW) PAGE
SECTION – VI, PART-B PT & LET PLANT, DM PLANT & CWT
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 SYSTEM (MECHANICAL) 1 of 3
CLAUSE NO.
QUALITY ASSURANCE

Test/Check

Appd. Data Sheets
WPS/PQR/Welder
Performance Test
Assembly Fit up
/ Vacuum test
Material Test
Other Tests
Dimension
DPT/MPI
Remarks
Items / Components
RT
8. Plug/ Ball Valves (Low Pr.) Ya Yb Y Y Y Y Y Y3 Y7 : Heat Treatment of the Tank/Vessel shall be done per fabrication code
9. Blowers/ Compressors Ya Yb Y Y Y Y Yc, Yd requirement. Welded dished ends shall be stress relieved. Dished ends
10. Tanks/ Pressure Vessels Ya Y Yb Y Y Y8 Y Y Y7 manufactured by cold working shall also be stress relieved as per the
11. Rubber Lining Ya Y Y Y9 requirement of code.
Y8 : RT as per fabrication code requirements. However, dished ends welds, if
12. Strainers Ya Y Yb Y Y Y Y manufactured by using welded plates shall be subjected to 100% RT.
13. Pipe & Pipe Fittings Ya Y Y Y Y8 Y Y Y9 :Rubber Lining Mix shall be subjected to Bleed Resistance Test on mould
14. Agitators /Flash Mixer/ Ya Y Yb Y Y Y Y10 sample. Adhesion Test, Spark Test and Hardness Test for the Rubber
Flocculator lined jobs shall also be conducted.
15. Ventilation/Exhaust Fan Ya Yb Y Y Y1 Y Yc, Yd Y10 :Gear Boxes shall be checked for smooth No Load Operation at shop to
1
verify noise and vibration levels. Gear Ratio and Kerosene Leak Test
16. Hoists & Cranes Ya Y Yb Y Y Y8 Y Y shall also be conducted.
17. Wrapping & Coatig Y Y Y Y11 :One Fan of each type & size shall be routine performance tested as per
Material corresponding code for air flow, static pressure, total pressure, speed,
18. Package/ Split AC Y Y Y Y14 efficiency, power consumption, noise & temperature rise. Also all Fans
PT & LET PLANT: shall be subjected to run test of 4 hours during which noise, vibration,
temperature rise and current drawn shall be measured.
1. Clariflocculator / Reactor Ya Y Yb Y Y Y Y10 Y12 :Dry cycle test on valve spring for 1, 00,000 cycles shall be carried out as
Clarifier / Plate or Tube type test, if not carried out earlier, for the similar MOC, size and type of
Settler spring.
2. Chlorine Tonner / Chlorine Ya Y Yb Y Y Y8 Y Y Y13: :Test as per approved supplier practice.
Evaporator Y14 : Electronic leak test for condenser & evaporator unit.

CLAUSE NO.
QUALITY ASSURANCE

Test/Check

Appd. Data Sheets
WPS/PQR/Welder
Performance Test
Assembly Fit up
/ Vacuum test
Material Test
Other Tests
Dimension
DPT/MPI
Remarks
Items / Components
RT
3. Chlorinator / Ejector Ya Y Y Y Y Y
4. Chlorine Gas Filter Ya Y Y Y Y Note:
5. Pressure / Vacuum Relief Ya Y Y Y Y Y The complete Piping system along with valves & fittings shall be hydraulically
valve / Pressure Regulating tested at 1.5 times design pressure or 2 times working pressure whichever is
Valve higher after erection at site.
DM PLANT & CWT
SYSTEM:
1. Resins / Activated Carbon Y
2. Filter Membrane Y Y
3. RO Pressure tube Ya Y Y Y

SUB-SECTION–IIIE-02
INDUCED DRAFT COOLING

TOWERS

CLAUSE NO.
QUALITY ASSURANCE
INDUCED DRAFT COOLING TOWERS

SN
Test as per relevant Std/

TESTS/CHECK
Approved Data Sheets

Hydraulic / Water Fill
WPS/PQR/Welder
Assembly Fit up
Ultrasonic test
Material Test
Qualification
Other Tests
Dimension
Balancing
DPT/MPI
Remarks
ITEMS / COMPONENTS
RT
1 GEAR BOX Y1 Y Y2 Notes: Applicable tests are identified by ‘Y’.
1.1 Shaft and gear blanks Ya Y Yb a) One per Heat/Heat Treatment batch./Lot
2 FAN ASSEMBLY Y Y Y Y3 b) On machined surfaces only. Also 100% on Butt Welds
& 10% on Fillet Welds.
2.1 Fan hub Ya Y Yb Y4 Y3
c) UT shall be done for shafts with Diameter 50 mm or
2,2 Fan blades Ya Y Y3 above
3A DRIVE SHAFT (SS) FOR FAN Ya Y Y Yb Y Y 1. Backlash of the gears shall be checked.
3B CARBON FIBER DRIVE SHAFT SEE NOTE - 15 2. No load run test for 4 hours to check noise, vibration, oil
4 PVC FILL & DRIFT Y5 Y Y Y Y6 leakage and temperature rise.
ELIMINATOR 3. Proof load test, moment weight test on blades, blade
5 STOP LOG GATES Ya Y Yb Y Y Y7 track variation & tip clearances shall be checked.
Galvanizing tests as per relevant IS.
6 GATE/ GLOBE/ CHECK Ya Yb Y Y Y Y8 4. Random 10% RT on Butt welds of Fan Hub only (in
VALVES case fabricated).
7 BUTTERFLY VALVES Y Y Y Y Y Y9 5. PVC material shall meet the requirements of CTI
7.1 Body (Cast) , Disc (Cast) Ya Yb Y Bulletin STD-136. However impact test may be done as
per ASTM-D-256 and Flammability test may be done as
7.2 Body & Disc both fabricated Ya Y Y Yb Y Y10
per ASTM-D-635 with extinguishing type PVC. Density
7.3 Shaft Ya Yc Yb Y & VICAT softening temperature tests shall also be
8 ROLLED & WELDED PIPES. Ya REFER NOTE – 11 FOR ALL CHECKS
conducted.
9 WRAPPING & COATING OF PIPES Y12 Y Y 6. UV exposure shall be carried out on samples, at
9 HOISTS & CHAIN PULLEY Ya Y Y Y Y Y Y13 reputed third party laboratories as per ASTM -G26
BLOCKS method- C / standard specified in engineering portion of
10 VENTILATION FANS Ya Y Yc Yb Y Y Y Y Y14 the specification for cooling tower. Impact test before
and after UV exposure shall be conducted as per ASTM
D-256.

SECTION – VI, PART-B INDUCED DRAFT COOLING TOWERS
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 (MECHANICAL) 1 of 2
CLAUSE NO.
QUALITY ASSURANCE
7. Smooth operation and leak tightness shall be checked at site.

8. Blue matching, Wear travel for Gate valves & reduced pressure test for Check valves shall be conducted as per relevant standards.
9. For POD of Butterfly Valves refer respective engineering section of the technical specification.
10. In case of fabricated construction of Butterfly Valves and companion flanges, UT on Plates of Thickness 20 mm or above for body and disc, and RT on 100%
Butt welds shall also be carried out. Welders and WPS shall be qualified as per ASME section -IX. Stress reliving after complete welding shall be carried out
as per ASME Section - IX
11. Tests Quantum of Check
WPS, PQR, Welder Qualification Test 100%
DPT on root run 100% on pipes up to 1200 mm diameter
DPT after back gauging 100% on pipes above 1200 mm diameter
RT 5% (covering 100% of `T’-joints)
DPT on finished welds 10%
Hydraulic Test 100%, Test pressure = 1.5 times the design pressure or 2 times the working pressure which ever is higher.
Note:- After erection, the complete piping system shall be tested at 1.5 times, the design pressure or two times the maximum working pressure whichever
greater. No leakage/seepage is acceptable. Butt weld joints which would not be hydro-tested shall be subjected to 100% RT test.
12. Spark test, adhesion test and material tests for primer & enamel and coal tar tapes as per AWWA-C-203.
13. Ropes shall meet relevant Code requirements. All motions & safety features shall be tested at Works. Full load & 25% overload test shall also be conducted at
works. At site, Full load test shall be conducted with all motions and safety features.
14. One Fan of each type & size will be performance tested as per corresponding Code, for Air Flow, Static pressure, Total pressure, Speed, Efficiency, Power
Consumption, Noise, and Vibration & Temperature rise. Also, all fans shall be subjected to run test of 4 hours during which Noise, Vibration, Temperature rise
& current drawn shall be measured.
15. In case of Carbon Fiber Shaft, following checks are applicable
a. Manufacturer Test Certificate for Carbon Fiber and Resin
b. Dimensional Check, Run out Test and Dynamic Balancing Test on Finished Shaft
c. Torsional Test on Drive Shaft Assembly along with flange as a type test.
d. Type test for bonding strength at joint between shaft & shaft flange. In case of proven design, test reports of the previous test conducted shall be
reviewed.
e. UV test for demonstrating the compliance with respect to requirement of UV ray stabilization.
Acceptance criteria of the above tests shall be mutually discussed during pre-award discussions based on proven practices of the manufacturer or relevant
standards as available

SECTION – VI, PART-B INDUCED DRAFT COOLING TOWERS
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 (MECHANICAL) 2 of 2
CW AND RAW WATER SYSTEM

CLAUSE NO.
QUALITY ASSURANCE
Tests/Check
All Test as per relevant Std/

Functional/operational Test
Hydraulic / Water Fill test
Approved Data Sheets

Performance Test
Assembly/ fit up
Pneumatic Test
Ultrasonic test
Material Test
Dimensions
Other Test
Balancing
DPT/MPI
Remarks
Items / Components
RT
A. CW PUMPS, VT PUMPS & CENTRIFUGAL Y1 Y Y2
PUMPS (HORIZONTAL / VERTICAL), SUMP
PUMPS, SUBMERSIBLE PUMPS, DRAINAGE
PUMP
1 Shaft Ya Yb Yc Y Y
2 Impeller Ya Yb Y3 Y Yd
3 Suction Bell / Bowl Castings/ Inserts Ya Yb Y Y Y6
4 Discharge Head / Column Pipes / Distance Ya Yb Yc Y4 Y Y
Piece/Base Plate
5 Companion Flanges Ya Yb Yc Y5 Y
5 Thrust Bearing (Tilting Pad type) Ya Y Y Y Y Y
B. BUTTERFLY VALVES Y7 Y Y Y Y8 Y
1 Body & Disc (Cast) Ya Yb
2 Body & Disc (fabricated) Ya Yb Yc Y9
3 Shaft Ya Yb Yc
4 EH Actuators Ya Y Y Y Y Y
C. RE JOINTS Ya Y10 Y Y Y11
D. STOP LOG GATES Ya Yb Y Y Y12

SECTION – VI, PART-B CW AND RAW WATER SYSTEM
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 (MECHANICAL ) 1 of 5
CLAUSE NO.
QUALITY ASSURANCE
E. R & W PIPES Ya REFER NOTE 13
F. CRANES & HOISTS REFER BELOW FOR QA CHECKS ON EOT CRANES AND HOISTS
G. VENTILATION FANS Y Y Y
1) Hub/Blades/Casing Y Y Y
/Impeller
2) Shaft Ya Y Yc
3) Pre/Fine Filters Y14
H. GATE, GLOBE, CHECK VALVES, Ya Yb Yc Y15 Y Y Y Y Y15 Y
PIPINGS, & SPECIALITIES
Notes:
a One per Heat/ Heat Treatment Batch/ Lot.
b On machined surfaces only for Castings / Forgings and on Welds of Fabricated Components.
c For Shaft diameter. ≥ 50 mm and for plate thickness ≥ 25 mm
d Inter Grannular Corrosion (IGC) Test shall be carried out on SS Castings.
1 Trial assembly of all Vertical Turbine Pump components with Column Pipes, Discharge Head, and Motor Stool shall be carried at shop.
2 Performance testing of Pumps shall be carried out at shop, as per HIS standard to determine Head & Flow Characteristics.
3 In case of CW pump impellers, Radiographic Examination shall be conducted as per ASTM E186/446 with Severity Level 2 for Gas porosity,
Level 3 for Sand, Slag and Shrinkage. Cracks, Inserts and Mottling are not acceptable. Radiographic Examination should cover Vanes,
Vane Junctions, Full Radial depth of Hub & other accessible areas of the rest of the Impeller.
4 Random 10% RT to be conducted on butt welds for Thk ≥ 10 mm & ≤ 25 mm and 100% RT to be conducted on butt welds for Thk > 25 mm
(RT may be replaced by Ultrasonic Test due to constraint if any.) Stress relieving shall be carried out as per norms of ASME Section VIII.
5 Segmental Flanges exceeding 37.5 mm thickness shall be stress relieved after welding. All butt weld joints in segmental flange shall be
examined by Radiographic Test. (RT may be replaced by Ultrasonic Test due to constraint if any.)
Maximum number of segments shall be 4 only.

CLAUSE NO.
QUALITY ASSURANCE
6 No repair welding is permitted on Cast Iron / Alloy Cast Iron Castings.

7 Hydraulic Test of Body, Seat and Disc strength shall be carried out in accordance with latest edition of AWWA C-504. Actuator operated
Valves shall be checked for Seat Leakage by closing the Valve with Job Actuator. Seat Leakage test shall be carried out in both directions.
8 For Proof of Design Test refer respective chapters of engineering portion in the technical specification.
9 For Butterfly Valves of Fabricated construction (Sizes 600mm and above), butt Welds of thickness 20mm & above shall be subjected to
100% Radiography and Components shall undergo stress relieving.
10 During Hydraulic & Vacuum test at 30 mm Hg absolute in 3 different positions, the change in Circumference of the Arch should not be more
than 1.5%. Permanent Set, after 24 hours of the test, should not exceed 0.5% of Arch.
11 Tests on Rubber for Tensile, Elongation, Hardness, Hydraulic Stability as per ASTM D-471, Ozone Resistance test as per ASTM D-1149,
Aging test, Adhesion strength of Rubber to Fabric and Rubber to Metal shall be carried out.
12 Smooth operation and Leakage test shall be carried out at site.
13 Followings are the testing requirements for fabrication of pipes at site
Tests Quantum of Check
DPT on root run 100% for pipes up to 1200 mm diameter
DPT after back gauging 100% for pipes above 1200 mm diameter
RT 5%
DPT on finished butt weld joints 10%
Hydraulic Test 100%, 1.5 times the design pressure or 2 times the working pressure which ever is higher.
Note:- Butt weld joints which can not be hydraulic (pressure) tested; shall be examined 100% by Radiographic Test (RT)
14 Type / Routine tests as per requirements of BS-6540/ ASHRAE-52-76 for Dust arrestance shall be carried out.

CLAUSE NO.
QUALITY ASSURANCE
15
a. All pipes and fittings shall be tested as per applicable code.
b. All strainers shall be subjected to Hydraulic pressure test for leakage and Pressure drop v/s Flow for each type and size.
c. All valves shall be hydraulically tested for body, seat and back-seat (if applicable) as per relevant standard. Check valves shall also
be tested for leak tightness test at 25% of the specified seat test pressure.
d. Valves shall be offered for hydro test in unpainted condition.
e. Functional checks of the valves for smooth opening and closing shall also be done.
f. Anti-corrosive protection shall be tested as per applicable code.
EOT CRANES AND HOIST

1.00.00 HOOKS
All Tests including Proof Load Test as per relevant IS shall be carried out. MPI / DPT shall be done after proof load test.
2.00.00 STEEL CASTINGS

DPT on machined surface shall be carried out.
3.00.00 GIRDERS, END CARRIAGE, CRAB, GEAR BOX AND ROPE DRUM
UT shall be carried out on plates of thickness 25 mm and above as per ASTM A 435
NDT requirements on weldments shall be as follows
i. Butt Welds in Tension 100% RT & 100% DPT
ii. Butt Welds in Compression 10% RT & 100% DPT
iii. Butt Welds in Rope Drum 100% RT & 100% DPT
iv. Fillet Welds 10% DPT
4.00.00 FORGINGS ( Wheels, Gears, Pinions, Axles, Hooks, & Hooks Trunion)
All forgings greater than or equal to 50 mm diameter or thickness shall be subjected to ultrasonic testing (UT).
DPT / MPI shall be carried out after hard-facing and machining. Hardness and Case depth shall be measured

CLAUSE NO.
QUALITY ASSURANCE
5.00.00 WIRE ROPES

Wire ropes shall be tested as per relevant standard.
6.00.00 REDUCTION GEARS

Reduction Gears shall be tested for reduction ratio, backlash and contact pattern. Gear box shall be subjected to No – load run test for 4
hours to check for oil leakage, temperature rise, noise and vibration.
7.00.00 Chemical and Mechanical test of all components as per relevant material specification shall be carried out.
8.00.00 COMPLETE CRANE

The crane shall be completely assembled at shop for final testing. All tests as per IS 3177 shall be carried out at shop.
9.00.00 HOISTS
All Electric Hoist shall be tested as per IS 3938 and chain pulley blocks shall be tested as per IS 3832.

CHLORINE DI-OXIDE PLANT

CLAUSE NO.
QUALITY ASSURANCE
WPS/PQR/Welder Qualification
Test as per relevant Std/ Appd.

Tests/Check
Performance Test
Assembly Fit up
Material Test
Data Sheets
Other Tests
Dimension
DPT/MPI
Remarks
Items / Components
RT
1. Horizontal & Vertical Y Y Y1 Y LEGENDS:
Pumps Y Applicable
1.1. Casing Ya Yb Y Ya One per Heat/Heat Treatment batch./Lot
1.2. Impeller Ya Yb Yd Yb On machined surfaces only of castings and forgings. Also 100% after root run/
1.3. Shaft Ya Y Yc back gauging for butt welds and 10% after final butt welds and fillet welds.
2. Dosing/ Metering Pumps Ya Y Y1 Y Yc UT shall be done for shafts with Dia 50 mm or above & Plates of Thickness 20
mm or above.
3. Rubber lining Ya Y Y Y2 Yd Dynamic Balancing per ISO: 1940, Grade 6.3 minimum.
4. FRP Tank Y Y Y Y Y3 Y1 As per HIS, USA/ API 598 (In case of Metering Pump)
Note: Y2 Rubber Lining Mix shall be subjected to Bleed Resistance Test on mould
1) In case of items other than those identified above, the quality requirements sample. Adhesion Test, Spark Test and Hardness Test for the Rubber lined
shall be decided based on system design requirements. jobs shall also be conducted.
2) After erection, the complete Piping system along with valves & fittings shall Y3 The test for UV protection shall be carried out and shall be finalized with the
be hydraulically tested at 1.5 times design pressure or 2 times working approved supplier.
pressure whichever is higher.

SECTION – VI, PART-B CHLORINE DI-OXIDE PLANT
LOW PRESSURE PIPING

CLAUSE NO.
QUAL ITY ASSURANCE
LOW PRESSURE PIPING

PIPES, FITTINGS, BENDS, VALVES, COATING-WRAPPING, STRAINERS EXPANSION,
JOINTS, TANKS, FASTENERS, LINING ETC.
Tests/Check
Functional/operational
Assembly Fit up
WPS/ WQS/PQR
Pneumatic Test
All Tests as per

Ultrasonic Test
DPT/MPI / RT
Material Test
t Std
Dimensions
Other Tests
REMARKS
Test
Test
Items /
l
Components
1 Ya Yb Y1 Y Y
Pipes & Pipe Fittings
2 Diaphragm Valves Ya Y5 Y Y6
3A Cast Butterfly Valves Y Y Y Y Y7
(Low Pressure)
Body Ya Yb
Disc Ya Yb
Shaft Ya Y Yc
3B Fabricated Butterfly Valves REFER NOTE 14
4 Gate/ Globe/Swing Check / Ya Yb Yc Y5 Y Y Y Y Y8
Ball Valves
5 Dual Plate Check Valves Ya Yb Yc Y Y Y Y Y Y4
6 Rolled & Welded Pipes and Ya Y3 Y Y3 Y Y3&15 Y
Mitre Bends
7 Coating & Wrapping of Pipes Y2 Y2
8 Tanks & Vessels Ya Yb Y Y Y Y16
9 Strainers Ya Yb Y# Y Y11 #For Fabricated Strainer
10 Rubber Expansion Joints Ya Y12 Y Y Y13
11 Internal Lining of Pipes Ya Y Y9
12 Site Welding Y10 Y Y
NOTES (MEANING OF SUPERSCRIPTS)

a One per heat/heat treatment batch/lot.
b On machined surfaces only for castings and on butt welds.
c For shaft/spindles > or = 40 mm
1 100% Hydraulic test shall be carried out. Weld joints not subjected to hydraulic test shall be subjected
to 100% RT
2 Spark Test, Adhesion Test and Material Test for primer and enameled & Coal Tar Tapes as per
AWWA-C-203-91/ IS-10221/IS 15337 as applicable.
3 Followings are the testing requirements for fabrication of pipes at site
TESTS QUANTUM OF CHECKS
DPT on root run 100% for pipes up to 1200 mm diameter
DPT after back gauging 100% for pipes above 1200 mm diameter

SUB-SECTION-IIIE-05 PAGE
LP PIPING PACKAGE 1 OF 3
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 (MECHANICAL)
CLAUSE NO.
QUAL ITY ASSURANCE
RT / UT by TIME OF FLIGHT 5% ( 100% of T Joints)

DEFRACTION (TOFD) Technique
DPT on finished butt weld joints 10%
Hydraulic Test 100%, 1.5 times the design pressure or 2 times the working-
pressure whichever is higher.
4 Dry Cycle Test on Dual Plate Check valve spring for one lakh Cycles shall be carried out as a type
test. If Dry Cycle test carried out earlier for same material & diameter, Test report shall be reviewed.
5 Seat Leakage Test for Actuator Operated Valves, shall be done with by closing the valves with
actuator.
6 Tests on rubber parts shall be conducted per batch of rubber mix for tensile, Elongation, hardness,
adhesion, spark test, bleed resistance test. In addition, type test for 50,000 cycles of each type of
diaphragm shall also be conducted.
7 Hydraulic Test of Body, Seat and disc-strength shall be carried out in accordance with governing
design standard in presence of owner / owner’s representatives. Actuator operated valves shall be
checked for Seat Leakage by closing the valves with actuator. For Proof of Design Test refer
respective chapters of engineering portion in the technical specification.
8 Blue matching, wear travel for gates, valves, pneumatic seat leakage, and reduced pressure test for
check valves shall be done as per relevant standard. Maximum allowable vacuum loss is 0.5 mm of
Hg abs. for valves to be tested for vacuum operation for internal pressure 25 mm of Hg abs. for a
period of 15 minutes. Fire safe test for ball valve shall be done wherever specified. In case of already
carried out, the test report shall be submitted for review and acceptance by owner / owner’s
representatives. Valves shall be offered for hydro test in unpainted condition.
9 Tensile, Elongation, Hardness, Specific Gravity, Lining Thickness, Humidity Check, Pipe temperature
check, Adhesion Test and Holiday Detection Test etc as per applicable standard shall be done for all
lining material and application.
10 10% of welds (Root and finished welds) shall be subjected to DPT. (100% DPT for compressed air line
and boiler & deaerator fill line.).
11 Pressure drop across the strainer for each type and size as a special test shall be carried out. In case
of already carried out, the test report shall be submitted for review and acceptance by owner / owner’s
representatives.
12 During hydraulic and vacuum tests at 25mm Hg abs in 3 positions, the change in the circumference of
arch should not be more than 1.5%. 24 hrs after the test permanent set in dimension should not
exceed 0.5%.
13 Tests on rubber for tensile, elongation, hardness, hydraulic stability check as per ASTM D 471, ozone
resistance test as per ASTM D 1149 aging test and adhesion strength of rubber to fabric, rubber to
metal adhesion shall be carried out.
14 In addition of all tests as indicated for Cast Butter Fly valve being applicable for fabricated butterfly
valves, following test shall be done for Fabricated Butter Fly Valve:
a. UT as per ASTM A-435 on plate material for body and disc shall be carried out for plate
thickness 25mm and above.
b. 100% RT and DPT as per ASTM, Section-VIII, Division-I, on butt joins of body and disc. 10%
DPT on other welds shall be done.
c. Post weld heat treatment as per ASME, Section-VIII, Division-I on butt joints of body and disc.
d. Welders and WPS shall be qualified as per ASME- section IX

CLAUSE NO.
QUAL ITY ASSURANCE
15 Maximum number of segments in segmental flanges shall be four (04) only. All butt weld joints in the
segmental flanges shall be examined by RT/UT.
Segmental flanges exceeding 37.5 mm thickness shall be stress-relieved as per norms of ASME
Section VIII after welding.
16 For pressure vessel welds RT shall be done as per design code requirements.

AIR CONDITIONING &

VENTILATION SYSTEM

CLAUSE NO.
QUALITY ASSURANCE
CLAUSE QA MODULE FOR AIR CONDITIONING AND VENTILATION SYSTEM

NO
1.00.00 CHILLING UNIT
1.01.00 REFRIGERANT COMPRESSOR (SCREW/SCROLL)
1.01.01 Hydraulic/Pneumatic test of castings of casings shall be carried out. No leakage
shall be permitted.
1.01.02 DPT of screw, impeller, shaft, vanes, casing etc. after machining shall be carried
out.
1.01.03 All rotating parts of screw and centrifugal compressor shall be dynamically
balanced to ISO 1940 Gr. 6.3.
1.01.04 Leak tightness & vacuum check for chilling units / compressor in assembled
condition shall be carried out. No leakage shall be permitted.
1.01.05 Performance test of assembled compressor and Chiller assembly shall be done to
check for following :
1.01.05.01 No load air run (free run) test of all types of compressor to check FAD (Free air
delivery), Noise, Vibration & Temp. rise of bearing & body.
1.01.05.02 Functional run test for Chiller assembly shall be carried out.
1.02.00 CONDENSER & EVAPORATOR

1.02.01 DPT shall be carried out on welds if applicable
1.02.02 10% RT of butt weld joint on shell shall be carried out if applicable.
1.02.03 Dimensional check including tube hole dia, ligament, pitch etc. shall be carried out.
1.02.04 Mock-up test of tubes to tube sheet expansion shall be carried out. In case such
test is already carried out for similar tube/tube sheet thickness and materials,
records for the same shall be furnished for review and acceptance of owner /
owner’s representatives.
1.02.05 Hydraulic/Pneumatic test of Shell Side and Tube Side of condenser and
evaporator as applicable shall be carried out. ‘No leakage’ shall be permitted
2.00.00 FANS
2.01.00 20% DPT of welding on fan hub, blades, casing and impeller as applicable shall be
carried out.
2.02.00 DPT of fan shafts shall be carried out after machining.
2.03.00 UT of fan shafts (diameter equal to or above 40mm) shall be carried out.
2.04.00 Rotating components of all fans shall be dynamically balanced to ISO-1940 Gr. 6.3
2.05.00 All Fans shall be subjected to run test for 4 hrs. or till temperature stabilization is
reached. Vibration, Noise level, Temp. rise and current drawn shall be measured
during the run test.
2.06.00 One fan of each type and size will be performance tested as per corresponding
BIS /AMCA for Air flow, Static Pressure, Speed, Efficiency, Power Consumption,
Noise, Vibration and Temp. Rise.
3.00.00 AIR HANDLING UNIT

3.01.00 For Fans refer tests as mentioned at 2.00.00
3.02.00 One per type of assembled AHU (AHU casing and fan assembly) shall be
subjected to free run test. Noise, Vibration and Temp. Rise of bearing shall be
measured during run test.
3.03.00 All cooling coil shall be pneumatically tested and no leakage shall be permitted.

TECHNICAL SPECIFICATION SUB-SECTION-IIIE-06 PAGE
(2X660 MW) AC & VENTILLATION SYS
BID DOC NO.: THDC/RKSH/CC-9915-373 (MECHANICAL)
CLAUSE NO.
QUALITY ASSURANCE
4.00.00 CENTRIFUGAL PUMP

4.01.00 UT on pump shaft (dia equal to or above 40 mm) and MPI/DPT on pump shaft and
impeller after machining shall be carried out.
4.02.00 All rotating components of the pumps shall be dynamically balanced to ISO-1940
Gr. 6.3
4.03.00 A standard hydrostatic test shall be conducted on the pump casing with water at
1.5 times the shut off pressure on the head characteristics curve or twice the rated
pressure whichever is higher, for a minimum duration of 30 minutes.
4.04.00 Standard Running Test
4.05.01 All pumps shall be tested in the manufacturer’s works preferably with contract
motor for capacity, efficiency, head and brake horse power. Pump shall be given
running test over the entire operating range covering from the shut-off head to the
maximum flow. The duration of test shall be minimum one (1) hr. A minimum of
seven readings approximately equidistant shall be taken for plotting the curves
with one point at design flow. Testing of pumps shall be in accordance with
stipulations of Hydraulic Institute Standard (HIS) and/or as per applicable Indian
Standard or equivalent. Acceptance norms shall be as per approved datasheet &
HIS standard only.
4.05.02 Noise and vibration shall be measured at shop for reference purpose only.
4.05.03 Pumps shall be subjected to strip down examination visually to check for
mechanical damages after testing at shop in case abnormal noise level and/or
excessive vibration are observed during the shop test.
4.05.04 NPSH test shall be conducted with water as the medium, if required as per
approved data sheets.
5.00.00 LOW PRESSURE AIR DISTRIBUTION SYSTEM

5.01.00 Functional test for fire damper along with solenoid shall be done.
5.02.00 Prototype tests report of fire damper (duly approved/accepted by owner / owner’s
representatives.) for each type and size as per UL-555 for fire rating shall be
furnished.
5.03.00 Site Test- After completion, all ducting system shall be checked/tested for air
leakages/tightness (smoke test) at site.
6.00.00 INSULATION
6.01.00 Insulation material shall be tested for all mandatory tests only as per relevant
code/standard.
6.02.00 Thermal conductivity tests (for thermal insulation only) shall be done once in 12
months for insulation material manufactured during 12 months period for the same
density and thickness of material as applicable as per IS:3346 or equivalent
standard.
6.03.00 XLPE/Nitrile Rubber: Thermal conductivity tests (for thermal insulation only) shall
be done as per relevant code for the same density and thickness of material and
validity of test shall be as per relevant standard.
7.00.00 COOLING TOWER

7.01.00 UT of fan shaft and drive shaft (dia equal to or above 40mm) shall be carried out.
7.02.00 DPT of fan hub and shafts shall be carried out after machining.
7.03.00 Color of fills shall be as per approved data sheet.

CLAUSE NO.
QUALITY ASSURANCE
7.04.00 Fan assembly shall be statically/dynamically balanced.

7.05.00 Cooling Towers being supplied to site in assembled condition shall be subjected to
run test at shop to measure FAD, Noise & Vibration. For Cooling Towers being
supplied in knocked-down condition, these tests shall be done at site.
8.00.00 AIR FILTERS

8.01.00 Pre/Fine filters shall be tested for initial and final pressure drop Vs flow and
average synthetic dust weight arrestance as per the requirement of BS
6540/ASHARE-52-76/EN779.
HEPA (Absolute) filters shall be tested as per applicable code.
9.00.00 PIPES & FITTINGS

9.01.00 All pipes and fittings shall be tested as per applicable codes / standard.
9.02.00 Site test- Pipes shall be tested at site hydraulically/pneumatically as per application
requirement
10.00.00 VALVES & SPECIALTIES

10.01.00 Visual and dimensional check of valves as per relevant codes and approved
drawing.
10.02.00 All the water line valves shall be hydraulically tested for body, seat and back seat
(wherever provided) as per the relevant standard to which these valves are
supplied irrespective of the working pressure for which these valves are selected.
Check valves shall also be tested for leak tightness test at 25% of the specified
seat test pressure.
10.03.00 Refrigerant line valves shall be pneumatically tested for body and seat leakage
test.
10.04.00 Valves shall be offered for hydro test and pneumatic test in unpainted condition.
10.05.00 Functional check of the valves for smooth opening and closing shall be done.
10.06.00 Performance test to check pressure drop Vs flow shall be carried out for one valve
of each type, size and rating for ‘Balancing Valve’/Globe Valves with orifice.
11.00.00 SPLIT/CASSETTE / WINDOW AC/ PAC/PEC

11.01.00 Split/Cassette/ Window AC will be accepted on the basis of Manufacturer Standard
Guarantee and Warrantee certificate.
11.02.00 PAC/PEC: Each Unit shall be subjected to production routine Test excluding
performance test carried out as per relevant standard.
11.03.00 Performance test of PAC/PEC shall be carried out as per relevant standard on one
unit of each type and rating at site.
12.00.00 Air Washer and Unitary Air Filter (UAF)
12.01.00 Random 10% DPT on weld joints shall be carried out

12.02.00 Hydraulic test of pressure parts at 1.5 times the design. Pressure and water fill test
of tanks shall be carried out
12.03.00 Trial assembly of Air washer/UAF for one of each size shall be done in shop.

FIRE DETECTION & PROTECTION

SYSTEM

CLAUSE NO.
QUALITY ASSURANCE
1.00.00 FIRE DETECTION & PROTECTION SYSTEM
1.01.00 HYDRANT SYSTEM: Shop Tests
1.01.01 Hydrant Valve:
(a.) All valves shall be hydro tested for body and seat.
(b.) Capacity test / flow test shall be done as per relevant standard.
1.01.02 Water Monitor, Hoses, Branch Pipes, Couplings and Nozzles:
(a.) All tests including hydraulic test shall be done as per relevant Indian /
International standard.
1.01.03 For Pumps, Diesel Engine, refer the requirements are indicated separately.
1.02.00 HIGH / MEDIUM VELOCITY WATER SPRAY : Shop Tests
1.02.01 For Pipes, Fittings, Valves and specialties, requirements are indicated
separately.
1.02.02 Deluge Valves and Spray Nozzles
(a.) All valves shall be hydro tested for body and seat.
(b.) Performance test / functional test of ‘Deluge Valves’ and ‘Spray

Nozzles’ shall be carried out.
1.02.03 Detectors: All ‘Detectors’ shall be tested as per relevant Indian / International
Standards. Detectors shall also meet the requirements of UL / FM /
LPC/VDS etc.
1.03.00 HORIZONTAL CENTRIFUGAL PUMP:
1.03.01 SHOP TESTS
(a.) UT on Pump Shaft (>= 50mm dia ) and MPI / DPT on Pump Shaft and
Impeller shall be carried out.
(b.) All rotating components of the pumps shall be statically and dynamically
balanced as per ISO: 1940 Gr. 6.3 or better.
(c.) Hydraulic test shall be conducted on pump casing with water at 1.5
times the shut off pressure or twice the rated pressure whichever is
higher for a minimum duration of 30 minutes.
(d.) Performance test and Standard Running test:
(1.) All the pumps shall be tested in the manufacturer’s works for
capacity, efficiency, head and brake horsepower. Pump shall be
KHURJA SUPER THERMAL POWER PROJECT SUB-SECTION-IIIE-07
(2X660 MW) FIRE DETECTION &
WATER SYSTEM PACKAGE PROTECTION SYSTEM
CLAUSE NO.
QUALITY ASSURANCE
given running test over the entire operating range covering the
shut off head to the maximum flow. The duration of test shall be
minimum one hour. A minimum of five readings approximately
equidistant shall be taken for plotting the curves with one point
at design flow. Testing of pump shall be in accordance with
stipulations oh Hydraulic Institute Standard (HIS) and / or as per
applicable Indian Standard or equivalent. Tolerance of
parameters shall be as per HIS.
(2.) The test shall be conducted at the rated speed preferably with
the type tested contract drive motor being furnished. However,
in case of any limitation test bed motor duly calibrated can also
be used.
(3.) Noise and vibration shall be measured.
(4.) Pumps shall be subjected to strip down examination visually to

check for mechanical damages after testing at shop in case
abnormal noise level / vibration performance are observed
during the shop test.
1.04.00 COMPRESSION IGNITION DIESEL ENGINE
1.04.01 Shop Tests:
(a.) All pressure parts shall be subjected to hydraulic pressure tests at 1.5
times the design pressure.
(b.) All Diesel engine shall be performance tests as per relevant IS /

equivalent code.
1.04.02 Performance Test :
Performance test of diesel engine shall be carried out as per BS-5514 to

determine the rated power and specific fuel consumption and governor’s
function. Performance test of engine in shop shall be done with actual job
accessories for minimum four hours (three hours for full load and one hour for
over load at 110% of full load). All the engine parameters like RPM, inlet airs
temp and pressure, water inlet and outlet temp. and pressure, lub. Oil pressure,
fuel consumption, ambient condition shall be measured and recorded for every
half an hour. No positive tolerance shall be allowed on the specific fuel
consumption (contractor to specify in the offer.)
1.05.00 STORAGE VESSELS: Shop Test
1.05.01 Atmospheric Tank
(a.) All weld joints shall be DP Tested and complete tanks shall be water fill
tested.

CLAUSE NO.
QUALITY ASSURANCE
(b.) All atmospheric storage tanks fabricated and erected at site shall be
subjected to all tests (Hydro, NDT, and Vacuum) according to design
code as applicable.
1.06.00 PIPING, VALVE AND SPECIALITIES
1.06.01 SHOP TESTS
(a.) All pipes and fittings shall be tested as per applicable code.
(b.) DPT of pipe welds (in case of rolled and welded pipes only) shall be
carried out for root and finished welds.
(c.) All strainers shall be subjected to hydraulic pressure test for leakage
and Pressure drop v/s Flow for each type and size.
(d.) All valves shall be hydraulically tested for body, seat and back seat (if
applicable) as per relevant standard. Check valves shall also be tested
for leak tightness test at 25% of the specified seat test pressure.
(e.) Valves shall be offered for hydro test in unpainted condition.
(f.) Functional checks of the valves for smooth opening and closing shall
also be done.
(g.) Anti-corrosive protection shall be tested as per applicable code.
1.07.00 FOAM SYSTEM:
1.07.01 SHOP TEST
(a.) For tanks, pipes, fittings, valves and specification refer respective
section of this specification.
(b.) System shall meet any other test requirements as specified in TAC / UL
/ FM / NFPA / VDS etc.
1.08.00 PORTABLE & MOBILE FIRE EXTINGUISHERS
1.08.01 SHOP TEST
(a.) All fire extinguishers shall be tested as per relevant standard.
(b.) Performance / function test shall be carried out on sampling basis as

per relevant code / standard.
1.09.00 EOT Crane/ Electric Hoist/Chain pulley block

a) Chain pulley Blocks shall be tested as per IS: 3832.
b) Electrical wire rope hoists shall be tested as per IS : 3938

CLAUSE NO.
QUALITY ASSURANCE
c) Following NDT requirements shall be met :

(i) 100% RT of Butt welds in tension and 10% RT of butt
welds in compression.
(ii) DP at random on all weldments.
d) Deflection, load, overload & travel check on EOT crane assembly

shall be carried out as per IS:3177.
1.10.00 SITE TESTS:
(a.) Fire Extinguishers: A performance demonstration test at site of five (5)

percent or one (1) number, whichever is higher, of each type and
capacity of the extinguisher shall be carried out by the contractor. All
consumables and replaceable items require for the contractor without
any extra cost to employer would supply this test would be supplied by
the Contractor without any extra cost to employer.
(b.) Foam System :
(1.) The operation of the foam generation shall be demonstrated by

the Vendor after installation either in the tank to be protected or
in the dyke area.
(2.) Any other equipment found necessary for the demonstration of

the above testing like portable foam water monitor hose etc.
shall be provided by the contractor during testing.
(c.) Piping Protection:
(1.) Thickness, Holiday by spark test, Adhesion test shall be carried

out as per relevant standard.
(2.) Complete piping shall be Hydro pressure tested, at 1.5 X DP or

2 X MWP whichever is higher, before protection.
(d.) Welding of Pipes:
(1.) ERW Black / rolled welded:
100% DPT on root of butt and finish weld of butt and fillet.
RT on 10% randomly selected joints shall be carried out (for
underground piping).
(2.) GI Pipes
Welding on GI Pipes in general shall not be done. Welding of GI

Pipes, if permitted by design, (butt / socket / fillet weld) shall be
done strictly as per approved drawing and procedure approved
by EMPLOYER Engineering. For all such welds 100% DP test
and random 1% RT shall be done.

CLAUSE NO.
QUALITY ASSURANCE
1.11.00 Clean Agent Direct / Indirect Low Pressure Automatic Fire Detection &
Suppression System with Linear Pneumatic Heat Detection Tube
1) Shop Tests
i) Complete system selection as well as supplier of major items /

components (if applicable) shall be UL / FM / VDS / LPCB.
ii) Storage cylinders / Containers with all accessories, valves, tubing,

nozzles (if applicable) shall be subjected to all tests as per the
design code to which they are supplied and shall also meet the
requirements of UL / FM / VDS / LPCB.
iii) Storage containers shall also meet the statutory requirements of

approval / acceptance by CCE (if applicable).
iv) Tests for fill density, weight, leakage, etc. shall be done for charged
cylinders / containers.

PART-B (QA-ELECTRICAL)

SUB-SECTION TITLE
PART – B (QA-ELECTRICAL)
IIIE – 08 MOTOR
IIIE – 09 LT SWITCHGEAR & BUSDUCT
IIIE – 10 CABLING, EARTHING, LIGHTNING PROTECTION
IIIE – 11 CONTROL CABLES
IIIE – 12 LT POWER CABLES
IIIE – 13 H.T. CABLES
IIIE – 14 LIGHTING
IIIE – 15 OUTDOOR TRANSFORMER
IIIE – 16 BATTERY AND BATTERY CHARGER
IIIE – 17 CONSTRUCTION POWER – RING MAIN & LT S/S
IIIE – 18 DRY TYPE TRANSFORMER
IIIE – 19 VARIABLE FREQUENCY DRIVES

MOTOR

CLAUSE NO.
QUALITY ASSURANCE
MOTOR
TESTS/CHECKS
/General
per IS-325/IS-4722 /IS- 9283/IS

Routine & Acceptance tests as
2148/IEC60034\IEC 60079-I/ IS-
&
&
Tan delta, shaft voltage
Hydraulic/Leak/Pressure Test
thickness
Welding/Brazing(WPS/PQR)
Electrical Characteristics
Magnetic Characteristics
Thermal Characteristics
Mech/Chem. Properties
polarization index test

Physical Inspection
Dynamic Balancing
Make/Type/Rating
NDT /DP/MPI/UT
shade,
Heat Treatment
Metallography
Dimensional
Over speed
adhesion
Vibration
Run out
12615
Visual
TEMS/COMPONENTS
Paint
Plates for stator frame, end Y Y Y Y Y Y
shield, spider etc.
Shaft Y Y Y Y Y Y Y
Magnetic Material Y Y Y Y Y Y Y
Rotor Copper/Aluminium Y Y Y Y Y Y
Stator copper Y Y Y Y Y Y Y
SC Ring Y Y Y Y Y Y Y Y
Insulating Material Y Y Y Y Y
Tubes, for Cooler Y Y Y Y Y Y Y
Sleeve Bearing Y Y Y Y Y Y Y
Stator/Rotor, Exciter Coils Y Y Y Y Y
Castings, stator frame, Y Y Y Y Y Y
terminal box and bearing
housing etc.
Fabrication & machining of Y Y Y Y Y
stator, rotor, terminal box

SECTION – VI, PART-B MOTOR
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 (ELECTRICAL ) 1 of 2
CLAUSE NO.
QUALITY ASSURANCE
Wound stator Y Y Y Y
Wound Exciter Y Y Y Y
Rotor complete Y Y Y Y Y
Exciter, Stator, Rotor, Y Y Y
Terminal Box assembly
Accessories, RTD, BTD,CT, Y Y Y
Space heater, antifriction
bearing, gaskets etc.
Complete Motor Y Y Y Y Y Y Y1 Y
Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality Plan indicating the practices & Procedure followed
along with relevant
supporting documents during QP finalization. However, No QP for LT motor up to 50KW.
2. Additional routine tests for Flame proof motors shall be applicable as per relevant standard
3. Makes of major bought out items for HT motors will be subject to Employer approval.
4. Y1 = for HT Motor / Machines only.

SECTION – VI, PART-B MOTOR
LT SWITCHGEAR & BUSDUCT

CLAUSE NO.
QUALITY ASSURANCE
SQE _10
LT SWITCHGEAR
( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL MOTOR
STARTERS)
ATTRIBUTES / CHARACTERIS-
Functional & Operational Features as per
Degree of Protection Routine test as per

TICS
Paint Shade, Adhesion, Thickness & Finish

Item to conform to relevant Standards
All Routine tests as per spec. & IS

Make, Model, Type, Rating & TC
Pretreatment as per IS 6005

Mechanical Properties
Dimensions & Finish
Chemical properties
Electrical properties
Functional Checks
Milli-volt drop Test
IR – HV – IR Test
Spec.
spec
ITEMS/ COMPONENTS/ SUB
SYSTEM ASSEMBLIY
Sheet Steel (IS : 513) Y Y Y Y Y
Aluminum Bus bar Material Y Y Y Y Y Y

(IS : 5082)
Copper Bus bar Material Y Y Y Y Y Y
(IS : 613)
Support Insulator Y Y Y Y Y
Air Circuit Breaker ( IS: 13947) Y Y Y Y Y Y Y
Energy Meters ( IS : 13010, 13779 Y Y Y Y Y Y
)
Power & Aux. Contactors Y Y Y Y Y
(IS : 13947 )
Protection & Aux. Relays Y Y Y Y Y Y
(IS : 3231)
(IEC 60255 / IEC 61850)
Control & Selector Switches Y Y Y Y Y
( IS : 13947)
CT’s & PT’s ( IS 2705 / 3156) Y Y Y Y
MCCB ( IS : 13947 ) Y Y Y Y
Indicating Meters ( IS : 1248 ) Y Y Y Y Y Y
Indicating Lamps ( IS : 13947 ) Y Y Y Y Y
Air Break Switches Y Y Y Y Y
( IS : 13947 )
Control Terminal Blocks Y Y Y Y

(2X660 MW) LT SWITCHGEAR &
SECTION – VI, PART-B BUSDUCT 1 OF 3
BID DOC NO.: THDC/RKSH/CC-9915-373 (ELECTRICAL)
CLAUSE NO.
QUALITY ASSURANCE
LT SWITCHGEAR
( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL
MOTOR STARTERS)
ATTRIBUTES /
Functional & Operational Features as
Paint Shade, Adhesion, Thickness &
Degree of Protection Routine test as per

CHARACTERIS-TICS
Item to conform to relevant Standards
All Routine tests as per spec. & IS

Make, Model, Type, Rating & TC

Dimensions & Finish
Chemical properties
Functional Checks
Milli-volt drop Test
ITEMS/ COMPONENTS/ SUB
SYSTEM ASSEMBLIY
per Spec.
Finish
spec
Fuse ( IS 13703) Y Y Y Y
Control Transformer Y Y Y Y Y Y
( IS : 12021)
Push Buttons ( IS : 4794 ) Y Y Y Y Y
Transducer ( IEC : 60688) Y Y Y Y Y Y
MCB ( IS : 8828) Y Y Y Y Y
Breaker Handling Trolley Y Y Y Y Y Y
Synthetic Rubber Gasket Y Y Y Y Y

(IS : 11149 )
LT SWITCHGEAR Y Y Y Y Y Y Y Y Y Y
( IS : 8623 )
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality
Plan indicating the practice and procedure along with relevant supporting documents.
2. Makes of all major Bought Out Items will be subject to approval.

CLAUSE NO.
QUALITY ASSURANCE
LT BUSDUCT
ATTRIBUTES ,
Galvanizing Test as per IS 2629/ 2633/

Paint Shade, Thickness, Adhesion &
Degree of Protection routine test as per

Weld Quality Check ( DP test & x-ray
CHARACTERISTICS
WPS Approval, Welder Qualification
Tightness by Torque measurement

Item to conform to relevant IS
Dimension & Surface Finish
Make, Type, Rating & TC
Phase Sequence Check

Electrical Clearances
Chemical Properties
Electrical Properties
ITEM, COMPONENTS, SUB
spec.
SYSTEM ASSEMBLY
Aluminum Sheets / Plates / Strips Y Y Y Y Y Y Y

/ Flexibles / tubes
( IS : 5082 / 737 )
CRCA Flats / ISMC ( IS 2062 ) Y Y Y Y Y
Neoprene / Synthetic Rubber Y Y Y Y
Gaskets ( IS 11149 / 3400 )
Rubber Bellows (IS : 3400) Y Y Y Y
Support Insulator ( BS : 2782, Y Y Y Y
IEC : 660, IS : 10912 )
Galvanized Structure & GI Y Y Y Y
Earthing Flat
(IS : 2629 / 2633 / 4749 )
Space Heater & Thermostat Y Y Y
LT Busduct (IS : 8623 PART 2) Y Y Y Y Y Y Y Y Y Y Y
Notes:
Plan indicating the practice and
procedure along with relevant supporting documents.
2. Makes of all major Bought Out Items will be subject to approval.

CABLING, EARTHING, LIGHTNING

PROTECTION

CLAUSE NO.
QUALITY ASSURANCE
CABLING, EARTHING, LIGHTNING PROTECTION

ATTRIBUTES /
relevant standard &
Acceptance tests as per relevant standard &

CHARACTERISTICS
Constructional feature as per Specification

Paint shade, paint thickness, adhesion
Bought out items/Bill of material

Galvanise Test (If Applicable)
Routine tests as per

Pre-treatment of sheet
Deflection test*
Surface finish
IP protection
specification
specification
Proof load*
Dimension
Functional
HV & IR
ITEMS/COMPONENTS /
SUB SYSTEMS
Wall Mounted-Lighting Panel Y Y Y Y Y Y Y Y Y Y Y Y

(IS-513, IS:5, IS:2629, 2633,
6745)
Switch box/junction box/ Y Y Y Y Y Y Y Y Y Y Y Y
Receptacles Panel (IS-513,
IS:5, IS:2629, 2633, 6745)
Cable glands(BS-6121) Y Y
Cable lug Y Y
Lighting wire (IS-694) Y Y
Flexible conduits Y Y Y
Conduits (Galvanise & Epoxy) Y Y Y Y Y
IS-9537 & IS-2629, 2633,
6745
RCC Hume Pipe (IS-458) Y
Cable termination & straight Y Y Y
through joint (VDE-0278)
Cable Trays, bends, tees, Y Y Y Y Y Y Y Y Y Y Y
crosses, Flexible supports
system & accessories IS-513,
2629,2633,6745
Trefoil clamp Y Y
GI flats for earthing & lighting Y Y Y Y Y
protection (IS 2062, 2629,
6745,2633)
GI wire (IS-280) Y Y
Fire Sealing System (BS – Y Y Y
476)
Note:1.This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality Plan
indicating the practice and procedure along with relevant supporting documents.
2.* Deflection Test on cable trays and Proof Load test on cable trays support system will be as per details
given in the technical specification & approved MQP. The above acceptance tests shall be done only on one
sample from each size of offered lot. This test is not applicable on bends, tees & crosses.
3. Make of all items will be subject to Employer approval.

(2X660 MW) CABLING, EARTHING,
WATER SYSTEM PACKAGE LIGHTNING PROTECTION
(ELECTRICAL)
CONTROL CABLES

CLAUSE NO.
QUALITY ASSURANCE
Control Cables
Armour coverage, cross
T.S & elongation before &
&
Routine & Acceptance Tests
finish/
gap
Sequential marking/ Batch
on
ageing on outer sheath &
Constructional requirements
feature as per specification
Attributes /
Spark Test(as applicable)

Characteristics
Dimension/surface finish
Anti termite coating

Lay length & Sequence
Chemical Composition
standard
Mechanical properties
per relevant standard
Make, Type & T.C as
looseness,
surface
between two wires
Thermal stability
wooden drums
specification
cable length
FRLS Tests
insulation
marking/
relevant
as per
Item / Components /
over,
after
Sub System Assembly
Copper (IS-8130) Y Y Y Y Y
PVC insulation Compound (IS: 5831) Y Y Y Y Y
FRLS PVC Compound Y Y Y Y Y
(IS-5831, ASTM-D2843, IS10810( Part 58),
IEC-60754 Part-1)
Extrusion & curing /Manufacturing of Core Y Y Y
Core Laying Y
Armour wire/strip Y Y Y
Inner sheath Y Y
Armouring Y Y
Outer Sheathing Y Y
Finished Cable (IS-5831, ASTM-D2843, IS10810( Y Y Y Y Y Y Y Y
Part 58), IEC-60754 Part-1, IEC 60332 part III cat B)
Wooden drum(IS-10418) /Steel Drum Y Y Y
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with
relevant supporting documents.
2. Make of all major Bought out items will be subject to Employer approval.

SECTION – VI, PART-B CONTROL CABLES
CLAUSE NO.
QUALITY ASSURANCE
ROUTINE TESTS Following routine tests shall be carried out on each drum of finished cables for all sizes.
1) Conductor Resistance test

2) High voltage test
ACCEPTANCE TESTS Following Acceptance tests shall be carried out on each size of cables, in the offered lot.
A) For Conductor (as per sampling plan mentioned in IS: 1554)

1) Annealing test (Copper)
2) Resistance test
B) For Armour Wires / Formed Wires ( If applicable ) (as per sampling plan mentioned in IS: 1554)
2. Tensile Tests
3. Elongation Test
4. Torsion Test For Round wires only
5. Wrapping Test
6. Resistance Test
7. Mass of Zinc coating test For G S wires / Formed wires
only
8. Uniformity of Zinc coating For G S wires / Formed wires
only
9. Adhesion test For G S wires / Formed wires
only
10. Freedom from surface defects
C) For PVC insulation & PVC Sheath (as per sampling plan mentioned in IS: 1554)
1) Test for thickness
2) Tensile strength & Elongation before ageing (for tests after ageing see “D”)

CLAUSE NO.
QUALITY ASSURANCE
D) Ageing test:
Criteria Condition Test Requirements Remarks
PVC Samples as per relevant IS, from each All sizes which The size which has maximum In case the size
insulation size of cables in the offered lot, shall be meet the criteria negative deviation from type test does not meet the
& outer tested for tensile strength & elongation report values will be put on requirement in
sheath: (before ageing). Tensile & elongation accelerated ageing test. The accelerated
testing shall preferably be done with a samples shall be aged in air oven at ageing test then
computerized machine. temperature of 130ºc+/- 2ºc for 5 all sizes (which
The values will be compared with hours and tested for TS & had met the
corresponding values mentioned in the elongation. criteria) will be
Type Test report accepted by Employer. Acceptance norms shall be as per put on ageing
These values of Tensile Strength & IS. test as per IS.
Elongation (before ageing) should be
within +/ - 15% of the corresponding Sizes which do not Every size will be put on ageing test
values of Type Test report. (Please note meet the criteria as per IS. ----
that test values should be more than the
minimum values indicated in relevant
standard).
E) Following tests will be carried out on completed cables as per IS on each size:
1) Insulation resistance test ( Volume resistivity method )
F) Following tests shall be carried out on only one size of offered lot (comprising of all sizes):
1) Thermal stability test on PVC insulation and outer sheath
2) Oxygen index test on outer sheath
3) Smoke density rating test on outer sheath
4) Acid gas generation test on outer sheath
G) Flammability test as per IEC 60332 - Part- 3 (Category- B) on completed cable will be carried out as per following
sampling plan:
This test will be carried out using composite sampling i.e. irrespective of size; cables of one

CLAUSE NO.
QUALITY ASSURANCE
particular type (i.e. armoured, unarmoured) will be bunched together, as per calculations in
line with the IEC. All sizes of armoured & unarmoured cables shall be covered.
H) Following tests shall be carried on one length of each size (armoured & unarmoured) of offered lot:
1) Constructional / dimensional check, surface finish, length measurement, sequence of

cores, armour coverage, Gap between two consecutive armour wires / formed wires,
Sequential marking, drum / outer sheath extrusion’s batch number marking
2) Measurement of Eccentricity & Ovality

LT POWER CABLES

CLAUSE NO.
QUALITY ASSURANCE
LT Power Cables
Batch
marking/ surface finish/ cable
Routine & Acceptance Tests as

relevant standard &
Hot Set Test/ Eccentricity &
Armour coverage, cross over,

looseness, gap between two
outer sheath &
Anti termite coating on wooden

T.S & elongation before & after
Attributes /
Constructional requirements
feature as per specification
Characteristics

marking/
per relevant standard
Make, Type & T.C as
Thermal stability
specification
FRLS Tests
ageing on
Sequential
insulation
Ovality
drums
length
Item / Components /
wires
per
Sub System Assembly
Aluminum (IS-8130) Y Y Y Y Y
XLPE Compound (IS-7098) Y Y Y Y Y
PVC insulation Compound (IS: 5831) Y Y Y Y Y
(IS-5831, ASTM-D2843, IS10810( Part 58),
IEC-60754 Part-1)
Extrusion & curing /Manufacturing of Core Y Y Y Y
( PVC / XLPE)
Core Laying Y
Inner sheath Y Y
Armouring Y Y
Outer Sheathing Y Y
Power Cable (Finished) (IS-5831, ASTM-D2843, IS10810( Y Y Y Y Y Y Y Y
Part 58), IEC-60754 Part-1, IEC 60332 part III cat B)
Wooden drum(IS-10418) /Steel Drum Y Y Y
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with
2. Make of all major Bought out items will be subject to Employer approval.

SECTION – VI, PART-B LT POWER CABLES
CLAUSE NO.
QUALITY ASSURANCE
ROUTINE TESTS Following routine tests shall be carried out on each drum of finished cables for all types
(PVC / XLPE insulated) & sizes.
ACCEPTANCE TESTS Following Acceptance tests shall be carried out on each size of each type (PVC / XLPE
insulated) of cables, in the offered lot.
A) For Conductor (as per sampling plan mentioned in IS: 1554 / 7098)
1) Annealing test (Copper)
2) Tensile Test ( Aluminum)
3) Wrapping Test ( Aluminum)
4) Resistance test
B) For Armour Wires / Formed Wires ( If applicable ) (as per sampling plan mentioned in IS: 1554 / 7098)
2. Tensile Tests
3. Elongation Test
4. Torsion Test For Round wires only
5. Wrapping Test
6. Resistance Test
7. Mass of Zinc coating test For G S wires / Formed wires only
8. Uniformity of Zinc coating For G S wires / Formed wires only
9. Adhesion test For G S wires / Formed wires only
10. Freedom from surface defects
C ) For PVC / XLPE insulation & PVC Sheath (as per sampling plan mentioned in IS: 1554 / 7098)
2) Tensile strength & Elongation before ageing (for tests after ageing see “D”)
3) Hot set test (For XLPE insulation)

CLAUSE NO.
QUALITY ASSURANCE
D) Ageing test:
Criteria Condition Test Requirements Remarks
PVC Samples as per relevant IS, from All sizes which The size which has maximum In case the size
insulation each size of cables in the offered meet the criteria negative deviation from type test does not meet
& outer lot, shall be tested for tensile report values will be put on the requirement
sheath: strength & elongation (before accelerated ageing test. The in accelerated
ageing). Tensile & elongation samples shall be aged in air oven ageing test then
testing shall preferably be done at temperature of 130ºc+/- 2ºc for all sizes (which
with a computerized machine. 5 hours and tested for TS & had met the
The values will be compared with elongation. criteria) will be
corresponding values mentioned in Acceptance norms shall be as put on ageing
the Type Test report accepted by per IS. test as per IS.
Employer. These values of Tensile
Strength & Elongation (before Sizes which do Every size will be put on ageing
ageing) should be within +/ - 15% of not meet the test as per IS. ----
the corresponding values of Type criteria
Test report. (Please note that test
values should be more than the
minimum values indicated in
relevant standard).
XLPE
insulation Samples as per relevant IS, from each size of cables in the offered lot,will be put on ageing test as per IS.
E) Following tests will be carried out on completed cables as per IS on each size of each type (PVC / XLPE
insulated)

CLAUSE NO.
QUALITY ASSURANCE
F) Following tests shall be carried out on only one size of offered lot (comprising of all sizes & types)
3) Smoke density rating test on outer sheath
4) Acid gas generation test on outer sheath
G) Flammability test as per IEC 60332 - Part- 3 (Category- B) on completed cables as per following sampling plan:
This test will be carried out using composite sampling i.e. irrespective of size;
cables of one particular type (i.e. armoured PVC insulated, unarmoured PVC
insulated, armoured XLPE insulated, unarmoured XLPE insulated) will be bunched
together, as per calculations in line with the IEC. All sizes of PVC & XLPE
insulated, armoured & unarmoured cables shall be covered.
For one particular type, cables with OD less than or equal to 30 mm shall be
clubbed together in touching formation while cables with OD greater than 30 mm
shall be clubbed together leaving a gap equal to OD of cable having least
diameter. Cable OD shall be taken as nominal overall diameter as per Employer
approved datasheet.
H) Following tests shall be carried on one length of each size of each type (PVC / XLPE insulated) of offered lot:
1) Constructional / dimensional check, surface finish, length measurement, sequence
of cores, armour coverage, Gap between two consecutive armour wires / formed
wires, Sequential marking, drum / Batch (outer sheath extrusion batch )number
marking on sheath

H.T. CABLES

CLAUSE NO.
QUALITY ASSURANCE
Armour coverage, cross over, looseness, gap
Routine & Acceptance Test as per relevant

T.S & elongation before & after ageing on
per
Sequential marking/surface finish/ cable length
Attributes /
Characteristics
Constructional requirements feature as

Metallic ( Cu ) Screening ( If applicable)
Anti termite coating on wooden drums
Hot Set Test/ Eccentricity & Ovality
Thermal seability on outer sheath

Make, Type, Rating & T.C
outer sheath & insulation

standard & specification

Mechanial properties
Curing Properties
between two wire

Item /
Components /
specification
FRLS Test
Sub System
Assembly
Aluminium (IS-8130) Y Y Y Y Y
Semiconducting Y Y Y Y
Compound
XLPE Compound Y Y Y Y Y
(IS-7098 Part-II)
(IS-5831, ASTM-D2843,
IS10810( Part 58)
,IEC-60754 Part-1)
Triple Extrusion & curing Y Y Y Y
/Manufacturing of Core
Copper Tape Y Y Y Y
Polyster tape Y Y
Copper tapping Y Y Y
Inner sheath Y Y
Armouring Y Y
Outer Sheathing Y Y Y Y Y Y
Power Cable (Finished) Y Y Y Y Y Y Y Y Y
(IS : 7098 Part II,
IEC : 60332 (Part 3 Cat.
B), IS-5831, ASTM-
D2843, IS10810(Part 58)
, IEC-60754 Part-1)
Wooden drum(IS-10418) Y Y
/Steel Drum
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating
the practice and procedure along with relevant supporting documents.
2. Make of all major Bought Out Items will be subject to Employer approval.

(2X660 MW)
SECTION – VI, PART-B HT CABLES 1 OF 3
CLAUSE NO.
QUALITY ASSURANCE
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all
types & sizes.
Following shall constitute routine tests:
3) Partial discharge test ( for Screened cables only )
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size
of the cables on the cable drums selected at random as per sampling
plan mentioned in IS: 7098 Part 1I
A) For Conductor
1) Tensile Test
2) Wrapping Test
3) Resistance test
B) For Armour Wires / Formed Wires ( If applicable )

1) Measurement of Dimensions
2) Tensile Tests
3) Elongation Test
4) Torsion Test For Round wires only
5) Wrapping Test
6) Resistance Test
7) Mass of Zinc coating test For G S wires / Formed wires
only
8) Uniformity of Zinc coating For G S wires / Formed wires
only
9) Adhesion test For G S wires / Formed wires
only
10) Freedom from defects
C) For XLPE insulation & PVC Sheath

2) Tensile strength & Elongation before ageing
3) Hot set test (For XLPE insulation)
D) For completed cables

3 Partial discharge test ( for Screened cables only )

(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
E) Following tests shall be carried out and only one sample shall be taken
from each offered lot of all sizes for these tests:-
3) Smoke density rating test on outer sheath as per ASTM –D 2843
4) Acid gas generation test on outer sheath as per IEC –60 754 (Part 1)
5) Flammability test as per IEC 60332 - Part- 3 (Category- B) on completed
cable
F) Ageing test on XLPE insulation and PVC outer sheath as per following:
In case of regular manufacturers:-

Samples as per relevant IS from every size per type of cable in the offered lot
shall be tested for tensile strength & elongation (before ageing). The values
will be compared with corresponding values mentioned in the type test report
accepted by Employer. In case values of tensile strength & elongation (before
ageing) are within + /- 15% of the type test reports then 1 sample per type of
cable of offered lot will be put on accelerated ageing test. The accelerated
ageing test procedure: sample to be put in air oven at temperature of 130^c
+/- 2^c for 5 hours, tensile strength & elongation acceptance norms as per
relevant IS. However in case the tensile strength and elongation values are
not within +/- 15% of type test values then ageing test will be carried out on
that particular size of cable of offered lot as per relevant IS.
In case of new manufacturers / suppliers (supplying first time to

Employer through corporate contract):-
Samples as per relevant IS from every size per type of cable in the offered lot
shall be tested for tensile strength & elongation (before ageing). The values
will be compared with corresponding values mentioned in the type test report
accepted by Employer. In case values of tensile strength & elongation (before
ageing) are not within + /- 15% of the type test reports then sample from that
particular cable size will be put on ageing test as per relevant IS. However
not withstanding above condition, 1 sample per cable type of offered lot will
be put on ageing test as per relevant IS.
G) Following tests shall be carried on one length of each size of offered

lot:
1) Surface finish, length measurement, sequence of cores, armour coverage,

Gap between two consecutive armour wires / formed wires

(2X660 MW)
LIGHTING

CLAUSE NO.
QUALITY ASSURANCE
LIGHTING SQE_17
Item Components
Functional Check as per spec.

Sub System
Constructional Feature as per
Routine Test as per relevant

Assembly
Item to conform to relevant

Make, Type , Rating/ TC
Bought Out Items/ Bill of
Acceptance Test as per

Pre-Treatment of sheat
Paint Shade Thickness
relevant std and spec

Galvanization Tests
Adhesion & Finish
std and spec

Attributes
Dimension
Characteristics
standard
HV & IR
Material
IP Test
spec.
Luminaries (IS-10322 Y Y Y Y Y Y
Part-5 Sec.1 ( non –LED
type)
Electronic Ballast Y Y Y
Y
Lighting Wire (IS-694) Y
Y
Fans (IS-374) Y
Y
Pole (IS-2713) Y Y Y Y
Y
Lamps (IS-9800, IS- Y Y Y
9974)
Lighting Mast (with raise Y Y Y Y Y
& lower lantern type) Y
Wall Mounted Lighting Y Y Y Y Y Y Y Y Y Y Y Y
Panel (IS-513, IS-5)
Switch Box/ Junction Y Y Y Y Y Y Y Y Y Y Y Y
Box/Receptacles/ Local
Push Button Station /
Lighting Panel (IS-513,
2629, 2633, 4759,
6745)
Cable Gland (BS-6121) Y Y Y
Cable Lug (IS-8309) Y Y Y
Flexible Conduit Y
Y
Lighting Transformer (IS- Y Y Y
11171)
Epoxy & Galvanised Y Y Y
Conduit (IS-9537, 2629, Y
2633, 4759, 6745)

(2X660 MW)
SECTION – VI, PART-B LIGHTING 1 OF 2
CLAUSE NO.
QUALITY ASSURANCE
LED Luminaire quality requirements:
1) LED modules to conform to IS: 16103 part 2.

2) Control gear to conform to IS 15885 part 2 section 13. Manufacturer to issue a
certificate of compliance for the same.
3) LED modules batch test reports as per IS 16103 part 2, to be verified at the time of
final inspection.
4) LED luminaire to conform to IS 16107 part 2 section 1.
5) LED luminaire marking to be as per IS 16107 part 2 section 1.
6) Acceptance tests as per IS 16107 part 2 section 1 to be carried out on LED
luminaire except long duration tests i.e. a) Chromaticity coordinates & correlated
color temperature ( CCT); b) Color rendering index (CRI). Manufacturer will submit a
COC for above tests i.e. CCT & CRI
7) LED driver make, model, type & rating may be as per recommendations of LED
module manufacturer.
Notes:
2. Make of all major Bought Out Items will be subject to Employer approval.

(2X660 MW)
SECTION – VI, PART-B LIGHTING 2 OF 2
OUTDOOR TRANSFORMER

CLAUSE NO.
QUALITY ASSURANCE
OUTDOOR TRANSFORMER

Dimensional
Make / Type / Rating / Model

/ TC / General Physical
Voltage Ratio, Vector Group
& Polarity, Magnetic Balance
Attributes / Characteristics
standard / Specification
NDT / DPT / MPI / UT

Compatibility with oil
Thermal properties
Electrical strength
Functional check
WPS & PQR

Ageing Test.
&
Inspection.
Items/Components
Checks
Sub Systems
Visual
Test
Tank, H.V. & L.V. Cable Box / Flange throat
Y Y Y Y
Conservator / Radiator / Cooler / Pipes Y Y Y
Copper Conductor (IS:191) Y Y Y Y
Insulating Material Y Y Y Y Y Y
CRGO Lamination & Built Core Y Y Y Y Y Y
Bushing / Insulator
Y Y Y Y
( IS:2544 / 5621)
Gasket Y Y Y Y Y Y Y
Transformer Oil (IEC296) Y Y
OLTC / Off-Circuit Tap Changer Y Y Y
Core Coil Assembly & Pre-tanking Y Y Y
Marshalling Box Y Y Y Y
WTI, OTI, MOG, PRD, Breather, Terminal Connector, Bucholz Relay,
Y Y Y
Valves
Welding (ASME Sect-IX) Y Y Y
Complete Transformer
Y Y
(IS:2026/ IEC-60076)
Note: 1) This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant
supporting documents.
2) All major Bought Out Items will be subject to Employer approval.

SECTION – VI, PART-B OUTDOOR TRANSFORMER
BATTERY AND BATTERY

CHARGER

CLAUSE NO.
QUALITY ASSURANCE
DC SYSTEM SQE_19
LEAD ACID BATTERY
ATTRIBUTES /
Test for Capacities for 10 hrs. discharge rate

along with the test for voltage during
Conformance to CPWD Spec. for Teak
&
Lead Coating Thickness (min. 25 microns,
Paint Process checks, Paint Shade,
Checking of Polarity & absence of short

CHARACTERISTICS
Constructional requirements as per Spec.

drg.
Marking ( Routine & Acceptance Test)
circuit (Routine & Acceptance Test)

IS: 6848 App.F) & Adhesion Check
part
Thickness, Adhesion & Finish
discharge ( Acceptance Test)

Conformance to relevant
Manufacturer’s standards
Chemical composition
Insulation Resistance
Dimensions & Finish
ITEMS, COMPONENTS, SUB
Wood
SYSTEM ASSEMBLY
Container & Lids ( IS : 1146) Y Y

Vent Plugs Y Y
Sealing Compound Y Y
( IS : 3116 )
Positive & Negative Plates Y Y
Separators ( IS : 6071 ) Y Y
Electrolyte Y Y
( Water / Sulphuric Acid )
( IS : 1069 / 266 )
Inter-cell Connectors & Fasteners Y Y Y
Battery Stand Y Y Y Y
Cell Insulators Y Y Y
Stack Assembly Y Y
Lead Acid Battery Y Y Y Y Y
( IS : 1652 )
Note: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality

(2X660 MW) BATTERY AND BATTERY
WATER SYSTEM PACKAGE CHARGER
(ELECTRICAL)
CLAUSE NO.
QUALITY ASSURANCE
Ni- Cd BATTERY
Conformance to relevant part drg. & Manufacturer’s
Polarity & absence of short circuit (Routine &

ATTRIBUTES /
CHARACTERISTICS
Marking & Mass (Routine & Acceptance Test)
Retention of Charge Test ( Acceptance Test)

Paint Shade, Thickness, Adhesion & Finish
Air Pressure Test (Acceptance Test)

Air Pressure Test after heat sealing
ITEMS, COMPONENTS, SUB
SYSTEM ASSEMBLY
AH Test (Acceptance Test)

Nickel Plating thickness
Chemical composition
Insulation Resistance
Dimensions & Finish
Resistance to Alkali
(Acceptance Test)
Acceptance Test)
Impact Strength
standards
Container & Lids Y Y Y Y
Vent Plugs Y Y Y
Perforated Steel Strips Y Y Y Y
Active Material for Positive & Y Y
Negative Plates
Separators Y Y Y
Electrolyte Y Y
Inter-cell Connectors & Fasteners Y Y Y Y
Battery Stand Y Y Y
Cell Insulators Y Y Y
Stack Assembly Y Y Y Y Y Y
Ni-Cd Battery Y Y Y Y Y Y Y
( IS : 10918)
Notes:
2. Makes of all major Bought Out Items will be subject to Employer approval.

(ELECTRICAL)
CLAUSE NO.
QUALITY ASSURANCE
BATTERY CHARGER
Burn-In Test at 50^C for 48 hrs in energised

Verification of Routine test reports as per relevant
Dimensional check and Paint shade, thickness,
features as per Employer approved drgs &

Complete physical examination for constructional
Sheet Steel Pretreatment & Painting process
Ripple Content Test, Load Limiter & AVR Operation

Temperature Rise Test on one unit of each rating if
Degree of Protection Test as per Spec.

Conform to relevant Standard & spec
Alternating current measurement test

Make, Model, Type, Rating & Finish
Operational & Functional Checks

adhesion & Finish checks
Type testing is waived off
Dynamic Response Test

Items / Components /
Sub- assembly
HV & IR Test
specification
condition
checks
Test
IS
Rectifier Transformer and Y Y Y Y Y

Reactors IS : 4540, 2026)
Electronic Components Y Y Y
including Potentiometer
( Vernier Type)
Electronic Cards Y Y Y
PCB & racks for electronic Y Y
cards
Control & Selector Switches Y Y Y
( IS : 6875)
Indicating Meters (IS:1248 ) Y Y Y
Indicating Lamps (IS: Y Y Y
13947)
Air Break Switches / Fuses Y Y Y
( IS : 13947 / 13703 )
Control Terminal Blocks Y Y
(IS : 13947)
Control Transformer Y Y Y
( IS : 12021)
Push Buttons ( IS : 4794 ) Y Y Y
MCB ( IS : 8828) Y Y Y
PVC insulated Copper Y Y
control wires (IS : 694 )
Sheet Steel ( IS : 513 ) Y Y Y
Synthetic Rubber Gaskets Y Y
Annunciator Y Y Y
Battery Charger Y Y Y Y Y Y Y Y Y Y Y
Notes:

(ELECTRICAL)
CONSTRUCTION POWER – RING

MAIN & LT S/S

CLAUSE NO.
QUALITY ASSURANCE
CONSTRUCTION POWER – RING MAIN & LT S/S SQE_23


Make, Model, Type, Rating
Functional & Operational
All Routine / Acceptance

Tests as per Spec. & IS
Paint shade, thickness,
features as per spec.
Dimensions & finish
Functional Checks
Galvanizing Tests
adhesion & finish

standards
Items / Components
& TC
/ Sub System Assembly
HT AC Switch Outdoor type ( IS : 9920 ) Y Y Y Y Y Y Y Y

Outdoor HT Fuse & Fuse base ( IS : 9385 ) / Y Y Y Y Y Y
Drop Out Fuse Assembly
HT Outdoor Type Lightning Arrester Y Y Y Y
( IEC : 99 - 4 )
ONAN Transformer ( IS 2026) Y Y Y Y
LT Power Control Centers ( IS 8623 ) Y Y Y Y
Distribution Boards / Fuse Boards ( IS 8623) Y Y Y Y
HT armoured Cable ( IS : 7098 ) Y Y Y Y
LT armoured Power & Control cable ( IS : Y Y Y Y
1554 )
Cable Termination Kits and Straight Through Y Y Y Y
Joints ( VDE 0278)
ACSR Conductor (IS : 3835) Y Y Y Y
Earth wire & Guy wire/ Stay set ( IS : 6594) Y Y Y Y
Galvanised Steel Structure ( IS 2633 / 2629 / Y Y Y Y Y
6745 / 802 )
Steel Tubular Poles ( IS 2713) Y Y Y Y Y Y
Rail Poles ( IRS : 90 L ) Y Y Y Y Y Y
ISMC Channel / Angle / Flat ( IS 2062) Y Y Y
Hardware ( IS 1367) Y Y Y
Disc & Pin Insulator ( IS 731 ) Y Y Y Y
Strain Porcelain Insulator ( IS 5300 ) Y Y Y Y
Suspension / Tension Clamp for Earthwire Y Y Y Y
( IS 398 Pt 2)
Hardware for insulator ( IS 2586) Y Y Y Y
Vibration damper ( IS 9708) Y Y Y Y
LT Air Circuit Breaker ( IS : 13947) Y Y Y Y Y Y
LT CT / PT ( IS : 2705 / 3156 ) Y Y Y Y
MCB ( IS : 8828 ) Y Y Y Y Y
MCCB ( IS : 13947 ) Y Y Y Y Y
Air Break Switch / LT Fuse ( IS : 13947 / Y Y Y Y
13703 )
Control & Selector Switches ( IS : 6875 ) Y Y Y Y Y
CT / PT ( IS : 2705 / 3156 ) Y Y Y Y Y
Energy Meters ( IS 722 ) Y Y Y Y Y
Indicating meters ( IS : 1248 ) Y Y Y Y Y
Push Buttons ( IS : 4794 ) Y Y Y Y Y

(2X660 MW) CONSTRUCTION POWER –
WATER SYSTEM PACKAGE RING MAIN & LT S/S
(ELECTRICAL)
CLAUSE NO.
QUALITY ASSURANCE

Make, Model, Type, Rating
Functional & Operational
All Routine / Acceptance

Tests as per Spec. & IS
Paint shade, thickness,
features as per spec.
Dimensions & finish
Functional Checks
Galvanizing Tests
adhesion & finish

standards
Items / Components
& TC
/ Sub System Assembly
Indicating Lamps (IS: 13947) Y Y Y Y Y
PVC insulated copper wires ( IS : 694) Y Y Y Y

Cable Lugs / Cable Glands ( IS 8309 / BS Y Y Y Y
6121 )
Lighting Fixtures (IS 10322) Y Y Y Y
GI Pipe for Earthing (IS : 2629 / 2633 / 4749 Y Y Y Y
)
Fence ( IS : 278 ) Y Y
Danger Plate ( IS 2551) Y Y
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan

(2X660 MW) CONSTRUCTION POWER –
WATER SYSTEM PACKAGE RING MAIN & LT S/S
(ELECTRICAL)
DRY TYPE TRANSFORMER

CLAUSE NO.
QUALITY ASSURANCE
DRY TYPE TRANSFORMER

Attributes /
Voltage Ratio, Vector Group &

Make / Type / Rating / Model /TC
Characteristics
/ General Physical Inspection

Visual & Dimensional check
standard / Specification
Chemical Properties
Thermal Properties
Electrical strength
NDT / DP / MPI
Items/Components
Polarity
Sub Systems
Enclosure door, H.V. & L.V.

Y Y Y
Cable Box / Flange Throat
Copper Conductor Y Y Y Y
Insulating Material Y Y Y
CRGO Lamination & Built
Y Y
Core
Porcelain Bushing /Insulator
Y Y Y Y Y
( IS:2544 / 5621)
Gasket (IS 2712) Y Y Y Y
Off-Circuit Tap Changer Y Y Y
Core Coil Assembly Y Y
Marshalling Box Y Y
WTI, Thermistor, Terminal
Y Y
Connector
Complete Transformer
Y Y
(IS:11171 / IEC 60076)
Notes: 1) This is an indicative List of test/checks. The manufacturer is to furnish a detailed

Quality Plan indicating his practice and procedure along with relevant supporting
documents during QP finalisation for all item.
2) All major Bought out Items will be subject to Employer approval.

(2X660 MW) DRY TYPE
WATER SYSTEM PACKAGE TRANSFORMER

CLAUSE NO.
QUALITY ASSURANCE
VFD MODULE
ATTRIBUTES / Visual & Make / Final Remarks
Dimensional Type / Inspection as
checks Rating per IS / IEC
CHARACTERISTICS etc.
ITEMS/COMPONENTS,
SUB SYSTEM
ASSEMBLY
HT Breaker (IEC 56) Y Y Y
DC Reactor Y Y For details refer table

for DC Reactor
Transformer Y Y For details refer table
for Transformer
Motor Y Y For details refer
separate table for Motor
VFD Panel Y Y For details refer table
for VFD
Note : 1) This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality
Plan indicating the practices & Procedure followed along with relevant supporting
documents during QP finalization.
2) Make of all major Bought Out Items will be subject to Employer approval.

(2X660 MW)
SECTION – VI, PART-B VFD 1 OF 3
CLAUSE NO.
QUALITY ASSURANCE
VFD PANEL
Attributes
Characteristics
Final testing as per Relevant IS/IEC

Routine test as per relevant std.
Interlock Functional & Operation

Type/ Rating/Functional check
Paint finish/ shade/thickness

IS:6005 ,Seven tank process
Testing / Simulation check

Mountings / BOM/ Make,
Degree of Protection Test

Constructional Features
Chemical Properties
Electrical Properties
Dimensions / Finish
Item Components
Sub System Assembly
Completeness
/ Wiring
adhesion
HV/IR
Sheet Steel (IS-513) Y Y Y
Aluminum / Copper Bus- Y Y Y Y
bar(IS-5082/IS-613/IS-
1987)
Support Insulator (BS- Y Y Y Y
2782/IEC-660/IS-10912)
Control / Selector Y Y Y
Switch(IS-6875)
Contactor/ MCB(IS-13947) Y Y Y
O/L Protection relays(IS- Y Y
3231)
C.T /V.T/ Indicating Y Y Y
Meter(IS-2705/3156/1248)
Fuse/ Fuse carrier(IS- Y Y Y
13703)
Terminals/lugs/pvc Y Y Y Y Y
wires(IS-13947//IS-694)
Timers(IS-3231) Y Y Y
Push Button/ Lamp/ (IS- Y Y Y
6875)
Control Transformer (IS- Y Y Y
12021)
Mimic, Annunciater Y Y
GASKET(IS-11149) Y Y Y Y Y
Fabrication Y
Pretreatment & Painting Y Y
VFD panel Y Y Y Y Y
NOTE:
1. This is an indicative list of Test/ Checks. The manufacturer to furnish a detailed Quality Plan
2. All major Bought Out Items will be subject to Employer approval.

(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
DC REACTOR
ATTRIBUTES /
CHARACTERISTICS
Final Inspection as per IS-2026

Pretreatment by Seven Tank
Painting by Stove Enamling

Electrical Characteristics
Mech. & Chem Property
Welding/NDT
Dimensional
ITEMS/COMPONENTS, SUB
SYSTEM ASSEMBLY
Visual
Winding Material (Aluminium) Y Y Y Y
Insulation Material Y Y Y
Sheet Steel Y Y Y
Winding Y Y Y
Fabrication of Enclosures Y Y Y Y Y
Assembly Y Y
Routine Tests Y Y Y
Note : 1) This is an indicative list of tests/checks. The manufacturer to furnish a detailed Quality
Plan indicating their practice & procedure along with relevant supporting documents
during QP finalisation for all items.
2) All major Bought Out Items will be subject to Employer approval.

(2X660 MW)
PART-B (QA-C&I)

SUB-SECTION TITLE
PART – B (QA-C&I)
IIIE – 20 DDCMIS
IIIE – 21 MEASURING INSTRUMENTS (PRIMARY & SECONDARY)
IIIE – 22 POWER SUPPLY FOR C&I SYSTEMS
IIIE – 23 PROCESS CONNECTION & PIPING
IIIE – 24 INSTRUMENTATION CABLE
IIIE – 25 CONTROL VALVE ACTUATORS & ACCESSORIES
IIIE – 26 ELECTRICAL ACTUATOR WITH INTEGRAL STARTER
IIIE – 27 CONTROL DESK, PLC PANEL, SMOKE DETECTOR, FIRE ALARM &
CONTROL SYSTEM

DDCMIS

CLAUSE NO.
QUALITY ASSURANCE
1.00.00 REQUIREMENTS OF AUTHORISATION-TO-SHIP-TEST (ATST) FOR

DDCMIS
1.01.00 (a) Authorization-to-ship-test (ATST) or Factory Acceptance Test (FAT)

(both terms have been used interchangeably) shall include all required
tests to fully demonstrate to Employer’s satisfaction that each
equipment/sub-system/system as well as software modules furnished
as per this specification as well as DDCMIS as a whole, fully meets the
functional, parametric and other requirements of this specification and
Employer’s approved drawings/documents under all operating regimes.
The procedure defined here is applicable for one DDCMIS system.
Number of DDCMIS systems and their sub-systems shall be as defined
in Part-A of technical specifications.
(b) Contractor to note that ATST / FAT procedure given below in

subsequent clauses are only indicative in order to help the Contractor in
understanding the requirements and help him in submitting a detailed
procedure based on these guidelines meeting all the specification
requirements.
(c) The results of the following activities shall be made available to the
Employer’s representative before start of ATST / FAT.
(i) Compliance check for Major Design Feature (including

Customization if any), as per Part-C, GTR or agreements
regarding this.
(ii) Implementation check of various applications including those

based on Employer input, as per Part-C, GTR or agreements
regarding this.
(d) Generally, the ATST / FAT shall be carried out with the equipment
earmarked for the particular project and unit. However, for the following
item, the testing can be carried out with similar / equivalent dummy
equipment fulfilling the following condition, subject to Employer’s
approval.
SN ITEM CONDITION
1 LVS Testing of LVS functionalities can be done by using

monitors connected to the LVS Workstations. Dispatch
of LVS can be allowed like a cat-III item, but only after
successful testing of functionalities as indicated above.
2 LVS WS / OWS LVS WS / OWS for the first unit to be tested on the
target machines. In case the testing carries over to
next unit, dummy equipment may be used. Dispatch of
LVS WS / OWS of subsequent units can be allowed
like a cat-III item, but only after successful testing of
first unit as indicated above.
3 MASTER CLOCK Can be directly dispatched if alternate test set-up for

(2X660 MW)
SECTION – VI, PART-B DDCMIS 1 OF 8
WATER SYSTEM PACKAGE (C&I)
CLAUSE NO.
QUALITY ASSURANCE
time synchronization can be arranged.
4 NETWORK To be done with target machines only for first unit. In

COMPONENT case the testing carries over to next unit, dummy
equipment may be used. Dispatch of network
components of subsequent units / station can be
allowed like a cat-III item, but only after successful
testing of functionalities as indicated above.
5 VARIOUS BUS For FAT, the target Main system bus shall be used. In
SYSTEM case the testing carries over to next unit, dummy
CABLES equipment may be used.
1.01.01 The Authorization-To-Ship-Test (ATST) shall include all reasonable exercises

which the combination of equipment and software can be expected to perform.
These tests shall be divided into, as a minimum, but not limited to the following
categories:
(a) Hardware tests
(b) Functional tests
(c) Parametric test
All reference documents like all approved drawings / documents, specifications,

DDCMIS system manuals, etc. shall be available at the start of ATST. The
Quality Assurance related tests shall be as per approved QP (Quality Plan) for
DDCMIS. The ATST tests are briefly described in subsequent clauses.
1.01.02 Hardware tests
These tests shall include but not be limited to the following tests. These tests
will be conducted on full population on sample basis as finalized during ATST
procedure finalization and EMPLOYER engineer’s decision during ATST.
(a.) Verification of healthiness of all types of modules e.g., I/O modules,

controller modules, processors, peripherals, etc. on a sample basis.
(b.) System configuration:
(1.) Verification of system configuration with reference to approved

configuration diagrams including verification of controller
configuration, group / sub-group segregation; grouping of control-
lers, I/O redundancy, verification of multiple measurement scheme,
HMIPIS configuration, etc.
(2.) Verification of major features of complete DDCMIS like on line

removal of I/O and controller modules, etc. in line with specification
requirements.
(3.) Verification of spare capacity for example spare channels, spare

wired-in space in cabinets/ cubicles, terminal blocks, peripherals,
etc. as per approved documents.
(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
(c.) Simulation of inputs / Outputs
System shall have feature to simulate/ forcing I/Os on OWS / LVS

OWS. Additionally hardware simulation of I/Os shall be available for
specific applications like fail safe system.
(d.) Accuracy test:
System accuracy for each type of analog input shall be demonstrated

on sample basis, if this test is not carried out in MDFT.
(e.) Demonstration of the manual and auto switchover from master to
standby system bus, controllers, I/Os, processors etc.
(f.) Loop reaction time shall be demonstrated for loops / logics / functions
applicable as per specification and ATST procedure.
(g) SOE function shall be tested as follows, where the same is applicable
(refer Part-A of specifications). For SER function, verification of
resolution of SOE inputs, time synchronization with master clock, data
base modification, SOE report, printout, other features etc. For this
purpose a test-simulator to generate sequences of 1 ms resolution for
50 points (or as agreed during finalization of ATST procedure)
distributed in different panels shall be made available during testing.
(h) Power supply:

Testing of power supply system to DDCMIS, tolerance of DDCMIS
w.r.t. voltage & frequency limits as specified, performance of DDCMIS
with power supply break as specified .(One sample of each type)
(i) Diagnostics Tests :
On – line diagnostic tests on HMIPIS, individual peripherals, Control

System, programmer stations, etc.
1.01.03 Functional Tests
The following tests shall be carried out on Contractor’s DDCMIS.
(a.) Functional tests of CLCS:
(1.) Verification of proper signal acquisition, conditioning and

distribution, 2 transmitters / 3 transmitter selection.
(2.) Verification of proper realization of controller functions like bump

less transfer from auto to manual and vice versa, functional
checking of bias circuit (wherever provided), etc.
(3.) Verification of response of control system by simulating changes in

the system inputs in line with the approved ATST procedure.

(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
(4.) Verification of signal exchange between FGs and from other

systems (if applicable)
(b.) Functional tests of OLCS:
(1.) Verification of proper signal acquisition, conditioning and

distribution, 1v2, 2v3 implementation.
(2.) Verification of proper realization of logic functions, sequence control

functions, running of complete start up program sequence in all
modes of operation, shut down program, etc.
(3.) Verification of logic computation in controller by simulating inputs.
(4.) Verification of signal exchange between FGs and from other

systems (if applicable)
(c.) Functional tests for HMIPIS
(1.) Verification of all types of displays, logs including their formats,

bar graphs, X-Y plots etc. availability of all operator functions.
(2.) Verification of event generation and handling capabilities of

HMIPIS processors by simulating various types of events/data and
observing associated event sequence display and alarms..
(3.) Calculations:
All calculations shall be tested on sample basis to demonstrate

that these are in accordance with the specification and
Employer’s inputs as applicable. The Contractor shall prepare all
tests cases for calculations for proper verification for the
features required for each type of computations.
(4.) Checking historical storage and retrieval functions including long

term storage.
(5.) Testing of initialization and loading of configuration data, etc.
(6.) Verification of all programmer’s stations functions for HMIPIS and

Control System, as well as for documentation facility as specified.
(7.) Testing of each peripheral viz., monitors, printers, optical disks, hard
disk drive, etc.
(8.) Testing of time synchronization function of system time of DDCMIS

(Control System, HMIPIS & Systems on LAN). In case it is not

(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
possible to bring the master clock procured under this package,

then signal generator with stable source, capable of generating all
required type of synchronizing signal to be arranged by Contractor.
(9.) Testing of the Station LAN shall be carried out with unit DDCMIS
(with panels), standalone DDCMIS (with panels or software
simulation) and at least one (1) other DDCMIS system (with panels
or software simulation), as well as two client PC’s, one third party
PLC and Numerical relay system (if applicable). Bidder shall
arrange a PC with OPC server (excluded from his scope of supply)
which shall be used by the Bidder to simulate signal exchange
between Bidder’s Station LAN and third party PLC during the testing
of Station LAN, at Bidder’s works.
(10.) Unified HMIPIS:
Testing of Unified HMIPIS functionality as per respective approved

documents.
(d.) Security Audit (as applicable)
(1.) For checking compliance to the security policies & procedures in

Station LAN/HMI of all DDCMIS, security audit by a certified auditor
(as per CERT- IN panel) is to be arranged by the Contractor during
ATST. This shall include vulnerability assessment of the
workstations/ servers and penetration testing of the Station LAN
through the firewall from a node outside the network. Suitable
actions based on the findings of the security audit shall be carried
out by the Contractor.
1.01.04 Parametric tests
Following tests shall be carried out to test Contractor’s DDCMIS w.r.t.

specification requirements.
(a.) For control system (CLCS+OLCS):
(1.) CPU loading
(2.) Cycle time/controller reaction time.
(3.) Memory spare capacity
(b.) For MMIPIS
(1.) CPU loading
(2.) Spare duty cycle
(3.) Spare memory capacity
(c.) Spare duty cycle for system bus

(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
(d.) Various display & command response time
(e.) System accuracy (if not carried out in MDFT)
(f.) Display update time on OWS LVS
Parametric tests of Unified HMIPIS for complete Unit DDCMIS shall also be
carried out, if specified in Part-A of specifications.
1.02.00 Integrated Test Set-Up
For integrated testing of the total DDCMIS system, the Contractor shall employ
a test set-up, which will be capable of generating I/O signals in a requisite
manner. It is preferable to adopt soft signal simulating device to avoid /
minimize the cumbersome process of physical connection of I/Os through
potentiometers, switches, Lamps / LEDs etc. The exact configuration / set-up
shall be as finalized during detailed engineering.
1.02.01 The Contractor is to submit Authorization-To-Ship-Test (ATST) procedure and

requirements of above and other applicable clauses of this specification. Since,
the exact definition & extent / parameters of ATST can be finalized only when
the engineering of DDCMIS has been finalized to a great extent, it is required
that the detailed draft ATST procedure be submitted by the Contractor at a later
date as intimated by the Employer during engineering stage for Employer’s
comment and finalization. Contractor shall incorporate all modifications,
additions/ deletions to the ATST procedure as indicated by the Employer. The
ATST shall be conducted as per Employer approved procedure for ATST. The
Employer reserves the right to ask the Contractor to conduct any other test not
covered in ATST procedure also during the ATST which may be required to
fully satisfy the Employer regarding full compliance with specification require-
ments. Contractor shall conduct all such tests also within the quoted lump sum
price for this contract.
1.02.02 The results of all ATS Tests shall be properly documented by the Contractor
and submitted to Employer along with all annexures.
1.02.03 Following the tests, if in the opinion of the Employer, the system has not been
adequately manufactured, programmed, tested or debugged the Contractor
shall make good all deficiencies, and re-run the test to fully satisfy the
Employer regarding full compliance with specification requirements and
requisite quality standards.
1.02.04 The system shall not be shipped without approval of Employer in writing.
1.02.05 Upon successful completion of Authorization-To-Ship Test, the Employer will

provide the Contractor with a written authorization for shipment of the system
equipment to the project site.
1.02.06 All final documentation as per requirement of this specification shall be

available at the time of Authorization-To-Ship-Test and this shall be dispatched
along with the equipment in required number of copies.
(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
1.02.07 Contractor shall note that no payments towards dispatch of equipment and
subsequent activities shall be due and payable to the Contractor till the
Contractor is able to successfully demonstrate to Employer’s satisfaction that
the DDCMIS and parts thereof fully meet the Authorization-To-Ship Test
requirements.
1.02.08 The ATST or FAT of DDCMIS shall be conducted at the employer approved
works of the DDCMIS supplier or DDCMIS Supplier’s Associate. Further
DDCMIS shall be supplied from the same works.
2.00.00 The ATST requirements as indicated above shall form an integral part of
QAP (Quality Assurance Plan) of DDCMIS system(s) envisaged for the
package/project. Over and above the tests and requirement indicated
above, the QP for DDCMIS system shall be submitted to employer for
approval. The QAP envisaged for the offered DDCMIS system for
employer shall also include testing of following attributes of the offered
system by Employer.
2.01.00 The tests indicated in the following QA tables are indicative list of tests/checks.
The manufacturer is to furnish a detailed quality plan indicating the Practices
and Procedure adopted along with relevant supporting documents, if desired by
employer.

(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
DISTRIBUTED DIGITAL CONTROL MONITORING & INFORMATION SYSTEM

(DDCMIS)
TESTS
Louvers, Fans, wire mesh, Lifting arrangement (R)
Paint Shade, Thickness and Illumination (R)

Door Alignment, waviness, and Locking (R)
Environmental Stress Screening test (R).

Internal cabling / Wiring checking(R)
Hardware/Make as per BOM (R)

Post Power on Check (%) (R)
Pre Power on Check (#) (R)
HV / IR on wired panels (R)
Dimensions, GA, layout (R)

ITEMS
DDCMIS
DDCMIS Y Y Y Y Y Y Y Y Y Y
CUBICLES
OWS and Y
Peripherals
R-Routine Test A- Acceptance Test Y – Test applicable
Note: 1) These test are minimum requirement and necessary covered in Manufacturing
Quality Plan and manufacturer is also need to include their practices and
Procedure in MQP along with relevant supporting documents.
# Pre power on check: - Wire dressing, looseness, Availability of Fuses and MCB,
Modules are inserted properly, Earthing connection, Input Voltage checking,
Availability of resistance matt near panels, Availability of Electro Static
Discharge measure for electronics components.
% Post Power On Check: - Current & power consumption of DDCMIS Cabinets, I/O
check as per signal flow.

(2X660 MW)
MEASURING INSTRUMENTS
(PRIMARY & SECONDARY)

CLAUSE NO.
QUALITY ASSURANCE
MEASURING INSTRUMENTS (PRIMARY AND SECONDARY) Page- 1/2

TESTS
Process / Electrical connection (R)
IBR Certification (if applicable )(R)

Make, Model, Type, Rating (R)
Material Test certificate ®

Insulation Resistance (R)
ITEMS
Test as per standard(R)

Dimensions (R)
Calibration (R)
Hydro Test(R)
1. PR Gauge (IS-3624) Y Y Y Y Y
2. Temp. Gauge (BS-5235) Y Y Y Y Y
3. Pr./D.P.Switch(BS-6134) Y Y Y Y Y Y
4. Electronic Transmitter(IEC-60770) Y Y Y Y Y Y
5. Temp. Switch Y Y Y Y Y Y
6. Recorder(IS-9319/ANSI C-39.4) Y Y Y Y Y Y
7. Vertical indicators Y Y Y Y Y
8. Digital Indicators Y Y Y Y Y
9. Integrators Y Y Y Y
10. Electrical Metering Instrument (IS- Y Y Y Y Y Y
1248)
11. Transducer (IEC-688) Y Y Y Y Y Y
12. Thermocouples (IEC – 754 / ANSI-MC- Y Y Y Y Y Y
96.1)
13. RTD(IEC-751) Y Y Y Y Y Y
14. Thermowell Y Y Y Y Y
1) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed

quality plan indicating the Practices and Procedure adopted along with relevant
KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION SUB-SECTION-IIIE-21

PAGE
(2X660 MW) SECTION – VI, PART-B MEASURING 1 OF 2
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 INSTRUMENTS
(C&I)
CLAUSE NO.
QUALITY ASSURANCE
MEASURING INSTRUMENTS (PRIMARY AND SECONDARY) Page- 2/2
TESTS
Process / Electrical connection (R)
IBR Certification as applicable (R)

Requirement as per standard (R)
Make, Model, Type, Rating (R)
Calculation for accuracy (R)

Non-destructive testing (R)
Material test certificate (A)

Insulation Resistance (R)
ITEMS
WPS approval (A)

Dimensions (R)
Calibration (R)
Hydro test (R)

15. Cold junction Y Y Y Y Y
compensation box
16. Orifice plate(BS-1042) Y Y Y Y Y Y Y Y Y Y
* ** ** **
17. Flow nozzle(BS-1042) Y Y Y Y Y Y Y Y Y Y
*
18. Impact head type element Y Y Y Y Y
19. Level transmitter/float Y Y Y Y Y Y Y Y
type switch
20. Analysers Y Y Y Y
21. Dust emission monitors Y Y Y Y
*Calibration to be carried out
on one flow element of each
type and size if calibration
carried out as type test same
shall not be repeated.
** If applicable
Note: 1) This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the Practices and Procedure adopted along
with relevant supporting documents.

PAGE
(2X660 MW) SECTION – VI, PART-B MEASURING 2 OF 2
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 INSTRUMENTS
(C&I)
POWER SUPPLY FOR C&I

SYSTEMS

CLAUSE NO.
QUALITY ASSURANCE
POWER SUPPLY FOR C&I SYSTEMS (UPS/BATTERY/BATTERY

CHARGER/ACDB/DCDB)
TESTS
Visual/dimension/rating/ Paint Adhesion/ Thickness
General arrangement/BOM/make of components
Restart with PRI A.C and battery (separately)(R)
Tests as per standard &specification (R)&(A)

Out put voltage and frequency adj.range(A)
Parralel operation and current divison(R)
System transfer and retransfer (R)*

AC input faliure and return test (R)
Load transfer retransfer test (R) *
Relative harmonic content(R)

Premilinary light load test(R)
Input voltage variation (A)
Asynchronous transfer(R)
Load limiter operation (R)

Efficiency ,regulation(R)
Ripple content(R)
IR/HV(R)
/Mimic ®
ITEMS
(R)
UPS/CONVERTER
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
(IEC-146 PT-4)
VOLTAGE
Y Y Y Y Y Y Y Y
STABILISER
LEAD ACID
BATTERY(TUBLAR Y
)-IS-1651
LEAD ACID
BATTERY Y
(PLANTE)-IS-1652
NICKEL CADMIUM
BATTERY(IS- Y
10918/IEC-623)
SMF BATTERY Y
ACDB/DCDB Y Y Y Y
BATTERY
Y Y Y Y Y Y Y Y Y Y
CHARGER
* Transfer time and Over shoot /under shoot during load & system transfer shall be
recorded .
Note: 1) This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the Practices and Procedure adopted alongwith

POWER SUPPLY 1 OF 1
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 (C&I)
PROCESS CONNECTION & PIPING

CLAUSE NO.
QUALITY ASSURANCE
Process, Connection & piping FOR C&I SYSTEMS
TESTS
Flattening,flaring,hydrotest,hard
Proof pressure test,Dismantling

Chemical/physical properties of
Accessability of TBs/Devices ®
impulse and vibration test (R)

Make, Model, Type, Rating®
& reassembly test,Hydrulic

component & construction
Illumination,grounding ®
ness check as per ASTM
Tests as per standards &

Paint Shade/thickness ®
Component Ratings ®
instrument/devices (R)
GA, BOM, Layout of
Leak/Hydro test(A)
Review of TC for
Dimension ®
standard (A)
specification
material (A)
IR & HV ®
Tubing ®
feature®
Wiring ®
Visual ®
ITEMS
Local Instrument enclosure Y Y Y Y Y Y Y Y Y Y Y Y Y
Local instruments racks Y Y Y Y Y Y Y Y Y Y Y Y Y
Junction Box Y Y Y Y* Y Y Y
Gauge Board Y Y Y Y Y Y Y Y Y
Impulse pipes and tubes Y Y Y Y Y
Socket weld fittings ANSI B-16.11 Y Y Y Y Y
Compression fittings Y Y Y Y Y Y
Instrument valves & Valve Y Y Y Y Y
manifolds
Copper tubings ASTM B75 Y Y Y
*-applicable for painted junction boxes.
Note: R-Routine Test A- Acceptance Test Y – Test applicable
Note: This is an indicative list of tests/checks. The manufacturer is to furnish a detailed quality plan indicating the Practices and Procedure adopted alongwith

SECTION – VI, PART-B PROCESS CONNECTION PIPING
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 (C&I ) 1 of 1
INSTRUMENTATION CABLE

CLAUSE NO.
QUALITY ASSURANCE
INSTRUMENTATION CABLE
TESTS
Vol. Resistivity. at room & Elevated Temp. (A) ++

Tensile & Elongation before & after aging (A) ++
Outer-Sheathe/core marking, end sealing (A)
Swidesh chimney Test (SS-4241475) (A) ++

Constructional detail, dimensions (A)
ITEMS
Overall/Coverage/Continuity (A)
Conductor Resistance ® & (A)
Insulation Resistance ® & (A)
Electrical Parameters ** (A) +

Visual, Surface finish (A) +
Spark test report review ®

Persulphate Test (A) +
Thermal Stability (A) +
High Voltage ® & (A)
FRLS Test * (A) ++

1. Instrument cable
twisted and shielded
Conductor(IS-8130) Y Y Y
Insulation(VDE-207) Y Y Y Y Y Y
Pairing/Twisting Y Y Y
Shielding Y Y Y
Drain wire Y Y Y Y Y
Inner Sheath Y Y Y Y Y Y
Outer Sheath Y Y Y Y Y Y
Over all cable Y Y Y Y Y Y Y Y Y
Cable Drums(IS- Y Y
10418)
Note : High Temp. cables shall be subjected to tests as per VDE-207(Part-6)
Compensating cables shall be checked for Thermal EMF/Endurance test as per IS
8784.
Note : This is an indicative list of tests/checks. The manufacture is to furnish a
detailed Quality Plan indicating his practice & Procedure along with relevant
supporting documents during QP finalization for all items.
Note : ® - Routine Test A - Acceptance Test Y - Test Applicable
Note : Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable)
 * FRLS Tests: Oxygen / Temp Index ( ASTM D-2863), Smoke Density Rating (
ASTM – D 2843), HCL Emission ( IEC-754-1)
 ** Characteristic Impedance, Attenuation, Mutual Capacitance, Cross Talk ( As
applicable)
+ Sample size will be One No. of each size/type per lot.
++ Sample size will be One No. sample for complete lot offered irrespective of
size/type.

PAGE
(2X660 MW) SECTION – VI, PART-B INSTRUMENTATION 1 OF 1
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-9915-373 CABLE
(C&I)
CONTROL VALVE ACTUATORS &

ACCESSORIES

CLAUSE NO.
QUALITY ASSURANCE
cONTROL VALVE ACTUATORS AND ACCESSORIES.

TESTS
FUNCTIONAL TEST, REVIEW FOR MAKE AND TC

UT/RADIOGRAPHY FOR >900 LB RATING®
MATERIAL TEST CERTIFICATES®
PRESSURE RESISTANCE®
LINEARITY/HYSTERISIS®
MAKE,MODEL, TAG (R)
TIMING OPEN/CLOSE®
IBR CERTIFICATES®
HEAT TREATMENT®
OF ACCESSORIES®
HYDRAULIC TEST®
SURFACE FINISH®
SEAT LEAKAGE®
DIMENSION®
MPI/DP®
ITEMS
CONTROL VALVE
AND ACTUATOR
OVERALL Y Y Y Y Y Y Y Y Y
BODY Y Y Y Y Y Y Y
BONNET Y Y Y Y
TRIM Y Y Y*
PNEUMATIC Y Y Y
ACTUATOR
ELECTRO Y Y
PNEUMATIC
POSITIONER
R- ROUTINE TEST A - ACCEPTANCE TEST Y - TEST APPLICABLE
Y* - UT ON SPINDLE DIA >= 40 MM.
NOTE : 1) THIS IS AN INDICATIVE LIST OF TESTS/CHECKS. THE MANUFACTURE IS
TO FURNISH A DETAILED QUALITY PLAN INDICATING HIS PRACTICE &
PROCEDURE ALONG WITH RELEVANT SUPPORTING DOCUMENTS
DURING QP FINALISATION FOR ALL ITEM.

CONTROL VALVE 1 OF 1
ELECTRICAL ACTUATOR WITH

INTEGRAL STARTER

CLAUSE NO.
QUALITY ASSURANCE
ELECTRICAL ACTUATOR WITH INTEGRAL STARTER

Test/Attributes
Safety check (Single phasing, Phase correction, Tripping etc.) (A)

Characteristics
Function of Aux. like Potentiometer, space heater, position

Operation & Setting of limit Switch/Torque Switch®
Hand Wheel operation/ Auto de clutch function (A)

All routine Test as per Standard & Specification®
Local/ Remote ( Open-Stop-Close) Operation®

Correct Phase Sequence®
Stall Torque/Current (A)

Mounting Dimension®
No Load Current ®
Grease leakage ®
IR & HV Test®
EPT output ®
ITEM/
i di t ®
COPONENT/
RPM ®
SUB SYSTEM
ASSEMBLY/
TESTING
ELECTRICAL ACTUATOR
WITH INTEGRAL
STARTER(IS_9334)
Motor Y Y Y Y Y
Final Testing Y Y Y Y Y Y Y Y Y Y Y Y Y
Note: 1) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed
quality plan indicating the practices and procedure adopted along with relevant
® - Routine Test (A) - Acceptance Test Y - Test applicable

ELECTRICAL ACTUATOR 1 OF 1
CONTROL DESK, PLC PANEL,

SMOKE DETECTOR, FIRE ALARM &
CONTROL SYSTEM

CLAUSE NO.
QUALITY ASSURANCE
CONTROL DESK, LVS PANEL, PLC PANEL, SMOKE DETECTOR, FIRE

ALARM & CONTROL SYSTEM
TESTS
,
Review of TC for instruments/ Devices/ Recorders,
Element
Indicators/ mosaic Items/ Transducers ®
Functional test of complete system(a)

Control
GA, BOM ,Lay Out of components ®
Paint Shade/Thickness/Adhesion ®
Component Rating/ Make / Type ®
Accessibility of TBS/ Devices ®
for
Test as per IEC 1131 ® *

Test as per Std ® & ( A)
Alignment of Section ®
Check
Dimensions ®
Illumination ®
IR & HV ®
Functional
Wiring ®
Visual ®
Mimic ®
ITEMS
1. Control Desk Y Y Y Y Y Y Y Y Y Y Y Y Y
2. LVS Panel Y Y Y Y Y Y Y Y Y Y Y
3. Annunciation, Y Y Y Y Y Y Y Y Y Y Y Y Y
Control, PLC Panel
4.Smoke Detectors Y Y
( UL-268,EN-54
PT-7), Heat
Detectors( UL-
521/EN 54 PT-5 )
Annunciation/
Control Panel ( UL
-864, EN-54, PT-2)
Note: 1) This is an indicative list of test/ checks. The manufacturer is to
furnish a detailed quality plan indicating the Practice and Procedure
along with relevant supporting documents.
 *Applicable for PLC
 Y - Test Applicable , ® - Routine Test (A) - Acceptance Test

CONTROL DESK 1 OF 1
PART-B (QA-CIVIL)

SUB-SECTION TITLE
PART – B (QA-CIVIL)
IIIE – 28 CIVIL WORKS
ANNEXURE-I
ANNEXURE-II
ANNEXURE-III
ANNEXURE-IV
ANNEXURE-VA
ANNEXURE-VB
ANNEXURE-VI
ANNEXURE-VII
ANNEXURE-VIII

CIVIL WORKS

CLAUSE NO.
QUALITY ASSURANCE FOR CIVIL WORKS
QUALITY ASSURANCE AND INSPECTION FOR CIVIL WORKS
1.0.0 INTRODUCTION
1.1.0 This part of the specification covers the sampling, testing and quality assurance
requirement (including construction tolerances and acceptance criteria) for all civil and
structural works covered in this specification.
1.2.0 This part of the technical specification shall be read in conjunction with other parts of the
technical specifications, general technical requirements & erection conditions of the
contract. Wherever IS code or standards have been referred they shall be the latest
revisions.
1.3.0 The rate for respective items of work or price shall include the cost for all works,
activities, equipment, instrument, personnel, material etc. whatsoever associated to
comply with sampling, testing and quality assurance requirement including construction
tolerances and acceptance criteria and as specified in subsequent clauses of this part of
the technical specifications. The QA and QC activities in all respects as specified in the
technical specifications/ drawings / data sheets / quality plans / contract documents shall
be carried out at no extra cost to the owner.
1.4.0 The contractor shall prepare detailed construction and erection methodology scheme
which shall be compatible to the requirements of the desired progress of work execution,
quality measures, prior approvals if any and the same shall be got approved by the
Owner. If required, work methodology may be revised/ reviewed at every stage of
execution of work at site, to suit the site conditions by the contractor at no extra cost to
the owner.
2.0.0 QUALITY ASSURANCE PROGRAMME
2.1.0 The contractor shall adopt suitable Quality Assurance Programme (QAP) to ensure that
the equipments and services under the scope of contract whether manufactured or
performed within contractor’s works or at his sub-contractor’s premises or at the
OWNER’s site or at any other place of work are in accordance with the specifications.
Such QAP shall be outlined by the contractor and shall be finally accepted by the
OWNER or their authorized representative after discussions before the start of work.
The QAP shall be generally in line with IS/ISO Systems.
The contractor shall furnish complete QA & QC programme for the work envisaged
which may include the following
 Organization structure for the management and implementation of the proposed

quality assurance programme
 Quality System Manual
 Design Control System
 Documentation and Data Control System
 Qualification data / details for Contractor’s key personnel
 The procedure for purchase of materials, parts, components and selection of sub-
contractor’s services including vendor analysis, source inspection, incoming raw-
material inspection, verification of materials purchased, etc.
 System for shop manufacturing and site erection controls including process,
fabrication and assembly
(2X660 MW) SUB-SECTION-IIIE-28
CLAUSE NO.
 Control of non-conforming items and system for corrective actions and resolution of
deviations
 Inspection and test procedure both for manufacture and field activities
 Control of calibration and testing of measuring testing equipment
 System for Quality Audits
 System for identification and appraisal of inspection status
 System for authorizing release of manufactured product to the OWNER
 System for handling, storage and delivery
 System for maintenance of records
 Quality plans for manufacturing and field activities detailing out the specific quality
control procedure adopted for controlling the quality characteristics relevant to each
item of work/ equipment/component.
3.0.0 QA AND QC MANPOWER
3.1.0 The contractor shall nominate one overall QA coordinator for the contract detailing the
name, designation, contact details and address at the time of post bid discussions. All
correspondence related to Quality Assurance shall be addressed by the contractor’s QA
coordinator to OWNER. OWNER shall address all correspondence related to Quality
issues to the contractor’s QA coordinator. The contractor’s QA coordinator shall be
responsible for co-ordination of Quality activities between various divisions of the
contractor and their sub-vendors on one hand & with OWNER on the other hand.
3.2.0 The contractor shall appoint a dedicated, experienced and competent QA&QC in-charge
at site, preferably directly reporting to the Project Manager, supported as necessary by
experienced personnel, to ensure the effective implementation of the approved QAP. An
indicative structure of contractor’s QA&QC manpower required to be deployed at site is
enclosed at Annexure-I. Based on the finalized L-2 network and the approved Field
Quality plan, the contractor shall finalize and submit a deployment schedule of QA&QC
personnel along with their details to OWNER for approval/ acceptance and further shall
ensure their availability well before the start of the concern activity.
3.3.0 The QA&QC in-charge shall have the organizational freedom and authority to implement
the requirements of these quality assurance arrangements, free from commercial and
programme restraints. The QA&QC setup of the contractor shall consist of qualified and
experienced Civil, Electrical, Mechanical Engineers and Laboratory assistants with their
supporting staff both at their works and site.
3.4.0 The deployment of man power for QA & QC set up shall be affected on the basis of
agreed manpower deployment schedule, which shall be prepared by the contractor
based on the L-2 network and the same shall be submitted to the Owner for acceptance.
4.0.0 SAMPLING AND TESTING OF CONSTRUCTION MATERIALS
4.1.0 The method of sampling for testing of construction materials and work / job samples shall
be as per the relevant IS / standards / codes and in line with the requirements of the
technical specifications / quality plans. All samples shall be jointly drawn, signed and
sealed wherever required, by the contractor and the Owner or his authorized
representative.
4.2.0 The contractor shall carry out testing in accordance with the relevant IS / standards /
codes and in line with the requirements of the technical specifications / quality plans.
Where no specific testing procedure is mentioned, the tests shall be carried out as per
CLAUSE NO.
the best prevalent engineering practices and to the directions of the Owner. All testing
shall be done in the presence of the Owner or his authorized representative.
4.3.0 Before execution of any civil work the contractor shall conduct full-scale suitability tests
on various construction and building material such as fine and coarse aggregates,
cement, reinforcement, construction chemicals, supplementary cementitious materials
and construction water to ascertain their suitability for use and the concrete mix designs
conducted from reputed institutes such as NCB-Ballabgarh, CSMRS-Delhi, selected
IIT’s, etc. as agreed by the Owner. A list of OWNER acceptable specialist laboratories is
enclosed at Annexure-II. The test samples for such full scale testing shall be jointly
sampled and sealed by the Owner and contractor, thereafter these shall be sent to the
concerned laboratory through the covering letter signed by field quality assurance
department (FQA) representative of the Owner. Format for sampling and testing of
cement, coarse aggregate, fine aggregate, chemical admixture, fly ash, water, concrete
mix design is enclosed at Annexure-III.
4.4.0 The contractor shall timely initiate the action with regard to the evaluation of aggregates
and other building material including concrete mix design, so as to ensure completion of
these tests before start of civil works at site, thereby not affecting any project work. The
test reports and recommendations for suitability of the materials including concrete mix
design shall be promptly submitted by the contractor to the Owner.
4.5.0 Evaluation of aggregate for potential alkali-aggregate reactivity shall be carried out as
per following scope of work
A. Evaluation of Aggregates for Mechanical / Physical Properties
a) To carry out different tests on coarse aggregate sample i.e. specific gravity, water
absorption, sieve analysis, deleterious material; soundness, crushing value, impact
value, abrasion value, elongation index and flakiness index, as per IS: 2386.
b) To carry out different tests on fine aggregate sample i.e. specific gravity, water
absorption, sieve analysis, deleterious material, soundness, silt content, clay
content and organic impurities as per IS: 2386.
c) To prepare evaluation report based on test results of a) and b) above and to advise
regarding suitability of fine and coarse aggregates.
B. Evaluation of Aggregates for Potential Alkali-Aggregate Reactivity:
a) To carry out petrographic analysis and accelerated Mortar bar Test on aggregate
samples (1N NaOH at 80 deg. Centigrade for 14 days as per ASTM 1260, or the
method established/ developed by CSMRS for 22days test).
b) If rock type is limestone, alkali carbonate reactivity test shall also be carried out
wherein the parameters shall be reported in conjunction with the petrographic
analysis. Additionally, X-Ray diffraction test (XRD) shall be carried out to determine
critical clay mineral in the rock for preliminary conclusions. For limestone
aggregates to be used in dynamic foundations like TG, BFP, Fans, mills and
crushers, repeated temperature cycle test shall also be carried out, to determine
residual expansion of aggregate for concrete.
c) To prepare a report based on test results of a) and b) above and to advise
regarding suitability of aggregates to be used and further testing required if any.

CLAUSE NO.
5.0.0 LABORATORY AND FIELD TESTING
5.1.0 The field laboratory for QA and QC activities shall be constructed and set-up by the
contractor in line with the indicative field QA&QC laboratory set-up enclosed at
Annexure-IV. The Laboratory building shall be constructed and installed with the
adequate facilities to meet the requirement of envisaged test setup. Temperature and
humidity controls shall be available wherever necessary during testing of samples. The
quality plan shall identify the testing equipments/ instrument, which the contractor shall
deploy and equip the field quality laboratory for meeting the field quality plan
requirements. The contractor shall furnish a comprehensive list of testing equipments/
instrument required to meet the planned/scheduled tests for the execution of works for
OWNER acceptance/ approval. The contractor shall mobilize the requisite laboratory
equipment and QA&QC manpower at least 15 days prior to the planned test activity as
per the schedule of tests.
5.2.0 All equipments and instruments in the field shall be calibrated before the commencement
of tests and then at regular intervals, as per the manufacturer’s recommendation and as
directed by the OWNER. The calibration certificates shall specify the fitness of the
equipments and instruments within the limit of tolerance for use. Contractor shall arrange
for calibration of equipments and instruments by an NABL / NPL accredited agency and
the calibration report shall be submitted to OWNER.
5.3.0 The tests which cannot be carried out in the field laboratory shall be done at a laboratory
of repute. This includes selected IITs, NCB, CSMRS, reputed government / autonomous
laboratories / organizations, NITs and other reputed testing laboratories. The test
samples for such test shall be jointly selected and sealed by the Owner and thereafter
these shall be sent to the concerned laboratory through the covering letter signed by
OWNER engineer. The test report along with the recommendations shall be obtained
from the laboratories without delay and submitted to OWNER.
5.4.0 Based on the schedule of work agreed with the Owner and the approved FQP, the
contractor shall prepare a schedule of tests and submit them to the Owner and organize
to carry out the tests as scheduled / agreed.
6.0.0 PURCHASE AND SERVICE
6.1.0 The major items/ equipments/ components to be manufactured in the shop of the
contractor i.e. in-house items and those procured from sub-vendors / sub-manufacturer /
sub-contractors i.e. bought out items (BOIs) shall be listed out by the contractor in their
bid proposal.
6.2.0 The list of manufacturers/ sub-vendors for all the BOIs envisaged in contract shall be
included in the bid proposal by the contractor which shall be discussed / reviewed by the
OWNER during post bid discussions and the list of proposed manufacturers / sub-
vendors for each of the BOIs shall be agreed/ approved. If any item is left out or gets
included during detailed engineering, the contractor shall propose the manufacturer’s /
sub-vendor’s details for review / approval of OWNER, prior to initiating the procurement
of such materials.
6.3.0 Where the manufacturers are placed in details required (“DR”) category, the details of
the manufacturers / sub-vendors placed in the “DR” category shall be submitted to the
OWNER for approval in the prescribed OWNER format within the period agreed at the

CLAUSE NO.
time of post bid discussions. The contractor’s proposal shall include vendor’s site
facilities, expertise, facilities established at the respective works, the process capability,
process stabilization, QC systems followed, experience list, etc. along with his own
technical evaluation for identified sub-Contractors proposed. The formats for furnishing
above details shall be given to the Contractor at post bid discussion stage. Monthly
progress reports on sub-contractor detail submission / approval shall be furnished. Such
manufacturers / sub-vendors approval shall not relieve the contractor from any
obligation, duty or responsibility under the contract.
6.4.0 To facilitate advance planning of material testing/ approval of bought out items, well
before the start of activity as per L-2 network, representative samples shall be procured
by the contractor from approved sub-vendors and submitted to the Owner for his
approval before bulk procurement at least two months prior to start of works. In case of
manufacturers test certificate (MTC) is submitted for acceptance, it shall be clearly
traceable and correlated with the consignment received at site. MTC of all bought out
items shall essentially contain all the test parameters / characteristics specified in the
technical specifications / standards / codes. In case the manufacturer’s test certificate
does not mention these details, sample from each lot shall be tested for these properties
at the third party lab acceptable to OWNER. Approval of material / sample by the Owner
shall not relieve the contractor of his responsibility, for their conformance to the
specification, as well as the requisite performance and quality of material.
6.5.0 Monthly progress reports on sub-contractor detail submission / approval shall be

furnished as per Engineering Co-ordination Procedure. Such vendor approval shall not
relieve the contractor from any obligation, duty or responsibility under the contract. Sub-
vendor whose details are not submitted within the agreed cut-off date, shall be deemed
to be withdrawn by the contractor.
6.6.0 Structural steel and Reinforcement steel supply if in the scope of the contractor shall be
procured from Main Steel Producers SAIL, JSW Steel Ltd, Jindal Steel & Power, Tata
steel Ltd. (for Reinforcement steel/TMT bars), RINL (for long products/Rolled sections
and Reinforcement steel/TMT bars), Essar Steel India Ltd. (for Flat products/ Steel
Plates), Electrosteel steel Ltd. (for Reinforcement steel/TMT bars) and Monnet Ispat and
Energy Ltd. (for long products/Rolled sections and Reinforcement steel/TMT bars) as
approved by owner.
7.0.0 MANUFACTURING QUALITY PLAN AND FIELD QUALITY PLAN
7.1.0 All materials / components and equipment covered under the scope of work, shall be
procured by the contractor for the purpose of the contract, after obtaining the written
approval of the OWNER, which are to be manufactured at shop/ factory of the
vendor/sub vendor shall be covered under a comprehensive quality assurance
programme. The contractor’s purchase specifications and inquiries shall call for
Manufacturing Quality Plans (MQP) to be submitted by the sub-contractor/ sub-supplier/
sub-vendor. The MQP called for from the sub-contractor shall detail out for all the
components and equipment, various tests / inspection, to be carried out as per the
requirements of this specification and standards mentioned therein, quality practices and
procedures followed by contractor’s / sub-contractor’s / sub-supplier's quality control
organization, the relevant reference documents and standards, acceptance norms,
inspection documents raised etc., during all stages of materials procurement,
manufacture, assembly and final testing/ performance testing. Such quality plans of the
vendors / sub-vendors shall be submitted to the OWNER for approval in the prescribed
format enclosed at Annexure VI and such approved quality plans shall form a part of the
CLAUSE NO.
purchase order / contract between the contractor and sub-contractor. The quality plans
shall be submitted on electronic form e.g. CD or E-mail in addition to hard copy, for
review and approval of OWNER. After approval the same shall be submitted in compiled
form on CD in addition to hard copy.
7.2.0 The contractor shall furnish copies of the reference documents/ plant standards /
acceptance norms/ tests and inspection procedure etc., as referred in quality plans.
These quality plans and reference documents/standards etc. will be subject to OWNER
approval without which manufacturer shall not proceed. These approved documents
shall form a part of the contract. In these approved quality plans, OWNER shall identify
customer hold points (CHP), i.e. test/ checks which shall be carried out in presence of
the OWNER engineer or his authorized representative and beyond which the work shall
not proceed without consent of OWNER in writing. All deviations to this specification,
approved quality plans and applicable standards must be documented and referred to
OWNER along with technical justification for approval and dispositioning.
7.3.0 Within three weeks of the release of the purchase orders /contracts for such bought out
items /components, a copy of the same without price details but together with the
detailed purchase specifications, quality plans and delivery conditions shall be furnished
to the OWNER for reference / record by the contractor along with a report of the
purchase orders placed so far for the contract.
7.4.0 Well before the start of the work, the contractor shall prepare and submit the Field
Quality Plans (FQP) on the format enclosed at Annexure VII, and obtain approval of
OWNER, which shall detail out for all the works, equipments, services, quality practices
and procedures etc in line with the requirement of the technical specifications to be
followed by the contractor at site. This FQP shall cover for all the items / activities
covered in the contract / schedule of items required, right from material procurement to
completion of the work at site. An Indicative Field Quality Plan for civil works is enclosed
at Annexure – V-A (Indicative FQP for civil works) & Annexure – V-B (Indicative FQP
for structural steel works).
7.5.0 Monthly progress reports on MQP / FQP submission / approval shall be furnished by the
contractor. List of items requiring quality plans and sub-supplier approval shall be
finalized with the contractor on the format enclosed at Annexure VIII during the post bid
discussions.
8.0.0 DISPOSITIONING OF NON CONFORMITIES
8.1.0 The non-conformity for the site works on being detected / noted shall be reported by the
contractor as per OWNER procedure. The dispositioning of the NCR relating to
equipment, assemblies, materials condition or process during construction / erection
shall describe the proposed correction and also include the preventive / corrective action
plan for future.
9.0.0 QUALITY AUDIT
9.1.0 OWNER reserves the right to carry out quality audit and quality surveillance of the quality
management and control activities, systems and procedures of the contractor or their
sub-contractor. The contractor shall provide all necessary assistance to enable the
OWNER carry out such audit and surveillance. The contractor shall also take necessary
measures, raise NCRs wherever required based on the audit findings / observations.

CLAUSE NO.
10.0.0 QA DOCUMENTATION PACKAGE
10.1.0 The contractor shall be required to submit the QA documentation in two hard copies and
two CD ROMs, as identified in respective quality plan with tick (√) mark. Typical contents
of QA documentation pertaining to field activities as per approved MQP, FQP and other
agreed manuals / procedures, prior to commissioning of individual system shall generally
contain the Quality Plan, Material mill test reports, Non-destructive examination results /
reports, Heat Treatment Certificate/Record, Non-conformance Reports, CHP, Certificate
of Conformance (COC) and MDCC.
11.0.0 GENERAL QA REQUIREMENTS
11.1.0 The contractor shall ensure that the works, BOIs and services under the scope of
contract whether manufactured or performed within contractor’s works or at his sub-
contractor’s premises or at the OWNER’s site or at any other place of work are in
accordance with the OWNER technical specification, applicable standards / codes,
approved drawings / data sheets / quality plans and BOQ. All the works, BOIs and
services shall be carried out as per the best prevalent engineering practices and to the
directions of the Owner.
11.1.1 STORAGE AND HANDLING OF CONSTRUCTION MATERIALS
All materials shall be stacked and stored by the Contractor as per IS-4082 and as per
the requirements specified in OWNER Technical Specification.
11.1.2 EXCAVATION AND FILLING WORKS
The contractor shall submit a work methodology covering various items of works for all
stages of excavation and filling works. This methodology shall broadly include the
quantity wise and classification wise identification of source of excavation and filling,
suitability tests as per specification requirements, method of stockpiling, transportation,
placement, spreading , compaction, equipment, list of protocols, in-situ tests, third party
lab test if required, acceptance checks for final clearance.
For blasting work at site if required, the contractor shall associate themselves with the
reputed specialized blasting agency such as CMRI, NIRM for trials blasts, design blasts,
blasting pattern, monitoring of blast during the blasting operations at site. The contractor
shall install and operate equipment (such as tri-axial seismograph) for continuous
monitoring and control of blast induced vibrations, noise level/ air pressure, dust, silica
and noxious gases during all blasting operations in line with the technical specification
requirements in association with the specialized blasting agency. The contractor shall
submit the un-priced copy of the award on the specialized blasting agencies to OWNER,
highlighting the scope of services / work awarded to them by contractor. The services of
such specialized blasting agency shall be available through out the period in which the
blasting work is undertaken at site. The blasting operation shall remain in charge of a
responsible, competent, authorized and experienced supervisor (man-in-charge) and
thoroughly acquainted workmen. All blasting work shall be done as per approved
blasting scheme/ design/ pattern in line with the technical specification requirements and
all statutory laws, rules, regulations, relevant standards pertaining to the acquisition,
transport, storage, handling along with use of explosives shall be strictly followed by the
contractor.
Tolerance for finished surface level shall be within 20 mm of the level shown in the
drawing. For an unimportant area, tolerance up to +75mm shall be acceptable at the
CLAUSE NO.
discretion of the Owner. However, these tolerances shall be applicable for localized
areas only.
Acceptance criteria shall be
a) When only one set of sample is tested, then all individual samples collected and
tested should pass without any deviation
b) For retest of any sample two additional samples shall be collected and tested, and
both should pass without any deviation.
c) Where a large number of samples are tested for a particular test then 9 samples out
of every 10 consecutive samples tested shall meet the specification requirement.
11.1.3 MASONRY AND ALLIED WORKS
The execution, finishing, testing and acceptance of masonry related works shall be as
per the provisions of technical specifications / relevant practices IS code. Local
depressions on account of faulty workmanship, broken / chipped edges shall not be
acceptable.
All masonry shall be built true and plumb within the tolerances prescribed as below.
Care shall be taken to keep the perpends properly aligned. Unless specified otherwise
the tolerances in construction of masonry works shall be as below:
Sl. No. Type of Check Tolerance

Deviation in verticality in total Shall not exceed  12.5mm (more than
height of any wall of a building one storey)
 6mm per 3m height (within a storey)
Deviation from the position Shall not exceed 12.5mm (more than
shown on the plan of any one storey)
brickwork
Relative displacement between Shall not exceed 6mm
load bearing walls in adjacent
storeys intended to be in vertical
alignment
Deviation of bed joint from Shall not exceed 6mm (upto 12m)
horizontal in any length, and it Shall not exceed 12.5mm total (in any
length over 12m)
Deviation from the specified Shall not exceed  3mm

thickness of bed-joints, cross-
joints or perpends
Finished plastered surface Deviation not more than 4 mm when
checked with a straight edge of 2 m
length placed against the surface
The average thickness of plaster Not be less than the specified thickness
The minimum thickness over any Not less than the specified thickness by
portion of the surface more than 3 mm for plaster thickness
above 12mm and 1 mm for ceiling
plaster

CLAUSE NO.
11.1.4 CONCRETE WORKS
For concreting works provisions of technical specifications and IS: 456 shall apply. A
detailed methodology for concrete works shall be submitted by the contractor to
OWNER for approval. The methodology may require change / modification based on the
site conditions, for which suitable revisions shall be submitted.
The methodology for concrete works shall broadly contain the suitability of source of
aggregates, cement, admixture, water and reinforcement steel, etc. The available
concrete mix design recommended from a specialist institute, results of trial mix carried
out at site, method / control of batching, mixing, transportation, layer wise placement,
compaction, fixing / removal of form work, staging, fixing of water stops at appropriate
locations along with specials, expansion joints, contraction joints and construction joints,
cover blocks and method of curing, methodology of repair of newly placed hardened
concrete, testing and sampling of concrete during production and placement and
acceptance checks for final clearance.
The equipment, deployment of manpower and machinery shall arranged by the

contractor to ensure the continuous rate of placement of specified grade of concrete so
as to prevent segregation, bleeding, formation of cold joints, temperature control for
concreting in extreme weather conditions and for mass concreting works.
Exposed surfaces of concrete shall be kept continuously in a damp or wet condition for
at least seven days from the date of placing concrete in case of ordinary Portland
cement, not be less than 10 days for concrete exposed to dry and hot weather
conditions, at least 10 days or period may be extended to 14 days where mineral
admixtures or blended cements are used. Approved curing compounds may be used in
lieu of moist curing with the permission of Owner.
Reinforcement steel shall conform to relevant IS codes. Lapping / spacing of

reinforcement shall be so staggered that under no circumstances more than 50% of bars
at any cross section shall be lapped. Corrosion resistance Steel shall be used for the
foundations wherever specified in the technical specification. Sample test for 3% of the
number of mechanical bars grips subject to a minimum of three, shall be carried out up
to the yield strength of reinforcement of bars.
Test shall be conducted for the water tightness of the liquid retaining structures as per
technical specifications, IS 3370 and IS 6494.
All the materials, equipments, processes used in pre cast concrete work shall conform to
the requirements for the cast-in-situ concrete.
If fly ash is used in concrete, source of supply shall be checked for suitability as per IS
3812 (Part-I). Routine tests for retention of particles on 45μ sieve and loss on ignition
shall be carried out on each lot of fly ash before its use. The storage of fly ash shall be
similar to that of cement. Separate Silo for fly ash shall be provided in the batching plant.
Validation of Mix design using fly ash shall be carried out by an approved specialist
agency, before start of concrete production.
The acceptance criteria of concrete shall be in accordance with clause no.16 of IS 456.
However in exceptional circumstances and that too in non-critical areas, the Owner may

CLAUSE NO.
accept concrete work which is marginally unacceptable as per the criteria laid down in IS
456. For such accepted work, payment shall be made at a reduced rate pro rata to the
concrete cube strength obtained, against that stipulated.
All records of concreting, reinforcement, testing of materials, as-built dimensions, the
details of the rectification, etc, shall be maintained as given below. Four copies of such
record in a bound form shall be submitted to owner for their record and future reference.
a. Testing data / report of aggregates including petrographic examination & potential
reactivity of aggregate and repeated temperature cycle tests wherever specified
b. Mix design details and record of trial mixes carried out at site
c. Testing records of admixture as per IS-9103 / ASTM C494 including third party test
reports.
d. Approved scheme for concreting
e. Hourly records of concreting including pour card
f. Protocol indicating the dimensional tolerance and details of inserts
g. Records giving the details of rectification giving the location of grouting, the
quantity of grout used at each location, type of grout used
h. Bar bending schedule
i. Location and details of mechanical anchoring used for reinforcement
j. Protocol giving the details of checking of reinforcements before concreting and
conformance to the reinforcement details as shown in the construction drawings
k. Photographs showing the areas where rectification works have been carried out.
Photographs should be taken before and after rectification
l. Temperature control record of concrete at the time of placement if applicable
m. Details of curing, staging and fixing / removal of formwork, checklist for formwork
as per Clause 9.9 and Annexure-C of IS 14687 including all machine foundations
n. Batching Plant shall be calibrated regularly at least once in a 3 months.
Computerized output shall be taken for each batch of production of concrete. For
concreting works of ash pipe pedestals, mixer with weight batcher may be used.
o. Dimensions (length, cross sectional dimensions, straightness, squareness, and
flatness) and tolerances for pre cast members as per OWNER Technical
Specification. Load test on Pre cast members (except precast tiles to be laid in
the reservoir) shall be carried out @ 1% up to 1000 nos., @0.5% from more than
1000 nos. precast members of one type. The load test shall be carried out as per
the provisions of IS-456 and relevant IS code.
TOLERANCES
Description of Item/ Structural Element Max Min
(mm) (mm)
Cast In Situ Concrete
1. Faces of concrete in foundations and structural members +25 -10
against which back fill is placed
2. Eccentricity of footing as percentage of footing width in the 2% but limited
direction of placement to 50mm
3. Top surfaces of slabs and of concrete to receive base +5 -5
plates to be grouted
4. Alignment of beams, lintels, columns, walls, slabs and +5 -5
CLAUSE NO.
TOLERANCES
Description of Item/ Structural Element Max Min
(mm) (mm)
similar structural elements
5. Cross sectional dimensions of walls, slabs and similar +5 -5
structural elements
6. Deviation from specified dimensions of cross-section of +12 -6
columns and beams
7. Alignment of holding down bolts without sleeves +1.5 -1.5
8. Alignment of holding down bolts with sleeves +5 -5
9. Level of holding down bolt assemblies +10 -10
10. Embedded Parts (in any direction). +5 -5
11. Level of embedment for equipment support +1.5 0
12. Level of embedment for other embedded parts +5 -5
13. Centers of pockets or holes with greatest lateral dimension +10 -10
not exceeding 150mm
14. Variation in steps
 Riser +1.5 -1.5
 Tread +3.0 -3.0
Pre- Cast Concrete
15. Length: +/- 0.1 percent +/- 5 + 10
16. Straightness or Bow 1/750 of the length +/- 5 +/- 10
17. Cross-sectional +/- 3 mm or +/- 0.1 percent whichever is greater
dimensions
18. Squareness: When considering the squareness of the corner the
length of the two adjacent sides being checked shall be
taken as the base line. The shorter side shall not vary
in length from the perpendicular by more than 5 mm.
19. Flatness: The maximum deviation from a 1.5m straight edge
placed in any position on a nominal plant surface shall
not exceed 5 mm.
Placing of reinforcement and for cover (Cover blocks Clause 12.3.1
shall be of same grade of concrete in which these would and 12.3.2 of IS
be embedded) 456
Formwork Clause 9.6 of IS
14687 and 11.1
of IS 456
Batching Clause 10.2.2
of IS 456
11.1.5 STRUCTURAL STEEL WORK
11.1.5.1 For structural steel works provisions of technical specifications and IS: 800 shall apply.
A detailed methodology for structural steel works shall be submitted by the contractor to
OWNER for approval. The methodology may require change / modification based on the
site conditions, for which suitable revisions shall be submitted.
11.1.5.2 The contractor shall submit the welding procedures specification (WPS), heat treatment
procedures, NDT procedures etc. at least ninety days before scheduled start of erection
work at site. All welding and brazing shall be submitted to the OWNER and carried out as

CLAUSE NO.
per procedure drawn and qualified in accordance with requirements of ASME Section
IX/BS-4870 or other International equivalent standard acceptable to the OWNER.
11.1.5.3 All brazers, welders and welding operators employed on any part of the contract either in
the contractor’s / sub-contractor’s works or at site or elsewhere shall be qualified as per
AWSD1.1/ASME Section-IX or BS-4871 or other equivalent International Standards
acceptable to the OWNER.
11.1.5.4 The records of welding procedure qualification and welder qualification test results shall
be furnished to the OWNER for approval. However, where required by the OWNER, the
tests shall be conducted in presence of OWNER / authorized representative.
11.1.5.5 No welding shall be carried out on cast iron components for repair. All the heat treatment
results shall be recorded on time temperature charts and verified with recommended
regimes.
11.1.5.6 All Non-destructive examination shall be performed in accordance with written
procedures as per International Standards and as mentioned elsewhere in the technical
specification. The NDT operator shall be qualified as per SNT-TC-IA (of the American
Society of non-destructive examination). NDT shall be recorded in a report, which
includes details of methods and equipment used, result/evaluation, job data and
identification of personnel employed and details of co-relation of the test report with the
job. The records of RT (Films) and UT (inspection records or printed reports if possible)
shall be documented and produced to OWNER.
11.1.5.9 The following tests / checks shall be carried out for structural steel works
SL. TESTS / CHECKS QUANTUM / STANDARD

NO.
1. Physical and chemical properties of As per relevant codes, review of
material if supply in the scope of correlated mill test certificates or
contractor check testing in absence of MTC
2. Ultrasonic test on plates above 40mm As per ASTM A578 Level B-S2
3. Welding procedure & welders AWSD1.1/ASME Section-IX or
qualification test BS-4871 or other equivalent
International Standards
Fillet Weld
4. Macro-etch examination on production Minimum one joint per built up
test coupons for main fillet welds beams, columns and crane girder
etc.
5. Tension member of crane girder Dye penetration test on 25% weld
length
6. All other fillet welds DPT on 5% of weld length with
minimum 300mm at each location
Butt Weld
7. DPT 100% after back gouging on all
butt welds except for coal bunker
bins
10% after back gouging-For coal
bunker bins

CLAUSE NO.

NO.
8. Mechanical testing of production test Minimum one joint per built up
coupons beam, column and crane girder.
9. Radiography test on butt welds 100% RT on butt welds of tension
(In case of failure of any welds in flange (bottom flange) of crane
SPOT/RT or UT the % of retesting girders
shall be doubled at that particular 10% RT weld length of each
location. Acceptance criteria of NDT welder on butt welds, except for
on welds shall be as per AWS D1.1. crane girders and coal bunker
Wherever RT is not feasible UT to be
carried out with the approval of the 5% spot RT on butt welds / at
Owner) inaccessible locations UT on butt
welds- For coal bunker bins
10. Ultrasonic testing on full penetration 100% UT on the web to flange
welds (other than butt welds) joint of crane girder
10% UT on other full penetration
joints
11. Control assembly check in shop 1st and further every 10th set of
before erection identical structure
12. Dimensional tolerances during as per IS-7215 and IS-12843
fabrication and erection
13. Surface Preparation and Paint SA 2 1/2 , By elcometer random
thickness after each coat, each member
11.1.6 CW LINER/DUCT
The following tests / checks shall be carried out for CW Liner works:

NO.
CW Liner Fabricated at Site (Field Shop) and Factory Fabricated CW Liner using
Steel Plates with Longitudinal & Circumferential Weld Joints
Option-1
1. WPS,PQR& welder’s 100%
Qualification
2. DPT on root run 100% for pipes upto 1200mm diameter
3. DPT after back gouging 100% for pipes above 1200mm diameter
4. UT Not recommended.
5. RT 5%
6. DPT on finished butt welds 10%
7. Hydro test 1.5 times the design pressure or 2 times
the working pressure whichever is higher.
Option-2
Qualification

CLAUSE NO.

NO.
4. UT Not recommended
5. RT - 100 % RT on circumferential joints in the
bottom 1/3 portion of CW liner for weld
length as per Fig 1
- 5% RT on top 2/3 portion of circumferential
joints and
- 5% RT on longitudinal joints

7. Hydro test No Hydro test
Factory fabricated CW liner using H.R. coils with spiral weld joints
1. WPS,PQR& welder’s Qualification 100%
2. DPT on root run 100% DPT for pipes upto 1200mm diameter
3. DPT after back gouging 100% DPT for pipes above 1200mm diameter
5. RT 5% RT
6. DPT on finished butt welds 10% DPT
7. Hydro test Hydro test at 1.5 times the design pressure or
2 times the working pressure whichever is
higher.
CW Liners erection site test
Qualification
5. RT 5%
7. Hydro test 1.5 times the design pressure or 2 times
the working pressure whichever is higher.
In exceptional cases where hydraulic test
is not possible the same may be
substituted with 100%RT
11.1.7. SHOP TEST EOT Cranes, Other cranes & Hoist
1.0 HOOKS
1.01 ALL TESTS INCLUDING PROOF LOAD TEST AS PER RELEVANT IS/BS/DIN
SHALL BE CARRIED OUT.
1.02 MPI/DPT SHALL BE CARRIED OUT AFTER PROOF LOAD TEST.
2.0 STEEL CASTING
2.01 DPT ON MACHINED SURFACE SHALL BE CARRIED OUT.
3.0 GIRDERS, END CARRIAGE,CRAB, GEAR BOX AND ROPE DRUM

CLAUSE NO.
3.01 THE PLATES OF THICKNESS 25MM AND ABOVE SHALL BE

ULTRASONICALLY TESTED.
3.02 NDT REQUIREMENTS ON WELDMENTS SHALL BE AS FOLLOWS:
a) BUTT WELDS IN TENSION:- 100% RT AND 100% DPT

b) BUTT WELDS IN COMPRESSION:- 10% RT AND 100% DPT
c) BUTT WELDS IN ROPE DRUM:- 100% RT AND 100% DPT
d) FILLET WELDS:- RANDOM 10% DPT
4.0 FORGING (WHEEL, GEARS, PINIONS, AXLE, HOOKS & HOOK TRUNION)
4.01 ALL FORGINGS GREATER THAN OR EQUAL TO 50 MM DIAMETER OR

THICKNESS SHALL BE SUBJECTED TO ULTRASONIC TESTING.
4.02 DPT/MPI SHALL BE DONE AFTER HARDFACING AND MACHINING.
5.0 WIRE RPOE SHALL BE TESTED AS PER RELEVANT STANDARD.
6.0 REDUCTION GEARS SHALL BE TESTED FOR REDUCTION RATIO,

BACKLASH & CONTACT PATTERN. GEAR BOX SHALL BE SUBJECTED TO
NO-LOAD RUN TEST TO CHECK FOR OIL LEAKAGE, TEMPERATURE RISE,
NOISE AND VIBRATION.
7.0 THE CRANES SHALL BE COMPLETELY ASSEMBLED AT SHOP FOR FINAL

TESTING. ALL TESTS FOR DIMENSION, DEFLECTION, LOAD, OVERLOAD,
HOISTING MOTION, CROSS TRAVEL ETC. AS PER IS-3177 SHALL BE
CARRIED OUT AT SHOP.
8.0 ALL ELECTRIC HOISTS SHALL BE TESTED AS PER IS-3938 AND CHAIN
PULLEY BLOCKS SHALL BE TESTED AS PER IS-3832.

CLAUSE NO.

PAGE
(2X660 MW) SECTION – VI, PART-B SUB-SECTION-IIIE-28
16 OF 21
WATER SYSTEM PACKAGE BID DOC NO.: THDC/RKSH/CC-373 CIVIL WORKS
CLAUSE NO.
11.1.8 PAINTING WORKS

Painting works shall be carried out as per the provisions of technical specifications. A
detailed methodology for painting works shall be submitted by the contractor to OWNER
for approval. The methodology may require change / modification based on the site
conditions, for which suitable revisions shall be submitted.
The methodology for painting works shall broadly contain the source of approved brand
of paints, blast cleaning as specified, minimum acceptable size of shot used for blasting,
application of primer, intermediate coat and final coat, experience of applicator, etc.
testing of painting work and acceptance checks for final clearance. For PU coating
works if specified, material shall be procured from OWNER approved source and the
application of the PU coating shall be carried out by an experienced authorized
applicator of the material supplier approved by OWNER. A separate quality plan and
methodology for PU coating works shall be submitted by the contractor for approval of
OWNER. Based on the approved quality plan, the tests on material and works shall be
got conducted at specialist laboratories like IICT Hyderabad, CECRI Karaikudi.
11.1.9 SHEETING WORKS
All bought out items shall be procured from the approved manufacturers and tested as
per relevant Codes/ Specification. Raw material of colour coated sheets shall meet the
chemical & physical properties as per relevant standards / codes referred in the
approved data sheet. It shall be tested for colour match, bare metal thickness, weight of
Z/AZ coating, thickness of painting system, reverse impact, T-Bend adhesion, scratch
resistance, salt spray test for 1000 Hrs and any other test / properties as specified in the
technical specifications. Colour coated sheets shall be marked with video jet printing at
the interval not more than 2m bearing manufacturer’s name, date & time of
manufacturing. Fasteners shall also be tested for 1000 hrs salt spray test as per the
requirement of technical specifications.
Bonded Mineral Wool Insulation shall meet the requirements of thickness, density,
thermal Conductivity, all other tests as per the technical specifications and IS-8183.
For sheet installation no gas cut opening shall be allowed at the site, whenever opening
is specified these shall be properly cut in the factory and shall be filled with lipping /
flashing for true shape / dimension etc. The sheets/ packets shall be stacked neatly
clear off the ground at an angle to the ground, over a base pallet to provide drainage.
Water / moisture should not be allowed to stagnate on surface, or in between layers.
This can damage the coating, and cause corrosion.
11.1.10 TILE WORKS
The contractor shall submit the work methodology which shall include the type, grade
and make of materials along with their technical data sheets, details, etc, clearance from
E-I-C regarding leak proofness and damp proofness of parent concrete surface, surface
preparation, the procedure of application, curing, testing and acceptance.
The agencies having adequate experience to execute the acid / alkali resistant lining
works shall be engaged for executing the acid / alkali resistant lining works after
obtaining the approval from the E-I-C.
The execution, finishing, testing and acceptance of tile works shall be as per the
provisions of technical specifications. The material for tile works shall be procured from
the OWNER approved brand / source. Local depressions on account of faulty
workmanship, tiles / natural stones with cracked or broken / chipped edges shall not be
acceptable.
The tests shall be carried out on acid resistant bricks / tile- water absorption,
compressive strength, resistance to acid, flexural strength, dimensions and all other

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17 OF 21
CLAUSE NO.
tests as per IS 4860 and IS 4457, bitumastic ready mixed paint as per IS 158, bitumastic
as per IS 9510, potassium silicate, resin type and sulphur type mortars as per IS 4832,
part I, II and III, surface preparation for painting as per IS 2395, epoxy painting shall be
carried for required coating thickness and dry film thickness.
11.1.11 FIRE PROOF DOORS
Fire Proof doors shall be tested for the requirements mentioned in the Technical
Specification. The type test of the doors shall be carried out at CBRI Roorkee for
minimum 2 hours fire rating and its Fabrication drawing shall also be approved by
CBRI, Roorkee. DFT of paint of Fire Proof Doors and its fittings and fixtures as per
BOQ shall be checked. The doors shall be finished with suitable fire retardant painting
system
11.1.12 WATER PROOFING
The execution, finishing, testing and acceptance of water proofing works shall be as per
the provisions of technical specifications. The material for the works shall be procured
from the OWNER approved brand / source and the works shall be executed by the
authorized applicator of the supplier.
Water proofing shall be tested for water tightness by creating a pond of water minimum
25 mm height on area of 6 m x 6 m, for the period of 48 hrs on fully dried elastomeric
membrane surfaces. Minimum 5% area of the roof shall be subjected to water tightness
test. Such test necessarily be conducted on vulnerable areas like drain channel / drain
head. No dampness shall be visible on the underneath side of roof (i.e. ceiling), parapet
and well junctions etc. which have been subjected for testing. The above testing shall be
carried out prior to application of wearing course.
11.1.13 PILING WORK (If Applicable)
For piling works provisions of technical specifications, approved drawings, BOQs and
relevant IS codes / standards shall apply. The piling works shall be executed by the
agency meeting the qualifying requirements as specified. A detailed methodology for
piling works shall be submitted by the contractor to OWNER for approval. The
methodology may require change / modification based on the site conditions, for which
suitable revisions shall be submitted.
The methodology for piling works shall broadly contain the method of boring, stability of
bore hole, termination criteria, tests / checks for termination level, fabrication of cage,
cage lowering, concrete batching / mixing, transportation, placing, recording of the time
of construction operations, method of conducting initial and routine load tests, testing
and sampling of concrete during production and placement and acceptance checks on
piles for final clearance.
The equipment, deployment of manpower and machinery shall be arranged by the
contractor to prevent the collapse of bore hole and to ensure continuous rate of
placement of specified grade of concrete.
The piling works shall be executed as per the technical specifications, approved
drawings, relevant codes / standards, FQP and BOQ. In addition to the requirements of

PAGE
18 OF 21
CLAUSE NO.
technical specifications, the following shall also be ensured while execution of piling
works:
a) Time gap between completion of pile boring and start of concreting should be kept to
the minimum. However the maximum time gap shall not be more than 6 hours.
b) Muck Debris should be removed from the pile bore by air lift technique(by keeping
the tremie & air pipe as close as to bottom of pile bore) i.e. after completion of boring,
after completion of SPT(wherever applicable), after lowering reinforcement cage, but
before start of concreting.
c) Density of bentonite slurry shall be checked from the sample taken from the bottom
of pile bore( not at 1.0 m above the bottom of the pile bore)
d) Minimum two welding sets shall be kept ready to join the two cages of reinforcement
by engaging 3 or more welders. This will ensure the lowering of R/F cage in minimum
time.
e) While lowering the R/F cage into the pile bore, two hooks shall always be used to
ensure balanced/symmetrical insertion of cage into the pile bore.
f) Concrete cover blocks at the junction of two R/F cage shall be ensured before
lowering the second segment.
g) Surge concreting of about 1.0 cum shall be ensured at the start of concreting (i.e. in
the first pour), by suddenly allowing to fall through the tremie pipe from the funnel.
This will help in displacing left out muck/debris in the pile bore (by the impact).
h) Continuous feeding of concrete shall be ensured by deploying at least two transit
concrete mixers (if required to be deployed) and mixing done through concrete
batching plant (if deployed). Cold joints in the pile shall be avoided.
i) In a pile group, SPT shall be carried out at termination level in the pile, taken up first.
j) Bentonite slurry circulation to be ensured from start of boring to start of concreting.
Flushing of bentonite slurry will only ensure maintaining of density of bentonite slurry
uniformly and will not allow bentonite jelly to settle at the bottom, whereas air lift
technique with bentonite circulation will ensure removal of muck debris from the
bottom of pile bore.
k) Properties of drilling mud shall be checked prior to commencement of the piling work
and thereafter, minimum once per week or as found necessary by the Owner. One
sample consisting of 3 specimens shall be tested for the above.
l) Low strain pile integrity test on all job piles and test piles shall be conducted as
specified in the Technical Specification. This test shall be suitably used to identify
the piles for routine tests. High Strain dynamic test shall be done as per the technical
specification. The frequency of the test shall be as per the BOQ
m) For Working Piles: Minimum one sample consisting of 6 test cubes shall be made for
first ten piles. Out of these 3 shall be tested for 7 days cube strength and 3 for 28
days cube strength. Minimum one sample of 6 test cubes for every 25 nos. of piles
shall be tested, out of these 3 shall be tested for 7 days cube strength and 3 for 28
days cube strength
PILE LOAD TEST
Pile load testing shall conform to the requirements of IS-2911 (Part IV) and the
technical specification. Initial load tests as specified in the contract documents shall be

PAGE
19 OF 21
CLAUSE NO.
conducted to assess the safe load carrying capacity of pile before start of work. To
verify the load carrying capacity of the working piles, routine load test shall be
conducted.
Pile load-testing procedure and the test setup / scheme shall be submitted for
approval of OWNER. The contractor shall use the test setup having arrangement for
anchor piles / rock anchors alone or combination of anchor piles / rock anchors and
kentledge for both vertical compression and uplift (tension) Load test (initial) on piles.
The cost of reaction system / piles shall deem to be included in the cost of test piles
All the gauges and instruments shall be calibrated before the start of the tests on test
piles and working piles and the calibration record shall be verified before start of
execution of the test.
11.1.14 WATER SUPPLY, DRAINAGE & SANITATION
Material used for sanitary and plumbing fittings and fixtures shall conform to and be
tested as per the requirements of relevant IS Codes specified in OWNER technical
specification.
The obstructions in sewer lines shall be checked by inserting a smooth ball, of diameter
13 mm less than the pipe bore at the high end of the sewer or drain. If absence of any
obstructions, such as yarn or mortar projecting through the joints, ball shall roll down the
invert of the pipe and emerge at the lower end. The straightness shall be checked by
means of a mirror at one end of the line and lamp at the other. If the pipeline is straight,
the full circle of the light may be observed. The mirror will also indicate obstruction in the
barrel, if the pipeline is not straight.
The service pipes shall be slowly and carefully charged with water, allowing all air to
escape avoiding all shock or water hammer. The service pipe shall then be inspected
under test / working condition of pressure and flow, when all draw-off taps are closed.
The service pipes shall be checked for satisfactory support and protection from damage,
corrosion and frost.
11.1.15 ARCHITECTURAL & MISC. WORKS

Material used for sanitary and plumbing fittings and fixtures, floor finishes and allied work
shall conform and tested as per the requirements of relevant IS Codes specified in
OWNER technical specification.
Fabricated item like metal doors, windows, ventilators, louvers, rolling shutters and grills
etc. shall be checked for correctness of locations and smoothness of operation and
fixtures. All controls and locking devices shall give fault free performance. Door and
window shutters shall operate without jamming. The clearance at head and jamb for door
shutters shall not exceed 1.5 mm. For double leaf doors, the gap at the meeting stiles
shall not be more than 2.5 mm.
Materials used in glass and glazing shall be procured from source approved by OWNER
and shall conform to the requirements of the Technical Specification and IS Codes.
False ceiling panels shall be best quality material in thickness and properties called for in
the specification / schedule of items. Material Test Certificate to be submitted before
bulk supply.

PAGE
20 OF 21
CLAUSE NO.
All bought items covered in the scope of contract shall be procured from sources
approved by OWNER and shall conform to the requirements of the technical
specifications and referred standards /codes.
11.1.16 ROAD WORK

Quality Assurance and testing requirements for roadwork shall be as per the MORTH-
Specification (latest), IRC specifications as specified in the technical specifications and
BOQ of the contract.
The testing and sampling shall include the checks on earth work for embankment and
subgrade, sub bases and bases and bituminous constructions. The sampling and testing
of concrete pavements shall be as per the respective items of earthwork, subgrade / sub-
base, concrete, etc.

PAGE
21 OF 21
CLAUSE NO.
QUALITY ASSURANCE
ANNEXURE-I
QA&QC ORGANISATION SETUP
Project Manager
Manager (Quality)
Civil Engineer (lab incharge) Geotechnical Engineer

( I/c Earth work)
Civil Engineer (Field 1*)
.Civil Engineer (Field 2**) Civil Engineer (Field 3***) Engineer (NDT) (Mech) Engineer (welding & fitup)
Lab Assistant & Qualified Manpower

sufficient skilled manpower RT level II - 1No
UT level II - 2 No
NOTE:
1. The above organization setup is minimum however their deployment shall be

as per the agreed deployment schedule. The contractor shall prepare a
manpower deployment schedule in line with the finalized work plan and the
same shall be submitted to the engineer-in charge for acceptance/ approval.
2. The contractor shall mobilize the QA& QC manpower in line with the finalized
manpower deployment schedule and shall ensure their availability well in
advance (15 days approx.) of the beginning of the concerned activity/ work.
3. The contractor shall further mobilize required number of skilled & supporting
staff and additional resources, if any to meet the work schedule.
4. * For concrete work 2 Nos ( one for foundation work & one for superstructure)
5. ** For lines and levels - 1 No.
6. *** For Finishes and cladding work - 1 No

(2X660 MW)
SECTION – VI, PART-B CIVIL WORKS 1 OF 1
WATER SYSTEM PACKAGE ANNEXURE-I
ANNEXURE - II
LIST OF SPECIALIST INSTITUTES / ORGANIZATIONS FOR TESTING AND EVALUATION OF BUILDING MATERIALS
Sl No. Name of the Institute Contact Person Test Facilities Special Studies / Investigation
1 Indian Institute of Technology Head, Deptt of Civil Engg, Mix design and material properties on In situ non destructive testing (UPV) of
Bombay, Phone : 022 25722545 selective basis concrete structures, design of mass
Powai, Mumbai - 400076 concrete, temperature studies, distress
assessment
2 Indian Institute of Technology Head, Deptt of Civil Engg. Selective specialised studies such as design
Madras, Chennai- 600 036 Phone: 044 22574266/5255 of fly ash concrete and special concrete, non
destructive testing (UPV) of structures
3 Indian Institute of Technology Head, Deptt of Civil Engineering, Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Guwahati -781039 Phone : 0361 2582401, 258 2442, and chemical), aggregates (mechanical concrete structures (selective basis),
258 2440 properties), fly ash (physical and chemical), design of mass concrete, studies on
admixtures, water, steel reinforcement, properties of fly ash concrete
petrography, alkali aggregate reactivity, mix
design
4 Indian Institute of Technology Kanpur Head, Deptt of Civil Engineering, Testing and evaluation of cement (physical Non destructive testing (UPV) on concrete
(UP) - 208016 Phone: 0512 2597346 and chemical), aggregates (mechanical structures, structural health assessment
properties), fly ash (physical and chemical),
admixtures, water, mix design
5 Indian Institute of Technology Head, Deptt of Civil Engineering, Testing and evaluation of cement (physical
Kharagpur (WB) -721302 Phone: 03222 283421 and chemical), aggregates (mechanical
admixtures, water, mix design, petrography
6 Indian Institute of Technology Delhi, Head, Deptt of Civil Engineering, Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Hauz Khas, New Delhi - 1100 016 Phone:01126591191 and chemical), aggregates (mechanical concrete structures (selective basis)
7 Indian Institute of Technology, Head, Deptt of Civil Engineering, Testing and evaluation of cement(physical Various tests on other building materials
Roorkee - 247667 Phone: 01332 285439, 273560 and chemical), aggregates (mechanical), fly such as silica fume, mass concrete, steel,
ash (physical and chemical), admixtures, bricks, tiles, doors, ferrocement covers,
water, steel reinforcement, mix design, pipes, bridge bearings, PVC water tanks,
petrography, alkali aggregate reactivity etc
8 Indian Institute of Science Head, Deptt of Civil Engineering, Design of roller compacted concrete, IISc basically involved in r&d activities
Bangalore 560012 IISC Bangalore radiation shield concrete, high volume fly ash relatred to civil enginnering and may only
concrete, fire bahavior of concrete, micro be contacted in case of specific studies /
cracking of concrete, non destructive testing consultancy.
(research & development) activities, behavior
of concrete under shrinkage and creep,
assessment of fire damaged concrete
9 Institute of Technology, Head, Deptt of Civil Engineering, Testing and evaluation of cement physical
Banaras Hindu University (BHU) Phone: 0542-2307016 properties), aggregates (mechanical
Varanasi (UP) -221005 properties), admixtures, water, mix design,
petrography
0000-999-QOG-R-002 REV 02 DATE 26.08.2014

10 Central Building Research Institute Head, Structural engineering Testing and evaluation of cement (physical Fire rating of doors, non destructive testing
(CBRI), Roorkee - 247667 division, Phone: 01332 283382 and chemical), aggregates (mechanical), fly of structures, various tests on other
ash (physical and chemical), admixtures, building materials such as bricks, steel,
water, mix design, alkali aggregate reactivity tiles,etc
11 Central Soil and Materials Research Joint Director Testing and evaluation of cement (physical Various tests on other building materials
Station (CSMRS), Near IIT Phone: 011 26962608 and chemical), aggregates (mechanical such as steel, geotextiles, geomembrane,
Delhi, Olof Palme Marg, New Delhi - properties), fly ash (physical and chemical), soil, instrumentation, monitoring, etc
110016 admixtures, water, petrography, alkali
aggregate reactivity, mix design
12 National Council for Cement and Head, Center for Construction Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Building Materials (NCB), 34 KM Development & Research and chemical), aggregates (mechanical concrete structures and special studies,
Stone, Delhi Mathura Road Phone : 0129 2246173 properties), fly ash (physical and chemical), testing of bricks, paving blocks, steel bars,
Ballabgarh(Har) admixtures, water, petrography, alkali silica fume, etc
aggregate reactivity, temperature cycle test,
XRD, steel reinforcement, mix design
13 National Council for Cement and General Manager, Testing and evaluation of cement (physical In situ Non destructive testing (UPV) of
Building Materials (NCB), NCB Phone 040 23000344, 040- and chemical), aggregates (mechanical concrete structures (selective basis)
Bhawan, Old Bombay Road 23000343 properties) , fly ash (physical and chemical),
Hyderabad 500008 admixtures, water, petrography, alkali
aggregate reactivity, steel reinforcement, mix
design
14 National Test House, Taramani S.O.(Civil) Testing and evaluation of cement (physical Various tests on other building materials
Chennai 600 113 Phone:04422432374, and chemical) , aggregates (mechanical such as paving blocks, Gi pipes, wires,
Fax:04422433158 properties) , fly ash (physical and chemical), steel plate, flush doors, salt spray test,
admixtures, steel reinforcement, water, mix etc
design
15 National Test House, Block CP S.O. (Civil), Testing and evaluation of cement(physical Various tests on other building materials
Sector V, Salt Lake city Phone:033 2367 3870 and chemical), aggregates (mechanical such as paving blocks, GI pipes, wires,
Kolkata-700 091 properties) , fly ash (physical and chemical) , steel plate, flush doors, etc
admixtures, water, steel reinforcement, mix
design
16 National Test House (NTH), S.O. (Civil), NTH Ghaziabad Testing and evaluation of cement (physical Timber, clay products, water proofing
Kamla Nehru Nagar, Ghaziabad and chemical), aggregates (mechanical compound, flush doors, laminated sheets,
(UP) properties), fly ash (physical and chemical), plywood, etc
admixtures, water, stel reinforcement
17 Structural Engineering Research Head, Department of Material Testing and evaluation of cement (physical In situ Non destructive testing (UPV) of
Centre (SERC), Testing, and chemical) , aggregates (mechanical concrete structures (selective basis) and
Taramani, Chennai 600 113 Phone: 044 22549152, 22541735 properties), fly ash (physical and chemical), special studies such as cement admixture
admixtures, steel reinforcement water, mix compatibility, design of special concrete,
design evaluation of structures
0000-999-QOG-R-002 REV 02 DATE 26.08.2014

18 Vishveswaraiya National Institute of Director, VNIT Nagpur, Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Technology(VNIT), Phone:0712 2223710, 2222828 and chemical), aggregates (mechanical concrete structures and soil tests
Nagpur (MH) - 440010 properties), fly ash (physical and chemical),
admixtures, water, mix design, petrography
19 Anna University, Department of Head, Deptt of Civil Engineering Testing and evaluation of cement (physical
Structural Engineering, and chemical) , aggregates (mechanical
Chennai - 600 025 properties) , fly ash (physical and chemical) ,
20 Shriram Institute for Industrial Dr (Mrs) Laxmi Rawat, Testing and evaluation of cement (physical Various tests on other building materials
Research, 19 University Road, Delhi Asstt Director & Chief and chemical), aggregates (mechanical such as steel, geotextiles, geomembrane,
110007 Phone:011 27667267 properties), fly ash (physical and chemical), soil, bricks, tiles, etc
21 Spectro Analytical Lab, E-41, Okhla Phone: 011 26383048-49 Testing of cement (physical and chemical), Chemical and physical tests on steel
Indl Area, Ph II, New Delhi 110021 Fax: 40503150, 40503151 aggregates (mechanical properties), fly ash reinforcement
(physical and chemical), admixtures, water
22 Motilal Nehru National Institute of Director, MNIT Allahabad, Testing and evaluation of cement (physical In situ non destructive testing (UPV) of
Technology (MNIT), Allahabad - Phone: 0532 2271305, Fax: 0532 and chemical) , aggregates (mechanical concrete structures.
211004 2545341 properties), fly ash (physical and chemical),
admixtures, steel reinforcement water, mix
design
23 Govt Enginering College, Jalpaiguri Head Deptt of Civil Engg, Testing and evaluation of cement (physical ),
(WB) - 735102 Fax: 03561256143 aggregates (mechanical properties), water,
mix design
24 College of Engineering Head Deptt of Civil Engg, Testing and evaluation of cement (Physical
Pune - 411005 Phone No : 02025507067, & Chemical properties), fly ash (Physical &
Fax : 02025507299 Chemical properties), aggregates
(Mechanical properties except alkali
aggregate reactivity & Petrography), water,
admixtures and mix design
25 Maulana Azad National Institute of Head Deptt of Civil Engg, Testing and evaluation of cement (physical ), In situ non destructive testing (UPV) of
Technology, Bhopal (MP) Phone No : 07554051390 aggregates (mechanical properties),water, concrete structures and soil tests.
mix design
26 National Institute of Technology, Head Deptt of Civil Engg, Testing and evaluation of cement (physical ), In situ non destructive testing (UPV) of
Rourkela (Odisha) Phone No : 06612462300 aggregates (mechanical properties), mix concrete structures and soil tests. Test on
design, steel reinforcement, bricks and bitumen
0000-999-QOG-R-002 REV 02 DATE 26.08.2014

CLAUSE NO.
QUALITY ASSURANCE
ANNEXURE - III
Format of Request Letter for Evaluation of Materials
Ref: _____________ Date: _____________
To,
Sub.: Evaluation of materials and concrete mix design
Dear Sir,
We have awarded the work of …………………… on M/s ……………….. vide our LOA
No. ……………………….dated…………………for execution of Civil Works. Based on provisions
of contract, M/s ………………….. are expected to get the following tests/ evaluation done
through your laboratory and accordingly the tests have been described below.
M/s ………………… have been advised to deposit the requisite evaluation/ testing charges and
to deliver the test samples of quantities, specified below.
1. Evaluation of Cement:
a) To carry out different physical tests on cement samples i.e. Blaine’s fineness, initial and final
setting time, soundness and compressive strength at 3, 7 and 28 days as per IS: 4031 and
drying shrinkage and specific gravity in case of PPC.
b) To carry out chemical analysis of the cement samples as per IS: 4032, including the total
alkali content of the cement (Na2Oequivalent).
c) To advise the suitability of cement based on the test results of a) and b) above.
2. Evaluation of Aggregates:
a) To carry out different tests on coarse aggregate sample i.e. specific gravity, water
absorption, sieve analysis, deleterious material; soundness, crushing value, impact value,
abrasion value, elongation index and flakiness index, as per IS: 2386.
b) To carry out different tests on fine aggregate sample i.e. specific gravity, water absorption,
sieve analysis soundness, deleterious material, silt content, clay content and organic
impurities as per IS: 2386 and mica content.
c) To prepare evaluation report based on test results of a) and b) above and to advise
regarding suitability of fine and coarse aggregates to be used with the cement of 1) above.
3. Evaluation of Aggregates for Potential Alkali-Aggregate Reactivity:

a) To carry out petrographic analysis and accelerated Mortar bar Test on aggregate samples
(1N NaOH at 80 deg. Centigrade for 14 days as per ASTM 1260, or the method
established/ developed by CSMRS for 22days test).
b) If rock type is limestone, X-Ray diffraction test (XRD) shall be carried out to determine clay
mineral in the rock for preliminary conclusions and to carry out repeated temperature cycle
test to determine residual expansion of aggregate for concrete to be used in dynamic
foundations like TG, Fans, mills, crushers etc. Additionally, Alkali carbonate reactivity test
shall be carried out as per ASTM C 1105 wherein the parameters shall be reported in
conjunction with the petrographic analysis.

(2X660 MW)
WATER SYSTEM PACKAGE ANNEXURE-III
CLAUSE NO.
QUALITY ASSURANCE
c) To prepare a report based on test results of a) and b) above and to advise regarding
suitability of aggregates to be used with the cement of 1) above and further testing required
if any.
4. Evaluation of Flyash Sample:

a) To carry out various physical and chemical tests on fly ash sample i.e. Blaine’s fineness,
lime reactivity, specific gravity, loss on ignition and other chemical tests as per IS: 3812,
conforming to grade-I.
b) To advise the suitability of fly ash sample based on the test results of a) above.
5. Evaluation of water: To carry out various physical and chemical tests as per IS: 456 and IS:
3025.
6. Evaluation of admixtures: To carry out various physical and chemical tests as per IS:
9103.
Note: Test certificate shall be obtained from the supplier to compare the values given in Table 2
of IS: 9103 i.e. uniformity requirements.
7. Concrete Mix Design: Based on the provisions of technical specification, the Following
may be specified by site Construction department/Quality department **
a) For RCC Work
i) Grade of concrete
ii) Slump required, mm:
iii) Cement- Type and grade
iv) Max Size of Aggregates, mm
v) Exposure conditions
vi) Maximum water-cement ratio
vii) Minimum cement content
viii) Plasticizer/ admixture to be used or not (If yes, specify the brand/ type/batch no. of
plasticizer)
ix) Fly ash to be used or not (If yes, indicate % of fly ash to be used)
b) For PCC work: Same as i) to ix) of a) above

c) For piling work (if required): Same as i) to ix) of a) above
8. Details of material sampled: In order to facilitate the above mentioned tests, specified
quantities of samples have been collected and sealed jointly (by OWNER – Quality
department and contractors’ representative) is being sent for testing. The impression of
seal has also been punched below.
a) Quantity of material required for each mix-design:

Sl. Material Description Quantity Required
No.
i) Cement 2 bags (sealed in double polythene bags)
ii) Coarse Aggregates 100 Kg of each fraction as explained below :

e.g.; If Maximum size of aggregates (MSA) is
20mm, then 100 Kg each of 20-10mm and
10mm down are required. If MSA is 40mm then
100Kg each of 40-20mm, 20-10mm and 10mm
down are required.
iii) Fine Aggregates 200Kg
iv) Chemical Admixtures 2 Litres

(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
v) Water 100 Litres
vi) Fly ash (If decided to be 100Kg

used)
b) Quantity of material required for Alkali-Aggregate reactivity
Sl. Material Description Quantity Required

No.
i) Coarse aggregate
a) 80-40mm 60Kg
b) 40-20mm 60Kg
c) 20-10mm 60Kg
d) <10mm 60Kg
ii) Fine aggregates 60Kg
iii) Cement 2 samples (1 bag each), contemplated for use

in construction.
c) Impression/ Punch Mark of seal:
You are requested to kindly forward us the test reports along with the recommendations
regarding the suitability of materials to us at the earliest.
Thanking you,
Yours faithfully,
Name:
Contact Number:
Email ID:
(Quality department Representative of OWNER)
Note:
1. Based on provisions of technical specification, the testing charges for all the above
mentioned tests shall be borne by the contractor.
2. The content of the letter is for guidance only, and if required may be suitably modified to
suit the specific requirements of the package in consultation with QA-Civil.
** This line may be deleted in the letter sent to the institute.

(2X660 MW)
CLAUSE NO.
QUALITY ASSURANCE
ANNEXURE -IV
TYPICAL QA/QC LAB EQUIPMENT
Project: Package:
Sl. Equipment Nos.

No.
1 Vicat Apparatus with deskpot 2
2 Le Chatelier flask & Mould 2 each
3 Automatic/Manual concrete & Mortar Mixer 1 set each
4 Cube Moulds for cement testing 12
5 Vibration Machine 1
6 Length comparator 2
7 Shrinkage Bar mould 2
8 Automatic Sieve shaker 1
9 IS Sieves for coarse & fine aggregate 1 set for each
10 IS Sieves for coarse aggregate for Road 1 set
11 Proctor testing equipment 2 sets + 18 cores
12 Slump testing equipment 6 sets
13 Oven 2
14 Physical balance 1
15 Rapid moisture meter 2
16 Thermometer 4
17 Burret 2
18 Measuring cylinders 9
19 Measuring flasks 3
20 Compression testing machine 2 sets of 2000 kN capacity
each
21 Cube moulds 30
22 Electronic balance 2 (12 kg capacity), 2(
200 mg capacity)
23 pH balance As per requirement
24 Radiographic facilities As per requirement, Party
should deploy BARC
approved agency for carrying
out RT
25 Mechanical weighing machine 1 (100 kg capacity)
26 Ultrasonic testing machine As per requirement
27 D.P. Test kit 10
28 Vernier 300 mm, 600 mm 2
29 Micrometer (0.25 mm) out side (25.00) 2
30 Radiography film viewer 2
31 Inside Micrometer 25-750 dia 2
32 Digital elcometer for paint thickness 2
33 Baking oven for electrode 3
34 Portable ovens 2
35 Rebar detector to locate the reinforcement 1
before core cutting operation
36 Concrete coring machine (55mm, 60mm 1
upto 150 mm dia core bit)
37 Rebound hammer 1
38 Ultrasonic pulse velocity tester May be arranged from
specialist laboratory.
(2X660 MW)
WATER SYSTEM PACKAGE ANNEXURE-IV
CLAUSE NO.
QUALITY ASSURANCE
39 Curing tank 1 set

40 Flakiness and elongation index test gauges 2 each
41 Atterberg Limits set-up (Liquid Limit and 1 set each
Plastic Limit) and Shrinkage Limit
Apparatus with mercury
42 Impact testing machine 1 set
43 Pycnometer 2 set
44 Crushing value apparatus 1 set
45 Los angeles Abrasion Testing Machine 1 set
46 Free swell Index Apparatus 1 set
47 Bitumen Extractor Machine 1 set
Note:
1. The equipments listed above are indicative and required to be mobilized
as minimum requirement. Additional equipment if any, required for
successful completion of work shall be provided /arranged by the
contractor.
2. All test reports/ inspection reports have to be computerized and
maintained on LAN with an access to the owner
3. Computers - 2 Nos shall be deployed with Windows operating system
and connected to the OWNER server
Based on the schedule (L2/L3 Network), Quality control & Quality Assurance work plan
shall be finalized by the contractor and the same shall be submitted to the engineer-in-
charge for acceptance/approval. The Finalized work plan shall be maintained on the
computer to be accessed by the owner for database and day to day monitoring.

(2X660 MW)
WATER SYSTEM PACKAGE ANNEXURE-IV
INDICATIVE FIELD QUALITY PLAN Annexure- V A
ITEM : CIVIL WORK QP NO. : 1 PROJECT: Khurja STPP (2 X 660 MW)
SUPPLIERS NAME AND
LOGO SUB-SYSTEM : GEOTECH INVI, FOUNDATIONS, REV. NO .: 0 PACKAGE: Water System Package
ADDRESS:
EXCAVATION & FILL, SITE LEVELLING, CONCRETE, ROAD, DATE : CONTRACT NO.
BUILDING ETC. PAGE : MAIN CONTRACTOR
Class of Acceptance Format of
Sl. No Activity and operation Characteristics / instruments Type of Check Quantum Of check Reference Document Remarks
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
1 GENERAL REQUIREMENTS
Functioning of laboratory equipment in
Setting up of Field QA&QC Once prior to start of
A As agreed / required A Physical Tech Specs and Const. Drawings SR  proper working condition to be verified on
laboratory work
monthly basis
Availability of requisite
laboratory set up and
Once prior to start of
equipment in good working
B As agreed / required A Physical work and thereof Tech Specs and Const. Drawings SR 
condition well before
monthly
commencement of concerned
activity
Submission of QA & QC
manpower deployment Once prior to start of
C - A Physical Tech Specs and Const. Drawings 
schedule based on agreed L-2 work
network .
Availability of QA& QC Once prior to start of
D manpower based on - A Physical work and thereof Tech Specs and Const. Drawings SR 
deployment schedule . monthly
Test report along with the
Sampling for testing of building
recommendations from OWNER
E materials, concrete admixture, As agreed / required A Physical Once per each source Tech Specs and Const. Drawings SR/TR 
approved laboratories as mentioned in TS
concrete mix design etc.
to be submitted to Owner.
Submission of schedule of
tests to be done monthly /
Once prior to start of
quarterly and maintenance of
F - A Physical work and thereof Tech Specs and Const. Drawings SR 
the same on a computer
monthly
connected to LAN of OWNER
for monitoring
Stacking and storage of
Tech Specs and Const. Drawings and
G construction materials and As per IS:4082 B Physical Random SR 
IS: 4082
components at site
All bought out items to be The TC submitted should bear proper
procured from the approved identification or correlation with the batch
Verification of TC
H vendor and on approval of - B 100% OWNER Tech. Spec. /BOQ SR/LB  of material supplied and same shall be
and/or Testing
Quality plans by OWNER as brought out in the challan/ consignment
per inspection Category note .
Submission of list of Bought
out items and their vendors for
To be submitted to CQA for approval with
I each of the bought out item - A Physical One time OWNER Tech. Spec. /BOQ SR/LB
a copy to site .
identified for approval within
the period agreed in LOA.
2 EXCAVATION AND FILLING IN FOUNDATION WORKS
Excavations-
Nature, type of soil/rock before and
2.1 As agreed / required B Visual Random in each shift Tech Specs and Const. Drawings SR
during excavations
Initial ground level before start of
2.2 As agreed / required B Measurement 100% Tech Specs and Const. Drawings SR 
excavations
Page 1 of 20
SUPPLIERS NAME AND
ADDRESS:
check Norms Record
1 2 3 4 5 6 7 8 9 D* 10
Final shape and Dimensions of
2.3 As agreed / required B Measurement 100% Tech Specs and Const. Drawings SR
excavations.
2.4 Final excavation levels As agreed / required B Measurement 100% Tech Specs and Const. Drawings SR 
2.5 Side slope of final excavation As agreed / required B Measurement Random in each shift Tech Specs and Const. Drawings SR
2.6 Excavation in Hard Rock- If required
Receipt, Storage, accountability of Indian Explosive Act 1940/all statutory

I As agreed / required B Physical Random in each week SR 
Explosive norms, Tech Specs and Const. Drawings OWNER approved specialist blasting
agency such as CMRI, NIRM shall be
IS:4081, Tech Specs and Const. deployed at site for trial blasts, design
ii Execution of Blasting Operation As agreed / required B Physical Random in each shift SR 
Drawings blasts, blast vibration monitoring etc.
Seismographs shall be deployed at site
iii Submission of Blasting report to EIC As agreed / required C Physical Each blast Tech Specs and Const. Drawings 
for monitoring of blast operation
Excavation in Hard Rock (Blasting As per approved drawing/ scheme, Tech vibrations.
2.7 As agreed / required B Physical 100% SR 
Prohibited) Specs and Const. Drawings
Fill/ Backfill -
2.8 Suitability of borrow fill material-
Once per each type of
Set of Sieves, source or change of IS:2720 (Pt.IV), Tech Specs and Const.
i Grain size analysis B Physical SR/TR 
Hydrometer etc. source subject to a min. Drawings
of 2 samples
Mechanical liquid limit
device, grooving tools, Once per each type of
Evaporating Disc, source or change of IS:2720 (Pt.IV) , Tech Specs and Const.
ii Liquid & plastic limit B Physical SR/TR 
Spatula, Palette source subject to a min. Drawings
knives, Balance oven of 2 samples
containers, etc.
source or change of IS:2720 (Pt.IV), Tech Specs and Const.
iii Shrinkage limit -do- B Physical SR/TR 
source subject to a min. Drawings
of 2 samples
Measuring cylinders, source or change of IS:2720 (Pt.XI), Tech Specs and Const.
iv Free Swell Index B Physical SR/TR 
etc. source subject to a min. Drawings
of 2 samples
v Chemical Analysis
Oven chemical
balance, volumetric
flasks, burettes,
source or change of IS:2720 Pt.XXII, Tech Specs and Const.
a Organic Matter pipettes, conical flasks, B Physical SR/TR 
source subject to a min. Drawings
set of sieves,
of 2 samples
measuring cylinders
etc.
As per IS: 2720, One in every 10000 cum
Optimum moisture content and max. dry IS 2720 (Pt.VII), Tech Specs and Const.
2.9 Standard proctor Test Proctor needle A Physical for each type and SR/TR 
density before fill Drawings
apparatus etc. source of fill materials
One in every 10000 cum
Moisture content of fill before As per IS: 2720, IS 2720 (Pt.II), Tech Specs and Const.
2.10 Moisture content A Physical for each type and SR/TR 
compaction balance, oven etc. Drawings
source of fill materials
2.11 Degree Of Compaction Of Fill / Backfill
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I) For foundation fill/
Dry density by core cutter method backfill one for every 10 IS 2720 (Pt. XXIX), Tech Specs and
SR/TR 
As per IS: foundations for each Const. Drawings
---- OR---- 2720/compaction test compacted layer.
i A Physical
(core cutter), balance ii) For area filling, one
Dry density in place by sand etc. every 10000 SQM area IS 2720 (Pt. XXVIII), Tech Specs and
SR/TR 
displacement method for each compacted Const. Drawings
layer.
As per IS: 2720, IS 2720 (Pt. XIV), Tech Specs and
ii Relative density (Density Index) A Physical ----do----- (I) & (ii) above SR/TR 
balance oven etc. Const. Drawings
As per IS-2720, Random checks to be
Dry Density by proctor needle
iii proctor needle B Physical carried out for each Tech Specs and Const. Drawings SR/TR 
penetration
apparatus etc. compacted layer
I) For foundation fill/
Where rock boulders (broken into the
backfill one for every 10
pieces not more than 200 mm size),
foundations for each
construction debris have been used for
Compaction using Rock boulders & compacted layer.
iv As agreed / required A Physical Tech Specs and Const. Drawings SR/TR  filling, it shall be compacted to minimum of
construction debris (if applicable) ii) For area filling, one
85% of original stack of material after
every 10000 SQM area
filling the interstices with the selected
for each compacted
excavated material.
layer.
3.0 MATERIALS
3.1 CEMENT
Each consignment of cement shall be duly
correlated with manufacturers TC,in case
the cement is supplied by the contractor
one sample from each lot shall be tested
Test for setting time and compressive strength
Retesting of cement as per IS:4031 A Testing At Random As per relevant IS Codes 
Report . Acceptance norms shall be as per
relevant IS. If cement is
stored more than 90 days in godown of
contractor same shall be retested for
comp. Strength & setting time.
Once for each stack of
during monsoon when this has to be
3.2 Coarse Aggregate Moisture content IS:2386 B Physical 100 Cum. or part there IS : 456/IS : 383/Tech Spec SR/LB 
done every day before start of concreting
of
Once for each source & SR/LB/
IS: 2386 Part-III, IS:456,
ii Specific gravity, water absorption IS:2386 A Physical for every change of Test 
IS:383/Tech Spec
source Report
Sieve analysis, flakiness index, One per 100 cum., or IS: 2386 Part-I, IS:383/Tech
iii IS:2386 B Physical SR/LB 
elongation index, part thereof Spec
Deleterious materials (coal & lignite, clay SR/LB/
Once per source/ on IS: 2386 Part-II,
iv lumps, material finer than 75 micron IS:2386 A Physical Test 
every change of source IS:383/Tech Spec
sieve, soft fragment, shale) Report
SR/LB/
v Soundness IS:2386 A Physical -do- IS: 2386 Part-V, IS:383 Test 
Report
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SR/LB/ The aggregate type
IS: 2386 (Part-VII), IS:383
vi Alkali aggregate reactivity A Physical -do- Test  (deleterious/innocuous result should be
/Tech Spec/ASTM C-1260 / ASTM 1293
Report supported by petrographic examination
SR/LB/
IS: 2386 Part-VIII, IS:383
vii Petrographic examination IS:2386 Pt VIII A Physical -do- Test 
/Tech Spec
Report
SR/LB/
Crushing value abrasion value and
viii IS:2386 A Physical -do- IS:383, IS-2386 Part IV/Tech Spec Test 
impact value
Report
3.3 Fine Aggregate
To be done every day SR/LB/
i Moisture content, water absorption balance , oven etc. B Physical IS: 2386 Part-III IS:383 
before start of work TR
Deleterious materials (coal & lignite, clay
Once per source& for on SR/LB/
ii lumps, material finer than 75 micron IS:2386 A Physical IS: 2386 Part-II, IS:383 
every change of source TR
sieve, soft fragment, shale)
As One per 100 cum., or SR/LB/
iii Silt content
agreed/required
B Physical CPWD/Tech Spec/IS 2386/IS 456/IS 383 
part thereof TR
All other tests similar to coarse SR/LB/ except test for flakiness index, elongation
iv IS-2386, IS-383 
aggregates as mentioned above. TR index, abrasion value, impact value
3.4 Water
Once for each source
and then after yearly
Burette, conical flask, SR/LB/
i Complete Testing as per IS:456-2000 A Testing and on every Seasonal IS:456-2000 
pipette etc. TR
change in case of water
collected from open well.
3.5 CONCRETE
After receiving the
4 Trial mixes to ascertain the workability recommended mix One for each mix
i A Physical OWNER Tech specification SR/LB 
and cube strength design from specialist proportion
agency,
One set of 6 cubes per
50 Chum or part thereof SR/LB/ Min. of 6 cubes for each mix, 3 specimen
ii Crushing strength (works Tests cubes) IS:516 A Physical for each grade of IS:516, IS:456, OWNER Tech. Spec. Test  shall be tested at 7 days remaining 3 shall
concrete per shift Report be for 28 days comp. Strength.
whichever is earlier.
At the time of concrete
SR/LB/
iii Workability - slump test IS:1199 B Physical pouring at site every two IS:456/OWNER Tech. Spec. 
TR
hrs
iv Water content B Physical Once per shift As per approved design mix. SR/LB  At batching plant
OWNER
Approved source For each lot received at Test
3.5.1 Admixtures for Concrete Type of admixture As per IS:9103 A Designed mix and IS:9103 
and review of site Report
MTC/ test reports
3.6 Concrete conveying, placing & compaction
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Batching Plant shall be calibrated
To be calibrated at the
mixing of concrete shall be Calibrati regularly at least once in a 3 months in-
batcher should comply time of starting and
done in a approved mixer such Review of calibration chart/ Certificate/IS on house. The weights for batching plant
i Calibration of Batching Plant with requirement of IS A Physical subsequently once in 
as to produce a homogenous 4926 Certificat calibration to be calibrated once in year by
4926/IS:4925 three months, and shall
mix e NPL/NABL accredited lab./Weights &
conform to IS:4925
Measures Dept.
Inspecti
Arrangement for transportation &
ii As required C Visual 100% Before clearance for concreting on 
placement of concrete.
Report
As per construction/erection methodology
iii Handling and Transportation of concrete As required B Physical 100% (to be approved one week prior to start of SR
work)
As per construction/erection methodology

iv Placement of concrete Visual B Physical 100% SR 
and tech.specs / No segregation
v Compacting As required B Physical At Random IS:456 SR 

Period of curing as per IS 456 (use
vi Curing As required B Physical At Random SR 
gunny bags / curing compound)
3.7 TEST/CHECK ON RCC STRUCTURE IN HARDENDED CONDITIONS
Visual inspection of concrete surface of
i all dynamic foundations just after As required A Visual 100% As per Technical Specification SR 
removal of shuttering
Embedment of inserts in concrete shall
ii be checked for gap if any using hammer Hammer B Physical 100% As per Technical Specification SR  No hollow sound
for all dynamic foundations
Compressive strength based on core test
is required to be carried out only if in case
SR/LB/
As required by OWNER of doubt regarding the grade of concrete
iii Core Test IS:516 A Physical As per IS:456, IS 516 Test 
Engineer. used, either due to poor workmanship or
Report
based on the results of cube strength test
as per 3.5 ii) above.
This test may be carried out to assess the
as required by the strength of concrete in case of non-critical
iv Rebound Hammer test IS:13311 A physical As per relevant / tech. Specification. SR/LB 
OWNER engineer and lightly loaded structures as the
discretions of EIC
Dimensional check on finished
v As required B Measurement Approved Drawing As per IS:456/ tech. Specification. SR/LB 
structures & Dimensional tolerances
Water Tightness Test of liquid retaining
vi As required A Test 100% IS:3370/ Tech. Specification SR/LB 
structure/ tanks
3.8 REINFORCEMENT STEEL
Physical and Chemical Properties for Review of MTC/ IS : 1786, IS:432, IS:1566, Tech Specs To be procured from OWNER approved
i As required/ agreed A Each batch of delivery MTC 
each lot test reports and Const. Drawings source
To be checked at site. Steel collected

Freedom from cracks surface flaws, IS: 1852, IS:432, IS:1786, Tech Specs from source should be free from
ii As agreed / required B Visual Random in each shift SR
Lamination & excessive rust. and Const. Drawings excessive rust. To be stored as per
Technical Specs.
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rust/ loose scale As required B Physical 100% IS:456, approved drawing and OWNER SR/TR
3.9 PLACEMENT OF REINFORCEMENT STEEL
Bar bending schedule with necessary Visual & Approved Drawings, Tech Specs and
i As agreed / required B Random in each shift SR 
lap, Spacers & Chairs Measurement Const. Drawings, IS:2502
Visual & Approved Drawings, Tech Specs and
ii Bending of bars, cutting tolerance As agreed / required B Random in each shift SR 
Measurement Const. Drawings, IS:2502
Acceptance - Cover, spacing of bars,
spacers and chairs after the Visual & Approved Drawings, Tech Specs and
iii As agreed / required B Random in each shift SR 
reinforcement cage is put inside the Measurement Const. Drawings
formwork
3.10 STAGING AND FORMS
Once before start of As per relevant IS, Tech Specs and
i Materials and accessories As agreed / required B Visual SR
work Const. Drawings
Soundness of staging, shuttering and As per manufacturer's spec.and as per
Once before start of
ii scaffolding including application of As agreed / required B Visual 3696,4014, 4990, Tech Specs and SR
work
mould oil / release agent Const. Drawings
Acceptance of formwork before start of Before start of each As per provisions and tolerances, Tech
iii B Physical / visual SR 
concreting concreting Specs and Const. Drawings
3.11 INSPECTION OF CONCRETE SURFACE JUST AFTER REMOVAL OF FORM WORK
Concrete surface, position and As per provisions and tolerances of
Visual inspection jointly with Once for TG, BFP & Inspection protocol shall be signed Jointly
i alignment of embedded parts and -- B Visual equipment supplier, Tech Specs and 
Owner MILL foundations by Contractor and OWNER Erection
inserts Const. Drawings
Submission of grouting / repair

methodology if concrete
Review and once for each type of As per provisions and tolerances, Tech
ii surface / position and -- B 
approval defect Specs and Const. Drawings
alignment of embedded parts /
inserts are found defective
3.12 EMBEDDED PART(INCLUDING LAYING OF RAILS & ANCHOR FASTENERS)

Exposed surface of the embedded parts
Position / alignment / levels of
Physical/ As per drawing, Tech Specs and Const. SR/ other than holding down bolts are to be
i embedded parts / bolt hole / pipe As agreed / required B 100% 
measurement Drawings Protocol painted with as per technical
sleeves / rails / PVC pipes / etc
specifications
Welding / tieing of embedment to Physical/ As per drawing, Tech Specs and Const.
ii As agreed / required B Random in each shift SR
reinforcement measurement Drawings
3.13 PRE-CAST CONCRETE
one sample of six cubes A minimum of three specimen shall be
compression strength
i Crushing strength A Physical per 50m m3 or part IS:516 & IS: 456 SR/LB  tested for 7 and 28 days compressive
testing machine
thereof strength
As per IS:456/OWNER Tech.
ii Workmanship and dimensions Visual B Physical 100% Register
specification.
1% up to 1000 nos. and Inspecti

IS:456/ As decided by OWNER Site
iii Load Test As required B Physical 0.5% for more than on  Applicable members i.e. drains covers .
Engr. In charge.
1000 nos. for each type Report
3.14 JOINTS IN CONCRETE
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Joint material - bitumen impregnated
EIC Approved
fibre board, PVC water stops, Sealing
As per manufacturer source and Tech Specs and Const. Drawings, IS
i compound, Expanded polystyrene A Each batch of delivery MTC 
Standards review of MTC/ 1838, IS 1834, IS12200
board, Hydrophilic strip, Acrylic polymer
test reports
etc.
Each installation
ii Acceptance of installation As agreed / required B Acceptance Tech Specs and Const. Drawings
randomly
3.15 DAMP PROOF COURSE Tech Specs and Const. Drawings
EIC Approved
Material - Hot bitumen and water source and Each batch of delivery at Tech Specs and Const. Drawings, IS
i As agreed / required A SR 
proofing materials etc. review of MTC/ site 702
test reports
ii Acceptance of damp proof course As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
3.16 GROUTING
Review of MTC/
i Material As agreed / required A Each batch of delivery Tech Specs and Const. Drawings SR 
test reports
Type of mix - fluid mix, plastic mix, stiff

ii As agreed / required B Physical Prior to start of work Tech Specs and Const. Drawings SR 
mix etc.
Mixing, placement, application and
iii As agreed / required B Physical Random in each shift Tech Specs and Const. Drawings SR
grout pressure
iv Compressive strength As agreed / required A Physical Random in each shift Tech Specs and Const. Drawings SR 
v Acceptance of the grouts As agreed / required B Physical Each grout section Tech Specs and Const. Drawings SR
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4.00 BRICK MASONARY
4.1 Test on Bricks
Dimensions , shape, compressive As per relevant IS Code/ Inspecti
Measurement/ IS: 1077, IS:13757, IS: 12894 / Tech Efflorescence shall be checked at each
strength, water absorption, warpage, As agreed / required A One Sample for 30,000 on 
Physical Test Specs and const. Drawings source.
efflorescence. nos. or part thereof Report
4.2 Test on Mortar
IS 2250-1981, Tech Specs and Const.
i Compressive strength As agreed / required B Test At random LB
Drawings
ii Sand Grading As agreed / required B Test IS:2116 SR/LB
IS 2212, IS 1905 , Tech Specs and
4.3 Masonry construction Workmanship, verticality and alignment As agreed / required B Visual/ Physical 100% SR/LB
Const. Drawings
5.00 FINISHING AND ALLIED WORKS .
5.1 PLASTERING- MATERIAL
IS : 2386 (Part-I &II) & IS :2116, Tech
i Sand Deleterious Material As agreed / required B Physical Once per source Specs and Const. Drawings SR
Tech Specs and Const. Drawings

ii Grading As agreed / required B Physical 50 Cum./or part thereof SR
As One per 100 cum., or SR/LB/

iii Silt content
agreed/required
B Physical CPWD/Tech Spec/IS 2386/IS 456/IS 383 
part thereof TR
EIC Approved
Galvanized hexagonal wire netting for source and
iv Galvanized wire mesh As agreed / required B Each batch of delivery Tech Specs and Const. Drawings SR
lath plastering review of MTC/
test reports
5.2 PLASTERING - WORKMANSHIP

Tech specifications, construction
i Curing As agreed / required C Physical 100% SR
drawings and agreed methodology
Thickness and finishing of plaster, Visual/
ii As agreed / required B Random in each shift Tech Specs and Const. Drawings SR/LB
grooves etc. Measurement
iii Trueness of plastering system As agreed / required B Visual/ Physical Random in each shift Tech Specs and Const. Drawings SR
5.3 STONE GRIT PLASTER/ GRANULAR TEXTURED COAT FINISH
Approved source
For each lot received at
i Material As agreed / required B and review of Tech Specs and Const. Drawings SR 
site
MTC
Visual/
ii Thickness, finishing and grooves etc. As agreed / required B Random in each shift Tech Specs and Const. Drawings SR 
Measurement
6.00 SHEETING AND OTHER WORKS
6.1 PAINTING SYSTEM - CONCRETE WORKS AND PLASTERED MASONARY SURFACES
Materials and accessories- Oil
Bound, Acrylic Emulsion, Shade, type from brand and Review of MTC/ Materials to be procured from OWNER
i As agreed / required A Each batch of delivery Tech Specs and Const. Drawings SR/MTC 
Chemical Resistant, Oil manufacturer as approved by Owner. test reports approved source
Resistant Paint etc.
ii Surface preparation As required As agreed / required C Physical /visual Random in each shift Tech Specs and Const. Drawings SR
Acceptance of painted
iii As required As agreed / required B Physical/visual Each surface at random Tech Specs and Const. Drawings SR
surfaces
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6.1.1 PAINTING SYSTEM - STEEL WORKS (OTHER THAN STRUCTURAL STEEL WORKS)
Materials to be procured from OWNER
Review of MTC/
i Paining Materials and accessories - A Each batch of delivery Tech Specs and Const. Drawings SR/MTC  approved source. Mfr.’s T.C. shall be
test reports
correlated with the consignment received.
Tech Specs and Const. Drawings,
ii Surface preparation As agreed / required B Physical /visual Each Erection Mark SR 
Relevant code/ standards
iii Primer Thickness Elcometer B Measurement Each Erection Mark Tech Specs and Const. Drawings SR 
iv DFT of paint Elcometer A Measurement Each Erection Mark Tech Specs and Const. Drawings SR 
Visual and
v Acceptance of painted surfaces Elcometer B Each Erection Mark Tech Specs and Const. Drawings SR
measurement
Review of test
6.2 Modular aerated panel As required As agreed / required A Each batch of delivery Tech Specs and Const. Drawings SR/LR 
report
6.3 Permanently colour coated sheets, metal decking
Prevention of distortion / blemishing /
i Storage As agreed / required B Visual Random in each shift Tech Specs and Const. Drawings SR
water staining
Installation, lap alignment &
ii As agreed / required B Visual/ Physical Random in each shift Tech Specs and Const. Drawings SR No gas cutting of sheets acceptable .
workmanship.
iii Finishing and acceptance As agreed / required B Visual/ Physical Random in each shift Tech Specs and Const. Drawings SR/LB
6.4 INSULATION WORKS
EIC Approved
Insulation material, galvanized wire net, source and For each lot received at
i Material As agreed / required A Tech Specs and Const. Drawings SR / LB  All tests as per specification
aluminium foil, fasteners review of MTC/ site
test reports
ii Acceptance of each type of installation As agreed / required B Visual/ Physical Each installation Tech Specs and Const. Drawings SR/LB
EIC Approved
PRE-ENGINEERED source and From approved source / fabricated as per
6.5 Installation and acceptance As agreed / required A For each building Tech Specs and Const. Drawings SR/LB 
BUILDING review of MTC/ MQP
test reports
7.00 DOORS , WINDOWS VENTILATORS & GRILL

7.1 Steel doors
Materials (MS sheet, fasteners, hinges, Visual/ Physical / For each lot received at
i As agreed / required A Tech Specs and Const. Drawings SR / LB  Review of test report
jambs, lock strike plate etc test report site
Check for shape tolerances thickness, Physical &

ii As agreed/required A Random for each delivery Tech Specs and Const. Drawings SR
welding & finishing of sections acceptance
Acceptance of steel glazed doors, windows As Physical &

iii Checking of works B Random Tech Specs and Const. Drawings SR
and T-iron shapes sections after fixing agreed/required acceptance
As
iv Acceptance of fixing after completion B Acceptance Random Tech Specs and Const. Drawings SR
agreed/required
7.2 Wood Work
Electrical Moisture meter For each lot received at Tech Specs and Const. Drawings/ IS To be carried out from Forest Research
i Wood/Timber Moisture content A Physical SR/LB √
as per IS 287 site 287 Institute Dehradun. Frequency of check may be
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As decided by EIC based on quantity and
anatomy A Physical One for each lot of timber Tech Specs and Const. Drawings SR/LB √ requirement
agreed/required
As Random for each

ii Wood work in frames Check for dimensions, surface finish B Physical Tech Specs and Const. Drawings SR
agreed/required installation
EIC Approved
End emersion
As source and For each lot received at IS 2202, Tech Specs and Const.
iii Flush Door shutter test, knife test, A SR √ Review of test report
agreed/required review of MTC/ site Drawings
adhesion test
test reports
EIC Approved
source and For each lot received at IS:12823, Tech Specs and Const.
iv Particle Door As agreed / required A SR  Review of test report
review of MTC/ site Drawings
test reports
v Acceptance As agreed / required B Visual/ Physical Random Tech Specs and Const. Drawings SR/LB
7.3 Anodized aluminium works
IS: 1948, IS: 1949, IS:733, IS1285, Review of test report
Visual/ Physical / For each lot received at
i Materials- Aluminium sections, Coating As agreed / required A IS:1868, IS:11857/ Tech Specs and SR / LB  For aluminium door/windows, check for
test report site
Const. Drawings anodization as per Tech. Spec
ii
iii Acceptance As agreed / required B Visual/ Physical Random Tech Specs and Const. Drawings SR
7.4 Fire proof doors
Review of
Procured from OWNER Approved
purchase order
Source.
(unpriced copy) /
The door drawing proposed for supply
i Source of supply As agreed / required A drawings of For each source Tech Specs and Const. Drawings SR 
should have been tested and approved by
suppliers /
CBRI Roorkee for the similar dimensions
certificate of
for minimum 2 hours fire rating.
CBRI
Visual/ Physical/ For each lot received at
ii Receipt inspection As agreed / required A Tech Specs and Const. Drawings SR 
Review of MTC site
iii Finishing and acceptance As agreed / required B Visual / physical Random Tech Specs and Const. Drawings SR
7.5 Rolling shutters
Surface finish and thickness of plate of Physical / visual / Random for each lot of
i As agreed / required A Tech Specs and Const. Drawings SR 
approved make and DFT review of MTC delivery
Physical and
ii Finishing and acceptance As agreed / required B Random Tech Specs and Const. Drawings SR
acceptance
7.6 Steel windows / Grills/ Louvre
EIC Approved
source and IS: 1038 / IS:1361, IS: 7452 and Tech
i Material fabrication and fixtures As agreed / required A Each lot of delivery SR 
review of MTC/ Specs and Const. Drawings
test reports
IS: 1038 / IS:1361, IS: 7452 and Tech
ii Finishing and acceptance As agreed / required B Visual / physical Random SR 
Specs and Const. Drawings
7.7 Glass and glazing
EIC Approved
Clear float glass, wired glass,
source and For each lot received at IS: 14900, IS:1081, IS: 3548, IS:5437
i tinted glass, curtain glass, Material As agreed / required B SR 
review of MTC/ site Tech Specs and Const. Drawings
hermetically sealed glass
test reports
Leak proof installation with neoprene
ii Installation finishing and acceptance As agreed / required B Visual/ Physical Random Tech Specs and Const. Drawings SR
gasket
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7.8 Curved dome on roof/ Poly Carbonate Sheet
EIC Approved
Impact strength, K value, light
source and For each lot received at
i Source of supply transmission value with class -I fire As agreed / required A Tech Specs and Const. Drawings SR 
review of MTC/ site
rating
test reports
ii Installation finishing and acceptance As agreed / required B Visual / physical Random Tech Specs and Const. Drawings SR
7.9 Reflective toughened glass
EIC Approved
source and For each lot received at
i Material As agreed / required A Tech Specs and Const. Drawings SR 
review of MTC/ site
test reports
7.10 False Ceiling
Materials ( gypsum glass, glass fibre EIC Approved
For each lot received at Compare MTC with technical specification
i membrane, fibre board acoustical tiles As agreed / required A source and Tech Specs and Const. Drawings SR 
site and requirement
etc) review of MTC/
7.11 WATER PROOFING
Methodology for the application of water for each type of
As required B Review Tech Specs and Const. Drawings SR 
proofing system treatment
7.11.1 General Requirement- Water Proofing
EIC Approved
source and For each lot received at MTC shall contain all the parameters
i Material As agreed / required A Tech Specs /Const. Drawings SR 
review of MTC/ site specified in the technical specifications
test reports
ii Acceptance of water proofing work As agreed / required B Physical 100% Tech Specs and Const. Drawings
7.11.2 Roof / Basement Treatment
i Graded under bed Levels / slopes As required C Physical 100% Tech Specs and Const. Drawings
EIC Approved
source and
ii Elastomeric coatings Material- Primer coat, finishing coat As required B Each lot of delivery Tech Specs and Const. Drawings SR 
review of MTC/
test reports
Materials - PCC, chicken wire mesh,
iii Wearing course As required B Review of MTC Each lot of delivery Tech Specs and Const. Drawings SR 
elastomeric sealant
iv Acceptance of water proofing work As agreed / required B Physical 100% Tech Specs and Const. Drawings
7.12 Fencing and Gates
PVC coated chain link fencing EIC Approved

(IS 2720), Welded wire mesh source and MTC shall contain all the parameters
i Materials As agreed / required A Each batch of delivery Tech Specs and Const. Drawings SR/MTC 
(IS 1566), Reinforced barbed review of MTC/ specified in the technical specifications
tape galvanized (IS 2629) etc. test reports
EIC Approved
Structural steel, painting
source and MTC shall contain all the parameters
ii system, caster wheel, ball and Materials As agreed / required A Each batch of delivery Tech Specs and Const. Drawings SR/MTC 
review of MTC/ specified in the technical specifications
bearing, fixtures and fasteners
test reports
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Physical /
iii Alignments, erection painting, DFT etc. As agreed / required B Each installation Tech Specs and Const. Drawings SR
measurements
Acceptance of the installation and Physical /

iv As agreed / required B Each installation Tech Specs and Const. Drawings SR
working measurements
7.13 FLOOR FINISHES AND ALIED WORKS
7.13.1 Cement Concrete Flooring
i Glass/ PVC strips in joints As agreed / required B Physical Random in each shift Tech Specs and Const. Drawings SR
ii Finishing and acceptance As agreed / required B Physical 100% Tech Specs and Const. Drawings SR
7.13.2 Tiles
Ceramic, vitrified, glass BIS Approved MTC shall contain all the parameters
mosaic, acid alkali resistant, source and specified in the technical specifications. In
i Materials As agreed / required A Each lot of delivery Tech Specs and Const. Drawings SR 
heavy duty cement concrete review of MTC/ case non-availability of MTC, sample to
tiles test reports be tested as per relevant IS code.
7.13.3 Interlocking Blocks
EIC Approved
MTC shall contain all the parameters
i Materials As agreed / required A source and test Each lot of delivery Tech Specs and Const. Drawings SR 
specified in the technical specifications
reports
7.13.4 Kota Stone, Granite and Marble
Quality, texture, thickness, colour for

i As agreed / required B Physical Each batch of delivery Tech Specs/ BOQ and Const. Drawings SR 
each lot of delivery
7.13.5 Metallic / non-metallic hardener

i Material As agreed / required B Physical Each batch of delivery Tech Specs and Const. Drawings SR 
7.13.6 Acid / alkali and oil resistant high built seamless epoxy based resin and treatment
EIC Approved
Bricks, vitreous tiles, mortar, sealing, source and
i Material As agreed / required A Each batch of delivery Tech Specs and Const. Drawings SR  work to be done by skilled manpower
paints, coatings, sheets, fillers etc review of MTC/
test reports
ii Surface preparation As agreed / required B Physical Random in each shift Tech Specs and Const. Drawings, IS
iii Finishing and acceptance As agreed / required B Physical 100% Tech Specs and Const. Drawings SR
7.13.7 Rubber Flooring
Page 12 of 20
SUPPLIERS NAME AND
ADDRESS:
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1 2 3 4 5 6 7 8 9 D* 10
EIC Approved
source and Tech Specs and Const. Drawings / IS MTC shall contain all the parameters
i Material As agreed / required A Each batch of delivery SR 
review of MTC/ 809 specified in the technical specifications
test reports
7.14 Doors/Windows Sections
EIC Approved
Material - Rolled Steel, Z
Review of MTC/ make / Physical source and For each batch of
i Sections,T-iron frames As agreed / required A Tech Specs and Const. Drawings SR 
checks, tests ( if MTC is not available) review of MTC/ delivery
sections, Plates etc.
test reports
Acceptance of Steel Glazed doors and Physical and Random for each
ii As agreed / required B Tech Specs and Const. Drawings SR
T-iron frames sections after fixing acceptance installation
8.0 WATER SUPPLY / SANITORY INSTALLATIONS

8.1 Water supply fittings and fixtures
EIC Approved
source and Each lot of delivery as
i Materials GI/ MS pipes and fittings As agreed / required A Tech Specs and Const. Drawings SR 
review of MTC/ per Specifications
test reports
ii Disinfection Before use As agreed / required B Physical Each installation Tech Specs and Const. Drawings SR
iii Hydraulic test Before use / leakage As agreed / required A Physical Each installation Tech specs and const drawings SR 
iv Acceptance and working As agreed / required B Acceptance Random Tech Specs and Const. Drawings SR
Page 13 of 20
SUPPLIERS NAME AND
ADDRESS:
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1 2 3 4 5 6 7 8 9 D* 10
8.2 Sand cast iron / cast iron pipes
EIC Approved
i Material SCI / CI pipes and fittings / joints As agreed / required A Tech Specs and Const. Drawings SR 
test reports
ii Acceptance and leakage As agreed / required B Physical Random Tech Specs and Const. Drawings SR
8.3 Sanitary fittings and fixtures

Sanitary items and fixtures i.e. water
closets, urinals, wash basins, sinks, EIC Approved
mirrors, shelves, towel rail, soap source and Each lot of delivery as
i Material As agreed / required B Tech Specs and Const. Drawings SR 
containers, geyser, water cooler, etc, review of MTC/ per Specifications
water supply / sanitation pipes, manhole test reports
cover and frames etc
Acceptance of installations of all sanitary
ii As agreed / required B Acceptance 100% Tech Specs and Const. Drawings SR
items and fixtures
8.4 RCC Pipes

BIS Approved
i Material RCC pipes As agreed / required A Tech Specs and Const. Drawings SR 
test reports
ii Acceptance and leakage As agreed / required B Physical Random Tech Specs and Const. Drawings SR
8.5 Water Storage Tanks
BIS Approved
i Material Over head / loft type As agreed / required A Tech Specs and Const. Drawings SR 
test reports
ii Acceptance and leakage As agreed / required B Acceptance Random Tech Specs and Const. Drawings SR
9.0 SPECIAL ITEMS
9.1 Earthing Mat (Grounding System)
EIC Approved
source and Each lot of delivery as As per relevant IS and Tech. Specs /
i Material Earthing mat As agreed / required A SR/MTC 
review of MTC/ per Specifications Manufacturer's, IS 3043
test reports
Visual/ OWNER approved electrodes shall be
ii Weld sizes & length Visual/Tape B 100% Tech Specs and Const. Drawings
Measurement used
10% at random of the
iii D P test DP test Kit A Physical Tech Specs and Const. Drawings TR 
offered lot
iv Earth test Earthing test kit A Physical 100% Tech Specs and Const. Drawings, SR 
9.2 Bitumen layer for tank foundation
APPROVED SOURCE FOR MATERIAL
Review of MTC/ Each lot of delivery as As per relevant IS and Tech. Specs
i Material Grade of bitumen As agreed / required A SR/MTC  PROCUREMENT SHALL BE ALL
test reports per Specifications /MTC GOVERNMENT REFINARIES
ii Acceptance and workmanship Application / workmanship As agreed / required B Physical Random Tech Specs and Const. Drawings SR
9.3 Composite Aluminium Panels and structural glazing
Page 14 of 20
SUPPLIERS NAME AND
ADDRESS:
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1 2 3 4 5 6 7 8 9 D* 10
EIC Approved
Type of aluminium panels / structural
source and Each lot of delivery as MTC shall cover all the properties /
i Material glazing / fasteners and fixtures / silicon As agreed / required A Technical specifications / drawings SR/MTC 
review of MTC/ per Specifications parameters as per technical specifications
sealant
test reports
ii Acceptance and workmanship Installation / workmanship As agreed / required B Physical Random Technical specifications / drawings SR
Page 15 of 20
SUPPLIERS NAME AND
ADDRESS:
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1 2 3 4 5 6 7 8 9 D* 10
9.4 Pressure Relief Valves
EIC Approved
source and Each lot of delivery as IS 4558/Technical specifications /
i Material As agreed / required A SR/MTC 
review of MTC/ per Specifications drawings
test reports
ii Acceptance and workmanship Acceptance / Installation / workmanship As agreed / required B Physical Random Tech Specs and Const. Drawings SR 
10.0 ANTI WEED TREATMENT
EIC Approved
source and
i Anti-weed treatment materials As agreed / required A Each batch of delivery Tech Specs and Const. Drawings SR 
review of MTC/
test reports
Random check for each
ii Execution of treatment As agreed / required B Physical Tech Specs and Const. Drawings SR
treatment
11.0 PILING WORK (If Applicable)
11.1 Execution
i Borehole diameter As required B Physical 100% OWNER Tech. Specs SR/LB  If carried out by the contractor
ii Pile layout Total station B Measurement 100% As per appd. Drawings and technical SR/LB 
IS:2911, as per appd. Drawings and
iii Recording ground level As required B Measurement Random SR/LB 
technical specification
As per appd. Drawings and technical
iv Cleaning/Flushing of pile bore As required B Visual Random SR/LB 
specification
Size of bore and During boring of pile

record commencement of SPT/ core
As per appd. Drawings and technical
v recovery to ensure socketing length As required B Measurement 100% SR/LB 
specification
equivalent in terms of the Diameter of
the pile below the socketing horizon.
After receiving the Necessary correction for moisture content

Trial mix to ascertain the workability and recommended mix One for each mix and water absorption according to mix
vi B Physical OWNER tech specification SR/LB 
cube strength design from specialist proportion design recommendation may be carried
agency, out during the trial mix
vii Cement content As required B Physical Once per shift As per approved design mix. SR/LB  At batching plant
Pouring of concrete to project above As per appd. Drawings and technical

viii As required B Measurement 100% SR/LB 
cut off level. specification
As per OWNER As per appd. Drawings and technical

ix Pile termination level SPT & core recovery A Soil data SR 
specifications specification
Page 16 of 20
SUPPLIERS NAME AND
ADDRESS:
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1 2 3 4 5 6 7 8 9 D* 10
11.2 Testing
i Bentonite IS:2720 A Physical / testing Once per source As per IS:2720 / tech. Specs. SR/LB  Review of test report
Tests to be done before placing concrete.

Density check on sample of mud
ii Sample collection A Physical As per Tech. Spec. As per OWNER Tech Spec. SR/LB  Samples to be collected from pile bore
collected from pile bore bottom
bottom.
Every 2 hrs at pouring IS:2911, As per appd. Drawings and

iii Slump test of concrete IS:1199 B Physical SR/LB 
point of concrete technical specification
One set of 6 cubes per
50 CuM or part thereof
IS:2911, As per appd. Drawings and
iv Cube sampling for works cube test IS:456 B Physical for each grade of SR/LB 
technical specification
concrete per shift
whichever is earlier.
Initial pile load test, Vertical 100% for 3 nos. for each
IS:2911, As per appd. Drawings and In case of compression test method the
v (Compression), Lateral (horizontal) and IS:2911 / as required A Testing type or as specified in SR/LB 
technical specification loading shall be cyclic.
pull-out (tension). BOQ / Tech. Spec.
100% for 0.5% of the

Routine pile tests, compression and Calibrated dial gauges total number of piles IS:2911, As per appd. Drawings and Routine Test shall be conducted by direct
vi A Testing SR/LB 
horizontal etc. as required. provided for each type technical specification loading method.
of test/Tech. Spec.
IS:2911, As per appd. Drawings and

Test
vii Integrity Tests PEM A Testing 100% technical specification and suppliers  CHP
Report
manual
12.0 FOUNDATION SYSTEM
SHALLOW FOUNDATIONS
Foundation excavation - Location, As per technical specifications and

i As required / agreed B Physical Each location SR lines and levels to be checked
Layout, size, depth etc. construction drawings
Foundation casting - Layout, Shape,
As per technical specifications and lines and levels to be checked. Concrete
ii dimensions, Reinforcement, concreting, As required / agreed B Physical Each foundation SR
construction drawings Grade to be checked as per Mix Design
curing etc.
13.0 ROAD WORKS

1.1 Tests on Embankment, Subgrade Construction and Cut Formation
A) Suitability of Borrow Fill material
As per Tech Specs and Const. Drawings,
2 tests per 3000 cum of
i Sand Content As per IS 2720 A Physical Section 900 of MOSRTH specification, IS SR/TR 
soil
2720 (Part IV)

Each type to be tested,
ii Plasticity Test As per IS 2720 A Physical Section 900 of MOSRTH specification, IS SR/TR 
2 tests
2720 (Part V)
Page 17 of 20
SUPPLIERS NAME AND
ADDRESS:
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1 2 3 4 5 6 7 8 9 D* 10
Each soil type to be
iii Density Test As per IS 2720 A Physical Section 900 of MOSRTH specification, IS SR/TR 
tested, 2 tests
2720 (Part VIII)
As and when required
iv Deleterious Content Test As per IS 2720 B Physical Section 900 of MOSRTH specification, IS SR/TR 
by Engineer in charge
2720 (Part XXVII)
v Moisture Content Test As per IS 2720 A Physical Two Tests Section 900 of MOSRTH specification, IS SR/TR 
2720 (Part II)
One CBR test (Avg. of
three specimens) or
vi CBR Test As per IS 2720 A Physical Section 900 of MOSRTH specification, IS SR/TR 
closer as and when
2720 (Part XVI)
required by EIC
Once per each type of As per Tech Specs and Const. Drawings,
vii Free swell Index Measuring Cylinder A Physical source or change of Section 900 of MOSRTH specification, IS SR/TR 
source 2720 (Part XI)
B Compaction
One in every 2000 cum As per Tech Specs and Const. Drawings,
i Standard proctor Test As per IS: 2720 A Physical for each type and Section 900 of MOSRTH specification, IS SR/TR 
source of fill materials 2720 (Pt.VII)
One in every 2000 cum As per Tech Specs and Const. Drawings,
Moisture content of fill before
ii As per IS: 2720 B Physical for each type and Section 900 of MOSRTH specification, IS SR/TR
compaction
source of fill materials 2720 (Pt.II)
Dry density by core cutter method
One in every 2000 SQM As per Tech Specs and Const. Drawings,
---- OR----
iii As per IS: 2720 A Physical area for each Section 900 of MOSRTH specification, IS SR/TR 
Dry density in place by sand
compacted layer. 2720 (Pt. XXIX)/ IS 2720 (Pt. XXVIII),
displacement method
One in every 500 SQM
iv Lines, grade and cross section As required / agreed B Physical As per Tech Specs and Const. Drawings SR Template, straight edge
area
1.2 Granular Sub-Base (GSB) ( if applicable)

i Grading of aggregate Set of IS Sieves B Physical One test per 400 cum SR/TR 
Section 900 of MOSRTH specification,
Atterberg limits As per Tech Specs and Const. Drawings,

ii Atterberg limits A Physical One test per 400 cum SR/TR 
determination Section 900 of MOSRTH specification,

iii Moisture Content prior to compaction As required / agreed B Physical One test per 400 cum SR/TR 
Section 900 of MOSRTH specification

iv Density of compacted Layer As required / agreed B Physical one test per 1000 sqm. SR/TR 

v Deleterious Constituents As required / agreed B Physical As required SR/TR 

vi CBR As required / agreed B Physical As required SR/TR 
Page 18 of 20
SUPPLIERS NAME AND
ADDRESS:
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1 2 3 4 5 6 7 8 9 D* 10
1.3 Water Bound Macadam (WBM)
Aggregate Impact One test per 1000 cum As per Tech Specs and Const. Drawings,
i Aggregate Impact Value A Physical SR/TR 
value Test Apparatus of aggregate Section 900 of MOSRTH specification,

ii Grading of aggregate Set of IS Sieves B Physical One test per 250 cum SR/TR 
combined Flakiness and Elongation Flakiness & Elongation One test per 500 cum of As per Tech Specs and Const. Drawings,
iii B Physical SR/TR 
Indices test gauge aggregate Section 900 of MOSRTH specification,
Atterberg limits One test per 50 cum of As per Tech Specs and Const. Drawings,
iv Atterberg limits of binding material A Physical SR/TR 
determination binding material Section 900 of MOSRTH specification,
Atterberg limits One test per 100 cum of As per Tech Specs and Const. Drawings,
v Atterberg limits of screenings A Physical SR/TR 
determination aggregate Section 900 of MOSRTH specification,
1.4 RCC Pavements

Quality checks for Materials used for Pavement concrete As per Table 900-6 of MORTH Spec.
Quality checks for concrete used for Pavement concrete As per Table 900-6 of MORTH Spec.
1.5 Alignment, Level, Surface regularity and rectification
Horizontal alignment, Surface levels and As per section 900 of As per Tech Specs and Const. Drawings,
i As required / agreed B Physical SR/TR
Surface regularity MOSRTH specification Section 900 of MOSRTH specification

ii Rectification As required / agreed B Physical Each rectification SR/TR 
Section 900 of MOSRTH specification
14.0 GEOTECHNICAL INVESTIGATION WORK

Deployment of approved Geotechnical
Once before As per technical specifications and
i Investigation Agency - Equipments, As required / agreed A Physical SR 
commencement of work relevant IS Codes
Manpower etc.
Execution of Geotechnical Investigation As per technical specifications and
ii As required / agreed B Physical Each Location SR 
- locations, type etc. as per scheme relevant IS Codes
Collection of disturbed and undisturbed As per technical specifications and

iii As required / agreed B Physical each sampling SR
samples , their packing and storage relevant IS Codes
Conducting filed tests as per
As per technical specifications and
iv investigation scheme- such as, As required / agreed B Physical each field test SR
relevant IS Codes
SPT/ERT/SCPT/PLT/PMT etc.
Submission of Field Bore logs in Within 24 hours after As per technical specifications and
v As required / agreed B Review SR 
approved format completion of each BH relevant IS Codes
as per consultation with
Submission of laboratory test schedule
Review and engineer during dispatch As per technical specifications and
vi and selection of samples for laboratory As required / agreed A SR 
acceptance of samples to approved relevant IS Codes
testing
laboratory
Page 19 of 20
SUPPLIERS NAME AND
ADDRESS:
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1 2 3 4 5 6 7 8 9 D* 10
Submission of Final Geotechnical After completion of
vii investigation report along with As required / agreed B Physical investigation work and - 
relevant IS Codes
recommendations review of draft reports
Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB

Manufactu Categorization Witnessing & Accepting (As per OWNER QA&I System)
rer/ Sub- Main-supplier Category ‘A’ FQA Engineer in association with Executing Engineer, Category ‘B’ Executing Engineer, Category For OWNER USE
supplier ‘C’ Executing Engineer ;SR = Site Register , TR= Test Report,MfrTC = Manufacturer's Test Certificate
Signature This document shall be read in conjunction with OWNER Tech. Specifications, BOQ, Drawings REVIEWED BY APPROVED BY APPROVAL SEAL
Page 20 of 20
INDICATIVE FIELD QUALITY PLAN ANNEXURE- V B
QP NO. : 2 PROJECT: Khurja TPP (2 X 660 MW)
SUPPLIERS NAME AND ITEM : STRUCTURAL STEEL WORK
LOGO
ADDRESS: REV. NO .: 0 PACKAGE: Water System Package
SUB-SYSTEM : FABRICATION & ERECTION DATE : CONTRACT NO.
PAGE : MAIN CONTRACTOR
Class of Acceptance
Sl. No Activity and operation Characteristics / instruments Type of Check Quantum Of check Reference Document Format of Record Remarks
check Norms
1 2 3 4 5 6 7 8 9 D* 10
1.00 MATERIALS
Structural steel procured from
Correlated MTC shall be verified. In the
OWNER approved sources- For each batch of
Technical Specification and Construction event of non submission of MTC ,
i Mechanical (YS, UTS, Elg, UT if A Review each section delivered SR 
Drawings, IS 2062 sample shall be selected by FQA for
specified),,and Chemical at site
testing as per specification.
properties (CE as per IS)
2.00 FIT-UP
As agreed / Visual & Tech Specs and Const. Drawings/
i Marking and Cutting B Each plate/ Section SR
required Measurement Approved cutting plan
Match markings for trial As agreed /
ii B Physical Each fit-up Tech Specs and Const. Drawings SR
assembled components required
As agreed /
iii Weld Fit Up B Physical Each fit-up Tech Specs and Const. Drawings SR  Edge Preparation/ Gap/ Alignment
required
3.00 PRE HEATING (wherever applicable)

As agreed / Tech Specs and Const. Drawings,
i Pre-Heating Temperature B Measurement Each pre-heating SR 
required Approved WPS
Post Weld Heat Treatment As agreed / Time & Tech Specs and Const. Drawings,
ii A Each PWHT SR 
(PWHT), if required required Temperature Approved WPS
4.00 WELDING REQUIREMENTS

Approved WPS/ PQR, AWS-D1.1/ASME-
As agreed / IX, Tech Specs and Const. Drawings Test
i PQR and Welder's Qualification A Physical Each welder 
required Report
As agreed / Approved WPS/ Owner Rationalized list of
ii Welding consumables B Physical Random in each shift SR 
required Electrodes.
As agreed /
iii Sequence of welding B Physical Random in each shift Tech Specs and Const. Drawings SR
required
Removal/ grinding of temporary As agreed / Tech Specs and Const. Drawings, IS-
iv B Measurement All cleats/ attachments SR
attachments required 7215
Completeness after welding- As agreed / Each structure
v B Visual Tech Specs and Const. Drawings SR
Dimensions/ distortion required component
5.00 NON DESTRUCTIVE AND DESTRUCTIVE TESTING

5.01 Fillet Welds
As required/ Visual/ As per technical specifications and
i Visual B Each welded joint SR As per requirement of Owner Engineer
agreed Measurement construction drawings
Main fillet weld with

As required/ min one joint per built As per technical specifications and
ii Macro-Etch Examination B Physical SR 
agreed up beam, columns and construction drawings
crane girders
25% weld length of

tension member of
crane girder- For crane
girder
As required/ As per technical specifications and
iii Dye Penetration Test (DPT) B Physical SR 
agreed 5% of Weld length with construction drawings
min. 300mm at each
location - Except
Crane Girder, for all
other Fillet Welds
5.02 Butt Welds
i Visual B Visual Random in each shift SR
agreed construction drawings
PAGE 74 OF 7
LOGO
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
100% DPT after back
gouging on all butt
welds except for coal
As required/ bunker bins As per technical specifications and All butt welds to be back gouged before
ii Dye Penetration Test B Physical SR
agreed construction drawings DPT
10% DPT after back
gouging-For coal
bunker bins
Min. one joint per built

Mechanical testing on As required/ As per technical specifications and
iii A Physical up beams, columns SR  Test on production test coupons
production test coupons agreed construction drawings
and crane girder.
100% RT on butt
welds of tension flange
(bottom flange) of
crane girders
In case of failure of any welds in
SPOT/RT or UT the % of retesting shall
5% spot RT on butt
be doubled at that particular location.
welds / at inaccessible
Acceptance criteria of NDT on welds
As required/ locations UT on butt As per technical specifications and
iv Radiography Test (RT) A Physical SR  shall be as per AWS D1.1.
agreed welds- For coal bunker construction drawings
bins
Wherever RT is not feasible UT to be
carried out with the approval of the
10% RT weld length of
Engineer
each welder on butt
welds, except for
crane girders and coal
bunk
5.03 Full Penetration Welds (Other than butt welds)

100% UT on the web
to flange joint of crane In case of failure of any welds in
girder SPOT/RT or UT the % of retesting shall
i Ultrasonic Testing (UT) A Physical IR  be doubled at that particular location.
agreed construction drawings
10% UT on other full Acceptance criteria of NDT on welds
penetration joints shall be as per AWS D1.1.
5.04 NON DESTRUCTIVE AND DESTRUCTIVE TESTING FOR CHIMNEY STEEL LINER

i Visual examination As required/ agreed B Visual 100% SR  As per requirement of OWNER Engineer
construction drawings, IS 822, AWS D 1.1

ii DPT As required/ agreed B Physical 100% IR 
10% FOR SHOP BUTT

iii RT As required/ agreed A Physical WELD AND 15% FOR
SITE BUTT WELDS
6.00 FOUNDATION CHECKS
As agreed / Physical/ Shape, lines (including diagonal

i Dimensions and levels B Each Foundation Tech Specs and Const. Drawings SR 
required Measurement checks)
Foundation bolts shall conform to

As agreed / Physical and Once for each lot of
ii Foundation Bolts (materials) A Tech Specs and Const. Drawings SR/MTC  IS:5624 and property class shall be 4.6
required MTC Review delivery
as per IS:1367 (Part-3).
PAGE 75 OF 7
LOGO
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
Foundation Bolts and As agreed / Physical/ Measurement of Verticality, Levels,
ii B Each Foundation Tech Specs and Const. Drawings SR 
Embedment's required Measurement pitch distance
Receipt of shop Visual/

As agreed / Each structural Checks for visual defects and
7.0 fabricated steel Material A Physical & Tech Specs and Const. Drawings SR 
required member completeness of painting as per CHP
structure at site Review of CHP
Submission of Erection
sequence/ methodology Once prior to erection of Approved drawings and Technical
8.0 - A Approval
Specifications
SR √
of erection for all each structure
structures
9.00 PRE-ASSEMBLY CHECKS

Markings for -
Punch Erection marks and As agreed / Visual/ Each structural Assembly designation, Part number,
i B Tech Specs and Const. Drawings
match marks on members required Physical member Weight, Any other important
identifications.
Pre-assembly as per match As agreed / Visual/ Each structural
ii B Tech Specs and Const. Drawings
mark required Physical member
Camber, sweep and total length As agreed / Visual/ Each structural
iii B Tech Specs and Const. Drawings SR 
after trial assembly of structure. required Physical member
Every first and tenth
As agreed / Visual/
iv Control assembly check at shop B set of identical Tech Specs and Const. Drawings
required Physical
structure
10.00 ERECTION CHECKS
Alignment, slopes, level, As agreed / Each structural

i B Measurement Tech Specs and Const. Drawings SR 
tolerances of erected member required member
Tightening of bolts including As agreed / Visual/ Each structural

ii B Tech Specs and Const. Drawings SR 
foundation bolts with lock nuts required Physical member
To be verified w.r.t. approved

As agreed / Visual/ Tech Specs and Const. Drawings, IS 7215
iii Acceptance of erected structure A Each erected structure SR  methodology for erection / erection
required Physical and IS 12843
sequence
11.00 PAINTING SYSTEM

Painting Materials and As agreed / Material to be procured from OWNER
i A Review of MTC Each batch of delivery Tech Specs and Const. Drawings SR/MTC 
accessories required approved sources.
As agreed / Tech Specs and Const. Drawings,
ii Surface preparation B Physical /visual Random in each shift SR 
required Relevant code/ standards
As agreed / Each surface at
iii DFT of paint - Over steel surface A Physical Tech Specs and Const. Drawings SR 
required random
As agreed / Each surface at
iv Acceptance of painted surfaces B Physical Tech Specs and Const. Drawings SR
required random
12.00 PERMANENT BOLTS AND NUTS AND WASHERS

All bolts , nuts and washers for
As agreed / Physical and Once for each lot of connections shall be conforming to
i Material A Tech Specs and Const. Drawings SR/MTC 
required MTC Review delivery relevant IS as given in the Tech. Spec./
Construction Drawing
As agreed / Random before
ii Contact surfaces before bolting B Physical Tech Specs and Const. Drawings, IS 4000 SR
required assembly for bolting
Inspection of the assembled As agreed / Randomly in each shift
iii B Physical Tech Specs and Const. Drawings, IS 4000 SR
bolts required for assembled bolts
PAGE 76 OF 7
LOGO
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
Randomly during snug
As agreed /
iv Tensioning B Physical tight test and after full Tech Specs and Const. Drawings, IS 4000 SR 
required
tensioning
As agreed /
v Acceptance of installed bolts B Physical Each bolt Tech Specs and Const. Drawings SR
required
13.00 ELECTROFORGED GRATINGS
Material from approved source A Physical and Once for each lot of Tech Specs and Const. Drawings SR/MTC Also refer the approved MQP
i As agreed / required 
CHP Review delivery
Acceptance of Erection, alignment B Physical 100% Tech Specs and Const. Drawings SR
ii As agreed / required
and each Installation
14.00 STAINLESS STEEL HAND RAILS

Physical/MTC
As agreed / Review(In case Once for each lot of Tech Specs and Const.
i Material A SR/MTC  Also check grade of steel
required procured by delivery Drawings
contractor)
WPS shall be submitted for Owner

As agreed / Random for each AWS D1.1 / 'Tech Specs and Const.
ii DPT for welding A Physical SR/LB  approval , electrodes used shall be as
required fabrication Drawings
specified in WPS
Acceptance of stainless steel As agreed /
iii B Physical Each installation Tech Specs and Const. Drawings SR
hand rails required
15.00 PTFE SLIDING BEARINGS AND ELASTOMERIC BEARINGS

As agreed / Physical and Once for each lot of Tech Specs and Const. Drawings
i Material from approved source A SR/MTC 
required MTC Review delivery
Acceptance of installation of As agreed / Tech Specs and Const. Drawings
ii B Physical Each installation SR
bearings required
16.00 STOP LOG GATE, TRASH RACK AND LIFTING BEAM

16.1 MATERIAL
Check Quantity (in case of receipt) C Visual 100% Challan / Release No damage, surface defect SR √
and completeness and damage, note
surface defects
16.2 ERECTION
Alignment leveling Plumb, Piano wire, C Measurement 100% Specification/ Approved drawing Inspect-ion Welding ,if any, involved at site will be
water level Report done by welders and procedure qualified
as per ASME-IX in presence of Owner
(FQA)
16.3 PAINTING / SURFACE PREPARATION
Shade - B Visual 100% Specification/ Approved drawing Inspect-ion The type of painting/ surface treatment of
i
Report parts shall be as per Technical
ii DFT Elcometer A Measurement Random Specification/ Approved drawing -do- √ specification
16.4 TESTING
Free movement of stop log / Lowering or raising for full length A Physical 100% Smooth operation, Owner Tech. Specification, -do-
trash rack in guides under for 2/3 times IS:4622
i dry and under full water
condition
Leakage for stop Log Measurement of leakage As reqd. A Physical 100% Leakage rate within limit -do- √ Maximum leakage rate 5
ii litre/minute/metre length of seal under
max.head as per IS:4622
iii Load test for lifting beam Load Test As reqd. A Physical 100% No deflection /No Deformation -do- √
17.00 CW LINERS
17.1 MATERIALS
Steel Plates/ Sections for liners and Material- Visual B Visual Each plate/ Section Tech Specs and Const. Drawings
i flanges Examination
Inspection of Materials on receipt at Steel tape/Visual C Visual 100% Physical Visual verification , No damage LB √
ii site
iii Storage of materials at work site - C Visual 100% As per SCC LB √
Check for Pittings distortion rolling - C Visual 100% IS 2062 LB √
iv defects etc.
PAGE 77 OF 7
LOGO
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
v Plate thickness Dmeter C Measurement 100% IS 2062 LB √
PAGE 78 OF 7
LOGO
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
17.20 FABRICATION
Marking, squaring, cutting Steel Tape - C Visual 100% As per approved drawing LB
i and edge preparation
ii Prebend of Plate Template C By template 100% As per approved drawing SR
iii Roll to required size - C By template 100% As per approved drawing -
Tack weld and provision of - B Measurement of 100% As per approved drawing SR
iv internal bracings to keep in Dia
proper shape
17.30 PAINTING
Submission of painting - B For Review of Before start of painting Tech Specs and Const. To be accepted by Engineer In Charge
i methodology painting system work Drawings
Surface preparation Cleaning As reqd. B Visual 100% Tech Specs and Const. Inspn √
ii Drawings Report
Primer and subsequent Elcometer As reqd. B Visual 100% Tech Specs and Const. Inspn √ Uniform thickness & type of paint and
iii coats Drawings Report shade for each coat
17.40 WELDING (SHOP / FIELD WELDS)
Approval of welding - A Visual and 100% ASME sec.IX/ Approved WPS Test Report √
procedures/specification and destructive as
i subsequent welding procedure per ASME-IX
qualification
Welder's Qualification test - A Visual and 100% ASME sec.IX/ Approved WPS Test Report √
ii destructive as
per ASME-IX
Fit up and gap By Filler gauge B 100% As per approved drawing /IS-3589 Shop
iii Register
Check of surface defects B 100% Free from surface defects Shop
iv Register
17.50 INSPECTION OF WELDS (shop and field erection welds)
DPT on root run after back gauging DPT Kit B NDT 100% IS-3658 No Line and round indication and no Shop √ Pipe diameter where back gouging is not
i / grinding of butt welds crack Register possible grinding of root run for DPT
ii DPT on fillet welds DPT Kit B NDT 100% -do- -do- √

iii DPT on finished butt welds DPT Kit B NDT 10% -do- -do-
Radiography test on shop but welds RT Equipments A NDT 5% ASME sec.V and ASME Sec. VIII Div.1 RT Films √ The extent of check shall be modified to
iv ( welding done on the floor other the criteria written elsewhere in the
than pit area) technical specification if any.
Radiography on field Butt welds ( RT Equipment A NDT 5% ASME sec.V and ASME Sec. VIII Div.1 RT Films √
v welding done on the pit)
17.60 DIMENSIONS
i Dimensional Conformity steel tape B Measurement 100% As per approved drawing SR √
ii Tolerance OD / ovality steel tape B Measurement 100% As per approved drawing SR
17.70 HYDRO TESTING
Leakage tightness Hydro test A Leakage tests 100% SR √ For shop welded joints before encasement
Arrangement Tech Specs and Const. Drawings in concrete/ painting and erection joints
18.00 MAKEUP WATER PIPES

18.1 MATERIALS
Inspection of Materials on Steel tape/Visual C Visual 100% Physical Visual verification, No damage LB √
i receipt at site
18.2 PAINTING
Submission of painting - B For Review of Before start of painting Tech Specs and Const. Drawings To be accepted by Engineer In Charge
i methodology painting system work
Surface preparation Cleaning As reqd. B Visual 100% Inspn √
iii Tech Specs and Const. Drawings Report
Primer and subsequent Elcometer As reqd. B Physical 100% Inspn Uniform thickness & type of paint and
iv Tech Specs and Const. Drawings
coats Report shade
18.3 COAL TAR PROTECTION TAPE/ WRAPPING AND COATING
Submission of coating - B For Review of Before start of coating To be accepted by Engineer In Charge
i methodology coating system work Tech Specs and Const. Drawings
Surface preparation As reqd. B Visual 100% Inspn √
ii Tech Specs and Const. Drawings
Report
Holiday detection Test Electrical Testing As reqd. B Physical 100% surface area Inspn √
iii Tech Specs and Const. Drawings
Report
PAGE 79 OF 7
LOGO
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
Adhesion Test As reqd. A Physical 2 Tests per days Inspn √
iv Tech Specs and Const. Drawings
production Report
Coating Thickness As reqd. A Physical Once for every 100 Sq M Inspn √
v Tech Specs and Const. Drawings
Report
18.4 FABRICATION
Cutting and edge Steel Tape - C Visual Each pipe/ fitting As per approved drawing LB
i preparation
Fit-Up - B Measurement of Each fit up As per Technical Specifications/ approved SR
ii Dia drawings
18.5 WELDING
Approval of welding - A Visual and 100% ASME sec.IX/A Approved WPS Test Report √
procedures/specification and destructive as
i subsequent welding procedure per ASME-IX
qualification
Welders Qualification test - A Visual and 100% ASME sec.IX/A Approved WPS Test Report √
ii destructive as
per ASME-IX
Check to fit up gap By Filler gauge B 100% As per approved drawing /IS-3589 Shop
iii Register
Check of surface defects B 100% Free from surface defects Shop
iv Register
18.6 INSPECTION OF WELDS (shop and field erection welds)
DPT on root run and after back DPT Kit B NDT 100% IS-3658 No Line and round indication and no Shop √ Pipe diameter where back gouging is not
i gauging / grinding of butt welds crack Register possible grinding of root run for DPT
ii DPT on fillet welds DPT Kit B NDT 100% -do- -do- √

iii DPT on finished butt welds DPT Kit B NDT 10% -do- -do-
Radiography test on shop butt RT Equipments A NDT 5% ASME sec.V and ASME Sec. VIII Div.1 RT Films √ The extent of check shall be modified to
iv welds ( welding done on the floor the criteria written elsewhere in the
other than pit area) technical specification if any.
Radiography on field Butt welds ( RT Equipment A NDT 5% ASME sec.V and ASME Sec. VIII Div.1 RT Films √
v welding done on the pit)
18.7 DIMENSIONS
Dimensional Conformity steel tape B Measurement 100% As per approved drawing SR √ Grade of concrete and thickness of
encasement and top level of encasement
i from ground shall be as per approved
drawings
ii Tolerance OD / ovality steel tape B Measurement 100% As per approved drawing SR
18.8 HYDRO TESTING
Leakage tightness Hydro test A Leakage tests 100% SR √ Both for liners fabricated at shop and at
Tech Specs and Const. Drawings
Arrangement site after erection
LEGEND: D * Records, identified with “Tick” () shall be essentially included by supplier in QA documentation. DOC. NO.: REV: 0
Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB

Categorization Witnessing & Accepting (As per Owner QA&I System)
Manufactu Category ‘A’ FQA Engineer in association with Executing Engineer, Category ‘B’ Executing Engineer, Category ‘C’
rer/ Sub- Main-supplier Executing Engineer ;SR = Site Register , TR= Test Report, Mfr TC = Manufacturer's Test Certificate For Owner USE
supplier
This document shall be read in conjunction with Owner Tech. Specifications, BOQ, Drawings REVIEWED BY APPROVED BY APPROVAL SEAL
PAGE 80 OF 7
Annexure VI
MANUFACTURER’S NAME AND

ADDRESS MANUFACTURING QUALITY PLAN PROJECT :
ITEM : QP NO.: PACKAGE :
MFGR.’s REV. NO.:
LOGO CONTRACT NO. :
SUB-SYSTEM: DATE:
PAGE: …. OF…. MAIN-SUPPLIER:
SL. COMPONENT & CHARACTERISTICS CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO OPERATIONS CHECK OF CHECK DOCUMENT NORMS RECORD
M C/O M C O
1. 2. 3. 4. 5. 6. 7. 8. 9. D* ** 10. 11.
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (  ) SHALL BE DOC. NO.: REV…… CAT…..
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M: MANUFACTURER/SUB-SUPPLIER C: MAIN SUPPLIER, O: OWNER
P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE,
MANUFACTURER/ MAIN-SUPPLIER CHP: OWNER SHALL IDENTIFY IN COLUM “O” AS ‘ W” FOR
SUB-SUPPLIER OWNER
SIGNATURE USE REVIEWED BY APPROVED BY APPROVAL
SEAL
1/1
Annexure VII
SUPPLIER’S NAME AND ADDRESS

FIELD QUALITY PLAN PROJECT :
ITEM : QP NO.: PACKAGE :
SUPPLIER’S REV. NO.:
LOGO CONTRACT NO. :
SUB-SYSTEM: DATE:
PAGE: …. OF…. MAIN-SUPPLIER:
SL. ACTIVITY AND CHARACTERISTICS / INSTRUMENTS CLASS OF TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF REMARKS
NO OPERATION CHECK # CHECK OF CHECK DOCUMENT NORMS RECORD
1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10.
DOC. NO.: REV……

LEGEND: * RECORDS, INDENTIFIED WITH “TICK” () SHALL BE
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR, C=MINOR;
MANUFACTURER/ MAIN-SUPPLIER ‘A’ SHALL BE WITNESSED BY OWNER FQA, ‘B’ SHALL BE WITNESSED BY FOR
SUB-SUPPLIER OWNER ERECTION / CONSTRUCTION DEPTT. AND ‘C’ SHALL BE OWNER
WITNESSED BY MAIN SUPPLIER (A & B CHECK SHALL BE OWNER CHP USE
SIGNATURE REVIEWED BY APPROVED BY APPROVAL SEAL
STAGE)
1/1
Annexure VIII
Project : Stage : LIST OF ITEMS REQUIRING QUALITY PLAN DOC. NO.:

Package : AND SUB-SUPPLIER APPROVAL REV. NO.:
Supplier : DATE :
Contractor No. : SUB-SYSTEM : PAGE : OF
S. N. Item QP/ QP No. QP Sub. Proposed sub-supplier Place Sub- Sub-supplier Remarks
Insp. Schedule suppliers Details
Cat. approval submission
status / schedule
category
LEGENDS
1. SYSTEM SUPPLIER/SUB-SUPPLIER APPROVAL STATUS CATEGORY (SHALL BE FILLED BY OWNER)
A – For these items proposed vendor is acceptable to OWNER. To be indicated with letter “A” in the list alongwith the condition of approval, if any.
DR – For these items “Detailed required” for OWNER review. To be identified with letter “DR” in the list.
2. QP/INSPN CATEGORY:
CAT-I : For these items the Quality Plans are approved by OWNER and the final acceptance will be on physical inspection witness by OWNER.
CAT-II : For these items the Quality Plans approved by OWNER. However no physical inspection shall be done by OWNER. The final acceptance by OWNER shall be on the basis review
of documents as per approved QP.
CAT-III : For these items Main Supplier approves the Quality Plans. The final acceptance by OWNER shall be on the basis certificate of conformance by the main supplier.
UNITS/WORKS : Place of manufacturing Place of Main Supplier of multi units/works.
1/1

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THDC INDIA LIMITED

(A Joint Venture of Govt. of India & Govt. of U.P.)

KHURJA SUPER THERMAL POWER PROJECT

BIDDING DOCUMENT NO.: THDC/RKSH/CC-9915-373

KHURJA SUPER THERMAL POWER PROJECT

BIDDING DOCUMENT NO.: THDC/RKSH/CC-9915-373

KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

IIIA – 01 EQUIPMENT SIZING CRITERIA

IIIA – 03 WATER TREATMENT PLANT

IIIA – 04 COOLING TOWER

IIIA – 05 METERING PUMPS

IIIA – 06 LOW PRESSURE PIPING

IIIA – 07 FIRE DETECTION & PROTECTION SYSTEM

IIIA – 08 AIR CONDITIONING & VENTILATION SYSTEM

KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

EQUIPMENT SIZING CRITERIA

KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

1.00.00 WATER SYSTEM

a) Number of working CW : 2 X 50 % per unit

KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

1.02.00 Raw Water System

a) Raw Water System to Water PT Plant

b) Raw Water System to Ash Handling Plant

1.03.00 Auxiliary Water System (AWS)

a) Makeup (Clarified water) water system to CW system

KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

b) HVAC, FGD & AHS Cooling Makeup Pumps

Number of Pumps – 02 x 100% (2x100%) (1W+1S)

Capacity of each Pump –85 cum/hr (min.).

c) DM Make-up water System

d) Boiler Fill System

KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

f) Potable Water System

g) Air Pre Heater (APH) wash water system

h) FGD Make-up water system

1.04.00 A. PRE-TREATMENT SYSTEM

KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

5) Interconnection provision shall be provided between the clarified water outlet

6) Chemical House: A common two (2) storey Chemical house of RCC

b) Alum Solution preparation & dosing system consisting of minimum

c) FeCl3 (35–45 % conc.) (in case of PT-RO) preparation & dosing

d) PE dosing system consisting of minimum two (2) nos. of dosing tanks,

e) PAC dosing system shall consist of minimum two (2) numbers of

f) Bulk Coagulant storage tanks (2 nos), Coagulant unloading cum

KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

g) Anti-scalant preparation tanks (2 nos), Anti-scalant dosing pumps

h) Anti-oxidant preparation tanks (2 nos), Anti-oxidant dosing pumps

i) Hydrochloric Acid (HCl) unloading cum transfer pumps (2x100%),

j) Alkali (NaOH) unloading pumps (2x100%) (1W+1S), Alkali transfer

k) Two (2) numbers of electrically operated mono-rail hoists each of 1

l) Two (2) numbers of weighing scales at ground floor for weighing of

m) Emergency safety showers with eyewash units shall be provided in

n) One (1) number Overhead (OST) Storage Tank shall be provided on

7) Chemical house and Filter house shall be RCC buildings.

B. CHLORINE DI-OXIDE (ClO2) SYSTEM

c) Following minimum safety features/interlocking shall be available in the

KHURJA SUPER THERMAL POWER PROJECT TECHNICAL SPECIFICATION

a. Safety features at Chemical Storage Facility

2) Chemical Storage Facility is provided with neutralizing pits.

3) Chemical Storage Facility shall have safety shower with arrangements

b. Safety features at Equipment Room

2) ClO2 generator along with dosing skid shall be located in a well-

3) Typical Safety equipment shall be provided as mentioned elsewhere.