ScheduleETechnicalSpecificationHQ120111 PDF

NTPC Limited
(A Government of India Enterprise)
FARAKKA SUPER THERMAL POWER PROJECT
TECHNICAL SPECIFICATION
FOR
COAL CONVEYING PLANT PACKAGE
BIDDING DOCUMENT NO. :

NTPC Limited
(A Government of India Enterprise)
FARAKKA SUPER THERMAL POWER PROJECT
FOR
BIDDING DOCUMENT NO. :
This document is meant for the exclusive purpose of bidding against this specification and shall not be transferred, reproduced
or otherwise used for purposes other than that for which it is specifically issued.
TABLE OF CONTENTS
PART SECTION NO TITLE

Sub Section – II : Scope of Supply & Services
PART-A
IIA-01 Intent of Specification
PART-B
Sub Section III : Technical Parameters
IIIA MECHANICAL
IIIA-01 System Parameters and Operation & Control
Philosophy
IIIA-02 Brakes & Clamps
IIIA-03 Monorails and Hoists
IIIA-04 Chutes & Hoppers
IIIA-05 Belt Conveyor System
IIIA-06 Drive Equipment
IIIA-07 Belt Scale
IIIA-08 Dust Control & Miscellaneous System
IIIA-09 Ventilation System
IIIA-10 CHP Building
IIIA-11 Inline Magnetic Separator
IIIA-12 Metal Detector
IIIA-13 Coal Sampling Unit
IIIA-14 Vibrating Feeder
PART-B III-B ELECTRICAL

IIIB-01 Motors
IIIB-02 LT Switchgear & Bus Duct
IIIB-03 LT Power Cables
IIIB-04 H T Cables
IIIB-05 Control Cables
IIIB-06 Instrumentation cables
IIIB-07 Illumination System
IIIB-08 Cabling, Earthing & Lightning Protection
IIIB-09 Transformers
IIIB-10 H T Switchgear
IIIB-11 PLC Control Cables
IIIB-12 Battery
Page : 1 of 2
PART SECTION NO TITLE
IIIB-13 Battery Charger
IIIB-14 Measuring Instruments
IIIB-15 CCTV
PART-B III-D CIVIL

IIID-01 CHP System - Civil Works
PART-B IIID-02 Foundation System and Geotechnical Data
(Turnkey)
PART-B III-E QA & I SECTION

E-01 Coal Conveyors Belt
E-02 Motors
E-03 LT Switchgear
E-04 LT Busduct
E-05 LT Power Cables
E-06 LT Control Cables
E-07 Instrumentation Cables
E-08 Station Lighting
E-09 Cabling, Earthing & Lightning Protection
E-10 H T Cables
PART-B
E-11 H T Switchgear
E-12 HT Capacitor Bank
E-13 Measuring Instruments
E-14 Power Supply For C&I System
E-15 Transformer
E-16 Battery
E-17 Battery Charger
E-18 Control Panels
E-19 Control System
E-20 CHP System - Civil Works
PART-E List of Tender Drawings
Page : 2 of 2
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES
1.00.00 INTENT OF SPECIFICATION
This specification is intended to cover the following activities and services in respect
of all the equipment of Coal Conveying Plant from jetty to plant site to be installed
for Farakka Super Thermal Power Project, of the NTPC Limited, located in
Murshidabad district,in the state of West Bengal, India.
(a.) (i) Detailed design and engineering of all the equipment and equipment
system(s).
(ii) Complete manufacture including shop testing/ type testing.
(iii) Providing engineering data, drawings, Commissioning procedures

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

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

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

Guarantee Tests after successful completion of initial operation.
(ix) Furnishing of spares on FOR site basis and handing over to NTPC
stores.
(x) Reconciliation with custom authorities, if applicable.
(xi) Satisfactory completion of the contract.
(b.) The Contractor shall be responsible for providing all materials, equipment
and services, specified or otherwise (unless specifically excluded) which are
required to fulfill the intent of ensuring operability and the reliability of the
complete system covered under this specification.
(c.) It is not the intent to specify completely herein, all aspects of design and
construction of equipment. Nevertheless, the equipment shall conform in all
FARAKKA SUPER THERMAL POWER SUB-SECTION-IIA-01
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 1 OF 16
COAL CONVEYING PLANT PACKAGE SPECIFICATION
BID DOCUMENT NO.:
CLAUSE NO.
respects to high standards of engineering, design and workmanship and

shall be capable of performing in continuous commercial operation.
(d.) Whenever a material or article is specified or described by the name of a

particular brand, manufacturer or trade mark, the specific item shall be
understood as establishing type, function and quality desired. Other
manufacturer’s products may also be considered provided sufficient
information is furnished so as to enable the Employer to determine that the
products are equivalent or superior to those named.
(e.) Before submitting his bid, the Bidder should inspect and examine the site and
its surroundings and should satisfy himself as to the nature of the ground and
subsoil, the quantities and nature of work, materials necessary for completion
of the work and their availability, means of access to site and in general shall
himself obtain all necessary information as to risks, contingencies and other
circumstances which may influence or affect his offer. No consequent extra
claims on any misunderstanding or otherwise shall be allowed by the
Employer.
(f.) For all the related buildings and facilities in Employer’s scope and not
covered under the scope of this package, the contractor shall furnish all the
related input data/ details for preparation of Mechanical/ Electrical/ Civil
Drawings within 45 days of award of contract.
(g.) The sizes of various buildings/conveyor galleries indicated in the tender

drawings and the parameters of equipment indicated in various sections of
technical specifications are the minimum requirements of the employer. Any
increase in these sizes or the parameters, if required to meet the
system/maintenance/operational requirement shall be supplied by the
contractor without any extra cost implication to the employer.
(h.) Bidder shall take all necessary precautions to protect all the existing
equipment, structures, facilities and buildings etc. from damage. In case any
damage occurs due to the activities of the contractor on account of
negligence, ignorance, accidental or any other reason whatsoever, the
damage shall be immediately made good by the contractor at his own cost to
the satisfaction of the Employer. The contractor shall also take all necessary
safety measures with specific reference to excavation in rock, at his own
cost, to avoid any harm or injury to his workers and staff from the equipment
and facilities of the power plant.
(i.) Bidder should note that the existing rail lines within the plant area are
operational with rail traffic of coal and liquid fuel rakes. Bidder shall take all
precautions to ensure the safety of existing rail tracks and other associated
facilities as well as the safety of his men, material and equipment from the
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 2 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
operating rail traffic. The bidder shall plan and make all arrangements to
ensure that disruption to the existing rail traffic is minimum and shall follow
the instructions of the Employer in this regard. Further, bidder shall plan and
co-ordinate all his activities considering restrictions, if any, on free access to
his work areas due to the rail traffic.
(j.) After award of work, before finalising his layout especially the layout / levels
of conveyors, cable / pipe routes and other services, the contractor shall
carry out a site survey to identify the location & details of existing facilities
that may interfere with his proposed facilities. The contractor shall suitably
modify his layout / levels to prevent dislocation of existing facilities and any
cost / time implication arising out of such modifications will be to his account.
Contractor shall also be responsible to determine and obtain the necessary
details at site as required for interfacing and interconnection with the existing
system / facilities.
If during the execution of works it is found that there is interference with the
existing facilities / structures, the contractor shall revise his design / detailed
drawings to clear the interference and shall provide all necessary measures
for the safety of existing structures. No claim in terms of cost or relaxation in
time shall be entertained for any redesign, rework and for safety measures
provided. If at any stage of work, any dismantling or modification or
relocation of any existing facility is required to be done to complete the work
in bidder’s scope and which has been agreed by the Employer, the same
shall be done by the bidder at no extra cost or time implication to the
Employer. All such changes will be as per drawings and work plan approved
by the employer.
1.02.00 Equipment and services covered under COAL CONVEYING PLANT package are
described in the following sub-sections :
MECHANICAL
III-A-01 : System parameters and Operation & Control Philosophy
III-A-02 : Brakes and Clamps
III-A-03 : Monorails and Hoists
III-A-04 : Chutes and Hoppers
III-A-05 : Belt Conveyor System
III-A-06 : Drive Equipment
III-A-07 : Belt Scales
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 3 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
III-A-08 : Dust Control & Miscellaneous Systems
III-A-09 : Ventilation System
III-A-10 : CHP Buildings
III-A-11 : Inline Magnetic Separator
III-A-12 : Metal Detector
III-A-13 : Coal Sampling Unit
IIIA-14: Vibrating Feeder
ELECTRICAL
IIIB-01: Motors
IIIB-02 : LT Switchgear & Bus Duct
IIIB-03 : LT Power Cables
IIIB-04: HT Cables
IIIB-05 : Control Cables
IIIB-06 : Instrumentation cables
IIIB-07 : Illumination System
IIIB-08 : Cabling, Earthing & Lightning Protection
IIIB-09 : Transformers
IIIB-10 : HT Switchgear
IIIB-11 : PLC CONTROL PANEL
IIIB-12 : Battery
IIIB-13 : Battery Charger
IIIIB-14 : MEASURING INSTRUMENTS
IIIB-15: CCTV
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 4 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
CIVIL
III-D-01 : CHP System – Civil and Structural Works
III-D-02 : Foundation System and Geotechnical Data
QUALITY ASSURANCE
E-01 : Coal Conveyors Belt
E-02 : Motors
E-03 : LT Switchgear
E-04 : LT Busduct
E-05 : LT Power Cables
E-06 : LT Control Cables
E-07 : Instrumentation Cables
E-08 : Station Lighting
E-09 : Cabling, Earthing & Lightning Protection
E-10 : H T Cables
E-11 : H T Switchgear
E-12 : HT Capacitor Bank
E-13 : Measuring Instruments
E-14 : Power Supply For C&I System
E-15 : Transformer
E-16 : Battery
E-17: Battery Charger
E-18 : Control Panels
E-19 : Control System
E-20 : CHP System - Civil Works
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 5 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
1.03.00 TENDER DRAWINGS
The drawings listed in the specification at Part-E, form part of the specification and
shall supplement the requirements specified herein. The scope and terminal points
for the equipment to be furnished under this package shall be as identified in these
drawings and read in conjunction with the text of these specifications. These
drawings are preliminary drawings for bidding purpose only and subject to changes
that may be necessary during the detailed engineering.
1.04.00 In case of any conflicts / contradiction among various volumes / sections / annexures
/ chapters / appendices / tender drawings of bid documents, the same shall be
referred to the Employer for clarifications whose decision shall be final and binding.
No extra claims shall be allowed on this account.
1.05.00 SCOPE
1.05.01 The scope of Coal Handling Plant to be furnished, erected and commissioned under
this specification shall be as detailed hereinafter. The Contractor shall be fully
responsible for system and detailed design, engineering, manufacture, shop
fabrication, assembly, testing and inspection at manufacturer’s works, packing,
dispatch, transportation, transit insurance, custom clearance etc. as applicable,
delivery to site, unloading, handling and storage at site, insurance during storage,
construction, erection, including erection supervision, testing, inspection,
commissioning and handing over to Employer and Guarantee testing including all
associated electrical, civil, structural & architectural works as specified, unless
specifically excluded as per Section-Terminal Points & Exclusions.
1.05.02 The scope of the contractor shall be deemed to include all such items which
although are not specifically mentioned in the bid documents and/or in Contractor’s
proposal but are needed to make the system complete in all respects for its safe,
reliable, efficient and trouble free operation and the same shall be furnished and
erected unless otherwise specifically excluded as per Section Terminal Points &
Exclusions. The general description of the proposed system and the broad scope of
work under the specification shall include but not be limited to as elaborated below.
2.00.00 DESCRIPTION, SCOPE AND TERMINAL POINTS
2.01.00 BRIEF DESCRIPTION OF PROJECT
Farakka Super Thermal Power Project (STPP) was originally conceived as a pit
head coal based power plant of 2100 MW (3x200 MW+3x500 MW + 1x500MW)
capacity to be implemented in three stages. Stage-I comprising three units of 200
MW and Stage-II comprising two units of 500 MW of the plant which are under
commercial operation. Presently Stage-III comprising one unit of 500 MW is under
commissioning and on implementation of the same, the overall plant capacity would
thus become 2600MW i.e. the planned ultimate capacity.
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 6 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
The present proposal of Coal Conveying Plant is for carrying coal as received from
Jetty to the plant site and feeding all the stages through various interconnection in
the existing Coal handling Plant.
2.01.01 Brief description of proposed Coal Conveying Plant.
This shall be read in conjunction with Coal Flow Diagram and the Coal Conveying
Plant layout enclosed else where in the specification.
PHASE-I
(i) Coal as received from barges shall be unloaded by either slewing type grab
cranes or mobile type grab cranes to an feed hopper. From feed hopper the
coal shall be conveyed through series of Conveyors of 800 TPH capacity
(Conveyor A, Conveyor B, Conveyor C) through Junction house JH-1, JH-2
and shall drop coal at existing Stockyard no. 4 & 5 of Stage-I & Stage-II.
From Stockyard 4 & 5, coal shall be bull dozed to stockyard for further
conveying to bunker of Stage-I, II & III via existing stacker reclaimer and
Conveyors.
PHASE-II
(ii) At Junction House JH-2 Conveyor D shall receive coal from conveyor B and
shall convey coal through series of conveyors of 800 TPH capacity (Conv. E,
Conv. F, Conv. G) through junction houses JH-3,JH-4,JH-5 & JH-6.
2.02.00 DETAILED SCOPE
PHASE-I
2.02.01 Non drive house(NDH), feed hopper with grating, complete with civil, structural,
architectural and electrical works including vibro feeder, equipment handling facilities
for feeders and other equipment/systems such as DS system, ventilation system,
drinking water system, drainage system etc. as specified elsewhere in the
specification.
2.02.02 Conveyor A complete with conveyor gallery along with its supporting structures,
short supports, stringers, deck-plate, seal-plate, conveyor foundations, drive motors,
pulleys, idlers, gravity take ups, take up structure, internal and external belt cleaners,
pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster
brakes, all electricals and accessories. including all civil, structural and architectural
works for tunnel, conveyor gallery, gallery supporting trestle and their associated
foundation etc.
2.02.03 Belt Conveyors B & Conveyor C complete with conveyor galleries, conveyor
supporting structures, short supports, stringers, deck plate, seal plate, conveyor
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 7 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
foundations, drive motors, drive units, pulleys, idlers, gravity take ups including
guides, pits etc., internal and external belt cleaners, pull chord switches, belt sway
and zero speed switches, electro-hydraulic thruster brakes, all electricals etc.
including all civil, structural and architectural works for conveyor gallery, gallery
supporting trestles and their associated foundations.
2.02.04 Junction Houses JH-1 & JH-2, complete with all civil, structural, architectural and
electrical works including chutes, monorails, hoists/chain pulley blocks, hoist
maintenance platforms, external staircases, dust debris chutes etc. All overground
junction houses shall have separate debris disposal chute up to the ground floor.
2.02.05 Two (2) nos. Vibro feeders to feed the coal on to Conveyor A complete with drives,
all mechanical, electrical accessories and supporting structures etc.
2.02.06 One (1) No. coal sampling unit, for (-) 50 mm size coal in Junction house-1 complete
with all accessories, and electrical, civil, structural works, supporting structures,
approach/maintenance platforms, hoists etc.
2.02.07 One(1) No. In-line Magnetic Separators on Conveyor A complete with reject chutes,
reject trolleys, supporting arrangement, and all mechanical, electrical, civil, structural
works and accessories.
2.02.08 One(1) No. Electronic Belt weighers complete with all mechanical, supporting
arrangement, electrical, and accessories on conveyors A.
2.02.09 One(1) No Metal Detector complete with all mechanical, electrical, civil, structural
works and accessories on Conveyor B.
2.02.10 One (1) No. belt vulcanizing machine of adequate size complete with all mechanical,
electrical, accessories and consumables for one year consumption. Further, belt
jointing facilities as specified shall be provided.
PHASE-II
2.02.11 Belt Conveyors D, Conveyor E, Conveyor F & Conveyor G complete with conveyor
galleries, conveyor supporting structures, short supports, stringers, deck plate, seal
plate, conveyor foundations, drive motors, drive units, pulleys, idlers, gravity take
ups including guides, pits etc., internal and external belt cleaners, pull chord
switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all
electricals etc. including all civil, structural and architectural works for conveyor
gallery, gallery supporting trestles and their associated foundations.
2.02.12 Junction Houses JH3, JH-4, JH-5 & JH-6, complete with all civil, structural,
architectural and electrical works including chutes, monorails, hoists/chain pulley
blocks, hoist maintenance platforms, external staircases, dust debris chutes etc. All
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 8 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
overground junction houses shall have separate debris disposal chute up to the
ground floor.
2.02.13 Modification of existing conveyor 24A/B alongwith its gallery in order to retrofit
junction house JH-6.
Common for Phase I and II
2.02.14 Complete chute work along with chute block switches and actuator operated flap
gates (as applicable) in all Junction Houses between various conveyors.
2.02.15 Pressurized Ventilation system for all Switchgear rooms, MCC rooms complete with
all mechanical, electrical, accessories, civil and structural works.
2.02.16 Exhaust fans to be provided in all battery rooms, all toilets complete with electrical,
civil & structural works etc. Exhaust fans along with required ducting shall also be
provided for all underground Structures/Junction Houses.
Air conditioning of Coal conveying plant control room and office room, RIO room ,
complete with all electrical, civil & structural works etc.
2.02.17 Complete plain water dust suppression system for control of fugitive dust in
underground feed hopper complex, junction houses complete with enclosed pump
houses, water tanks, pumps, drives, hoisting arrangements, piping, valves etc.
electrical, accessories, civil, structural and architectural works.
2.02.18 Service water, potable water system and cooling water system for complete coal
conveying plant.
2.02.19 Cooling water system for scoop couplings, for complete coal conveying plant as
specified elsewhere in the specification.
2.02.20 Monorails and electrically operated hoist blocks as well as hand operated chain
pulley blocks for servicing/installation/easy replacement of drive machinery, different
types of pulleys for all conveyors, GTU and other equipment from ground level to
their locations and vice-versa & landing inside the respective Buildings.
2.02.21 All buildings in contractor’s scope shall be complete with all electrical, civil,
structural, architectural works, cable trenches, fire safety walls, foundation, earth
mat, fencing, earthing for transformers. All cables, duct banks, trenches, cable
trestles shall be complete with associated civil/ structural work and necessary civil
foundations.
2.02.22 Drainage of all coal conveying buildings, conveyor galleries including all civil &
structural works as detailed out elsewhere in the specification.
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 9 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
2.02.23 All equipment/fittings, supporting structure, along with insert plates, bolts,
accessories, MS sleeves, base plates, grouting as may be required and proper
alignment etc.
2.02.24 Complete unused set of all special tools and tackles, which are necessary or
convenient for erection, commissioning and overhauling of any equipment, covered
under the scope.
2.02.25 First fill of all consumables e.g.; oils and lubricants for one year toppings
requirements.
2.02.26 Preservative shop coating, final painting of all structures and equipment under the
scope.
2.02.27 All inserts, anchor bolts, foundation bolts for Contractor’s equipment, platforms etc.
in the entire Coal conveying plant.
2.02.28 All necessary grouting & finishing of the floor after welding at all such pockets & else
where is in Contractor’s scope.
2.02.29 (i) All inserts, anchor bolts, foundation bolts for Contractor’s equipment,
platforms etc. in the entire Coal conveying plant.
(ii) All necessary grouting & finishing of the floor after welding at all such pockets
& else where is in Contractor’s scope.
2.02.30 FIRE DETECTION AND PROTECTION SYSTEM
The scope of equipment to be furnished and erected under this specification shall
cover all the systems and equipments detailed hereunder.
For the basic Fire Detection and Protection System specified, any other items,
needed to make the system complete, safe and sound in operation shall be included
under the scope of work by the Bidder at no extra cost to the Owner.
Fire Water Storage and Pumping System
Complete fire water storage and pumping system consisting of MS construction fire
water storage tank, spray pumps & drives and Battery Chargers for the diesel
engines drives, required instruments, controls, and panels as per detailed
specifications. Tapping from nearby water source shall be taken to fill the fire water
storage tanks. Further, suitable capacity monorail electic hoist inside fire water
pump house shall also be provided by the Contractor.
MVW & Hydrant System
Automatic MVW system shall be provided for conveyors & JH/DH protection.
Further, hydrant valves (taped from spray header) at strategic location shall be
provided as per detailed specifications.
Fire Extinguisher
To be provided by the bidder at MCC, RIO rooms & Control room.
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 10 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
Analogue addressable type Fire Alarm System / Annunciation Panels

a) LHSC, IRD, cabling, junction boxes, instrumentation, etc. for various
areas/equipments as detailed out elsewhere. For long distance transmission
Booster / Repeater station (if applicable) suitable for field shall be provided.
b) PLC based Control Panels complete with all accessories for Fire detection
and protection system shall be provided in Fire water pump house. This PLC
panel shall also be connected with Fire alarm panel at Control room.
c) Fire alarm panel along with PC & Printer in Control room. Further, due to long
distance between fire alarm panel at control room and various field devices,
suitable qty. of fire alarm panels shall be required at intermediate locations.
These panels shall be located at RIO room envisaged in JHs. All these fire
alarm panels shall be interconnected with each other as well as with fire
alarm panel at Control room through fibre optic cables.
c) Manual call points, hooters etc., shall be provided as per system
requirements.
d) All interconnection cables (instrumentation cables from instruments to panels,
control cables to MCC, instrument cables from MCC to control panel, power
cables to drives, network cables and fibre optical cables, etc.) shall be
provided by the Contractor.
Guarantee tests for PLC with HMI system
Set of commissioning spares as may be required during erection and
commissioning.
One (1) set Special tools and tackles required for maintenance of all the mechanical,
electrical and C & I equipments under the scope of Contractor.
Any additional item/ equipment required to make the system complete.
All other services described under “Intent of Specifications”.
All civil works related to fire detection and protection system shall be in the scope of
works of Contractor.
Supply of all consumable materials like initial fill of lubricants, grease, etc. required
to complete the erection and commissioning of the total fire protection system.
Further, all consumables required for PG test shall also be in Bidder’s scope of
supply.
Preparation of necessary detailed drawings including schematics, layouts,
isometrics, fabrication drgs, erection drgs, etc. as required and also development of
“As Built Drawings”.
Conductance of Performance and Guarantee test as per Standard Guaranteed test

procedure to be finalized during detailed engineering.
2.02.31 Electrical System / Equipment
2.02.31.01 ELECTRICAL SYSTEM / EQUIPMENT (FOR PHASE-I & PHASE-II) :
Unless specifically excluded in clause no. 2.04.00, contractor’s scope of work shall
include all electrical works, as required for putting into successful operation of the
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 11 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
Coal handling plant covered in this specification. The sizing of various equipments
shall be as defined in the specification. Main equipment included in the scope is
given below.
2.02.31.02 6.6KV Switchgear :-
6.6KV switchgear as indicated in enclosed single line diagrams. Two (2) spare
feeders (one transformer feeder and one motor feeder of highest rating) shall also
be provided on 6.6 KV switchgear. In addition
addition to
tothis
thisOwner's/ future1000A
two (2) nos. use feeders
feedershall
for
owner’s use shall also be provided.
be provided as per Electrical SLD
2.02.31.03 Motors :-
All HT and LT motors along with lugs and glands.
2.02.31.04 415V MCCs / Switchgear / Distribution boards :-
415V Motor control centers (as indicated in the electrical single line diagram), AC &
DC Distribution boards / Fuse boards, Local push button stations for all drives and
local motor starters as required for the system and equipment.
In each MCC contractor shall provide 20% spare feeder(minimum One (1) no) for
each type and rating of the outgoing feeders provided in that MCC.
Two (2) nos. of 125A Switch fuse feeders (total load 50KVA) shall be provided in
each bus of the above indicated MCCs for Owner’s future use.
2.02.31.05 Cables :-
All HT/LT Power cables, LT control cables, instrumentation cables, fiber optic
cables, signal cables and any special cables for the completeness of the system.
a) Required for connection between equipment / devices in Contractor’s scope.
b) Required for connection between Contractor’s equipment and Owner’s

equipment.
2.02.31.06 Illumination system :-
AC Illumination system for complete internal and external lighting of associated plant
and equipment like JH’s, Conveyors, transformer yards, switchgear & control
buildings, Drive houses, Pump houses etc. and roads under Contractor’s Scope.
2.02.31.07 Cabling, Earthing and Lightning Protection :-
Cabling viz., cable laying along with cable accessories, cable trays with supporting
structure, terminations & jointing kits, trenches, trestle, duct banks etc required for
the cables to be supplied by the contractor.
Earthing / Grounding and lightning protection for the plant and equipment under
contractor’s scope.
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 12 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
2.02.31.08 Transformers :-
6.6KV/0.433KV, ONAN, Outdoor transformers as indicated in the single line

diagram.
2.02.31.09 Battery :-
220V DC, 150 AH (min.) Lead acid plante type / 90 AH (min.) Ni-Cd Battery as per
electrical single line diagram.
2.02.31.10 Battery Charger :-
One (1) sets of 220V, 40A (min.) float cum boost chargers as per electrical single
line diagram. Each set consists of two (2) nos. battery chargers.
2.02.31.11 PLC and Control panels :-
Main control desk with HMI, Large video Screens, PLC panels, Remote I/O stations,
UPS, 24V DC battery and battery chargers, for the control of entire Coal handling
equipment & HT/ LT Switchgear.
Local control panels for ILMS, Belt weighers, Metal detectors, Coal sampling units
sump pumps, DS/DE, ventilation etc. as required for the system. Local control
desks with HMIs shall be provided in main control room as per PLC configuration
drawing.
2.02.31.12 Closed circuit TV(CCTV) System, Telephone & Public address system :-
CCTV system with 3 nos. of cameras in each JH & 2 nos. in each switchgear room.
Public address and telephone system for entire phase-I & phase-II shall also be
provided by contractor.
2.02.31.13 Electrical buildings :-
i) Phase-I
i) One(1) no HT/LT Switchgear room shall be provided near Jetty area to
accomodate 6.6KV switchgear, 415V MCC, MLDB, WDB, DCFB’s etc. One air
conditioned control room shall be provided adjacent to HT/LT switchgear room to
accomodate CHP control desk,operator work station, processor panels,I/O panels,
EPABX panels UPS, printers, etc. One (1) no. 6.6/0.433KV transformer shall be
located adjacent to switchgear building.
ii) One(1) no Switchgear room shall be provided near JH-2 to accomodate 415V
MCC, MLDB, WDB, DCDB, battery charger panels etc. One air conditioned RI/O
room shall be provided near switchgear room. A separate battery room shall also be
provided to accomodate 220V dc battery. One(1) nos. 6.6/0.433KV transformer shall
be located adjacent to switchgear room.
ii) Phase-II
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 13 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
i) One(1) no Switchgear room shall be provided near JH-5 to accomodate 415V

MCC, MLDB, WDB, DCFB’s etc. One air conditioned RI/O room shall be provided
near switchgear room.
2.02.32.00 CIVIL
2.02.32.01 The work to be performed under this specification consists of providing all labour,
materials, construction equipment, tools and plant, scaffolding, supplies,
transportation, all incidental items not shown or specified, but reasonably implied or
necessary for successful completion of the work including Contractor’s supervision
and in strict accordance with the drawings and specifications. The nature of work
shall generally involve earthwork in excavation including controlled blasting & very
deep underground excavation, extensive de-watering, shoring and strutting, sheet
piling, back filling around completed structures and plinth protection, area paving ,
disposal of surplus excavated materials, piling, concreting including reinforcement
and form work, brick work, fabrication and erection of structural / miscellaneous steel
works, inserts, architectural items & finishes such as plastering, painting, flooring,
doors, windows & ventilators, glass and glazing, rolling shutters etc., permanently
colour coated profiled steel sheeting, anchor bolts, R. C. C. trenches with covers,
laying and testing of water pipes, sanitation, water supply, drainage, damp proofing,
water proofing and other ancillary items.
2.02.32.02 The work shall have to be carried out both below and above ground level and shall
be involving, basements, equipment foundations including grounding, slabs, beams,
columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, access
roads, culverts, conveyer galleries, trestles, penthouses, underground tunnels,
junction house, finishes, complete architectural aspects, drainage, sanitation, water
supply (from terminal points to various buildings, conveyor galleries) and all other
civil, structural and architectural works associated with the complete Coal
Conveying Plant.
2.02.32.03 Scope of the Contractor shall also include supply and laying earthing mat all around
the periphery of buildings, structures, and outdoor equipments, as per the approved
drawings.
2.02.32.04 The analysis design and detailed drawing for Underground JH, tunnels, culverts, etc.
coming directly below the railway track shall be got approved by the Contractor from
the Concerned railway authority before taking up construction. All necessary
payment for above work shall be made by the contractor to the Railway authority.
2.02.32.05 The work shall also involve arranging construction water from underground sources,
storage in underground/ overground tanks and taking the water to construction site
through pipelines by pumping or by road tankers etc., including all necessary
accessories, tools & tackles etc.
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 14 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
2.02.32.06 Access roads 4m wide bituminous roads to all buildings/facilities (in Contractor
Scope) will be in the Scope of Contractor.
2.03.00 TERMINAL POINTS
Broad terminal points for coal conveying plant have been indicated in the tender
drawings. Within these terminal points, all equipment and services, civil, structural
and architectural works, electrical distribution, piping network etc. as required for
coal handling plant will be furnished and erected by the contractor unless specifically
excluded as follows:
2.03.01.01 Wherever Contractor is permitted by Employer to take support from any of the
Employer’s Structures, the Contractor shall ensure that no damage is done, to the
Employer’s Structures including Painting thereof. In case of any damage to the
Employers Structure and/or Painting, then the Contractor shall rectify the same to
the complete satisfaction of the Employer.
2.03.01 Water supply connections for dust suppression, service water system, and potable
water shall be provided at one location by the employer, details of which are given in
the tender drawing. Further network of piping including all pumps, tanks, necessary
accessories, supports and fittings etc. for distribution of potable water, water for dust
suppression and service water system in all JHs, non drive house, control rooms,
MCC rooms, toilets, shall be under the scope of the contractor.
2.03.02 Electrical Terminal Points
(a) Owner’s 6.6 KV switchgear/415V MCC as indicated in electrical single line

diagram.
2.04.00 EXCLUSIONS
Nil
3.00.00 SYSTEM DESIGN BASIS
3.01.00 The rated capacity of the Coal conveying plant shall be 800 TPH. The mechanical
and structural / civil system shall be designed for 880 TPH capacity and round the
clock operation with both the streams operating simultaneously.
3.02.00 Following shall be considered while designing the CHP:
a) The Coal delivered to the power station shall be of size (-)50 mm & below.
However occasionally 1-2% coal above (-) 50 mm lump size may also be
encountered.
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 15 OF 16
BID DOCUMENT NO.:
CLAUSE NO.
b) HGI of the Coal shall be between 44 to 65. Normally moisture content in coal
will vary between 12% to 15%. However for design purposes, moisture
content of 20% shall be considered.
c) The coal “as received” shall contain varying percentage of fines. Coal with
such fines may tend to form adhesive lumps, particularly during monsoon
when surface moisture is at its maximum value.
d) The sizing and selection of the vital equipment viz. vibro feeders, etc.
covered under the system shall be based on the above characteristic of coal
and operating conditions. Contractor shall ensure that equipment/ system
efficiency shall not be affected particularly during monsoon when surface
moisture is at its maximum value.
3.03.00 For the purpose of volumetric computation, the bulk density of the coal shall be
taken as 800 kg/m3. Therefore for calculation of belt conveyor capacity, for their
drives & drive motors kW requirement, and sizing (volume calculations) of chute,
hoppers etc. the above bulk density shall be considered. For all other purposes viz.
for stresses/ load on structures, torque calculations of VF tables, sizing of actuators
for flap gates, calculations of plugged chute/ hopper loads etc. the bulk density of the
coal shall be taken as 1100 kg/ m3.
SECTION-VI PAGE
PROJECT INTENT OF
PART-A 16 OF 16
BID DOCUMENT NO.:
CLAUSE NO. TECHNICAL REQUIREMENTS
A-01 : SYSTEM PARAMETERS AND OPERATION &

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

i. Rated Capacity (Guaranteed) : 800 TPH
ii. Design capacity : 880 TPH
iii. Belt width : Minimum 1000 mm
iv. Maximum Belt speed : 3.2 M/sec.

2.01.01 Belting and Pulleys
(a.) Belt ratings shall be selected in such a way that there are only three (3) ratings
for Nylon/Nylon/polyester/polyamide belting. (Belting shall be completely
interchangeable among same rating of belt.) Minimum number of plies for
belting shall be four (4). Other details of belting shall be as specified else
where in the specification.
(b) For Pulley, following minimum parameters shall be followed:
(1.) Shell thickness : 16 mm (Min.)
(2.) End disc plate thickness : 24 mm(Min.)

(3.) Maximum allowable deflection of shaft at hubs : 5 Minutes
(4.) Diameter :
(i) All drive pulleys : 800 dia (min.)

(ii) All balance pulleys : 630 dia (min)
Further approval from belt manufacturers shall be obtained by the contractor

regarding the adequacy of the pulley diameters.
c) Maximum type of pulleys permitted based on pulley diameter and shaft diameter
shall be limited to five (5). These shall comprise of two (2) nos. drive pulleys and
three (3) nos. for all balance pulleys. Pulleys for SS pulleys are not included in
the above categories.
SUB-SECTION-IIIA-01
FARAKKA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS
SYSTEM PARAMETERS PAGE
PROJECT SECTION-VI
AND OPERTION & 1 OF 4
COAL CONVEYING PLANT PACKAGE PART-B
CONTROL PHILOSOPHY
2.01.02 Vibrating Feeders

(a) Nos. required : Two (2) each
(b) Guaranteed (rated) capacity : 400 MTPH
2.01.03 Dust Control System
The capacity of the dust control system specified hereinafter is for Contractor’s
guidance only. Contractor shall provide adequately sized and fool proof dust control
system, the performance of which should be guaranteed by the Contractor as
required in the Technical specifications. The performance guarantee test procedure
is to be submitted by the Contractor. However, the capacity of the offered system
shall not be less than the specified values below.
a) Dust Suppression System (Dry fog type)
(1) Operation : Water & air sprayed by Fogging

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

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

at inlet of spray head 5.0 Kg/cm2 for air (min.)
2.01.04 Service Water System
Service water connections are to be provided in conveyor galleries & tunnels at 50

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

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

simultaneously
2.01.05 Potable Water System : As specified elsewhere in the spec.
2.01.06 Ventilation System
SUB-SECTION-IIIA-01
PROJECT SECTION-VI
CONTROL PHILOSOPHY
A Mechanical Ventilation System
Battery rooms/ Toilet: Minimum 10 supply air changes per hour.
B. Pressurized Ventilation System: Minimum 15 supply air changes per hour
C. Air Conditioning System : Adequate number of air changes to

Maintain in uniform temp. & humidity as
specified elsewhere.
2.01.07 Chutes
Minimum clear cross section of chute : 650 mm x 1000 mm (inside both ways).
2.01.08 Hoists
Suitable hoists as specified elsewhere shall be provided for erection & servicing of
all major equipment. The equipment to be covered shall include (but not limit to) all
conveyor drive units, all pulleys, along with drive units, in line magnetic separators,
sampling units, various DS/service water/potable water pumps, gravity take up units,
lifting of belt drum at all transfer houses etc.
2.01.09 All other equipment under the scope shall be suitable to the system capacities
parameters as specified above.
3.00.00 OPERATION AND CONTROLS
3.01.00 This section is intended to cover control/instrumentation and operational philosophy

as specified hereinafter complete in all respects, required for complete coal handling
plant.
3.02.01 Standards / Codes
All construction, installation, workmanship, design & equipment shall conform to

acts, rules & regulations of the jurisdiction within which the project is to be located,
and to the current edition of the following or equivalent standards or codes, in so far
as they apply :
American Iron & Steel Institute (AISI)
American Society for Mech. Engineers (ASME)
American Society for Testing & Materials (ASTM)
American Wire Gauge (AWG)
SUB-SECTION-IIIA-01
PROJECT SECTION-VI
CONTROL PHILOSOPHY
Institute of Electrical & Electronic Engrs. (IEEE)
Instrument society of America (ISA)
National Electrical Code (NEC)
National Electrical Manufacturers Association (NEMA)
United States of America standards (USAS)
Bureau of Indian Standards (BIS)
Conveyor Equipment Manufacturers Association (CEMA)
3.02.02 This Sub-section shall be read in conjunction with Electrical Sub-sections.
3.03.00 General Construction and Design
3.03.01 General Construction
Control desks/panels and annunciation system shall be as per the requirement of

electrical Section. Annunciations, indications, electrical meters and instrumentation
shall be provided as specified.
3.03.02 Design
The complete coal handling plant shall be controlled from PLC system as detailed
elsewhere.
SUB-SECTION-IIIA-01
PROJECT SECTION-VI
CONTROL PHILOSOPHY
A-02: BRAKES AND CLAMPS
1.00.00 GENERAL
Brakes shall be provided for decelerating of driven equipment/conveyors as per

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

SUB-SECTION-IIIA-02 PAGE
PROJECT SECTION-VI
BRAKES AND CLAMPS 1 OF 2
1.0.0 GENERAL
1.1.0 Brakes (i) For decelerating of conveyors &

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

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

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

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

braking torque.
2.1.3 Brake Shoes Operated directly by spring
2.1.4 Shoe lining Asbestos with interwoven brass wires.
2.1.5 Max. Temperature for shoe lining 200 degree C.
2.1.6 Thrustor Class-B insulation, IP-65 protection.

PROJECT SECTION-VI
BRAKES AND CLAMPS 2 OF 2
A-03: MONORAILS AND HOISTS
1.01.00 GENERAL
Suitable handling arrangements shall be provided for all equipment’s included in

Contractor’s scope to transfer the equipment to maintenance area within the building
and/or to transfer the equipment outside the building upto ground level for further
transportation by the Employer. For this purpose Contractor shall provide monorails
and hoist blocks with cross travel facility.
1.01.01 CODES AND STANDARDS
The design, manufacture, inspection and testing of Monorails and Hoists shall
comply with all the currently applicable statutes, regulations and safety codes in the
locality where the equipment is to be installed. The Monorails & Hoists shall conform
to the latest edition of the following standards & codes. Other internationally
acceptable standards/codes, which ensure equal or higher performance than those
specified, shall also be accepted. Nothing in this specification shall be construed to
relieve the contractor of the required statutory responsibility. In case of any conflict
in the standard and this specification, the decision of the Employer shall be final and
binding.
IS:3938 : Specification for Electric Wire Rope Hoist
IS:3832 : Chain pulley blocks
IS:2429 : Round steel short link chain
IS:6216 :Short link chain grade 80
IS:8610 :Points hooks with shank for general engineering purposes
IS:210 : Cast Iron Castings
1.02.00 DESIGN REQUIREMENTS
1.02.01 For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift, with
the exception of hoists for GTU and bend pulleys motor operated hoist blocks for
both long travel and lift shall be provided. Other hoist blocks shall be of hand
operated type for both travel and lift. Minimum 3 meter length of Cantilever from
edge of building/cladding, shall be provided in monorails coming out of the building
to lower the equipment to ground level clearing the building sidewalls / cladding and
any other facilities beneath the floor upto ground level.
1.02.02 The exact lift/travel and the number of the hoisting mechanisms and the mode of
lifting equipment’s to various floors of the buildings shall be as decided by the
employer at the time of detailed engineering. Clear height shall be maintained when
handling one equipment over other, in such case dismantling of any equipment shall
not be permitted. The center line of monorail shall not deviate by more than 500 mm
from the center of gravity of any equipment that is to be lifted. Contractor shall take
clear note of the fact that the number and monorail hoisting systems shall also be

PROJECT SECTION-VI
MONORAIL AND HOISTS 1 OF 6
decided considering the movement of the equipment being lifted over/by the side of
other equipment’s without removing the later. The necessary levels of floors in
various buildings shall be decided considering the above requirement.
1.02.03 Monorails shall be extended outside the building to handle the equipment to ground
level. For monorail/hoist routed inside the buildings, suitable machinery well and
removable handrailing and grating shall be provided on various floors of buildings,
as necessary, to handle the equipment.
1.02.04 Electrically operated monogirder type hoists shall consist of following major
components.
(a.) Electrically operated trolley complete with drive motor (Trolley travel speed
maximum 15 m/min.).
(b.) Hoist cable, hoisting block and hooks complete with drive motor (Hoisting
speed maximum 6m/min.).
(c.) Limit switch to prevent overhoisting, over lowering and over travel.
(d.) Festoon arrangement of feeding power to trolley assembly.
(e.) Erection hardware.
(f.) Pendent control station suspended from hoist.
(g.) Control panel mounted on wall.
1.02.05 The electric hoist shall be designed and constructed in accordance with the latest
revision of IS:3938 and shall be suitable for duty class 2.
1.02.06 For electric hoists, trolley movement and hoisting shall be effected by using two
separate motors. Motors shall be as per technical requirements discussed
elsewhere. However the motors shall be suitable for 150 starts per hour at 40%
CDF.
1.02.07 Trolley for motorized / manual cross travel shall be designed to accommodate a
wide range of I beams and shall be capable of travelling on straight as well as
curved monorails with the design being such to maintain uniform distribution of
pressure on the flanges.
1.02.08 Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which
shall be driven through motor.
1.02.09 Wire rope shall be of pre-formed type, hemp cored, regular lay 6/36 construction
with a breaking strength of 160 -175 kgf/ sq. mm. Reverse bend of ropes is not
acceptable. Minimum number of falls of rope shall be four (4).
1.02.10 All gears and pinions shall be of hardened and tempered steel with machine cut
teeth in metric modules. Surface hardening of steel is not acceptable.

PROJECT SECTION-VI
1.02.11 All running shafts and wheels shall be fitted with ball / roller bearings with a rated life
not less than 20 years based on equivalent running time as per IS:3938.
1.02.12 An electromechanical brake shall be provided for hoisting as well as cross travel.
Brake lining shall be of asbestos.
1.02.13 Cast iron parts, wherever used, shall be of minimum grade 30, IS:210.
1.02.14 All chain pulley blocks shall be designed to IS:3832, the operating hand chain shall
conform to IS:2429 grade 30 pitched and polished and the load chain to IS:6216
grade 80. The chain pulley block shall be suitable for duty class 2. Hooks shall be
as per IS: 15560 & with antifriction bearing.
1.02.15 All hoists/chain pulley blocks shall be selected to have minimum headroom and shall
be selected to lift heaviest piece of equipment. Further, it shall be possible to handle
any equipment without disturbing other equipment.
1.02.16 The hand chain wheels shall be of cast steel, the wheels shall be with flanges and
designed to ensure effective operation of hand chain. Further, suitable local brake
shall be provided as per IS:3832 to arrest and sustain loads in all working positions.
1.02.17 The velocity rates, effort on chain required to raise the safe working load and travel
and speed shall be within the limit specified in IS:3832. Proof load test shall be
carried out as per IS:3832. Balance requirements shall be as discussed in earlier
clauses pertaining to electric hoists.
1.02.18 Hoist for Gravity Take up arrangement and bend pulley.
For handling bend pulley, take-up pulley and counter weights following hoisting
arrangement shall be provided:
(1) For handling bend pulleys, hooks of adequate capacity shall be provided at
the top of gallery. Further minimum four (4) nos. manually operated chain
pulley blocks of adequate capacity shall also be provided for the entire coal
handling plant for handling bend pulleys.
(2) For handling take-up pulleys, manual hoist along with mono rail beam of
adequate capacity having cross travel, arrangement shall be provided at
bottom of gallery to handle take-up pulley only of conveyors.
(3) For handling take-up weight, a separate manual hoist with mono rail beam of
adequate capacity shall be provided to hold complete counter weight
(inclusive of all counter weight blocks). This hoist shall be provided for
holding the counter weight and shall be located in the zone of counter weight
travel.
1.03.01 The hoist mechanism shall consist of a grooved rope drum driven by electric motor
through gears. Each end of the rope shall be anchored to the drum in such a way as
the anchorage is readily available for maintenance. Each rope shall have two (2) full
turns of the drum when the hook is at its lowest position and one (1) spare groove
when the hook is at its highest position. The leading rope taken by the drum should
not slope sideways when slack and it should not be caught between the gear wheel.

PROJECT SECTION-VI
1.03.02 Rope drum, gear box, block etc. should be fabricated out of weldable quality steel.
1.03.03 Trolley wheels shall be of single flange type in the taper treads. The wheels shall be
mounted on antifriction bearings and shall be easily removable for repair/
replacement.
1.03.04 The load hook shall be swiveling type forged circular shank section and shall confirm
to IS:15560.
1.03.05 All gears and bearings shall be lubricated by grease. All lubricating points shall be
grouped together in easily accessible position.
1.03.06 The bottom block shall be of enclosed type and shall have guard against rope
jamming in normal use. It shall have standard forged swivel shank hook fitted on
antifriction thrust bearing. Lock to prevent hook from rotation and locking
arrangement to prevent accidental unlocking shall be provided. Pulley of the bottom
block shall be provided with antifriction bearings.
1.03.07 All parts requiring replacement/inspection/lubrication shall be accessible without

need for dismantling of other parts/structures.
1.03.08 All components of hoists of identical capacity and duty shall be interchangeable.
1.03.09 Hoists shall have permanent inscription in English on each side readily recognizable
from floor level stating safe working load.
1.03.10 Pendant shall be provided with flourscent up/down/forward/reverse travel push

buttons and indicating lamps. Its power supply shall be limited to 24V AC.
1.03.11 The control panel shall be wall mounted type & easily approachable from the floor by
a standing man.
1.03.12 For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x
1.5m) with ladder shall be provided for each electrical hoist.
1.03.13 Inline magnetic separator shall have motorised hoist for handling / maintenance
purpose. Each suspended magnet shall be provided with a dedicated motorised
trolley.

PROJECT SECTION-VI
DATA SHEET : MONORAILS AND HOISTS
1.0.0 GENERAL
1.1.0 Functional Requirement : To transfer equipment’s to

maintenance area or outside the
building.
2.1.0 Hoists
2.1.1 Drive
(i) More than 2.0 tonne or more than Motor driven for both travel & lift.
10.0 m lift or hoists coming out-side
the buildings
(ii) Other hoists including the hoists for Manual for both travel & lift.
handling takeup pulley and takeup
weight
2.1.2 Maximum trolley travel speed for electric 15m/min

hoists
2.1.3 Maximum Hoisting speed for electric 6 m/min

hoists
2.1.4 Drive Motors SQIM, Separate for travel & lift
2.1.5 No. of starts for drive motor 150 starts/hr at 40% CDF
2.1.6 Wire Rope
(i) Type/Construction Pre-formed type, hemp cored, regular

lay 6/36 construction
(ii) Breaking Strength 160-175 kgf/sq. mm
2.1.7 Bearing
(i) Type Ball/Roller bearing
(ii) Life 20 years
2.1.8 Brake Electro Mechanical type with asbestos

lining.

PROJECT SECTION-VI
2.1.9 Load Hook Swiveling type forged circular shank

section.
2.1.10 Duty Class –2
2.2.0 Monorail location/layout
2.2.1 Cross section I beam
2.2.2 Distance between C/L of monorail & Maximum 500 mm

C.G. of equipment to be lifted
2.2.3 Power Cables Support Festoon type arrangement
2.3.0 Manual Hoists
2.3.1 Maximum manual effort for operation. 30 Kg

PROJECT SECTION-VI
A-04: CHUTES AND HOPPERS

1.00.00 GENERAL
Chutes & Hoppers, flap gates shall be furnished integral with coal handling system
being supplied. All necessary accessories, electricals etc. shall be provided to
ensure proper flow/storage/bifurcation of coal as per system requirements.
The design, manufacture, inspection and testing of Chutes & Hoppers shall comply
where the equipment is to be installed. The chutes, hoppers shall conform to the
latest edition of the following standards and codes. Other internationally acceptable
standards/codes, which ensure equal or higher performance than those specified,
shall also be accepted. Nothing in this specification shall be construed to relieve the
contractor of the required statutory responsibility. In case of any conflict in the
standard and this specification, the decision of the Employer shall be final and
binding.
IS:4682 :Code of practice for lining of vessels and equipment for chemical
processes.
IS:2062 : Structural Steel (Standard Quality)
IS:11592 : Code of practice for selection and design of Belt Conveyors.
1.02.00 DESIGN AND CONSTRUCTION
1.02.01 Chutes, Hoppers
1.02.02 The minimum valley angle of chutes shall be 60 degrees from horizontal.
1.02.03 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal
without any accumulation anywhere.
1.02.04 Complete chute work above the drive floor for conveyors provided with ‘In-line belt
magnetic separators’ shall be of 10 mm thick SS - 304 in the zone of magnetic field.
1.02.05 Direct impact of material on conveyor belt shall be avoided by providing an inclined
surface at 60 degrees valley angle at the feeding point to guide the material in the
direction of belt travel. Further, chute construction below flap gate shaft shall be
such that there will not be any accumulation of coal dust between chute and flap
gate in that zone.
1.02.06 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL / SAILHARD
/ LSLAS07 or equivalent material. Long chutes guiding flow from considerable height
shall be provided with impact plates wherever change in direction of flow takes
place. Hinged inspection doors of leak proof construction shall be provided for
access/ maintenance purpose, at approachable heights for chutes and flap gates. All
PROJECT SECTION-VI
CHUTES AND HOPPERS 1 OF 6
chutes should have one inspection door at every floor and for the ones in between
the floors (more then 1.5 meter above the operating floor level) suitable access for
trouble free maintenance shall be provided. For sealing of inspection doors labyrinth
type arrangement to be provided. In addition to positive locking arrangement,
mounting bolts, to tighten the door further against rubber shall also be provided.
1.02.07 Bottom side of the chutes on which the coal slides shall be welded to the side plates
to form a trough. Bottom sides along with its adjacent sides shall be flanged and
made from TISCRAL or equivalent material of 20 mm thickness. The non-striking
surface i.e. the covers of the trough shall be of 10 mm thick mild steel and bolted to
the flange provided on the trough. Inside welding shall be provided in the corners for
permanent sealing. Further, the chute boxes not more than 1.5 m in length shall be
joined through bolted flange connection to form the chute legs. Adequate care shall
be taken to locate the flange joint away from floor level for easy maintenance.
Bolted flange joints shall be of dust tight construction and necessary sealing material
shall be provided in all the flange connections for adequate sealing.
Complete chute work in the region of flap gates shall be fabricated from 20 thk
TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree)
complete chute, work shall be of 20 mm thick TISCRAL or equivalent material. While
finalising the chute work inside the building, arrangement for shifting and replacing
chute legs, proper handling arrangement/wall openings, trolleys, hoists shall also be
provided.
1.02.08 Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum
4 mm M.S. Plates and shall be provided with hinged and gasketed inspection doors
with suitable access to them. Further, serrated rubber seal shall also be provided at
the very inlet of head chute to minimize dust nuisance.
1.02.09 Separate maintenance sealed door shall be provided for access to belt cleaners in
head pulley hood, flap gates for maintenance and inspection doors shall be of
hinged with positive locking facility.
1.02.10 (a) There should be sufficient clear space to install, remove and maintain
scrappers without cutting structures.
(b) Slope of plates below scrappers to direct coal scrapped by these to the main
stream shall be 60O min.
1.03.00 Skirt Boards
1.03.01 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage.
Suitable ‘Skirt Plates’ shall be provided for entire feeding chute and shall be
extended minimum 3m ahead of front edge of chute and 500 mm beyond rear edge
of chute. The width of the Skirt Boards shall be two-third the conveyor belt width. In
the belts where coal of appreciable lump size (250 mm) is being conveyed, the gap
between the bottom of the skirt board and the belt shall be made to increase
uniformly in the direction of belt travel. The height of the skirt boards shall be
PROJECT SECTION-VI
sufficient to contain the material volume as it is loaded on the belt and shall not be
less than 750 mm. The skirt plates shall be fitted with modular segmented and
replaceable rubber skirting pads having facility of adjusting the pressure on the belt
conveyor and shall have provision of on line removal for the purpose of easy
maintenance. Such segmented rubber pads with its holding down adjustment
arrangements shall be of proven design. The edges of segmented pads shall be
installed at an angle for providing a better seal. All care shall be taken while
designing, to combine good sealing with minimum belt wear.
1.04.00 Flap Gates
1.04.01 The motor operated 2 position flap gates shall be provided in transfer chutes as
specified and shall be complete with electrically operated actuators. The gates shall
be of robust construction and suitable for trouble free operation. The face of the flap
gate shall be made out of 20 mm thick TISCRAL or equivalent material.
1.04.02 The equipment shall be capable of being operated for at least 15 switchings per hour
at rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at
rated load and thrust.
1.04.03 The motor rating for the actuator shall be so selected as to provide sufficient thrust
for operation of the flap gates against the moving weight of coal and/or flap gate.
The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be
completely dust tight.
1.04.04 Lever arm shall be provided between actuator and flap gate shaft for obtaining
required thrust.
1.04.05 The actuators shall be capable of preventing any over travel. Suitable travel
dependent limit switches controlling the travel of the flap gates on either direction
shall be furnished. These shall be placed internal to the drive unit and shall be
completely dust-proof. The limit switches shall be capable of adjustments to vary the
total length of travel of the gates.
1.04.06 Suitable thrust dependent limit switches shall be provided in the actuator, which shall
trip off the actuator motor in case of excessive thrust due to jamming of the gates
during its travel in either direction. The same shall also be integral to the drive unit
and shall be dust proof.
1.04.07 Provision for alternative manual operation shall also be made using declutchable
hand wheel. The diameter of hand wheel shall be selected considering convenient
force to be applied by a single operator. However, minimum diameter of hand wheel
shall be 500 mm. Limit switch for safety of person operating the hand wheel shall be
provided. Manual effort required to operate the flap gate shall not exceed 25 kgs.
1.04.08 All the two way chutes, one way of which is leading towards the future conveyor
shall be provided with blind flange.

PROJECT SECTION-VI
1.04.09 All the actuators in the plant should be selected based on heaviest loading, but the
rating shall not be less than 2500 kg with a lever arm of 1.0 m in any case.
1.04.10 Suitable stiffening arrangement shall be provided between the two faces of the gate
plate. At the end of the travel the total length of edge of the flap gate shall rest on a
suitable projected surface from chute to prevent leakage of coal dust through the
available clearance between chute and flap gate.
1.04.11 Maximum feasible counterweights shall be provided for better utilisation of system.
However, for calculation of thrust required, the benefit of counterweight shall not be
taken into considerations.
1.04.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the
gate shaft. Suitable provision for regreasing shall be provided.
1.04.13 For standardization purposes, only one standard type of actuator for flap gates shall
be provided. The standard type actuator shall be selected for maximum thrust as
calculated for various locations. Flap gate actuator as a whole and individual
component wise shall be completely interchangeable for all locations.
1.04.14 The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall be
suitable for motor stalled condition and associated twisting.
1.04.15 Approach/maintenance platforms complete with the chequered plate floor, hand
rails, ladders etc. shall be provided for all flap gates.
1.04.16 Shaft & flap gate shall be tightly fitted to each other.

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

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

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

connection
(b) Joints Bolted Flange joints of dust tight

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

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

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

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

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

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

declutchable hand wheel regardless
of electrical power.
(b) Minimum Handwheel 500 mm
Diameter
2.4.5 Flap gate shaft
(i) Diameter minimum 150 mm
(ii) Material EN-8

PROJECT SECTION-VI
A-05: BELT CONVEYOR SYSTEM

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

Manufacturers’ Association.
IS:7155 : Codes of Practice for Conveyor Safety.
IS:1891 (Part-I) : General Purpose Belting
IS:8598 : Idlers and Idler Sets for Belt Conveyors
IS:4009 (Part-II) : Conical Head Grease Nipples
IS:8531: Pulleys for Belt Conveyors.
IS:226 : Structural Steel (Standard Quality)
IS:4682 : Codes of Practice for Lining of Vessels and Equipment for Chemical
Processes.
IS:11592 :Code of practice for selection and design of Belt Conveyors.
CAN / CASA - M422 M87 : Canadian standard association.
1.02.01 Design of belt conveyor system shall be suitable for coal parameters specified
elsewhere.
FARAKKA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS SUB-SECTION-IIIA-05

PAGE
PROJECT SECTION-VI BELT CONVEYOR
1 OF 15
COAL CONVEYING PLANT PACKAGE PART-B SYSTEM
1.02.02 Slopes of conveyors, wherever applicable, shall not exceed 16 deg. depending on
the lump size, and other governing factors.
1.02.03 The guaranteed capacity of all conveyors shall be the rated capacity.
1.02.04 All conveyors shall be designed for 110% of rated capacity. Design capacity of the
conveyor system shall be considered for the selection of belt width, belt speed and
the continuous motor rating at 50 deg C Ambient.
1.02.05 The drive chain equipment’s for various belt conveyor systems shall consist of drive
motors, fluid couplings, gear reduction units, low speed flexible couplings and
pulleys. For the ratings of various equipment’s as mentioned above in the drive
chain of conveyor systems relevant sections of this specification shall be referred to.
1.02.06 Conveyors shall be provided with electro hydraulic thrustor brakes or fly wheels to
adjust the coasting time of conveyors such that there will not be any build up of
material in the chutes. Further conveyor shall come to halt as early as possible. All
conveyors with HT drives (except bunker conveyors) shall be provided with brakes.
1.02.07 Belt conveyor system shall be designed as per the latest edition of ‘Belt Conveyors
for Bulk Materials’ published by Conveyor Equipment Manufacturer’s Association’ or
equivalent International Standard. Ai value for idler shall be considered 2.8lb (min.)
for the purpose of conveyor design calculation only.
1.04.00 Belting
1.04.01 The belting shall be of either synthetic fabric such as Nylon-Nylon, polyester,
polyamide, etc. with rubber covers of adequate flexibility to give a troughing angle of
35 deg. For all the conveyors the number of plies, cover thickness, factor of safety
etc. shall be as per the recommendation of belt manufacturer, but not inferior to the
figures as tabulated in data sheet.
1.05.00 Idlers
1.05.01 Carrying idlers shall be provided with three equal rolls with troughing angle of 35
deg. and 2 deg. forward tilt (except in case of reversible conveyors).
1.05.02 In no case, shall the diameter of the idler roll be less than 152 mm for both carrying
side and return side. However for impact idlers roll the steel diameter shall not be
less then 139 mm and rubber thickness shall be minimum 25 mm.
1.05.03 Roller used in idlers shall be made from ERW steel tube. Wall thickness shall be
minimum 4.0 mm without any negative tolerance. The rollers shall be mounted on
EN-8 or equivalent material spindles by means of ball bearings of either deep groove
type or seize resistant type (SKF/Equivalent), of 30 mm size for carrying idlers and
20 mm size for return idlers. The bearings shall be adequately sealed and lubricated
for life. The rolls shall be supported from fabricated steel brackets. Fixing
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2 OF 15
arrangement of rollers with brackets shall be drop-in type. For adjusting the
alignment of the idlers, slotted holes shall be provided in idler supporting base
plates. Direction of belt travel shall be clearly marked on the brackets of carrying
idlers by embossing / punching.
1.05.04 Idler rollers shall be waterproof, dust proof and weather proof against a high velocity
water jet. All idlers shall be provided with minimum double labyrinth dust seal.
1.05.05 Impact idlers used at the loading and transfer point shall be so designed as to avoid
direct loading impact, belt damage and excessive punishment to the carrier. The
material used in construction of this type of idlers shall be of resilient type.
1.05.06 The return idlers for all conveyors shall be single roll type. For conveyors longer
than 400m, two roll return idlers with 10 deg. troughing angle shall be provided.
1.05.07 The self-aligning idlers shall be direct acting type, complete with actuating rollers
fitted with the ball bearings and mounted inclined towards the belt. The idler frame
shall be suitably cradled about a vertical pivot, supported in bearing over a fixed
plate. Adequate sealing arrangement shall be provided to prevent contamination of
the lubricant by dirt and moisture.
1.05.08 Transition type troughing idlers shall be used adjacent to all pulleys to permit proper
support of the loaded belt near the pulleys without excessive stretch of the belt
edges. The transition idlers shall be provided with preferably adjustable concentrator
(end) rolls and long center rolls to suit the troughed belt contour between the last
regular troughing idler and the adjacent pulleys. The transition length and the
number of the transition idlers shall be selected depending upon the tensions, type
and size of belt, number of plies and other necessary governing factors.
1.05.09 All the conveyors shall be provided with one self cleaning type rubber disc return
idler located near the head pulley for cleaning the return belt.
1.05.10 Proper arrangement shall be provided in the brackets of all types of idlers for
preventing the rollers from coming out of the brackets during normal / abnormal
conditions.
1.06.00 Belt Cleaners
1.06.01 External Belt Cleaner
Spring loaded scraper type cleaner with modular segmented and replaceable
polyurethane scrapers blades complete with main cleaner, pre-cleaner (mounted
separately) along with accessories and necessary fines (reject of scrapper) chutes
shall be provided for all belt conveyors, tripper head pulley and belt feeders at
discharge pulleys. The modular units shall be easily replaceable. The scraper
assembly shall be easily maintainable from outside without any interference with the
chute arrangement and assembly.

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3 OF 15
1.06.02 Internal Belt Cleaner
V-plough type belt cleaner made of mild steel flats and hard rubber strips with
automatic wear adjustment and necessary accessories shall be furnished for
cleaning internal surface of the conveyor belt.
1.07.00 Belt Take-up Arrangement
1.07.01 Automatic take-up of gravity type shall be generally provided with necessary take-up
arrangements complete with bend pulleys, take-up pulley, with its supporting / sliding
assembly, wire ropes with turn buckle arrangement (to adjust the level) for
suspending the separate take - up weight sliding assembly close to the ground,
counter weights and other accessories. Suitable guards marked up scale attached to
the frame to monitor belt stretch and access/maintenance platforms with handrails
all around etc. shall be provided. Adequate access from conveyor gallery/transfer
house/ground etc., as the case may be shall be provided to inspect, repair and
maintain the gravity take-up arrangement. Guides of take up pulley/counter weights
shall be sufficiently strong so that they do not bend during belt snapping.
1.07.02 The prime consideration should be to locate the automatic take-ups at a place where
these will work best, in relation to the drive, to keep belt tension at a minimum.
Other considerations such as available space, maintenance considerations and the
economics of the location should also be taken into account while designing. Take
up shall not be located over buildings unless indicated in tender drawings. Height of
take-up guide structure shall be sufficient to allow the take-up weight movement up
and down for all operating conditions of conveyor and to allow minimum two (2)
vulcanizing lengths margin in the belt or percentage of conveyor length (2.5% for
synthetic belting) whichever is larger. Suitable guides shall be provided both for take
up pulley and take up weight.
1.07.03 Two (2) meter safety fencing along with suitable gate and locking arrangement shall
be provided around gravity take-up at the base level / ground level.
1.07.04 Irrespective of take-up location, the travel zone of take-up weight shall start from a
suitable height above ground level.
1.07.05 Suitable buffer arrangement shall be provided to arrest the fall of take-up pulley in
order to avoid damage of the pulley assembly in case of belt snapping. Similar
buffer arrangement shall be provided for take-up weight also, in case of, take-up
weight travel zone terminating above a building floor. Sandpits of 600 mm deep
shall be provided at ground below the take-up weights.
1.07.06 In case of double stream conveyors, a partition of 3 mm steel plate shall be provided
between the two take-up pulleys along entire travel zone of take-up pulleys.
Intermediate platforms shall be provided in the take-up zone for maintenance of take
- up pulleys / counter weight.

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4 OF 15
1.07.07 Take-up weight shall consist of multi-blocks of RCC/Cast Iron and not of single block
to facilitate adjustment in weight if required during operation. Single heaviest piece
shall be suitable for easy handling. Take-up weight block shall be provided with edge
protection angle to take care of any damage. Take up weights shall be kept inside a
take up weight box frame structure and shall be properly anchored / bolted with the
main frame, so that the none of the weight shall be loose/free inside the box. The
box shall be painted with counter weight and conveyor number and shall have good
aesthetic look.
1.08.00 Hold Back Devices
1.08.01 Suitable hold back devices for preventing running back of the conveyor belt in case
of conveyor being stopped in loaded conditions due to power failure or during normal
operational delays shall be provided to give positive protection. The hold back shall
instantaneously engage without shock and be capable of protecting equipment and
personnel. It shall be released instantly when ‘power’ resumes or the ‘delay’ is
removed. The holdback devices shall be integral with gearbox.
1.09.00 Pulleys
1.09.01 Pulleys shall be provided as required for various conveyors. In determination of

pulley diameter, no account shall be taken of the pulley lagging. The nominal
diameter and face width of the pulleys shall be as stated in IS: 8531.
1.09.02 The snub pulleys on each conveyor shall be located to provide a belt wrap on the
drive pulleys of not less than 210 deg. wrap is envisaged for single snub drive only.
1.09.03 All drive pulley surfaces shall be hot lagged with vulcanised natural rubber lagging
grooved in diamond pattern.
1.09.04 All non-drive pulleys shall be vulcanised natural rubber lagged (hot) with plain
lagging.
1.09.05 The rubber to be used for lagging of pulleys shall confirm to specifications listed in
data sheet of this section.
1.09.06 The rubber lagging of pulleys and method of lagging and testing the same shall
conform to IS:4682.
1.09.07 The pulleys shall be made from mild steel conforming to IS:2062 (Tested Quality).
However, for conveyors with in line magnetic separators, the head end pulleys shall
have shell and end disc made of non-magnetic stainless steel material..
1.09.08 All the pulleys shall be mounted on the forged steel shafts of EN-8 or equivalent
material of adequate proportion by taper lock arrangement, running in heavy duty
roller bearings with proper greasing arrangement. The plummer blocks for pulleys
shall be of horizontally split type construction with minimum (4) nos. bolts holding the
two split halves and with min (4) nos. foundation bolts. The plummer blocks shall be
dust tight with double labyrinth seals. Conical head shape nipples conforming to
IS:4009, suitable drain plug and eye bolt shall be provided. Side covers of plummer
blocks shall be heavy duty metallic sheets. No plastic components shall be used.

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5 OF 15
1.09.09 Pulleys shall be mounted on machined & ground surfaces. Suitable guards shall be
provided for all tail pulleys and bend pulleys for safety of operating personnel.
1.09.10 Suitable stiffening arrangements shall be provided in all pulleys as required. For
selection of pulley shaft dia of all the pulleys, a margin of atleast 20% shall be
considered on the maximum tension at designed Conveyor capacity. Selection of
pulley diameter, shell thickness, stiffening and shaft diameter shall be subject to
approval of Employer during detailed engineering.
1.10.00 Belt Protection Equipment
1.10.01 Pull chord Switch
Pull chord type (manually reset type) emergency stop switches shall be located on
both sides of belt conveyors along the walkways for the entire length of conveyors
for emergency stopping of conveyor. The enclosure shall be of cast aluminum with
degree of protection IP-65. It shall have a separate terminal box with a separate
hinged cover which shall be totally sealed from main box containing actuating
mechanism / limit switch etc. Local pull chord actuation shall be provided by means
of mechanical flap. Each switch shall have two NO and two NC contacts, which shall
be wired out to the terminal block. The terminal block shall have facilities of cable
looping. The Contact rating of the switches shall be rated for atleast 5 Amps,
breaking at 240 VAC at 0.3 p.f. lagging. Adequate length of rope and all accessories
shall be furnished. Pull chord in stone picking area shall be routed inside G.I. pipe of
1” size.
1.10.02 Belt Sway Switches
Belt sway switches of self resetting type shall be furnished at periodic intervals to
limit belt sway to permissible extent. The enclosure shall be of cast aluminum having
degree of protection of IP-65. It shall have a separate terminal box with a separate
hinged cover totally sealed from the main box containing actuating mechanism/ limit
switch etc. Each switch shall have two NO and two NC contacts one for alarm and
one for trip, which shall be wired upto terminal block. The terminal block shall have
facilities for cable looping. The contacts of the switches shall be rated for atleast 5
Amps. breaking at 240 VAC at 0.3 p.f. lagging. The roller length of the switch shall
be at least 150 mm. Belt sway switches shall also be provided at HGTU & VGTU to
detect excessive belt away.
1.10.03 Zero Speed Switch
Zero speed switch shall be non-contact (proximity) type electronic switch. Mounting
arrangement/ location shall be such that operation, effective sensing distance,
sensitivity etc. shall not be effected by accumulation of dust on rotating part or
surface of probe. Adequate mechanical protection by means of non-metallic shields
shall be provided on top of the switch to prevent any damage due to falling coal /
metallic pieces etc. In built initial start up delay and nuisance, tripping delay through
timers shall be provided. Each switch shall have two NO and two NC contacts wired
out to the terminal blocks. The contact of the switches shall be rated for atleast 5
Amps. breaking at 240 VAC at 0.3 p.f. lagging. The monitoring unit shall have cast
aluminum body having IP-65 degree of protection. A separate terminal box with a

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6 OF 15
separate cover, which shall be totally sealed from main box, shall be provided.
Terminal blocks shall be suitable for terminating 1.5 mm sq. standard copper cable.
1.10.04 Chute Blockage Switches
One no. chute blockage switch of proven type (subject to approval of the employer)
shall be provided at a suitable height on each leg of the conveyors discharge chute,
vibrating screening feeders by pass chutes, crusher feeding chutes, tripper
discharge and feeding chutes nearest to the skirt boards. Chute blockage switch
shall trip the feeding conveyor in case of Chute blockage and protect the feeding
conveyor equipment. Chute blockage switch shall also be provided at each leg of
mobile tripper and shall trip the tripper conveyor.
The switch and its operating arrangement shall be suitable for working in dusty
areas. The minimum degree of protection of switch shall be IP-65. Local indication
of chute blockage switch actuation shall also be provided. Location of chute block
switch shall be such that washing does not affect it.
1.10.05 Sensing arrangement shall be provided in the DDCMIS based control system for
detecting the presence of material on the belt which shall in turn be used for
operating solenoid valves of dust suppression/extraction system elaborated
elsewhere. The arrangement shall detect three events simultaneously as follows:
(a.) Belt loaded
(b.) Belt running at more than preset speed.
(c.) Preset initial start delay.
1.10.06 The terminal boxes of all the belt protection equipments / switches shall be such that
all the components / terminals inside are easily accessible for inspection and
maintenance without removing the cables / connections / components.
1.10.07 Each pull cord and Belt sway switch shall have necessary chip for using in circuit for
the identification of the operated switch in main control room. The scheme for switch
identification shall be fail safe and shall have all diagnostic features. The scheme
shall have facility to by pass one or more switches, if required.
1.11.00 Drive Motors
1.11.01 Rating of all drive motors of conveyors shall not be less than 120% of the power
required at drive motor output shaft at specified design capacity. The motor rating
shall be at 50 deg Cent. ambient.
1.11.02 Single LT drive motors shall be used for conveyor drive ratings up to 160 KW. For
conveyor drive rating beyond 160 KW, single HT drive shall be used for conveyors.
However for boom conveyor drive and intermediate conveyor drive on stacker-
reclaimer, single LT motor may be used above 160 KW also.

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7 OF 15
1.12.00 Conveyor Bridges
1.12.01 All overground and overhead conveyors shall be located in suitably enclosed bridge
structure. Structural steel bridges of adequate width and depth (2700 mm clear
head room) shall be provided complete with conveyor bottom deck plates, seal
plates, walkways of chequered plates with anti-skid arrangement(s), hand rails (on
both sides of each conveyor belt except where equipment (like paddle feeders,
stacker/ reclaimer, trippers etc.) traverse over conveyor supports.
1.12.02 The conveyor bridge shall have permanently colour coated steel sheeting covers on
roof and both sides, properly screwed or locked to steel structure as required.
Adequate provision of windows shall be kept. A continuous slot opening of 500 mm
shall be provided on both sides just below the roof sheeting.
1.12.03 The floors of outdoor conveyor galleries shall be designed and constructed as
follows:
The side walkways for single conveyors shall be 800 mm on one side and 1100mm
on the other side. However, if the centre to centre of conveyors or the width of the
gallery is decided by some other criteria, maximum walkway widths consistent with
gallery sizes shall be provided. In the complete length of conveyor gallery minimum
walkway clearance as indicated above is to be maintained inclusive of all
equipments and clearances.
All conveyors shall be provided with 12 G steel seal plates throughout the length of
the conveyor gallery in such a way that complete gallery bottom surface area forms
a single water proof floor and no water / coal falls down from conveyor gallery incase
of cleaning / washing. It is envisaged to clean the conveyor gallery with water
periodically. All the water / coal slurry shall be suitably guided to down comers
provided at every trestle. Each downcomer shall lead the coal slurry into a 2 cub
meter brick wall tank at ground level having 2 Nos. decanting taps at suitable
elevations. Decanted water shall be led to the nearest drain in the Contractor’s
scope. Necessary arrangement shall be provided to avoid choking of downcomers
by bigger coal lumps and for cleaning of choked downcomers.
1.12.04 The conveyors shall be provided with continuous decking plate of minimum 3 mm
thickness plain steel sheet.
1.12.05 Structures and floors shall be so designed as to provide suitable space for routing of
200 NB fire fighting pipe with water, cables and conduits.
1.12.06 Steel trestles to support the conveyor bridge shall rest upon concrete foundations to
be provided by the Contractor. Complete trestle structures shall also be supplied by
the Contractor. Suitable approach/access platforms with hand railings shall be
provided to approach the conveyor gallery (like in case of fire) through monkey
ladders on the trestles. Suitable wire mesh doors on steel frame construction
lockable from outside only shall be provided in the conveyor galleries at these
locations. All monkey ladders shall have cage for safety of personnel using them.

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1.12.07 Independent supports for walkways, conveyor structures shall be provided. The
width of conveyor galleries shall be decided by the Contractors depending on the
equipment’s size and the walkway width as specified. However, in no case the width
of gallery shall be less than the width specified in tender drawings.
1.12.08 Provision shall be kept with platforms and ladders for crossing over the conveyors at
approximately every 100m intervals of route length and minimum one per conveyor.
1.13.00 Special Cleaning, Protection and Painting
All equipment’s of Coal Handling Plant inclusive of belt conveyor system and
technological structures shall be kept clean. Surfaces to be painted shall be
thoroughly cleaned of loose mill scale, rust etc. by wire brushing. All ferrous surfaces
shall be applied with one shop coat of 35 micron and one 35 micron site coat of red
oxide zinc chromate and two coats, each of 25 micron, synthetic enamel finishing
paints unless specified otherwise. A minimum of 120 microns Dry Film Thickness
(DFT) after finished coat of paint shall be ensured. However for deck plate in track
hopper and tunnels, painting specifications mentioned at sub section IIID-01 shall be
applicable. However idler rolls shall be applied with two coats & each 35 micron of
red oxide zinc chromate only.
The painting colour code shall be provided to the Contractor during detailed
engineering.
1.15.00 Belt Vulcanizing Machine
1.15.01 Belt Vulcanizing Equipment shall be suitable for hot vulcanizing of belt splice and
shall be of easy-to-handle type.
1.15.02 Equipment should be suitable for vulcanizing of entire splice width in single setting.
1.15.03 Equipment should be capable of applying uniform pressure over the splice by
pneumatic or hydraulic means.
1.15.04 Heating element should be preferably of flexible type.
1.16.00 Belt Jointing Facilities
For the purpose of jointing the belting or replacement of belting, following belt
facilities shall be provided:
1.16.01 5M X 5M paved area near take up to make joints.
1.16.02 Hooks shall be provided on TPs, Conv. Gallery to pull the old belt while replacing the
same with new belt.

PAGE
9 OF 15
DATA SHEET: BELT CONVEYOR
1.0.0 GENERAL
1.1.0 Design Capacity 110% of rated (guaranteed) capacity for

all conveyors.
1.2.0 Maximum slope 16 deg
1.3.0 Max. belt Sag between idlers 2%
1.4.0 Minimum Radius
(i) Concave curve 250 m (In case of travelling trippers, the

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

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

Resistance Test: Conforming to
Canadian standard association CAN
/ CSA M-422- M87 Grade - C.
2.1.3 Cover Thickness (without –ve
tolerances). Synthetic belting
(a) Face 5.0 mm (min.)
(b) Bottom 2.0 mm (min.)
2.1.4 No. of plies Minimum 4
2.1.5 Drive Arrangement Snub drive
2.1.6 Factor of Safety - 10 (Minimum) for N-N belt.

- 7 (minimum) for Steel Cord Belt.
2.1.7 Normal Working tension at design Less than 80% of max. allowable working
PAGE
10 OF 15
capacity tension
2.2.0 Idlers
2.2.1 Type
(a) Carrying Three roll, 35 degree troughing,

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

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

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

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

seize resistance type of min. 20 mm size,
lubricated for life.
2.2.4 Material
(a) Roller ERW Steel tube min. wall thickness

4.0 mm

PAGE
11 OF 15
(b) Spindle E.N. 8 or equivalent.
2.3.0 Belt Cleaners
2.3.1 External Spring loaded scraper type cleaner with

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

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

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

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

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

with grooves 6 mm wide x 6 mm deep
(3) Minimum angle of wrap 210° degrees
(4) Maximum Out of roundness 0.5% of nominal diameter
2.6.3 Other pulleys
(1) Lagging Hot lagged with vulcanised natural rubber

PAGE
12 OF 15
(2) Lagging thickness 12 mm thick plain
2.6.4 Rubber for lagging
(1) Type Natural rubber blended with styrene

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

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

material.
2.7.0 Belt Protection Equipment
2.7.1 Emergency Stop Switch System
(1) Type Pull chord type (manually reset)
(2) Location Both sides of conveyor for entire length
(3) Spacing Approx 30 m
2.7.2 Belt Sway Switches
(1) Type Limit switches snap action.
(2) Spacing One pair at 50m interval (Minimum two

(2) pairs)
PAGE
13 OF 15
2.7.3 Zero Speed Switches
(1) Type, Location Proximity switch, mounted on Bend pulley

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

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

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

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

fashion)
(b) Size 1.2 m x 1.5 m
(c) Window material Refer Civil Section
2.10.0 Trestles
2.10.1 Spacing of monkey ladders on

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

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

gallery (Walkway level) is
PAGE
14 OF 15
less than 10m.

PAGE
15 OF 15
A-06: DRIVE EQUIPMENT

1.00.00 GENERAL
Suitable Drive Chain Equipment’s like electric motors, gearboxes (where applicable),
fluid couplings (where applicable), flexible couplings and other accessories shall be
provided for all the belt conveyor systems, paddle feeders, crushers, mobile trippers,
various pumps of dust suppression/extraction system, fans for ventilation system,
monorail electrical hoists and other equipment’s specified in this specifications.
Various requirements as spelt out in the Technical Specifications for individual
equipment’s shall be taken into consideration while designing the associated drive
chain equipment’s.
The design, manufacture, inspection and testing of Drive Equipment shall comply
where the equipment in to be installed. The Drive Equipment’s shall conform to the
binding.
IS:3688 : Dimensions for shaft ends
IS:3681: General plan for spur & helical gears
IS:7403 : Code of practice for selection of standard worm and helical gear boxes
1.02.00 DESIGN AND CONSTRUCTION REQUIREMENTS
1.02.01 GEAR BOXES
1.02.02 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces.
1.02.03 The gearboxes shall be designed for 24 hours continuous duty. For thermal and
mechanical rating of the gearbox the data sheet shall be referred to. Gearboxes with
cooling coils are not acceptable.
1.02.04 The gears used shall be helical conforming to IS:3681 (latest revision) or worm
reduction units or spiral bevel speed reduction units conforming to suitable Indian
Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest
revision. Above 40 kW drive rating, all gearboxes shall be helical or bevel helical
type only.
1.02.05 Recommended oil grade shall be compatible with gear internals like material of
bearing, cages. Further, all gearboxes shall have suitable breather plugs, dipstick,
drain plug etc.
PROJECT SECTION-VI
DRIVE EQUIPMENT 1 OF 4
1.02.06 Couplings
1.02.07 Flexible / Rigid Couplings
Couplings shall be used for power transmission depending upon duty requirements.
The design of the coupling shall be such that it can take shock and misalignment
without sacrificing its efficiency. Flexible couplings shall be used for low speed
application only. Geared type flexible coupling shall be used on low speed side for
all conveyors and other drive chains where gear box is provided. Other couplings in
the drive chains shall be either rigid or flexible type, depending upon the requirement
of equipment design.
1.02.08 Fluid Couplings
Fluid couplings shall be provided in all the drive machinery for belt conveyor systems
if the actual power requirement at motor output shaft is more than 40 kW. The fluid
coupling for LT motors shall be of traction type. Cooling water coils for traction type
fluid coupling shall not be accepted. Scoop tube type fluid coupling shall be
provided for conveyors with HT motors and ring granulator type coal crushers.
Suitable electrically operated actuators shall be provided for scoop tube operation
from local as well as remote. Suitable provision for alternate manual operation shall
also be kept. Separate pump with motor or integral shaft driven oil pump shall be
provided for circulating the fluid coupling oil through oil cooler. Arrangement for
forced cooling water supply to oil cooler shall be provided by Contractor. Suitable
interlock using flow switches shall be provided in both oil as well as water lines to trip
the drive motor in the event of flow in either lines falling below acceptable levels.
Suitable pressure indicators and flow indicators shall be provided in the cooling
water lines along with all-relevant valves, and accessories. Necessary isolation
valves shall be provided in the oil / water line for maintenance of any equipment in
the line. Necessary interlock shall also be provided so that the HT motor cannot be
started from remote / local unless position of scoop tube permits no load start of the
motor. Tripping of downstream equipment while the system is under normal
operation shall result in scoop tube re-positioning to permit no load run of the
concerned HT motor. Temperature switch shall be provided in the oil circuit and shall
trip the system in case of high oil temperature.
Selection of rating & speed of actuator for scoop type fluid coupling shall be made
taking into consideration the coasting time of down stream and up stream conveyors
and the engagement/disengagement time achievable. The scoop tube operation
must be such so to ensure draining of oil from the operating circuit by providing a
double speed motor. The speed (for draining) shall be selected to match the
coasting time of down stream equipment/conveyor.
DATA SHEET : DRIVE EQUIPMENT
1.0.0 GENERAL

PROJECT SECTION-VI
1.1.0 Continuous Motor Rating (Name Plate Rating) at

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

drive motor output shaft at
specified design capacity
b) Mono-rail hoists (travel and hoisting), *110% of actual power

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

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

cooling coil
2.1.2 Service Factor As per accepted engineering

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

Surfaces
2.1.5 Output Rating
a) For belt conveyor systems

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

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

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

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

nameplate rating

PROJECT SECTION-VI
A-07: BELT SCALE

1.00.00 GENERAL
Belt weigh scale for measurement of coal flow rate and quantity shall be provided at
specified locations. System shall be complete with flow rate indicator, totaliser,
control panel etc.
1.01.00 Codes & Standards
The design, manufacture, inspection and testing of Belt Scales shall comply with all
the currently applicable statutes, regulations and safety codes in the locality where
the equipment is to be installed. The Belt Scales shall conform to the latest edition of
the following standards and codes. Other internationally acceptable
binding.
NEMA
NEC For electronic circuit enclosures.
IS:11547 Electronic weighing in motion system.
1.02.00 Design & Construction Requirements
1.02.01 The weigh scale shall be automatic and electronic type. It should be designed for
continuous automatic weighing, metering and printing of coal flow.
1.02.02 Each belt weigh scale shall comprise of a belt weigh scale platform with minimum 4
nos. weighing idlers. It shall have unitised construction for ease of installation and
shall be fully floating type (without pivot points). Minimum 4 nos. hermetically sealed
load cells of precision strain gauge type shall be applied in tension to support the
weigh bridge. The load cells shall have 100% overload protection and shall be
structurally safe upto to 250% of rated belt scale capacity.
1.02.03 Belt scale shall be electronic microprocessor based with its program stored in non-
volatile memory.
1.02.04 It shall be provided with self diagnostic features for trouble shooting of the entire belt
scale system.
1.02.05 Fully automatic zero and span calibration facility shall be provided.
1.02.06 The electronic systems offered by the Contractor shall include all signal conditioning,
power amplifiers and printed circuits etc. The printed circuits shall be encapsulated
against dust and moisture.

PROJECT SECTION-VI
BELT SCALE 1 OF 3
1.02.07 The flow rate indicator shall have minimum 4 digits. The flow totalizer should have 8
digits display scale with reset facility.
1.02.08 Complete belt scale system shall be suitable for 50°C ambient temperature and
100% relative humidity. It shall be suitable for out door installation in a dusty area.
The electronic circuit enclosure, sensors housing shall be dust and watertight. The
electronic printed circuits shall be encapsulated with epoxy or other suitable material
for protection against dust and moisture.
1.02.09 Minimum three years battery back up power failure protection shall be provided.
1.02.10 Belt scale shall be designed for a range of 20% to 120% of rated capacity with an
accuracy of atleast (+) 0.25 percent throughout its range.
1.02.11 Per two (2) belt weighers, the contractor shall furnish one (1) necessary test load
chain sets required for calibration and periodic testing of the equipment. The test
load chain shall be ‘two idler spaces’ longer than the weighing length of the weighers
and shall be complete with chain reset equipment with weight adding reels of
adequate size. The calibrated weight parameter length of the test chain shall be
stamped at a suitable location on the body of the equipment. The test chain shall be
installed near belt weigher with suitable arrangement for easy mounting/dismounting
of chain onto/from conveyor belt. Alternatively, supply of test weights for calibration
of belt scales is also acceptable.
1.02.12 Local panel for belt scale shall be of sheet metal.

PROJECT SECTION-VI
BELT SCALE 2 OF 3
DATA SHEET : BELT SCALE
1.0.0 GENERAL
1.1.0 Ambient Temperature 50°C
1.2.0 Relative Humidity 100%
2.1.0 Type Electronic load cell type
2.2.0 Operation Microprocessor based fully automatic
2.3.0 No. of floating idlers Minimum four (4)
2.4.0 Load Cells
2.4.1 Type Strain gauge type hermetically sealed
2.4.2 Minimum Nos. Four (4)
2.4.3 Overload protection 100 % of rated belt scale capacity
2.4.4 Structural capacity 250 % of rated belt scale capacity
2.5.0 Flow Rate Indicator Electronic Digital Display Minimum 4

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

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

TECHNICAL SPECIFICATIONS
STAGE-II (2X195 MW) SUB-SECTION-IIIA-08 PAGE
SECTION-VI
COAL HANDLING PLANT PACKAGE BELT SCALE 3 OF 3
PART-B
BID DOCUMENT NO. : CS-0350-155-2
A-08: DUST CONTROL AND MISCELLANEOUS SYSTEM
1.00.00 GENERAL
1.01.01 The specification is intended to cover design, engineering, manufacture, supply,

erection, testing and commissioning of the complete, Dust Control and
Miscellaneous Systems as specified hereinafter required for the Coal Handling
Plant.
The Contractor shall refer to the other sections and scheme indicated in the tender
drawings to appraise himself of the work and scope of supply of the other
Contractors/Employer's and shall coordinate his work with the work of other
Contractors.
1.01.02 General Information/Description
1.01.03 Dust Control System
The dust control system to be furnished under this specification is required for
control of fugitive dust emissions from dust generation points such as transfer points,
feeders, crushers etc. Dust control is achieved by dust suppression/extraction
system.
Contractor shall guarantee and offer dust control system which shall not allow a dust
concentration in the ambient air inside the buildings more than acceptable limits as
per Employer approved guidelines or any internationally recognized hygienic
Standards/Codes.
The Capacity of dust control system specified elsewhere is for Contractor’s guidance
only. Contractor shall provide adequately sized fool proof dust control systems the
performance of which should be guaranteed by the Contractor. However, the
capacity of the offered system shall not be less than the specified values. Further,
for computation of design capacity of the pumps, permanent recirculation lines as
shown in tender drawings shall also be considered.
1.01.04 Miscellaneous Systems
Service water system, potable water system, cooling water system & sump pumps
shall be provided as specified elsewhere in this specification and as indicated in
tender drawings.
1.02.00 Dust Suppression System
1.02.01 (a) Dry Fog Type Dust Suppression System
Complete with water supply system, compressed air system, pressure

regulating units, flow activation system, necessary instrumentation for auto &
manual operation, drives, pumps, maintenance platforms, alongwith
associates civil/structures & electrical works.
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
MISCELLANEOUS 1 OF 15
SYSTEM
Service water distribution system complete with water supply system, valves, quick
couplings, hose pipes with nozzle, piping, pumps, drive motors with canopy,
couplings with enclosure, electricals, including supporting structures, handling for
equipment’s, civil and structural works and necessary accessories shall be provided
throughout the coal handling plant area in Contractor’s scope.
1.02.04 Pipings, Fittings, Valves and Specialities
The material to be supplied for completing the pipe work shall include but not be
limited to the following:
(1) Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing
unions, couplings, caps, blank flanges, saddles etc. necessary for making
reliable piping system.
(2) Gaskets, ring joints, jointing material etc. as required.
(3) Instrument tapping connections, stubs.
(4) Gate / plug, globe and check valves to start/stop, regulate and to prevent back
flow.
(5) Duplex Strainers.
(6) Anchors, hangers and supports as required including secondary steel

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

routed/supported on concrete pedestal and conveyor galleries. Wherever the
layout does not permit the pipes to be routed over ground, the same shall be
buried in conformity to the relevant standards & shall be provided with
necessary protective coating as per relevant standards and as specified
elsewhere in the specification.
(9) Painting, anti-corrosive coatings etc. outside pipes as necessary.
(10) Welding electrodes and welding rods.
(11) The area around storage tanks, strainers, valves etc. (located out side pump
house) shall be paved.
1.03.00 Codes and Standards
The design, manufacture, inspection and testing of Dust Control & Miscellaneous
Systems shall comply with all the currently applicable statutes, regulations and
safety codes in the locality where the equipment is to be installed. The Dust Control
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
& Miscellaneous Systems shall conform to the latest edition of the following
standards and codes. Other internationally acceptable standards/codes, which
ensure equal or higher performance than those specified, shall also be accepted.
required statutory responsibility. In case of any conflict in the standard and this
specification, the decision of the Employer shall be final and binding.
IS:778 : Gun Metal gate, globe & check valves for general purpose.
BS:5150 :Cast Iron Gate Valve for water works purposes
BS:5152 :Cast Iron Globe Valve for water works purposes
BS:5312 :Cast Iron Check Valve for water works purposes
S:1239 : Mild Steel tubes & fittings.
IS:2379 :Colour for the identification of pipe line.
IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm)
IS:5312 : Swing check type reflux (non return) valves.
IS:1520 : Horizontal centrifugal pump for clean, cold fresh water.
IS:5120 :Centrifugal pump for clean, cold & fresh water.
BS: 5169 & BS:1123 : Air Receivers.
ANSI B 31.1:Code for pressure piping.
Hydraulic institute Standards of U.S.A.
Dry Fog Dust Suppression
1.04.01 At specified locations dry fog dust suppression system shall be provided which
comprises spray nozzles discharging plain water & air in a fine spray to form dry fog
to capture air borne dust particles and direct them into the main coal flow. This dry
fog shall be discharged through spray heads at the dust suppression zones.
The dry fog dust suppression system shall consist of the following:
(a) Fogging system & controls consisting of:
(i) Spray bar assemblies.
(ii) Pressure regulating units
(iii) Flow activation system
(iv) Instrumentation for auto spray

SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
(b) Compressed air system consisting of:
(i) Two (2) nos. (one no. working and one (1) no. standby) air
compressors (screw type) for each group of dry fog dust suppression
system, alongwith air receivers as specified elsewhere.
(ii) Air receivers

(iii) Various instrumentation & valves.
1.04.02 Each spray head in CHP shall have a provision for installing a pressure gauge
whenever required. Further, pressure gauges shall be provided at least at two
locations.
1.04.03 Service Water (SW) System
Service water connections are to be provided in conveyor galleries and tunnels at 50

meter intervals. Adequate number of these connections shall be provided in all
transfer houses with minimum one no. at each floor and with minimum two (2) nos.
at each floor in crusher house. Each connection shall be provided with one (1) no.
32 NB globe valve and quick coupling. One (1) no. hose pipe with nozzle shall be
provided in each building.
Service water distribution system shall be designed considering the water scheme
and water requirement indicated in tender drawings.
1.04.04 Potable water (PW) system
Potable water connections are to be provided in all transfer points, wagon tippler top,
crusher house, all tripper floors, the machinery well at both ends of track hopper,
track hopper top at both ends and all control rooms/MCC rooms and toilets etc.
Water shall be drawn from the water storage tank by electric motor driven pumps
and discharged via a pipe work system to the overhead drinking water storage PVC
tanks of 250 litres capacities. The drinking water storage tanks shall have provision
for maintenance & drain.
1.04.05 Hoists with monorail of adequate capacity shall be provided in the service water/dust
suppression/potable water pump houses.
1.05.01 Water Supply Pumps
1.05.01.01 Water supply pumps shall be provided as required.
1.05.01.02 The pumps shall be complete with drive motors, baseplate and other accessories.
The constructional features of the pump shall be as follows:
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
a) Pump casing may be axially or radially split. The casing shall be of robust
construction. Casing drain and vent connections shall be provided.
b) Impeller shall be made in one piece and securely keyed to the shaft. Locking
device shall be provided to prevent its loosening during all conditions of
operation.
c) Wearing rings shall be of renewable type. Opposed wearing surface shall be

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

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

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

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

coupling.
i) Couplings guards made of expanded metal and bolted to the base plate shall
be furnished.
j) The common base plate for pumps and motor shall be in one piece and shall
be made of fabricated steel.
k) Pump speed shall be less than 1500 rpm for pumps of capacity more than 10
m3/hr.
1.05.01.03 The power, head and flow characteristics of each pump shall be suitable for parallel
operation. The Power characteristics of the pumps shall be of non overloading type.
1.05.01.04 All rotating parts of the pumps shall be statically and dynamically balanced.
1.05.01.05 The motor shall be rated for continuous operation and confirm to companion
electrical specification. However, motor rating shall not be less than the max. power
demand throughout the entire range of operation of pump.
1.05.01.06 Design duty point of pump shall match with the average value of maximum and
minimum flow rates of the pump in the stable operation zone.
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
1.05.01.07 Materials of construction of pump components shall be as stated in data-sheet to

this section.
1.05.02 Piping, Fittings, Valves and Specialties
1.05.02.01 Piping & Fittings
(a) Material of construction of piping and fittings shall not be inferior to those
given in data sheet of this section.
(b) All piping shall be capable of withstanding the maximum pressure in the
corresponding line at the relevant temperature.
(c) In general pipe sizes 65 mm NB and larger are to be joined by butt welding
and pipe work of size 50 mm NB and below by socket welding/screwed
connections. Joints at valves or specialities shall be flanged for sizes 65 mm
NB or large and screwed for sizes 50 mm NB and below. All galvanised
piping shall be joined by screwed connections. Minimum pipe diameter
selected for DS/SW/PW/Cooling Water System (along with branch pipes)
shall be 32 NB. However, for dry fog DS system, the minimum pipe size shall
be 15 NB.
(d) End preparation for butt welding shall be done by machine/flame cutting.
Socket weld and preparation shall be saw/machine cut.
(e) Hangers and supports shall be capable of carrying the sum of all
concurrently acting loads. They shall be designed to provide the required
supporting effects and allow pipe line movements as necessary. All guides,
anchors, braces, dampers, expansion joints and structural steel to be
attached to the building/structure, trenches etc. shall be provided.
(f) All piping shall be routed on ground on concrete pedestals and at road
crossings, these shall be buried through hume pipes.
1.05.02.02 Valves and Specialities
(a) Valves & Specialities shall be used to start, stop or regulate the flow. All
valves/specialities below 50 mm size in service water/dust suppression/
potable water lines should be plug type of proven make.
(b) All valves shall be suitable for most stringent service conditions i.e. flow,
temperature and pressure under which they may be required to operate.
(c) Gate/sluice valves shall be used for isolation of flow of pipe lines above
50NB and Globe valves shall be used for regulating the flow.
(d) Valves shall be provided with back seating bush to facilitate gland renewal
during full open operation.
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PROJECT SECTION-VI
SYSTEM
(e) All gate and globe valves of size 65 NB and large shall be bolted bonnet,
outside screw, rising type with flanged ends. Valves of size 50 NB and
smaller shall be with screwed ends.
(f) Valves shall be provided with the following as necessary :
(1) Hand wheel
(2) Position indicator
(3) Draining arrangement.
(g) Material of construction of valves shall not be inferior to those given in data
sheet of this section.
(h) Globe valves shall be provided with contoured plug to have well
controllability.
(i) Non-return valves shall be swing check type. These valves will have a
permanent ‘arrow’ inscription on its body to indicate direction of motion of the
fluid.
(j) All valves shall be provided with hand wheel, chain operated, extension
spindle and floor stand wherever required so that they can be easily operated
either at a lower or higher elevation as the case may be.
(k) Strainer shall be of duplex type designed with 3 way valves so that one filter
can be cleaned while the other is in operation. Suitable vent and drain
valves shall also be provided. Screen opening area shall be at least four
times the pipe cross sectional area. Pressure drop in clean conditions shall
not exceed 1.5 MWC at full flow.
(l) Bib cocks provided for potable water system shall be made of Copper Alloy /
Cast Iron.
1.05.03 Special cleaning, protection and painting
1.05.03.01 Piping & Fittings
(a) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust
etc. by wire brushing.
(b) For overground exposed steel pipes, one shop and one site coat of red oxide
zinc phosphate and two coats of synthetic enamel finishing paints unless
specified otherwise shall be applied. A minimum of 120 microns Dry Film
Thickness (DFT) after finished coat of paint shall be ensured.
(c) For steel buried pipeline, three (3) coats of heavy duty bitumastic paint shall
be applied on the cleaned surface. Finally, it should be wrapped with
minimum 3 mm thick bitumen impregnated tar felt. The lap joint of the felt
shall be generally touched with heavy duty bitumastic paint.
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
1.05.03.02 Pumps for DS/SW/CW/PW/DE systems shall be selected with minimum 10%
margin on capacity and 20% margin on computed head.
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
DATA SHEET: DUST CONTROL & MISCELLANEOUS SYSTEM
1.0.0 GENERAL
1.1.0 Dust Control Dust suppression/ extraction

system
1.2.0 Miscellaneous systems Service water system, Potable

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

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

2.3.0 Dry Fog Dust Suppression
(i) Compressor Screw Type

(ii) No. of Compressors to be provided One working & one Standby, per
group
(iii) Air receivers One no. of min. 2 cu.m capacity
located near compressors & 200
litres capacity at various location
(iv) Nozzles Dry fog type
2.6.1 Water connections
(a) Conveyor Galleries and tunnels every 50 m
(b) Transfer points Min. 1 no. at every floor
(c) Crusher House Min. 2 nos. at every floor

SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
2.6.2 Connection details 32 NB plug valve
2.6.3 Hose pipes with hose reel One in each building of 25 mtr.
Length with nozzle
2.7.0 Potable Water System
2.7.1 Pumps 2 X 100% electric motor driven
2.7.2 Water connections
a) Transfer points Minimum one (1) no. at each floor
(b) Crusher house Minimum two (2) no. at each floor
(c) Tripper floor Minimum one (1) no. at every

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

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

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

vent connection
3.1.2 Impeller One piece, keyed to shaft along

with locking device
3.1.3 Shaft Critical speed atleast 20% away

from operating speed
3.1.4 Shaft sleeves At bearings & stuffing boxes.
3.1.5 Bearings Antifriction type
3.1.6 Wearing rings Renewable type (preferable)

SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
3.1.7 Pump speed Below 1500 rpm for capacity more

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

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

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

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

416 hardened.
(g) Gland packing Impregnated teflon
3.3.0 Pipings & Fittings

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

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

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

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

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

for Globe valve & screwed ends for
plug valve
3.3.5 Materials for Pipework
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
(a) For sizes 200 NB and Larger ERW carbon steel pipes to API-5L-
Gr.B/IS:3589 with minimum
thickness 6.35 mm
(b) For sizes 150 NB to 65 NB ERW carbon steel black pipes to

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

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

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

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

316
(c) Pressure Gauge/Switch (to be

provided with isolating valves,
gauge cock, snubber and
syphon)
(i) Dial size 150 mm
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
(ii) Accuracy (+/-) 1% of range span
(iii) Bourdon AISI 316 SS
(iv) Block AISI 316 SS
(v) Movement AISI 316 SS
(vi) Case and Bezel Die cast Alum. Weather proof case
stove enameled block with
screwed type inner bezel of ABS
plastic and glycerin filled.
(vii) No. of contacts 2 NO + 2 NC
(viii) Type of contact Adjustable throughout the range.
(ix) Degree of protection IP. 65
(d) Solenoid valve (to be provided

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

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

with isolating valves)
(i) Body Forged steel
(ii) Extension Rod/wire SS-304
(iii) Sleeve and Sleeve pipe SS-304
(iv) Cover Die cast aluminum
(v) Max. working pressure 10 kg/sq.cm
(vi) Repeatability ± 0.5%
(vii) No. of contacts 2 NO + 2 NC
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
(viii) Type of contact Adjustable throughout the range.
(ix) Protection class IP – 65
(f) Level Switch
(i) Type Displacer operated magnetic type
(ii) Displacer SS – 316
(iii) Wire rope SS – 316
(iv) Spring Housing Spring and SS – 316

sleeve pipe
(iv) Cover Cast Aluminum
(v) No. of Contacts 2 NO + 2 NC
(vi) Type of Contact Adjustable throughout the range.
(viii) Protection class IP – 65
(g) Level gauges
(i) Type Float type mechanical gauge with

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

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

against damage.
(i) Y Strainer
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
(a) Body SS 304
(b) Plug SS 304
(c) Filter Element SS 316, 60 mesh
SUB-SECTION-IIIA-08
DUST CONTROL & PAGE
PROJECT SECTION-VI
SYSTEM
A-09: VENTILATION SYSTEMS

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

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

SECTION-VI
COAL HANDLING PLANT PACKAGE VENTILATION SYSTEM 1 OF 11
PART-B
1.03.00 VENTILATION AND AIRCONDITIONING SYSTEM
1.03.01 Mechanical Ventilation System
Exhaust fans shall be provided for tripper floor, Toilets, Battery rooms. The exhaust
fans for toilets and battery rooms will be propeller type
1.03.02 Pressurised Mechanical Ventilation System
The ventilation system generally consisting of adequate number of supply fans,

metallic pre filters, HDPE fine filters, ducting along with 3 phase AC motor drives,
electricals, supporting structures, approach / maintenance platforms, necessary
shed, civil & structural works and necessary accessories shall be furnished for all
MCC/switchgear rooms.
1.03.03 Air Conditioning System
1.03.03.01 2x100% capacity air conditioning packaged units (PAC) with air cooled condensers
shall be provided for Main Control Room, office room of Main Control Room &
various MCC Rooms as specified elsewhere in spec. complete with supply and
return air ducting.
1.03.03.03 Supply and return air distribution ducting complete with insulation, of resin bonded
mineral wool equivalent of density at least 24 Kg/m³ and thermal conductivity of max.
0.49 mw/cm°C conforming to IS:8183 including supporting structures, approach/
maintenance platforms, civil and structural works and necessary accessories shall
be provided.
1.03.03.04 Area around centrifugal fans, filters, motor foundation shall be paved to have a clear
surrounding.
1.04.00 Codes & Standards
The design, manufacture, inspection and testing of Ventilation & A/C System shall
comply with all the currently applicable statutes, regulations and safety codes in the
locality where the equipment is to be installed. The Ventilation & A/C System shall
conform to the latest edition of the following standards and codes. Other
internationally acceptable standards/codes, which ensure equal or higher
performance than those specified, shall also be accepted. Nothing in this
specification shall be construed to relieve the contractor of the required statutory
responsibility. In case of any conflict in the standard and this specification, the
decision of the Employer shall be final and binding.
IS:3588 : Specification for electrical axial flow fans.
IS:2312 :Propeller type AC Ventilation fans
IS:3963 :Specification for roof-extractor units

SECTION-VI
PART-B
IS:4894 :Centrifugal Fans
IS:655 :Specification for Metal Air Duct
ARI:210 :Standard for Unitary air conditioning equipment.
ARI:270 :Standard for application, installation and servicing of unitary equipment.
IS:8183 :Specification for bonded mineral wool.
IS:661 :Thermal insulation for cold surfaces.
IS:4671:Expanded polystyrene for thermal insulation purpose.
IS:8148 :Packaged Air conditioners.
1.05.01 Axial Fans
1.05.02 Design duty point of the fan shall match with the average value of maximum and
minimum flow rates of the fan in the stable operation zone. The speed of the fan
shall not preferably exceed 960 rpm for fan with impeller diameter above 450 mm
and 1440 rpm for fan with impeller diameter 450 mm and less. The first critical
speed of rotating assembly shall be at least 25% above operating speed.
1.05.03 Impellers shall be axial flow type single piece.
1.05.04 Centrifugal Fans
1.05.05 The fan units shall be centrifugal type with radial bladed impeller. For design,
purpose out door ambient temperature shall be taken as 50 deg.C.
1.05.06 Fans shall be manufactured vibration free in operation and shall be designed to limit
noise level within limits specified in Data Sheet.
1.05.07 The motor shall be rated for continuous operation and conform to companion
electrical specification. However, motor rating shall not be less than the max. power
demand throughout the entire range of operation of fan.
1.05.08 All fan mountings shall have adequate arrangement for vibration isolation.
1.05.09 The reverse flow through non-working fan shall be prevented by dampers. The
dampers shall be made out of 18 SWG MS sheets.
1.05.10 Design duty point of the fans shall match with the average value of maximum and
minimum flow rate of the fan in the stable operation zone.

SECTION-VI
PART-B
1.05.11 Filters
1.05.12 Metallic Filters
Metallic cleanable filters shall be provided as required. Max. air velocity considered
shall be 2 m/sec.
1.05.13 HDPE Filters
HDPE filters should have an efficiency of 90% down to 5 microns. Velocity across
the filter shall be limited to 2.5 m/sec.
1.05.14 High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99%
down to 5 microns. Pr. drop across the filter under clean condition shall not be more
than 10 mm w.c.
1.05.15 Packaged Air-Conditioning Unit
PAC units shall be provided as required.
1.05.16 PAC units shall be factory tested and assembled self contained units complete with
refrigerant compressor, coils, fans, insulation and wiring. Various parts of PAC units
wherever required shall be insulated with expanded polyethylene conforming to
IS:4671.
1.05.17 The PAC unit shall comprise of an evaporator (indoor air) blower section and an air
cooled condenser (outdoor air) section. Heavy gauge steel cabinet finished with
paint of approved colour, shall be used to house components of PAC.
1.05.18 The evaporator and condenser coils shall be arranged for direct expansion cooling
and shall be formed of aluminum fins mechanically bonded to seamless copper
tubes and electrically tinned. The inter-connecting refrigerant circuits shall comprise
of hermetically sealed scroll compressor and motor with all necessary isolation
valves, with adjustable set point, sight glass, copper tubing and pipeline ancillaries.
The condenser coils shall be air cooled by propeller type fans complete with safety
guards. The condensing coils shall be suitably arranged to avoid radiant heat pick-
up from solar sources.
1.05.19 Condenser capacity control shall be provided by means of fans and ‘head pressure’
sensing.
1.05.20 The evaporator air blower(s) shall be centrifugal forward curved type belt driven by
individual motor(s) and suitable for the external static pressure. The fan assembly
shall be isolated from the casing by anti-vibration mounts. The fan/motor drive shall
be capable of capacity adjustment by pulley changes within +15% of design duty.

SECTION-VI
PART-B
1.05.21 High efficiency filters shall be provided in the main supply air duct and in the fresh air
connection to return air duct.
1.06.00 Construction Requirements
1.06.01 General construction details of various equipment under Contractor’s scope shall be
as elaborated in subsequent clauses below.
1.06.02 Axial Flow Fans
Axial flow fans shall be provided as required.
1.06.03 Impellers shall be axial flow type and single piece cast aluminum with aerofoil blades
construction. It shall be finished all over and balanced dynamically. Impeller shall
be mounted directly on the motor shaft.
1.06.04 Casing shall be of heavy gauge construction properly reinforced for rigidity. It shall
be provided with suitable supports. Access door shall be provided in the casing for
easy access to motor and impeller. Suitable arrangement for mounting of motor
shall be provided.
1.06.05 Rain protection cowls will be designed to suit wall exhausters/supply fans for
protecting fans/motors from rain. It will be provided with bird screen.
1.06.06 Inlet cone or bell and outlet cone shall be provided as required. It should be made of
G.I. or M.S.
1.06.07 Motor shall be of totally enclosed type complying with the companion electrical
specification. Suitable rain/sun shade for motors shall also be provided.
1.06.08 Centrifugal Fan
Centrifugal fans shall be provided as required.
1.06.09 The casing shall be of welded construction fabricated with heavy gauge material. It
shall be rigidly reinforced and supported by structural angles. The seams shall be
permanently sealed airtight. Split casing shall be provided on larger sizes of fans.
Casing drain with valves shall be provided wherever required.
1.06.10 The impeller shall have die formed curved blades fabricated out of MS heavy gauge
welded to the rim and back plate to have a non overloading characteristics of the
fan. Rim shall be spun to have a smooth contour. If required intermediate stiffening
rings shall be required. The impeller, pulley and shaft sleeves shall be secured to the
shaft by key and/or nuts. The impeller along with driven pulley shall be dynamically
balanced. Fan shaft shall be of EN-8 equivalent.

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

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

SECTION-VI
PART-B
shall be fabricated and installed in conformity to the requirements of IS:655. Steel

supports for the ductwork shall be furnished as required. The thickness of ducting
steel shall be 1 mm min. For ducting with large size exceeding 1300 mm it shall be
1.25 mm. The flexible connection between fan and ducting shall be on teflon
impregnated canvas. The zinc coating on GI sheet shall be 275 gm/m2.

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

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

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

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

hour.
1.3.4 Equipment 2 x 100 % roof mounted

package AC units along with
ducting etc.
1.4.0 Outside Ambient Conditions As per weather data given in

project synopsis
2.1.0 Roof Ventilators
2.1.1 Capacity 10% more of actual

requirement

PROJECT SECTION-VI
VENTILATION SYSTEM 8 OF 11
2.1.2 Head 20% more of actual

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

requirement
2.2.2 Head 20% more of actual

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

requirement
2.3.2 Head 20% more than actual

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

Continuous
2.3.5 Rating
2.4.0 Packaged Air-Conditioning Unit
2.4.1 Type Roof top mounting
2.4.2 Service/application Continuous, round the

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

compressor
2.4.5 Condenser Air cooled type
2.4.6 Fan Forward curved centrifugal

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

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

density at least 15 kg/cub.m.
2.5.0 Filters
2.5.1. Metallic Filters
(1) Max. air velocity 2m/sec.
2.5.2 HDPE filters
(1) Efficiency 90% down to 5 microns
(2) Max. velocity 2.5 m/sec.
(3) Testing As per BS 2831 / Sqv.
2.5.3 High Efficiency Filter
(1) Efficiency 99% down to 5 microns.
(2) Pr. drop across 10 mm W.C.
(3) Testing As per BS 2831 / Sqv.

PROJECT SECTION-VI
2.6.0 Insulation for A/C Ducting Resin Bonded

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

PROJECT SECTION-VI
A 10: CHP BUILDINGS

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

as per the Civil/Structural specifications.
The design and construction of CHP Buildings shall comply with all the currently
applicable statutes, regulations and safety codes in the locality where the equipment
is to be installed. The CHP Buildings shall conform to the latest edition of the Indian
standards and codes. Other internationally acceptable standards/ codes, which
ensure equal or higher performance than those specified, shall also be accepted.
required statutory responsibility. In case of any conflict in the standards and this
specification, the decision in the Employer shall be final and binding.
1.02.00 Design Requirements
1.02.01 All CHP buildings shall have sufficient space to accommodate the entire equipment
like head end, drive unit and tail end of various conveyors, crushers, hoppers,
chutes, control equipments, MCCs, batteries, supports for conveyor bridges,
tensioning arrangements, approach/maintenance platforms with ladders, external /
internal stairs, handrails, RCC floors, foundations etc. Moreover, ample space shall
be provided for maintenance purposes. Outside stairs to transfer points and crusher
house shall be open type. However, a weather canopy shall be provided at the top.
1.02.02 Mechanical Handling arrangements with adequate monorails etc. shall be furnished
for servicing and installation of various housed equipment as described elsewhere.
1.02.03 Building floors shall be washed periodically with water for which necessary slope &
drains shall be provided from each floor leading to minimum 4 nos down comers of
minimum 273mm OD each building. However for MCC, control buildings and pump
houses, minimum 150 mm dia, 4 nos galvanized MS pipes conforming to IS :1239
shall be provided. The system shall be designed considering water mixed with coal.
A drain pit shall be provided near each building to collect water/coal mixture.
Overflow from this pit shall be connected to nearest drain. 1 mtr x 1 mtr size
dust/debris MS chutes from all the floors to ground floor shall be provided at all
buildings/transfer houses and crusher house. The plate thickness shall note be less
than 6mm.
1.02.04 Various dimensions and relative elevations shown in tender drgs. for various
buildings/structures are minimum acceptable to the Employer. However, final
dimensions for various buildings/structures and relative elevations shall be decided
PROJECT SECTION-VI
CHP BUILDINGS 1 OF 5
based on actual details/maintenance requirements of contractor’s equipment to meet

technical specification requirements without any implication to the Employer. The
sizes of these houses shall be approved by the Employer at the stage of detailed
employer.
Openings in the floors of CHP buildings (i.e. TPs etc.) shall be provided with curb of
100mm high to avoid water falling down to lower floors.
1.02.05 Vertical bracings in transfer points shall be provided only along four sides. No
bracing system projecting outside the building shall be allowed.
1.02.06 Floor at ground shall be provided in all transfer points, ground conveyors etc. Level
of floor at ground shall be 500 mm above ground/grade level unless noted
otherwise. For enclosed ground conveyor 750mm wide plinth protection along with
drainage arrangement shall be provided along the conveyor on both sides. Suitable
opening at every 50mtr interval shall be provided on either side in a staggered
manner for exit / entry of personals. Necessary drains must be provided all along the
floors of ground conveyor.
1.02.07 The accessories for dust control & miscellaneous system like water pumps etc. shall
be housed in separate pump houses.
1.02.08 For areas where ground floor is located less than 500 mm above ground level/grade
level, outside face of the brickwalls shall be plastered with rich cement-sand mortar
(1:4) with neat cement finishing over it for a height of 500 mm above ground
level/grade level.
1.02.09 Toilet with potable water facilities shall be provided in all MCC Control Rooms, and
potable water shall also be provided at all transfer houses,
1.02.10 Necessary facilities for ventilation of control/MCC rooms, shall be provided as

specified elsewhere.
1.02.11 External fire escape stair case alongwith internal staircase(wherever applicable)
shall be provided for all MCC/ control rooms & Crusher house.
1.02.12 5 mtr wide paving beyond the surface drains shall be done around all transfer points,
Crusher house for movement of trucks. The approach for trucks should be provided
around transfer point, crusher house and upto hoist lifting area.
1.02.13 All building shall have the fire protection provisions to meet TAC and IS – 3034
regulations.
1.03.00 Construction Requirements
1.03.01 Junction Houses
1.03.02 All overground buildings shall be of steel frame construction.
1.03.03 All underground & partially underground structures shall be entirely in RCC.

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

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

underground Transfer Houses
1.2.0 Overground Transfer Houses, Steel Construction

Crusher House
1.3.0 Control/MCC rooms & S&T room RCC construction

REQUIREMENT
2.1.0 Junction Houses
2.1.1 Space requirement To accommodate all equipments drive

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

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

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

handle coal slurry.
2.1.9 Vertical bracing Only along four sides.
2.1.10 Maintenance platform with handrails. Chequered plate floors Min.1500 mm

wide
2.1.11 Flooring 50 mm thick metallic hardener like
ironite floor finish.
2.1.12 Level of ground floor 500 mm above ground level.

PROJECT SECTION-VI
2.2.0 Control/MCC Rooms
2.2.1 Construction RCC construction with Brick Enclosure
2.2.2 MCC Rooms Pressurised with dust free air
2.2.3 Control Rooms Air conditioned Environment

PROJECT SECTION-VI
A11: IN-LINE MAGNETIC SEPARATOR

1.00.00 GENERAL
Inline Magnetic Separators shall be provided for continuous and automatic extraction
and discharge of tramp magnetic pieces from coal being discharged from conveyors
as specified. The sets shall be complete in all respects with drives, magnets, inline
belts, hoppers, chutes, tramp-iron boxes and all electrical ancillaries like control
panels etc.
1.01.00 CODES & STANDARD
The design, manufacture, inspection and testing of In line Magnetic Separators shall
comply with all the currently applicable statutes, regulations and safety codes in The
Magnetic Separators shall conform to the latest edition of standards and codes.
Other internationally acceptable standards/codes, which ensure equal or higher
performance than those specified, shall also be accepted. Nothing in this
specification shall be construed to relieve the contractor of the required statutory
responsibility. In case of any conflict in the standard and this specification, the
decision of the Engineer shall be final and binding.
1.02.01 Inline Magnetic Separator
1.02.02 Magnet core material shall be pure annealed iron or equivalent high permeability
magnetic material. The coil shall be of aluminum wire with class ‘H’ insulation, to
limit the absolute temperature of the winding to 140 deg. centigrade. The oil used for
cooling the ILMS shall be silicon based.
1.02.03 The ‘Force Index’ i.e. the product of flux density in gauss and rate of change of flux
density w.r.t. distance, at the bottom of falling material trajectory shall be 100,000
(gauss x gauss/inch) minimum in hot condition for mounting height of 400 mm in the
conveyors carrying crushed coal. However, the strength of the magnet shall not be
less than 1000 gauss in hot running condition at distance of 400mm in the conveyors
carrying coal. The minimum strength of the magnet shall be 1000 gauss at the
specified mounting height at the centre of Belt width. Contractor shall select magnet
width to suit above.
Mounting height of 400 mm in the conveyors carrying coal shall be taken between
top of conveyor belt or bottom of falling material trajectory and the surface of
magnetic separator belt. Characteristic curve of magnet with the value of flux
density varying between 50 mm to face of conveyor belt shall be provided. The
cross section of magnet shall be suitably designed to provide sufficient area for
magnetising the coil effectively covering full cross section of the discharge material.
The magnetic separator shall be located such that it picks-up tramp iron from coal
trajectory after it has been discharged from head pulley.

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

PAGE
2 OF 4
DATA SHEET : ILMS
1.0.0 GENERAL
1.1.0 Type In line type as specified.
2.1.0 In-line Magnetic Separator
2.1.1 Location of ILMS Over discharge pulley.
2.1.2 Force index (As defined earlier) Minimum 100,000
2.1.3 Strength of magnet at the specified mounting 1000 gauss.

height
2.1.4 Mounting height Mounting height of In Line

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

margin.
(ii) Belting Suitable to withstand high

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

15 Kg.)
(iii) MS plate of 250 x 250 x 100 mm size.
(iv) Shovel Teeth and spikes.
Material Carbon Steel

PAGE
3 OF 4
Size Typical
(v) MS round bar of 50 Kg with L/D ratio not

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

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

travel facility.

PAGE
4 OF 4
A12: METAL DETECTOR

1.00.00 GENERAL
Metal detectors shall be provided at specified location to detect metallic objects in

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

lightning and radio-transmitters, and to nullify the effect of climate
changes/aging, dual receiver coils are to be used.

PROJECT SECTION-VI
METAL DETECTOR 1 OF 3
(c.) In order to allow passing of steel cord belt and metal belt fasteners without
giving alarm and at the same time detecting tramps, suitable arrangements
shall be provided.
(d.) In case a few non-magnetic idlers or non magnetic deck plates are required,
the Contractor shall provide these. However, these shall be metallic. Wood is
not to be used.
(e.) LED display of COAST COUNT to indicate the number of pieces of tramp iron
detected since last reset shall be provided so that the operator is alerted for the
pieces of tramps, if any, between tramp marker and coil before restoring
conveyor.
(f.) TOTAL COUNT, which is not resettable, shall also be provided on the same
LED display on demand.
(g.) The location of tramp metal pieces shall be indicated by sand bag marker.
1.03.00 CONSTRUCTION REQURIEMENT
1.03.01 Fiber glass enclosure (with IP 65 degree of protection) shall be provided for all type
of coils.
1.03.02 Sand bag markers shall be provided.
1.03.03 Local control panel shall be provided with IP:65 degree of protection.

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

below coal for synthetic
belting.
- 35mm Aluminum sphere

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

calibration with adjustable
sensitivity.

PROJECT SECTION-VI
A13: COAL SAMPLING UNIT

1.00.00 GENERAL
a) Coal Sampling Unit shall be complete with necessary samplers, crushers,

flap valves, chutes, hoppers, belt feeders and sample collectors etc. to give
samples from any of the two streams running at guaranteed capacity.
b) Bidder shall source coal sampling system from a manufacturer / supplier who
has engineered and supplied two (2) numbers of coal sampling systems for
sampling coal / other bulk mineral from conveyor of 1000 MTPH and above
and working successfully for two years as on date of bid opening.
The design, manufacture, inspection and testing of Coal Sampling Unit shall comply
where the equipment is to be installed. The Coal Sampling Unit shall conform to the
latest edition of standards and codes. Other internationally acceptable
binding.
ASTM-D-2234 :Standard Methods for collection of a Gross Sample of Coal.
ASTM-D-2013 :Standard Method of Preparing Coal Samples for Analysis.
1.02.01 Coal sampling unit shall be automatic & provided at place specified elsewhere.
1.02.02 The coal sampling units suitable to give “Samples” conforming to ASTM-D-2234
shall be selected by the Contractor for taking samples from any of the two streams
running at guaranteed capacity. The different Equipment selected for coal sampling
unit shall be such that there shall be no loss of fines and moisture from the samples.
The capacity, make and model of all equipments of coal sampling unit shall be
subject to approval of Project Manager.
1.02.03 The normal input feed size shall be considered as (-) 50 mm for coal sampling unit.
However occasionally (-) 100 mm lumps may also arrive.
1.02.04 Primary samplers (separate for each conveyor) shall be rugged, able to withstand
severe shock loads and operate trouble free.
1.02.05 Belt feeders shall be provided for entire sampling path upto sample collector. The
feeders shall meter the flow accurately, produce a non-plugging condition and resist
sticky and wet coal.

PROJECT SECTION-VI
COAL SAMPLING UNIT 1 OF 3
For rejects path also, belt feeders shall be preferred. Screw conveyors for the same
shall be accepted only where space constraints do not permit distribution of coal
rejects to receiving conveyors below.
1.02.06 Sample crushers (make subject to Employer’s approval) shall be provided for
reducing the main input feed coal to 95% minus 8 mesh size and 100% minus 4
mesh size. Single stage crushing shall be provided. There should be no re-
circulation of fines in the crushers.
1.02.07 ‘Lot size’ shall be equivalent coal quantity handled in 8 hours operation assuming
average conveyor loading at 75% of rated conveyor capacity. However sampling
system shall also be suitable for taking one gross sample for each lot of “3500 Te”
coal (approx. equal to one rake load).
1.03.01 The traversing mechanism and all electric parts shall have dust tight protection.
1.03.02 Belt feeders shall be positively self cleaning and have dust tight construction. It shall
be provided with flanged belt, rubber lagged head pulleys and inspection doors. No
chain/belt drives shall be accepted.
1.03.03 The crusher’s base should be built of reinforced concrete and be sufficiently large in
mass.
1.03.04 The primary / secondary samplers shall be of dust tight construction and self
contained type.
1.03.05 The sample chutes shall have minimum valley angle of 60 degrees to horizontal and
shall be of stainless steel plates. The chutes shall be suitable to handle wet sticky
coal as specified elsewhere. The welding of chutes shall be done externally only.
The inside surface of the material near welds shall be smooth. Radius at corners not
less than 1" shall be provided in chutework. All solid connected members shall be by
means of bolting flanges with atleast 6 mm thick standard grade neoprene gasket
material between the metal flanges. No control gates to regulate the flow of material
shall be incorporated in the chute work.
1.03.06 Bias connections shall be provided at suitable locations. The materials rejected from
samplers shall be returned to main conveyor stream.
1.03.07 Minimum 4 nos. sample collecting bins shall be provided with auto indexing. The
bins shall be provided with air tight connection.
1.03.08 The system shall be suitable for operation through Employer’s DCS/DDCMIS.

PROJECT SECTION-VI
DATA SHEET : COAL SAMPLING UNIT
1.0.0 GENERAL
1.1.0 Type Automatic
2.1.0 Codes & Standard ASTM D-2234
2.2.0 feed coal size (-) 50 mm
3.0.0 CHUTES
3.3.1 Min. angle 60 deg
3.3.2 Cross section Square/rectangular with

rounded corners.
3.3.3 Joints Bolted flanges with 6 mm

thick standard grade
neoprene gasket.
4.0.0 CRUSHER
4.4.1 Uncrushed (as received) feed coal size (-) 50 mm
4.4.3 Output size ASTM D-2234
4.4.3 Stages of size reduction Single stage crushing
5.0.0 BELT FEEDER
5.5.1 Belt Flanged type, FR grade
5.5.2 Pulleys Rubber lagged head pulley
5.5.3 Drive Electric Motor

PROJECT SECTION-VI
CLAUSE NO.
TECHNICAL REQUIREMENTS
A:14 – VIBRATING FEEDER
1.00.00 GENERAL
Vibrating feeder shall be provided below each reclaim hopper to feed coal reclaimed
by dozers to the conveyor..
1.01.00 CODES & STANDARD
The design, manufacture, inspection and testing of Vibrating Feeder shall comply
where the equipment is to be installed. The Vibrating Feeder shall conform to the
standard and this specification, the decision of the Project Manager shall be final and
binding.
IS:3823 - Dimensions for vibrating conveyors and feeders with rectangular or

trapezoidal trough.
1.02.00 DESIGN REQUIREMENTS
1.02.01 The vibrating feeder shall be of mechanical type and shall be provided below each
reclaim hopper to feed coal reclaimed by dozers to the conveyor. The drive unit shall
be complete with mechanical type of vibrator.
1.02.02 The vibrating feeder shall be suitable for maximum lumps size of 20 mm. The feeder
shall be designed to feed coal to the conveyor without material sticking to it. The flow
of material shall cease as soon as vibration of the trough or pan ceases.
1.02.03 One (1) sets of Gates each comprising of one rod gate and one actuator operated
rack & pinion gate at inlet to each of the vibrating screening feeder shall be provided.
1.03.00 CONSTRUCTION REQUIREMENTS
1.03.01 The vibrating feeders shall be mounted on the floor with the help of helical springs
made of alloy steel. No rubber/synthetic material for the support shall be acceptable.
1.03.02 Vibrator bearings shall be grease lubricated, double spherical roller type suitable for
vibrating equipment. The bearings shall be sized for minimum 8,000 hours of
operation
1.03.03 Vibrating feeders shall be provided with removable abrasion resistant liner plate.
FARAKKA SUPER THERMAL POWER TECHNICAL SPECIFICATION

PROJECT SECTION-VI
VIBRATING FEEDER 1 OF 1
MOTORS
1.00.00 GENERAL REQUIREMENTS
1.01.00 For the purpose of design of equipment/systems, an ambient temperature of 50 deg.

Centigrade and relative humidity of 95% shall be considered. The equipment shall
operate in a highly polluted environment
1.02.00 All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3%
& -5%, and 10% combined variation of voltage and frequency unless specifically
brought out in the specification.
1.03.00 Contractor shall provide fully compatible electrical system, equipments, accessories
and services.
1.04.00 All the equipment, material and systems shall, in general, conform to the latest
edition of relevant National and international Codes & Standards, especially the
Indian Statutory Regulations.
1.05.00 The auxiliary AC voltage supply arrangement shall have 6.6 KV and 415V systems.
It shall be designed to limit voltage variations as given below under worst operating
condition :
(a.) 6.6 KV +/- 6%
(b.) 415/240V +/- 10%
1.06.00 The voltage level for motors shall be as follows (other than VFD motors) :-
(a.) Upto 0.2 KW : 240V, Single phase AC / 415V AC Three phase
(b.) Above 0.2KW to 200 KW : 415V, Three phase AC
(c.) Above 200 KW : 6.6 KV, Three phase AC
For CHP, conveyor motors above 160KW rating, 6.6KV supply shall be used.
Voltage rating for special purpose motors viz. screw compressors and those with
VFD shall be as per manufacturer standard.
1.07.00 Fault level shall be 40KA RMS for 1 second for 6.6 KV system and 45 KA RMS 1
second for 415V system. 415V system shall be solidly grounded and 220 VDC
system shall be isolated type.
1.08.00 Paint shade shall be RAL 5012 (Blue) for indoor and outdoor equipment.
1.09.00 The responsibility of coordination with other agencies and obtaining all necessary
clearances shall be of the contractor.
1.10.00 Degree of Protection
FARAKKA SUPER THERMAL POWER

TECHNICAL SPECIFICATION SUB-SECTION-IIIB-01 PAGE
PROJECT SECTION-VI, MOTORS 1 OF 9
Degree of protection for various enclosures as per IS:13947 shall be as

follows :-
i) Indoor motors – IP 54
ii) Outdoor motors – IP 55
iii) CW motors (in case of Screen prot. Drip proof) – IP 23
iv) Cable box – indoor area – IP 54
v) Cable box – outdoor area – IP 55
1.) Three phase induction motors : IS:325, IEC:60034
2.) Single phase AC motors : IS:996, IEC: 60034
3.) Crane duty motors : IS:3177, IEC: 60034
4.) DC motors/generators : IS:4722
5.) Energy Efficient motors : IS 12615
3.00.00 TYPE
3.01.00 AC Motors:
(a.) Squirrel cage induction motor suitable for direct-on-line starting.
(b.) Continuous duty LT motors upto 160 KW Output rating(at 50 deg.C ambient
temperature) ,shall be Energy Efficient motors ,Efficiency class – Eff 1,
conforming to IS 12615.
(c.) Crane duty motors shall be slip ring / squirrel cage type induction motor as per
the requirement
3.02.00 DC Motors Shunt wound.
4.00.00 RATING
(a.) Continuously rated (S1). However, crane motors shall be rated for S4 duty,
40% cyclic duration factor.
(b.) Whenever the basis for motor ratings are not specified in the corresponding
mechanical specification sub-sections, maximum continuous motor ratings
shall be at least 10% above the maximum load demand of the driven
equipment under entire operating range including voltage and frequency
variations.

5.00.00 TEMPERATURE RISE

Air cooled motors
70 deg. C by resistance method for both thermal class 130(B) & 155(F) insulation.
Water cooled
80 deg. C over inlet cooling water temperature mentioned elsewhere, by resistance
method for both class 130(B) & 155(F) insulation.
6.00.00 OPERATIONAL REQUIREMENTS
6.01.00 Starting Time
6.01.01 For motors with starting time upto 20 seconds at minimum permissible voltage during
starting, the locked rotor withstand time under hot condition at highest voltage limit
shall be at least 2.5 second more than starting time .
6.01.02 For motors with starting time more than 20 second and upto 45 seconds at minimum
permissible voltage during starting, the locked rotor withstand time under hot
condition at highest voltage limit shall be at least 5 second more than starting time.
6.01.03 For motors with starting time more than 45 seconds at minimum permissible voltage
during starting, the locked rotor withstand time under hot condition at highest voltage
limit shall be more than starting time by at least 10% of the starting time.
6.01.04 Speed switches mounted on the motor shaft shall be provided in cases where above
requirements are not met.
6.02.00 Torque Requirements
6.02.01 Accelerating torque at any speed with the lowest permissible starting voltage shall be
at least 10% motor full load torque.
6.02.02 Pull out torque at rated voltage shall not be less than 205% of full load torque. It shall
be 275% for crane duty motors.
6.03.00 Starting voltage requirement

(a) 85% upto 1500KW
(b) 80% from 1500KW to 4000KW
(c) 75% > 4000KW

7.00.00 DESIGN AND CONSTRUCTIONAL FEATURES
7.01.00 Suitable single phase space heaters shall be provided on motors rated 30KW and
above to maintain windings in dry condition when motor is standstill. Separate
terminal box for space heaters & RTDs shall be provided.

7.02.00 All motors shall be either Totally enclosed fan cooled (TEFC) or Totally enclosed
tube ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors
rated 3000KW or above can be Closed air circuit water cooled (CACW). CW motors
can be screen protected drip proof (SPDP) type. Motors located in hazardous areas
shall have flame proof enclosures conforming to IS:2148 as detailed below
(a) Fuel oil area : Group - IIB
(b) Hydrogen generation plant Group – IIC (or Group-I Div-II as

area : per NEC)
7.03.00 Winding and Insulation
(a) Type : Non-hygroscopic, oil resistant, flame resistant
(b) Starting duty : Two hot starts in succession, with motor initially at
normal running temperature. However, conveyor
motors shall be suitable for 3 consecutive hot
starts.
(c) 6.6 KV AC : Thermal class 155(F) insulation with winding

motors temperature rise limited to thermal class 130(B).
The winding insulation process shall be total
Vacuum Pressure Impregnated i.e. resin poor
method. The lightning impulse & interturn
insulation surge withstand level shall be as per
IEC-60034 Part-15.
(d) 415V AC & : Thermal Class 130(B) or better

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

either joint less or welded type. Brazed joint is not
acceptable.
7.04.00 Motors rated above 1000KW shall have insulated bearings to prevent flow of shaft
currents.
7.05.00 Motors with heat exchangers shall have dial type thermometer with adjustable alarm
contacts to indicate inlet and outlet primary air temperature.
7.06.00 Noise level for all motors shall be limited to 85dB (A). Bearing housing vibration shall
be limited within the limits prescribed in IEC 60034-14/IS: 12075. Motors shall
withstand vibrations produced by driven equipment. HT motor bearing housings shall
have flats in both X and Y directions suitable for mounting 80mmX80mm vibration
pads.

7.07.00 In HT motors, at least four numbers simplex / two numbers duplex platinum
resistance type temperature detectors shall be provided for each phase of stator
winding. Each bearing shall be provided with dia type thermometer with adjustable
alarm contract and minimum one(1) number duplex Platinum resistance type
temperature detector.
7.08.00 Motor body shall have two earthing points on opposite sides.
7.09.00 HT motors can be offered with either Elastimold termination or dust tight phase
separated double walled (metallic as well as insulated barrier) cable boxes. In case
Elastimold terminations are offered, then protective cover and trifurcating sleeves
shall also be provided. Removable gland plates of thickness 3 mm (hot/cold rolled
sheet steel) or 4 mm (non magnetic material for single core cables) shall be provided
in case of cable boxes.
7.10.00 The spacing between gland plate & centre of terminal stud shall be as per Table-I.
7.11.00 All motors shall be so designed that maximum inrush currents and locked rotor and
pullout torque developed by them at extreme voltage and frequency variations do not
endanger the motor and driven equipment.
7.12.00 The motors shall be suitable for bus transfer schemes provided on the 6.6 KV/415V
systems without any injurious effect on its life.
7.13.00 For motors rated 2000 KW & above, neutral current transformers of PS class shall be
provided on each phase in a separate neutral terminal box.
7.14.00 6.6 KV Terminal Box shall be suitable for fault level of 500MVA for 0.12 second.
7.15.00 The size and number of cables ( for HT motors) will be intimated to the contractor
during detailed engineering and the contractor shall provide the terminal box, cable
gland & lugs suitable for the same.
7.16.00 The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the
following (without any further tolerance) except for BFP motor.
(a) Upto 110KW 11.0
(b) Above 110KW & upto 1500KW 10.0
(c) Above 1500KW & upto 4000KW 9.0
(d) Above 4000KW 6 to 6.5

8.00.00 TYPE TEST
8.01.00 HT MOTORS
8.01.01 The contractor shall carry out the type tests as listed in the “LIST OF TESTS TO BE
CONDUCTED” on the equipment mentioned there in. The Bidder shall indicate the
charges for each of these type tests separately in the relevant schedule of BPS and
the same shall be considered for the evaluation of the Bids. The type test charges
shall be paid only for the test(s) actually conducted successfully under this contract
and upon certification by the Employer's Engineer.
8.01.02 The type tests shall be carried out in presence of the Employer’s representative, for
which minimum 15 days notice shall be given by the Contractor. The Contractor shall
obtain the Employer’s approval for the type test procedure before conducting the
type test. The type test procedure shall clearly specify the test set-up, instruments to
be used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.
8.01.03 In case the contractor has conducted such specified type test(s) within last ten years
as on the date of bid opening, he may submit during detailed engineering the type
test reports to the owner for waivel of conductance of such type test(s). These
reports should be for the test conducted on the equipment similar to those proposed
to be supplied under this contract and test(s) should have been either conducted at
an independent laboratory or should have been witnessed by a client. The owner
reserves the right to waive conducting of any or all the specified type test(s) under
this contract. In case type tests are waived, the type test charges shall not be
payable to the contractor.
8.01.04 Further the Contractor shall only submit the reports of the type tests as listed in “LIST
OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED” and carried out
within last ten years from the date of bid opening. These reports should be for the
tests conducted on the equipment similar to those proposed to be supplied under this
contract and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client. However if the Contractor is
not able to submit report of the type test(s) conducted within last ten years from the
date of bid opening, or in case the type test report(s) are not found to be meeting the
specification requirements, the Contractor shall conduct all such tests under this
contract at no additional cost to the Owner either at the third party laboratory or in
presence of client/owner’s representative and submit the reports for approval.
8.01.05 All acceptance and routine tests as per the specification and relevant standards shall
be carried out. Charges for these shall be deemed to be included in the equipment
price.
8.01.06 The type test reports once approved for any projects shall be treated as reference.
For subsequent projects if NTPC, an endorsement sheet will be furnished by the
manufacturer confirming similarity and “No Design Change”. Minor changes if any
shall be highlighted on the endorsement sheet.
8.01.07 LIST OF TESTS TO BE CONDUCTED
The following type tests shall be conducted on each type and rating of HT motor
(a) No load saturation and loss curves upto approximately 115% of rated voltage
(b) Measurement of noise at no load.
(c) Momentary overload test (subject to test bed constraint).
(d) Full load test
(e) Temperature rise test at rated conditions . During heat run test, bearing temp.,
winding temp., core temp., coolant flow and its temp. shall also be measured.
In case the temperature rise test is carried at load other than rated load,
specific approval for the test method and procedure is required to be
obtained. Wherever ETD's are provided, the temperature shall be measured
by ETD's also for the record purpose.
8.01.08 LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED
The following type test reports shall be submitted for each type and rating of
HT motor
(a) Degree of protection test for the enclosure followed by IR, HV and no load
run test.
(b)Terminal box-fault level withstand test for each type of terminal box of HT motors
only.
(c) Lightning Impulse withstand test on the sample coil shall be as per clause
5.1.3.2, IEC-60034, Part-15.
(d) Surge-withstand Voltage test on interturn insulation as per IEC 60034-158

8.02.00 LT MOTORS
8.02.01 All equipment to be supplied shall be of type tested design. During detailed
engineering, the contractor shall submit for Owner’s approval the reports of all the
type tests as per relevant standards and carried out within last ten years from the
date of bid opening. These reports should be for the tests conducted on the
equipment similar to those proposed to be supplied under this contract and the
test(s) should have been either conducted at an independent laboratory or should
have been witnessed by a client.
8.02.02 However if the Contractor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in case the type test report(s)
are not found to be meeting the specification requirements, the Contractor shall
conduct all such tests under this contract at no additional cost to the Owner either at
third part laboratory or in presence of client/owners representative and submit the
reports for approval.

8.02.03 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.
For subsequent projects if NTPC, an endorsement sheet will be furnished by the
manufacturer confirming similarity and “No Design Change”. Minor changes if any
9.00.0 Drawing Submission Procedure
Unique manufacturer specific reference drawing nos. shall be allotted by owner to

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

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

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

150KW
Above 150KW 19.0mm

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

charged, horizontal drawout type,
suitable for electrical operation.
Switchgear Fully drawout type single front
MCC Fully drawout type single front/Double

front.
ACDB/DCDB Fixed type single front
3.00.00 SYSTEM PARAMETERS
415VAC +/- 10 %(SOLIDLY GROUNDED)

50 Hz +3%/-5%
45KA RMS(105 KA PEAK) / 1SEC (FAULT LEVEL)
240V DC ISOLATED TYPE
The temperature rise of the horizontal and vertical busbars and main bus link
including all power draw out contacts when carrying 90% of the rated current along
the full run shall in no case exceed 55 deg. C with silver plated joints and 40 deg. C
with all other types of joints over an ambient of 50 deg C. The temperature rise of the
accessible parts/external enclosures expected to be touched in normal operation
shall not exceed 20 deg.C. The temperature rise of manual operating means shall
not exceed 10 deg. C for metallic & 15 deg. C for insulating material. The above
temperature rise limits are applicable for busducts also without any current derating.
5.00.00 OPERATIONAL REQUIREMENTS
5.01.00 Breakers
5.01.01 Breakers shall have anti-pumping feature.
5.01.02 The incomer and bus coupler breakers for switchgear shall be electrically operated
with Numerical communicable relays.
5.01.03 Breakers shall have inherent fault making and breaking capacities. They shall have
shunt trip coils. All breakers shall have built in interlocks for equipment and
personnel safety.
FARAKKA SUPER THERMAL POWER PART-B

SUB-SECTION-IIIB-02
PROJECT SECTION-VI, PAGE 1 OF 11
L.T. SWITCHGEAR &
BUS DUCT
5.01.04 Paralleling of two supplies shall be avoided by interlocking except for switchgear
where auto-changeover is provided. Breaker contact multiplication, if required, shall
be through latch relay.
5.01.05 Mechanical tripping shall be through red ‘Trip’ push button outside the panels for
breakers, and through control switches for other circuits.
5.01.06 Provision of mechanical closing of breaker only in ‘Test’ and ‘Withdrawn’ position
shall be made. Alternatively, mechanical closing facility should be normally
inaccessible, accessibility rendered only after deliberate removal of shrouds. It shall
be possible to close the door with breaker in test position.
5.01.07 Clear status indication for each circuit shall be provided through lamps, switch
positions or other mechanical means.
5.02.00 Switches, Contactors and Fuses
5.02.01 Incomers for MCCs and DBs rated below 250A could be load break isolators.
5.02.02 Motor starter contactors shall be of air break, electromagnetic type suitable for DOL
starting of motor, and shall be of utilisation category AC-3 for ordinary and AC-4 for
reversing starters. For conveyor motors, minimum rating of power contactors shall be
200% of the full load current of the motors. For other motors minimum rating of
power contactors shall be 160% of full load current of motor. DC contactor shall be of
DC-3 utilisation category.
5.02.03 Fuses shall be HRC type with operation indicator. Isolating switches shall be of AC
23A category when used in motor circuit, and AC 22A category for other
applications. Fuse switch combination shall be provided wherever possible.
5.02.04 The 250A & above feeders up to 630A shall have MCCB. MCCB shall be provided
with Microprocessor based inbuilt front adjustable releases(overload & short circuit)
and shall have adjustable earth fault protection unit also . MCCB shall have current
limiting feature. ON and OFF position of the operating handle of MCCB shall be
displayed and the rotary operating handle shall be mounted on the door of the
compartment housing MCCB. The compartment door shall be interlocked
mechanically with the MCCB, such that the door can not be opened unless the
MCCB is in OFF position. Means shall be provided for defeating this interlock at any
time by making use of special tools/tackles. MCCB shall be provided with padlocking
facility to enable the operating mechanism to be padlocked.
5.03.00 Panels
5.03.01 All switchgears, MCCs, DBs, panels, modules, local starters and push buttons shall
have prominent engraved indentification plates.
5.03.02 Local push button stations shall have metal enclosure of die cast aluminium or rolled
sheet steel of 1.6mm thickness & shall be of DOP IP55. The DOP shall be IP-65 in
case the same are located in dusty areas. Push buttons shall be of latch type with
mushroom knobs.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUS DUCT
5.03.03 Where breaker/starter module front serves as compartment cover, suitable blanking
covers, one for each size of modules per switchboard shall be supplied for use when
carriage is withdrawn.
5.03.04 All non-current carrying metal work of boards/panels shall be effectively bonded to
earth bus of galavanised steel, extending throughout the switchboard/MCC/DB.
Positive earthing shall be maintained for all positions of chassis and breaker frame.
5.03.05 Suitable trolley arrangement shall be provided for breaker/starter modules. Two
trolleys per switchgear room shall be provided so that top most breaker module of all
types, sizes and rating can be withdrawn on trolley and lowered for maintenance
purpose.
5.03.06 The incoming connection to transformer of more than 1000KVA and inter-connecting
sections between switchboards shall preferably be of busducts. The busduct
enclosure shall be made of minimum 3mm thick aluminium alloy. The section of the
busduct should have adequate strength to withstand internal and external forces
resulting from the various operating conditions. Aluminium sheet hood shall be
provided for outdoor busduct enclosure joints to provide additional protection against
water ingress. The busduct top shall be sloped to prevent retention of water.The
busduct enclosure shall have DOP of IP55 and paint shade RAL 5012.
5.03.07 It should be possible to carryout maintenance on a feeder with adjacent feeders

alive.
5.03.08 DC fuse board shall consist of:

-1 no.63A switch as incomer with meters, lamps and auxiliary contactors.
-8 nos.outgoing feeders with 16A HRC fuses.
5.03.09 AC fuse board shall consist of:
-1 no 63A TPN SFU as incomer with lamps and meters.
-9 nos.16A SPN SFU & 3 nos.16A TPN SFU as outgoing.
5.03.10 Main lighting distribution board(MLDB) to be located in MCC room shall consist of:-
a) Two(2) nos. x 100% rated, lighting transformers (415V/433V, delta/star, epoxy
insulated, air cooled, dry type). Transformer shall be 50KVA/100KVA rating for
10/15 nos. outgoing feeder.
b) TPN SFU on primary and secondary side of the transformer
c) 63A TPN SFU as outgoing feeders including 20% spare.
d) Voltmeter, ammeter with selector switches, indicating lamps.
e) The two incomers (One from Bus-A and One from Bus-B of the MCC) and one
bus-coupler for the power supply to each MLDB shall be provided with castle key
networks.
5.03.11 Welding distribution board(WDB) to be located in MCC room shall consist of:-
a) One(1) no welding transformer (415V/433V, delta/star, epoxy insulated, air
cooled, dry type). Transformer shall be 50KVA/100KVA.
b) TPN SFU on primary and secondary side of the transformer
c) 63A TPN SFU as outgoing feeders including 20% spare.
d) Voltmeter, ammeter with selector switches, indicating lamps.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUS DUCT
5.03.12 MCCs located on the Stacker reclaimer, paddle feeders, travelling trippers shall be
fixed type, compartmentalized, single front and suitable for the system fault level.No
spare feeders are to be provided on these MCCs. Degree of protection for the MCCs
mounted on paddle feeders and travelling trippers shall be IP-65.
5.04.00 Control, Protection & Metering Requirements
5.04.01 Control circuits shall operate at suitable voltage of 110V AC or 240V DC. Necessary
control supply transformers having primary and secondary fuses shall be provided
for each MCC, 2 x 100% per bus section. However the breakers shall operate on
240V DC The auxiliary bus bars for control supply shall be segregated from main bus
bars. The control supplies shall be monitored.
DC operated spring charging motor shall be suitable for voltage variation between
198V to 242V DC. The closing coil of circuit breaker shall operate correctly at all
values of voltage between 187V-242V DC. The trip coil of circuit breaker shall
operate satisfactorily at all values of voltage between 154V-242V DC.
DC operated contactor coil shall have an economy resistor and shall be suitable for
satisfactory continuous operation at 187V-242V DC.
5.04.02 Contractor shall fully co-ordinate overload and short circuit tripping of breaker with
upstream and down stream breakers/fuses/MCCBs motor starters. Various
equipments shall meet requirement of Type-II class of coordination as per IEC.
5.04.03 The protective relays shall be communicable numerical relays These numerical
relays shall be of types as proven for the application and shall be subject to
Employer’s approval Numerical relays shall have appropriate setting ranges,
accuracy, resetting ratio and other characteristics to provide required sensitivity. All
equipments shall have necessary protections as detailed in the standard scheme
drawings.
5.04.04 All equipments shall have necessary protections. However, following minimum
protections shall be provided:
1) Contactor controlled motor feeders (Motors up to 200 kW)
a) Instantaneous short circuit protection on all phases through HRC

cartridge type fuses rated for 80 kA rms (prospective breaking
capacity at 415V).
b) Thermal overload protection
c) Single phasing protection for motors protected by fuses
2) Incomers / buscoupler / outgoing breaker feeders other than motor feeders.
a) Three phase overcurrent protection (50)

b) Three phase earthfault protection (50N3)
c) Restricted earth fault protection for transformer incomers(64R)
d) Sync Check

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

5.05.11 Ethernet switches shall be “substation hardened” and shall comply to IEC61850-3 for
communications and environment requirements. The Ethernet switches shall be of
managed type with four(4) no Fibre optic cable ports and sixteen/eight nos. Copper
ports to achieve the owners’ LAN configuration. One (1) no. Ethernet switch per
switch board shall be provided & these switches shall be mounted inside the
switchgear Panels. Ethernet switches shall be suitable for single mode FO Cable
connections.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUS DUCT
5.05.12 In case of remote controlled breaker panels, following shall be ensured.

The circuit breaker will normally be controlled from remote control panels (employer’s
DDCMIS) through closing and shunt trip coils. The Local control console of the relay
flush mounted on the switchgear would normally be used only for testing of circuit
breaker in isolated position, and for tripping it in an emergency. Provision for closing
& tripping of the circuit breaker locally from laptop through serial port shall be
possible to facilitate commissioning activities. The basic control scheme of breaker
feeders shall be developed as per the schematic logics in the relay. The schematics
shall be developed in soft inside the relay. Numerical relays shall be interfaced with
employer’s DDCMIS through 24V DC signal for closing / opening operations.
5.05.13 Hardwired contacts from the relay shall be wired to PLC / DCS system as per
requirements. The numerical relay shall be capable of measuring and storing values
of a wide range of quantities, events, faults and disturbance recordings.
5.05.14 The alarm / status of each of protection function and trip operation shall be
communicated to PLC/DCS. The numerical relays shall have built in feature /
hardware interface to provide such inputs to PLC / DCS for analog / digital values..
5.05.15 It shall be possible to carryout open / close operation of breakers from a laptop by
interfacing from the relay front port (RS232) during initial commissioning.
5.06.00 Meters / instruments
All meters/ instrument shall be flush mounted on front panel, at least 96 sq.mm. size
with 90 degree linear scales and accuracy class of 2.0.
5.06.01 All motors of 30kW and above upto 100 KW shall have an Ammeter & current
transducer. Each bus-section shall have bus VT, voltmeter with selector switch, and
other relay and timers required for protection. Adequate control and selector switches,
push buttons and indicating lamps shall be provided. Thermostatically controlled space
heaters with switches shall be provided to prevent condensation.
5.06.02 For all motor feeders related to dust suppression system and for all other motor feeders
having 100KW & above rating, contractor shall provide multifunction Digital Energy
Meter with communication facility to display the current, voltage, power factor, power,
energy related data locally and shall communicate these for remote metering
/audit/analysis purposes. The technical specification for Digital indicating energy meter
shall be as follow:
a) Input Voltage: 110 V AC/ 240 V DC
b) Input Current:1A
c) Size: 96X96 sq. mm
d) Accuracy:1.0% for power & energy
e) Mounting: Flush mounting
f) Type: True RMS 3-PHASE V, I, KW, PF & KWHr indication

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUS DUCT
g) 4 Digit, seven segment LED display/LCD display, with floating decimal
h) Communication: In built RS 485 serial bus port
i) Operating Frequency: 45 HZ-65HZ
j) Dielectric Test: 2KV RMS for 1 minute
k) Over current: 10 times for 3 sec.
l) Aux. supply: 90V-300V AC/DC
m) Compliance: EMC/EMI
n) Field programmable CT ratio
5.07.00 Control from Remote
Necessary hardware shall be provided in the switchgear panel like coupling relays (if
required ) of 24V DC, with max. burden of 2.5VA, auxiliary relays, current/voltage
transducers (4-20 mA, dual output) etc. to effect interlocks, exchange information /
status and exercise control from remote.
6.01.00 All 415V switch gear motor control centers (MCCs), AC & DC distribution boards (DB
s), etc shall have following features :
1) Shall be of metal enclosed, indoor, floor mounted and free
standing type.
2) All frames and load bearing members shall be fabricated

using mild steel structural sections or pressed and shaped
cold rolled sheet steel of thickness not less than 2mm.
3) Frame shall be enclosed in cold rolled sheet steel of thickness

not less than 1.6mm.Doors and covers shall also be of cold
rolled sheet steel of thickness not less than 1.6 mm. Stiffeners
shall be provided wherever necessary. Removable gland
plates of thickness 3mm (hot/cold rolled sheet steel) or 4 mm
(non-magnetic material) shall be provided for all panels.
4) All switchboards/panels shall be of dust and vermin proof. All

cutouts shall have EPDM/Neoprene gaskets.
5) All switchboards, MCCs and DB s shall have following distinct

vertical sections.
a) Completely enclosed bus bar compartment for

horizontal and vertical bus bars.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUS DUCT
b) Completely enclosed switchgear compartments (one

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

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

enclosed cable compartment shall also be acceptable.
e) Compartment for relays and other control devices

associated with a circuit breaker, wherever necessary.
f) The switchboards/MCC/DBs of 1600A & above rating

shall be of DOP IP42 & of IP52 for less than 1600A
rating.
g) All 415V switchgears, MCC’s, AC & DC distribution

boards etc. shall be painted by powder coating
process. Paint shade for complete panels excluding
end covers shall be RAL9002 & RAL5012 for extreme
end covers of all boards.
h) All draw out modules shall have distinct service, test

and isolated positions with provision of external pad
locking facility in each position. Power contacts shall
get disconnected in both test and isolated positions
whereas the control contacts shall get disconnected in
isolated position only.
6) Busbars shall be of high conductivity aluminium alloy or

copper & entire busbar system shall be insulated with PVC
sleeves.
7) The cross section of the horizontal bus bars shall be uniform

through out the length of the switchboard and both horizontal
as well as vertical bus bars shall be adequately supported and
braced to withstand the stresses due to the specified short
circuit currents. Neutral bus bar short circuit strength shall be
same as the main bus bars.
8) Minimum air clearance in air between phases and phase-earth
shall be 25 mm for busbars and cable terminations. For all
other components, the Clearances shall be at least 10mm.
SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUS DUCT
Wherever above is not possible except for horizontal and

vertical busbars, insulation shall be provided by anti tracking
sleeving or barriers. However for horizontal and vertical
busbars, clearances specified above shall be maintained even
when busbars are insulated/sleeved. In case of DC DBs/ fuse
boards, the busbar system shall be insulated or physically
segregated with barriers to prevent interpole short circuit.
9) Busbar insulators shall be of track-resistant high strength non-

hygroscopic, non-combustible type and suitable to withstand
stresses due to over-voltages and short circuit current.
Insulators and barrier of inflammable material such as Hylam
shall not be accepted.
10) All types of relays and timer shall be subject to Employer’s

approval. They shall be flush mounted with connections from
inside, and shall have transparent & dust tight cover,
removable from front, drawout construction for easy
replacemernt and testing facility. The auxiliary relays and
timer may be provided in fixed cases.
11) Terminal Blocks

Terminal blocks shall be 650V grade, 10Amps rated, made
up of unbreakable polyamide 6.6 grade. The terminals shall
be either screw type or screw-less (spring loaded) / cage
clamp type with lugs. Marking on terminal strips shall
correspond to the terminal numbering in wiring diagrams. All
metal parts shall be of non-ferrous material. In case of
screw type terminals the screw shall be captive, preferably
with screw locking design. Maxi terminal / cage clamp type
terminal blocks shall be provided for signals to be interfaced
with DDCMIS / PLC.
12) The switchgears/MCC shall be designed to offer adequate

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

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUS DUCT
CTs PTs
Protection 5P20,5VA 3P
Metering 1.0 0.5
REF PS
6.02.00 Indicating lamps shall be cluster LED type.All overload relays shall have overload
reset push button.
6.03.00 Switchgear/MCC shall have bottom cable entry.
7.00.00 TYPE TESTS
7.01.00 GENERAL
(a.) All equipments to be supplied shall be of type tested design. During detailed
engineering, the contractor shall submit for Owner’s approval the reports of
all the type tests as listed in this specification and carried out within last ten
years from the date of bid opening. These reports should be for the test
conducted on the equipment similar to those proposed to be supplied under
this contract and the test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client.
(b.) However if the Contractor is not able to submit report of the type test(s)
conducted within last ten years from the date of bid opening, or in case the
type test report(s) are not found to be meeting the specification requirements,
the Contractor shall conduct all such tests under this contract, at no additional
cost to the Owner either at third party lab or in presence of client/owners
representative and submit the reports for approval.
(c.) All acceptance and routine tests as specified below and in relevant standards
shall be carried out. Charges for these shall be deemed to be included in the
equipment price.
(d.) The type test reports once approved for any projects shall be treated as
reference. For subsequent projects if NTPC, an endorsement sheet will be
furnished by the manufacturer confirming similarity and “No Design Change”.
Minor changes if any shall be highlighted on the endorsement sheet.
7.02.00 BUSDUCTS (as applicable)
The following type test certificates on each rating of bus duct shall be submitted.
(a.) Heat run test on an assembly of representative sections and fittings
(b.) Short circuit test for a duration and current as covered in the specification on
an assembly of representative section.
(c.) One minute high potential power frequency voltage withstand test.
(d.) Degree of protection test.

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUS DUCT
7.03.00 L. T. SWITCHGEAR
The following type test certificates on each type & rating of L.T. Switchgear and MCC
panel shall be submitted.
(a.) Short time withstand test.
(b.) Temperature rise test.
(c.) Type II - Short circuit co-ordination test for any three ratings of MCC module
as selected by the Employer.
(d.) Test sequence –1 & combined test sequence shall be carried out on each
rating of circuit breaker mounted inside the panel.
(e.) Degree of protection tests
(f.) Type test certificates for numerical relays.
8.00.00 Drawing Submission Procedure
Unique manufacturer specific reference drawing nos. shall be allotted by owner to

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

SUB-SECTION-IIIB-02
L.T. SWITCHGEAR &
BUS DUCT
10/01/07
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10/01/07
10/01/07
CLAUSE NO.
POWER CABLES
1.00.00 CODES & STANDARDS
1.01.00 All standards, specifications and codes of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions as on date
of opening of bid. In case of conflict between this specification and those (IS : codes,
standards, etc.) referred to herein, the former shall prevail. All the cables shall
conform to the requirements of the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working

voltages upto and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanised steel wires, formed wires and tapes
for armouring of cables.
IS : 5831 PVC insulation and sheath of electrical cables.
IS:7098 (Part -I) Cross linked polyethylene insulated PVC sheathed cables for
working voltages upto and including 1100V.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D -2843 Standard test method for density of smoke from the burning
or decomposition of plastics.
ASTM-D-2863 Standard method for measuring the minimum oxygen

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

SUB-SECTION-IIIB-03 PAGE
PROJECT SECTION-VI,
L.T. POWER CABLE 1 OF 8
CLAUSE NO.
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 burried installation with chances of flooding by water.
2.02.00 Cables shall be armoured, flame retardant, low smoke (FRLS), type designed to
withstand all mechanical, electrical and thermal stresses develop under steady state
and transient operating conditions as specified elsewhere in this specification.
2.03.00 Aluminium conductor used in power cables shall have tensile strength of more than
100 N/ sq.mm. Conductors shall be multi stranded.
2.04.00 XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg.
C and short circuit conductor temperature of 250 deg.C. PVC insulation shall be
suitable for continuous conductor temperature of 70 deg C and short circuit
conductor temperature of 160 deg. C.
2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It
shall not stick to insulation and inner sheath. All the cables, other than single core
unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as
per IS : 5831.
2.06.00 For single core armoured cables, armouring shall be of aluminium wires. For
multicore armoured cables armouring shall be of galvanised steel as follows : -
Calculated nominal dia Size and Type of armour
of cable under armour
i) Upto 13 mm 1.4mm dia GS wire
ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6
mm dia GS wire
iii) Above 25 & upto 40 mm 0.8mm thick GS formed wire /
2.0mm dia GS wire
iv) Above 40 & upto 55mm 1.4 mm thick GS formed wire
/2.5mm dia GS wire
v) Above 55 & upto 70 mm 1.4mm thick GS formed wire /
3.15mm dia GS wire
vi) Above 70mm 1.4 mm thick GS formed wire / 4.0
mm dia GS wire

PROJECT SECTION-VI,
CLAUSE NO.
2.06.01 The aluminium used for armouring shall be of H4 grade as per IS:8130 with
maximum resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of
aluminium wires/formed wires for armouring shall be same as indicated above in
clause 2.06.00 for galvanised steel.
2.06.02 The gap between armour wires / formed wires shall not exceed one armour wire /
formed wire space and there shall be no cross over / over-riding of armour wire /
formed wire. The minimum area of coverage of armouring shall be 90%. The
breaking load of armour joint shall not be less than 95% of that of armour wire /
formed wire. Zinc rich paint shall be applied on armour joint surface of G.S.
wire/formed wire.
2.07.00 Outer sheath shall be of PVC as per IS:5831 & black in colour. In addition to meeting
all the requirements of Indian standards referred to, outer sheath of all the cables
(including trailing cables) shall have the following FRLS properties.
(a.) Oxygen index of min. 29 (As per ASTMD 2863)
(b.) Acid gas emission of max. 20% (As per IEC-754-I).
(c.) Smoke density rating shall not be more than 60% during Smoke Density Test
as per ASTMD-2843.
2.08.00 Cores of the cables shall be identified by colouring of insulation. Following colour
scheme shall be adopted:
1 core Red, Black, Yellow, Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
2.09.00 For reduced neutral conductors the core shall be black.
2.10.00 In addition to manufacturer's identification on cables as per IS, following marking

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

PROJECT SECTION-VI,
CLAUSE NO.
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 voltag
(c) Short circuit withstand capability
This will depend on the feeder type. For a fuse protected circuit, cable
should be sized to withstand the let out energy of the fuse. For
breaker controlled feeder, cable shall be capable of withstanding the
system fault current level for total breaker tripping time inclusive of
relay pickup time.
2.14.02 Derating Factors
Derating factors for various conditions of installations including the following

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

PROJECT SECTION-VI,
CLAUSE NO.
2.14.04 All power cables of sizes more than 120 sq.mm. shall be XLPE insulated and
preferable sizes are 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm.
3.00.00 CONSTRUCTIONAL FEATURES
(a.) 1.1 KV grade XLPE power cables shall have compacted aluminium conductor,
XLPE insulated, PVC inner-sheathed (as applicable), PVC outer-sheathed
conforming to IS:7098. (Part-I).
(b.) 1.1KV grade PVC power cables shall have aluminium conductor (compacted
type for sizes above 10 sq.mm), PVC Insulated, PVC inner sheathed (as
applicable), PVC outer-sheathed conforming to IS:1554 (Part-I).
(c.) Trailing cables shall have tinned copper (class 5) conductor, insulated with heat
resistant elastomeric compound based on Ethylene Propyline Rubber (EPR)
suitable for withstanding 90 deg.C continuous conductor temperature and
250deg C during short circuit, inner-sheathed with heat resistant elastomeric
compound, nylon cord reinforced, outer-sheathed with heat resistant, oil
resistant and flame retardant heavy duty elastomeric compound conforming to
IS 9968.
4.00.00 CABLE DRUMS
(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be
covered with water proof layer. Both the ends of the cables shall be properly
sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to
eliminate ingress of water during transportation, storage and erection. Wood
preservative anti-termite treatment shall be applied to the entire drum. Wooden
drums shall comply with IS : 10418.
(b.) Each drum shall carry manufacturer's name, purchaser’s name, address and
contract number, item number and type, size and length of cable and net gross
weight stenciled on both sides of the drum. A tag containing same information
shall be attached to the leading end of the cable. An arrow and suitable
accompanying wording shall be marked on one end of the reel indicating the
direction in which it should be rolled.
5.00.0 TESTS
years from the date of bid opening. These reports should be for the tests

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

PROJECT SECTION-VI,
CLAUSE NO.
S.No. Type Test Remarks
12. Adhesion test For G.S. Formed wires /wires only.
For PVC/XLPE insulation & PVC Sheath
13. Test for thickness
14. Tensile strength & elongation tests before ageing and after ageing
15. Ageing in air oven
16. Loss of mass test For PVC insulation and sheath only
17. Hot deformation test For PVC insulation and sheath only
18. Heat shock test For PVC insulation and sheath only
19. Shrinkage test
20. Thermal stability test For PVC insulation and sheath only
21. Hot set test For XLPE insulation only
22. Water absorption test For XLPE insulation only
23. Oxygen index test For outer sheath only
24. Smoke density test For outer sheath only
25. Acid gas generation test For outer sheath only
For completed cables
26. Insulation resistance test

(Volume resistivity method)

PROJECT SECTION-VI,
CLAUSE NO.
27. High voltage test
28. Flammability test as per IEC - 332 Part-3 (Category -B)
5.01.02 The reports for all the type tests as per IS 9968 (Along with test reports for FRLS
Properties and flammability test) shall be submitted for one size of each voltage grade of
trailing cables.
5.02.00 Acceptance Tests and Routine tests

Refer QA table enclosed with specification.

PROJECT SECTION-VI,
CLAUSE NO.
HT CABLES
of opening of bid. In case of conflict between this specification and those (IS : codes,
conform to the requirements of the following standards and codes :
IS:7098 Specification for Cross linked polyethylene insulated
(Part -II) PVC sheathed cables. Part-II: For working voltages from
3.3 KV upto and including 33 KV.
IS : 3975 Low Carbon Galvanized steel wires, formed wires and
tapes for armouring of cables.
IS : 4905 Methods for random sampling.
IS : 8130 Conductors for insulated electrical cables and flexible
cords.
ASTM-D - Standard test method for density of smoke from the
2843 burning or decomposition of plastics.
IEC-754 Tests on gases evolved during combustion of electric
(Part-I) cables.
IEC-332 Tests on electric cables under fire conditions. Part-3:
Tests on bunched wires or cables (Category-B).
under ground (buried) installation with chances of flooding by water.
2.02.00 Cables shall be armoured, flame retardant, low smoke (FRLS) type designed to
withstand all mechanical, electrical and thermal stresses 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.

SUBSECTION IIIB-04 PAGE
PROJECT SECTION-VI,
HT CABLES 1 OF 8
CLAUSE NO.
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 Size and Type of armour

under armour
i) Upto 13 mm 1.4mm dia GS wire
ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6
mm dia GS wire
iii) Above 25 & upto 40 0.8mm thick GS formed wire /

mm 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
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.

PROJECT SECTION-VI,
HT CABLES 2 OF 8
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)
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.

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.
2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC-332
Part-3.
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.
Cable selection & sizing
2.15.00 HT cables shall be sized based on the following considerations:
a) Rated current of the equipment

PROJECT SECTION-VI,
HT CABLES 3 OF 8
CLAUSE NO.
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
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.
are avoided.
2.16.01 Cables shall be armoured type if laid in switchyard area, coal handling area or
directly buried.
2.17.00 The eccentricity shall be calculated as

tmax -tmin
------------ x 100
t max
and the ovality shall be calculated as
dmax -dmin
------------ x 100
d max
Where t-max/t-min is the maximum/minimum thickness of insulation and d-max/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% .

PROJECT SECTION-VI,
HT CABLES 4 OF 8
CLAUSE NO.
3.01.00 3.8/6.6 KV 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 carrying the
system earth fault current of 9kA for 1 seconds, 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 19/33KV 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 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 of 1kA for 1 second, 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.
4.00.00 CABLE DRUMS

4.01.01 Cables shall be supplied in non returnable wooden or steel drums of heavy
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
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 power cables shall not be less than 500 meters. The
length per drum shall be subjected to a maximum tolerance of +/- 5% of the standard
drum length. The Employer shall have the option of rejecting cable drum with shorter

PROJECT SECTION-VI,
HT CABLES 5 OF 8
CLAUSE NO.
lengths. For each size, the variance of total quantity, adding all the supplied drum
lengths, from the ordered quantity, shall not exceed +/-2%.
5.00.00 TESTS
5.01.00 GENERAL
equipment price.
(d.) The type test reports once approved for any project shall be treated as
5.01.02 Following type tests reports shall be furnished on one size of each type(voltage
grade) of cable:
S. Type Test Remarks
No
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

PROJECT SECTION-VI,
HT CABLES 6 OF 8
CLAUSE NO.
S. Type Test Remarks

No
8(a) Mass & uniformity of Zinc For GS wires/formed wires
Coating tests only.
8(b) Adhesion test For GS wires/formed wires
only
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- For completed cable only
332
Part-3 (Category -B)
5.01.03 The following type tests shall be submitted for each type(voltage grade) & size of the
cable:
S. Type Test For all cables
No
.
1. Insulation resistance test (Volume Resistivity method)
For cables of 6.6 KV & above Grade only.

3. Partial discharge test
4. Bending test
5. Dielectric power factor test

PROJECT SECTION-VI,
HT CABLES 7 OF 8
CLAUSE NO.
a As a function of voltage
b As a function of temperature
)
6. Heating cycle test
7. Impulse withstand test
5.02.00 Indicative list of tests/ checks, Routine and Acceptance tests shall be as per Quality
Assurance & Inspection table of H.T. Cables enclosed with this chapter.

PROJECT SECTION-VI,
HT CABLES 8 OF 8
CLAUSE NO.
CONTROL CABLES
of opening of bid. In case of conflict between this specification and those (IS: codes,
conform to the requirements of the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working

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

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

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

PROJECT SECTION-VI,
CONTROL CABLES 1 OF 6
CLAUSE NO.
under ground burried installation with chances of flooding by water.
2.02.00 Cables shall be armoured. flame retardant, low smoke (FRLS), type designed to
withstand all mechanical, electrical and thermal stresses develop under steady state
and transient operating conditions as specified elsewhere in this specification.
2.03.00 Conductor of control cables shall be made of multi stranded, plain annealed copper.
2.04.00 PVC insulation shall be suitable for continuous conductor temperature of 70 deg C
and short circuit conductor temperature of 160 deg. C.
per IS : 5831.
2.06.00 For multicore armoured cables, the armouring shall be of galvanised steel as follows:
-
Calculated nominal dia. Size and Type of armour
of cable under armour
1) Upto 13 mm 1.4mm dia GS wire
2) Above 13 upto 25 mm 0.8 mm thick GS formed wire / 1.6 mm dia

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

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

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.

PROJECT SECTION-VI,
CLAUSE NO.
2.13.00 Inplant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc.
are not acceptable.
2.14.00 Cable selection & sizing

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

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

PROJECT SECTION-VI,
CLAUSE NO.
preservative anti-termite treatment shall be applied to the entire drum. Wooden

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

For Conductor
1. Resistance test
For Armour Wires / Formed Wires
4. Tensile Test

PROJECT SECTION-VI,
CLAUSE NO.
5. Elongation test
6. Torsion test For round wire only
7. Wrapping test
8. Resistance test
9(a). Mass of zinc Coating test For GS wires/formed wires only
9(b). Uniformity of zinc coating For GS wires/formed wires only
10. Adhesion test For GS wires/formed wires only
For PVC insulation & PVC Sheath
12. Tensile strength and elongation before ageing and after ageing
test
14. Loss of mass test For PVC insulation and sheath only
15. Hot deformation test For PVC insulation and sheath only
16. Heat shock test For PVC insulation and sheath only
17. Shrinkage test
18. Thermal stability test For PVC insulation and sheath only
19. Oxygen index test For outer sheath only
20. Smoke density test For outer sheath only
21. Acid gas generation test For outer sheath only
For completed cables
22. Insulation resistance test(Volume resistivity method)

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

Refer QA table enclosed with specification.
.

PROJECT SECTION-VI,
INSTRUMENTATION CABLES
1.00.00 INSTRUMENTATION CABLES
1.01.00 GENERAL
1.01.01 The Contractor shall supply, erect, terminate and test all instrumentation cables for
control and instrumentation equipment/devices/systems included under Contractor's
scope.
1.01.02 Any other application where it is felt that instrumentation cables are required due to
system/operating condition requirements, are also to be provided by Contractor.
1.01.03 Other type of cables like fiber optic/co-axial cables for system bus, cables for
connection of peripherals etc. (under Contractor's scope) are also to be furnished by
the Contractor.
1.01.04 Contractor shall supply all cable erection and laying hardware trays, supports,
flexible conduits, cable glands, lugs, pull boxes etc. on as required basis for all the
systems covered under this specification.
1.02.00 Instrumentation Cable Specifications
1.02.01 All the instrumentation cables shall be Armoured, twisted, shielded multipair, pre
fabricated, flame retardant low smoke (FRLS) type. The Cables shall be provided in
non-returnable drums. The drum length shall be 1000m (+/-5%) up to & including 12
pairs and 500 m (+/- 5%) above 12 pairs.
1.02.02 Voltage grade of the instrumentation cables shall be 225V (peak value).
1.02.03 All instrumentation cables covered in this specification shall comply with VDE 0815,
VDE 0207, Part 4, Part 5, Part 6, VDE 0816,VDE 0472, SEN 4241475, ANSI MC
96.1, IS-8784, IS-10810 (latest editions) and its amendments read along with this
specification.
1.02.04 The conductor shall be of minimum 0.5-sq.mm size, high conductivity, multi-stranded
copper for all types of instrumentation cables where as the same shall be min.
1.5sqmm when used in the trailing cables.
1.02.05 The insulation of individual conductor shall be extruded PVC meeting the
requirements of VDE 0207 Part 4 compound Y I3. The outer sheath of
instrumentation cables shall be extruded PVC (compound YM1) as per VDE 0207
Part 5 and shall be of flame-retardant low smoke (FRLS) type. The cable shall be
provided with marking including manufacturer's name, insulation material, and
conductor sizes, no of pairs, voltage ratings, type of cable etc. at intervals not
exceeding 625mm. Progressive sequential marking of the length of the cable at
every one meter & progressive markings to read 'FRLS' at every 5 meters shall be
provided on the outer sheath of all instrumentation cables. The colour of outer sheath
shall be sky blue.

TECHNICAL SPECIFICATION SUB-SECTION-IIIB-06
PROJECT PAGE
SECTION-VI, INSTRUMENTATION
COAL CONVEYING PLANT PACKAGE 1 OF 11
PART-B CABLES
Fillers in multiple conductor cables shall be flame retardant and moisture resistant.
Cable accessories such as harnessing components, markers, bedding, cable jointer,
binding tape etc. shall also have flame retardant quality.
1.02.06 All instrumentation cables shall be provided with overall shielding. However, multipair
cables carrying analog signals shall be provided with individual pair shielding in
addition to overall shielding. Shielding shall be of Aluminium-Mylar tape with 100%
coverage and with atleast 20% overlapping. The thickness of individual pair shield
shall be 28 micron (minimum) and that of overall shield shall be 55 microns
(minimum). Separate drain wires for individual pair shield (wherever applicable) as
well as overall shield shall be provided. Drain wire shall be of seven (7) strand 20
AWG (0.51 Sq.mm) tin coated copper conductor. Maximum lay of individual twisted
pair shall be 50 mm. Bidder to ensure that individual core diameter shall be suitable
for maxi-termi connection. Insulation thickness of individual core shall be between
0.28 and 0.35 mm for 0.5 mm2 cables.
1.02.07 The outer sheath of the instrumentation cables shall meet the following minimum
requirements:
(i) An Oxygen index of not less than 29% and a Temperature index of not less
than 250 deg.C as per ASTMD-2863.
(ii) Maximum acid gas generation by weight as per IEC-754-I shall not be more
than 20%.
(iii) Smoke Density Rating shall not be more than 60% during Smoke Density
Test as per ASTMD-2843. The results of smoke density test shall be plotted
on a curve indicating light absorption vs. time as per ASTMD2843. The
average area under the curve (smoke density rating) shall not be more than
60%.
(iv) Complete cable assembly shall pass Swedish Chimney test as per SEN-
4241475 and flammability test as per IEEE-383.
The thickness of outer sheath shall be as per the guidelines given in VDE 0816. Thickness of outer
sheath shall not be less than 1.8 mm in any case. Allowable tolerance of overall diameter
of the cables shall be +/-2 mm max. over the declared value in technical data sheets.
The variation in diameter and the ovality at any cross section shall not be more than 1.0
mm.
1.02.08 All instrumentation cables shall be suitable for continuous operation at 70 deg.C,
except for high temperature resistant teflon insulated cables which shall be suitable
for continuous operation at 205 deg.C. The cables shall be suitable for laying in wet
or dry locations in trays, conduits, ducts, trenches and under ground buried
installations.
1.02.09 The thermocouple extension cables shall be of single/multi pair, twisted & shielded,
PVC insulated, FRLS PVC sheathed and compatible for the type of thermocouples
employed. The material of conductor shall be as per ANSI MC-96.1. The material
PROJECT PAGE
PART-B CABLES
and requirements of conductor insulation, shielding and outer sheath shall be as per
the above clauses.
1.02.10 Cable parameters such as mutual capacitance between conductors, conductor

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

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

capacitance at
0.8 kHz (max.)
Conductor 73.4 ohm/km 73.4 ohm/km

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

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

impedance
(max.)

PROJECT PAGE
PART-B CABLES
Attenuation at 1 1.2 dB/Km 1.2 dB/Km

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

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

instrumentation cable (2/4/8/12/24/48 pair) for binary
signals with stranded copper conductor.
I 0.5 mm2 Type F cable/type G cable with heat resistant teflon

insulation & outer-sheath for high temperature
application.
S As per Multi core/ Multi pair shielded cable for system specific
specific cables. Like conductivity type level switches, Vibration
Standard/ monitoring system cable, System Bus cable, Bus
Requirement communications cable etc. as applicable.
for each
application
1.03.00 INSTRUMENTATION CABLE INTERCONNECTION AND TERMINATION

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

PROJECT PAGE
PART-B CABLES
TABLE C:- CABLE TERMINATION TO BE FOLLOWED
Application Type Of Termination Type Of

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

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

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

connector Cage clamp
Type
RTD Temperature Plug in Screwed/

thermocouple transmitter connector Cage clamp
Type
Local Junction Marshalling Maxitermi/ Post moun F,G

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

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

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

cubicle/ cabinet mounted mounted
Termination Maxi Maxi
Cabinet termi/cage termi/cage
clamp type. clamp type.
PROJECT PAGE
PART-B CABLES
Marshalling / UCP mounted Post moun Plug in F,G (with

Termination equipments ted Maxi connector/ plug-in
system cabinets termi/cage Cage clamp connector at
clamp type. type (rail one end)
mounted).
DDCMIS/PLC PC, Printers etc. Plug in Plug in Mfr.’s

cabinets connector connector Standard
Notes 1 Normally 10% spare core shall be provided when the number
of pairs of cables are more than four pairs.
2 For analog signals individual pair shielding & overall

shielding & for Binary signals only overall shielding of
instrumentation cables shall be provided.
3 * For high temperature application only.
2.00.00 TERMINAL BLOCKS
2.01.00 All terminal blocks shall be rail mounted/post mounted, cage clamp type/maxi-termi
type (MTP) with high quality non-flammable insulating material of melamine suitable
for working temperature of 105 deg. C. The terminal blocks in field mounted junction
boxes, CJC boxes, etc., shall be suitable for cage clamp/ MTP connections. The
terminal blocks in Control Equipment Room logic/termination/marshalling cubicles
shall be suitable for post mounted maxi-termi/cage clamp connection at the field
input end. The terminal blocks for DDCMIS input/output connections from/to
SWGR/MCC, Actuators with Integral Starter (for coupling relays and check back
signals of 11 kV and 3.3 kV auxiliaries, LT drives/valves & dampers/solenoids, CT &
VT, etc.) shall be provided with built in test and disconnect facilities complete with
plug, slide clamp, test socket, etc. The exact type of terminal blocks to be provided
by the Contractor and the technical details of the same including width etc. shall be
subject to Employer's approval.
2.02.00 All the terminal blocks shall be provided complete with all required accessories
including assembly rail, locking pin and section, end brackets, partitions, small
partitions, test plug bolts and test plug (as specified above for SWGR connections)
transparent covers, support brackets, distance sleeves, warning label, marking, etc.
2.03.00 The marking on terminal strips shall correspond to the terminal numbering on wiring
diagrams. At least 20% spare unused terminals shall be provided everywhere
including local junction boxes, instrument racks/enclosures, termination/marshalling
cabinets, etc. All terminal blocks shall be numbered for identification and grouped
according to the function. Engraved labels shall be provided on the terminal blocks.
2.04.00 The terminal blocks shall be arranged with atleast 100 mm clearance between two
sets of terminal blocks and between terminal blocks and junction box walls.
2.05.00 For ensuring proper connections, Contractor shall provide suitable accessories,
along with insulation sleeves. The exact connecting accessory shall be finalised as

PROJECT PAGE
PART-B CABLES
per application during detail engineering stage subject to Employer's approval

without any cost repercussions.
2.06.00 Internal wiring in factory prewired electronic equipment cabinets may be installed
according to the Contractor's standard as to wire size and method of termination or
internal equipment. Terminal blocks for connection of external circuits into factory
prewired electronic equipment cabinets shall meet all the requirements as specified
above.
3.00.00 INTERNAL PANELS/CABINETS/SYSTEM CABINETS WIRING
3.01.00 Internal panel/cabinet wiring shall be of multistranded copper conductor with FRLS
PVC insulation without shield and outer sheath meeting the requirements of VDE
0815.
3.02.00 Wiring to door mounted devices shall be done by 19 strand copper wire provided
with adequate loop lengths of hinge wire so that multiple door opening shall not
cause fatigue breaking of the conductor.
3.03.00 All internal wires shall be provided with tag and identification nos. etched on tightly
fitted ferules at both ends in Employer's approved format. All wires directly
connected to trip devices shall be distinguished by one additional red colour ferrule.
3.04.00 All external connection shall be made with one wire per termination point. Wires shall
not be tapped or spliced between terminal points.
3.05.00 All floor slots of desk/panels/cabinets used for cable entrance shall be provided with
removable gasketed gland plates and sealing material. Split type grommets shall be
used for prefabricated cables.
3.06.00 All the special tools as may be required for solderless connections shall be provided
by Bidder.
3.07.00 Wire sizes to be utilised for internal wiring.
(i) Current (4-20 mA), low voltage signals (48V) 0.5 Sq.mm.
(ii) Power supply and internal illumination. 2.5Sq.mm. minimum (shall be

as per load requirement.)
4.00.00 CABLE INSTALLATION AND ROUTING
4.01.00 All cables assigned to a particular duct/conduit shall be grouped and pulled in
simultaneously using cable grips and suitable lubricants. Cables removed from one
duct/conduit shall not be reused without approval of Employer.
Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the higher voltage cable
shall be in higher position and instrumentation cable shall be in bottom tier of the tray
stack.
4.02.00 Cables shall terminate in the enclosure through cable glands. All cable glands shall
be properly gasketed.
PROJECT PAGE
PART-B CABLES
4.03.00 All cables shall be identified by tag. Nos. provided in Employer's approved format
at both the ends as well as at an interval of 5 meters.
4.04.00 Line voltage drop due to high resistance splices, terminal contacts, insulation
resistance at terminal block, very long transmission line etc. shall be reduced as far
as practicable.
4.05.00 The cables emanating from redundant equipment/devices shall be routed through
different routes.
5.00.00 CABLE LAYING AND ACCESSORIES
5.01.00 CABLE LAYING
1 Cables shall be laid strictly in line with cable schedule.
2 Identification tags for cables.
Indelible tags to be provided at all terminations, on both sides of wall or

floor crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in
cable trench/tray.
3 Cable tray numbering and marking.
To be provided at every 10m and at each end of cable way & branch
connection.
4 Joints for less than 250 Meters run of cable shall not be permitted.
5 Buried cable protection
With concrete slabs; Route markers at every 20 Meters along the route &
at every bend.
6 Road Crossings
Cables to pass through burried high density PE pipes encased in PCC. At

least 300 mm clearance shall be provided between
- HT power & LT power cables,
- LT power & LT control/instrumentation cables,
Spacing between cables of same voltage grade shall be in accordance with

the derating criteria adopted for cable sizing.
7 Segregation (physical isolation to prevent fire jumping)
a All cable associated with the unit shall be segregated from cables of
other Units.
PROJECT PAGE
PART-B CABLES
b Interplant cables of station auxiliaries and unit critical drives shall be

segregated in such a way that not more than half of the drives are lost
in case of single incident of fire.
8 Cable clamping
All cables laid on trays shall be neatly dressed up & suitably clamped/tied to
the tray. For cables in trefoil formation, trefoil clamps shall be provided.
6.00.00 FIELD MOUNTED LOCAL JUNCTION BOXES
(i) No. of ways 12/24/36/48/64/72/96/128 with 20% spare terminals.
(ii) Material and 4mm thick fiberglass reinforced polyester.

Thickness
(iii) Type Screwed at all four corners for door. Door handle shall
be self locking with common key. Door gasket shall be
of synthetic rubber.
(iv) Mounting clamps Suitable for mounting on walls, columns, structures etc.
and accessories The brackets, bolts, nuts, screws, glands and lugs
required for erection shall be of corrosion resistant
material, included in Bidders scope of supply.
(v) Type of terminal Rail mounted maxitermi or cage-clamp type suitable

blocks for conductor size upto 2.5 mm2. A M6 earthing stud
shall be provided.
(vi) Protection Class IP:55 minimum for Indoor & IP-65 Outdoor applications
(vii) Colour To be decided during detailed engineering & subject to

Employer’s approval.
7.00.00 CONDUITS
7.01.00 All rigid conduits, couplings and elbows shall be hot dipped galvanised rigid mild
steel in accordance with IS:9357 Part-I (1980) and Part-II (1981). The conduit interior
and exterior surfaces shall have continuous zinc coating with an overcoat of
transparent enamel lacker or zinc chromate. Flexible conduit shall be heat resistant
lead coated steel, water leak, fire and rust proof. The temperature rating of flexible
conduit shall be suitable for actual application.

PROJECT PAGE
PART-B CABLES
8.00.00 TESTS
8.01.00 GENERAL
equipment price.
8.02.00 TYPE TEST
8.02.01 Following type tests reports shall be submitted for one size of each type of
instrumentation cables:
8.02.02 For Conductor (including Drain Wire)

Sl. Test Reference Standard Remarks
No.
1. Resistance Test VDE:0815
2. Diameter IS:10810
3. Tin coating test* As per relevant *Applicable for drain wire
(Persulphate Test) standard only
8.02.03 For PVC Insulation And PVC Sheath

Sl.No. Test Reference Remarks
Standard
1. Test for thickness** IS:10810
2. Tensile strength and elongation test VDE:0472
before and after ageing**
3. Ageing in air ovens** - do-
4. Loss of Mass Test -do-
PROJECT PAGE
PART-B CABLES
5. Hot deformation test -do-

6. Heat shock test - do-
7. Shrinkage test** -do-
8. Cold bend/ cold impact test - do-
9. Colour fastness to water -do-
10. Thermal stability test -do-
11. Bleeding and blooming -do-
12. Oxygen index test (for sheath & fillers) ASTMD-2863
13. Smoke density test (for sheath & ASTMD-2843
fillers)
14. Acid gas generation test (for sheath & IEC-754-1
fillers)
8.02.04 For Al-Mylar Shield
Sl.No. Test Reference Standard Remarks
1. Continuity test As per relevant standard
2. Shield thickness test -do-
3. Overlap test -do
4. Noise interference IEEE-Transaction

test March'67
8.03.00 Acceptance tests and routine test
Refer QA table enclosed with the specification.

PROJECT PAGE
PART-B CABLES
ILLUMINATION
1.00.00 GENERAL
1.01.00 This specification covers the general description of design, manufacture and
construction features, testing, supply, installation and commissioning of the
illumination system equipment required to be provided by the bidder.
1.03.00 All standards and codes of practice referred to herein shall be the latest edition
including all applicable official amendments & revisions as on date of bid opening. In
case of conflict between this specification and those (IS codes, standards etc.)
referred to herein, the former shall prevail. All work shall be carried out as per the
following standards & codes.
1.04.00 Lighting Fixtures and Accessories
IS:1913 General and safety requirements for luminaries.
IS:2148 Flame proof enclosures of electrical apparatus.
IS:418 Tungsten filament general service electric lamps.
IS:1258 Bayonet lamp holders.
IS:1534 Ballast for fluorescent lamps.
IS:1569 Capacitors for use in tubular fluorescent, high pressure

mercury vapour and low pressure sodium vapour discharge
lamp circuit.
IS:1777 Industrial luminaire with metal reflectors.
IS:2149 Luminaire for Street lighting.
IS:2215 Starters for fluorescent lamps.
IS:2418 Tubular fluorescent lamps for general lighting services.
IS:3323 Bi-pin lamp holders for tubular fluorescent lamps.
IS:3324 Holders for starters for tubular fluorescent lamps.

PROJECT SECTION-VI,
ILLUMINATION 1 OF 12
IS:4013 Dust-tight electric lighting fittings.
IS:6616 Ballasts for high pressure mercury vapour lamps.
IS:8224 Electric Lighting fittings for Division 2 areas.
IS:9900 High-pressure mercury vapour lamps.
IS:9974 High pressure Sodium vapour lamps.
IS:10276 Edison screw lamp holders.
IS:10322 Luminaires.
IS:13021 AC Supplied Electronic Ballasts for tubular fluorescent

lamps.
1.05.00 Lighting Panels, Switch-boxes, Receptacles and Junction Boxes
IS:2147 Degree of protection provided by enclosures for low-voltage

switchgear and control gear.
IS:1293 Plugs & socket outlets of rated voltage upto and Including
250volts & rated current upto and including 16 Amps.
IS:2551 Danger notice plates.
IS:13947 Low voltage switchgear and controlgear
IS:3854 Switches for domestic and similar purposes.
IS:6875 Control switches (switching devices for control and auxiliary

circuits including contactor relays) for voltages upto and
including 1000 V AC and 1200 V DC.
IS:13703 Low voltage fuses for voltages not exceeding 1000V AC or

1500 V DC.

PROJECT SECTION-VI,
1.06.00 Conduits, Pipes and Accessories
IS:2667 Fittings for rigid steel conduit for electrical wiring.
IS:3837 Accessories for rigid steel conduits for electrical wiring.
IS:9537 Conduits for electrical installations.
1.07.00 Lighting Wires/Cables
IS:694 PVC insulated cables for working voltages upto and

including 1100 V
IS:3961 Recommended current ratings for cables.(PVC

Insulated and PVC sheathed heavy duty cables and
light duty cables).
IS:8130 Conductors for insulated electric cables and flexible

cords.
IS:10810 Methods of tests for cables.
1.08.00 Electrical Installation Practices & Miscellaneous
IS:1944 Code of practice for lighting of public thorough fare
IS:3646 Code of practice for interior illumination.
IS:5572 Classification of Hazardous areas (other than

Mines)having flammable gases and Vapours for
electrical installation
IS:6665 Code of practice for industrial lighting.

. National Electrical Code
. Indian Electricity Rules.
Indian Electricity Act
IS:5 Colour for ready mixed paints & enamels.
IS:280 Mild steel wires for general engineering purposes.
IS:374 Electric ceiling type fans & regulators.

PROJECT SECTION-VI,
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
2.00.00 LIGHTING SYSTEM DESCRIPTION

2.01.00 Normal AC Lighting System
Normal AC lighting system 415V, 3Phase, 4wire, will be fed from lighting panels
(LPs) which will be fed from the lighting distribution boards (LDBs) which in turn will
be fed from LT MCCs.
2.02.00 Emergency Lighting System
Self contained emergency lighting fixtures shall be provided, 2 nos. in each control
area and in each TP and in each MCC rooms, mounted suitably on wall/columns at
strategic points for safe exit of the personnel. Each fixture shall be fed from a
dedicated 20A, 240V socket. In the control room these fixtures shall also be
provided in the control panel area for emergency operation of the plant. The fixtures
shall be switched ‘ON’ automatically in case of failure of AC supply. These shall be
switched off automatically after the normal AC supply is restored and the luminaries
have attained their full glow. Emergency lighting is to be provided through self
contained 4 hour duration fixtures located strategically. Each shall be provided with
Ni-Cd battery, battery charger & 2 x 10W fluorescent lamps. These emergency
lamps shall be mounted in pilfer proof enclosure having pad locking arrangement.
PROJECT SECTION-VI,
In addition to the above, 3 nos. of 100W, 110V DC lighting fixtures shall also be
provided in each HT Swichgear room and in each control room
2.03.00 DESIGN PHILOSOPHY
1. A comprehensive illumination system shall be provided.

2. All lighting system shall be automatically controlled by synchronous timer.
Provision to bypass the timer shall be provided in the panel for manual
control.
3. The system shall include distribution boards, lighting panels, lighting fixtures,
junction boxes, receptacles, switch boards, lighting pole/masts, conduits,
cables and wires, etc. The system shall cover all interior and exterior lighting
such as area lighting, including Transformer yard etc. The constructional
features of lighting distribution boards shall be similar to AC/DC distribution
boards described in chapter of LT Switchgear. Outgoing circuits in LPs shall
be provided with MCBs of adequate ratings.
4. The illumination system shall be designed on the basis of best engineering
practice and shall ensure uniform, reliable, aesthetically pleasing and glare
free illumination. The lighting fixtures shall be designed for minimum glare.
The design shall prevent glare/luminous patch seen on VDU/ Large video
screens, when viewed from an angle. The finish of the fixtures shall be such
that no bright spots are produced either by direct light source or by reflection.
The diffusers/ louvers used in fluorescent fixtures shall be made of impact
resistant polystyrene sheet and shall have no yellowing property over a
prolonged period. The Lux levels to be adopted for various area are indicated
at Annexure – A.
5. Apart from maintenance factor as given below, Temperature correction
factor shall be considered in the lighting design for fluorescent fixtures
located in non air conditioned area.
(a) Air conditioned area : 0.8
(b.) Non Air conditioned and other indoor area : 0.7
(c.) Dust prone indoor areas and outdoor areas : 0.6

6. All outdoor fixtures shall be weather proof.
7. All lighting fixtures & control gears shall be powder coated.
8. Wires of different phase shall normally run in separate conduit. For areas
illuminated by more than one circuit, the adjacent circuits shall be from
different phases.
9. Power supply shall be fed from suitable number of conveniently located
PROJECT SECTION-VI,
lighting distribution boards (LDB) and lighting panels (LP). AC lighting supply
shall be isolated from main supply by isolation transformers (415/433V, delta
/ star, epoxy insulated, air cooled, dry type) of max. rating of 100KVA and
fault level restricted to 3 KA at Lighting Panels. Minimum 2 ways shall be
kept as spare feeders in the lighting panels.
10. Lighting panels shall be constructed out of 2 mm thick CRCA sheet steel.
The door shall be hinged and the panel shall be gasketted to achieve
specified degree of protection. The panel shall be provided with terminal
bocks for incoming and outgoing circuits, earthing terminals, removable
gland plates at bottom and canopy shall be provided with slope towards the
rear side of the panel. Wiring inside the panel shall be carried out with 1100
V grade PVC insulated stranded copper wires of adequate size. Terminal
blocks shall be 750 V grade, clip-on stud type, moulded in melamine and
shrouded.
All MCBs/ Isolators/ Switches/ Contactors etc. shall be mounted inside the
panel and a fibre glass sheet shall be provided inside the main door such
that the operating knobs of MCBs etc., shall project out of it for safe
operation against accidental contact. MCB’s shall be current limiting type
with magnetic and thermal release suitable for manual closing and automatic
tripping under fault condition with short circuit interrupting capacity of 9 KA
rms. Isolators of AC lighting panels shall be of TPN, continuous duty, load
make-break type and fuses shall be of HRC plug in type.
Synchronous timers shall be quartz controlled electronic type, complete with

rechargeable nickel cadmium cell, 24 hours range day dial, NO/NC contacts
etc. and suitable for operation on 240V AC supply. The exterior side of
panel, shall be powder coated with smoke grey, shade RAL9002 and the
interior side of panel, shall be white.
Lighting panels shall have IP55 degree of protection in general. However LP
located in dusty areas shall have IP65 degree of protection.
Ladder approaches shall be provided for maintaining the fixtures wherever
applicable.
12. 20A, 240V AC industrial type receptacles shall be provided in the
following areas :
- Two in each switchgear / MCC room, Pump house and on stacker-
reclaimer.
- One on each floor of TPs and crusher house building

PROJECT SECTION-VI,
- At 30m interval on both sides of the conveyor gallery and track

hopper shed. At 50m interval on one side of yard conveyor
- These receptacles shall be energized from lighting panel. Maximum
three receptacles shall be connected in one circuit.
10A, 24V AC receptacles with IP55 DOP shall be provided in the following
areas.
- One in each switchgear / MCC room, Pump house and on stacker-
reclaimer.
- One on each floor of TPs and crusher house building
- It shall not be possible to insert 24V plug into 240V receptacle
- These receptacles shall be energized from lighting panel. Maximum
three receptacles shall be connected in one circuit.
13. All fluorescent fixtures shall have energy efficient ‘T5’ type fluorescent
lamps except those in div 2 hazardous area. The louvers of these fixtures
shall be designed for ‘T5’ type fluorescent lamps. All fluorescent lamps
shall have ‘cool day light colour designation. The mirror optics type
fluorescent fixtures shall have no iridescence effect.
2.03.00 Ballasts
2.03.01 All HPSV and HPMV lamp fixtures shall be provided with wire-wound ballasts. All
fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings (Div-
II/Hazardous Area) shall be provided with electronic ballasts.
2.04.00 All luminaires and their accessories and components shall be of type readily
replaceable by available Indian makes.
2.05.00 Fans & Regulator
2.05.01 Ceiling Fans, to be provided in non air-conditioned office / control room area shall be
suitable for operation on 240 V, 50 Hz, AC supply comprising of class ‘F’ insulated
copper wound single phase motor, 1200mm sweep, aerodynamically designed well
balanced MS blades (3 Nos.), down rod, die cast aluminium housing, capacitor,
suspension hook, canopies etc. finished in stove enameled white. Power factor of
fans shall not be less than 0.9. Each fan shall cover approximately 10sq.m. area.
2.06.00 Switch Box
2.06.01 Switch boxes shall be made of 1.6 mm thick, MS sheet with 3 mm. thick decorative,
perspex cover. Switchbox shall be hot dip galvanised
2.07.00 Junction boxes
Junction box for lighting fixtures shall be deep drawn or fabricated type made of min.
1.6 mm thick CRCA Sheet. The box shall be hot dip galvanised .

PROJECT SECTION-VI,
2.08.00 Conduits, Fittings & Accessories

Conduits, Pipes and Accessories Galvanised heavy duty steel conduits for normal
area and galvanised heavy duty steel conduits with an additional epoxy coating for
corrosive area shall be offered. Alternatively glass reinforced epoxy conduits with
comparable compressive and impact strength with that of heavy duty steel conduits
may be offered.
2.08.01 Rigid Steel Conduits
(a.) Rigid steel conduits shall be heavy duty type,hot dip galvanised conforming to
IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses, threaded
on both sides and threaded length shall be protected by zinc rich paint.
Conduits shall be smooth from inside and outside.
2.08.02 Flexible Steel Conduits
2.08.03 Flexible conduit shall be water proof and rust proof made of heat resistant lead
coated steel.
2.08.04 Pull-out Boxes
2.09.00 Pull out boxes shall be provided at approximately 4 (four) metre interval in a conduit
run .Boxes shall be suitable for mounting on Walls, Columns, Structures, etc.. Pull-
out boxes shall have cover with screw and shall be provided with good quality gasket
lining. Pull out boxes shall be weather proof type suitable for IP :55 degree of
protection. Pull out box & its cover shall be hot dip galvanised.
2.10.00 Lighting Wires
2.10.01 Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed, stranded
copper/aluminium wire for fixed wiring installation. colour of the PVC insulation of
wires shall be Red, Yellow, Blue and Black for R,Y,B phases & neutral, respectively
and white & grey for DC positive & DC negative circuits, respectively. Minimum size
of wire shall not be less than 1.5.sq.mm. for copper and 4 sq.mm. for aluminium. The
size of the lighting wires/ cables shall be selected such that the total voltage drop
from the LDB to the lighting fixture / receptacle does not exceed 3%.
2.11.00 Lighting Poles
2.11.01 The poles wherever required shall be of ERW tubes of specified lengths, stepped
tubular or swaged tubular and joined together. Lighting poles shall be painted with
two coats of red Oxide and Zinc chromate in Synthetic compound primer on the
exposed outside surface and with Bituminous paint all along the inside of the pole
and outside portion which shall be embedded in foundation at manufacturing stage.
2.12.00 Lighting Masts
2.12.01 Each lighting mast shall be provided with minimum 12 nos. of 2x400W HPSV
fixtures. Lighting Masts shall be of continuously tapered polygonal cross section hot
dip galvanised presenting a pleasing appearance. The Mast shall be of 30M height
with lantern carriage to enable raising / lowering for ease of maintenance, including
PROJECT SECTION-VI,
the Head Frame, Double Drum Winch, continuous stainless steel wire rope, in built
power tool, luminaries, suitable aviation warning light, lightning along with necessary
power cables within the mast. The mast shall be delivered only in three sections &
shall be joined together by slip stressed fit method at site. No site welding or bolted
joints shall be done on the mast.
2.13.00 Lighting fixtures shall generally be group controlled directly from lighting panel.
However, in office areas, control shall be provided through switch boxes. Each
switch shall control a maximum of three fluorescent fixtures.
2.14.00 Wiring shall run throughout in separate conduits. Wires of different phases shall run
in different conduits. Wiring for lighting circuits and receptacle circuits shall be
carried out in separate conduits and from separate feeders.
2.15.00 Lighting panels etc. shall be earthed by two separate and distinct connections with
earthing system. Switch boxes, junction boxes, lighting fixtures, fans, single phase
receptacles etc. shall be earthed by means of separate earth continuity conductor.
The earth continuity conductor 14 SWG GI wire shall be run alongwith each conduit
run. Cable armours shall be connected to earthing system at both the ends.
3.00.00 TESTS
3.01.01 All lighting fixtures, lamps and other items shall be subjected to acceptance and
routine test, as per relevant specified standards.
3.01.02 Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to
physical and dimensional checks.
3.02.00 Galvanizing Tests
3.02.01 The quality of galvanizing shall be smooth, continuous, free from flux stains and shall
be inspected visually.
3.03.00 In addition following tests shall be conducted as acceptance tests.
(a.) Uniformity of coating - The coating of any article shall withstand four 1minute
dips in standard copper sulphate solution without the formation of an adherent
red spot of metallic copper upon the basic metal.
(b.) The quality of cadmium/zinc plating on items with screw threads shall be free
from visible defects such as unplated areas, blisters and modules and shall be
inspected visually.
(c.) In addition, the plating thickness shall be determined

microscopically/chemically or electronically.

PROJECT SECTION-VI,
4.00.00 COMMISSIONING CHECKS
1. On completion of installation work, the Contractor shall request the Project

manager for inspection and test with minimum of fourteen (14) days
advance notice.
2. The Project manager shall arrange for joint inspection of the installation for
completeness and correctness of the work. Any defect pointed out during
such inspection shall be promptly rectified by the Contractor.
3. The installation shall be then tested and commissioned in presence of the

Project manager.
4. The contractor shall provide all, men material and equipment required to
carry out the tests.
5. All rectifications, repair or adjustment work found necessary during

inspection, testing and commissioning shall be carried out by the
Contractor without any extra cost. The handing over the lighting installation
shall be effected only after the receipt of written instruction from the
Employer/his authorized representative.
6. The testing shall be done in accordance with the applicable Indian

Standards and codes of practices. The following tests shall be specifically
carried out for all lighting installation.
(a) Insulation Resistance.
(b) Testing of earth continuity path.
(c) Polarity test of single phase switches.
(d) Functional checks.
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.

PROJECT SECTION-VI,
ANNEXURE-A
Sl No. Location Average Type of Fixture

Illumination
Level(Lux)
(a) Switchgear rooms 200 Industrial trough type

fluorescent
(b) Control room, 300 Mirror optics with anti-glare

computer room, features
control equipment
room
(c) Offices, conference 300 Decorative mirror optics type

rooms,etc.
(d) Battery rooms 100 Totally enclosed corrosion

proof
(e) Transformer yard 10(general) HPSV flood light

50(on
equipment)
(f) Diesel generating 150 HPSV medium bay/Industrial

room, Compressor trough type fluorescent
room, pump house
etc.
(g) Fuel oil pump house 150 Flame proof fluorescent

fixtures suitable for division-2
hazardous area
(h) Cable galleries 50 Industrial trough type

fluorescent
(i) Street lighting-
primary roads - 20 HPSV street lights
secondary roads 10 Degree of Protection IP54
(j) Outdoor storage 20 HPSV flood light

handlingand
unloading area

PROJECT SECTION-VI,
(k) DM plant,water 150 Industrial trough

treatment plant type/corrosion proof
fluorescent
(l) Chemical stores 150 Corrosion proof fluorescent
(m) Permanent stores 150 Industrial trough type/HPSV
(n) Workshop.general 150 Industrial trough type

work bench fluorescent
(o) Laboratory
General 150 Mirror optics fluorescent
Analysis area 300 Corrosion resistant,

fluorescent
(p) Garage/Car Parking 50 Industrial trough type

fluorescent
(q) Switchyard and all 20(general HPSV flood light

outdoor areas
50(on strategic
equipment)
(r) Stone picking area 300 HPSV dust tight well glass
fixture (flood light type)
(s) Transfer points, 100 HPSV dust tight medium bay

crusher house, track or well glass fixture.
hopper, track hopper
shed, tunnels, bunker
house.
(t) Conveyor galleries 70 HPSV dust tight well glass

fixture.
(u) Stair cases 100 Min. one fixture at every

landing.
NOTE:- Any additional fixtures required to take care of the dark patches /
shadows shall also be provided.

PROJECT SECTION-VI,
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PROJECT
STANDARD
TITLE
GINERALARRANGEMINT
t}F STREIT LIGHTINGPOLTS
SIZE 5L:ALL uKG.N().0000-a17-PDE-A_001 IEV. NO.
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S.TANDARD
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TITLE. . 11: -i
G.A. OF STREET LIGHTING POLE TYPE-A2 & A3. i
SIZE SCALE DRG. NO. 0 0 0 0 - 2 1 7 - p t ~ ~ - ~ - 0 0 2 R3'. '-3.
A4 NTS SH. I OF 1
b.
m q
OLE
VIEW-AA
I
FOR POLE TYPE- C1 8 E2
G.I. CONDUIT
FALSE
FIXTURE
- TYPICAL FIXING DETAIL OF R E C E S S E D I IGHTING

FIXTURE IN FALSE CEILING AREA
(TYPE-BJ
WALL MOUNTING (TYPE-J) CEIL!NG MOUNTING (TYPE-5:J
STRUCTURE STEEL
STRUCTURE MOUNTING (TYPE- L) G.I. CONDI; i
COLUMN MOUNTING (TYPE-M)

ANCHOR FASTNER
SUITABLE BRICK
MASONARY BLOCK
CONTROL GEAR BOX FLEXIBLE CONDUIT
G.1 CONDUIT
ROOF MOUNTING (TYPE-P)
M.S. ANGLE 50X50X6
M.S. ANGLE 5 0 X 5 0 X 6
CONTROL GEAR BOX
COLUMN MOUNTING (TYPE-Q)
ALL DIMENSIONS ARE IN MM.

WALL MOUNTING (TYPE-S)
NOTES:
ALL DIMENSIONS ARE IN MM
NTPC
- . Limited
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PROJECT
STANDARD
TITLE TYPICAL MOUNTING DETAIL OF
AREA LIGHTING FIXTURES 7
sm ORG-
0000-2 17 -POE-A-O~ 1
REV. NO.
A4 NTS SH. 17 OF 20
R:B
GALVANISED M S PLATE
1 5 0 W X 2 0 0 L X 6 THK
WELDED TO CONDUIT
ELEVATION SIDE VIEW
DETAIL- ' A '
10 DIA HOLE
F O R M 8 8017
GALVANISED M S PLATE
1 5 0 W X 2 0 0 L X 6 THK
WELDED TO CONDUIT
L17.DWG
55
P U : iDVhIlL- JN
P U T HCUNTFD I ANTFRN TYPF-FL
I D C D TO FQE
PCC FDLNI!AT!IN
POST MDUNTED Fl n f l D I IGHT TYPE-
LS DVG , L
56
I NOTES: I
. S I Z E OF STEEL FOR1
a) SINGLE RUN OF CONDUIT-
25x5 HS FLAT.
b) TWO t THREE RUNS OF CONDUIT-
2 5 X 2 5 X 3 MS ANGLE.
C) FOUR RUNS OF CONDUIT ONWARD-
3 5 X 3 5 X 6 MS ANGLE.
A L L STEEL FABRICATION S H A L L BE
P A I N E D WITH COATS OF METAL
PRIMER FOLLOWED BY THE TWO
E A T S OF AL. PAINT.
L2O.DWG I..
-u.
CABLING, EARTHING & LIGHTNING PROTECTION
latest editions including all applicable official amendments and revisions as on date of
opening of bid. In case of conflict between this specification and those (IS codes,
standards, etc.) referred to herein, the former shall prevail. All work shall be carried
out as per the following standards/ codes as applicable.
IS:513 Cold rolled low carbon steel sheets and strips.
IS:802 Code of practice for the use of Structural Steel in Overhead

Transmission Line Towers.
IS:1079 Hot Rolled carbon steel sheet & strips
IS:1239 Mild steel tubes, tubular and other wrought steel fittings
IS:1255 Code of practice for installation and maintenance of power cables

upto and including 33 KV rating
IS:1367 Part- Technical supply conditions for threaded Steel fasteners. (Hot dip
13 galvanized coatings on threaded fasteners).
IS:13947 Degree of protection provided by enclosures for low voltage

switchgear and control gear
IS:2309 Code of Practice for the protection of building and allied structures
against lightning.
IS:2629 Recommended practice for hot dip galvanising of iron & steel
IS:2633 Method for testing uniformity of coating on zinc coated articles.
IS:3043 Code of practice for Earthing
IS:3063 Fasteners single coil rectangular section spring washers.
FARAKKA SUPER THERMAL POWER TECHNICAL SPECIFICATION SUB-SECTION-IIIB-08

SECTION-VI, CABLING EARTHING PAGE
PROJECT
PART-B & LIGHTNING 1 OF 22
COAL CONVEYING PLANT PACKAGE PROTECTON
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 for working voltages
from 6.6kv upto and including 33kv performance requirements and
type tests.
BS:476 Fire tests on building materials and structures
IEEE:80 IEEE guide for safety in AC substation grounding
IEEE:142 Grounding of Industrial & commercial power systems
DIN 46267 Non tension proof compression joints for Aluminium conductors.
(Part-II)
DIN 46329 Cable lugs for compression connections, ring type ,for Aluminium
conductors
VDE 0278 Tests on cable terminations and straight through joints
BS:6121 Specification for mechanical Cable glands for elastomers and

plastic insulated cables.
Indian Electricity Act.
Indian Electricity Rules.

PROJECT
1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS,
DIN, USA, VDE etc. will also be considered if they ensure performance and
constructional features equivalent or superior to standards listed above. In such a
case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in
English of the latest revision of the standards alongwith copies of all official
amendments and revisions in force as on date of opening of bid and shall clearly
bring out the salient features for comparison.
2.00.00 DESIGN AND CONSTRUCTIONAL FEATURE

2.01.00 Transformer yard and Switchyard
In transformer yard and switchyard area, cables shall be laid in RCC concrete
trenches with RCC covers. Inter-pole cabling in switchyard shall be in GI
conduits/shallow trenches. Minimum clear height of trestle shall be 3mtr and for
Rail/road crossing it shall be as per rail/road crossing norms.
2.01.01 False floors are not to be provided for cabling purpose.

2.01.02 Cable entry
Cable entry from outdoor underground/cable routes to the buildings, if any, shall be
above the finished floor level of the building to avoid water entry in to the room
through the trenches.
2.01.03 Trenches
PCC flooring of built up trenches shall be sloped for effective drainage with sump
pits and sump pumps.
2.01.04 Interplant cabling for main routes shall be laid along overhead trestles/duct banks.
However, from tap-offs, same can be through shallow trenches with approval of
Employer. In case of Duct banks, pull-pits shall be filled with sand and provided with
a PCC covering. Directly buried cables, if essential, shall not have concentration of
more than 4 cables in one route. For overhead trestles, the bottom of the steel
supporting structure shall be generally at 3.0M above the grade level except for
rail/road crossings where it shall be at 8.0M above grade level.
All overhead cable routes shall be along the route of the conveyor gallery on
separate supporting structures and cables shall be laid in vertical trays. The bottom
of the steel shall be such that the existing facilities, movement of trucks / human
beings etc. does not get affected. The cable trestle shall have a minimum 600mm
clear walk way and shall have maintenance platforms as required.
Cables shall not be routed through the conveyor galleries except for the equipment
located in the conveyor galleries for a particular conveyor i.e. protection switches,
etc.
Cables for PCS and BSS shall be routed along the conveyors through GI conduits.
2.-01.05 Cable trenches shall be provided only in Switchgear/MCC rooms.

PROJECT
3.00.00 EQUIPMENT DESCRIPTION
3.01.00 Cable trays, Fittings & Accessories
3.01.00 Cable trays shall be ladder type for power cables & perforated type for control
cables complete with matching fittings (like brackets, elbows, bends, reducers, tees,
crosses, etc.) accessories (like side coupler plates, etc. and hardware (like bolts,
nuts, washers, G.I. strap, hook etc.) as required.
3.01.01 Cable trays, fittings and accessories shall be fabricated out of rolled mild steel
sheets free from flaws such as laminations, rolling marks, pitting etc. These
(including hardware) shall be hot dip galvanized as per relevant IS. Cable trays shall
be ladder type for power/control cables and shall be perforated type for
instrumentation cables.
3.01.02 Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard
lengths of 2.5 metre. Minimum thickness of mild steel sheets used for fabrication of
cable trays and fittings shall be 2 mm. The thickness of side coupler plates shall be
minimum 3 mm. Typical details of cable trays, fittings and accessories are shown in
the enclosed drawings
3.01.03 Cable troughs shall be required for branching out few cables from main cable route.
These shall be U-shaped, fabricated of mild steel sheets of minimum thickness 2
mm and shall be hot dip galvanised as per relevant IS. Troughs shall be standard
width of 50 mm & 75 mm with depth of 25 mm
3.02.00 SUPPORT SYSTEM FOR CABLE TRAYS
3.02.00 Cable tray support system shall be pre-fabricated similar or equivalent to "Unistrut
make”.
3.02.01 Support system for cable trays shall essentially comprise of the two components i.e.
main support channel and cantilever arms. The main support channel shall be of
two types: (i) C1:- having provision of supporting cable trays on one side and (ii)
C2:-having provision of supporting cable trays on both sides. The support system
shall be the type described hereunder
a. Cable supporting steel work for cable racks/cables shall comprise of

various channel sections, cantilever arms, various brackets, clamps, floor
plates, all hardware such as lock washers, hexagon nuts, hexagon head
bolt, support hooks, stud nuts, hexagon head screw, channel nut, channel
nut with springs, fixing studs, etc.
b. The system shall be designed such that it allows easy assembly at site by
using bolting. All cable supporting steel work, hardware fittings and
accessories shall be prefabricated factory galvanised.
c. The main support and cantilever arms shall be fixed at site using
necessary brackets, clamps, fittings, bolts, nuts and other hardware etc.
to form various arrangements required to support the cable trays. Welding
PROJECT
of the components shall not be allowed. However, welding of the bracket

(to which the main support channel is bolted) to the overhead beams,
structural steel, insert plates or reinforcement bars will be permitted. Any
cutting or welding of the galvanised surface shall be brushed and red lead
primer, oil primer & aluminium paint shall be applied.
d. All steel components, accessories, fittings and hardware shall be hot dip
galvanised after completing welding, cutting, drilling and other machining
operation.
e. The typical arrangement of flexible support system is shown in the

enclosed drawings and described briefly below:
The main support channel and cantilever arms shall be fabricated out of
minimum 2.5 thick rolled steel sheet conforming to IS.
f. Cantilever arms of 300 mm, 600 mm and 750 mm in length are required,
and shall be as shown in the enclosed drawing. The arm portion shall be
suitable for assembling the complete arm assembly on to component
constructed of standard channel section. The back plate shall allow
sufficient clearance for fixing bolt to be tightened with tray in position.
3.02.02 The size of structural steel members or thickness of sheet steel of main support
channel and cantilever arms and other accessories as indicated above or in the
enclosed drawings are indicative only. Main support channels may be supplied in any
suitable lengths to minimise the wastage. Nevertheless, the support system shall be
designed by the bidder to fully meet the requirements of type tests as specified. In
case the system fails in the tests, the components design modification shall be done
by the Bidder without any additional cost to the Employer.
3.03.00 Pipes, Fittings & Accessories
3.03.00 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
3.03.01 GI Pipes shall be of medium duty as per IS:1239
3.04.00 Junction Boxes
(a) Junction Boxes shall be made of Fire retardant material. Material of JB shall be
thermoplastic or thermosetting or FRP type. The box shall be provided with the
terminal blocks, mounting bracket and screws etc. the cable entry shall be
through galvanized steel conduits of 20 mm diameter. The JB shall have suitable
for installing glands of suitable size on the bottom of the box. The JB shall be
suitable for surface mounting on ceiling/structures. The JB shall be of grey in
color RAL 7035. All the metal parts shall be corrosion protected. Junction boxes
surface should be such that it is free from crazing, blistering, wrinkling, color
blots/striations. There should not be any mending or repair of surface. JB’s will
be provided with captive screws so that screws don’t fall off when cover is
opened. JB’s mounting bracket should be of powder coated MS.
PROJECT
3.04.00 Terminal blocks shall be 650 volts grade, 10 Amps rated, made up of unbreakable
polyamide 6.6 grade, complete with insulating barriers. Clip on type terminals,
washer, nuts and identification strips. Marking on terminal strips shall correspond to
the terminal numbering in wiring diagrams. All metal parts shall be non ferrous.
WAGO terminal of cage clamp with lugs shall also be acceptable. All terminal blocks
shall be suitable for terminating on each side two (2) nos. stranded copper
conductors of size up to 2.56 sq mm each.
3.05.00 Terminations & Straight Through Joints
3.05.00 Termination and jointing kits for 6.6 kV grade XLPE insulated cables shall be of
proven design and make which have already been extensively used and type tested.
Termination kits and jointing kits shall be pre-moulded type, taped type or heat
shrinkable type. 6.6 kV grade joints and terminations shall be type tested as per IS-
13573. Critical components used in cable accessories shall be of tested and proven
quality as per relevant product specification/ESI specification. Kit contents shall be
supplied from the same source as were used for type testing. The kit shall be
complete with the aluminium solder less crimping type cable lugs & ferrule as per
DIN standard.
3.05.01 Straight through joint and termination shall be capable of withstanding the fault level
of 40 kA for 0.12 sec with a dynamic peak of 100 kA for 6.6 kV system. Straight
through joints shall have provisions for shield connection and earthing wherever
required and complete with all accessories and consumables suitable for storage
without deterioration at a temperature of 50 deg. C with shelf life of more than five
years. 1.1 kV grade straight through joints shall also be of proven design.
3.05.02 1.1 KV grade STJ shall be of proven design.
3.05.04 Motor terminal boxes should of sufficient size to accommodate the selected cables.
In case the cable sizes can not be accommodated, power Junction boxes shall be
provided with cable interconnection between Junction boxes and motor terminal box.
3.06.00 Cable glands
3.06.00 Cable shall be terminated using double compression type cable glands. Cable glands
shall conform to BS:6121 and be of robust construction capable of clamping cable
and cable armour firmly without injury to insulation. Cable glands shall be made of
heavy duty brass machine finished and nickel chrome plated. Thickness of plating
shall not be less than 10 micron. All washers and hardware shall also be made of
brass with nickel chrome plating Rubber components shall be of neoprene and of
tested quality.
3.06.01 Cable lugs/ferrules
3.06.02 Cable lugs for power cables shall be tinned copper solder less crimping type
conforming to IS: 8309 suitable for aluminium compacted conductor cables. Cable
lugs and ferrules for control cables shall be tinned copper conforming to IS:8309 . The
cable lugs for control cables shall be provided with insulating sleeve and shall suit the
type of terminals provided on the equipments.

PROJECT
3.07.00 Trefoil clamps
3.07.00 Trefoil clamps for single core cables shall be pressure die cast aluminum or fiber
glass or nylon and shall include necessary fixing accessories like G.I. nuts, bolts,
washers, etc. Trefoil clamps shall have adequate mechanical strength to withstand the
forces generated by the system short circuit current of 105 KA peak.
3.08.00 Cable Clamps & Straps
3.08.00 The cable clamps required to clamp multicore cables on vertical run shall be made
up of Aluminium strip of 25x3 mm size. For clamping the multicore cables, self-
locking, de-interlocking type nylon clamps/straps shall be used. The clamps/straps
shall have sufficient strength and shall not get affected by direct exposure to sun
rays and outdoor environment
3.09.00 Receptacles
3.09.00 Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot
dipped gavanised or of die-cast aluminium alloy of thickness not less than 2.5 mm.
The boxes shall be provided with two nos. earthing terminals, gasket to achieve
IP55 degree of protection, terminal blocks for loop-in loop-out for cable of specified
sizes, mounting brackets suitable for surface mounting on wall/column/structure,
gland plate etc. The ON-OFF switch shall be rotary type heavy duty double break,
AC23 category, suitable for AC supply. Plug and Socket shall be shrouded Die-cast
Aluminium. Socket shall be provided with lid safety cover. Robust mechanical
interlock shall be provided such that the switch can be put ON only when the plug is
fully engaged and plug can be withdrawn only when the switch is in OFF position.
Also cover can be opened only when the switch is in OFF position. Wiring shall be
carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of
adequate size. The Terminal blocks shall be of 750 V grade
3.10.02 For Coal Handling Plant 415V TPN 63A welding sockets with switch having degree
of protection of IP-55 shall be provided in the following areas.
1) 1 Number on each floor of TPs and 2 nos. on each floor of the crusher house
building.
2) At 50m interval (starting from one end) on both sides of the conveyor galleries.
At 50m interval on one side of the yard conveyor.
3) 1 no. in each Switchgear / MCC rooms and Pump house and in stacker /
reclaimer machines.
4) Maximum three (3) nos. of receptacles can be connected to one circuit.

These receptacles shall be energised through welding distribution board.

PROJECT
3.10.00 Galvanising
3.10.00 Galvanising of steel components and accessories shall conform to IS:2629, IS:2633
& IS 4759. Additionally galvanising shall be uniform, clean smooth, continuous and
free from acid spots
3.10.01 The amount of zinc deposit over threaded portion of bolts, nuts, screws and
washers shall be as per IS:1367. The removal of extra zinc on threaded portion of
components shall be carefully done to ensure that the threads shall have the
required zinc coating on them as specified. However nuts and bolts of size lesser
than M12 can be electro galvanised / electro plated.
3.11.00 Welding
3.11.00 The welding shall be carried out in accordance with IS: 9595. All welding procedures
and welders qualification shall also be followed strictly in line with IS:9595
3.12.00 EXPANSION FASTNER
3.12.00 Expansion Fastener shall be 'HILTI' make HSA-KA type or equivalent. Expansion
fastener shall only be used wherever insert plates are not available for supporting
the cable structure.
4.00.00 INSTALLATION
4.01.00 Cable tray and Support System Installation
4.01.00 Cables shall run in cable trays mounted horizontally or vertically on cable tray
support system which in turn shall be supported from floor, ceiling, overhead
structures, trestles, pipe racks, trenches or other building structures. All cable trays
shall be in vertical configuration in boiler, CHP & ESP areas.
4.01.01 Horizontally running cable trays shall be clamped by bolting to cantilever arms at an
interval of 2000 mm. Vertically running cable trays shall be bolted to main support
channel by suitable bracket/clamps on both top and bottom side rails at an interval
of 2000 mm. For vertical cable risers/shafts cable trays shall be supported at an
interval of 1000mm. Fixing of cable trays to cantilever arms or main support
channel by welding shall not be accepted. Cable tray installation shall generally be
carried out as per the enclosed drawings.
4.01.02 The cantilever arms shall be positioned on the main support channel with a
minimum vertical spacing of 300 mm unless otherwise indicated in the relevant tray
layout drawings
4.01.03 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.
PROJECT
4.01.04 In certain cases it may be necessary to site fabricate portions of trays, supports and
other non standard bends where the normal prefabricated trays, supports and
accessories may not be suitable. In such cases the Contractor shall fabricate at site
suitable sections of trays, supports and accessories to make the installation
complete for the specific purpose after obtaining Project Manager's prior approval,
which shall be neat in appearance and shall match with the prefabricated sections in
the dimensions. They shall be applied with one coat of red lead primer, one coat of
oil primer followed by two finishing coats of aluminium paint.
4.02.00 Conduits/Pipes/Ducts Installation
4.02.00 The Contractor shall be fully responsible for properly embedding conduit pipe
sleeves wherever necessary for cabling work. All openings in the floor/roof/wall /
cable tunnel/cable trenches made for conduit installation shall be sealed and made
water proof by the Contractor.
4.02.01 GI pull wire of adequate size shall be laid in all conduits before installation. Metallic
conduit runs at termination shall have two lock nuts wherever required for junction
boxes etc.
4.02.02 Conduit runs/sleeves shall be provided with PVC bushings having round edge at
each end. All conduits/pipes shall have their ends closed by caps until cables are
pulled. After cables are pulled, the ends of conduits/pipes shall be sealed with
Glass wool/Cement Mortar/Putty to prevent entrance of moisture and foreign
material
4.02.03 Exposed conduit/pipe shall be adequately supported by racks, clamps, straps or by

other approved means. Conduits /pipe support shall be installed square and true to
line and grade with an average spacing between the supports as given below,
Conduit /pipe size (dia). Spacing
Upto 40 mm 1M
50 mm 2.0 M
65-85 mm 2.5 M
100 mm 3.0 M
4.02.04 For bending of conduits, bending machine shall be arranged at site by the
contractor to facilitate cold bending. The bends formed shall be smooth.
4.03.00 Junction Boxes Installation
4.03.00 Junction boxes shall be mounted at a height of 1200mm above floor level or as
specified in the drawings or as decided by Project Manager and shall be adequately
supported/mounted on masonry wall by means of anchor fasteners/ expandable bolts

PROJECT
or shall be mounted on an angle, plate or other structural supports fixed to floor, wall,
ceiling or equipment
4.03.01 Cable Installation (for cables upto & including 6.6kV grade)
4.03.02 Cable installation shall be carried out as per IS:1255 and other applicable standards.
Cable drums shall be unloaded, handled and stored in an approved manner on hard
and well drained surface so that they may not sink. In no case shall be drum be
stored flat i.e. with flange horizontal. Rolling of drums shall be avoided as far as
possible. For short distances, the drums may be rolled provided they are rolled
slowly and in proper direction as marked on the drum. In absence of any indication,
the drums may be rolled in the same direction as it was rolled during taking up the
cables. For unreeling the cable, the drum shall be mounted on suitable jacks or on
cable wheels and shall be rolled slowly so that cable comes out over the drum and
not from below. All possible care shall be taken during unreeling and laying to avoid
damage due to twist, kink or sharp bends. Cable ends shall be provided with sealed
plastic caps to prevent damage and ingress of moisture.
4.03.03 While laying cable, ground rollers shall be used at every 2 mtr interval to avoid cable
touching ground. The cables shall be pushed over the rollers by a gang of people
positioned in between the rollers. Cables shall not be pulled from the end without
having intermediate pushing arrangements. Pulling tension shall not exceed the
values recommended by cable manufacturer. Selection of cable drums for each run
shall be so planned so as to avoid using straight through joints. Care should be taken
while laying the cables so as to avoid damage to cables. If any particular cable is
damaged, the same shall be repaired or changed to the satisfaction of Project
Manager.
4.03.04 Cables shall be laid on cable trays strictly in line with cable schedule furnished.
Where specific cable layouts are not shown on drawings, Contractor shall route
these as directed by the Project Manager
4.03.05 Power and control cables shall be laid on separate tiers. The laying of different
voltage grade cables shall be on different tiers according to the voltage grade of the
cables. In horizontal tray stacks, H.T. cables shall be laid on topmost tier and cables
of subsequent lower voltage grades on lower tiers of trays. Single core cable in trefoil
formation shall be laid with a distance of four times the diameter of cable between
trefoil center lines and clamped at every 2mtr. All multicore cables shall be laid in
touching formation. Power and control cables shall be secured fixed to trays/support
with self locking type nylon cable straps with de-interlocking facilities. For horizontal
trays arrangements, multicore power cables and control cables shall be secured at
every five meter interval. For vertical tray arrangement, individual multicore power
cables and control cables shall be secured at every one meter by nylon cable strap.
After completion of cable laying work in the particular vertical tray, all the control
cables shall be binded to trays/supports by aluminium strips at every five meter
interval and at every bend.
4.03.06 Bending radii for cables shall be as per manufacturer’s recommendations and
IS:1255.
4.03.07 Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/PVC pipe.

PROJECT
4.03.08 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.
4.03.09 Wherever few cables are branching out from main trunk route troughs shall be used.
4.03.10 The installation work shall be carried out in a neat workman like manner & areas of
work shall be cleaned of all scraps, water, etc. after the completion of work in each
area every day. Contractor shall replace RCC/Steel trench covers after the
Installation work in that particular area is completed or when further work is not likely
to be taken up for some time.
4.03.11 Separation
In vertically stacked trays, at least 300mm clearance shall be provided between :

- HT power & LT power cables,
- LT power & LT control cables
4.03.12 Segregation
1) Segregation means physical isolation to prevent fire jumping.

2) All the cables of one stream shall be segregated from the cables of the other
stream and shall run on either side of the trestle.
4.03.13 All field switches for equipments corresponding to a stream located within a radius of
4-5 mtr. shall be wired out to a field junction box and from field junction box to control
panel/Input – Output cabinet by screened instrumentation cables.
4.03.14 Directly Buried Cables
a) Cable trenches shall be constructed for directly buried cables.

Construction of cable trench for cables shall include excavation,
preparation of sieved sand bedding, riddled soil cover, supply and
installation of brick or concrete protective covers, back filling and
compacting, supply and installation of route markers and joint markers.
Laying of cables and providing protective covering shall be as per IS:1255
and the enclosed drawings showing cabling details.
b) RCC cable route and RCC joint markers shall be provided wherever
required. The voltage grade of the higher voltage cables in route shall be
engraved on the marker. Location of underground cable joints shall be
indicated with cable marker with an additional inscription “Cable Joint”.
The marker shall project 150 mm above ground and shall be spaced at an
interval of 30 meters and at every change in direction. They shall be
located on both sides of road crossings and drain crossings. Top of cable
marker/joint marker shall be sloped to avoid accumulation of water/dust
on marker.
4.03.15 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
PROJECT
provided inside the switchgear, motor control centers, control and relay panels etc.
where a number of cables enter together through a gland plate. Cable tag shall be
of rectangular shape for power cables and control cables. Cable tag shall be of 2
mm thick aluminum with number punched on it and securely attached to the cable
by not less than two turns of 20 SWG GI wire conforming to IS:280. Alternatively,
the Contractor may also provide cable tags made of nylon, cable marking ties of
‘TY-CAB’ or equivalent type with cable number heat stamped on the cable tags
4.03.16 While crossing the floors, unarmoured cables shall be protected in conduits upto a
height of 500 mm from floor level if not laid in tray.
4.04.00 Cable Terminations & Connections
4.04.00 The termination and connection of cables shall be done strictly in accordance with
cable termination kit manufacturer’’ instructions, drawings and/or as directed by
Project Manager. Cable jointer shall be qualified to carryout satisfactory cable
jointing/termination. Contractor shall furnish for review documentary
evidence/experience reports of the jointers to be deployed at site.
4.04.01 Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumbing,
soldering, drilling, cutting, taping, preparation of cable end, crimping of lug, insulated
sleeving over control cable lugs, heat shrinking (where applicable), connecting to
cable terminal, shorting and grounding as required to complete the job to the
satisfaction of the Project Manager.
4.04.02 The equipment will be generally provided with undrilled gland plates for
cables/conduit entry. The Contractor shall be responsible for punching of gland
plates, painting and touching up. Holes shall not be made by gas cutting. The holes
shall be true in shape. All cable entry points shall be sealed and made vermin and
dust proof. Unused openings shall be effectively sealed by 2mm thick aluminium
sheets.
4.04.03 Control cable cores entering control panel/switchgear/MCC/miscellaneous panels

shall be neatly bunched, clamped and tied with self locking type nylon cable ties
with de interlocking facility to keep them in position.
4.04.04 The panels where a larger number of cables are to be terminated and cable
identification may be difficult, each core ferrule shall include the complete cable
number as per the drawings. The ferrules shall be indelible interlocking type and
shall fit tightly on cores. Spare cores shall have similarly ferrules with a suffix letter
‘S’ alongwith cable numbers and coiled up after end sealing.
4.04.05 All cable terminations shall be appropriately tightened to ensure secure and reliable
connections.
4.04.06 It is the responsibility of the Contractor to terminate the cables at motor terminals in
correct phase sequence to ensure the proper direction of rotation.

PROJECT
5.00.00 EARTHING SYSTEM
5.01.00 Earthing system shall be in strict accordance with IS: 3043 and Indian Electricity
Rules/Acts.
All buildings / structures shall be interconnected together by min. two parallel

conductors. Contractor shall furnish the detailed design calculations for the earthing
system. Contractor shall obtain all necessary approvals for the system.
5.02.00 The earth conductors shall be free from pitting, laminations, rust, scale and other
electrical, mechanical defects
5.03.00 The material of the earthing conductors shall be as follows :
1) Conductors above ground level and in built up - Galvanized steel

trenches.
2) Conductors buried in earth - Mild steel
3) Earth electrodes - Mild steel rod
5.04.00 The sizes of earthing conductors for various electrical equipments shall be as below:
Equipment Earth Earth conductor

conductor above ground
buried in earth level & in built-
up trenches
a) Main earth grid 40 mm dia.MS 65x8mm GS flat

rod
b) 33KV/11KV --- 65x8mm GS flat

switchgear/equipment 415V
switchgear
c) 6.6 kV switchgear / 415 V --- 50x6mm GS flat

MCC/ Distribution boards /
Transformers
d) LT Motors above 125 KW --- 50 x 6mm GS

flat
25 KW to 125 KW --- 25 x 6mm GS

flat

PROJECT
1KW to 25 KW --- 25 x 3mm GS

flat
Fractional House power motor --- 8 SWG GS wire
e) Control panel & control desk --- 25 x 3 mm GS

flat
f) Push button station / Junction --- 8 SWG GI wire

Box
g) Columns, structures, cable --- 50x6mm GS flat

trays and busduct enclosures
h) Crane, rails, rail tracks & other 25x6mm GS flat

non-current carrying metal
parts
5.05.00 Metallic frame of all electrical equipment shall be earthed by two separate and
distinct connections to earthing system, each of 100% capacity, Crane rails, tracks,
metal pipes and conduits shall also be effectively earthed at two points. Steel RCC
columns, metallic stairs, and rails etc. of the building housing electrical equipment
shall be connected to the nearby earthing grid conductor by one earthing ensured by
bonding the different sections of hand rails and metallic stairs. Metallic
sheaths/screens, and armour of multi-core cables shall be earthed at both ends.
Metallic Sheaths and armour of single core cables shall be earthed at switchgear end
only unless otherwise instructed by the Employer. Every alternate post of the
switchyard fence shall be connected to earthing grid by one GS flat and gates by
flexible lead to the earthed post. Railway tracks within the plant area shall be bonded
across fish plates and connected to earthing grid at several locations. Portable tools,
appliances and welding equipment shall be earthed by flexible insulated cable. One
separate core in the trailing/flexible cables shall be used for earthing purposes of the
moving machines. PLC equipment shall be earthed separately as per the
recommendations of the PLC manufacturer.
5.06.00 Each continuous laid lengths of cable tray shall be earthed at minimum two places by
G.S. flats to earthing system, the distance between earthing points shall not exceed
30mtr. Wherever earth mat is not available Contractor shall do the necessary
connections by driving an earth electrode in the ground.
5.07.00 Neutral points of HT transformer shall be earthed through NG resistors. The

Contractor shall connect the NGR earthing point to earth electrodes by suitable earth
conductors.
5.08.00 Neutral connections and metallic conduits/pipes shall not be used for the equipment
earthing. Lightning protection system down conductors shall not be connected to
other earthing conductors above the ground level.

PROJECT
5.09.00 Connections between earth leads and equipment shall normally be of bolted type.
Contact surfaces shall be thoroughly cleaned before connections. Equipment bolted
connections after being tested and checked shall be painted with anti corrosive
paint/compound.
5.10.00 Suitable earth risers as approved by Project Manager shall be provided above
finished floor/ground level, if the equipment is not available at the time of laying of
main earth conductor.
5.11.00 Connections between equipment earthing leads and between main earthing
conductors shall be of welded type. For rust protection the welds should be treated
with red lead compound and afterwards thickly coated with bitumen compound. All
welded connections shall be made by electric arc welding.
5.12.00 Resistance of the joint shall not be more than the resistance of the equivalent length
of conductors.
5.13.00 Earthing conductors buried in ground shall be laid minimum 600 mm below grade
level unless otherwise indicated in the drawing. Back filling material to be placed
over buried conductors shall be free from stones and harmful mixtures. Back filling
shall be placed in layers of 150 mm.
5.14.00 Earthing conductors embedded in the concrete floor of the building shall have
approximately 50 mm concrete cover.
5.15.00 A minimum earth coverage of 300 mm shall be provided between earth conductor
and the bottom of trench/foundation/underground pipes at crossings. Earthing
conductor’s crossings the road can be installed in pipes. Wherever earthing
conductor crosses or runs at less than 300 mm distance along metallic structures
such as gas, water, steam pipe lines, steel reinforcement in concrete, it shall be
bonded to the same.
5.16.00 Earthing conductors along their run on columns, walls, etc. shall be supported by
suitable welding / cleating at interval of 1000mm and 750mm respectively.
5.17.00 Earth pit shall be constructed as per IS:3043. Electrodes shall be embedded below
permanent moisture level. Minimum spacing between electrodes shall be 600mm.
Earth pits shall be treated with salt and charcoal if average resistance of soil is more
than 20 ohm metre.
5.18.00 On completion of installation continuity of earth conductors and efficiency of all

bonds and joints shall be checked. Earth resistance at earth terminations shall be
measured in presence of Employer’s representatives. All equipment required for
testing shall be furnished by contractor.
5.19.00 Earthing conductor shall be buried at least 2000mm outside the fence of electrical
installations. Every alternate post of the fences and all gates shall be connected to
earthing grid by one lead.
6.00.00 LIGHTNING PROTECTION SYSTEM
6.01.00 Lightning protection system shall be in strict accordance with IS:2309

PROJECT
6.01.01 Lightning conductor shall be of 25x6mm GS strip when used above ground level
and shall be connected through test link with earth electrode/earthing system
6.01.02 Lightning system shall comprise of air terminations, down conductors, test links,
earth electrode etc. as per approved drawings
6.02.00 Down Conductors
1. Down conductors shall be as short and straight as practicable and shall

follow a direct path to earth electrode.
2. Each down conductor shall be provided with a test link at 1000 mm above
ground level for testing but it shall be in accessible to interference. No
connections other than the one direct to an earth electrode shall be made
below a test point.
3. All joints in the down conductors shall be welded type.
4. Down conductors shall be cleated on outer side of building wall, at 750

mm interval or welded to outside building columns at 1000 mm interval.
5. Lightning conductor on roof shall not be directly cleated on surface of

roof. Supporting blocks of PCC/insulating compound shall be used for
conductor fixing at an interval of 1500 mm.
6. All metallic structures within a vicinity of two meters of the conductors

shall be bonded to conductors of lightning protection system.
7. Lightning conductors shall not pass through or run inside GI Conduits.
8. Testing link shall be made of galvanized steel of size 25x 6mm.
7.00.00 QUALITY ASSURANCE PROGRAMME
7.01.00 Bidder shall furnish detailed Quality Assurance Program and Quality Plans for all
materials and accessories to be supplied and installed under the scope of the
specification as per General Technical Conditions of technical specification. The
Quality Plans shall include all tests/ checks as per relevant National/International
Standards and the requirements of this specification including tests listed in this
section.
8.00.00 TESTS
GENERAL
engineering, the contractor shall submit for Owner’s approval the reports of all
the type tests as listed in this specification and carried out within last ten years
from the date of bid opening. These reports should be for the test conducted
on the equipment similar to those proposed to be supplied under this contract
and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client.
PROJECT
equipment price.
8.01.00 Type Test reports shall be furnished for the following
8.01.00 Type tests on Cable Trays support system
Test 1: On main support channel type-C2 for cantilever arms fixed on one
side only.
a) Test 1A: A 3.5 metre length of main support channel shall be fixed vertically at
each end to a rigid structure as per the fixing arrangement as shown
in the enclosed drawing. Eight (8) nos. 750 mm cantilever arms shall
be fixed to the main channel and each arm shall be loaded over the
outboard 600 mm with a uniform working load of 100 kg.
Subsequently a point load of 100 kg shall be applied on arm 2. A
uniform proof load on all the arms equal to twice the working load
shall be then be applied. Deflections shall be measured at the points
shown in the enclosed drawings and at the following load intervals:
i) Working load
ii) Working load + point load
iii) Off load
iv) Proof load + point load
v) Off load
The deflection measured at working loads shall not exceed 16mm. The
permanent deflection after removing the combination of working load and
point load shall not exceed 10 mm at the arm tips and 6 mm on the
channel. No collapse of the structure shall occur with a combination of

PROJECT
proof load and point load applied.
b) Test 1B: Test 1A shall be repeated with Eight Cantilever arms uniformly loaded
and with the same point load on arm 2.
Test 2: On Main support channel type -C2 for cantilever arms fixed on both
sides
a)Test 2A: A 3.5 m length of main support channel C2 for cantilever arms fixing
on both sides shall be fixed at each end to rigid structure as per the
fixing arrangement as shown in the enclosed drawing. Six (6), 750
mm cantilever arms shall be attached to each sides and each arm
uniformly loaded to a working load of 100 kg over the out board 600
mm. A point load of 100 kg shall than be applied to arm 2, followed
by a uniform proof load of twice the working load on all the arms;
deflection shall be measured at points shown in the enclosed
drawings at the following load intervals.
i) Working load
ii) Working load + Point load
iii) Off load
iv) Proof load + Point load
v) Off load
The deflection measured at working loads shall not exceed 16mm.

The permanent deflection after removing the combination of working
load and point load shall not exceed 10 mm at the arm tips and 6 mm
on the channel. No collapse of the structure shall occur with a
combination of proof load and point load applied
b) Test 2 B: The test 2 A shall be repeated with the assembly but with an
asymmetrical load on the C2 column and point load applied to arm 8.
The 100 kg and 200 kg uniformly distributed loads shall be applied to
the upper three arms on one side and the lower three arms on the
opposite side.
Test 3: Tests on Channel Fixed on Beam/Floor
A length of main support channel section shall be fixed to steel structure/floor and
have loads applied as shown in the drawing enclosed and as detailed below

PROJECT
a) Test 3A : A length of steel structure shall be rigidly supported. It should be

fitted on a metre length of channel section using beam clamps
welded/bolted. A point load of 1200 kg shall be applied to the
centre point via two brackets. No distortion or pulling of the
components shall take place.
b) Test 3B : With the components assembled as in Test 3A, two perpendicular

point loads of 600 kg shall be simultaneously applied at positions
150 mm either side of the centre line, no distortion or pulling of the
components shall take place.
c) Test 3C : With the components assembled as in Test 3A, a perpendicular

point load shall be applied at a point 150 mm on one side of the
centre line.
The load shall be gradually increased to the maximum value that

can be applied without causing distortion or pulling of the
components. This value shall be recorded.
Test 4 : Channel Insert Test
A 2.5 m length of C1 channel fixed to the concrete wall/ steel structure as per
actual site installation conditions. 6 nos. of 750 mm cantilever arms shall be
attached to C1 channel as shown in enclosed drawing. Each arm uniformly
loaded to a working load of 100 kg over the out board 600 mm. A point load of
100 kg shall than be applied to arm 2, followed by a uniform proof load of twice
the working load on all the arms; deflection shall be measured at points shown
in the enclosed drawings at the following load intervals.
i) Working load
ii) Working load + Point load
iii) Off load
iv) Proof load + Point load
v) Off load
The deflection measured at working loads shall not exceed 16mm. The
permanent deflection after removing the combination of working load and point
load shall not exceed 10 mm at the arm tips and 6 mm on the channel. No
collapse of the structure shall occur with a combination of proof load and point
load applied

PROJECT
Test 5: Channel nut slip characteristics (what ever applicable)
Tests 5A1,5A2,5A3 : A length of channel C1 section 200mm long shall have

fitted bracket with the two bolts fixing as shown in
drawing enclosed.
With loads applied at the position shown in drawing

enclosed nut slip shall be determined with bolt torque of
30NM, 50 NM and 65 NM No fewer than three
measurements shall be made for each torque setting.
A minimum loading of 720 kg shall be obtained before

nut slip with bolt torque of 65 NM.
Tests 5B1,5B2,5B3: The length of channel C1 section 200 mm long shall

have fitted bracket with the one bolt fixing as shown in
drawing enclosed. With loads applied at the position
shown in drawing, nut slip shall be determined with bolt
torques of 30 NM, 50 NM and 65 NM. No fewer than
three measurements shall be made for each torque
setting.
A minimum loading of 350 kg shall be obtained before

nut slip with a bolt torque of 65 NM.
Test 6 Weld Integrity Test
After deflection test as per test 1A, 1B, 2, 3, 4 & 5, weld integrity shall be
checked by magnetic particle inspection to detect sub-surface cracks
developed, if any.
8.01.01 Cable termination kit and straight through joints should have been tested as per IS:
13573 for above 3.3 kV class and as per VDE 0278 for 3.3 kV class.
8.02.00 Routine/ Acceptance Tests
7.03.01 Routine Tests
a) Routine tests as per specification and applicable standards shall be carried

out on all equipments/items covered in the specification.
b) Physical & dimensional check on all equipments as per approved

drawings/standards.
c) HV/IR as applicable.
d) Check/measurement of thickness of paint/zinc coating/nickel-chrome plating

as per specification & applicable standard.
e)

PROJECT
7.03.02 Acceptance Test
a) Galvanising Tests as per applicable standards
b) Welding checks
c) Deflection tests on cable trays:
One piece each of 2.5m length of cable tray of 300mm & above shall be
taken as sample from each offered lot. It shall be supported at both end &
loaded with uniform load of 76 kg/meter along the length of cable tray. The
maximum deflection at the mid-span of each size shall not exceed 7mm.
d) Proof load tests on cable tray support system
i) Tests on Main Support Channel shall be done if only C1 Channel are

in scope of supply and cantilever arms shall be fitted on one side. This
test shall be same as test 4 of type test.
ii) Test on Main Support Channel shall be done with C2 channel and
cantilever arms fitted on both sides, if C2 channels are in scope of
supply. This test shall be same as test 2A of type test. Then test (i)
above shall not be done.
iii) Nut slip characteristic test (it shall support minimum load of 350kg
before nut slips with a bolt torque of 65 NM). This test shall be same
as test 5B3 of type test.
The procedure for carrying out tests at “d” above shall be as per
details given in Type Tests in specification thereafter Die-Penetration
test shall be carried out to check weld integrity.
e) The above acceptance tests shall be done only on one sample from each
offered lot.
9.00.00 COMMISSIONING
9.01.00 The Contractor shall carry out the following commissioning tests and checks after
installation at site. In addition the Contractor shall carry out all other checks and tests
as recommended by the Manufacturers.
9.01.01 Cables
a) Check for physical damage
b) Check for insulation resistance before and after termination/jointing.
c) HT cables shall be pressure tested (test voltage as per IS:7098) before

commissioning.
d) Check of continuity of all cores of the cables.

PROJECT
e) Check for correctness of all connections as per relevant wiring diagrams.

Any minor modification to the panel wiring like removing/inserting,
shorting, change in terminal connections etc., shall be carried out by the
Contractor at no extra cost.
f) Check for correct polarity and phasing of cable connections.
g) Check for proper earth connections for cable glands, cable boxes, cable
armour, screens, etc.
h) Check for provision of correct cable tags, core ferrules, and tightness of
connections.
9.02.00 Cable trays / supports and accessories
1) Check for proper galvanizing/painting and identification number of the

cable trays/supports and accessories.
2) Check for continuity of cable trays over the entire route.
3) Check that all sharp corners, burrs, and waste materials have been
removed from the trays supports.
4) Check for earth continuity and earth connection of cable trays.
9.03.00 Earthing and Lightning protection system
1) Earth continuity checks.
2) Earth resistance of the complete system as well as sub-system.

9.04.00 GENERAL COMMISSIONING CHECKS (Application to all electrical equipments)
(a.) Check for name plate details according to specification.
(b.) Check for physical damage, if any.
(c.) Check for tightness of all bolts, clamps & connecting terminals.
(d.) Check for earth connection.
(e.) Check for cleanliness of insulators & bushings.
(f.) Check for lubrication of all moving parts.
(g.) Check for provision of heater.

PROJECT
SECTION A-A
X - FOR 6Klrnrn. TRAY

3M)rnrn. TRAY
- 20-25
- 10-15
COUPLER PLATE
1. LUTERUL :- M.S. SHEE7 MIN. 2mm. mK.
R TENDER PURPOSE
TRAY3A-211-001.DWG
10DLA HOLE
f (MP)
t3
----,--------.------ -
f- / -* X
NOTE.
1. AU DIMENSK)NS ARE IN mm.
3. UlXRUL :- 2mm. M.S. S H m Uln.

LADDER TRAY HORIZONTAL TEE
A=(2R+W+4)
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ELEVATION
90" VERTICAL ELBOW
(OUTSIDE)
TWO NOS. 1 0 0
HOLES FOR COUPLER PLATE.
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( I D T H(w) 1 RADIUS (R) 1 A I

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I (I, ( A GOVERNMENT OF INDL4 ENTERPRISE )
+ -5 ENGINEERING DMSION
0
PROJECT
STANDARD
I
TITLE
CABLE TRAY DETAILS CROSS I
SIZE SCALE DRG. NO. REV. NO.
A4 NTS 0000-211-PIE-A-008 RB
TRAY2A-211-008
6
TWO LENGTHS OF C1 WELDED BACK TO BACK
I
CHANNEL NUT
90'
-
2=={=,
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--
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90'
--- - \-_'_-I - C1 CHANNEL
----- I -
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-
ART-3
ART-I
NOTES
1. MATERIAL MILD STEEL
2. MATERIAL HOT DIPGALVANISED
-/T
CHANNEL
(X*) NTPC Limited

( A GOVERNMENT OF INDIA ENTERPRISE )
ENGINEERING DMSION
PROJECT
STANDARD
TITLE
CANTIIEVER ARMS
'IZE SCALE DRG. REV. NO.
0000-21 1 -POE-A-()16
~4 NTS RB
CAD FILE NAME : STAND-211-016 DWG
\0
C2 CHANNEL C1 CHANNEL
ASSEMBLY- 1 ASSEMBLY-2
ASSEMBLY- 1
UPPER FIXING C2 CHANNEL
ASSEMBLY-2
UPPER FIXING C1 CHANNEL
UPPER FIXING FOR CHANNEL VERTICAL SUPPORTS

-
C2 CHANNEL
&
C1 CHANNEL
I
I ASSEMBLY 1
I I I I HEAVY DUTY FLOOR
FOR C2 CHANNEL
ASSEMBLY 2
ING FOR C l CHANNEL
FLOOR FIXING FOR CHANNEL VERTICAL SUPPORTS
( A GOMRNMENT OF INDL4 ENIERPRISE )
TYPICAL DETAILS OF CABLE
CAD FILE NAME I STAND-211-018.DWG
1%
/.-gHANNEL
ffi W
'RAWLBOLT
{
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FOR FIXINGRAWLBOLT
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RB FORTEIIDERPURPOSE
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RA rOR TENDER PURPOSE ONLY
IILV M E c c&l ARCH
NO. DESCRIPTION APPO D/IIE
CLFAREDBY
NTTPC T^irn-ited-
( A GryERNMET{T
OF INDA EITIIERPRISE
)
ENGINEERINGDMSKIiI
PROJECT
STANDARD
TITLE
FIXING OF CEANNEL IN TRENCE TAI,L
slzb. suALt NU. {tsv. Nu.
I luKtt. 0000-211-PoE-A-019
44 INTS I RB
CAD FILE NAME' STAND-211-019,I!VG
-
NOTES
1) MATERIAL : MILD STEEL.
2) FINISH : HOT DIP GALVANISED.

BRACKET-C2 CHANNEL CLAMP.
BRACKET-C1 CHANNEL CLAMP.
NOTES:
1) MATERIALS -MILD STEEL
2) FINISH-HOT DIP GALV.
1) 600mm TRAY-1 TO 6 TIER-C2
2 ) 3 0 0 m m TRAY-1 TO 3 TIER-C1
ANTILEVER ARM
ARRANGEMENT TYPE-B1
NOTES:
1) IN CASE OF HANGING SUPPORT
C2 TO BE USED AS MAIN SUPPORT.
2) ALL DIMENSIONS ARE IN MM.
ANTILEVER ARM ON
BOTH SIDES
ARRANGEMENT TYPE -B2

7INSERT PCATE
k . 1 CHANNEL
ARRANGEMENT TYPE-C1
NOTES:
1) U P TO 3 TIER C1 CHANNEL
2) ABOVE 3TIER & BOTH SIDE TRAY
C2 CHANNEL
3) ALL DIMENSIONS ARE IN MM.
ARRANGEMENT TYPE-Dl
BEAM OR RCC FLOOR
ANTILNER ARM
CC FLOOR L N E L
R TENDER PURPOSE
( A GOVERNMENT OF INDIA EWERPRISE )

ENGINEERING DIVISION
1 ) 600mm TRAY-1 TO 6 TIER-C2 CHANNEL
2) 300mm TRAY-1 TO 3 TIER-C1 CHANNEL
3) 300mm TRAY-4 TO 6 TIER-C2 CHANNEL
4) 1 5 0 m m TRAY-1 TO 6 TIER-C1 CHANNEL
MAIN SUPPORT
CHANNEL-C1 /CZ
ARRANGEMENT TYPE-S2
CHANNELS SUPPORTED BY -. -
-
tLUUH BtAM -
INSERT PLATE PROVIDED
FOR FIXING O F MAIN - -
SUPPORT CHANNEL
MAlN SUPPORT
CHANNEL IS
-.
VI a SUPPORTED BY
I.- 2 $ BRACKET-WELDED
q C C
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- -
r= ' >i
1) UP TO 3TIER-Cl CHANNEL
E ;I ABOVE 3 TIER-C2 CHANNEL.
E : 2 ) ALL DIMENSIONS ARE IN MM.
: ARRANGEMENT TYPE-S3
X
I:
I
BRACKET
WELDED
-flLI7
MAlN SUPPORT
X 0
-r
L -5
.-
CHANNEL C1/C2
a,
a
+
0 aJ
r4
a , "
I
ANTILEVER ARM
ARRANGEMENT TYPE-S4
DESCRIPTION
NOTE :
1. ALL DIMENSIONS ARE IN MM (SCALE NTs)
CONDUCTOR GRID
OUTSIDE THE BLDG.
INSERT IN RETAINING WALL
EARTH RISER WELDED TO MAIN

EARTH CONDUCTOR EMBEDDED
WELDED
7 \I IN CONCRETE.
RCC FLOOR SLAB
.Q 1 1 SO MIN
E A R T H RISER
~irxiited
PROJECT
NTPC
( A C O M R N M M OF INDIA ENTERPRISE )
ENGINEERING DMSION
-
I
STANDARD
TITLE I
SIZE SCALE
EARTHING D E T W
DRC. NO. REV. NO.
I
0000-211-POE-A-041
A4 NTS RB
CAD FILE N N E : STAND-Zil-C4I.W;
&
1 CAO FILE NAUE : STAND-211-MZ.D'*G
GROUND CONDUCTOR ALONG BUILDING WALL
h
10
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5
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GROUND CONDUCTOR
35x6 G I FLAT
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l1
l1
11
--
'
OC-
SEC. 5 - 5
I'
)-
If
1,
v" -
GROUND CONDUCTOR ALONG STEEL COLUMN STRUCTURE
NOTES
ALL DIMENSIONS A R E IN MM (SCALE-NTS)
1
2
C , 9
K~ TEPBEt fbKPt&
t'&/- p - - 4 EL
REV.
FA FDR TENDER PURPOSE ONLY
C& - 47 -
P F - - &,4y
E C Ul,-
NO DESCRIPTION m ~ c k 0 s . nM , r P P D m
--
CLEARED BY
.
iwX) NTPC Limited
(AcowwMENTOFlNDNDRD(TOOPR1M)
ENCWWlNC DNISK)F(
-
PROJECT
STANDARD
TITLE
EARTFIWG DETAlLS
SIZE SCALE ORG. NO. REV. '10.
0000-211-POE-A-043
A4 N TS R8
4
r 2MM Al SHEET
.
BUSHINGS THRO CABLE
i
I
i
EARTHING DETAILS TRANSFORMER I
j
i
i
il 1. THE TRANSFORMER NEUTRAL FOR H.T. TRANSFORMER SHALL BE EARTHED THROUGH j
FLATS AS SHOWN ABOVE. (SUPPLIED BY TRANSFORMER SUPPLIER) !
j
1
1
b
1
I
i
TYP. MFLON. TUBINIC LIGHTNING PROTECTION DOWN-COMER
(TO BE SEALED AFT€ ALVANISED BOX 2MM THK SHEET STEEL
INSTALLATION OF
CONDUCTOR)
2 7 x 8 OPENING
FOR WALL/COL./
60 HOLES FOR
FIXING C O M R
F R O N T 0
EARTH TERMINAL
LIGHTING PROTECTION DOWNCOMER TEST LINK WLDED TO BOX (TO BE
CONNECTED TO EARTHING
NOTES: - GRID)
1. THE DOWN COMER ENTRY AND EXIT POINTS IN TO BOX BE MADE
WATER- TIGHT AFTER LAYING OF CONDUCTOR.
SADDLE WTH
2. THE TEST LINK SHALL BE OF SAME WIDTH AND THICKNESS AS SPACER
THE DOWNCOMER.THE NUTS BOLTS AND WASHERS TO BE OF G.S SIDE VIEW
3. ALL DIMENSIONS ARE IN MM (SCALE-NTS)
DESCRIPTION
-
[m*] NTPC ~imited
( A C O M R N Y E N ~ O F M D ~ A ~ E )
ENWNEERIW DWSKHJ
PROJECT
. . STANDARD
TITLE
' LIGHTNING PROTCTION DETALIS.
SIZE SCALE DRG. NO. R&. NO-
0000-21 1 -FOE-A-047
A4 N TS RB
I CAD FILE NAME : STANC-211-O47.DK
33
BLOCK SPACING IOOOMM CENTRE TO CENTRE
TYPICAL DETAILS OF CLEATING HORIZONTAL

CONDUCTOR OVER WATER PROOFING
NOTE : ALL DIMENSIONS ARE IN MM
NTPC Lixxxited
( A GOVERNMN OF INDIA ENTERPRISE )
ENGINEERING DMSlON
PROJECT
STANDARD
TITLE
SIZE SCALE DRC. NO. REV. NO.

0000-21 1-POE-A-048 Re
A4 N TS
CM) FILE NAME : STAND-211-O&.DHC
I
SEE DETAIL
EARTH BACK FlLLED 'A'
AND RAMMED
PRECAST CONCRETE
C a M K i 50X250X4Mhi
\
T
+ C
(NTPC]
6- , , DIA. HOLES FOR
4 NOS. FIXING
1''0 CAST IRON

- NOTES:
LIGHTING 1. ALL DIMENSIONS ARE I N MM.
/ PU\TE
CABLE 2 . ROUTE MARKERS SHALL BE CONSTRUCTED
OF CONCRETE WITH CAST IRON PLATE.
WITH THE ROUTE INFORMATION ENGRAVED
ON IT. BOLTED ON TOP OF THE CONCRETE
j C C BLOCK AS SHOWN.
3. CAST l2ON PLATE SHALL BE OF 6 . 0 MM
THICKNESS
DETAIL- 'A'
GESCRl?T!O?4
CLEARED BY
[NTPC]
wffm NTPC
- ENClNWlNC
.- -.
Limited
( A o o M W M E N l O f INDU -RISE
D W
)
I I STANDARD I
I TITLE
SIZE
BURIED CABLE TRENCH DETAILS FOR LIGHTING
SCALE DRG. NO. R N . NO.
I
A4 NTS 0000-2 1 1 -POE-A-049 RB
21 1 -049.DWG
I
\
DIRECTLY BURIED CABLES DIRECTLY BURIED CABLES

IN SINGLE LAYER I N 'TWO LAYER
@-CABLE ROUTE MARKER DIMENSION l l D O V GRADE FOR 3.3 K V 22KV & 33KV
@-EARTH BACK FILLED & RAMMED MIN. CABLES TO l l K V
PROTECTIVE COVERS D1 750 900 1050
o) BRICKS FOR LOW d BETWEEN CABLES OF SAME CLASS

VOLTAGE CABLES
X300MM BETWEEN CABLES OF DEFT CLASS
b) RCC FOR HIGH VOLTAGE CABLES
WlTH HOLE AT EACH END TO TIE X400MM BETWEEN 1/C POWER CABLE AND
S
THE TO EACH OTHER WlTH G.S WlRE COMMUNICATION CABLE.
&----
ARMOURED POWR CABLE X300MM BETWEEN MULTlCORE POWER
CABLE & COMMUNlCATlON CABLE.
@- ARMOURED CONTROL CABLE
d - OVERALL DIAMETER OF THE BIGGER OF THE TWO CABLES
@- FINE SAND/RIDDLED SOIL COMPACTED x - SPACI~G SHALL BE TAKEN BOTH HORIZONTALLY AND
VERTICALLY.
1. SINGLE CORE CABLES SHALL BE RUN IN TREFOIL FORMATION AND SHALL BE BOUND B Y
SELFLOCKING CABLE n E s A T EMRY 750 MM.
2. CABLE IDENTIFICATION TAG SHALL BE TlED AT BOTH ENDS OF THE CABLE AN0 ALSO AT AN
INTERVAL OF 1 0 METRES.
3. I F THE MINIMUM CLEARENCE AS INDICATED THE A B O M TABLE FOR CABLES OF DIFFERENT
CLASSES ARE NOT FEASIBLE,BRICK BARRIERS SHALL BE USED BETWEEN ADJACENT CABLES
4. G.I.PIPE SHALL BE PROVlDED FOR ROAD CROSSING AT A MINIMUM DEPTH
OF 600 FROM THE GRADE LEVEL UNLESS OTHER WSE SPECIFIED.
5. ALL DIMENSIONS ARE IN MM (SCALE NTS)
ENGINEERING DMSlON
1 CAD RLE NAME : STAND-XK)-W3.CW-

NTPC Limited
, . ( A CoMRNMENT OF INDlA ENrmPRlSE )
ENGINEERING DMSION
PROJECT
Srmm
TITLE
TYPICAL DETAES OF F U C T U R E FOR TESTING
SIZE SCALE ORG' 0000-21 1-POE-A-03'7 REV. NO
A4 N TS
1 CAD FILE NAUE : STAND-211-OJ7.DW;
WORKING UDL = 100 KG
y,": :",',
AS INDICATED
PROOF UDL
POINT LOAD
= 200 KG
= 100 KG
CANTILEVER ARMS
ADDITIONAL POINT
LOAD OF 100 KG
INSTALLATION
SECTION
(ASWMETRIC LOADING)
OSITlON FOR APPLICATION
F 600 K G POINT LOAD FOR TEST 3C
POINT LOAD OF 600 KG

AT EACH POSITION FOR TEST 3 B
BEAM CLAMPS
AS ACTUAL
TWO BRACKETS
LENEHALLY FIXEL
POINT LOAD OF 1200 KG
FOR TEST 3 A
TEST 3 A , 3B & 3C
1 FIXING SHALL BE AS PER ACTUAL

SITE INSTALLATION CONDITION.
2. ALL DIMENSIONS ARE IN MM
CAO FILE NAME : STAND-211-OJ8.D%
& 3
Clause No. TECHNICAL REQUIREMENTS
TRANSFORMER
1.01.00 Transformers IEC:60076, IEC 60354, IEC:60726
Bushing CT’s IEC :60044-1
Insulating oil IEC: 60296
2.00.00 TYPE
2.01.00 Out-door Mineral oil filled ONAN type, Three phase unit
Transformers
2.02.00 Dry type Epoxy cast resin/resin encapsulated air cooled

Transformers type, three phase unit
3.00.00 FEATURES
Paint shade RAL 5012
Degree of protection:
Dry type transformer IP-23
Cable box, Marshalling box IP-55
4.01.00 Out-door Winding 55oC above ambient 50oC

Transformers oil 50oc above ambient 50oC.
4.02.00 Dry type Winding (by resistance method): 90oC or lower

Transformers as permissible for class of insulation offered,
above an ambient of 50oC.
5.00.00 OPERATIONAL REQUIRTEMENTS
5.01.00 Tap Changer
Off-circuit, +/-5% in steps of 2.5% shall be provided. It shall be hand operated by

an external handle with position markings, pad locking facility in each position and
mechanical stops to prevent over cranking beyond extreme positions in case of
outdoor type transformers. In case of indoor transformers, it shall be with
shrouded bolted links.
FARAKKA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS SUB-SECTION-IIIB-09 Page

PROJECT VOLUME-II, PART-B TRANSFORMERS 1of 7
5.02.00 Loading Capability
Continuous operation at rated KVA on any tap with voltage variation of +/-10%
corresponding to the voltage of the tap as well as in accordance with IEC 60354.
5.03.00 Flux Density
Not to exceed 1.9 Wb/sq.m. at any tap position with +/-10% voltage variation from
voltage corresponding to the tap. Transformer shall also withstand following
overfluxing conditions due to combined voltage and frequency fluctuations:
a) 110% for continuous rating.
b) 125% for at least one minute.
c) 140% for at least five seconds.
5.04.00 Noise Level :Not to exceed values specified in NEMA TR-1.
All transformers shall be suitable for cable or busduct termination as

contemplated. If cable connection is envisaged, a dust tight cable box shall be
provided. Also, a sheet steel, vermin and dust proof marshalling box shall be
furnished with each transformer to accommodate temperature indicators, terminal
blocks for control cables etc. The transformer shall be provided with all fittings
and accessories to be complete in all respects for satisfactory operation.
6.01.00 OUTDOOR TRANSFORMERS
6.01.01 a) Tank
Shall be fabricated from tested quality steel and designed to withstand

continuous internal pressure & vacuum as per CBIP guidelines. All steel
surfaces in contact with insulating oil shall be painted with two coats of
heat resistant oil insoluble insulating paint. Tank shields, if provided, shall
not resonate at natural frequency of equipment.
b) Tank mounting
Transformer tank shall be mounted on bi-directional rollers. Suitable

locking arrangement shall be provided to prevent accidental movement of
transformer. Tank shall also be provided with lifting lugs and minimum four
jacking pads.
c) At least two adequately sized inspection openings, one at each end of the
tank for easy access to bushings and earth connections shall be provided.

6.01.02 Core shall be High grade non-ageing cold rolled grain oriented silicon steel
laminations.
6.01.03 Winding conductor shall be Electrolytic grade copper. Windings of 66kV and
below shall be uniformly insulated.
6.01.04 Conservator tank of adequate capacity for expansion of oil from min. ambient
to100 deg.C. shall be provided. The transformers rated 7.5 MVA and above shall
be provided with air bag breathing through silica gel breather. For lower rating
transformers, conventional single compartment conservator with dry air filling the
space above oil and connected to silica gel breather shall be provided.
6.01.05 Porcelain Bushings shall be used.
6.01.06 Bushing CTs Shall be provided in the LV neutral side of adequate rating for REF
protection, Back up definite time earth fault protection (for HT transformers only),
WTI, etc.
6.01.07 Radiators shall be Tank mounted with shut off valves.
6.01.08 Insulating oil
No external inhibitors are permitted.
6.01.09 Marshalling box shall be provided with thermostatically controlled space heaters.
6.01.10 The insulation of core to core clamp shall be able to withstand a voltage of 2 KV
rms for one (1) minute.
6.01.11 Fittings
Transformer shall be provided with following fittings
a) Buchholz relay shall be provided with double float type with alarm and trip
contacts, along with suitable gas collecting device.
b) At least two numbers of spring operated pressure relief devices with

extension pipe to bring oil to plinth level along with electrically insulated
contact for alarm and tripping shall be provided for transformer rating
2MVA and above.
c) Diaphragm type explosion vent shall be provided for all transformers below
2 MVA rating.
d) Winding temperature indicator (WTI) and Oil temperature indicator (OTI),

Dial type (150mm) with alarm and trip contacts and max. reading pointer
along with resetting device shall be provided.
e) Magnetic oil level gauge with alarm contact shall be provided.

f) Oil level gauge Prismatic/toughened glass type.
6.01.12 Neutral grounding resistors (AS APPLICABLE) for neutral point earthing of 6600
volts, 3 phase AC systems shall be of punched stainless steel grid element type.
Resistor element shall be insulated from supporting base by mica tubes. NGR
shall be housed in a 2.5 mm thick sheet steel enclosure having IP 33 degree of
protection. NGR enclosure shall be supported on insulators placed on the
mounting structures of minimum height of 2.4 metre above ground level.
i) Resistance Value at 50 deg. C. 12.7 Ohms

ii) Rated current 300A for 10 seconds
iii) Application Neutral Grounding of Star connected LV
winding of 12.5 MVA transformer
iv) Service Outdoor
v) Resistor material & connection Punched stainless steel grid element type
vi) Maximum allowable temperature 350 deg. C
rise over ambient 50 oC
vii) Mounting 6.9 KV grade insulators.
viii) Power frequency test level 20 KV (rms)
6.02.00 DRY TYPE TRANSFORMERS
6.02.01 Enclosure
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.
6.02.02 Core
Shall be High grade non-ageing cold rolled grain oriented silicon steel laminations.
6.02.03 Winding conductor Shall be electrolytic grade copper or aluminium.

Windings shall be of class F insulation.
6.02.04 Bushings Shall be Solid porcelain / RIP.
6.02.05 Bushing CT’s Shall be provided in the LV neutral side with

adequate rating for REF protection, WTI, etc.
6.02.06 Fittings
Winding temperature Shall be Platinum resistance type temperature

Indicator (WTI) detector in each limb.
Thermistors Shall be embedded in each limb with alarm and trip

contacts for remote annunciation.
7.00.00 TRANSFORMER SIZING

7.01.01 Size of the transformer shall be decided based on following :
Size shall be greater than or equal to total KVA of continuous load
+ (coincident factor x total kVA of intermittent load other than valves)
+ 0.2 x total valves kVA
+ kVA of largest rated valve or damper motor
+ Employer's requirement, if any.
+ 10% margin on the sum of the above mentioned values.
Coincident factor of intermittent load, such as lifts, cranes, hoists etc shall be
taken as 0.5.
7.01.02 Normally 2 x 100% feeding arrangement shall be provided as shown in single line
diagram i.e. the total loads to be considered for sizing each transformer shall be
the loads working on both the buses. In case of 3 x 50% feeding arrangement, if
required, the loads to be considered on each transformer shall be the loads
working on any two of the buses.
8.00.00 TYPE TESTS
8.01.00 For each type and rating of transformers rated more than 2 MVA:
8.01.01 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 BPS
and the same shall be considered for the evaluation of the Bids. The type test
charges shall be paid only for the test(s) actually conducted successfully under
this contract and upon certification by the Owner's Engineer.
8.01.02 The type tests shall be carried out in presence of the Owner’s representative, for
which minimum 15 days notice shall be given by the Contractor. The Contractor
shall obtain the Owner’s approval for the type test procedure before conducting
the type test. The type test procedure shall clearly specify the test set-up,
instruments to be used, procedure, acceptance norms, recording of different
parameters, interval of recording, precautions to be taken etc. for the type test(s)
to be carried out.
8.01.03 In case the Contractor has conducted such specified type test(s) within last five
years as on the date of bid opening, he may submit the type test reports to the
Employer for waival of conductance of such type test(s). These reports should be
for the tests conducted on the equipment similar to those proposed to be supplied
under this contract and the test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client. The Employer
reserves the right to waive conducting of any or all of the specified type tests

under this contract. In case type tests are waived, the type test charges shall not
be payable to the Contractor.
8.02.00 For each type and rating of transformers rated up to and including 2 MVA:-
8.02.01 The Contractor shall submit for Owner’s approval the reports of all the type tests
as listed in this specification and carried out within last five years from the date of
bid opening. These reports should be for the tests conducted on the equipment
similar to those proposed to be supplied under this contract and the test(s) should
have been either conducted at an independent laboratory or should have been
witnessed by a client. In case the Contractor is not able to submit report of the
type test(s) conducted within last five years from the date of bid opening, or in
case the type test report(s) are not found to be meeting the specification
requirements, the Contractor shall conduct all such tests under this contract free
of cost to the Owner and submit the reports for approval.
8.02.02 All acceptance and routine tests as per the specification and relevant standards
equipment price.
For subsequent projects of NTPC, an endorsement sheet will be furnished by the
manufacturer conforming similarity and “No design change”. Minor changes if any
8.03.00 Following is the list of type tests to be conducted (as per IEC) for
transformers of rating more than 2 MVA (For transformer of rating upto &
including 2MVA, only the valid test reports are to be submitted in line with Cl
8.02.01).
(a) Short circuit test.
(b) Temp. rise test.
(c) Lightning impulse (Chopped Wave) voltage test on all three limbs and full
wave LI on neutral if grounded through NGR.
(d) Partial discharge test on dry type transformers only (Max. allowed PD shall
be 20 PC).
(e) Noise level test as per NEMA TR-1.
(f) Zero sequence Impedance measurement.
8.04.00 Following type test reports in line with clause no 8.02.01 shall be submitted
for each type & rating of transformer:-
(a) Tank pressure test as per CBIP norms (for oil filled transformers).
(b) Tank vacuum test as per CBIP norms (for oil filled transformers).

(c) Degree of protection test on marshalling box.
8.05.00 The following special tests on all transformers shall be conducted under
this contract as routine tests in addition to all routine tests as per IEC 60076:
(a) Oil leakage test for 24 hours (for oil filled transformers).
(b) Repeat no load loss tests after electrical tests.
(c) Measurement of capacitance & tan delta to determine capacitance

between winding and earth.

HT SWITCHGEAR
1.00.00 CODE AND STANDARDS
IEC: 62271, IS: 13118 and IS: 3427
2.00.00 TYPE
2.01.00 Switchgear
Free standing, Floor mounted, metal clad, fully compartmentalized draw-out type
2.02.00 Circuit Breaker
Vacuum type, restrike free, trip free, stored energy operated and with electrical
anti-pumping features
3.00.00 RATING
3.01.01 HT Voltage: 33 KV+/- 6%, 6.6KV +/-6%

3.01.02 Frequency: 50 Hz, 3%.-5%
3.01.03 Fault Level: 6.6 KV : 40 KA RMS for 1 sec. with short circuit making current of
100KA PEAK
33KV: 21KA RMS for 1 sec with short circuit making current of 52.5KA PEAK
3.01.04 Control Supply: 240 V DC
Temperature rise of busbars shall not exceed 55 deg. C for silver plated joints and
40 deg. C for other joints, over an ambient temperature of 50 deg. C under any
condition.
4.00.00 OPERATIONAL REQUIREMENT
4.01.00 The circuit breaker shall meet the following requirements
a) The breaker shall be remotely controlled. Facilities shall be provided for

mechanical tripping of breaker and manual charging of closing spring to
cater to emergency condition.

TECHNICAL SPECIFICATIONS SUB-SECTION-IIIB-10 Page
PROJECT
SECTION-VI, HT SWITCHGEAR 1 of 11
PART-B
b) Surge arrestor shall be provided for each motor feeder.
c) Shall have an Operation duty O-3 min -CO- 3min-CO.
d) Closing and tripping coils operating under extreme conditions of control

voltage variation.
e) Supervision relays provided for trip coil monitoring.
f) Suitable mechanical inter lock shall be provided to prevent inadvertent

earthing of any live part.
g) Suitable interlock shall be provided, which will ensure that breaker is OFF
before opening the back doors. For Incomer/Tie panels suitable interlock
shall be provided to prevent opening of any compartment doors which has
any of the MV (33kV/11kV/6.6kV/3.3kV) equipment, in case the incoming
supply is ON.
h) Testing of circuit breaker shall be possible in isolated position by keeping

the control plug connected.
i) Only motor wound closing spring charging arrangement is acceptable.
j) In a switchgear if there are more than one possible feed (including bus
coupler) then lockout relay (86) contact of incoming breakers shall be
connected in series in closing circuit of each of incoming breakers.
k) Automatic change-over shall be provided for bus sections with suitable

synchronizing check facility. The change-over shall be blocked in case of
fault on the bus section. Dead Bus change-over after voltage collapse
shall also be provided as back-up.
l) Core balance CTs shall be provided for outgoing motor and transformer
feeders having CT ratios greater than 50/1A.
m) Each breaker truck shall have Service - Isolated - Withdrawn Position.
n) Primary fuse replacement shall be possible with VT in isolated position.
4.02.00 Contactor
(a.) The Bidder shall offer only HRC fuse backed, mechanically latched type
contactor for outgoing conveyor motor feeder panels.
(b.) The medium voltage contactors shall be of AC-3 utilization category and
shall be vacuum type. The fuse and contactor assembly shall be mounted

PROJECT
PART-B
on a withdraw able truck. Circuits shall be provided with suitable single

phasing protection. If required the contactor coil shall have a suitable
economy resistor in series and shall be rated for satisfactory operation at
80 to 110% of rated voltage.
(c.) The fuse and overload relay shall be fully coordinated, so that the
contactor operates only for a fault current less than its interrupting
capability. The fuses shall be provided with mechanical trip indication.
(d.) The contactors shall close satisfactorily with a control voltage between 85
to 110 per cent and trip satisfactorily with a control voltage between 70 to
100 percent of the rated control supply voltage. Mechanical indication of
contactor open / closed shall be provided. An anti-pumping relay shall be
provided even if it has mechanical anti-pumping feature. Trip circuit
supervision relay shall be provided to monitor the healthiness of trip coil.
(e.) Surge suppressors shall be provided on all contactor controlled motor

feeders.
4.03.00 Surge Arrestor
The surge arrestors shall be provided for all motor feeders and shall be metal
oxide, gapless type generally in accordance with IEC 60099-4 and suitable for
indoor duty. These shall be mounted within the switchgear cubicle between line
and earth, preferably in the cable compartment. Surge arrestor selected shall be
suitable for non-effectively earthed system and rating shall be in such a way that
the value of steep fronted switching over voltage generated at the switchgear
terminals shall be limited to the requirements of switchgear.
5.00.00 Protection, Control and Metering
5.01.00 The switchgears shall have Communicable Numerical relays for Protection,
scheme, Metering and Status monitoring. The Numerical relays shall be
networked and integrated to the Coal Handling Plant PLC. Dynamic displays shall
be created in the PLC for the 33 KV & 6.6KV SWITCHGEAR for diagnostics and
status monitoring. All the feeders shall be remote controlled from PLC and from
the local console of the numerical relays.
5.02.00 General requirements of Numerical Relays
5.02.01 All numerical relays, auxiliary relays and devices shall be of types, proven for the
application; satisfying requirements specified elsewhere and shall be subject to
Owner's approval. Numerical Relays shall have appropriate setting ranges,
accuracy, resetting ratio, transient overreach and other characteristics to provide
required sensitivity to the satisfaction of the Owner. All the numerical relays shall
have communications on two ports, local front port communication to laptop and a
second port on IEC 61850 port.

PROJECT
PART-B
5.02.02 All relays and timers shall be rated for control supply voltage as mentioned
elsewhere under parameters and shall be capable of satisfactory continuous
operation between 80-120% of the rated voltage. Making, carrying and breaking
current ratings of their contacts shall be adequate for the circuits in which they are
used. Interrogation voltage for the binary inputs shall be suitably selected to
ensure avoidance of mal operation due to stray voltages.
5.02.03 The protective relays shall have at least 10 Nos potential free contacts
(Programmable) Auxiliary relays shall have contacts as required. Relay output
contacts shall be suitable for directly wiring in the breaker closing and trip circuit
operating from 220 V DC control voltage.
5.02.04 Failure of a control or auxiliary supply and deenergisation of a relay shall not
initiate any circuit breaker /contactor operation. All relays shall withstand a
minimum test voltage of 2 KV AC Rms for one minute.
5.02.05 Relays shall be suitable for electrical measurement including voltage, current,
power (active/reactive) and energy parameters.
5.02.06 Relays shall have separate output for individual functionality and the master trip
shall be software configurable in case of multi output relays. Relays shall have
event recording feature, recording of abnormalities and operating parameters with
time stamping
5.02.07 Preferably comprehensive single numerical relay shall have provision of both
current and voltage inputs. The current operated relay shall have provision for 4
sets of CT inputs, 3 nos. for phase fault & 1 CT input for earth fault. Relay shall
be suitable for both residually connected CT input as well as CBCT input. The
voltage-operated relay shall have provision for 3 PT inputs. Relays shall be
suitable for CT secondary current of 1A/5A selectable at site. Relays used in
incomers and bus couplers shall have provision of two sets of voltage signal
inputs for the purpose of synchronization.
5.02.08 All CT & PT terminals shall be provided as fixed type terminals on the relay to
avoid any hazard due to loose connection leading to CT opening or any other
loose connection. In no circumstances Plug In type connectors shall be used for
CT / PT connections. Vendor to ensure the same for all protective relay models
offered.
5.02.09 All numerical relay shall have key pad / keys to allow relay settings from relay
front. All hand reset relays shall have reset button on the relay front. Relay to be
self or hand reset shall be software selectable. Manual resetting shall be possible
from remote.
5.02.10 Relays shall have suitable output contact for breaker failure protection.
5.02.11 Relays shall have self diagnostic feature with self check for power failure,
programmable routines, memory and main CPU failures.

PROJECT
PART-B
5.02.12 Relays shall have at least two sets or groups of two different sets of adaptable
settings. Relays shall have multiple IEC/ ANSI programmable characteristics.
5.02.13 Design of the relay must be immune to any kind of electromagnetic interference.
Vendor to submit all related type test reports for the offered model along with the
offer.
5.02.14 Protections: Relay Types/ Protections
A. Motor Feeders
a) Thermal Overload Protection (50I)

b) Restart Inhibit Protection (49)
c) Earth Fault Protection (50N/50N2)
d) Negative Phase Sequence Protection (46)
e) Reversal Phase Sequence Protection (46 R)
f) Locked Rotor Protection (50 L/R)
g) Number of starts limitation (66)
h) Loss of Load Protection (37)
i) Under Voltage protection with timer(27 M)
j) Motor Differential protection (87 M) for Motor rating > 2 MW
k) Energy Metering
l) Monitoring
B. Transformer Feeder Protections
a) Three Phase Over current and Earth Fault protection (50 & 50 N1/50
N2))(The earth fault element should be suitable for both residually connected
CT input as well as CBCT input. )
b) Restricted Earth Fault protection (64 R)
c) Transformer Differential protection (87 T) for Transformers with rating more
than 5 MW
d) Stand by earth fault protection (51 N)
e) Transformer buchholz and WTI/OTI high trips
f) Energy Metering
g) Monitoring
C. Protections for Incomers, Bus couplers and Tie feeders.
a) Over current and earth fault protection.

b) Synchronizing check relay as a part of fast change over scheme.
c) Energy Metering
d) Monitoring

PROJECT
PART-B
5.03.00 Other Protections and Control functions in the Relays.
5.03.01 For Breaker control from PLC, hardwired potential free contacts shall be provided
from PLC, to the numerical relays. Preferably no separate coupling relays shall be
provided.
5.03.02 Trip circuit supervision shall be provided for all feeders to monitor the circuit
breaker/ contactor trip circuit both in pre trip and post trip conditions.
5.03.03 Schematics requiring auxiliary relays /timers for protection function shall be a part
of numerical relay. The number of auxiliary relay and timer function for protection
function shall be as required. Auxiliary relays for interlocking purpose shall be of
self reset type.
5.03.04 Bus no volt condition shall be configured to a output contact of the relay of all
incomers
5.03.05 Timer functions shall be programmable for on/off delays.
5.03.06 The numerical relay shall be able to provide supervisory functions such as trip
circuit monitoring, circuit breaker state monitoring, PT and CT supervisions and
recording facilities with Post fault analysis.
5.03.07 The numerical processor shall be capable of measuring and storing values of a
wide range of quantities, all events, faults and disturbance recordings with a time
stamping using the internal real time clock. Battery back up for real time clock in
the event of power supply failure shall be provided.
5.03.08 150 time tagged events /records should be able to store with time stamping Last 5
faults storage including the indication, protection operated , fault location relay and
operating time, currents, voltage and time.
5.03.09 Diagnostics Automatic testing, power on diagnostics with continuous monitoring to

ensure high degree of reliability shall be shall be provided. The results of the self
reset functions shall be stored in battery back memory. Test features such as
examination of input quantities, status of digital inputs and relay outputs shall be
shall be available on the user interface
5.03.10 The alarm/status of each individual protection function and trip operation shall be
communicated to PLC The numerical relay system shall have built-in
features/hardware interface to provide such inputs to PLC for analog/digital values
The provision of receiving the D.C. incoming supplies and its monitoring shall
preferably be made in one bus P.T. Panel.
5.03.11 Sequence of events shall have 1 ms resolution at device level.
5.03.12 Measurement accuracy shall be 1 % for RMS Current and voltage.

PROJECT
PART-B
5.03.13 It shall be possible to carryout open / close operation of breakers from a laptop by
interfacing from the relay front port (RS232) during initial commissioning.
5.04.00 Auxiliary power Supply
Relay shall be suitable to accept both AC & DC supplies with 110V AC or 220V
DC with tolerance of 80% to 120 % of rated voltage
5.05.00 Input / Output Interface, Filters And Optical Isolation
Relay shall be immune to capacitance effect due to long length of connected

control cables. Any external hardware, if required for avoiding mal operation of the
relay due to cable capacitance shall be included as a standard feature. All IOs
shall have optical isolation. Analog inputs shall be protected against switching
surges, harmonics etc.
No separate earth bus shall be required for the relays. It shall be possible to
connect the relay earth to the common earth bus in the switchgear panel which
shall be connected to the plant earth mat.
5.06.00 Soft ware Security, License and up gradations
Numerical relays shall have two level pass word protections, one for read only and
other for authorization for modifying the setting etc.
6.00.00 DESIGN AND CONSTRUCTION FEATURES
All HT switchgear panels and circuit breakers shall have the following features.
a) High conductivity aluminum alloy or copper for the horizontal bus bars,
vertical droppers and connectors to the fixed end of isolating contacts.
b) Height of the Switchgear Panel Not to exceed 2600 mm.
c) Insulators shall be track-resistant, high strength, non-hygroscopic, non-

combustible type and suitable withstand stresses due to over-voltages and
short circuit current. Inter pole barrier of inflammable material like hylam
not acceptable
d) Sealing Bushing or other sealing arrangement shall be provided between

breaker and bus bar / cable compartments to avoid air communication
around isolating contacts in the safety shutter area with truck in service
position.
e) Construction
i) The switchgear assembly shall be rodent and vermin proof.

PROJECT
PART-B
ii) In switchgear design where the breaker front itself serves as a door
suitable blanking covers one for each size of panel per switch
board shall be included.
iii) The switchgear enclosure shall be constructed with rolled steel

section of rolled sheet steel of at least 2.0 mm thickness.
iv) Pressure relief device shall be provided in each high voltage

compartment to vent out safely the gases produced in case of a
fault.
v) Contractor shall furnish calculation during detailed- engineering

stage to establish the adequacy of support insulator and bus bar
sizes for the declared continuous & short time current ratings.
vi) Breaker trucks shall have a secure locking in SERVICE position so

that they are not displaced during a short circuit.
vii) Current ratings of all switchgears, circuit breakers, CT's etc. Shall
be sufficient for carrying the connected load currents without
exceeding the permissible temperature limits or reduction in service
life. Use of two breakers in parallel to meet the required rating
shall not be acceptable.
viii) HT switchgear shall also have at least two (2) fully equipped spare
feeders (one each for highest size of motor/transformer) for any
future requirement.
ix) Suitable trolley arrangement, if required, shall be provided. One

trolley per switchgear room shall be provided suitable for each type
of rating of breakers.
f) Earthing Arrangement
(i) Internal earth bus shall be provided which has a capacity to

withstand short circuit currents for one second and all enclosures
shall be connected to this bus.
(ii) Earthing arrangement through and integral earth switch or through
separate Earthing truck shall be provided. Suitable mechanical
interlocks shall be provided to prevent the closing of earth switch
circuit on live circuit. In case of later arrangement one set of
different types of earthing trucks per switch board shall be
provided.

PROJECT
PART-B
(iii) Earthing switch/Earthing truck shall be short time (One second)

current withstand capability equal to the breaker.
iv) A clearly visible warning label "ISOLATE ELSEWHERE BEFORE

EARTHING" shall be provided on shutters of incoming and other
connections which could be energized from other end.
g) Switchgear panel shall be suitable for bottom entry and provided with
removable gland plates.
h) Instrument transformer
CTs and VTs shall be provided for protection and metering and shall be
cast-resin encapsulated type. Insulation class 'E' or better. VTs shall
have suitable HRC current limiting fuses to both primary and secondary
sides, under voltage relays, timers, etc. for motor tripping and remote
annunciation on supply failure. Each switchgear section shall have a three
phase VT. Single phase VT shall be provided for HT incomers for
synchronization. Accuracy class of CTs and VTs shall be as follows
CT Core balance CTS
Protection/ 5P 10 PS
Metering 1.0
Differential/REF PS - -
j) Identification plates
Each panel to be identified on front as well as back side by large engraved

plate giving detailed feeder description. Identification labels/painted (Not
stickers) plates to be provided inside each panel.
k) Safety Requirements
The switchgears shall be designed to offer adequate level of safety to

operating/ maintenance personnel. Means shall be provided to prevent
access to the live part to avoid accidents during service as well as
maintenance period. Bidder shall bring out the safety means provided to
achieve above. A detailed instruction plate shall be provided for each
switch gear room mounting on wall describing various safe operating
procedure / safety precautions for safe operation and maintenance of
switchgear.

PROJECT
PART-B
Safety shutters complying with IEC-60298 shall be provided to cover up

the fixed high voltage contacts on bus bar and cable sides when the truck
is moved to ISOLATED position .The breaker / contactor and the auxiliary
compartments provided on the front side shall have strong hinged doors.
Bus bar and cabling compartments provided on the rear side shall have
separate bolted covers with self retaining bolts for easy maintenance and
safety. Breaker / Contactor compartment doors shall have locking facility.
Suitable interlock shall be provided, which will ensure that breaker is OFF
before opening the back doors. For Incomer/Tie panels suitable interlock
shall be provided to prevent opening of any compartment doors which has
any of the MV (33kV/11kV/6.6kV/3.3kV) equipment, in case the incoming
supply is ON.
7.00.00 Type Tests
GENERAL
(a.) All equipments to be supplied shall be of type tested design. The

Contractor shall submit for Owner’s approval the reports of all the type
tests as listed in 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
(b.) In case the Contractor is not able to submit report of the type test(s)
type test report(s) are not found to be meeting the specification
requirements, the Contractor shall conduct all such tests under this
contract at no additional cost either at third party lab or in presence of
client/owners’s representative and submit the reports for approval.
(c.) All acceptance and routine tests as per the specification and relevant
standards shall be carried out. Charges for these shall be deemed to be
included in the equipment price.
reference. For subsequent projects of NTPC, an endorsement sheet will
be furnished by the manufacturer confirming similarity and “No design
Change”. Minor changes if any shall be highlighted on the endorsement
sheet.
The contractor shall submit the following type tests reports on the equipments to
be supplied under this contract.
a) The following type tests Reports shall be furnished circuit breaker / circuit
breaker panels, of each voltage class and current rating.

PROJECT
PART-B
1) Short circuit duty test on circuit breaker, mounted inside the panel
offered along with CTs, bushing and separators.
2) Short time withstand test on circuit breaker, mounted inside panel

offered together with CTs, bushings and separators.
3) Power frequency withstand test on breaker mounted in side
panel.
4) Lightning impulse withstand test on breaker mounted in side
panel.
5) Temperature rise test on breaker and panel together.
6) Test to verify pressure relief devices operation of the panel. This

shall be done on one panel of each voltage class.
7) Measurement of resistance of main circuit.
8) Mechanical operation test.
b) Contactor and Contactor panels of each type and rating.
1) Verification of rated making and breaking capacities of the

contactor.
2) Short time withstand test of panel.
3) Power frequency test on the contactor mounted in side panel.
4) Lightning impulse voltage withstand test of the contactor

mounted in side panel.
5) Measurement of resistance of main circuit.

6) Test to confirm coordination between fuse and contactor.
c) Short circuit withstand test of earthling device (truck / switch).
Type Tests Reports for Surge arrestors
Numerical relays
Type test Reports as per IEC 61850

PROJECT
PART-B
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
PLC & CONTROL PANELS
Programmable Logic Controller IEC: 1131
2.00.00 CONTROL TYPE
PLC based
3.00.00 PANEL CONFIGURATION
3.01.00 PLC based Control system
3.01.01 Main control desk
Mosaic based control desk type for mounting push buttons/meters etc. with doors at
the rear. The mosaic grid tiles shall be of 24mmx48mm (or 25mmx50mm) size, made
of heat and flame retardant, self-extinguishing and non-hygroscopic material with flat-
matt finish without glare and non-reflecting type. Industrial PC based OWS (Operator
Work Station) of PLC shall be mounted on control desk to house PC/ keyboards/
mouse etc. The profile and dimension shall be decided during detailed engineering
and shall be subject to Employer’s approval.
3.01.02 Separate vertical free standing PLC panel with Perspex/glass door for visual access
to LEDs.
3.01.03 Power distribution equipment i.e. Control transformers/ UPS/Power Supplies/Backup

Batteries/ MCBs etc shall be housed in a separate free standing vertical panels.
3.02.00 Local control panels:
3.02.01 Local control panels for Metal detectors, Sump pumps, ILMS, Belt weigher and
Hoists shall be free standing, floor / wall mounting type. They shall be provided with
the required Power equipment like Switches, Fuses, Contactors etc. and the required
control equipment like selector switches, meters, Push buttons, indications and
annunciations etc.
3.02.02 Local control panels shall be provided for CSU, hydraulic scoop coupling and dust
suppression system. However control of all these systems shall be through main
PLC with starters located in main MCCs only.
3.02.03 Separate control desk shall be provided in the Silo control room with HMI and R I/O
panels and their power supply system for the local operation of the silo equipment.
3.02.04 Necessary controls, indications and annunciations for all the above equipment shall
also be provided in main control desk as described elsewhere.
4.00.00 SYSTEM CONFIGURATION
a) Control shall be normally effected through OWS/Keyboard. However

miniaturised Stop push buttons shall be provided for drives/systems in
coal flow path (to be finalised during detailed engineering). These shall be
FARAKKA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS Sub-Section - IIIB-11 Page
PROJECT Section-VI, PLC CONTROL PANELS 1 of 11
COAL CONVEYING PLANT PACKAGE Part-B
sized compatible to mosaic grid.
b) The mimic diagram of the HT & LT switchgear with facilities to operate

6.6KV Breakers and LT MCC incomers shall be provided on the control
desk.
c) Indicating All indicating instruments (i.e. ammeters/ voltmeters)

instruments shall be digital type and of accuracy class 1.0.
Ammeters shall be provided on control desk for:
i) All motors in coal flow path and for other motors

rated 30 kW and above
6.6KV / LT switchgear. ( KWH display for HT &

ii) LT incomers shall also be provided on OWS)
iii) Voltmeters shall be provided on control desk for

6.6KV/LT buses.
Ammeters and Voltmeters shall be suitable for

4-20mA DC signals derived from analog I/O
cards in the PLC.
d) Mimic i) Scrolling Mimic of coal handling system shall be

configured on Large Video Screen (LVS) and
OWS. It shall be possible to control / monitor /
operate from LVS and OWS.
ii) Different colour schemes shall be used in the

mimic to indicate status of various equipment i.e.
ON/OFF/Ready to start/Trip conditions etc.
e) Large video LCD Projection type with rear - screen configuration

screen (LVS) (other type proven technology eg. that based on digital
light processing shall also be acceptable subject to
Employer approval) with redundant bulb and shall be
complete with screens (1280 x 1024 pixels). Separate
workstation/control unit fitted with necessary graphic
control card and required software for selecting
screens and for other required manipulation. The exact
make, model and technical particulars of the LVS shall
be approved by the employer during detail engineering
stage. Specially designed plant overview mimic,
display of important parameters, alarm, annunciation
facility etc. shall be provided on the LVS. Size of the
LVS shall be 80 – 84 inches diagonal minimum. CCTV
system shall be connected to the LVS also.
5.00.00 CONTROL SYSTEM
5.01.00 The control and sequential operation of the all the drives and equipment within the
plant shall be done by field proven Programmable Logic Controller (PLC) system.

5.02.00 The PLC system shall be provided with 2x100% processors in hot standby mode. It
shall be possible to keep any of the processors as master and other as hot standby.
The hot standby shall be hardware based and there shall be a dedicated link
between the two processors for data and program equalization. It shall be possible to
keep any of the processors as master and other as hot standby. One processor shall
be automatically updated in line with the changes made in software of the other
processor. Automatic “Forcing bit” update in the secondary processor/ Controller of
PLC when any “Forcing” is applied in the primary processor/controller of PLC shall be
provided. Standby processor shall be energised and continuously monitored for
healthiness. In case a failure of working processor, the standby processor shall take
over the operation automatically and necessary failure alarm shall be provided. The
processor along with their accessories shall be housed in a free standing vertical
type PLC panel separate from control desk and shall be located in the main control
room. I/O system shall be of distributed type. The number and location of I/O panels
shall be subject to Employer approval during detailed engineering. The operation
and supervisory system for the plant shall consist of Industrial PC (latest model), TFT
Monitors with key boards which shall be mounted as an integral part of the control
desk.
5.03.00 The processor along with OWS, printer etc. and control panels shall be interlinked
through independent dual data highway and independent dual I/O links.
5.04.00 In addition to operation from HMI, it shall also be possible to operate through push
buttons (stop command only) & selector switches mounted on control desk. The
operation of push button shall send necessary signals through PLC.
5.05.00 Mimic of entire system within the plant along with SLDs of HT/LT switchgear shall be
provided on PLC graphic and configured on LVS also. Group annunciation through
annunciation window shall be provided for various abnormal conditions through PLC.
The list of required annunciations shall be finalised during detail engineering.
5.06.00 In addition to the controls from the control desk/keyboard/local control panels, each
motor shall be provided with local stop push button station near the drive and shall be
wired to the PLC.
5.07.00 The PLC shall receive 4-20mA signals from belt weighers corresponding to the coal
flow rates for integration and indication. Coal flow print out shall also be provided.
5.08.00 PLC system shall provide the outputs for the following:
a) No. of starts per day conveyor wise
b) Number of times the conveyor motor was started 3 times consecutively in a day.
c) Total daily operating hours conveyor wise.
d) Weekly trip reports for each trip condition
e) Total daily coal flow conveyor wise.
5.09.00 The PLC Controller/processor unit shall be capable of executing the following
functions:-

a) Receiving binary and analog signals from the field and operator initiated
commands from Operator Station.
b) Implementing all logic functions for control, protection and annunciation of the
equipment and systems.
c) Implementing modulating control function for certain applications as specified

elsewhere in the specification.
d) Issuing control commands.
e) Providing supervisory information for alarm, various types of displays, status

information, trending, historical storage of data etc.
f) The PLC Control system shall have extensive self diagnostic capability which shall
include module level diagnostics as well as channel level diagnostics to detect any
short circuit/ open circuit at field I/O level.
6.00.00 CONTROL PHILOSOPHY
6.01.00 Normal / local mode of operation shall be selected from the key board.
(a) In normal mode of operation, which shall be the default mode, all drives
shall be operated from control desk through keyboard. Whenever required
for maintenance, the maintenance mode will be selected from the keyboard
of the operation, except trip interlocks is locked using a unique password.
After maintenance, the drives shall be started from operator's station
through all process interlocks, by re-entering the password. Normal mode
of operation can be selected then. Irrespective of any PLC mode of
operation, the running equipment can be stopped from keyboard or from
desk/panel or from emergency stop push button.
b) Incomers, bus couplers & transformers feeder including spares of HT

switchgear and Incomers & bus-coupler feeders of LT switchgear shall be
switched ON/OFF from the control desk through key board and also
through control switches/push buttons.
c) PLC system shall have facilities to detect the operated pull cord switch and
belt sway switch of the conveyor. In addition to the pull cord switch and belt
sway switch operation annunciation, conveyor number & operated pull cord
/ belt sway switch number shall also be displayed in the CRT.
7.00.00 TRAINING
Further to the relevant clause regarding training specified elsewhere, Contractor's

experienced personnel/engineers shall also provide training courses on offered PLC
system to Employer's engineers in the following areas:
(a.) Operator training
(a.) Hardware Maintenance training
(a.) Software training

(a.) Any other specalised training as required for system operation and
maintenance.
The maintenance training shall include lectures and hands on experience on similar
type of equipment / system at manufacturer works and recently commissioned
operating plant and / or training simulator. The Employer shall require training of two
hardware and two software engineers and the duration of each course shall be
minimum two weeks.
The details of hardware and software training shall be finalised during detailed
engineering and shall be subject to Employer's approval.
8.00.00 PLC EQUIPMENT AND SYSTEM REQUIREMENTS
8.01.00 PLC system shall consist of redundant processors. redundant Industrial PC with
TFT Monitors (latest version with latest application software) & keyboard, I/O
modules, UPS/power supply with battery backup, printer etc. The configuration of
PLC shall be as per enclosed drawing. Details of various components shall be as
given below :
a) Processor Two (2) numbers. one as hot standby
b) Memory Non volatile EPROM, Lithium or Ni-Cd battery for 360

hours backFPC
up, 40% spare capacity for future use.
c) Selection Normal/Test/Programme/Off facility shall be provided.

In test mode all outputs shall be blocked.
d) Monitors & Twenty (20) inches TFT flat monitors with resolution of
Keyboard 1280 x 1024 pixels non interfaced, refresh rate
minimum 75 Hz. with flat membrane type keyboard/
mouse. CRT shall have graphic display facility. CRT &
keyboard/ mouse shall be used for controlling,
monitoring and programming function. Provision for
erasing and duplicating the user program and long
storage facility, forcing facility for changing the status
of inputs and outputs, timers and flags to facilitate fault
finding and other testing requirements shall be
provided
e) Processors & I/O Modular design. Possible to change any module

racks without disconnection of any wire. Keying in of
individual wire connectors shall be provided to ensure
that only the correct card is plugged on the I/O
module. Twenty(20) percent spare capacity in input
output modules in each rack and forty(40) percent
spare capacity in CPU memory modules & in I/O
handling capability shall be provided over and above
system requirement. One additional Ethernet port shall
be made available in each PLC system so that
wireless communication modem can be connected by
the Employer in future.
All Output cards shall be sourcing type and Input

cards shall be sinking type.
The Contractor shall provide the following monitoring

features:-
a) Power supply monitoring.
b) Contact bounce filtering.
Further, keying-in of individual wire connectors shall

be provided to ensure that only the correct card is
plugged on the I/O module. It shall be possible to
remove the I/O module without disconnecting wiring
from field inputs or outputs. Wiring between I/O cards
& terminal blocks shall be through pre-fabricated
cables.
f) Isolation between 1.5 KV with opto couplers.

Input, Output and
controller
g) Indication Individual signal status of each Input / Output, power

supply status.
h) Fail safe mode On power supply failure / both PLCs failure /

communication failure etc. the output shall be
automatically switched over to fail safe mode. In CPU,
memory should exist where the sequence was
aborted. Further, in case of such failures, operating
drives / equipment shall be tripped or kept running as
per a pre-determined programmable requirement
finalised during detail engineering.
i) Fusing philosophy Individual fuses with blown fuse indicator for each
output. Individual fuses for each input/ group of inputs,
keeping in view of system availability.
j) Switching capacity Output modules shall be rated to switch on/off

coupling relays of 2.5 VA at 24V DC and solenoid
valves at 110 V AC. Coupling relays are provided in
HT/LT Switchgears and in local panels.
k) HMI /CPU and Input Hundred percent redundant Communication links

output through fiber optic cables routed in separate GI
communication links conduits
l) Printer - Type and number of printers shall be as shown in

the tender drawing ‘PLC Configuration’.
- Color laser printer shall be suitable for A4 size

paper, 4 pages per minite, 600 dpi (black) and

heavy duty(>_ 30000 pages per month)
- Dot matrix printer shall be Line impact type

suitable for 132 column continuous fan fold type
paper, 1000 LPM and heavy duty (>_ 50000 pages
per month)
m) Power supply i) Two(2) nos 415V AC feeders shall be provided for

each control panel / desk and remotely located I/O
panels.
ii) Power supply to PCs, printers, OWS, LVS, control

desk and CCTV system shall be fed through 2x100%
UPS with battery back-up rated for 30 minutes at full
load. Main and standby OPS shall have separate
battery back ups.The UPS shall be smart type line
interactive complete with software & hardware for
remote management along with features of surge
suppression & AVR facility. The UPS and batteries
shall be rated for 20% spare capacity.
iii) All separate UPS systems as indicated shall be

provided in each OWS system.
iv) The batteries for 24V DC system and for UPS shall be
sealed maintenance free NI-CD type.
v) For PLC (processor and I/O) panels, the power supply

shall be 24V DC. Necessary redundant transformers
and redundant 24V chargers with redundant battery
back-up rated for 30 minutes shall be provided for
each separately mounted I/O racks/PLC panels.
Power supply modules shall be of ample capacity with
20% spare capacity for future use. All voltage supplies
shall be monitored.
n) Command Manual command shall prevail over auto command.

hierarchy Protection command shall have priority over all other
commands.
o) Databus Hundred percent redundant. Necessary interface

hardware and software for dual fiber optic connectivity
and interconnection with CHP PLC for two way
transfer of signals shall also be provided for
integration with Employer’s PLC through OPC
compliant Ethernet link following TCP/IP standards.
p) Time To be synchronised with other PLC systems of

Synchronisation Employer.
system.
q) Date No disturbance due to change of date/year.

Insensitivity
r) System reaction Less than 100 msec. from input signal to output signal
time including logic processing.
s) Display Max 1 sec for control related displays. 2 to 3 sec for

response other displays.
t) Communication Min. 5 MBPS

speed at I/O
level
u) Feedback/field By 24V DC. Status feedback from MCC/field shall be

interrogation in the form of one changeover contact. Discrepancy
shall be alarmed. All analog signals shall be routed
through analog cards.
v) Programming Flow chart/Block logic ladder diagram. Tag based

format addressing format shall be used for programming in
the controller. The same shall be submitted for
Employer's review before programming of the system.
w) Long time stor- 168 hours latest data on hard disc. Data to be stored:
age & retrieval
i) Alarm list.
ii) Five analog points at scan rate.
iii) Fifteen analog points at one secs rate.
iv) Balance analog points at 5 minutes rate.
v) Binary points on status change.
vi) Log reports.
Software All application software with locks and passwords for

x) PLC functioning like input/output scanning,
acquisitions, condition processing, control and
communication, operator interface of monitors, display
trends, curves, bar charts, historical storage/ retrieval
and alarm functions. Complete set of documents for
modifications / editing / additions/ deletions of features
in software. Comprehensive list of all
application/system software.
y) Accessories Industrial grade furniture shall be provided along with

control desk/OWS/printer.
z) Software The contractor shall provide software license for all

license software being used in PLC based control system
including HMI. The software licenses shall be
provided for the project and shall not be

hardware/machine specific. All licenses shall be valid
for the continuous service life of the plant.
Software As a customer support the contractor shall periodically

upgrades inform the designated officer of the employer about
the software upgrades / new releases that would be
taking place after the system is commissioned so that
if required, same can be procured and implemented at
site.
8.02.00 Annunciation System
i) Facia Translucent glass/plastic window with

engraving.
ii) Operation Through PLC.
On occurrence Audible horn and flashing of facia lamp.

a) of trouble
b) Acknowledge Audible horn and flashing of facia lamp shall

button pressed stop. Facia lamp will become steady.
c) Reset button If fault is removed then facia lamp will go off.

pressed
d) Test button All lamps will glow.

pressed
iii) Monitoring Power supply to annunciator shall be

monitored.
9.00.00 DESK/PANEL CONSTRUCTION
a) Type Fabricated from cold rolled sheet steel
Frame thickness 2.0 mm
Enclosure thickness 1.6 mm
Gland plate thickness 3.0 mm
b) Switches AC22 category
c) Fuses HRC cartridge with visual operation indicator.
d) Name Plates & Each panel shall be identified by a name plate.

Labels Panel internal equipment shall be identified by
paint marking. Nameplates shall be non
rusting metal or 3-ply lamicoid, with engraved
lettering and shall be subjected to Employer’s
approval.

e) Grounding 25 x 3 mm copper ground bus to be provided

for each panel
f) Space heater 240V AC, single phase, thermostatically

controlled space heaters to be provided.
g) Terminal block 650V grade. clip-on type.
h) Type Elmex - CATD type for CTs. Elmex - CSLT for

other application.
i) Spare terminals 20 percent.
j) Wiring 650V grade. PVC insulated stranded copper

wire.
k) Panel Lighting Each free standing panel shall be provided

with a door switch operated fluorescent lamp
and a 240V AC plug point.
l) Painting Treatment as per IS:6005. Two coats of lead

oxide primer followed by powder painting with
final paint shade of RAL 9002. The paint
shade of the side end covers shall be RAL
5012.
m) Degree of For panels located in

enclosure
protection i) Air conditioned areas : IP-32
ii) Other areas : IP-52
iii)In dusty areas like : IP-65
Conveyor galleries, Transfer points,
Bunker area etc.
10.00.00 TYPE TESTS
the type tests as listed in this specification and carried out within last ten
(a.) However if the Contractor is not able to submit report of the type test(s)


(a.) All acceptance and routine tests as specified below and in relevant standards
equipment price.
furnished by the manufacturer confirming similarity and “No Design
Change”. Minor changes if any shall be highlighted on the endorsement
sheet
10.02.00 Programmable logic controller
10.02.01 Following test reports shall be submitted for the equipment:
a). Dry heat withstand test
b). Variation of temperature immunity test
c). Variation immunity test
d). Temperature cycle test
e). Noise immunity test
f). Dielectric test.
10.02.02 Following tests shall be conducted under this contract as routine tests:
a). Tests on internal and external wiring.
b). Incoming power supply voltage and frequency variation test.
c). Test for verification of functional characteristics of I/Os.
d). Task transition test (for each task, the contractor will list out the user
accessible conditions which shall be used in the simulation of the task).
e). Functional testing of software and hardware in accordance with the

approved block logic diagram with simulation of the system with switches,
relays and solenoid valves etc. or equivalent loads.

CLAUSE NO.
BATTERY
1.00.00 BATTERY RATINGS
As per system requirement.
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 bid.
In case of conflict between this specification and those (IS codes, Standards etc.)
referred to herein, the former shall prevail. All works shall be carried out as per
the following standards and codes:
IS : 10918 Specification for vented type Nickel Cadmium Batteries.
IS : 1069 Quality tolerances for water for storage batteries
Indian electricity rules

Indian Electricity Acts.
2.02.00 Equipment complying with other internationally accepted standards such as IEC.,
BS, VDE etc. will also be considered if they ensure performance and
English of the latest revision of the standards along with copies of all official
3.00.00 GENERAL TECHNICAL REQUIREMENT
3.01.00 Equipments
(a.) DC Batteries shall be stationary Nickel Cadmium Pocket plate type

conforming to IS:10918. For the purpose of design an ambient
temperature of 50 degree centigrade and relative humidity of 85% shall be
considered.
(b.) DC batteries shall be suitable for standby duty. The batteries shall
normally be permanently connected to the load in parallel with a charger
and shall supply the load during emergency conditions when AC supplies
are lost. Batteries shall be suitable for a long life under continuous float
operations and occasional discharges. The batteries shall be boost
charged at about 1.54 to 1.7 volts per cell maximum and float charged at
about 1.42 V/cell.
(c.) The number of cells for the 110 Volts shall be 84.

PROJECT SECTION-VI, BATTERY 1 OF 9
CLAUSE NO.
(d.) Batteries should be suitable for continuous operation for the maximum
ambient temperature as defined in technical parameters.
3.02.00 Construction Features
3.02.01 Containers
Containers shall be made of polypropylene plastic material. Containers shall be

robust, heat resistance, leak proof, non absorbent, alkali resistant, non-bulging
type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc.
Electrolyte level lines shall be marked on container in case of translucent
containers.
3.02.02 Vent Plugs
Vent plugs shall be provided in each cells. They shall be anti splash type, having
more than one exit hole shall allow the gases to escape freely but shall prevent
alkali from coming out. The design shall be such that the water loss due to
evaporation is kept to minimum. In addition the ventilator shall be easily removed
for topping up the cells and of such dimensions that the syringe type hydrometer
can be inserted into the vent to take electrolyte samples.
3.02.03 Plates
The plates shall be designed for maximum durability during all service conditions
including high rate of discharge and rapid fluctuations of load. The construction of
plates shall conform to latest revisions of IS:10918.
The separators shall maintain the electrical insulation between the plates and
shall allow the electrolyte to flow freely. Separators should be suitable for
continuous immersion in the electrolyte without distortion.
The positive and negative terminal posts shall be clearly marked.
3.02.04 Sediment Space
Sufficient sediment space shall be provided so that cells will not have to be
cleaned during normal life and prevent shorts within the cells.
3.02.05 Cell Insulator
Each cell shall be separately supported on PVC/porcelain/hard rubber insulators

fixed on to the racks with adequate clearance between adjacent cells. Minimum
distance between the adjacent cells shall be more than the budge allowed for two
cells in accordance with IS: 1146.

CLAUSE NO.
3.02.06 Electrolyte
The electrolyte shall be prepared from battery grade potassium hydroxide

conforming to BS: 1069.
The cells can be shipped either in charged condition or in dry condition
Necessary electrolyte for make-up shall be supplied separately.
3.02.07 Connectors and Fasteners
Nickel coated copper connectors shall be used for connecting up adjacent cells
and rows. Bolts, nuts and washers shall be effectively Nickel coated to prevent
corrosion. The thickness of Nickel coating of connectors should be not less than
0.02 mm. All the terminals and cells inter-connectors shall be fully insulated or
have insulation shrouds. End take off connections from positive and negative
poles of batteries shall be made by single core cables having stranded aluminium
conductors and XLPE insulation. Necessary supports and lugs for termination of
these cables on batteries shall also be supplied by the contractor. All connectors
and lugs shall be capable of continuously carrying the 30 minutes discharge
current of the respective batteries and through fault short circuit current which the
battery can produce and withstand for the period declared. Contractor shall
furnish necessary sizing calculations to prove compliance to the same. Suitable
number of Inter-rack connectors shall be supplied by the Bidder to suit the battery
room layout during detailed engineering.
3.02.08 Battery racks
Mild steel racks for all the batteries shall be provided. They shall be free standing
type mounted on procelain/hard rubber/PVC pads insulators. Batteries shall
preferably be located in the single tier arrangement. However, batteries having a
complete cell weight of lower than 50 Kg could be located in the double tier
arrangement. The batteries racks and supports for cable termination shall be
coated with three (3) coats of anti-alkali paint of approved shade. Name plates,
resistant to alkali, for each cell shall be attached on to the necessary racks. The
bottom tier of the stand shall not be less than 150 mm above the floor.
Wherever racks are transported in dismantled conditions, match markings shall

be provided to facilitate easy assembly.
3.02.09 Manufacturer’s Identification System
The following information shall be indelibly marked on outside of each cell.
(a.) Manufacturers’ name and trade marks
(b.) Country and year of manufacture.
(c.) Manufacturer type designation.

CLAUSE NO.
(d.) AH capacity at 5 hour discharge rate.
(e.) Serial number

4.00.00 THE FOLLOWING INFORMATION SHALL BE GIVEN ON THE INSTRUCTION
CARDS SUPPLIED WITH THE BATTERY:
(a.) Manufacturer's instructions for filling and initial charging of the battery
together with starting and finishing charging rate.
(b.) Maintenance instructions.
(c.) Designation of cell in accordance with IS:10918.
(d.) Storing conditions of electrolyte.
5.00.00 TESTS
5.01.00 GENERAL
(a.) All equipment to be supplied shall be of type test design. During detailed
all the type tests as per latest IS-1146 (for all applicable tests for containers) /
IS-10918 (for Ni-Cd Batteries) and carried out within last ten years from the
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. The complete type tests shall be
for any rating of battery in a particular group, based on plate dimensions.
(b.) However if the contractor is not able to submit reports of the type test(s)
the contractor shall conduct all such tests under this contract at no additional
cost to the owner either at third party lab or in presence of client/owners
(c.) All acceptance and routine tests shall be as per Quality assurance and
Inspection table of batteries.
furnished by the manufacturer confirming similarity and “No design Change”.
5.02.00 Commissioning checks.
All tests as listed below shall be carried out on sample cell selected at random by the
employer at site after completion of installation.

CLAUSE NO.
(a.) Physical Examination
(b.) Dimensions, Mass & layout
(c.) MARKING
(d.) Polarity and absence of short circuit.
(e.) Air pressure test
(f.) Ampere - hour capacity
(g.) Retention of charge
(h.) Insulation resistance
The Contractor shall arrange for all necessary equipment, including the variable
resistor, tools, tackles and instruments.
PART-B: LEAD –ACID PLANTE BATTERY

6.01.00 All standards, specification and codes of practice, referred to herein, shall be the
latest edition including all applicable official amendments and revisions as on
date of opening of bid.
In case of conflict between this specification and those (IS Codes Standards etc.)
referred to herein, the former shall prevail. All works shall be carried out as per
the following standards and codes :
IS : 266 Specification for sulphuric acid
IS : 1069 Specification for water for storage batteries
IS : 1146 Specification for rubber & plastic containers for lead acid storage
batteries.
IS : 1652 Specification for stationary cells and batteries, lead acid type (with
plant positive plates).
IS : 3116 Specification for sealing compound for lead acid batteries.
General requirements and methods of tests for lead acid storage

IS : 8320 batteries.
IS : 6071 Specification for synthetic separators for lead acid batteries.

CLAUSE NO.
Indian Electricity Rules
Indian Electricity Acts
6.02.00 Equipment complying with other internationally accepted standards such as IEC,
BS, VDE etc. will also be considered if they ensure performance and
English of the latest revision of the standards alongwith copies of all official
7.00.00 GENERAL TECHNICAL REQUIREMENTS
7.01.00 Equipments
DC Batteries shall be stationary lead acid Plante positive plate type conforming to
IS:1652. For the purpose of design an ambient temperature of 50 degree
centigrate and relative humidity of 85% shall be considered.
DC Batteries shall be suitable for standby duty. The Batteries shall normally be
permanently connected to the load in parallel with a charger and shall supply the
load during emergency conditions when AC supplies are lost. Batteries shall be
suitable for a long life under continuous float operations and occasional
discharges. The batteries shall be boost charged at about 2.7 volts per cell
maximum and float charged at about 2.25 V/cell:
The number of cells for the110 Volts shall be 53.
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.

CLAUSE NO.
The pole sealing arrangement should be such that no acid particle gets
entrapped due to acid creep as a result of capillary action and it should be
possible to remove and refix the sealing to carry out the maintenance.
7.02.02 Vent Plugs
Vent plugs shall be provided in each cell. They shall be antisplash type, having
more than one exit hole shall allow the gases to escape freely but shall prevent
acid from coming out. The design shall be such that the water loss due to
evaporation is kept to minimum. In addition the ventilator shall be easily removed
for topping up the cells and of such dimensions that the syringe type hydrometer
can be inserted into the vent to take electrolyte sample.
7.02.03 Plates
The plates shall be designed for maximum durability during all service conditions
including high rate of discharge and rapid fluctuations of load. The construction of
plates shall conform to latest revisions of IS: 1652 as applicable.
The separators shall maintain the electrical insulation between the plates and
shall allow the electrolyte to flow freely. Separators should be suitable for
continuous immersion in the electrolyte without distortion. The positive and
negative post shall be clearly marked.
7.02.04 Sediment Space
Sufficient sediment space shall be provided so that cells will not have to be
cleaned during normal life and prevent shorts within the cells.
7.02.05 Cell Insulator
Each cell shall be separately supported on PVC/porcelain/hard rubber insulators

fixed on the racks with adequate clearance between adjacent cells. Minimum
distance between adjacent cells shall be more than the buldge allowed for two
cells in accordance with IS: 1146.
7.02.06 Electrolyte
The electrolyte shall be prepared from battery grade sulphuric acid conforming to
IS:266 and distilled water conforming to IS:1069. The cells shall be shipped dry
uncharged. The electrolyte shall be supplied separately.
7.02.07 Connectors and Fasteners
Lead or Lead coated copper connectors shall be used for connecting up adjacent
cells and rows. Bolts, nuts and washers shall be effectively lead coated to prevent
corrosion. The thickness of lead-coating of connectors should not be less than
0.025 mm. The lead coating thickness shall be measured in accordance with
APPENDIX F of IS: 6848 (latest edition). All the terminals and cells inter-
connectors shall be fully insulated or have insulation shrouds. End take off
connections from positive and negative poles of batteries shall be made by single

CLAUSE NO.
core cables having stranded aluminium conductors and XLPE insulation.

Necessary supports and lugs for termination of these cables on batteries shall
also be supplied by the contractor. All connectors and lugs shall be capable of
continuously carrying the 30 minutes discharge current of the respective Batteries
and through fault short circuit current which the battery can produce and
withstand for the period declared. Contractor shall furnish necessary sizing
calculations to prove compliance to the same.
7.02.08 Battery racks
Wooden racks for all the batteries shall be provided. These racks shall be made
of good quality first class seasoned teak wood in line with CPWD specification.
They shall be free standing type mounted on porcelain/hard rubber/PVC pads
insulators. Batteries shall preferably be located in the single tier arrangement.
However, batteries having a complete cell weight of lower than 50 Kg could be
located in the double tier arrangement. The batteries rack and wooden support
for cable termination shall be coated with three (3) coats of anti-acid paint of
approved shade. Numbering tags, resistant to acid, for each cell shall be
attached on to the necessary racks. The bottom tier of the stand shall not be less
than 150 mm above the floor. Wherever racks are transported in dismantled
condition, suitable match markings shall be provided to facilitate easy assembly.
7.02.09 Manufacturer’s Identification Systems
The following information shall be indelibly marked on outside of each cell.
(a.) Manufacturer's name and trade marks
(b.) Country and year of manufacture.
(c.) Manufacturer type designation.
(d.) AH capacity at 10 hour discharge rate.
(e.) Serial number
8.00.00 TESTS
8.01.00 GENERAL
(a) All equipment to be supplied shall be of type test design. During detailed
the type tests as per latest IS-1146 (for rubber & plastic containers for Lead –
acid storage batteries) and carried out within last ten years from the 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

CLAUSE NO.
been witnessed by a client. The complete type tests shall be for any rating of
battery in a particular group, based on plate dimensions.
(b) However if the contractor is not able to submit reports of the type test(s)
conducted within last ten years from the date of bid opening, or in case the type
test report(s) are not found to be meeting the specification requirements, the
contractor shall conduct all such tests under this contract at no additional cost to
the owner either at third party lab or in presence of client/owners representative
and submit the reports for approval.
(c) All acceptance and routine tests shall be as per Quality assurance and
Inspection table of batteries.
(d) The type test reports once approved for any projects shall be treated as
8.02.00 Commissioning checks

All tests as listed below shall be carried out on sample cell selected at random by
the employer at site after completion of installation.
1) Verification of markings.
2) Verification of dimensions.
3) Test for capacities for 10 hrs discharge rate alongwith the test for voltage
during discharge.
The Contractor shall arrange for all necessary equipment, including the variable
resistor, tools, tackles and instruments. If a battery fails to meet the guaranteed
requirements the Employer shall have the option of asking the Contractor to
replace the same.

CLAUSE NO.
BATTERY CHARGER
of opening of bid. In case of conflict between this specification and those (IS codes,
standards etc.) referred to herein, the former shall prevail. All work shall be carried
out as per the following standards and codes.
ANSI-C Guide for surge withstand capability tests

37.90a
IS:5 Colours for ready mix paints.
IS : 694 PVC Insulated Cable for working voltages upto and including 1100 V.
IS : 1248 Specification for Direct acting indicating analogue electrical

measuring instruments.
IS:13947 Degree of protection provided by enclosures for low voltage switch

Part-1 gear and control gear.
IS : 13947 Specification for low voltage switch gear and control gear
IS : 3231 Electrical relays for power system protection.
IS : 3842 Application guide for Electrical relays for AC System
IS : 3895 Mono-crystalline semi-conductor Rectifier Cells and Stacks
IS : 4540 Mono crystalline semi-conductor Rectifier assemblies and equipment.
IS:6005 Code of practice for phosphating of Iron and Steel.
IS:6619 Safety Code for Semi-conductor Rectifier Equipment.
IS:6875 Control switches (switching devices for control and auxiliary circuits
including contactor relays) for voltages upto 1000 V AC or 1200 V
DC.
IS : 9000 Basic environmental testing procedures for electronic and electrical

items.
IS:13703 Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V
DC.
EEUA-45D Performance requirements for electrical Alarm Annunciation System
Indian Electricity Rules

PROJECT
SECTION-VI, BATTERY CHARGER 1 OF 11
CLAUSE NO.
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 alongwith copies of all official amendments and revisions in
force as on date of opening of bid and shall clearly bring out the salient features for
comparison.
2.00.00 EQUIPMENT DESCRIPTION
2.01.00 PART-I BATTERY CHARGER FOR LEAD ACID PLANTE TYPE BATTERY
(a.) The Battery Chargers as well as their automatic regulators shall be of static
type. Battery chargers shall be capable of continuous operation at the
respective rated load in Trickle mode i.e. Trickle charging the associated DC
lead-acid Batteries while supplying the D.C. loads. The Batteries shall be
Trickle charged at 2.25 Volts per cell. All chargers shall also be capable of
Boost charging the associated D.C. Battery at 2.0 to 2.7 Volts per cell at the
desired rate. The Chargers shall be designed to operate, as mentioned
above, at an ambient air temperature of 50°C.
(b.) Battery Chargers shall have a selector switch for selecting the battery
charging mode i.e. whether Trickle or Boost charging.
(c.) All Battery Chargers shall be provided with facility for both automatic and
manual control of output voltage and current. A selector switch shall be
provided for selecting the mode of output voltage/current control, whether
automatic or manual. Means shall be provided to avoid current/voltage
surges of harmful magnitude/nature which may arise during changeover from
Auto to Manual mode or vice-versa under normal operating condition.
(d.) Soft start feature shall be provided to build up the voltage to the set value
slowly within fifteen seconds. The chargers shall have load limiters which
shall cause, when the voltage control is in automatic mode, a gradual
lowering of the output voltage when the DC load current exceeds the load
limiter setting of the Charger. The load limiter characteristic shall be such that
any sustained overload or short circuit in DC system shall neither damage the
Charger nor shall it cause blowing of any of the changer fuses. The Charger
shall not trip on overload or external short circuit. After clearance of fault, the
Charger voltage shall build up automatically when working in automatic
mode.
(e.) When on automatic control mode during Trickle charging, the Charger output
voltage shall remain within +/-1% of the set value for AC input voltage
variation of +/-10%, frequency variation of +3/-5%, a combined voltage and
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

PROJECT
CLAUSE NO.
specified. Stepless adjustment of the load limiter setting shall also be

possible from 80% to 100% of the rated output current for Trickle charging
mode.
(f.) During Boost charging, the Battery Chargers shall operate on constant
current mode (When automatic regulator is in service). It shall be possible to
adjust the Boost charging current continuously over a range of 50 to 100% of
the rated output current for Boost charging mode. The charger output voltage
shall automatically go on rising, when it is operating on boost mode, as the
battery charges up. For limiting the output voltage of the charger, a
potentiometer shall be provided on the front of the panel, whereby it shall be
possible to set the upper limit of this voltage anywhere in the output range
specified for boost charging mode. All voltage and current setting
potentiometers shall be vernier type.
(g.) Energising the Charger with fully charged battery connected plus 10% load
shall not result in output voltage greater than 110% of the voltage setting.
Time taken to stabilise, to within the specified limits as mentioned elsewhere,
shall be less than fifteen seconds.
(h.) Momentary output voltage of the Charger, without the Battery connected shall
be within 94% to 106% of the voltage setting during sudden load Change
from 100% to 20% of full load or vice-versa. Output voltage shall return to,
and remain, within the limits specified as mentioned elsewhere in less than 2
seconds after the above mentioned change.
(i.) The Charger manufacturer may offer an arrangement in which the voltage
setting device for Trickle charging mode is also used as output voltage limit
setting device for Boost charging mode, and the load limiter of the trickle
charging mode is also used as Boost charging current setting device.
(j.) Suitable filter circuits shall be provided in all the Chargers to limit the ripple
content (peak to peak) in the output voltage to 1% irrespective of the DC
load, even when they are not connected to a battery.
(k.) The DC System shall be ungrounded and float with respect to the ground
potential when healthy. An earth fault relay shall be provided by the Employer
in the DC distribution board for remote annunciation.
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.

PROJECT
CLAUSE NO.
(b.) Battery Chargers shall have a selector switch for selecting the battery
charging mode i.e. whether Trickle or Boost charging.
(c.) All Battery Chargers shall be provided with facility for both automatic and
manual control of output voltage and current. A selector switch shall be
provided for selecting the mode of output voltage/current control, whether
automatic or manual. Means shall be provided to avoid current/voltage
surges of harmful magnitude/nature which may arise during changeover from
Auto to Manual mode or vice-versa under normal operating condition.
(d.) Soft start features shall be provided to build up the voltage to the set value
slowly within fifteen seconds. The chargers shall have load limiters which
shall cause, when the voltage control is in automatic mode, a gradual
lowering of the output voltage when the DC load current exceeds the load
limiter setting of the Charger. The load limiter characteristic shall be such that
any sustained overload or short circuit in DC system shall not damage the
Charger, nor shall it cause blowing of any of the charger fuses. The Charger
shall not trip on overload or external short circuit. After clearance of fault, the
Charger voltage shall build up automatically when working in automatic
mode.
(e.) When on automatic control mode during Trickle charging, the Charger output
voltage shall remain within +/-1% of the set value for AC input voltage
variation of +/-10%, frequency variation of +3 to -5%, a combined voltage and
frequency (absolute sum) variation of 10% and a continuous DC load
variation from zero to full load. Uniform and stepless adjustments of voltage
setting (in both manual and automatic modes) shall be provided on the front
of the Charger panel covering the entire Trickle charging output range
specified. Stepless adjustment of the load limiter setting shall also be
possible from 80% to 100% of the rated output current for Trickle charging
mode.
(f.) During Boost charging, the Battery Chargers shall operate on constant
current mode (When automatic regulator is in service). It shall be possible to
adjust the Boost charging current continuously over a range of 50 to 100% of
the rated output current for Boost charging mode. The charger output voltage
shall automatically go on rising, when it is operating on boost mode, as the
battery charges up. For limiting the output voltage of the charger, a
potentiometer shall be provided on the front of the panel, whereby it shall be
possible to set the upper limit of this voltage anywhere in the output range
specified for boost charging mode. All voltage and current setting
potentiometers shall be vernier type.
(g.) Energising the Charger with fully charged battery connected plus 10% load
shall not result in output voltage greater than 110% of the voltage setting.
Time taken to stabilise, to within the specified limits as mentioned elsewhere
shall be less than fifteen seconds.
(h.) Momentary output voltage of the Charger, without the Battery connected shall
be within 94% to 106% of the voltage setting during sudden load Change
from 100% to 20% of full load or vice-versa. Output voltage shall return to,

PROJECT
CLAUSE NO.
and remain, within the limits specified as mentioned elsewhere in less than 2
seconds after the above mentioned change.
(i.) The Charger manufacturer may offer an arrangement in which the voltage
setting device for Trickle charging mode is also used as output voltage limit
setting device for Boost charging mode, and the load limiter of the trickle
charging mode is also used as Boost charging current setting device.
(j.) Suitable filter circuits shall be provided in all the Chargers to limit the ripple
content (peak to peak) in the output voltage to 1% irrespective of the DC
load, even when they are not connected to a battery.
(k.) The DC System shall be ungrounded and float with respect to the ground
potential when healthy. An earth fault relay shall be provided by the Employer
in the DC distribution board for remote annunciation.
2.03.00 Printed Circuits Boards (PCB)
PCB shall be made of glass epoxy of 1.6 mm thick, fire resistant, bonded with 99.8%
pure copper foil, free of wrinkles, blisters, scratches and pinholes. The contact
surface of the edge connectors of the PCBs shall be plated with hard gold to a
minimum thickness of 5 microns. Component identification shall be printed on PCB
by silk screen method. All PCBs shall be tropicalised and masked.
2.04.00 CONTACTORS
All Battery Chargers shall have an AC contactor on the input side. It shall be of air
break type and suitable for continuous duty. The operating coil shall be rated for 415
Volts AC.
2.05.00 Thermal Overload Relay
A thermal overload relay incorporating a distinct single phasing protection (using

differential movement of bimetal strips) shall also be provided for the AC input. The
relay shall trip the above contactor.
2.06.00 Rectifier-Transformers and Chokes
The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating
of the rectifier-transformers and chokes shall correspond to the rating of the
associated rectifier assembly. The rectifier-transformers and chokes shall have
class-B insulation with temperature rise limited to class-A insulation value.
2.07.00 Rectifier Assembly
The rectifier assembly shall be full wave bridge type and designed to meet the duty
as required by the respective Charger. The rectifier cells shall be provided with their
own heat dissipation arrangement with natural air cooling. The rectifier shall utilise
diodes/thyristors and heat sinks rated to carry 200% of the load current continuously
and the temperature of the heat sink shall not be permitted to exceed 85°C absolute
duly considering the maximum charger panel inside temperature. The Contractor
shall submit calculations to show what maximum junction temperature will be and

PROJECT
CLAUSE NO.
what the heat sink temperature will be when operating at 200% and 100% load
current continuously duly considering the maximum surrounding air temperature for
these devices inside the charger panel assuming air ambient temperature of 50°C
outside the panel. Necessary surge protection devices and rectifier type fast acting
fuses shall be provided in each arm of the rectifier connections.
2.08.00 DIGITAL INDICATING INSTRUMENTS
Digital indicating instruments with built in communication port for remote data
transfer shall be provided for all chargers. The instruments shall indicate DC current,
DC voltage & AC voltage and instrument shall be 96 x 96 sqmm, with display
accuracy 0.5%, 4 digit – 7 segment LED/LCD display and RS 485 serial Bus port.
2.09.00 AIR BREAK SWITCHES
All Chargers shall have AC input and DC output switches of air break, single throw,
load break and fault make type. The contacts of the switches shall open and close
with a snap action. Switches shall be rated for 120% of the maximum continuous
load. ‘ON’ & ‘OFF’ position of the switch shall be clearly indicated.
2.10.00 CONTROL AND SELECTOR SWITCHES
Control and selector switches shall be of rotory stayput type with escutcheon plates
showing the functions and positions. The switches shall be of sturdy construction and
suitable for mounting on panel front. Switches with shrouding of live parts and
sealing of contacts against dust ingress shall be preferred. The contact ratings shall
be atleast the following :
(a.) Make and carry continuously – 10 Amps.
(b.) Breaking current at 220 V DC – 0.5 Amp. (inductive)
(c.) Breaking current at 240 V AC – 5 Amp. At 0.3 p.f.
2.11.00 FUSES
Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse
carriers which are mounted on fuse bases. Wherever it is not possible to mount
fuses on fuse carriers, fuses shall be directly mounted on plug in type bases. In such
cases one insulated fuse pulling handle shall be supplied for each charger. Kick-off
fuses (trip fuses) with alarm contacts shall be provided for all D.C. fuses.
2.12.00 Indicating Lamps
Three (3) indicating lamps shall be provided to indicate A.C. supply availability. The
indicating lamp shall be of panel mounting, filament type low wattage or LEDs and
capable of clear status indication under the normal room illumination. The lamps
shall be provided with series resistors (non-hygroscopic) preferably built in the lamp
assembly and replaceable from front. The lamp covers shall be preferably screwed
type, unbreakable and moulded from heat resistant material.

PROJECT
CLAUSE NO.
2.13.00 Blocking Diode
Blocking diode shall be provided in the output circuit of each Charger to prevent
current flow from the D.C. Battery into the Charger.
2.14.00 Annunciation System
Visual indications through indicating lamps/LEDs or annunciation facia as per

EEUA-45D shall be provided in all Chargers for the following:
(a.) A.C. supply failure
(b.) Rectifier fuse failure
(c.) Surge circuit fuse failure
(d.) Filter fuse failure
(e.) Load limiter operated
(f.) Charger trip
(g.) Battery on Boost
Potential free NO contacts of all above conditions shall be provided for following
remote alarms in the Employer’s Unit Control Board:
(h.) Battery on Boost
(i.) Charger trouble (this being a group alarm initiated by any of the faults other
than ‘Battery on Boost’)
2.15.00 Name Plates and Marking
The name plates shall be made of non-rusting metal/3 ply Lamicoid and shall have
black back-ground with white engraved letters and secured by screws. These shall
be provided near top edge on the front as well as on rear side of Charger. Name
plates with full and clear inscriptions shall also be provided on and inside the panels
for identification of the various equipments.
3.00.00 CONSTRUCTION
3.01.00 The Chargers shall be indoor, floor mounted, self supporting sheet metal enclosed
cubicle type. The Contractor shall supply all necessary base frames, anchor bolts
and hardware. The Charger shall be fabricated using cold rolled sheet steel shall not
less than 1.6 mm and shall have folded type of construction. The panel frame shall
be fabricated using cold rolled sheet steel of thickness not less than 2.0 mm.
Removable undrilled gland plates of at least 3.0 mm sheet steel and lugs for all
cables shall be supplied by the Contractor. The lugs for cables shall be made of
electrolytic copper with tin coat. Cable sizes shall be advised to the Contractor at a
later date for provision of suitable lugs and gland plates. The Charger shall be
tropicalised and vermin proof. Ventilation louvers shall be backed with fine brass wire

PROJECT
CLAUSE NO.
mesh. All doors and covers shall be fitted with synthetic rubber gaskets. The
Chargers shall have hinged double leaf doors provided on front and/or backside for
adequate access to the Charger internals. All the Charger cubicle doors shall be
properly earthed. The degree of protection of Charger enclosure shall be atleast IP-
42.
3.02.00 All indicating instruments, control & selector switches and indicating lamps shall be
mounted on the front side of the Charger. Design of panels shall be based on the
following dimensions.
1) Overall height - Maximum 2350 mm
2) Operating handles - Maximum 1800 mm

(highest and lowest Minimum 350 mm
positions reached by
operator’s hands),
protective mechanical
indicators
3) Doors and panel - Maximum 1800 mm

handles and locks Minimum 300 mm
3.03.00 Electronic equipments shall be of modular design consisting of plug in modules in
standard 19 inches metallic racks with metallic card guides. The cards should be
provided with proper handles. Card to card wiring should be preferably through a
mother board. Unplanned jumpering and track modifications are not permitted.
Mechanical interlocks to prevent wrong insertion of cards should be provided. Each
card shall have its junction and test points identified. Maintenance aids such as
extension printed wiring boards and jumper leads shall be provided.
3.04.00 The layout of Charger components shall be such that their heat losses do not give
rise to excessive temperature within the Charger panel surface. Location of the
electronic modules will be such that temperature rise of the location, in no case, will
exceed 10°C over ambient air temperature outside the Charger.
3.05.00 Each Charger panel shall be provided with an illuminating lamp and one 5 Amp.
Socket. Switches and fuses shall be provided separately for each of the above.
3.06.00 Locking facilities shall be provided as following:
(a.) For locking Trickle/Boost selector switch in the trickle position only. This
would be used for having key mechanical interlock between Trickle/Boost
selector switch and isolator in D.C. distribution board which is being procured
separately by the employer.
(b.) The Charger enclosure door locking requirements shall be met by the
application of padlocks. Padlocking arrangement shall allow ready insertion of
the padlock shackle but shall not permit excessive movement of the locked
parts with the padlock in position.

PROJECT
CLAUSE NO.
3.07.00 Wiring
3.07.01 Each Charger shall be furnished completely wired upto power cable lugs and
terminal blocks ready for external connection. The power wiring shall be carried out
with 1.1 KV grade PVC insulated cables conforming to IS:1554 (Part-I). The control
wiring shall be of 1.1KV grade PVC insulated stranded copper conductors of 2.5
sq.mm. conforming to IS:694. Control wiring terminating at electronic cards shall not
be less than 1.0 sq. mm. Control terminal shall be suitable for connecting two wires
with 2.5 sq.mm. stranded copper conductors. All terminals shall be numbered for
ease of connections and identification. At least 20% spare terminals shall be
provided for circuits.
3.07.02 Power and control wiring within panels shall be kept separate. Any terminal or metal
work which remains alive at greater than 415 V, when panel door is opened, shall be
fully protected by shrouding.
3.07.03 An air clearance of at least ten (10) mm shall be maintained throughout all circuits,
except low voltage electronic circuits, right upto the terminal lugs. Whenever this
clearance is not available, the live parts should be insulated or shrouded.
3.08.00 PAINTING
Treatment as per IS:6005. Two coats of lead oxide primer followed by powder
painting with final shade of RAL9002 for complete panel except end covers & RAL
5012 for end covers.
4.00.00 TESTS
4.01.00 GENERAL
1.
All equipment to be supplied shall be of type test design. During detailed
a) Complete physical examination

b) Temperature rise test at full load.
c) Temperature rise test of rectifier assembly at 200% of full load.
d) Insulation resistance test.
e) High voltage (power frequency) test on power and control circuits
except low voltage electronic circuits.
f) Ripple content test at
i) No load
ii) Half load

PROJECT
CLAUSE NO.
iii) Full load

g) Automatic voltage regulator operation test at specified A.C. supply
variations at
i) No load
ii) Half load
iii) Full load

h) Load limiter operation test
i) Efficiency and power factor measurement.
j) Input and output surge withstand capability test. Surge Voltage as per
ANSI-C37.90a shall be applied for period not less than 2 sec. At the
following points of the Charger operating at 50 deg. C at full load :
i) Across each A.C. input phase
ii) Across AC input line to ground.
iii) Across D.C. output terminals.
iv) Across each D.C. output terminal to ground
The Charger shall not exhibit any component damage

and there shall be no change in performance as per (g)
and (h).
k) Environmental Tests
Steady state performance tests (g) and (h))shall be carried out before
and after each of the following tests.
i) Soak Test
The electronic modules shall be subjected to

continuous operation for a minimum period of 72
hours. During last 48 hours, the ambient temperature
shall be maintained at 50 deg. C. The 48 hour test
period shall be divided into four equal 12 hour
segments. The input voltage during each 12 hours
shall be nominal voltage for 11 hours followed by
110% of nominal voltage for 30 minutes, followed by
90% of nominal voltage for 30 minutes.
ii) Degree of protection test.
2. However if the Contractor is not able to submit report of the type test(s)

PROJECT
CLAUSE NO.
type test report(s) are not found to be meeting the specification

requirements, the Contractor shall conduct all such tests under this contract
at no additional cost to the Owner either at third party lab or in presence of
client/owners representative and submit the reports for approval.
3. All routine tests as per QA table and relevant standards shall be carried out.
Charges for these shall be deemed to be included in the equipment price.
4. The type test reports once approved for any projects shall be treated as
5.00.00 COMMISSIONING
5.01.00 The contractor shall carryout the following commissioning tests and checks after
installation of the equipment at site:
(a.) Complete physical examination.
(b.) Checking of proper operation of annunciation system.
(c.) Temperature rise test at full load.
(d.) Insulation resistance test.
(e.) Automatic voltage regulator operation.
(f.) Load limiter operation.
(g.) Dynamic response test.
Overshoot/Undershoot in output voltage of the Charger as a result of sudden change

in load from 100% to 20% and 20% to 100% shall be measured with the Batteries
connected/disconnected. Output voltage of the Charger connected with Battery shall
be within 94% to 106% of the voltage setting in above conditions and shall return to,
and remain, within the limits specified as mentioned elsewhere, in less than 2
seconds (as applicable).

PROJECT
MEASURING INSTRUMENTS
1.00.00 MEASURING INSTRUMENTS
1.01.00 Measuring instruments/equipment and subsystems offered by the Bidder shall be

from reputed experienced manufacturers of specified type and range of equipment,
whose guaranteed and trouble free operation has been proven. Further, all
instruments shall be of proven reliability, accuracy, and repeatability requiring a
minimum of maintenance. They shall comply with the acceptable international
standards and shall be subject to Employer's approval. All instrumentation
equipment and accessories under this specification shall be furnished as per
technical specifications, ranges, makes/numbers as approved by the Employer
during detailed engineering.
1.02.00 Every panel-mounted instrument requiring power supply shall be provided with a pair
of easily replaceable glass cartridge fuses of suitable rating. Every instrument shall
be provided with a grounding terminal and shall be suitably connected to the panel
grounding bus.
1.03.00 All local gauges as well as transmitters, sensors, and switches for parameters like
pressure, temperature, level, flow etc. as required for the safe and efficient operation
and maintenance as well as for operator and management information (including all
computation) of equipment under the scope of specification shall be provided on as
required basis within the quoted lump sum price.
1.04.00 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve
manifolds and all the other accessories required for mounting/erection of these local
instruments shall be furnished, even if not specifically asked for, on as required
basis. The contacts of equipment mounted instruments, sensors, switches etc. for
external connection including spare contacts shall be wired out in flexible/rigid
conduits, independently to suitably located common junction boxes. The proposal
shall include the necessary cables, flexible conduits, junction boxes and accessories
for the above purpose. Double root valves shall be provided for all pressure tapping
where the pressure exceeds 40 Kg./sq.cm.
2.00.00 SPECIFICATION FOR ELECTRONIC TRANSMITTER FOR PRESSURE AND D.P.

2.01.00 ELECTRONIC TRANSMITTERS
Sr. Features Essential/Minimum Requirements
No.
1. Type of Transmitter Microprocessor based 2 wire type, HART protocol

compatible.
2. Accuracy ± 0.1% of calibrated span ( minimum)
3. Output signal range 4-20 Ma DC (Analog) along with superimposed

digital signal (based on HART protocol)
FARAKKA SUPER THERMAL POWER SUB-SECTION-IIIB-14

TECHNICAL SPECIFICATION PAGE
PROJECT MEASURING
SECTION-VI, 1 OF 10
COAL CONVEYING PLANT PACKAGE INSTRUMENTS
PART-B
4. Turn down ratio 10:1 for vacuum/very low pressure applications.
30:1 for other applications.
5. Stability ± 0.1% of calibrated span for six months for

Ranges up to and including70 Kg/cm².
± 0.25% of calibrated span for six months for

Ranges more than 70 Kg/cm² (g).
6. Zero and span drift +/- 0.015% per deg.C at max span.
+/-0.11% per deg.C at min. span.
7. Load impedance 500 ohm (min.)
8. Housing Weather proof as per IP-55 with durable

corrosion resistant coating.
9. Over Pressure 150% of max. Operating pr.
10. Connection (Electrical) Plug and socket type
11. Process connection 1/2 inch NPT (F)
12. Span and Zero Continuous, tamper proof, Remote as well as

adjustability manual from instrument with zero
suppression and elevation facility.
13. Accessories -Diaphragm seal, pulsation dampeners, siphon

etc. as required by service and operating
condition.
-2 valve manifold for absolute pressure

transmitters (3-valve manifold for gauge/ vacuum
pressure transmitters) and 5 valve manifold for
DP/level/flow transmitters.
-For hazardous area, explosions proof enclosure

as described in NEC article 500.
14. Diagnostics Self Indicating feature
15. Power supply 24V DC ± 10%.
16. Adjustment/calibration Total two (2) no. of hand- held type universal
/maintenance calibrators compatible with HART protocol , shall
be provided (for all three units).

PROJECT MEASURING
SECTION-VI, 2 OF 10
PART-B
Note.
In case it becomes necessary to use a DP transmitter for pressure

measurement, then a 3-valve manifold should be used in place of 2-valve
manifold.
LVDT type is not acceptable.
Where the process fluids are corrosive, viscous, solid bearing or slurry
type, diaphragm seals shall be provided. Parts below the diaphragm shall
be removable for cleaning. The entire volume above the diaphragm shall
be completely filled with an inert liquid suitable for the application.
2.02.00 ULTRASONIC LEVEL TRANSMITTERS
Sl. no Features Essential/Minimum requirements

1. Type of Transmitter Non contact Microprocessor based 2 wire
type, HART protocol compatible Ultrasonic
transmitter.
2. Output signal Galvanic ally isolated 4-20mA DC (Analog)
along with superimposed digital signal (based
on HART protocol).
3. Sensor Accuracy +/- 0.5% of calibrated span.
4. Sensor Repeatability 3 mm or better.
5. Power supply 24 V DC +/- 10%
6. Temperature To be provided within transducer.
compensation
7. Configuration Sensor unit and Electronic units are to be
separate. It shall be possible to mount the
Electronic unit at a remote accessible location
from the transducer. All cables and weather
proof fittings to interconnect transducer to
electronic unit shall be provided by Bidder.
8. Housing Weather proof as per IP-55 with durable
corrosion resistant coating.
9. Calibration Through HART Communicator.
10. Zero and Span Continuous, tamper proof, remote as well as
adjustment manual adjustability from instrument. It shall
be possible to calibrate the instrument without
any level in the tank/sump etc
11. Sensor Material Corrosion resistant material to suit individual
application requirement.

PROJECT MEASURING
SECTION-VI, 3 OF 10
PART-B
12. False signal tolerance Transmitter shall be capable of ignoring false

echoes from internal tank/sumps obstructions
such as pipes, heating coils or agitator blades.
Also transmitter shall have adjustable damping
circuitry
13. Range Range of transmitter shall be capable of
covering the complete level span of tank
taking care of blocking distance, frequency
attenuation due to surface, obstructions,
vapors etc
14. Display Minimum 4 character display with integral
keypad, access protected by user code.
15. Diagnostics Loss of echo alarm etc
16. Load Impedance 500 ohms minimum
17. Electrical Connection Plug and socket
18. Accessories • All weather canopy for protection from
direct sunlight and direct rain.
• All mounting hardware and accessories
required for erection and commissioning
mounting fittings material shall be SS 316.
• For hazardous areas, explosion proof
enclosure as described in NEC article 500.
Note:-
Contractor can also provide Radar type transmitter in place of ultrasonic transmitters
subject to approval by Employer during detailed Engineering.
3.00.00 TEMPERATURE ELEMENTS
3.01.00 RESISTANCE TEMPERATURE DETECTOR ( RTD )
Sr. Features Essential/Minimum Requirements

No.
1 Type of RTD. : Pt-100 (100 Ohms resistance at zero
degree centigrade)
2 No. of element : Duplex
3 Housing/Head : IP-55/Diecast Aluminium. Plug in
connectors are to be provided for
external signal cable connection.
4 Sheathing of RTD : Metal sheathed, ceramic packed
5 Calibration and accuracy : As per DIN-43760 Class-A
6 Characteristic : Linear with respect to temp, within ±1/2

PROJECT MEASURING
SECTION-VI, 4 OF 10
PART-B
percent of top range value.

7 Accessories : Thermo well (as specified below) and
shall be spring loaded for positive
contacts with the well.
8 Standard : DIN-43760 for RTD and ASME PTC-19.3
for Thermo-well.
3.02.00 THERMO WELL
Thermo well shall be one piece solid bored type of 316SS of Step-less tapered
design (as per ASME PTC 19.3, 1974).
TEMPERATURE TRANSMITTER
Following type of 2-wire temperature transmitter (directly powered from 4-20mA
input cards of DDCMIS) shall be provided. The temperature transmitter shall be
fully compatible with thermocouples and RTDs being provided by the contractor.
Temperature compensation of the thermocouples shall be performed in the
temperature transmitter itself.
Single Input DIN-rail mounted Temperature Transmitter
These shall be suitable for mounting on DIN-rails in JBs. The specifications of the
JBs shall be same as indicated in Subsection INST CABLE with additional DIN-
rails and IP 65 Protection class. This temperature transmitter shall be the ones
which are especially designed for DIN-rail mounting with IP 20 protection class.
These shall have terminals for input/output provided on front side when mounted
on DIN-rail. Head mounted temperature transmitter with clamps to make it suitable
for DIN-rail mounting shall not be acceptable under this category.
Requirements for each of the above type of temperature transmitters
Output : 2-wire (power supply from input card of

Control System) with 4-20mA output with
superimposed HART protocol signal.
Input : Same transmitter shall be capable to handle

Pt-100 RTD , Thermocouples –K&R types
(input type to be selectable at site through
HART terminal)
Isolation : min. 500 V AC
EMC compatibility : as per EN 61326

Operating ambient : 0 to 85 deg C (without indicator)
temperature
0 to 70 deg C (with indicator)
Power supply compatible with input module of Control

System

PROJECT MEASURING
SECTION-VI, 5 OF 10
PART-B
Accessories Mounting arrangements including clamps etc.
Composite Accuracy
(Refer note 2) RTD =<0.4% of 0-250 deg C span
T/C-K type =<0.4% of 0-600 deg C span
T/C-R type =<0.4% of 0-1000 deg C span
CJC accuracy (for thermocouples) shall be =<

1 deg C
Notes:-
1. In case of failure (open or burn-out) of RTD/thermocouple, temp. Transmitter

shall provide low temperature output.
2. Composite Accuracy is to be calculated as summation of all applicable

accuracies of temp transmitter, for converting sensor input to output in 4-20
mA (e.g., basic accuracy, digital accuracy, D/A accuracy, etc.) and
temperature effect on these accuracies at ambient temperature of 50 deg C,
based on the figure/ formula given in the standard product catalogue for span
as specified above for various types of Temperature Elements specified. All
such accuracy/ temp effect figures in catalogue shall be first converted to deg
C, and then percentage of this converted accuracy in specified span shall be
calculated to compare with the specified composite accuracy figures.
3.04.00 Hand held calibrator

Hand held calibrators (2 nos) shall be provided for adjustment/calibration/
maintenance of the HART compatible temperature transmitters.

PROJECT MEASURING
SECTION-VI, 6 OF 10
PART-B
4.00.00 SPECIFICATIONS FOR PR. GAUGE, D.P. GAUGE, TEMP. GAUGE AND LEVEL
GAUGE.
Sl. FEATURES ESSENTIAL/MINIMUM REQUIREMENTS

No
Pr. Gauge/ DP Temperature Level Gauge

Gauge/ Gauge
Draught
gauges
1 Sensing Bourdon for Mercury in steel Tempered * toughened

Element and high pressure, for below 450°C Borosilicate gauge
material Diaphragm/Bel and inert gas glass steel armoured
low for low pr. actuated for reflex or transparent
Of 316 SS above 450°C of type.
SS bulb and
capillary.
2 Body Die-cast Die-cast Forged carbon

material aluminium aluminium steel/304 SS
3 Dial size 150mm 150 mm Tubular covering entire

range
4 End 1/2 inch NPT 3/4" NPT (M) Process connection as

connection (M) per ASME PTC and
drain/vent 15 NB
5 Accuracy ±1% of span ± 1% of span ± 2%
6 Scale Linear, 270° Linear, 270° arc Linear vertical

arc graduated graduated in °C
in metric units
7 Range Cover 125% of Cover 125% of Cover 125% of max. of

selection max. of scale max. of scale scale
8 Over range Test pr. for the assembly shall be1.5 to the max. Design pr.
test at 38°C.
9 Housing Weather and Weather and dust CS/304 SS leak proof

dust proof as proof as per IP-55
per IP-55
10 Zero/span Provided Provided --

adjustment

PROJECT MEASURING
SECTION-VI, 7 OF 10
PART-B
11 Identification Engraved with service legend or laminated Phenolic name

plate
12 Accessories Blow out disc, SS Thermo well Gasket for all KEL-F
siphon, shields for transparent
snubber, type vent and drain
pulsation valves of Steel/SS as
dampener, per CS/Alloy process
chemical seal Requirement.
(if required by
process)
gauge
isolation valve
13 Material of 316 SS / 304 316 SS / 304 SS

Bourdon/ SS
movement
Notes:-
*Bicolor type level gauges will be provided for applications involving steam and
water except for condensate and feed water services.
Length of gauge glass shall not be more than 1400 mm. If the vessel is higher,
multiple gauge glasses with 50 mm overlapping shall be provided.
Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be removable
for cleaning. The entire volume above the diaphragm shall be completely filled
with an inert liquid suitable for the application.
5.00.00 ROTAMETERS
Sr. Features Essential / minimum requirements

No.
1. Type Variable Area Metal Tube
2. Fluid media Water/oil
3. Tube body SS316
4. Material of float 316 SS
5. Indicator Linear scale
6. Accessories Flange orifice in case of bypass rotameter (for line size

above 100 mm)

PROJECT MEASURING
SECTION-VI, 8 OF 10
PART-B
7. Housing IP-55
protection class
8. Accuracy + 2% of measured value.
6.00.00 PROCESS ACTUATED SWITCHES
FEATURES ESSENTIAL / MINIMUM REQUIREMENTS
Pressure/ Temperature Level switches

Draft switches
Switches/
DP
Switches
Sensing Piston Vapor pressure Capacitance types for oil and

Element actuated for sensing, liquid dirty medium, water,
high filled bellow type condensate application.
pressure with SS bulb and
and capillary (10 m Float type switches for
diaphragm minimum) applications as decided by
or bellows Employer during detailed
for low pr./ engineering.
vacuum
Capacitance/ Conductivity/
Ultrasonic type for acid and
alkali application.
Material 316 SS Bulb 316 SS/ 316 SS

capillary 304 SS
End ½ inch NPT ½ inch NPT (F) Manufacturer standard

connection (F)
Over range 150% of - 150% of max. design

proof max. design pressure
pressure pr.
Repeat-ability + 0.5% of full range
No. of 2 No.+2NC. SPDT snap action dry contact

contacts
Rating of 60 V DC, 6 VA (or more if required by DDCMIS or PLC)*

contacts

PROJECT MEASURING
SECTION-VI, 9 OF 10
PART-B
Elect. Plug in socket

Connection
Set point/ Provided over full range

dead band
adjustment
Enclosure Weather and dust proof as per IP-55
Accessories Siphon, Thermo well of All mounting accessories

snubber, 316 SS and
chemical packing glands
seal,
pulsation
dampeners
as required
by process
Mounting Suitable for Suitable for rack -

enclosure/ mounting or
rack direct mounting
mounting or
direct
mounting
Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be
removable for cleaning. The entire volume above the diaphragm shall be
completely filled with an inert liquid suitable for the application.

PROJECT MEASURING
SECTION-VI, 10 OF 10
PART-B
CLOSE CIRCUIT TELEVISION SYSTEM (CCTV)
1.01.01 The intent of the specification is to define the functional & design requirements for the
CCTV System meant for gathering video information from the various operational
areas of the Coal Handling Plant. The Contractor shall be responsible for selection,
design, engineering, manufacture, testing at manufacturer’s works/site, installation
and commissioning of the system to the satisfaction of Employer. All the cables,
cable trays, power packs, erection hardwares etc. are also included in contractor’s
scope.
1.01.02 The Contractor’s scope shall also include successful demonstration of performance
testing specified herein complete in all respects alongwith cables, cable trays,
junction boxes, earth wire and accessories like standard brackets, nut-bolts, glands,
lugs, conduit sleeves, etc., as required, to complete the proper installation
conforming to IS:1881, IS:1882 of all the equipments supplied as covered in this
specification. All equipment, accessories and facilities required for completeness of
this system are included in Contractor's scope, whether these are specifically
mentioned herein or not.
1.01.03 The CCTV System offered by the Contractor shall be from reputed manufacturer who
should have designed, manufactured, tested and commissioned a distributed type
CCTV systems as specified in any coal handling plants or any large industrial
installation as on the date of bid opening. All major equipment such as Cameras,
Video Switcher/Control System, Key Boards, Receiver Drivers, Pan Tilt Units, Post
equalisation Video amplifiers, Digital Video Recorder, (DVR) Archiving System etc.
shall be of the same make. Dome type cameras are also acceptable.
1.01.04 The system and all the equipment shall conform to the latest edition of Indian /
International and CCITT standards as applicable.
1.01.05 The Contractor shall guarantee satisfactory performance of the equipment under
stipulated variations of voltage and frequency. The design and manufacture shall be
such that equipments/components of same type and rating shall be interchangeable.
1.01.06 All the cameras shall be connected to a central redundant microprocessor based
video switcher/control system to be located in CHP control room.
1.01.07 Any other equipment, module required for the safe and satisfactory operation,
control, protection, monitoring, testing and maintenance of the system are also
included in Contractor's scope.
2.00.00 POWER SUPPLY ARRANGEMENT
2.01.00 The Contractor shall provide power to the CCTV System from UPS system for
microprocessor based switching / control unit, monitor, digital video recorder, etc. in
the control room.

PROJECT Section-VI, CCTV 1 of 8
3.00.00 DESIGN AND TECHNICAL REQUIREMENTS
3.01.00 The CCTV system shall be able to provide surveillance of different locations of the
plant.
3.02.00 The system shall comprise of Redundant Microprocessor based Video

Switcher/Control System capable of controlling
- 32 nos. of Cameras for Zoom, Pan/Tilt, Multiple pre positionsand auxiliaries
- 1 no. of digital video recorder.
- Multiplexor
- Required no. of 21” colour monitors with key board for controlling both
manually and automatically and all other accessories required to provide best
quality video with controls for making the system complete. It shall be
possible to view the CCTV out put on the large video screen also.
3.03.00 The system operation would be of covering the complete view of the areas with pan /
tilt, zoom, propositioning of the cameras and with programmability to monitor any
camera or number of cameras at a time on any monitor either manually or
automatically in a defined switching. The system shall be suitable for installation and
shall be able to work successfully in Coal dusty environment.
3.04.00 The system shall have the following facilities:
a) Zooming
b) Pan control
c) Tilt control
d) Computer interface
e) Logging printer part
f) Multiple prepositions
g) SALVO switching
h) Programmability
i) Alarm interface
3.05.00 The system supplied shall be complete in all respects for reliable performance. The
Contractor shall submit the details block schematic, video, signal & power wiring
diagram, describing the connections between the Microprocessor based Video
Switcher/Control System and various cameras, pan tilt, receiver driver units,
monitors, DVR and keyboard. Programming required shall be done by the Contractor
for satisfactory operation.

3.06.00 The system should be completely compatible to be integrated to Fire Alarm System.
When the fire is detected by a particular detector the camera assigned should
automatically focus the site of the fire.
3.07.00 The video switcher/control system shall permit the design of a distributed matrix
video switching system with control at one central location and individual control at
the local sites. The main control site could view/control local cameras plus cameras
located at any of the remotely distributed sites.
4.00.00 DETAILED DESCRIPTION OF THE SYSTEM COMPONENTS :
4.01.00 Microprocessor based Video Switcher/Control System
4.01.01 The Video Switcher/Control System shall be Redundant, Microprocessor based and
modular in construction. It should offer full matrix switching capability, i.e., the
system should be programmable to display the video from any camera or number of
cameras at a time on any monitor, either manually or via independent automatic
switching sequences.
4.01.02 The Video switcher/Control System should have provision for minimum 32 camera
inputs 2 monitor outputs, keyboards, Digital video recorders, 32 direct connect alarm
input points, an integral signal distribution unit, a computer interface port, and a
logging printer port including all other hardware / software.
4.01.03 The Video Switcher/Control System should be programmable with up to 30

sequences, which can run independently of each other in either forward or reverse
direction. Any of the sequences should utilise the Salvo Switching capability where
any number of system monitors may be selected to switch as a group.
4.01.04 The video switcher/control system should have easy provision for integral signal
distribution ports, connections to on-site receiver/drivers. It should have built-in
alarm interface capability, any monitor or group of monitors could be set to display
cameras under alarm conditions. In addition, 16-character alarm title could be
selected to appear instead of the camera title during alarm conditions.
4.01.05 The video switcher/control system should include on screen display for time-date,
camera number, camera Id, and monitor or status information. The system should
have provision for logging printer output port to provide permanent record of system
status showing time and date of changes such as : incoming alarms,
acknowledgement of alarms, loading of sequences, user log-on to keyboard,
transfer of system tables and sequence, video loss messages, and a power up reset
message, so that a hard copy of the system’s configuration tables and sequences
can be obtained.
4.01.06 The system shall also have the following provisions.
- User friendly spreadsheet format providing the ability to enter camera titles,
operator names, timely events, change system parameters, program camera
sequences and install lockouts.
- It should provide high performance programming, control and monitoring of all

the system functions by using on-screen icons to reflect real time status of the
devices being controlled by the system.

- Software should also provide the ability to monitor system status events.
System alarms, switching functions, sequence events, keyboard actions, and
video loss information.
4.01.07 All the video switcher/control system shall be connected to a 10/100 Base Fiber
Optic full Duplex Ethernet network, to be provided by the Contractor. In case it is the
standard practice of the Contractor to provide PC based video switcher / control
system to achieve all the above functions, the same is also acceptable.
4.01.08 The CCTV system shall be connected to LVS also.
4.02.00 Keyboard :
4.02.01 Keyboard should have full function used for system control and programming and
should be ergonomically designed. It should include integral pan/tilt joystick and
zoom lens controls. This would be connected to the video switcher/control system for
signal and power.
4.02.02 Keyboard shall have full function used for system control and programming for
selection of various video switcher/ DVR / camera functions including pan/tilt and
zoom lens controls and shall be ergonomically designed. The Key board shall be
able to access DVR and video switcher. Incase it is the standard practice of the
contractor to offer PC based integrated keyboard and monitor, then the same is also
acceptable, subject to Employer’s approval.
4.03.00 Cameras :
4.03.01 The cameras shall be rugged, 1/4 inch image format, full performance color CCD
cameras. These cameras should provide high resolution and high sensitivity suitable
for operation in a coal handling plant, both in natural and artificial lighted areas.
4.03.02 The cameras should have features as mentioned below :
- Suitable for night-time surveillance
- Manual or Automatic colour/infra red switching
- Automatic picture enhancement to give a balanced picture where there is too

little/too much light
- Remote camera setup, with on screen menu display.
- Character generator giving up to 24 character text-in-picture.
- Backlight composition
- Automatic white balance, with mode selection options
- Contour correction and contrast compression control.
- Synchronisation selection for Gen lock, external V-lock, mains lock and
internal free-running.
- All cameras shall be network compatible.

4.03.03 Detailed technical specifications are as under :
Imager : Interline transfer CCD, 1/4 inch image format
Horizontal resolution : 480TVL in PAL B mode
Sensitivity (at f1/4, 6dB), scene illumination 0.7 lux ( at 50 IRE color)
Light Range
Signal-to-noise : > 50dB.
AGC : Upto 18 dB
Shutter Speed : 1/50-1/1,00,000 LUX. Auto select
Lens Mount : Video Iris
Gamma Correction : 0.45/1.0
Auto-black contour correction : Colour
Contrast compensation : 2.5x
Power Supply : 230V AC
4.04.00 Lens :
4.04.01 The lens should be Auto-iris lens of 1/4 inch to be mounted on the above camera. It
should be zoom lens with CS-Mount. The details are as under:
Focal Length : 6 – 90 mm zoom lens (approx.)
Iris range : 1.2 to 360
4.05.00 Camera Housing
4.05.01 All the cameras and accessories are to be housed in Weather Proof (IP-65)
environmental housing made of aluminum. The housing with heater and blower
installed should provide protection for camera/lens assemblies in the ambient
temperature range of - 0 deg. C to 60 deg. C.
4.05.02 The housing should also have thermostatically controlled heater kit, continuous duty
blower kit, purge air arrangement and Window wipers available within the housing.
Complete assembly including camera shall be suitable for hot and highly polluted
environment of Coal Handling Plant.
4.06.00 Pan & Tilt Unit :
4.06.01 The Pan & Tilt unit should be weather proof (IP-65) with pan/tilts designed to meet
the rigorous requirement and should be constructed with corrosion resistant
hardware.

4.06.02 They should be capable of handling loads up to 10 kg and should be having 100%
duty cycle motors to permit continuous operation.
4.06.03 The pan & tilt should comply with the following :
- Electrical – 230V AC, 50 Hz
- Pan range : 120 deg movement in horizontal plane.
- Pan speed : 6 deg./sec.
- Tilt : +3 deg to –90 deg movement in vertical plane
- Tilt speed : 3 deg./sec.
- Construction : Cast aluminum base and yoke, corrosion resistant cover.
4.07.00 On-site Receiver/Driver Unit :
4.07.01 The on-site receiver/drive unit should be able to control the motor drives for pan/tilt
and cameras for zoom and aux control. These would be used in conjunction with the
Microprocessor based video switcher/controller systems.
4.07.02 The on-site receiver/driver unit should have features like focus/zoom/iris controls, 99
prepositions lockable enclosure latches, an integral local test function and IP 65 rated
environmental enclosure.
4.07.03 The On-site receiver/driver unit should be operated from 230V AC, 50 Hz and
provision to be within hazardous are in the vicinity of the camera and pan tilt unit.
The cable from the receiver drive unit to the pan/tilt unit and the camera is to be
provided with the receiver driver unit.
4.08.00 Monitor & Key board:
4.08.01 The monitors should be colour video monitors that the versatile and attractive units to
be mounted on the wall/desk. It should have built in audio. Monitors are to be
operable at 230V AC, 50 Hz. They should comply to the following specifications.
General : Automatic degaussing, Fast warm up time
Display tube : 51 cm diagonal, 90 deg deflection, integral implosion protection.
Resolution : 450 TVL minimum
Controls : Colour system select, volume, colour, brightness, contrast, power, video
input select and Y/C termination.
4.09.00 Digital Video Recorder:
Parameter Specification
Horizontal Resolution 720x570 lines

Color system PAL/ NSTC, compatible with the CCTV system being
proposed by the contractor.
Recording system Applied JPEG, MPEG, Wavelet or better with Motion
detection-Hi performance system.
Recording speed 1-50 frames per second ( fps) , programmable
Inputs 16 channel with Inbuilt Multiplexer and storage for
minimum eight days on HDD for all the connected
camera signals.
Characters generation Date, hours, minutes and seconds.
Record time by alarm Minimum range from 5 sec. To 3 min, to be finalised
during detailed engineering stage.
Input signal Compatible with the finally selected cameras/ network
View Multiple, 2x2, 4x4, single to be finalised during
detailed engineering stage.
Power supply Manufacturer’s standard
Search By date, time or cameras
Alarm Inputs Minimum 8.
Video I/P 1V p-p 75 Ohm to be finalised during detailed
engineering stage.
Video O/P 1 V p-p 75 Ohm to be finalised during detailed
engineering stage.
Zones Minimum 5 User Customizable Zones per camera

Archiving The recorder shall be fully compatible with any
standard 10/100 Base FO full Duplex Ethernet port for
networking to a central DVD or AIT or Hard Disk
Arrays after seven days of recording is over on the
HDD. All or selected portions of the recorder material
shall be shifted on to AIT or DVD and archived. The
Archiving unit shall be common for the stations.
4.09.01 In case the contractor’s standard practice is to provide Digital video recorder which
integrates the function of video switcher / controller, then the same is also
acceptable. In that case, the DVR shall record multiple camera signals while
simultaneously providing live multiscreen viewing and playback.
4.09.02 The images per second rate and image quality shall be selectable for each
connected camera. The digital recorders shall allow selectable frames per second
(fps) record rates from zero fps to minimum twenty five fps.
4.09.03 DVR shall also have features: on screen display which records time, date, number of
alarms etc
4.10.00 Post Equalisation Video Amplifier :

4.10.01 The post equalisation video amplifier should provide of controls of adjustable overall
gain and frequency boost while maintaining full video amplitude, contrast and detail.
It should work on 230V AC, 50Hz.
4.10.02 The post equalisation video amplifier should comply to the following :
Gain : adjustable from 1 dB to +8 dB
Frequency response : Adjustable from flat (+/- 1 dB) at 12 Mhz to greater than +18
dB at 12 Mhz.
Controls : Gain, HF boost, LF boost and indication of red LED when power is on.
5.00.00 OPERATIONAL REQUIREMENTS :
The CCTV system should comply to the following operational requirement.
1. From the master control panel(keyboard) it shall be possible to select any

camera and display the picture on any of the monitors.
2. Commands from the video switcher/control unit is sent via a onsite

receiver/drive unit to the camera which in turn controls the pan/tilt zoom etc.,
functions.
3. Operator shall be able to control all the cameras, pan / tilt and zoom functions
manually.
4. The video recorder shall record the activities of all the places where alarm
have been alerted. The time-lapse video recorder shall be able to record up to
720 hrs without reloading.
6.00.00 CABLES :
6.01.00 Power, control and instrumentation cables shall conform to the relevant section of
this specification. Any special cables for use in CCTV shall conform to the relevant
Indian/International standards. The signal / Video transfer from Cameras to the main
control room equipment shall be through fibre optic cable. However all cables shall
be FRLS type as specified elsewhere.

CONTENTS
CLAUSE DESCRIPTION
NO.
1.00.00 GENERAL
2.00.00 LAYOUT & LEVELS
3.00.00 DRAWINGS/DOCUMENTS
4.00.00 WORK DESCRIPTION
4.01.00 - Overhead / Ground Conveyor Galleries and
Trestles
4.02.00 – Transfer Houses
4.03.00 – Control Buildings, MCC Buildings
4.04.00 – Staircases
4.05.00 – Trenches
5.00.00 Drainage & Water Supply Works
5.01.00 – Drainage System
5.02.00 – Internal and external water supply, drainage
6.00.00 COLOUR COATED AND OTHER SHEETING WORK
7.00.00 ROOF DETAILS
8.00.00 FLOOR AND GRADE DETAILS
9.00.00 BRICKWORK & ALLIED MASONRY WORKS
10.00.00 EARTHING MAT
11.00.00 FENCING
12.00.00 LOADING
13.00.00 DESIGN CRITERIA
14.00.00 CONCRETE
15.00.00 EXCAVATION DETAILS
15.01.00 – Excavation in soil
15.02.00 – Excavation in rock
15.03.00 – Dewatering of deep foundations
15.04.00 – Backfilling, disposal & stacking of materials
16.00.00 Galvanising
17.00.00 Architectural Features
17.01.00 – Glazing
FARAKKA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS Sub-Section - IIID-01 Page 1 of 46

PROJECT SECTION VI, PART-B CHP CIVIL WORKS
BID DOC. NO.:CS- - -
17.02.00 – False ceiling

17.03.00 – Acid/Alkali Resistant Lining
17.04.00 – Finishing Schedule
17.04.01 – Flooring
17.04.02 – Interior wall/ ceiling finish
17.04.03 – Exterior finish
17.05.00 – Door, windows & rolling shutters
17.05.01 – Doors & Windows
17.05.02 – Rolling Shutters
18.00.00 Painting
19.00.00 Miscellaneous
20.00.00 Packaging & Transportation
21.00.00 Plant Life
22.00.00 PTFE Bearing
23.00.00 Tests for Materials/Workmanship
24.00.00 Materials
Annexure A Criteria for Earthquake Resistant Design of structures &
Equipment
Annexure B Criteria for Wind Resistant Design of structures &
Equipment

1.00.00 GENERAL
1.01.00 This section of the bidding document deals mainly with the technical specification
needed for the design and preparation of detailed drawings, getting the design and
drawings approved by the Engineering, fabrication, erection and construction of the
necessary civil, structural and architectural works associated with the coal handling
plant to be installed at FARAKKA SUPER THERMAL POWER PROJECT. The work
shall have to be carried out both below and above ground level and shall be
involving, basements, equipment foundations, slabs, beams, columns, footings, rafts,
walls, steel frames, brick walls, stairs, trenches, pits, finishes, complete architectural
aspects, drainage, sanitation, water supply (from terminal points to various buildings,
conveyor galleries), Bituminous access roads (3.75m wide) to all structures and all
other civil and structural works associated with the Coal Handling Plant.
1.02.00 The specifications are intended for the general description of the work, quality and
workmanship. The specifications are not, however, intended to cover minutest details
and the work shall be executed according to the relevant latest Indian Standard
Codes / I. R. S. / I. R. C. specifications. In absence of the above, the work shall be
executed according to the best prevailing local Public Works Department practices or
to the recommendations of relevant American and British Standards or to the
instructions of the Engineer. List of I. S. Codes to be followed is mentioned in the
Technical Specifications. The Contractor is expected to get clarified on any doubts
about the specifications, etc. before bidding, in writing with the Employer in respect of
interpretation of any portions of this document.
1.00.00 LAYOUT AND LEVELS
2.01.00 The layout and levels of all structures, etc. shall be made by the Contractor at his
own cost from the general grid of the plot and bench mark given by the Engineer. He
shall provide all instrument, materials and men to the Engineer for checking the
layout and levels. However, the Contractor shall be fully responsible for correctness
of layout and levels.
2.00.00 DRAWINGS / DOCUMENTS
3.01.00 The drawings included in the Bidding Document provide a general idea about the
work to be performed under the scope of this contract. These are preliminary
drawings for bidding purposes only and are by no means the final drawings or show
the full range of the work under the scope. Work has to be executed according to
drawings prepared by the contractor and approved by the Engineering.
3.02.00 Conceptual arrangement of civil works supported by calculations shall be submitted

along with tender bids. Later on, detailed construction drawings and design
calculations for all civil works for static as well as dynamic analysis (wherever
essential) shall be submitted for approval prior to undertaking construction work.
3.03.00 Design calculations shall be done in STRAPP / M.S. Office (latest version) and
Drawings shall be prepared in Auto Cad (latest version). The analysis shall be done
by using STADD PRO / ANSYS / STRAPP (latest version). However design may be
carried out by manually, using computer work sheets or by using suitable software
programmes, as mutually agreed by Employer. Final calculations and drawings shall
be submitted in Compact Disc (CD) (2 Sets)

3.04.00 Civil Task drawings indicating various equipment loading and supporting
arrangement and floor loads shall be submitted along with design calculations. Soft
copies of all STAAD input files shall be submitted along with the design calculations
for all revisions.
3.05.00 Consolidated B.O.Q. for major items of all Architectural, Civil and Structural works
shall be submitted structure wise and area wise for N.T.P.C. record. However each
drawing shall indicate approximate quantity of structure (Sectionwise) Concrete
(Grade wise) and reinforcement (Diameterwise.)
3.06.00 Structural steel fabrication drawings to be prepared by the contractor will not be
approved by the Employer. However, the Contractor for Employer’s reference shall
submit all fabrication drawings. Copy of detailed bar bending schedule as prepared
by contractor shall also be submitted to the Engineering and also to Engineer in
charge for the reference.
3.07.00 Approval of construction drawings prepared by the contractor shall not relieve the
Contractor of his responsibility regarding the adequacy of design and correctness of
the drawing.
4.00.00 WORK DESCRIPTION
It includes the Civil, Structural and Architectural works related mainly to the following
areas (but not limited to):
4.01.0 Overhead / Ground Conveyor Galleries and Trestles
Overhead conveyors shall be located in a suitably enclosed gallery of structural steel.

The overhead gallery shall consist of two vertical latticed girders having rigid jointed
portal frame at both ends. Cross beams at floor level supporting conveyor stringer
beams shall be made of single rolled steel beam or single channel section (ISMB or
ISMC) or plate girder. Horizontal bracings are to be provided at top & bottom plan of
the gallery (latticed girders shall be braced together in plan at the top and bottom).
Common end portal frame shall not be used for adjacent conveyor spans. Roof truss
shall be provided at upper node points of latticed girders to form an enclosure. The
maximum span of overhead gallery shall be limited to 25 meters unless higher span
is required due to site conditions, which shall be subject to approval of the Engineer.
The gallery should as far as possible be erected as a box section keeping all the
vertical and horizontal bracing tied in proper position. The gallery should be checked
for all erection stresses that are likely to develop during handling and erection and if
required, temporary strengthening of gallery members during erection shall be made.
Seal plates under the conveyor galleries shall be provided in such a way that
complete gallery bottom shall form a leak proof floor.
The ground conveyors shall be located in suitably enclosed gallery of structural steel
consisting of rigid portal frames spaced at regular intervals and suitably braced.
Plinth protection along with drains shall be routed along the ground conveyors.
For double stream conveyor gallery, two side and one central walkway of width 800
mm and 1100 mm respectively shall be provided. The width of two side walkways for
single stream conveyor gallery shall be 800 mm and 1100 mm respectively. Both
sides of central and side walkways shall be provided with pipe handrails all along the

conveyor gallery. Hand railing should not be supported on conveyor supporting

stringers. The walkways shall be chequered plate construction with anti - skid
arrangement. The anti - skid arrangement will consist of welding of 10 mm square
steel bars at a maximum spacing of 500 mm along the length of the gallery. Where
the slope of walkway is more than 10o, chequered plate steps with nosing and toe
guard shall be provided. The floor of conveyor gallery all along the gallery length,
shall be provided with minimum 12 gauge thick seal plates and other drainage
arrangements as specified elsewhere
Conveyor gallery shall have permanently colour coated steel sheet covers on roof
and both sides. However in roof, a panel of minimum 1.5 m x 1.5 m area at about 6.0
m center shall be provided with translucent sheets of polycarbonate material for
natural lighting. A continuous slit opening of 500 mm shall be provided on both sides
just below the roof sheeting. Adequate provision of windows shall be kept on both
sides of conveyor gallery as appended in Mechanical Section (Belt conveyor
system). Windows shall be provided with wire mesh as specified elsewhere in this
specification.
Cross - over with chequered plate platform and ladder for crossing over the
conveyors shall be provided at approximately every 100 M intervals of conveyor.
Crossover shall preferably be located over four-legged rigid trestle location.
For railway tracks passing below overhead conveyor gallery and along conveyors,
the railway clearances both underground as well as over ground shall have to be
adhered to for design, execution and erection of foundations, trestles, galleries etc.,
so that movement of locomotives and wagons is not hampered in any way during
execution and afterwards. However at the location where the overhead conveyor
gallery crosses road / rail line, minimum clearance of 8.0m above the road crest / rail
top shall be provided.
For calculation of coal load on moving conveyor, a multiplication factor 1.6 shall be
used to take care of inertia force, casual over burden and impact factor etc.
Thus coal load per unit length of each moving conveyor shall be
Rated Capacity of Conveyor system 1100
1.6 X ------------------------------------------------ X ---------
Conveyor Belt Speed 800
It should be noted that for structural design, unit weight of coal shall be assumed as
1100 Kgs. / Cu. M. instead of 800 Kgs. / Cu. M. considered for system sizing
purpose.
Conveyor Gallery structure shall be designed considering both conveyors operating

simultaneously.

Conveyor gallery and supporting trestles located between transfer houses / buildings
shall be arranged in any one of the following ways.
a) All gallery supporting trestles shall be four legged type only. One end of each
gallery span shall be hinged to the supporting trestle and the other end shall
be slide type. Slide type support shall be with P. T. F. E. bearings to allow
both rotation & longitudinal movements.
b) In between transfer houses / buildings, four legged trestles shall be placed at

a maximum interval of 90 metres. The arrangement shall be such so as to
ensure that force in the longitudinal direction (i. e. along the conveyor length)
of conveyor gallery of length not more than 90 m is transferred to any four
legged trestle. In the space between each successive four legged trestles,
two legged trestles shall be provided at regular intervals. The end supports
resting on the four-legged trestle can have either ends hinged or one hinge
and the other on slide type depending on the arrangements. Slide type
support shall be with P. T. F. E. bearings to allow both rotation & longitudinal
movements.
End of conveyor gallery which will be supported over transfer house, shall be so
detailed that only vertical reaction is transferred from conveyor gallery and no
horizontal force in longitudinal direction is transferred from conveyor gallery to
transfer house structure and vice - versa.
For trestles and trestle foundations for conveyor galleries located adjacent to existing
structures, over ground and under ground facilities, location and details of these
trestles and foundations shall have to be decided such that there is no interference
both underground as well as over ground with existing structures and facilities.
Trestle columns / ground conveyor portal column base shall be kept 300 mm higher
than the existing ground level.
4.02.00 Transfer Houses
The over ground portion of the transfer house shall be framed structure of structural
steel work with permanently colour coated profiled steel sheet side cladding and R.
C. C. floors over structural beams. However the lower portion of side cladding for a
minimum height of 0.9 m above the finished floor level at ground shall be one brick
thick wall plastered on both side. In some areas like MCC floors etc., one brick thick
wall cladding shall be provided. Brick wall cladding shall be supported on encased
wall beams and suitably anchored to adjoining columns and beams.
Adequate steel doors and windows for proper natural lighting and ventilation shall be
provided. In addition to steel windows, panels of suitable size to suit the architectural
treatment and made of translucent sheets of polycarbonate material shall also be
provided on the side cladding for natural lighting.
Roof shall be provided with troughed profile permanently colour coated sheet on
outside and plain permanently colour coated sheet on inside with 50mm thick mineral
wool insulation in between the two sheets. A slope of 1 in 5 shall be provided for
quick drainage of rain water.

4.03.00 Control building, M. C. C. Buildings
These shall be R. C. C. framed structures with columns, beams, slabs and

foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof
shall be provided with roof water proofing treatment, as specified elsewhere in the
Technical specification.
In case of control building suitable permanent interconnection shall be provided at

appropriate level with the existing respective buildings.
All air - conditioned areas, shall be provided with the suspended permanently colour
coated aluminium false ceiling system (details specified elsewhere).
Adequate aluminium doors and windows shall be provided for natural lighting,
ventilation and view.
4.04.00 Pump Houses
These shall be of R.C.C. or steel framed structure with columns, beams, slab and
foundations etc. cladding shall be of brick work with plastering on both sides. Roof
shall be provided with roof water proofing treatment as specified elsewhere.
Underground sump and water tanks shall be of R.C.C. Adequate number of doors,
Windows and Rolling Shutters shall be provided.
Galvanized steel ladder / rung ladder shall be provided for access to the roof level of
the pump house and water tanks.
4.05.00 Staircases
All floors of transfer houses shall be accessible through staircase. However, for the
pump houses, access to the roof will be provided by cage ladder
All stairs other than those of M. C. C. rooms and control rooms shall be of steel
(minimum 1000 mm wide)and maximum rise should not be more than 180 mm and
minimum tread width 250 mm. Stringers shall be of rolled steel channel( minimum
ISMC 250 )and tread shall be of steel gratings. Stairs shall be provided with 32 mm
dia nominal bore medium duty M. S. pipe hand rail.
Handrails (for staircases, around openings, in walkways etc.) shall be of standard

weight steel pipe of flush welded constructions, ground smooth using 32 mm nominal
bore medium class pipe provided with double rail, top rail about 1.0 metre above
platform level and pipe posts spaced not more than 1.5 metres apart. Angle handrail
post may be provided when specifically called for in drawings approved by
Engineering. Handrails around openings should have toe plates.
Smooth uniform curves and bends shall be provided at stair returns and also where
so ever required. Posts connected to curb plates shall have a neat closure at the
bottom and a 6 mm thick plate neatly welded to posts for attachment to curb plate. All
necessary fittings including inner dowels at splices, brackets, belts, bends, flanges
and chains, where required shall be plugged and welded. A minimum radius of 3
times the pipe diameter shall be provided at all points of direction changes in the
handrail.

Treads and landing shall be suitable for the prescribed loading. The maximum width
of openings in gratings shall not exceed 40 mm. The minimum thickness of main bars
shall be 6 mm. The usual span of grating will not generally exceed 1.5 meters. Stair
case gratings shall be galvanized to grade 610g/m2.
Out side stairs to transfer points shall be open type. However sheeting shall be
provided at the top.
All floors and roof of MCC/Control rooms shall be accessible through staircase. Stairs
of control room and M. C. C. room shall be of R. C. C. construction, and minimum
1200 mm wide, maximum rise should not be more than 180 mm and minimum tread
with 250 mm.
Numbers and arrangement (including enclosures etc.) of stair cases shall be such as
to meet the fire safety requirement as per guide lines of statutory regulatory bodies.
4.06.00 Trenches
All trenches for cables or any other underground facility as detailed out elsewhere
shall be of R. C. C. Cable trenches shall be provided with pre - cast R. C. C. covers /
chequered plate cover. Cable trenches as well as pre - cast covers shall be provided
with edge protection angles and lifting hooks. All embedments / block outs as
required and specified elsewhere in these specifications shall be provided. Proper
drainage arrangement shall be provided. Trench pre - cast cover weight shall not be
more than 65 Kgs. Trench covers near entry or at road crossings shall be designed
for 10 T wheel load at centre. Pre - cast covers shall be designed for central point
load of 75 Kgs. R. C. C. cable trenches shall be filled with sand after erection of
cables, up to top level and covered with pre - cast R. C. C. covers. For cable
trenches outside buildings, top level shall be 200 mm above G. L.
Minimum 50 x 50 x 6 mm size angles with lugs shall be provided as edge protection

all around cut outs / openings in floor slabs, edges of drains supporting
grating/precast RCC covers, edges of R. C. C. trenches supporting pre - cast covers,
supported edges of pre - cast cover, treads of RCC stairs.
5.00.00 Drainage & Water Supply Works
5.01.00 Drainage System:-
The drainage arrangements shall be so planned so as to ensure quick disposal of

drainage water without stagnation and / or overflow. It is envisaged to clean the
conveyor galleries, transfer points, crusher building, penthouse etc. with water
periodically.
Minimum 4 nos. down comers shall be provided in each transfer house / crusher
house. In case of enclosed conveyor galleries, the down comer shall be provided at
every trestle location.
For enclosed conveyor galleries each down comer shall lead the water / coal slurry to
pit (of 2 Cu.M capacity) to allow settling of coal. The water from the pit shall overflow
into contractor’s R.C.C drain, which will lead the discharge finally into existing
drain/water body.

For Non-Drive House/Transfer House each down comer shall lead the water / coal
slurry into the peripheral drains (Brick drains with steel gratings provided around the
building) which will lead the water / coal slurry to contractor’s RCC drain and finally to
the existing drain/water body.
In case of Control rooms and M. C. C. buildings Pump houses, etc, water / coal slurry
coming from down comers shall discharge into peripheral drains (Brick drains with
steel gratings provided around the building) which will lead the water / coal slurry into
contractor’s R.C.C drain, which will lead the discharge finally into existing drain/water
body.
Suitable kick plates/Curb beams shall be provided around the floor openings, stair
case landings, in the transfer points, and other buildings.
Contractor’s scope shall also include construction of necessary culverts under the rail
lines / roads as per railway / I. R. C. standards and approval of Railway culverts from
concern Railway authorities.
5.02.00 Internal and external water supply, drainage etc.:-
The scope for potable water supply includes all distribution systems, tanks, pipes,
fittings etc. as required and as described here or elsewhere in these specifications.
The scope for service water supply and dust control water supply shall be as
described elsewhere in these specifications.
For water supply, medium class galvanized mild steel pipes conforming to IS: 1239
shall be used.
The scope for drainage of surface water shall include design, layout and construction
of drains for and from buildings. Drainage system shall be designed for maximum
intensity of rainfall as 75 mm/hr and 60 % runoff coefficient. All buildings (including
transfer houses/drive house) shall be provided with open surface brick drains of
minimum size of 300 mm width and 300 mm depth all around the periphery. All
drains excepting the peripheral drains around the transfer points, crusher house,
control / M. C. C. buildings, pumps house etc., shall be of R. C. C. construction. All
open drains shall have removable steel grating designed for loads as specified under
loading clause. Minimum thickness of grating (Galvanised to 610 gm/m2) shall be 12
mm. However at entry or road crossing point’s minimum thickness shall be 40 mm.
The opening size of grating shall not be more than 90 mm x 35 mm. All drains as well
as pre - cast covers shall be provided with edge protection angles and lifting hooks.
For rain water down comer and those to be used for conveying water / coal slurry
generated from cleaning of conveyor gallery and buildings floors, Galvanised MS
pipes conforming to IS: 1239 (for 150 mm NB Medium grade pipes) with welded
joints shall be used for MCC buildings, pump houses, penthouse, control rooms.
Galvanised steel ERW pipes (273mm OD, 4mm thk) of steel grade Fe330
conforming to IS: 3589 with welded joints shall be used for all TP’s, Crusher house,
and Conveyor galleries.
Galvanising shall be as per IS: 4736. The minimum mass of zinc coating shall not be
less than 400 gms/sq.m. as per IS:6745. The zinc coating shall be smooth and shall

be subjected to testing as per IS: 2633, for uniformity of coating. The zinc coating
shall be free from all defects as per IS: 2629.
All rain water down comers shall be provided with roof drain heads and complete with
shoes bends, junctions, sockets, adapters, brackets and finished with anti corrosive
painting over a coat or primer.
For design of building drainage system IS: 1742 shall be followed.
For sanitary / sewerage pipes above ground, sand cast iron pipes conforming to IS :
1729 with leak proof lead joints.
For underground drain pipes, minimum class NP - 2 pipes conforming to IS: 458. At
road crossings, concrete pipes of class NP 3 conforming to IS: 458 and at rail
crossing R.C.C. box culvert to be provided.
For sewerage below ground stoneware pipes conforming to IS: 651 with concrete
bedding and haunch.
6.00.00 COLOUR COATED AND OTHER SHEETING WORK
6.01.00 For floor/roof decking, troughed permanently colour coated metal decking sheet,
shall conform to any one of the following –
(i) of steel with zinc coated to class Z275 with minimum bare metal thickness (
i.e. excluding the thickness of coating and painting) of 0.8mm of grade G250
as per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per
EN 10326.
(ii) of steel with zinc coated to class Z275 with minimum bare metal thickness (
i.e. excluding the thickness of coating and painting) of 0.6mm of grade G350
as per AS1397 / grade SS340 class 4 as per ASTM A653M / grade S350GD
as per EN 10326 / grade G550 as per AS1397 / grade SS550 as per ASTM
A653M / grade S550GD as per EN 10326.
6.02.00 For roofing & side cladding, troughed permanently colour coated sheets (internal or
external) shall conform to any one of the following –
(i) of steel with zinc coated to class Z275 with minimum bare metal thickness
(i.e. excluding the thickness of coating and painting) of 0.6mm of grade G250
as per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per
EN 10326.
(ii) of steel with aluminium-zinc alloy coated to class AZ150 with minimum bare
metal thickness (i.e. excluding the thickness of coating and painting) of
0.5mm of grade G350 as per AS1397 / grade SS340 class 4 as per ASTM
A792M / grade S350GD as per EN 10326.
(iii) of steel with aluminium-zinc alloy coated to class AZ150 with minimum bare
metal thickness (i.e. excluding the thickness of coating and painting) of
0.4mm of grade G550 as per AS1397 / grade SS550 as per ASTM A792M /
grade S550GD as per EN 10326.

6.03.00 Steel shall be colour coated with total coating thickness of 35 microns (nominal) dry
film thickness (DFT) comprising of Silicon Modified Polyester paint (SMP with silicon
content of 30% to 50%) or Polyester paint, of 20 microns (nominal) SMP or polyester
paint on one side (exposed side) over 5 micron (nominal) primer coat and 5 micron
(nominal) SMP or Polyester paint over 5 micron (nominal) primer coat on other
side,(SMP and Polyester paint shall conform to Product type 4 of AS/ANZ 2728.
Coated surface shall be provided with a protected guard film (polyethylene) of about
40 microns to avoid any damage to the coating during handling.
6.04.00 Sheet shall be of approved profile, sectional properties, colour and shade.
6.05.00 Chemical composition of troughed permanently colour coated metal decking sheets
and metal sheet for roofing and side cladding, shall conform to the provisions of the
same reference code to which the mechanical properties conform to. Mechanical
properties shall be confirmed by relevant tests.
6.06.00 Tolerance on minimum BMT (bare metal thickness) shall be (-)0.00mm and
(+)0.06mm.
6.07.00 Plain permanently colour coated steel metal sheets for ridge and hips, flashings,
trimmings, closure for vertical and horizontal joints, capping etc shall confirm to the
same requirements as those of troughed permanently colour coated metal sheet for
roofing and side cladding.
6.08.00 For metal decking the sectional modulus and moment of inertia of troughed profile
per meter width shall be so as to limit the deflection of sheets to span/250 for two
span condition. The sectional modulus and moment of inertia of troughed profile shall
be computed as per the provisions of IS:801 for satisfying the deflection and strength
requirements.
6.09.00 For metal roofing and side cladding, the sectional modulus and moment of inertia of
troughed profile per metre width shall be such that the deflection of sheets is limited
to span/250 for two span condition. The sectional modulus and moment of inertia of
troughed profile shall be computed as per the provisions of IS: 801 for satisfying the
deflection and strength requirements. No increase in allowable stress is permissible
under wind load condition.
6.10.00 Maximum spacing of the fasteners shall be 390 mm c/c along the length of
beams/purlins / runners. However exact spacing shall be as per the design done by
the bidder for the fasteners considering the wind load, self load and other associated
loads. Minimum diameter of the fastener shall be 5.5 mm and at least 3 nos. of
fasteners shall be used per sheet.
6.11.00 Sealant used for cladding shall be butyl based, two parts poly sulphide or equivalent
approved, non-staining material and shall be flexible enough not to interface with fit of
the sheets.
6.12.00 Filler blocks as a trough filler shall be used to seal cavities formed between the
profiled sheet and the support or flashing. The filler blocks shall be manufactured
from black synthetic rubber or any other material approved by the Engineer.
6.13.00 For insulation of cladding, mineral wool conforming to IS: 8183 shall be used. The
density shall be 32 or 48 kg. /Cu.M. for glass or rock wool respectively. The nominal
thickness of insulation shall be 50mm.

6.14.00 Special coated fasteners shall be used conforming to corrosion resistant class 3 as
per AS3566 and shall be tested to 1000 hours salt spray test.
6.15.00 The dimensional tolerances of profiled sheets for sheet length, sheet cover width,
straightness, squareness, depth of profile, radius and angle of curved sheets, ripple
of side lap, etc. shall be as per “Manufacturing tolerances for profiled metal roof and
wall cladding & roofing” by The Metal Cladding & Roofing Manufacturers Association
Limited, UK.
6.16.00 Sheets shall be laid with a minimum overlap of 15 cm at the ends and side laps shall
be of one trough length subject to a minimum of 50 mm, having a proper water tight
arrangement. The minimum lap of sheets with ridges, hips and valleys shall be 15 cm
measured at right angles to the line of the ridge, hip and valley respectively.
6.17.00 Metal decking sheets shall be laid over the supporting beams/purlins with a minimum
bearing of 50 mm and end projection of 75 mm at lap joints.
6.18.00 Flashings, cappings, trimming, closure for vertical/horizontal joints, ridge and hips etc.
shall be provided with a minimum lap of 15 cm. The lapping of sheets shall provide
the dust free, airtight enclosure. If required, this may be achieved by using 2-parts
polysulphide sealing compound or butyl tape.
6.19.00 Distorted, blemished or water stained sheets shall not be used.
6.20.00 Side and end laps of the sheets shall be made weather proof by securing them with
the fasteners not less than 4.8mm dia with 2.0 mm thick neoprene washer. Maximum
spacing of the fasteners should not exceed 500 mm.
6.21.00 Precautions shall be taken during the erection of the sheets to ensure that partially
erected sheets are protected from damage at all times and particularly during
inclement weather. Sheets shall be laid over the supporting purlins/runners with a
minimum bearing of 50 mm and end projection of 75 mm at lap joints.
6.22.00 Side cladding for Transfer points & conveyor galleries(including roof) shall have
single skin troughed profile permanently colour coated sheets. However, roof of
transfer points shall be provided with troughed profile permanently colour coated
sheet on outside and plain permanently coated sheet on inside with 50mm thick
mineral wool insulation in between the two sheets.
6.23.00 The polycarbonate sheet to be used for cladding and glazing purpose in conveyor
galleries shall have toughed profile to match with the metal cladding profile. Minimum
2.0mm thick fire retardant and UV resistant polycarbonate clean sheet of GE plastic
or equivalent approved make shall be used. The polycarbonate sheet shall be
installed along with the metal cladding so as to have a watertight lapping
arrangement. Suitable detailing shall be made to cater for the thermal expansion.
IS:14434 to be referred for other details.
6.24.00 Polycarbonate sheet minimum 6mm thick multi (twin) wall fire retardant (Continuous
use under temperature 100oC), impact resistant and ultraviolet resistant sheet shall
be provided (as glazing) in transfer houses etc.

7.00.00 Roof Details
Roof slab shall be minimum 150 mm thick and shall have minimum 10 dia HYSD
reinforcement bars placed at 200 mm center both ways at top and bottom.
For efficient disposal of rain water, the run off gradient for the roof shall not be less
than 1: 100. This gradient can be provided either in structure or subsequently by
screed concrete M-15 (using 12.5 mm coarse aggregate) and / or cement mortar (1:
4). However, minimum 25 mm thick cement mortar (1: 4) shall be provided on top to
achieve smooth surface.
900 mm high and minimum 100 mm thick R. C. C. parapet wall shall be provided
over roofs of all buildings. Parapet wall shall have suitable coping. External face of
parapet wall of the buildings provided with metal cladding shall also be finished with
metal cladding of design and colour as per approved architectural drawings.
Junction of roof and parapet shall be provided with 150 x 150 mm size concrete fillet.
Drain level shall be provided with 45 x 45 cm size khurras having minimum thickness
of 30 mm of M-15 concrete over PVC sheet of 1 m x 1m x 400 micron and finished
with 12 mm 1 : 3 cement : sand plaster.
Roofs of all transfer houses, crusher houses, control rooms, M. C. C. rooms,

penthouse etc., shall have roof water proofing treatment. Roof water proofing
treatment shall be as follows:
1) Application of polymerised mastic over the RCC roof to achieve smooth surface
as primer coat.
2) Application of high solid content liquid applied urethane based elastomeric water
proofing membrane, over the primer coat, to give uniform joint less dry film
thickness of minimum 1.5 mm (as per ASTM C 836 and C 898).
3) For efficient disposal of rain water, the run off gradient for the roof shall not be
less than 1: 100. This gradient shall be provided by screed concrete M-15 (using
12.5 mm coarse aggregate) and / or cement mortar (1: 4) over the elastomeric
water proofing membrane with 25mm thick cement mortar (1:4) topping.
4) Wearing course at top, shall consist of 25 mm thick P. C. C. (M-15) cast in panels
of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized
chicken wire mesh and sealing of joints using sealing compound / elastomeric
water proofing membrane. Pathways for handling of materials and movement of
personnel shall be provided with 22 mm thick chequered cement concrete tiles as
per IS : 13801 for a width of 1000 mm in place of P. C. C.
8.00.00 Floors and Grade level details
The floor slabs shall be minimum 150 mm thick and shall have minimum 10 dia
HYSD reinforcement bars placed at 200 mm center both ways at top and bottom
Floors of transfer points/drive house shall have cross slope of not flatter than 1: 80,
towards the floor washing drainage outlets, for efficient drainage. For ground
conveyor & crusher house slope shall be 1:100.
Chequered plates (used for floors, walkways etc.) shall be minimum 6 mm thick o/p
or as indicated on drawings. The chequered plate pattern shall be approved by

Employer / Engineer. Mild steel flats/angles of suitable size shall be welded to the
bottom portion of chequered plates at a designed spacing to stiffen chequered plates
suitably. Chequered plates shall be fixed by staggered welding of suitable size.
Floors of trenches shall have integral finish to concrete base.
Toe guard of size 100 x 6 mm shall be provided at various openings provided in

floors e.g. around stair case openings, chute openings and other similar cutouts. For
conveyor walkways, angle runner to act as toe guard shall be provided.
All along the periphery of R. C. C. floors (where no brick masonry walls are provided)
shall be provided with one brick thick 300 mm high brick wall and 700 mm high steel
hand rails all around over this brick work.
The grade slab shall consists of 230 mm thick rubble soling (63 mm downgraded
hard stone aggregate as per IRC specification, watering and compaction to minimum
of 90% Standard Proctor density, including filling the interstices of stone aggregates
with sand), over well compacted earth, overlaid by 75 mm thick P. C. C. M-7.5 and
100 mm thick R. C. C. of grade M-20 with minimum 8 mm dia bars placed at 200 mm
C / C in either direction respectively. There will be minimum 50 mm thick metallic
hardener finish over the R. C. C. slab.
All buildings (including transfer houses/drive house) and ground conveyors shall be
provided with 750 mm wide plinth protection all around. It consists of 50 mm thick
P.C.C. M-20 grade with 12 mm maximum size aggregate over 200 mm thick stone
soling using 40 mm nominal size rammed, consolidated and grouted with fine sand.
An area of 5 m width all round the transfer houses /drive house shall be paved. This
paving will be in addition to plinth protection. The paving construction shall be as per
specifications for the grade slab at ground level. However, 50 mm thick metallic
hardener finish is not required to be provided in paved area.
Plinth level of all buildings shall be kept at least 500 mm above the finished grade /
formation level.
9.00.00 Brickwork and allied masonry works
All brick walls shall be non - load bearing in-filled panel walls.
All brickwork shall be designed as per Indian Standards and shall be plastered on
both faces. All external walls shall be minimum one brick thick in 1: 6 cement: sand
mortar. Brick walls shall be provided with 12 mm and 18 mm thick 1: 6 cement: sand
plaster on smooth and rough face of the brick work respectively.
Bricks to be used in brickwork shall be of minimum Class designation 50.
Brickwork cladding for various structures shall be so provided that there is a clear
gap of 40 mm between inside face of external brick wall and outside face of column
flange. Structural steel wall beams supporting brickwork shall be suitably encased
with plaster or 1: 2: 4 concrete as the case may be. In case of box type steel beam,
encasement shall be done with cement sand plaster in specified thickness and
proportions over G. I. wire netting of 0.9 mm thickness.

Parapets, chajjas, windows and door heads, architectural faces, fins etc. shall be
provided with drip course in 1 : 4 cement sand mortar.
50 mm thick Damp proof course shall be provided at plinth level for all brick wall.
All R. C. C. ceilings shall be rendered smooth and finished with whitewash unless
otherwise specified. Ceiling of control rooms, M. C. C. rooms (except areas provided
with false ceiling) shall be provided with 6 mm thick plaster.
10.00.00 Earthing Mat
40 mm Dia MS Rods as earthing mat, placed at a distance of 1.0M away and at

depths between 0.60M and 1.00M shall be supplied and laid all around the periphery
of buildings, structures, and outdoor equipment, as per the approved drawings.
Risers of 40 mm Dia MS Rods and connecting to the above Earthing mat shall also
be supplied and laid in position by the Contractor, as per the approved drawings.
Risers shall be laid up to a height of 300 mm above the local Ground level, at each of
the columns of the buildings on outside of the buildings, and minimum 2 (Two)
numbers for structures and outdoor equipment. The contractor also supply and lay
necessary number of 3.0 M deep vertical 40 mm Dia MS Rods Earthing electrodes
and connecting them to the Earthing mat, as per the approved drawings and the
supplying and laying of 40 mm Dia MS Rods for connecting the Contractor's earthing
mat with the Employer's earthing mat separately at two locations.
11.00.00 Fencing
Fencing with toe wall and steel gates shall be provided around the transformers.
Fencing shall comprise of PVC coated GI chain link fencing of minimum 8G
(including PVC coating) of mesh size 75 mm and of height 2.4 m above the toe wall.
The diameter of the steel wire for chain link fence (excluding PVC coating) shall not
be less than 12G. Fence posts shall be of pre – cast R. C. C. of minimum M20 grade.
All corner posts will have two stay posts and every tenth post will have transverse
stay post. Suitable R. C. C. foundation for the post and stays shall be provided based
on prevailing soil conditions. Gates shall be sturdy with locking provisions.
Toe walls of brick masonry shall be provided between fence posts all along the run of
the fence with suitable foundation. Toe wall shall be minimum 200 mm above the
formation level with 50 mm thick P. C. C. coping (1: 1. 5: 3) and shall extend
minimum 300 mm below the formation level. Toe wall shall be plastered on both
sides and painted with two coats of cement paint of approved colour and shade. Toe
wall shall be provided with weep holes at suitable spacing.
12.00.00 LOADING
For consideration of loads on structures IS : 875 - ‘Code of practice for structural

safety of buildings’ shall be followed. In addition to the dead load, live load,
equipment load (including impact / vibration). Temperature loads etc. various loading
conditions arising due to operation and maintenance of equipment shall be
considered in the design. The structure and equipment shall also be designed for
seismic loads as per the “Criteria for Earthquake Resistant Design of Structures and
equipment" and the “Criteria for Wind Resistant Design of Structures and equipment"
specified in the Annexure A and B respectively in Civil Section, whichever is
governing. Wind and seismic forces shall not be considered to act simultaneously.

The following minimum live loads shall be adopted for the design of various
structures. If actual expected load is more than the specified load, then actual load is
to be considered.
a ) Roofs 150 Kgs. / Sq. M. for accessible roofs

and 75 Kgs. / Sq. M. for non -
accessible roofs.
In addition to this coal dust load (Dead
load) of 150 Kgs. / sq. m. on flat roofs &
75 Kgs. / sq. m. on inclined roofs shall
also be considered.
b ) R. C. C. floors 500 Kgs. / Sq. M.
c ) Stair and balconies 500 Kgs. / Sq. M.
d ) Toilet rooms 200 Kgs. / Sq. M.
e ) Chequered plate floors 400 Kgs. / Sq. M.
f ) Walkways ( including walkways in 300 Kgs. / Sq. M.

conveyor galleries )
g ) Conveyor galleries In addition to the live loads, loads due

to cable trays, fire fighting / service
water pipes shall also be considered @
125 Kgs. / m ( minimum ) on each of
the longitudinal girder.
Roof-truss members are to be checked
for supporting fire fighting pipes/
Service water pipes. Tentative locations
and diameter for pipes are shown in
Tender Drawing.
h ) Road Culverts and its allied For class 'AA' loading and checked for
structures including R. C. C. pipe class A loading as per IRC standard.
crossing & road crossing of
trenches.
i ) Channels / trenches In addition to earth pressure and water

pressure, etc. additional earth pressure
due to surcharge of 2T / Sq. M. shall
also be considered for design.
j ) Covers for trenches / channels Covers for channels & trenches, shall
be designed for a live load of 0.4T Sq.
M. and loading as mentioned under
clause in trenches, whichever is critical.
k ) Sumps and tanks and other In addition to earth pressure with a

underground basement type surcharge of 2T / Sq. M. (or surcharge
structures due to Railway loading whichever is
critical for Railway load bearing

structures etc.) and sub - soil water

pressure etc. These are also to be
designed for the following conditions :
i) Water / liquid inside and no
earth outside (applicable only to such
structures which are liable to be filled
up with water or any liquid ).
ii ) Earth with surcharge outside
and no water / liquid inside
iii ) For underground (basement)
structures protection against buoyancy
during execution and after execution
shall be ensured without superimposed
loadings with minimum factor of safety
of 1.2 against buoyancy.
l ) Unit weight of coal shall

be taken as 1100 Kgs. / cum. for
design purposes.
If the erection load is higher than the specified live loads on any floor or part thereof,
then the erection loads are to be considered for the design.
Permissible increase in stresses of materials and bearing pressure of soil due to wind
load or seismic load shall be as per relevant I. R. S. and I. S. code.
13.00.00 DESIGN CRITERIA
The design of all R. C. C. structures shall be carried out as per ‘code of practice for
plain and reinforced concrete for general building construction’, IS : 456 ( latest ).
The steel structures shall be designed and fabricated as per ‘code of practice for use
of structural steel in general building construction’, IS : 800 ( latest ) and other
relevant IS Standards. Minimum size of the angle section to be used as structural
members shall be 50 X 50 X 6. Minimum weld size shall be 6 mm. Connections shall
be designed for 70 % of shear capacity of the member or the actual shear force,
whichever is higher.
The building shall conform to local bye - laws, rules and regulations for industrial
buildings and also B. I. S. publications, SP 32 and 41.
Slotted holes shall not be assumed to act as expansion joint for relieving of stresses
and suitable bearings shall be provided at the supports.
All gallery supporting trestles shall be so proportioned that the transverse deflection
of gallery due to wind / seismic load should not exceed trestle height / 1000 as
stipulated in IS: 11592. This deflection condition shall be strictly followed. Peak wind
speed method shall be considered for checking the transverse deflection.

The transfer house structures shall be so designed that transverse deflection at

places where conveyor galleries meet, should be equal to the respective transverse
deflection of conveyor supporting trestles.
Stresses for all CHP structures shall be checked for the higher of the forces obtained
from gust factor method and the peak wind speed method.
The permissible vertical deflection for beams supporting drive machinery shall be
restricted to span / 500 and for other beams it shall be within span / 325.
Horizontal bracing system shall be provided at floor levels around the openings.
Shear force in steel columns shall be transferred to the pedestals / foundations

exclusively either through foundation bolts or the shear key arrangement.
For design of liquid retaining structures, IS : 3370 ( Part - I to IV ) ( latest ) shall be

followed. Face of the structure in contact with liquid shall be designed as un -
cracked section. For design of R. C. C. pipes for culverts, latest editions of IS : 458,
IS : 783 should be followed.
For design of all underground structures / foundations, ground water table shall be
assumed at the formation level ( i. e. the adjoining ground level ).
Design of masonry walls shall be made as per IS : 1905.
Civil task drawing indicating various equipment loading and supporting arrangement
and floor loads to be submitted along with the design calculation.
For metal roofing and side cladding, the spacing of purlins/runners shall be such that
the deflection of metal sheet used is limited to span/250 under adverse loading
condition.
Minimum reinforcement shall be provided at the top face of the footing, even if, no
reinforcements are required as per design.
14.00.00 CONCRETE
All R. C. C. works to the done under this specification, unless specified otherwise
shall be design mix concrete. Minimum grade of concrete for various structures shall
be as follows:
a) M30 - For underground / sub structural R. C. C. work (other than railway

load bearing structures).
b) M25 - For R. C. C. superstructure works including ground floor slabs,

trenches & drains.

Minimum 75 mm thick P.C.C M-7.5 shall be provided as mud mat below all
foundations.
For concreting of underground structures requiring water tightness, plasticizer cum

water proofing admixture shall be added to the concrete mix.
Both coarse and fine aggregates shall conform to IS: 383 for concrete, shotcreting
etc. unless otherwise mentioned.
15.00.00 Excavation Details
15.01.00 Excavation in soil
Excavation for foundation shall be to the bottom of lean concrete and as shown on
drawing or as directed by the Engineer. The bottom of all excavations shall be
trimmed to required levels and when excavation is carried below such levels by error,
it shall be brought back to the specified level by filling with concrete of nominal mix 1
: 3 : 6 (cement: coarse sand: 40 mm down aggregates ), as directed by the Engineer.
The Contractor shall ascertain for himself the nature of materials to be excavated and
the difficulties, if any, likely to be encountered in executing this work. Cofferdams,
sheet piling, shoring, bracing to maintain suitable slopes, draining etc. shall be
provided and installed by the contractor, to the satisfaction of the Engineer.
Surplus excavated materials shall be disposed off by the contractor at locations up to

a lead of 5 kms from the plant boundary wall as directed by the engineer.
The Contractor shall have to constantly pump out any water collected in excavated
pits and other areas due to rain water, springs etc. and maintain dry working
conditions at all times until the excavation, placement of reinforcement, shuttering,
concreting, Backfilling is completed. The Contractor shall remove all slush/muck from
the excavated areas to keep the work area dry. The Contractor, if required, shall
employ sludge pumps, for this purpose.
For other details, excavation clauses as given in Sub-Section III-D-02 are to be

referred.
15.02.00 Excavation in rock
For the work of excavation in rock, Contractor shall engage specialised agency
having experience of excavation in rock involving wedging and blasting. The agency
shall be subject to approval of Engineer and the Contractor shall furnish details of
relevant experience in support while seeking approval for the agency.
Blasting shall be resorted to only with the written permission of the Engineer. All the
statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc.
pertaining to the acquisition, transport, storage, handling and use of explosives etc.
shall be strictly followed.
The contractor shall obtain Licenses from Competent Authorities for undertaking
blasting work as well as for procuring, transporting to site and storing the explosives

as per Explosives Act. The Contractor shall be responsible for the safe transport,
use, custody and proper accounting of the explosive materials.
Surplus excavated materials shall be disposed off by the contractor at locations up to

a lead of 5 kms from the plant boundary wall as directed by the engineer.
The Contractor shall have to constantly pump out any water collected in excavated
pits and other areas due to rain water, springs etc. and maintain dry working
conditions at all times until the excavation, placement of reinforcement, shuttering,
concreting, backfilling is completed.
15.03.00 De-watering of Deep Excavations
For deep underground structures like track hopper, machinery hatches, tunnels and
underground transfer houses, requiring open excavation with extensive de - watering,
completely dry working conditions during excavation, shuttering, placement of
reinforcement, concreting, water proofing of structures, backfilling and any other
operation shall be maintained by suitable de - watering method of suitable capacity.
15.04.00 Backfilling, Disposal and Stacking of materials
Backfilled earth shall be compacted to minimum 90 % of the standard proctor density

at OMC. Sand filling shall be compacted to minimum 80 % of the relative density.
Also refer Sub-section III D-02 for more details.
However, the backfill under the rail lines and roads shall be compacted to minimum
95 % of the standard proctor density at OMC unless otherwise stated by rail
Authorities.
The contractor is required to excavate upto any depth as shown on the drawings or
as directed by the Engineer. Lifting of excavated materials shall be done either by
manual or mechanical or both means if called for by the Engineer.
The disposal / stacking areas for excavated materials shall be indicated by the
Engineer. The carriage of excavated materials shall be done by the methods
mentioned below:
The excavated materials shall be carried beyond the initial lead of 50 m but upto 500
m by manual / animal labour or by mechanical means. If directed by the Engineer this
material shall be used directly for filling purposes.
For leads exceeding 500 m the Contractor shall transport the excavated materials by
mechanical means only and as directed by the Engineer. The Contractor may be
allowed to carry materials through Kuccha roads. Providing and maintaining of the
Kuccha roads shall be the responsibility of the Contractor. The transported material
shall be neatly stacked as directed by the Engineer.
Some excavated materials required for filling purposes, may have to be carried upto
a lead of 500 m and stacked as per instructions of the Engineer. Excavated materials
carried beyond 500 m shall normally be for disposal purpose only. Double handling of
materials shall be avoided as far as possible. However, depending on site condition

excavated materials carried beyond a lead of 500 m may also be required to be

brought back for filling purpose.
Materials to be used for filling purpose shall be stone, sand or other inorganic
materials and they shall be clean and free from shingle, salts, organic matter, large
roots and excessive amount of sod, lumps, concrete or any other foreign substances
which could harm or impair the strength of the substances in any manner. All clods
shall be suitably broken to small pieces. When the materials are mostly rock
boulders, these shall be broken into pieces not larger then 150 mm size. Sand used
for filling shall be clean, medium grained and free from impurities. Fines less than 75
microns shall not be more than 20%. In any case, the materials to be used for filling
purposes shall have the prior written approval of the Engineer.
In case the materials have to be brought from pits / quarries, then it shall be the
Contractor’s responsibility for identification of such quarry areas, obtaining approval
from their use from concerned authorities, excavation / quarrying loading and
carriage of such material, unloading and filling at specified locations. The Contractor
shall pay any fees, royalties etc. that may have to be pain for utilisation of borrow
areas.
16.00.00 GALVANISING
All burrs and irregular edges of the structural steel members to be galvanised shall
be ground smooth before galvanising.
Purity of Zinc to be used for galvanising shall be 99.5 % as per IS : 209 ( latest
edition ).
The weight of the zinc coating shall be at least 610 Gms. / m2 unless noted
otherwise.
18.00.00 Architectural Features
All architectural features of buildings like control rooms, crusher houses, M. C. C.

rooms, transfer houses and conveyor galleries etc. shall be detailed by contractor’s
qualified architect. Necessary projections, fins etc. in addition to the minimum
specified elsewhere in this specification shall be provided as required. The
Contractor for Employer’s approval shall submit detailed architectural drawings along
with colour schemes. Nothing extra shall be payable for any changes required while
getting the drawings / schemes approved and for executing the same.
In case structural column base plates are proposed below the floor level, the same
shall be encased with adequate cover up to the finished floor level with minimum M -
20 grade concrete. Dowels shall be left from the pedestals to be lapped to the skin
reinforcement of the encasing.
18.01.00 Glazing
Window glazing for various locations shall be as below:
(i) In transfer houses, crusher house and pump houses etc:

6mm. thick toughened float glass & Polycarbonate sheet (Details described
elsewhere).
(ii) In Switchgear / M. C. C. buildings
(a) In air conditioned (A / C) areas:
Composite double glazing with clear float glass of 6 mm thick on one side and 6mm
thick tinted glass on the other side hermetically sealed and separated by 12 mm thick
gap for thermal insulation at partition of A / C and non A / C areas.
Composite double glazing with clear float glass of 6 mm thick on inside and 6mm
thick toughened reflective glass hermetically sealed and separated by 12 mm thick
gap for exterior windows.
(b) In toilets:
Frosted glass of minimum thickness 6 mm.
(c) In other areas:
Toughened glass of minimum thickness 6 mm
The above mentioned glass thickness are bare minimum only and actual thickness
will depend on the panel size of the glazing to be provided.
18.02.00 False Ceiling
All air - conditioned areas, shall be provided with the suspended permanently colour
coated aluminium false ceiling system with corrosion resistance aluminium alloy
panels of minimum thickness 0.5 mm. The suspension system for false ceiling shall
be as per manufacturers guidelines.
Additional hangers and height adjustment clips shall be provided for returns air grills,
light fixtures, A. C. ducts etc.
Under deck insulation shall be provided on the ceiling (underside of roof slab) and
underside of floor slab of air - conditioned areas depending upon the functional
requirements. This under deck insulation shall consist of 50 mm thick mineral wool
insulation mat conforming to IS: 8183 having a density of 32 kg/cum for glass wool or
48 kg/cum for rock wool, backed with 0.05mm thick aluminium foil and 24G x 25 mm
mesh wire netting and shall be fixed to the ceiling with 14G wire ties.
18.03.00 Acid / Alkali Resistant Lining
Battery Room
Acid, alkali and oil resistant high build self smoothing, seamless epoxy resin floor
finish, on horizontal and vertical surfaces, at all levels, for all types of works,
including all labour, material, equipment, scaffolding, handling, transportation,
preparation of surface, application of epoxy based primer coat, of approved colour,

quality and make to give minimum thickness of 300 micron (in two coats) and dado
upto 1200 mm, etc., all complete, shall be provided.
18.04.00 FINISHING SCHEDULE
The contractor's scope also includes all doors, windows, glazing, rolling shutters,
finishes, damp proofing, inserts, anchor bolts, embedments, stairs, nosing, railings,
toe - guards, ladders, edge protection angles, etc.
The Contractor shall adhere to the finishing schedule as given.
18.04.01 Flooring
I. P. S. (cement concrete flooring) with metallic hardener topping shall be provided for
all floors in track hopper, wagon tipplers, reclaim hopper, transfer houses, including
ground floors of transfer houses, ground conveyors, operating floor of pump houses,
M. C. C. rooms, cable vault / cable spreader rooms, maintenance and unloading
areas, general storage areas and all other areas in plant buildings where heavy duty
flooring is required.
Heavy Duty Ceramic Tiles (matt finish), 300mm x 300mm x 7mm of approved colour
shade & finish, shall be provided for floors of toilets, pantry, etc with 300 x 200mm
designer wall ceramic tiles for dado in toilets & pantries.
Vitrified ceramic tile (mirror polished) 600 x 600 x 10mm thick shall be provided for
floors of office rooms, conference room, laboratories, control room & control
equipment room and for dado upto false ceiling.
Well polished marble stone (20mm thick) shall be provided for staircases, passages,
lobbies and general circulation areas.
The nominal total thickness of floor finish shall be 50 mm i.e. under bed and topping.
The floor shall be laid on an already laid and matured concrete base.
Sunken R. C. C. slab shall be provided in false flooring area and toilet area so as to
keep the finished floor level of these areas same as that of the surrounding area.
Wherever specified metallic hardener topping shall be 12 mm with ordinary grey

cement.
Paving details shall be similar to grade slab excluding metallic hardener.
Skirting in general shall be 150 mm high. Dado in toilets and pantries shall be up to
2.1 m height from finished floor level. Skirting and dado shall match with the floor
finish.
18.04.02 Interior Wall / Ceiling Finish
For all air conditioned control room, 600 x 600 x 10mm th. Vitrified ceramic tile dado
shall be provided upto false ceiling and for other air - conditioned areas acrylic
emulsion paint of approved make and shade over 2 mm thick plaster of paris punning
shall be provided.

For toilets and pantries minimum 300 x 200 mm thick decorative coloured ceramic
tiles of approved make and shade with approved pattern up to 2.10 m. height from
finished floor level shall be provided. Oil bound distemper over plaster of paris
punning above 2.10 m height shall be provided.
For all other areas oil bound distemper ( IS : 428 ) of approved shade over 2 mm
thick plaster of paris punning shall be provided.
For battery room and other areas coming in contact with acid / alkali fumes, chemical
resistant chlorinated rubber paint shall be provided above 2.1 m height. Up to 2.1 m
height from finished floor level acid alkali resistant epoxy resin finish shall be
provided as specified elsewhere.
All R. C. C. ceilings shall be finished with acrylic distemper.
18.04.03 Exterior Finish
Permanently colour coated M. S. / High tensile steel metal cladding ( non - insulated )
of approved colour combination shall be provided for transfer points, conveyor
galleries, elevator shafts, and parapet walls of buildings where metal cladding is
specified. The cladding sheets shall be coated with silicon modified paint as specified
elsewhere.
Solvent based acrylic exterior paint in combination with textured paint with 2.5mm
stone chips in the ratio of 3 : 1 shall be provided for the under mentioned areas :
(a.) All buildings with R. C. C. framework unless specified otherwise in this

specification.
(b.) Brick work in the lower portion of metal cladding.
(c.) Fire walls
(d.) Projections and facia : R. C. C. parapets ( excepting parapets of buildings

where metal cladding is specified )
(e.) Exterior brick walls.
18.05.00 DOORS, WINDOWS AND ROLLING SHUTTERS.
18.05.01 Doors and Windows
All doors, windows and ventilators of control room building, S and T control room and
M. C. C. buildings shall have Electro colour coated (anodised) aluminium frame work
with glazing. All doors of office and toilet areas shall be of factory made pre-
laminated particle board (M D F exterior grade). All other buildings shall have steel
doors, windows and ventilators.
Single glazed panels with aluminium framework shall be provided as partition

between two air - conditioned areas wherever clear view is necessary.

Coal conveyor galleries shall have steel windows of openable type. The window
shutters shall be provided with M. S. louvers.
All steel doors shall consist of double plate flush door shutters. The door shutter shall
be 45 mm thick with two outer sheets of 18 G rigidly connected with continuous
vertical 20 G stiffeners at the rate 150 mm centre to centre. Side, top and bottom
edges of shutters shall be reinforced by continuous pressed steel channel with
minimum 18G. The door shall be sound deadened by filling the inside void with
mineral wool. Doors shall be complete with all hardware and fixtures like door closer,
tower bolts, handles, stoppers aldrops, etc.
Windows of coal galleries shall be provided with welded wire fabric of 1.6 mm thick
wire as per IS: 4948 and 12 mm x 30 mm mesh size.
Wherever functionally required rolling shutters shall be provided and these shall be
either electrically operated or manually operated or with geared arrangement.
In transfer points, windows near floors shall be steel and openable types. The
window shutters shall be provided with MS louvers. Windows / ventilators at higher
level can be of steel with fixed glazing. All openable windows shall be provided with
suitable stays.
All windows and ventilators on ground floor of all switchgear and M. C. C. buildings
shall be provided with suitable anodized aluminium grill.
Fire - Proof doors with panic devices and all necessary fixtures shall be provided at
all fire exit points as per the recommendations of statutory regulatory bodies These
doors shall generally be as per IS : 3614 ( Part I and Part II ) meeting TAC
requirements. Fire rating of the doors shall be as per requirements of statutory
regulatory bodies. However minimum rating shall be 2 hours. These doors shall be
double cover-plated types with mineral wool insulation.
Hollow extruded section of minimum 2 mm wall thickness as manufactured by INDAL

or equivalent shall be used for all aluminium doors, windows, and ventilators.
All doors should have opening as indicated in the drawings. Doors and windows on
external walls of the buildings having brick enclosures i.e. enclosure other than with
permanently colour coated steel sheet cladding, shall be provided with sunshade
over the openings with width 600 mm more than the opening width. Projections from
the wall for the sunshade shall be 500 mm over window openings and 500 mm over
door openings. Minimum size of door provided should be 2.1 m high and 1.2 m wide,
except for toiler rooms, where door may be 0.75 m wide. All doors ( other than those
in W/C and urinal area ) shall be double plate flush door shutters. For W/C and
urinals area, wooden panel doors shall be provided. Area of windows shall be at least
10 % of the floor area of the respective building. The area of translucent
polycarbonate sheet panels shall also be at least 10 % of the floor area of the
respective building.
Monorail doors shall be provided with steel stays / chains etc for convenient
operation of the shutters.
The louvre blade shall be ‘Z’ shaped and made out of 18G sheets in EZ7 steel
frames. The frames shall be of ISMC 100.

18.05.02 Rolling Shutters
Rolling Shutters/ grills shall be with motor drives, gear arrangement including all
accessories and shall conform to IS: 6248. All electrical work shall be in strict
accordance with the relevant Indian Electricity Rules.
After installing the shutters, the Contractor shall test the performance of the shutter in
presence of the Engineer. The shutters shall be smoothly operable under all ambient
conditions. All control and locking devices shall give fault free performance.
19.00.00 PAINTING
Painting of all steel structures, including seal plates, hand rails, steel doors &
windows, ventilators, louvers, Rolling Shutters Stair Cases (except gratings), etc.
shall be with paints as per following:
19.01.00 Materials
Zinc silicate primer (minimum 75 micron Dry Film Thickness - DFT) shall be inorganic
(Ethyl) self curing high built (Solid by volume minimum 60%) formulation as per BS :
5493 (Inorganic Zinc rich systems).
Intermediate (Under) coat (minimum 75 micron DFT) shall be of polyamide cured

titanium di-oxide / micaceous iron oxide pigmented high performance (solid by
volume minimum 60%) epoxy coating as per BS : 5493 ( two pack chemical resistant
under coats).
Finish coat (minimum 75 micron DFT) shall be of polyamide cured colored pigmented
high performance (solid by volume minimum 60%) epoxy coating as per BS: 5493
(two pack chemical resistant finishes).
Final finish coat (minimum 25 Micron DFT) shall be of polyurethane colour pigmented
(solid by volume minimum 40%) as per BS: 5493 (two pack chemical resistant
finishes).
All paints including primer shall be of reputed brand / manufacturer and as approved
by the engineer.
19.02.00 Preparation of Surface
The surfaces shall be blast cleaned to near white metal surface (Sa 2 ½) i.e. 2nd
quality (requiring at least 95% of the surface completely cleaned) as given in BS :
4232 . For blast cleaning shot blasting shall be used.
Approved type of abrasives shall only be used for blast cleaning of steel surfaces by
shot blasting. Suitable enclosure shall be provided to carry out the blast cleaning
operation. If required prior approval from the factory inspector / pollution control
board etc. shall be obtained regarding the method of blast cleaning and abrasives
used therein.
Immediately after blast cleaning of the steel surfaces, primer coat shall be applied
onto the surfaces.

19.03.00 Application of paint
The contractor shall submit the total painting scheme and works shall be started after
the approval of the scheme, from the engineer.
Painting works shall be carried out on structural as per the approved scheme. The
total painting scheme to be submitted to the engineer shall include the following:
i) Method of blast cleaning giving the details and sizing of various equipment
required, abrasive used, enclosure provided to avoid contamination of the
adjoining area, expected productivity on an eight (08) hour shift working etc.
ii) Arrangement of airless spray with the equipment rating.
iii) Drying time to be allowed before the application of subsequent coat.
iv) Recommended paint for primer, intermediate (under) coat, finish coat and
final finish coat with their brand name and designation, considering the
requirements of BS : 5493 for long range (typical time to first maintenance 10
to 20 years), life for exterior exposed non polluted inland atmosphere.
v) Number of coat and the thickness of each coat to be applied to

achieve the specified thickness of each coat i.e. primer, intermediate (under), finish
and final finish coats.
vi) Environmental conditions i.e. ambient temperature and humidity at the

time of application of the paint.
vii) Quality control setup for painting i.e. checking of surface preparation,
thickness of each coat, quality of applied paints vis-à-vis the approved sample etc.
viii) Method of touch up painting for surfaces damaged during handling,

transit, erection, welding, subsequent to painting, removal of the temporary supports
etc.
ix) Reference of relevant Indian / International standards for the testing

and acceptance.
Before application of inorganic zinc silicate primer, the steel surfaces shall be blast
cleaned to near white metal surface (Sa 2 ½).
Primer paint and intermediate (Under) coat shall be done by airless spray. However
finish coat and final finish coat can be applied either by spray and or brush.
All subsequent coats shall be applied only after acceptance of the previous applied
coat. Inaccessible surfaces shall be primer painted before shop assembly.
For final touch up painting of surfaces, which are damaged during handling, transit,
erection, etc. surfaces shall be well prepared, by rubbing the entire damaged area
using wire brush, emery paper etc. and shall be provided with minimum 100 micron
(DFT) of self priming high build epoxy based primer followed by intermediate, finish
and final finish coats as described elsewhere in this document. Touch up painting of

areas welded subsequent to painting and areas exposed after removal of temporary
supports shall also be carried out in same way.
Rectification of the damaged painted surfaces on account of welding / handling etc.

of each coat shall be done by touch up painting, before the application of next coat,
using minimum 100 micron (DFT) self priming high build epoxy based primer
followed by various coats in sequence of thickness as specified elsewhere.
19.04.00 Acceptance Criteria
All painted surfaces shall be uniform and pleasing in appearance.
Dry film thickness of each coat shall be checked and measured by using elcho-
meter. The thickness as measured shall not be less than the minimum thickness
specified for the coat of paint under relevant clauses of the technical specification.
Measurement of paint thickness shall be as per “SSPC : The society for Protective
Coatings Paint Application Standard no. 2” titled “Measurement of Dry Coating
thickness with magnetic gages”.
Colour, texture shall match exactly with the approved sample.
20.00.00 Miscellaneous
20.01.00 Ordinary form work shall be used in roofs and floor slabs in transfer houses,
footings, pedestals, cable trenches, pits etc., Plywood form work shall be used for
all over ground exposed work like columns, beams, floors and ceilings in control
room and M. C. C. buildings.
20.02.00 Monorail girders and fixtures shall be provided for monorails at the locations as
required and as described elsewhere in these specifications or drawings.
Monorail openings in the walls shall be provided with steel frame doors preferably
sliding type or otherwise open able inside, access platforms and ladders.
20.03.00 Steel frame around openings in roof and on external walls for mounting of exhaust
fans shall be provided.
20.04.00 Ready mix non - shrink cementitious grout of reputed manufacturer as approved by
the Employer shall be used for grouting of block outs and foundation bolts,
underpinning of base plates and machine bases. Crushing strength of grout shall
be one grade higher than the foundation concrete. Minimum crushing strength shall
be 30 N / mm2 unless higher strength requirement is specified by the equipment
supplier or the grout manufacturers.
20.05.00 The bottom of steel in case of cable / pipe galleries and trestles shall be generally
3m above the ground except for rail / road crossing where it shall be 8m above the
rail top / road crest/ground. Further in bunker areas it shall be 8 m above the
ground.
20.06.00 Polysulphide Sealing Compound shall be two-part polysulphide sealant and shall be
from approved manufacturer, conforming to IS : 12118. Materials shall consist of
polysulphide polymer and a curing agent. Gun grade material shall be used unless

otherwise specified. The application of the sealant shall be strictly followed as per
manufacturer’s guidelines.
24.00.00 Packaging and Transportation.
All the equipment shall be suitably protected coated, covered or boxed and crated to
prevent damage or deterioration during transit, handling and storage at site till the
time of erection. While packing all the materials the limitations from the point of view
of availability of railway wagon sizes in India should be taken into account. The
contractor shall be responsible for any loss or damage during transportation,
handling and storage due to improper packing.
25.00.00 Plant Life
The plant shall be designed for a minimum operating life of 30 years under the
conditions of operation. Assurance shall be given that plant components are
adequate for this lifetime. If there are any exceptional items of the plant on which an
assurance of meeting this clause cannot be given, life of such components and the
difficulties associated with them shall be stated.
26.00.00 PTFE (Poly Tetra Fluoroethylene) Bearing
The bearing shall be of reputed make and manufacturer as approved by the

Engineer, for required vertical load and end displacement/rotation. PTFE bearing
shall be sliding against highly polished stainless steel and the coefficient of friction
between them shall be less than 0.06 at 55 kg/sq.cm. In order to prevent cold flow in
PTFE surface it shall be rigidly bonded by a special high temperature resistance
adhesive to the stainless steel substrata. The stainless steel surface that slides
against the PTFE is mirror polished. The stainless steel shall be bonded to the top
plate by special high strength adhesive. The thickness of stainless steel plate shall
be between 1.0 mm to 1.5 mm.
27.00.00 TESTS FOR MATERIAL / WORKMANSHIP
All tests required for all materials, quality of workmanship or any other tests as
desired by the Engineer shall be at contractor’s cost.
28.00.00 MATERIALS
28.01.00 For Civil, Structural and Architectural works
Employer will not supply any material. All materials including cement, reinforcement
steel and structural steel, whatsoever required for execution and completion of the
entire scope of work covered under this specification shall be arranged by the
contractor at his own cost. All materials procured by the contractor shall meet the
quality requirements specified in this specification.
The contractor shall keep sufficient stock of cement and steel at site at any point of
time when the work is in progress excluding what has been already incorporated in
the works, so that any disruption / delay in availability of these materials during
procurement will not affect the progress of work at site. The minimum quantity of
such materials in stock at site shall not be less then the Requirement of one ( 1 )

month in case of Cement and Requirement of two ( 2 ) Consecutive months in case

of Steel.
28.02.00 Structural steel
28.02.01 Mild Steel
(a.) Rolled sections shall conform to E250A of IS 2062:2006 in as rolled and semi
killed condition.
(b.) Plates up to 20mm thickness shall conform to E250A of IS 2062:2006 in as

rolled and semi killed condition.
(c.) Plates beyond 20mm and up to 40 mm shall conform to E250B of IS 2062:2006

as rolled in killed condition.
(d.) Plates beyond 40mm shall conform to E250B of IS 2062:2006 in normalized

and ultrasonically tested quality.
(e.) Pipes for handrail shall conform to medium grade of IS : 1161.
(f.) Chequered plates shall conform to IS : 3502. Tensile properties shall conform
to E250A of IS 2062:2006.
(g.) Seal plates shall conform to IS : 1079 ( semi - skilled quality )
28.02.02 Medium & High Tensile Steel
(a.) Rolled section shall conform to Grade E350 of IS 2062:2006, Semi Killed.
(b.) Plates up to 20 mm thickness shall conform to Grade E350 of IS 2062:2006,
Semi Killed.
(c.) Plates beyond 20 mm and 40mm shall be as per Grade E350 of IS 2062:2006,
Killed type.
(d.) Beyond 40mm shall conform to Grade E350 of IS 2062:2006, in normalized
condition and ultrasonically tested quality.
28.02.03 All plates up to and including 40mm thickness shall be ultrasonically tested on audit
basis to check the laminations.
28.03.00 Fly ash based Portland pozzolona cement conforming to IS: 1489 Part - I shall
preferably be used. However, the contractor may use other types of cements
conforming to IS: 269, IS: 8112, IS: 12269, & IS: 455. However Ordinary Portland
cement conforming to IS: 269 or IS: 8112 shall necessarily be used for Crusher
Deck.
28.04.00 Reinforcement steel shall conform to:
a) Mild steel grade I of IS: 432 Part – I and grade A of IS: 2062.
b) High yield strength deformed bar of Gr. Fe 415/ Fe 500 produced by thermo-
mechanical treatment process, having elongation more than 14.5 percent and

conforming to other requirements of IS 1786 shall be used for the

reinforcement.
28.00.00 BITUMINOUS ROADS
28.01.00 Contents
This section deals with specifications for construction of flexible road pavements. The
details of work shall consist of :
a) Construction of sub grade
b) Construction of Water Bound Macadam base and sub – base
c) Bituminous surfacing
28.02.01 The Contractor shall mobilise at site all equipment, including paver, roller, water
tanker, etc.
28.02.02 The Contractor shall carry out the survey and setting out works, including alignment,
layout, grading, curves etc.
28.02.03 The contractor shall also hire the services of a specialized agency, wherever
required.
28.03.00 Construction of Sub-grade
28.03.01 The sub–grade shall be either in embankment, cutting or on the existing leveled
ground. The cutting and embankment works, wherever involved shall be carried out,
as per relevant specification of excavation and filling.
The excavation for laying of base and sub-base courses shall be carried out in the
required profile using box cutting. The lower 500 mm of the sub-–grade shall be
compacted to 95% of the Proctor Density at Optimum Moisture Content, if not done
earlier; otherwise the top surface of the sub-grade shall be compacted using 8 to 10
Tonne roller with 6 passes. All undulations in the surface that develop due to rolling
shall be made good with material or quarry spoils, as the case may be and the sub
grade shall be re-rolled.
The finished surface shall be uniform, and conform to the lines, grades and typical
cross-section shown in the drawings, when tested with the template and straight
edge. The permissible variation shall be 25 mm in the longitudinal profile and 15 mm
in the cross profile.
The shoulders area shall also be compacted in the same way maintaining the
required profile on the top surface.
28.04.00 WATER BOUND MACADAM

Water bound macadam using crushed stone aggregate shall be used for
construction of sub- base and base material.
28.04.01 Materials
Coarse aggregates shall be of crushed or broken stone meeting the requirements of

IRC specification with respect to physical properties and grading. Grade – I material
having size range of 90 to 45 mm shall only be used for sub–base. Grade – II and III
having size range of 63 to 45 mm and 53 to 22.4 mm respectively shall be used for
base construction.
Moorum (Non Plastic Material) shall be used in the screenings as the filling material
to fill the voids in the coarse aggregate. The moorum shall be obtained from pits of
weathered disintegrated rocks. It should preferably contain silicious material and
natural mixture of clay of calcareous origin. The size of moorum shall not be more
than 20 mm.
28.05.00 Binding Materials
No separate binding material is required and the same moorum used as screening
material shall also serve the purpose.
28.06.00 Construction Operations
The construction operation shall involve preparation of base, spreading of coarse

aggregates followed by rolling, application of binding material, setting and drying. The
details of construction activities quantity and the quality of various materials to be
used shall be as per the stipulations of IRC specification.
The spreading shall be done from stockpile along the side of the roadway or directly
from the vehicle. The segregation of large and fine aggregates shall be avoided.
It may be ensured that the thickness of each compacted layer is not more than 100
mm for grading 1 material and 75 mm for grading 2 and 3 materials, for sub-base and
base respectively. The number of layers and actual thickness of the base and sub-
base shall depend upon the CBR value of the sub-grade. The surface evenness and
finishes of the Water Bound Macadam shall be checked and defects, if any, shall be
rectified. In no case shall depressions be filled up with screenings and binding
materials.
28.07.00 Bituminous Macadam
28.07.01 The work shall consist of construction, in a single course of 75 mm thickness of

compacted crushed aggregates, premixed with a bituminous binder, to serve as base
/ binder course, laid immediately after mixing, on a base prepared previously in
accordance with the requirements of these specifications and in conformity with the
line, grades and cross sections shown on the drawings or as directed by the
Engineer.
28.08.00 Materials
28.08.01 Bitumen

The bitumen shall be paving bitumen of suitable penetration grade within the range S
35 to S 90 or A 35 to A 90 (30 / 40 to 80 / 100), as per Indian standards
specifications for “Paving Bitumen” IS : 73. The actual grade of bitumen to be used
shall be decided by the Engineer appropriate to the region, traffic, rainfall and other
environmental conditions.
28.08.02 Aggregates
The aggregates shall consist of crushed stone. They shall be clean, strong, durable
of fairly cubical shape and free from disintegrated pieces, organic or other deleterious
matters and adherent coating. The aggregates shall satisfy the physical requirements
set forth in IRC standards.
28.08.03 Proportioning of Materials
The bitumen content for premixing shall be 4 percent by weight of the total mix
except when otherwise directed by the Engineer.
The quantities of aggregates to be used shall be sufficient to yield the specified

thickness after compaction.
28.08.04 Construction Operations
The construction operation shall be carried out as per the stipulations of IRC
standards. This shall involve preparation of base, application of tach coat,
preparation and transportation of mix, spreading of mix, rolling, surface finish and
quality control. The mix shall be prepared in a hot mix plant of adequate capacity and
capable to yield a mix of proper and uniform quality works thoroughly coated
aggregates. The mix transferred from the tipper at site to the paver shall be spread
immediately by mixer, if self propelled. Mechanical road paver with suitable screeds
capable of spreading temping and finishing the mix trial to the specified lines, grades
and cross sections shall be used.
28.09.00 BITUMINOUS SURFACING
28.09.01 This shall involve laying and compacting of an open graded premix carpet of 25 mm
thickness in a single course composed of suitable small sized aggregates premixed
with a bituminous binder on a previously prepared base to serve as a wearing
course. This surface finish shall be provided directly on WBM or on Bituminous
Macadam depending on the type / category of road.
28.09.02 Materials
28.09.03 Binder
Bitumen of suitable grade conforming to IS: 73 shall be used as a binder.
28.09.04 Aggregates
Stone chips size, grading, physical properties shall be as specified in IRC standards.

28.09.05 Proportioning of different types of materials shall be as given in IRC specifications.

However, due to higher thickness of 25 mm, the quantity of material shall be
proportionately increased.
28.10.00 Construction operations
28.10.01 The construction operations shall involve the preparation of base, application of tack
coat, preparation of premix, spreading and rolling followed by a seal coat. The details
of construction activities and the quantity of various materials to be used shall be as
per the stipulations of IRC specifications. A mechanical road paver finisher shall be
used for laying of premix carpet.
28.11.00 Seal coat
28.11.01 A premixed seal coat (type-B) for sealing the voids in the bituminous surface
comprising of a thin application of fine aggregate (Stone dust / grit) premixed with
bituminous binder shall be provided, as per the stipulations of IRC specifications.
28.11.02 Tack Coat
Tack coat of low viscosity conforming to IRC shall be applied, as mentioned in

Schedule of Items.
28.12.00 SHOULDERS
28.12.01 Content
This section deals with specifications for construction of shoulder (hard) on either
side of the pavement, in accordance with the requirements of these specifications
and in conformity with the lines, grades and cross sections shown on the drawings or
as directed by the Engineer.
28.12.02 Materials
Shoulder on either side of the road shall be of WBM using stone aggregate.
28.12.03 Size of shoulder
Shoulder (hard) dimensions shall be minimum 10m wide.
28.12.04 Construction operations
Except in the case of bituminous constructions, shoulders shall be constructed in

advance of the laying of pavement courses. The compacted thickness of each layer
of shoulder shall correspond to the compacted layer of the pavement course to be
laid adjacent to it. After compaction, the inside edges of shoulders shall be trimmed
vertical and included area cleaned of all spilled material before proceeding with the
construction of the pavement layer.
In the case of bituminous courses, work on shoulder (hard) shall start only after the
pavement course has been laid and compacted.

During all stages of shoulder (earthen/hard) construction, the required cross-fall shall
be maintained to drain off surface water.
Regardless of the method of laying, all shoulder construction material shall be placed
directly on the shoulder. Any spilled material dragged on to the pavement surface
shall be immediately removed, without damage to the pavement and the area so
affected thoroughly cleaned.
28.12.05 Surface finish and quality control of works
The surface finish of construction shall conform to the requirements of IRC. Control
on the quality of materials and works shall be exercised by the Engineer in
accordance with IRC.
28.12.06 Brick edging
Brick edging shall be provided on both sides of the road all along the length. Fly ash
based bricks having strength not less than 7.5 MPa shall be used for this purpose,
unless otherwise specified. The edging shall be of one brick width and half brick
depth. In the case of hard shoulder, the brick edging shall not be provided. Trenches
shall be excavated after construction of the road and the bed of trenches shall be
compacted to a firm and even surface. The bricks shall be abutting to the wearing
course, true to line, gradient and in camber with the finished road surface at the
edges.
28.13.00 INSPECTION AND TESTING
The surfaces finish, alignment, profile, gradient, tolerance, quality control during
construction and characteristics of different materials shall be checked, as per the
requirements of IRC specifications, for road and bridge works.
All standards, specifications, acts and code of practice referred to herein shall
be the latest editions including all applicable official amendments and
revisions. Other Indian, foreign Codes and Standards not listed here but
referred to elsewhere within this specification shall also be deemed to be part
of this list.
In case of conflict between this specification and those (IS standards, codes
etc.) referred to herein, the former shall prevail.
Some of the relevant Indian standards, Acts and Codes applicable to this
section of the specification are listed below
IS : 383 Specification for coarse and fine aggregates from

natural sources for Concrete.

IS : 432 Specification for mild steel and medium tensile steel

bars and hard drawn steel wire for concrete
reinforcement.
IS : 456 Code of practice for plain and reinforced concrete.
IS : 458 Specification for concrete pipes.
IS : 516 Method of test for strength of concrete.
IS : 800 Code of practice for use of structural steel in general

building construction.
IS : 814 Specification for covered electrodes for metal arc

welding for weld steel.
IS : 816 Code of practice for use of metal arc welding for

general construction.
IS : 817 Code of practice for training and testing of metal arc

welders.
IS : 875 (Pt. I to V) Code of practice for design loads other than

earthquake) for buildings and structures.
IS : 1038 Steel doors, windows and ventilators.
IS : 1172 Basic requirements for water supply, drainage and

sanitation.
IS : 1361 Steel windows for industrial buildings.
IS : 1786 Specification for high strength deformed steel bars and

wires for concrete reinforcement.
IS : 1892 Code of practice for subsurface investigation for

foundation.
IS : 1893 Criteria for earthquake resistant design of structures.
IS : 1904 Code of practice for design and construction of

foundations in soils; general requirements.
IS : 1905 Code of practice for structural safety of buildings -

Masonry walls.
IS : 1948 Specification for aluminium doors, windows and

ventilators.
IS : 2062 Steel for general structural purposes.
IS : 2131 Method of standard penetration test for soils.
IS : 2212 Code of practice for brickwork.
IS : 2645 Specification for Integral cement water proofing

compounds.
IS:2720 (Part-II, Methods of test for soils - determination for water

IV TO VIII, XIV, content etc code of practice for earth work on canals.
XXI, XXIII, XXIV,
XXVII TO XXIX,
XL)
IS : 2911 Code of practice for design and construction of pile

foundations.
(Part-1/Sec.1) Driven cast in situ concrete piles.
(Part-1/Sec.2) Bored cast-in-situ concrete piles.
(Part-IV) Load test on piles.
IS : 2974 (Part - I Code of practice for design and construction of

TO V) machine foundations.
IS : 3370 (Part I Code of practice for concrete structures for the storage
to IV) of liquids.
IS : 3658 Code of practice for liquid penetrant flaw detection.
IS : 3664 Code of practice for ultra sonic testing by pulse echo

method.
IS : 4326 Code of practice for earthquake resistant design and

construction of buildings.
IS : 4990 Specification for plywood for concrete shuttering work.
IS : 5624 Specification for foundation bolts.
IS : 7215 Tolerances for fabrication steel structures.
IS : 8112 Specification for 43 grade Ordinary Portland Cement.
IS : 9103 Specification for admixtures for concrete.
IS : 9595 Code of procedure of manual metal arc welding of mild

steel.
IS : 10262 Recommended guidelines for concrete mix design.
IS : 13311 Method of non - destructive testing of concrete.
IS : 13755 Dust pressed ceramic tiles with water absorption of 3%,

E6% (Group B11a)
ASTM 898 -89 Standard guide for use of high solid content, cold
liquid-applied elastomeric water proofing membrane
for use with separate wearing course.
AS/NZS 2728 Pre finished / pre painted sheet metal product for
interior / exterior building applications – Performance
requirements.
AS : 1365 Standards for steel manufacturing.
AS : 1397 A steel sheet & strip – hot – dipped-zinc-coated or

Aluminium-Zinc coated.
AS : 3566 Self drilling screws for building and construction

industry.
IRC : 37 Guidelines for the design of flexible pavements.
- Manual on sewerage and sewage treatment (Published

by CPH & EEO) As updated.
Indian Explosives Act. 1940 as updated.

ANNEXURE-A
CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND

EQUIPMENT
All structures and equipment shall be designed for seismic forces adopting the site
specific seismic information provided in this document and using the other provisions
in accordance with IS:1893 (Part 1):2002 and IS:1893 (Part 4):2005. Pending
finalisation of Parts 2, 3 and 5 of IS:1893, provisions of part 1 shall be read along
with the relevant clauses of IS:1893:1984, for structures other than the buildings and
industrial structures including stack-like structures.
A site specific seismic study has been conducted for the project site. The peak
ground horizontal acceleration for the project site, the site specific acceleration
spectral coefficients (in units of gravity acceleration ‘g’) in the horizontal direction for
the various damping values and the multiplying factor (to be used over the spectral
coefficients) for evaluating the design acceleration spectra are as given at Annexure-
I.
Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding

horizontal values.
The site specific design acceleration spectra shall be used in place of the response
acceleration spectra, given at figure-2 in IS:1893 (Part 1) and Annex B of IS:1893
(Part 4). The site specific acceleration spectra along with multiplying factors specified
in Annexure-I includes the effect of the seismic environment of the site, the
importance factor related to the structures and the response reduction factor. Hence,
the design spectra do not require any further consideration of the zone factor (Z), the
importance factor (I) and response reduction factor (R) as used in the IS:1893 (Part 1
and Part 4).
Damping in Structures
The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:
a) Steel structures : 2%
b) Reinforced Concrete structures : 5%
c) Reinforced Concrete Stacks : 3%
d) ND Cooling Towers : 2%
e) 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).
In general, seismic analysis shall be performed for the three orthogonal (two principal
horizontal and one vertical) components of earthquake motion. The seismic response
from the three components shall be combined as specified in IS:1893 (Part 1).
For buildings, if the design base shear (VB) obtained from modal combination is less
than the base shear (⎯VB) computed using the approximate fundamental period (Ta)
given in IS:1893:Part 1 and using site specific acceleration spectra with appropriate
multiplying factor, the response quantities (e.g. member forces, displacements,
storey forces, storey shears and base reactions) shall be enhanced in the ratio of
⎯VB/ VB. However, no reduction is permitted if ⎯VB is less than VB.
For regular buildings less than 12m in height, design seismic base shear and its
distribution to different floor levels along the height of the building may be carried out
as specified under clause 7.5, 7.6 & 7.7 of IS:1893 (Part 1) and using site specific
design acceleration spectra. The design horizontal acceleration spectrum value (Ah)
shall be computed for the fundamental natural period as per clause 7.6 of IS:1893
(Part 1) using site specific spectral acceleration coefficients with appropriate
multiplying factor given in Annexure-I.
Further, the spectral acceleration coefficient shall get restricted to the peak spectral
value if the fundamental natural period of the structure falls to the left of the peak in
the spectral acceleration curve.
Design/Detailing for Ductility for Structures
The site specific design acceleration spectra is a reduced spectra and has an in-built
allowance for ductility. Structures shall be engineered and detailed in accordance
with relevant Indian/International standards to achieve ductility.

ANNEXURE – I
SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES AND

EQUIPMENT
The various site specific seismic parameters for the project site shall be as follows:
1) Peak ground horizontal acceleration : 0.24g
2) Multiplying factor to be applied to the site specific

horizontal acceleration spectral coefficients (in units of
gravity acceleration ‘g’) to obtain the design acceleration
spectra
a) for moment resisting steel frames designed and

detailed as per IS:800 and moment resisting RC
frames designed and detailed as per IS:456 : 0.08
b) for braced steel frames designed and detailed as per : 0.06

IS:800
c) for moment resisting RC frames designed and detailed

as per IS:456 and IS:13920 : 0.048
d) For steel chimney : 0.12

e) for design of structures not covered under 2 (a) to 2 (d)
above and under 3 below : 0.08
3) Multiplying factor to be applied to the site specific

horizontal acceleration spectral coefficients (in units of
gravity acceleration ‘g’) for design of equipment and
structures where inelastic action is not relevant or not : 0.16
permitted
Note: g = Acceleration due to gravity
The horizontal seismic acceleration spectral coefficients are furnished in subsequent

pages.

ANNEXURE – I
HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS

In units of ‘g’
Damping Factor (as a percentage of critical damping)

Time Period
(Sec) 5% 2%
0.000 1.000 1.000
0.030 1.000 1.000
0.050 1.353 1.479
0.100 2.040 2.515
0.150 2.593 3.431
0.162 2.714 3.639
0.170 2.714 3.774
0.200 2.714 3.774
0.250 2.714 3.774
0.300 2.714 3.774
0.350 2.714 3.774
0.400 2.714 3.774
0.450 2.714 3.774
0.500 2.714 3.774
0.525 2.714 3.774
0.550 2.714 3.774
0.600 2.714 3.774
0.650 2.714 3.774
0.670 2.714 3.774
0.700 2.714 3.774
0.750 2.714 3.774
0.809 2.714 3.774
0.849 2.587 3.774
0.900 2.440 3.559
0.950 2.312 3.372
1.000 2.196 3.203
1.050 2.091 3.050
1.100 1.996 2.912
1.150 1.910 2.785
1.200 1.830 2.669
1.250 1.757 2.562
1.300 1.689 2.464
1.350 1.627 2.373
1.400 1.569 2.288
1.450 1.514 2.209
1.500 1.464 2.135
1.550 1.417 2.066
1.600 1.373 2.002

ANNEXURE – I

In units of ‘g’

Time Period
(Sec) 5% 2%
1.650 1.331 1.941
1.700 1.292 1.884
1.750 1.255 1.830
1.800 1.220 1.779
1.850 1.187 1.731
1.900 1.156 1.686
1.950 1.126 1.643
2.000 1.098 1.602
2.050 1.071 1.562
2.100 1.046 1.525
2.150 1.021 1.490
2.200 0.998 1.456
2.250 0.976 1.424
2.300 0.955 1.393
2.350 0.934 1.363
2.400 0.915 1.335
2.450 0.896 1.307
2.500 0.878 1.281
2.550 0.861 1.256
2.600 0.845 1.232
2.650 0.829 1.209
2.700 0.813 1.186
2.750 0.799 1.165
2.800 0.784 1.144
2.850 0.771 1.124
2.900 0.757 1.104
2.950 0.744 1.086
3.000 0.732 1.068
3.050 0.720 1.050
3.100 0.708 1.033
3.150 0.697 1.017
3.200 0.686 1.001
3.250 0.676 0.986
3.300 0.665 0.971
3.350 0.656 0.956
3.400 0.646 0.942
3.450 0.637 0.928
3.500 0.627 0.915

ANNEXURE – I

In units of ‘g’

Time Period
(Sec) 5% 2%
3.550 0.619 0.902
3.600 0.610 0.890
3.650 0.602 0.878
3.700 0.594 0.866
3.750 0.586 0.854
3.800 0.578 0.843
3.825 0.574 0.837
3.850 0.570 0.832
3.900 0.563 0.821
3.950 0.556 0.811
4.000 0.549 0.801

ANNEXURE-B
CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT
All structures shall be designed for wind forces in accordance with IS: 875 (Part-3)
and as specified in this document. See Annexure – B for site specific information.
Along wind forces shall generally be computed by the Peak (i.e. 3 second gust) Wind
Speed method as defined in the standard.
Along wind forces on slender and wind sensitive structures and structural elements
shall also be computed, for dynamic effects, using the Gust Factor or Gust
Effectiveness Factor Method as defined in the standard. The structures shall be
designed for the higher of the forces obtained from Gust Factor method and the Peak
Wind Speed method.
Analysis for dynamic effects of wind must be undertaken for any structure which has
a height to minimum lateral dimension ratio greater than “5” and/or if the fundamental
frequency of the structure is less than 1 Hz.
Susceptibility of structures to across-wind forces, galloping, flutter, ovalling etc.

should be examined and designed/detailed accordingly following the
recommendations of IS:875(Part-3) and other relevant Indian standards.
It should be estimated if size and relative position of other structures are likely to
enhance the wind loading on the structure under consideration. Enhancement factor,
if necessary, shall suitably be estimated and applied to the wind loading to account
for the interference effects.
Damping in Structures
The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:
a) Welded steel structures : 1.0%
b) Bolted steel structures : 2.0%
c) Reinforced concrete structures : 1.6%
d) Steel stacks : As per IS:6533 &

CICIND Model Code
whichever is more
critical.

SITE SPECIFIC DESIGN PARAMETERS
The various design parameters, as defined in IS: 875 (Part-3), to be adopted for the
project site shall be as follows:
a) The basic wind speed “Vb” at ten

metres above the mean ground level : 47 metres/second
b) The risk coefficient “K1” : 1.07
c) Category of terrain : Category-2
Note: Notwithstanding the values of the above mentioned parameters, the design
wind pressure so computed at any point shall not be taken less than 1500 N/Sq.
meter for all classes of structures, i.e. A, B & C, as defined in IS: 875 (Part-3).

1.00.00 GEOTECHNICAL INVESTIGATION & FOUNDATION SYSTEM
1.01.00 Geotechnical investigation for the scope of work shall be done by the bidder. Owner
has carried out geotechnical investigation within plant. The details of few borelogs
are enclosed at Annexure-I. These are solely for the purpose of guidance of the
Bidder. The onus of correct assessment/interpretation and understanding of the
existing sub soil conditions/data is on the Bidder.
1.01.01 The geotechnical investigation shall be carried out in all work areas for establishing
the sub-soil conditions & to decide type of foundations for the structures envisaged,
construction methods, any special requirements/ treatment called for/ remedial
measures for sub-soil/ foundations etc. for soft sub-soils, aggressive sub-soils &
water, expansive/ swelling soils etc.
1.02.0 Scheme of Soil Investigation
1.02.01 The diameter of borehole shall be minimum 150 mm in soil and 76 mm in rock. The
diameter of UDS sampler shall be 90 mm minimum. Drilling in rock shall be done by
means of hydraulic feed equipment using double tube core barrel with diamond bid
attachment.
1.02.02 Field test shall include but not be limited to the following:-
Boreholes, Standard Penetration Test (SPT), collection of disturbed and undisturbed

soil samples (UDS), Trial Pits (TP), Electrical Resistivity Test (ERT), collection of
water samples, etc.
1.02.03 The minimum tests are indicated in Annexure A. Adequate number of tests shall be
conducted upto sufficient depth for complete determination of subsoil conditions. The
depth of boreholes shall be as specified in Annexure A. SPT shall be carried out in
all types of soil deposits and in all rock formations with core recovery upto 20%, met
within a borehole. This test shall be conducted at every 3.0 m interval or at change of
strata, upto the final depth. Number of blows shall be recorded for every 15 cm of
penetration upto 45 cm or 100 blows whichever occurs earlier. SPT ‘N’ of 100 and
above shall be referred as refusal. UDS shall be collected at every 3.0 m interval or
at change of strata upto depth of borehole. UDS may be replaced by additional SPT,
if SPT’N’ value in the strata is above 50.
1.02.04 Laboratory tests shall be done as per relevant IS codes. The laboratory tests, not be
limited to the following shall be conducted on disturbed and undisturbed soil / rock
samples & water samples collected during field investigations in sufficient numbers.
Laboratory tests shall be carried out on disturbed and undisturbed soil samples for
Grain Size Analysis, Hydrometer Analysis, Atterberg Limits, Trixial Shear Tests (UU),
Natural Moisture Content, Specific Gravity and Bulk Unit Weight, Consolidation
Tests, Unconfined Compression Test, Free swell Index, Shrinkage Limit, Swell
Pressure Test, Chemical Analysis test on soil and water samples to determine the
carbonates, sulphates, chlorides, nitrates, pH, organic matter and any other
chemicals harmful to concrete and reinforcement/ steel.
1.02.05 Geotechnical investigation shall be carried out in accordance with the provisions of
relevant Indian Standards.

PROJECT GEOTECHNICAL
SECTION VI, PART-B
COAL CONVEYING PLANT PACKAGE INVESTIGATION & FDN.
BID DOC. NO.:CS- - - SYSTEM
1.02.06 On completion of all field & laboratory work, geotechnical investigation report shall be
submitted for Owner’s information/review. The Geotechnical investigation report
shall contain geological information of the region, procedure adopted for
investigation, field & laboratory observations/ data/ records, analysis of results &
recommendations on type of foundation for different type of structures envisaged for
all areas of work with supporting calculations. Recommendations on treatment for
soil, foundation, based on subsoil characteristics, soft soils, aggressive chemicals,
expansive soils, etc.
1.03.00 Foundation System
1.03.01 General Requirements:
a) Contractor can either provide open foundations (isolated footing/ raft) or pile
foundations depending upon the results of the geotechnical investigations to be
carried out by him along with any special requirements/ remedial measurement/
treatment called for subsoil/ foundations as approved by the Owner.
b) All foundations shall be designed in accordance with provisions of the relevant parts
of the latest revisions of Indian Standards. For design purpose, ground water table
shall be considered at Finished Ground Level (FGL)
c) Roads, ground floor slabs, trenches, channels/ drains and other lightly loaded
structures (such as staircase foundation, pipe pedestals with foundation loading
intensity less than 5 T/ M2) may be supported on open/ shallow foundations resting
on virgin/ controlled compacted filled up soil. Minimum depth of foundation shall be
1.0 m below Finished Ground Level (FGL) for pipe pedestals and stair case
foundation. No other foundation shall rest on the filled up ground/ soil.
d) Foundation shall be designed for worst combination of loads as described elsewhere

in the specification.
1.03.02 Open Foundations
In case open foundations are adopted following shall be adhered to:

a) Minimum width of foundation shall be 1.0 m
b) Minimum depth of foundation shall be 1.0 m below NGL.
c) Permissible settlement of foundations.
The total permissible settlement and differential settlement shall be governed by

IS:1904 and IS: 13063 and from functional requirements, whichever is more
stringent. However, total settlement shall be restricted to the following:
i) All foundations including pipe supports, isolated/ strip/ continuous) for widths
upto 6.0 m - 40 mm
ii) Footings width greater than 6.0 m (raft) - 75 mm
Incase pile foundations are to be adopted the requirements under para "pile
foundations" shall be adhered to.
1.03.03 Pile Foundations

SECTION VI, PART-B
The pile foundation shall be cast-in-situ bored piles as per IS: 2911 (relevant part).
Piles shall be installed by using self erecting / supporting rotary hydraulic rig or
conventional tripod rigs. Two stage flushing of pile bore shall be ensured by air lift
technique or any other international method duly approved by Owner. The
construction methodology to be adopted shall be suitable to ensure proper
termination of pile in the strata as specified elsewhere to ensure pile bore free from
spoils.
a) Only RCC piles shall be provided.
b) Minimum diameter, vertical (compression) capacity and pile termination

criteria of reservoir side piles for the approach walk way / bridge shall be as
mentioned below.
Diameter Vertical Capacity
600 140 T
760 250 T
The uplift and lateral load capacities shall be restricted to 35% and 5%
respectively of the allowable load capacity in vertical compression. However,
the pile capacities to be adopted shall be the least of the estimated design
values and that obtained from the pile load tests.
c) Only Straight piles shall be used.
d) The piling work shall be carried out in accordance with the provisions of IS:
2911.
e) The Contractor shall furnish the design of piles (in terms of rated capacity,
length, diameter, termination strata and criterion to locate the founding level
for construction of pile, reinforcement for job as well as test piles etc.),
construction methodology/ specifications for construction of piles and scheme
of initial pile load tests in vertical, lateral and uplift, and the details of
equipment for Owner’s approval. The Contractor shall submit the proposed
locations of initial test piles for Owner’s information prior to their installation.
f) 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.
g) 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.
h) 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. The test equipment shall be of TNO or PDI make or

SECTION VI, PART-B
equivalent. The process shall confirm to ASTM D 5882 and method of testing
shall be Pulse Echo Method (PEM).
i) Regular QA checks for density of circulation mud, contaminated mud and
samples from pile bore bottom, slump of concrete, pile integrity test on all
piles etc. shall be done by the Contractor.
1.03.04 Pile Load Tests
Contractor shall install the piles for initial load test. Number of initial load tests to be
performed for each diameter and rated capacity of pile shall be as under:
i) Vertical (Compression) - 2
ii) Lateral (Horizontal) - 2
iii) Uplift (Tension) - 2
The initial pile load test shall be conducted with test load upto three times the
estimated pile capacity. In case of vertical load test, the method of loading shall by
cyclic as per IS:2911 (relevant part).
Safe load interpretation from pile load test shall be as per IS:2911 (Part-IV).
Number or routine pile load tests to be performed for each diameter/ allowable
capacity of pile shall be as under.
i) Vertical - 0.5% of the total number of piles
provided subject to a minimum of one.
ii) Lateral - 0.5% of the total number of piles
provided subject to a minimum of one.
The routine test on piles shall be conducted upto test load of one and half times the
allowable pile capacity by direct loading method. Piles for routine load test shall be
approved by the Owner.
1.03.05 A report on the pile load tests shall be submitted for Owner’s approval. 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 Contractor shall install
additional pile (s) as required and accordingly, pile cap design should be reviewed
and modified if required at no extra cost to the Owner.
1.03.06 Low strain integrity test shall be conducted on all the test and job piles through an
approved agency and as directed by the Engineer. The system shall have the
computer read out facility and report on the findings of this shall be furnished to the
Owner. This test shall be used to identify the piles for routine load test.
1.04.00 Other Requirements
i) Cement type - As approved by the Owner based on soil

water chemical environment.
Concrete grade - Minimum grade of concrete for piles shall
be M-25 unless specified otherwise
elsewhere. Concrete shall be dense &
durable.
Cement content - Min 400 kg/cum in case of piles.
Admixtures are not permitted in concrete
used for piling.

SECTION VI, PART-B
Reinforcement steel type - TMT bars Fe 500 grade

Cover to reinforcement - As per IS:456, subject to minimum of 50
mm.
(ii) 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 and back data for dewatering
shall be submitted for the owner’s information. The water table shall be
maintained at 0.5m below the founding depth.
(iii) 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.
(iv) Excavation for open foundations shall be covered with PCC immediately after
reaching the founding level. In case of any local loosening of soil at founding
level during excavation, the same shall be removed and compensated by
PCC.
(v) Backfilling, around foundations and bottom of pipes, thrust blocks, etc. shall
be compacted to 90% standard proctor density for cohesive soil and to 75%
of relative density for non-cohesive soils.

SECTION VI, PART-B
ANNEXURE - A
S.No Structure Tests
1 Junction House One borehole at each identified Junction House

Depth of borehole shall be
i) 35 m below ground level.
ii) 5 m into rock with RQD ≥ 50%
continuously
Whichever above occurs earlier.
2 Conveyors One borehole at 100 m c/c along the identified

conveyor.
Depth of borehole shall be
i) 25 m below ground level
ii) 5 m into rock with RQD ≥ 50% continuously
Whichever above occurs earlier.
3 MCC room, One borehole at each structure.

Pump house
Depth of borehole shall be 20m
Two Electrical Resistivity Test (ERT) at each
structure.
NOTE: Investigation in any other new building / structure / facilities / and associated
works / items in the scope of the package, which are not listed above shall also be
carried out.

SECTION VI, PART-B
KND Engineering
Technologies Ltd
BORELOG DATASHEET
Projects NTPC-FSTPP, Stage-Ill Barehaie diameter. 1SOmm

Location: Transformer Yard
Borehole No . Q3
Commenced on:23.07.2006 at: l.Wm BEGL
Completed on: 27.07.2006
--
Cosrdinafe: -/ --
-S-1147 E-250 -- - -- --
Depth Description of soil Details of samples
Ref. No. Type ~apth(m)
grey siRy clay, mixed with
- -- -- - .- --
1 50 soh light brwnleh grey,
3 00 ~ o d e r a g ystiff, li&j -
brownish grey Sllty Clay
small pockets of rust bro
12.00 stiff dark grey 8iG Cly.

Small pockets of rust b m
sills are also observed in the
strata occas~iona!ly.Cotour
of the strata changes to
Muiah grey belovv 21.Elm
nodubs are observed in the

4.75
strara below 26.50m depth.
.- -- -- -- -- -- -- - - -- -
27 25 Very Dense to compact,
light reddish brown Sandy
UD undtslurttedTube Sample
P PanelmmelerTesl
o r I3wulaad aacnprs CMleMma rroril petlslmfiieter DC Dlslurtted Sanlples Callecled From lubes Culttm Shoe
D Daunma Sample
KND Engineerin(
Technologies Ltc
BORELOG DATA-SHEET
Projects: NTPCFSTPP, Stage-Ill Borehole diameter. 150mm I
Location: TG Hall R.L. of ground: 26.50m

Borehole No.: 12 Soil boring termination depth: 26.15m BEGL
Commenced on:21.08.2006 Ground water struck at: 1.90 m BEGL
Completed on: 23.08.2006 Standing water level. 1.80 m BEGL
Co-ordinate: S-1108 IE-219 ----
Thickness .
Details of sampbs I
, Penetration
- -. I
Ref. ~ o - ~ ~~epth(m)
p e Blows115cm I
---- . - - -- -- I
0711 0 I
- oALap~---
-
7-
Ii --I/------ & --1 I
I
i
- .. --. - - -- .
0715 P 1.35-1.80 2
0716 u 2.95-3.40
ti717 D 3.50
0718 P 4.45-4.90 2 8 1
5719 U 6.154,6Q
(3720 D 6.70
0721 P 7.55-8.00
1 14.25 0722 U 9.05-9.50 ' 1
0723 D 9.60
0724 P 10.50-10.95 2 3
. . 0725 P 12.00-12.45 2
0726 U 73.80-14.05
0727 D 14.15
0728 P 15.00-95.45 2 3 6 1
F -- ---- - - - -
i 0731 U '16.50-16.95 I
Q730 D 17.05*-'1
. 0 3
0733
P
U
18 00-18.45
79.50-19.B
3 8 1 3 '
0734 D 20.05
I
!
depth. Colour of the strata W P 21.00-21.45 fi. 6 i 8 W
changes to brownish grey 0736 U 22.55-23.00
below 22.00m depth. 0737' D 23.10
-- --
- -- - - I
60/12cm sleo
0740 D
2.40
I
-- -
BEGL, as boring could not be progressed more than 15cm from 16.60m
J
KND Engineering
I BORELOG DATA-SHEET
Technologies LtdI
Projects: NTPC-FSTPP, Stage-Ill Borehole diameter: 150mm .

Location: Boiler And mills R.L. of ground:26.50m
Borehole No.:28 Soil boring termination depth. 28.50m BEGL
Commenced on:04.09.2006 Ground water struck at. 1 40m BEGL
Completed on: 05.09.2006 Standing water level: 1 25 m BEGL
Co-ordinate: S-I 065 1 €-I
. - . --
84 Method of bor~ng;Shell &Auger
Details of samples
Blows/l5cm
Fill consisting of dark grey

0.60 silty clay, mixed with fine
grained sand, stone pieces,
075 D 1.00
076 P 1.45-l.9tli
kankars and nodules. 077 U 3.15.3.60
Pockets of rust brown silts 078 D 3.70
are found occassionally 079 P 4.55-5.00
16.60 Colour of the strata changes OBO U 8.124.57
to dark bluish grey below 081 D 6.67
082 P 7.*-7.95
083 U 9.10-9.55
"U 12.70-12.55
OM D 12.85
089 D 45.70
090 P 1&10-16.55 3
093 bl 20.05-20.50
OM P 21.50-2-
088 P 21.5027.95 20 28 31 1I
099 P 28.10-28.33 40 i 6518crn 1 : 59
>lo0
100 D 28.50 I I I
ote:
II
BH-28 is m i n a t e d at 28.50m BEGL, as boring wutd not be progressed more than 15cm from 28.35m
I
y &Wling of 2 houw
b
UD undlslurbedTube Sample
P PenemmeterTest
DP: Disturbedtarnpie Collected From penelmmeter DC, Disturbed Samples Collected From lubes Cutllng Shoe
b No. CS-3236- b: D l t t u W Sample WS Water sampte
(1IlOIl5 L
-
KND Engineering
Technologies Ltc
BORELOG DATA-SHEET
Projects. NTPC-FSTPP, Stage-Ill Borehole diameter. 150mm

Location:Air Compressor House. Boiler And Mills R.L. of ground: 26.75m
Borehole No.: 33 Soil boring termination depth: 28.10 m BEGL
Commenced on:08.09.2006 Ground water struck at. 1.45 m BEGL
Completed on: 10.09.2006 Standing water level: 1.OO m BEGL
Co-ordinate S-1040 1E-216. -- - Method of boring; Shell &Auger
-.-
Depth
--I
in metre1
Description of soil of layer
-- --
Details of samples penetration test N' value! Remarks

I
Blows 1 15cm 1
EGL
. .-- - - -- -- --C 050 I
45 8 >-- -
Fill consisting of coal, ash, I

stone pieces followed by 2 2 4
brownish grey silty clay,
mixed with coal pieces, brick
2.75
I 2 2 * I A
I
2 75 Ibats, stone chips etc.

I
__ -1._.___
1
-
2 75 ,ModeratelyStiff, brownisg i^--- 11.9 U
- -- ' -A
'grey Silty Clay, wirh

occassional pockets of rust
1brown silt Colour of the
/ 1110
1111
11112
D
P
U
I
3.65
4.60-5.05
612-6.57
1
1 2
I 2 P 5
strata changes to Bluish

lgrey below 7.00m depth.
11 4.75 / 1113 D 6.67 ,
strata changes to reddish

brown with bluish patchec
below 17.00 m depth.
I
1
1148 P 20.00-20.45
1149 P 21.50-21.95-
-
16
--
1150 P 23.00-23.45
by chiselling of 2 hours.
UD undlsiulbstd Tube Sample

P: P e R e m n ~ WT a l
DP: D18Wedsample Ce&@w Fmm prnrelrompter DC. Dlslufbed Samples Collecled From tubes Cult~ngShoa
D: QbkBnd S@@e wS Water sample
KND Engineering
Technologies Ltd I
BORELOG DATA-SHET
Projects: NTPC-FSTPP, Stage-Ill Borehole diameter: 150mm

Location: ESP R.L. of ground: 26.2511
Commenced on:23.07.2006 Ground water struck at: 3.25m BEGL
Completed on: 26.07.200@- Standing water level: 3.20 m BEGL
Co-or din at^: 5-962 1E-178 ---
Method of boring; Shell &A-
I
Depth Description of soil
Thickness
of laym Details of s m p l m Penehtion test ! N' value
in.fm@
- i n metre !
I
- -- -... - -- .-- --- -----
EGL
f Fill consisting of light
/brownishgrey Silty Clay 1.5a
0930 D 1.00
1 50 mixed with brick bats etc.

-t
I a - I - - - - L---- L
1.50 ,ModeratelyStiff, light #031 P 1.50-1.95
'
browniosh grey Silty Clay tB32 U 3.05-3.50
with pockets of rust b r o w W 3 D 3.60
SR P 4.50-4.95 4
1 9 . 0 hMI35
a U 6.25-6.5Q
1 6.60
7 P 7.50-7.95 1
m 8 U 9.05-9.S
10.50 lx239 D 9.60
10.50 - % f f z e y kitty Claywith

p;ockets of rust brown Silts.
jColour of the strata changes I
0041
0042
U
D
12.15-12.50
12.60
1
I
/to yellowish brown below 0043 P 13.50-13.95; 5 5 7 1 2 '
18.00m depth. 0044 U 1505-15.50
9'00
I I
/
0045 D 15.60
10046 P 16.50-16.951
8
' 0047 U 18.17-18.67
1950 ! 0048 D 18.67
' . - - --- - -- .-- -
19.50 ~ e d i u mdense brownish 0049 P 19.50119.9%'-
grey Sandy Silt with very 0860 U 21.14-21.m
3'00
22.50 fine grained mica pieces. 0851 D 21.49
, . - -- .- - -- . -- -- -- - -.-- .-.
22.50 Very dense light yellowish 0182 P 22.57-23.02 17 38 - 64
brown, very fine r--'ned 8783 P 24.00-24.45 16
3.00
Silty sand
-- -
25.50
25.50 ' ~ a r dyellowish-b&-- 0184 P 25.35-2538' 9
Clayey Silt mixed & v&y 0185 P 26.25-26.70
fine grained sand partilck, 0186 P 27.25-27.35 100/10m I
27.25 Fragmented rock pieces are ' ?-74

observed below 26.25111 I
depth. I II
I
Note: BH-43 is terminated at 27.25rn BEGL, $s baring could not be progressed more than 10cm
by chisellin$ qf 2 bowa- .
UD: undislwhsd Tube Sam*

P: P s n a m t e r Tea
DP: D i a M m p l e Colleoled Fmrn penekimler Dislwbed Samples CollectedFmm tubes CutUng Srtoa
0: Dlsbrbed Sample WS: Water smnple
nrl r) ri f;
t KND Engineering
Technologies Ltd
Projects: NTPC-FSTPP, Stage-Ill

BORELOG DATA-SHEET
Borehole diameter: 150mm

I
Location: ID ducts R.L. of ground: 26.75m
Commenced on: 10.08.2006 Ground water struck at: 1.75m BEGL
Completed on: 14.08.2006 Standing water level: 1.65 m BEGL
-
Depth '
Co-ordinate 5-870 1 E-344
In metre1
Description of so11
m metre
Details of samples
----- -- -.
- -- --of boring; Shell &Auger
- Method
I
Penetrat~ontest
I
Ref. No. Type Depth(m) 1. -- -~ i o-
.. .- . - -
N' value; Remarks
w.s-l l 5 c m -- ,
30 - 45
- -
EGL 04427 D 0.53
F~llconsisting of coal, waste 0428 D 1.00 1
materials, stone chips, brick I 1
1 50 /bats etc. 'followed by,
1.50
1 brownosh grey silty clay, I
,mixedwith stone pieces,
Icoal, brick bats etc.
,- - -- -. --
, moderately stiff brownish
1 grey Silty Clay mixed with
very small pockets of black
1 silt nodulss.
5
"Sample
Slipped
I
light brownish grey Silty
Clay. Colour of the strata i
changes to bluish grey
below 10.25m depth.
i
1
1
Dense dark grey, coarse
grained Clayey Sand
- ---
Very. stiiclslrk grey Silty

1
I
I
-
Clay. Colour orthe strata
changes to brownish grey
/below 19.50m depth.
Calcareous nodules of
various sizes are also
observed in We strata.
Very dense to compact,
y e l M ~ hb r o w , Rw
pained Silty wnd.
Fragmented rock pieces
mix& with eYaygy silt A
observed below 26.60rn '
I I 1
depth.
I
BH-51 is terminated at 26.50mI BEGL, as 5.00m in refusal strata with SPT-'N' value >I00
. P: PenelpmeterTest
Tube emple
UD: ufl@~turbed
DP M.lrrrhn0 r.~qD(e@~@$*d Fmm pnralmtn@(ar DG DtsiluTbed SarnpIn~~
C01bet.d Fmm lubrss CuW@%O.
0.Proiwbea Sunpla W5: WaMC samph
b
----<
--- -KND
.
Engineerin(
--7-
Technologies Ltc
BORELOG DATA-SHEET
Projects: NTPC-FSTPP, Stage-Ill Borehole diameter: 150mm

Location: Chimney R.L. of ground: 26.75
Commenced on:22.08.2006 Ground water struck at:1.15m BEGL
Completed on: 24.08.2006 Standing water level: 0.80m BEGL
Co-ordinate: S-847 1E-216 -- --
,
-, -- .----Method of -boring;
.. . Shell
. . &Auger
- .. .~ - . -
-
i Thickness !
~ e s c r i ~ t i oofnsoil
Depth
in metre, ,N ' value! Remarks
-.
iI . 30 ' 45
EGL I ! 0628 11
.
0.50 :
2.75
{Fill consisting of brownish
grey silty day mixed with
I brick bats, boulders, stone
(
/
2,75 i
I
I
0629
0630 / P
!
;
1.00
1.50-1.95
1
I
2 2 2 4 '
chips, coal etc. I 1 1

I... - . ... i I 1
I i!. . . . .
2.75 i ~ o d e r i estiff,
l ~ brownish
'and stone chips are

I
igrey Silty Clay. Coal pieces :
I
[TI *U
0 6 3 5 ) D
2.85-3.30
4.05-4.50
4.50
P
1
i 2 3 4 7
'Samle
Slipped
1 observed at upper depth ; 0633 P 1
4.75-5.20 2 4 8
:
i 0634 U I 5.90-6.35
' 0635 D 6.45
' ,
,
1 9.00 I
1 7.40-7.85 2 1 3 ' 3 . 6 :'
11.75
1
;
i1 0638 D
9.10-9.55
9.65 1
1 I
I
j , 10.50-10.95 1 2 i 3
I
5 8
11.75
' . -- - . -. -
'very stiff to hard, bluish grey 1
4.- -~.. I -. - .. - 1~~ I
;Silty Clay. Colour of the , 0641 I D , 12.70
1 strata changes to bluish ; 1 0642 1 P 13.45-13.90 4
lgreyl yellowush brown I i 0643 U 15.10-15.55
I -
;below 15.00m depth.
/ kankars and nodules are
~occassionallyobserved in
'1 9.00
10644
I 0645
1 0646
D m 15.65
P 16.56-17.01 i
U 18.20-18.65 I1
/ 10 14
1
18 32
20.75 jthe strata between 15.00m i ' 0647 , D 18.75 ! 1

I
;to 17.00m depth. ; 0648 P /
19.40-19.85 13 : 18 ' 22 40
I
I . --
20 75 Very dense to compact, 0649 P 20 85-21.07 36 60t7cm ' >I&
yellowish brown, fine 1650 P 22 70-22.93 42 &/8crn >I00
grained Silty Sand. 5.61 0486 P 24 30-24 53 49 66/8crn >I00
,
I
26 36 0487 i P 26 15-26 36 50 1 BSBcm .I00

I
I 1 ' ,
I Note: BH-55 is terminated at 26.15m BEGL. in 5.00m refusal strata, with SPT-'N' >I00 .
UD umslumed Tube Sample

P Penelmmeter Twl
DP Dlslurb~dmnpla ColIecIed Fmrn penelmmeler DC Dlslurbed Samples Collected From lubes Cullvlg Shoe
D DlSIurtMd Sample WS Waler sample
1.01.00 Brakes and Clamps
1.01.01 Final testing of brakes shall include load, HV/IR & heat run tests.
1.02.00 Monorails and Hoists
1.02.01 All electric hoist shall be tested as per IS 3938 and chain pulley block shall be tested
as per IS 3832.
1.03.00 Hoppers & Liners
1.03.01 Rack & Pinion Gates/Flap Gates/Rod Gates

a) MPI/DP test shall be conducted on rack and
pinion / rod / weld joint
b) Functional checks on the gates shall be carried out alongwith respective
actuator, if applicable.
1.04.00 Belt Conveyor System
The details of the checks to be carried out in the various equipments are to be
submitted by the Contractor for Owner’s approval. However, some indicative checks
on different items are given below which should necessarily form a part of the Quality
Assurance Plan to be agreed with the Owner.
1.04.01 Idlers
a) Check for run out and free movement shall be carried out on idlers. Run out
shall be restricted as per IS:8598
b) Test for dust proofness, water proofness and dynamic friction factor of the
Idlers shall be conducted at shop. The detailed procedures for the same
shall be submitted for review and approval.
1.04.02 Belting
(a) Rubber cover of finished belt shall be checked for tensile strength and elongation at
break before and after ageing. Rubber cover shall also be checked for abrasion, tear
strength and hardness.
(b) For finished belts, checks for elongation at 10% nominal tensile strength, tensile and
elongation at break in longitudinal (warp) direction and tensile in transverse (weft)
direction shall be carried out.
(c) Adhesion test between ply to ply and cover to ply shall be carried out.
(d) Troughability test and Test for fire resistance shall be carried out.
(e) Test for procedure qualification for belt vulcanizing joint (at site) shall be done.
Procedure for belt vulcanizing joint shall be discussed and finalized during FQP
finalization.

TECHNICAL SPECIFICATION SUB-SECTION-IIIE-01 PAGE
PROJECT SECTION-VI, Coal Conveyors Belt 1 OF 7
(f) There will be a limitation on the no. of repairs allowed on the belts. Following will be
the acceptance norm for the cover repairs.
i) The maximum size of a repair shall be limited to a size equivalent to one fifth
the belt width. No single dimension shall exceed one fifth(1/5) of belt width.
ii) Small local repair by dough filling of size 25mm x 25mm to a limited extent
shall not be counted of repairs. However, in case of cluster of repairs, same
shall be counted as a patch repair.
iii) The maximum number of patch repair shall not exceed 5 per 100 mts.
However, the total number of patch and dough filling repairs shall not exceed
10 per 100 meters.
(g) In addition to above, Steel Cord belt shall also be tested for
following.
i. Cord dia and breaking strength

ii. Finished belt shall be tested for cord pull-out strength before and after
aeging, peeling resistance.
iii. Dynamic cord pull out test
iv. Cord dia, pitch and number of cords
(h) In no case shall the cover thickness or the width of belt be less than that given
in specification.
(i) For testing purpose,belt sample shall be taken from anywhere of the belt roll
length offered
1.04.03 Belt Vulcanizing Machine
a) Check for tensile strength shall be carried out on a sample vulcanized belt
joint for each type of belt in shop.However if such test has been done earlier,
the report for same shall be submitted for verification.
b) Complete assembly shall be tested at shop for temp. and pressure developed
1.04.04 Pulleys
a) In addition to chemical,mechanical,hardness,microstructure as per applicable

material specification, pulleys shaft forgings shall be subjected to ultrasonic
testing.
b) 100% MPI/DPT on all welds shall be conducted and 10% RT/UT on butt
welds shall be conducted.
c) Static balancing of pulleys shall be carried out after rubber lagging.

d) Checks on rubber lagging to include abrasion loss, shore hardness test, peel-
off strength test and physical properties. Peel-off strength shall be 10 Kg/Cm,
Abrasion loss shall be less than 250 cubic mm when tested as per DIN
53516.
1.04.05 Pull Chord & Belt Sway Switches
a. Acceptance tests
i) Over all dimension and functional test.
ii) HV & IR test
iii) Degree of protection test report.
1.04.06 Zero Speed Switch, Under Belt Switch and Chute Blockage Switch
a Acceptance test
i) Burn in test at 50 degree C for 48 hours shall be done for electronic

switches.
ii) Over all dimension and functional test shall be carried out.
iii) HV & IR
iv) Degree of protection test
1.05.00 Drive Equipments

1.05.01 Gear Boxes :
(a) In addition to checks for physical, chemical, hardness, microstructure as per

relevant standard, the shaft and gear/pinion forgings shall be subjected to
ultrasonic testing .
(b) MPI to be carried out on Gears/Pinions after machining. Case depth,

hardness and MPI after hardfacing shall be checked to ensure freedom from
defects.
(c) Gear reducer shall be checked for reduction ratio, backlash and contact
pattern. No load shop trial run to be conducted on gear boxes to check for oil
leakage, temperature rise, noise level and vibration.
1.05.02 Flexible Coupling
(a) Ultrasonic testing shall be conducted on forgings for gear sleeve and gear
hub, if gear coupling is provided.
(b) MPI shall be carried out after machining to ensure freedom from cracks.

1.05.03 Fluid Coupling
(a) Dynamic balancing shall be carried out for the rotating parts.
(b) Check for leak tightness of the coupling shall be carried out.
(c) Functional test on fusible plug for each type of coupling shall be conducted at
shop.
(d) All couplings to be run tested at shop on no load
(e) Check for temperature rise, torque-speed, torque-slip characteristics and over
speed test shall be included during performance test of one coupling of each
type preferably at full load.
1.06.00 Belt Scales
The details of the checks to be carried out in the various equipments are to be
submitted by the Contractor for Employer’s approval. However, some indicative
checks are given below which should necessarily form a part of the quality
assurance plan to be agreed with the Employer.
1.06.01 Mounting arrangement/Overall dimensional check shall be carried out on the Belt
Scales.
1.06.02 Belt scale shall be calibrated with test weight/test chain in static at works and with
test weight for dynamic condition at site.
1.06.03 All electronic modules shall be subjected to burn in test at 50 Degree C for 48
hours.
1.06.03.1.1 General check for load cell shall be carried out.
1.06.04 Test report for degree of protection on enclosure shall be furnished.
1.06.04.1.1 Accuracy/performance check shall be demonstrated at site.
1.07.00 Dust Control & Miscellaneous Systems (Dust Suppression System)
The details of the checks to be carried out on the various equipments are to be
submitted by the Contractor for Owners approval. However some indicative checks
on different items are given below which should necessarily form a part of the Quality
Assurance Plan to be agreed with by the Owner.
1.07.01 Pumps
(a) All materials should be of tested quality and test certificates to be provided.
(b) DPT of machined shaft and impeller shall be done.
(c) Shaft forgings to be also subjected to ultrasonic testing.

(d) Impellers to be dynamically balanced to ISO 1940 Gr.6.3
(e) All pressure parts shall be hydraulically tested at 150% of the shut-off head or
200% of rated head, whichever is higher for 30 minutes. No leakage is
allowed.
(f) All pumps to be performance tested as per Hydraulic Institute

Standard/Indian Standard. Performance test to include check for noise,
vibration level and temperature rise.
1.07.02 Valves & Specialties
(a) Valves and Specialties shall be tested as per relevant standards / codes.
(b) Seat Leakage and hydraulic test to be carried out as per relevant standards /
codes.
1.07.03 Pipes and Fittings
Pipes and fittings shall be tested as per relevant standards/

codes.
1.07.04 Air Compressor
a) All pressure parts shall be hydraulically tested at not less than 150% of design
pressure for a duration of 30 minutes prior to painting.
b) All other parts including inter-connecting piping shall be hydraulically tested

wherever possible, as per relevant codes.
c) Ultrasonic testing shall be carried out on all forgings and rotor for dia 50mm and
above. MPI/DPT shall be done on machined area of the components.
d) During assembly all clearances and alignments shall also be checked and
recorded
e) Rotor shall be statically and dynamically balanced
f) Performance Test(Shop Test)

i. Performance test on the compressor shall be carried out in
accordance with ISO:1217/Eq. The test shall also include
demonstration of loading and unloading mechanism(Capacity control)
and operation of safety valve
ii. Vibration and Noise level measurement shall be done during shop
performance test.

1.07.05 Air Receiver
a) Each finished vessel shall be hydraulically tested at 150% of the design pressure
for a duration of 30 minutes
b) NDT on weld joints shall be as per respective code requirements or the minimum
as specified below
i. 100% DPT on root run of butt welds

ii. 100% DPT on all finished butt welds and fillet welds
iii. 10% RT on butt welds which shall include all T-Joints
1.08.00 Dust Extraction, Ventilation Systems
1.08.01 Fan
(a) All materials should be of tested quality and test certificates should be
provided.
(b) Dynamic balancing of the fan impellers to be carried out.
(c) Shop run test shall be conducted on all centrifugal fans including check for
noise and vibration level.
(d) Performance test shall be conducted on one fan of each type at shop for
capacity, pressure, efficiency and power consumption.
1.08.02 Valves and Specialties
Refer 1.08.02 above
1.08.03 Pipes and Fittings
Refer 1.08.03 above
1.09.00 Vibrating Feeders

(a) Shaft forgings to be checked for ultrasonic testing in addition to check for
chemical, mechanical, hardness, microstructure etc. as per applicable
material specification
(b) Following minimum NDT requirements to be ensured for welds:
i) Butt welds - 10% UT/RT and 100% MPI/DPT.
ii) Fillet Welds - 10% MPI/DPT.
(c) Shop trial run test shall be conducted to checks for speed(RPM),
amplitude(stroke), temperature rise and noise level.

1.10.00 In-Line Magnetic Separators
i) Overall Dimensional, Visual check alongwith control panel.
ii) HV & IR.
iii) Operation, temperature rise, lifting capacity, force index and gauss strength.
1.11.00 Metal Detectors
i) Functional test including sensitivity, Burn in test, operation of liquid spray

marker, detection of smallest piece of different materials as specified.
ii) Test report for Degree of protection test to be furnished.
1.12.00 Coal Sampling Units
(a) Free carriage and cutter movement, speed of cutter and dust door closing
and sealing shall be tested for samplers.
(b) “No load test” shall be carried out for crushers.

INDUCTION MOTOR & SYNCHRONOUS MACHINE SQE_7
TESTS/CHECKS
&
All Routine tests as per IS-325/IS-
Make/Type/Rating/TC/General
Tan delta, shaft voltage

Hydrualic/Leak/Pressure Test
Welding/Brazing(WPS/PQR)
Electrical Characteristics
Magnetic Characteristics
Thermal Characteristics
Mech/Chem. Properties
polarisation index test

Physical Inspection
Dynamic Balancing
NDT /DP/MPI/UT
Heat Treatment
Metallography
4722 / 9283
Dimensional
Over speed
Vibration
Run out
Visual
TEMS/COMPONENTS
Plates for stator frame,end 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 Y
Rotor Copper/Aluminium Y Y Y Y Y Y Y
Stator copper Y Y Y Y Y Y Y
SC Ring Y Y Y Y Y Y Y Y Y
Insulating Material Y Y Y Y Y
Tubes for Cooler Y Y Y Y Y Y Y
Sleeve Bearing Y Y Y Y Y Y Y
Stator/Rotor, Exciter Coils Y Y Y Y Y
SUB-SECTION-IIIE-02
TECHNICAL SPECIFICATION INDUCTION MOTOR & PAGE
PROJECT SECTION-VI, SYNCHRONOUS 1 OF 2
COAL CONVEYING PLANT PACKAGE PART-B MACHINE
Castings, stator Y Y Y Y Y Y
frame,terminal box and
bearing housing etc.
Fabrication & machining of Y Y Y Y
stator, rotor, terminal box
Wound stator Y Y Y Y
Wound Exciter Y Y Y Y
Rotor complete Y Y Y Y Y
Exciter, Stator, Rotor, Y Y Y
Terminal Box assembly
Accessories, RTD, BTD,CT, Y Y Y
Brushes, Diodes,Space
heater, antifriction bearing,
cable glands, lugs, gaskets
etc.
Motor ( IS 325 / 4722/ 9283) Y Y Y Y Y Y Y1
Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality
Plan indicating the practices & Procedure followed along with relevant supporting
documents during QP finalization. However, No QP for LT motor up to 50KW.
2. Makes of all major bought out items will be subject to NTPC approval.
Y1 = for HT Motor / Machines only.
SUB-SECTION-IIIE-02
TECHNICAL SPECIFICATION INDUCTION MOTOR & PAGE
PROJECT SECTION-VI, SYNCHRONOUS 2 OF 2
COAL CONVEYING PLANT PACKAGE PART-B MACHINE
SQE _10
LT SWITCHGEAR
( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL
MOTOR STARTERS)
All Routine tests as per NTPC spec. &

of gasketting arrangement and by paper
Degree of Protection Routine test as
Functional & Operational Features as
Paint Shade, Adhesion, Thickness &
per NTPC spec (By physical verification

ATTRIBUTES /
Item to conform to relevant Standards

CHARACTERIS-TICS
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
insertion method)
per NTPC Spec.
ITEMS/
Fi i h
COMPONENTS/ SUB
IS
SYSTEM ASSEMBLIY
Sheet Steel (IS : 513) Y Y Y Y Y
Aluminum Bus bar Y Y Y Y Y Y

Material
(IS : 5082)
Copper Bus bar Y Y Y Y Y Y
Material
(IS : 613)
Support Insulator Y Y Y Y Y
Air Circuit Breaker ( IS: Y Y Y Y Y Y Y
13947)
Energy Meters ( IS : Y Y Y Y Y Y
13010, 13779 )
Power & Aux. Y Y Y Y Y
Contactors (IS : 13947 )
Protection & Aux. Y Y Y Y Y Y
Relays (IS : 3231)
Control & Selector Y Y Y Y Y
Switches ( IS : 13947)
CT’s & PT’s ( IS 2705 / Y Y Y Y
3156)
MCCB ( IS : 13947 ) Y Y Y Y
Indicating Meters ( IS : Y Y Y Y Y Y
1248 )
Indicating Lamps ( IS : Y Y Y Y Y
13947 )
Air Break Switches Y Y Y Y Y
( IS : 13947 )
Control Terminal Y Y Y Y
Blocks
PROJECT SUB-SECTION-IIIE-03 PAGE
SECTION-VI,
COAL CONVEYING PLANT PACKAGE LT SWITCHGEAR 1 OF 2
PART-B
LT SWITCHGEAR
( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL
MOTOR STARTERS)
Functional & Operational Features as per
Degree of Protection Routine test as per

Paint Shade, Adhesion, Thickness & Finish
ATTRIBUTES /
All Routine tests as per NTPC spec. & IS

CHARACTERIS-TICS

Make, Model, Type, Rating & TC

Dimensions & Finish
Chemical properties
Functional Checks
Milli-volt drop Test
ITEMS/ COMPONENTS/
SUB SYSTEM
NTPC Spec.
NTPC spec
ASSEMBLIY
Fuse ( IS 13703) Y Y Y Y
Control Transformer Y Y Y Y Y Y
( IS : 12021)
Push Buttons ( IS : 4794 ) Y Y Y Y Y
Transducer (IEC : 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 Y
( IS : 8623 )
Notes:
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.
Makes of all major Bought Out Items will be subject to NTPC approval.

PROJECT SUB-SECTION-IIIE-03 PAGE
SECTION-VI,
COAL CONVEYING PLANT PACKAGE LT SWITCHGEAR 2 OF 2
PART-B
LT BUSDUCT
ATTRIBUTES ,
Galvanizing Test as per IS 2629/ 2633/
Degree of Protection routine test as per

Weld Quality Check ( DP test & x-ray
Paint Shade, Thickness, Adhesion &
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
NTPC spec.
ITEM, COMPONENTS, SUB
4759
SYSTEM ASSEMBLY
Aluminum Sheets / Plates / Y Y Y Y Y Y Y

Strips / 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:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality
Plan indicating the practice and
procedure along with relevant supporting documents.
2. Makes of all major Bought Out Items will be subject to NTPC approval.

PROJECT TECHNICAL SPECIFICATION SUB-SECTION-IIIE-04 PAGE
COAL CONVEYING PLANT PACKAGE SECTION-VI, LT BUSDUCT 1 OF 1
PART-B
Attributes /
& after
Armour coverage, Cross over, looseness, Gap
Thermal Stability of insulation and outer sheath *
Constructional / requirement as per NTPC Spec.

Characteristics
Sequential marking/surface finish /cable length
Relevant Standard and NTPC specification

Anti ternite treatment on wooden drums
Tensile strength, elongation before
Routine and acceptance test as per

ageing of insulation & outer sheath
between two armour wire/strip
Make, Rating, Type & TC
Dimension/surface finish
Chemical Composition
Lay length / Sequence

Hot set test (XLPE)

Item / Components /
Spark Test
FRLS Test
Sub System Assembly
Aluminum (IS-8130) Y Y Y Y Y
PVC Compound (IS-5831) Y Y Y Y
XLPE Compound(IS-7098 Part-I) Y Y Y Y Y
FRLS PVC Compound(IS-5831 ) Y Y Y
ASTM-D-2843/ ASTM-D-2863
IEC-754 Part-I
Armour wire/strip (IS-3975) Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554 & 7098 – Part-1) Y Y Y Y Y Y Y Y Y
ASTM-D-2843/ IS 10810 ( Part- - 58 )
IEC-754 Part-I
Swedish Chimney SS 4241475 for (F3
category)
Flammability test IEC-332 Part –3 Cat-B
Wooden drum (IS-10418) / Steel drum Y Y
Note: 1.This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the practice and
procedure along with relevant supporting documents. All major BoIs to be of makes approved from owner.
∗ 2. Not applicable for XLPE insulation

COAL CONVEYING PLANT PACKAGE SECTION-VI, L.T POWER CABLES 1 OF 3
PART-B
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables

for all types & sizes.
Following shall constitute routine tests:
1) Conductor Resistance test
2) High voltage test at room temperature
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and
size of the cables on the cable drums selected at random as per
sampling plan mentioned in IS: 1554 Part 1 & IS 7098 Part-I
A) For Conductor
1) Annealing test For copper conductor only
2) Tensile test For aluminium conductor only
3) Wrapping test For aluminium conductor only
4) Resistance test
B) For Armour Wires / Formed Wires ( If applicable )

1) Measurement of Dimensions
2) Tensile Tests
3) Elongation Test
4) Torsion Test For Round wires only
5) Wrapping Test
6) Resistance Test
7) Mass of Zinc coating test For G S wires / Formed wires
only
8) Uniformity of Zinc coating For G S wires / Formed wires
only
9) Adhesion test For G S wires / Formed wires
only
10) Freedom from defects
C) For PVC / XLPE insulation & PVC Sheath

1) Test for thickness
2) Hot set test For XLPE insulation only
3) Tensile strength & Elongation before ageing

PART-B
D) For completed cables

1) Insulation resistance test ( Volume resistivity method )
E) Following tests shall be carried out and only one sample shall be
taken from each offered lot of all sizes for these tests:-
1) Tensile strength & elongation after ageing on PVC / XLPE insulation and
PVC outer sheath
2) Thermal stability test on PVC insulation and outer sheath
3) Oxygen index test on outer sheath
4) Smoke density rating test on outer sheath as per ASTM –D 2843
5) Acid gas generation test on outer sheath as per IEC – 754 (Part 1)
6) Flammability test as per IEC-332 - Part- 3 ( Category- B ) on completed

cable
7) Fire resistance test as per SS 4241475 (F3 Category ) on completed cable
F) Following tests shall be carried on one length of each size of

offered lot:
1) Surface finish, length measurement, sequence of cores, armour coverage,

Gap between two consecutive armour wires / formed wires

PART-B
Attributes /
relevant standard & page 2 & 3 of

Tensile strength, elongation before
looseness gap between two armour
& after ageing of insulation &outer
Routine & Acceptance test as per

marking/surface
Constructional feature as per NTPC

Thermal stability of insulation and
Armour coverage, cross over,
Characteristics
Anti termite treatment on wooden drums

Make, Type, Rating, T.C
Lay length/Sequence
finish/cable length
outer sheath
Spark Test
FRLS Test
Sequential
Item / Components /
Sub System Assembly
S
Copper Conductor (IS-8130) Y Y Y Y Y
PVC Compound (IS-5831) Y Y Y Y
FRLS PVC Compound IS- Y Y Y Y
5831
ASTM-D-2843/ IS 10810
(Part-58 )
IEC-754 Part-1
Armour wire/strip (IS-3975) Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554- 1 ) Y Y Y Y Y Y Y Y Y
ASTM-D-2843/ IS 10810
(Part-58 )
IEC-754 Part-1
Swedish Chimney: SEN SS
424-1475( F3 category)
Flammability test IEC-332
Part-3 Cat-B
Wooden drum( IS : 10418) / Y Y
Steel drum
• 1.Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed
quality plan indicating the Practice and procedure along with relevant supporting documents.

COAL CONVEYING PLANT PACKAGE SECTION-VI, CONTROL CABLE 1 OF 3
PART-B
CONTROL CABLE
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all
types & sizes.
ACCEPTANCE TESTS
sampling plan mentioned in IS: 1554 Part 1
A) For Conductor
1) Annealing test For copper conductor only
2) Resistance test

2) Tensile Tests
3) Elongation Test
5) Wrapping Test
6) Resistance Test
only
only
only
C) For PVC insulation & PVC Sheath



PART-B
1) Tensile strength & elongation after ageing on PVC insulation and PVC
outer sheath
2) Thermal stability test on PVC insulation and outer sheath

cable
7) Fire resistance test as per SS 4241475 (F3 Category ) on completed cable

offered lot:

PART-B
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
CableDrums(IS-10418) Y Y
Note : High Temp. cables shall be subjected to tests as per VDE-207(Part-6)
Compensating cables shall be checked for Thermal EMF/Endurance test as per IS
8784.
Note : This is an indicative list of tests/checks. The manufacture is to furnish a
detailed Quality Plan indicating his practice & Procedure along with relevant
supporting documents during QP finalization for all item.
Note : ® - Routine Test A - Acceptance Test Y - Test Applicable
Note : Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable)
• * FRLS Tests: Oxygen / Temp Index ( ASTM D-2863), Smoke Density Rating (
ASTM – D 2843), HCL Emission ( IEC-754-1)
• ** Characterisitic Impedence, Attenuation, Mutual Capacitance, Cross Talk ( As
applicable)
+ Sample size will be One No. of each size/type per lot.
++ Sample size will be One No. sample for complete lot offered irrespective of
size/type.
FARAKKA SUPER THERMAL POWER SUB-SECTION-IIIE-07

PROJECT TECHNICAL SPECIFICATION PAGE
INSTRUMENTATION
COAL CONVEYING PLANT PACKAGE SECTION-VI, 1 OF 1
CABLE
PART-B
STATION LIGHTING
Item Components
Paint Shade Thickness Adhesion &
Routine Test as per relevant std and

Constructional Feature as per NTPC
Acceptance Test as per relevant std

Sub System
Item to conform to relevant standard

Assembly
Bought Out Items/ Bill of Material
Functional Check as per spec.

Make, Type , Rating/ TC
Pre-Treatment of sheet
Galvanization Test
Attributes
Characteristics
Dimension
and spec
HV & IR
IP Test
Finish
spec.
spec
Luminaries (IS-10322 Part- Y Y Y Y Y
5 Sec.1)
Electronic Ballast Y Y Y Y
Lighting Wire (IS-694) Y Y
Fans (IS-374) Y Y
Pole (IS-2713) Y Y Y Y Y
Lamps (IS-9800, IS-9974) Y Y Y
Lighting Mast Y Y Y Y Y Y
Wall Mounted Lighting Y Y Y Y Y Y Y Y Y Y Y Y
Panel (IS-513, IS-5)
Switch Box/ Junction Y Y Y Y Y Y Y Y Y Y Y Y
Box/Receptacles/ Local
Push Button
Station,Lighting Panel (IS-
513, 2629, 2633, 4759,
6745)
Cable Gland (BS-6121) Y Y Y
Cable Lug (IS-8309) Y Y Y
Flexible Conduit Y Y
Lighting Transformer (IS- Y Y Y
1117)
Epoxy & Galvanised Y Y Y Y
Conduit (IS-9537, 2629,
2633, 4759, 6745)
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan
indicating the practice and procedure along with relevant supporting documents.
2. Make of all major Bought Out Items will be subject to NTPC approval.

STATION LIGHTING
PART-B
QUALITY ASSURANCE & INSPECTION MODULE
NO. SQE16
Page 1 of 1
CABLING, EARTHING, LIGHTNING PROTECTION
ATTRIBUTES /
relevant standard &

gasketting arrangement and by paper insertion
NTPC
IP protection (By physical verification of
Acceptance tests as per relevant standard &

CHARACTERISTICS
Paint shade, paint thickness, adhesion
per
Bought out items/Bill of material
as
Galvanise Test (If Applicable)
feature
Routine tests as per
Pre-treatment of sheet
Deflection test*
Constructional
Surface finish
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(IS-8309) Y Y
Lighting wire(IS-694) Y Y
Flexible conduits Y Y Y
Conduits(Galvanise & Y Y Y Y Y
Epoxy) IS-9537 & IS-
2629,2633 ,6745
RCC Hume Pipe (IS-458) Y
Cable termination & straight Y Y Y
through joint (VDE-0278)
Cable Trays, Flexible Y Y Y Y Y Y Y Y Y Y Y
supports system &
accessories IS-513,
2629,2633,6745
Trefoil clamp Y Y

PROJECT TECHNICAL SPECIFICATION CABLING, EARTHING, PAGE
COAL CONVEYING PLANT PACKAGE SECTION-VI, LIGHTNING 1 OF 2
PART-B PROTECTION
GI flats for earthing & Y Y Y Y Y

lighting 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
2.* Deflection Test on cable trays and Proof Load test on cable trays support system will be as
per details given in the NTPC technical specification & approved MQP. The above acceptance
tests shall be done only on one sample from each size of offered lot.
3. Make of all items will be subject to NTPC approval.

PROJECT TECHNICAL SPECIFICATION CABLING, EARTHING, PAGE
COAL CONVEYING PLANT PACKAGE SECTION-VI, LIGHTNING 2 OF 2
PART-B PROTECTION
Constructional requirements feature as per

T.S & elongation before & after ageing on
Routine & Acceptance Test as per relevant

Armour coverage, cross over, looseness,
Sequential marking/surface finish/ cable

Attributes/
Metallic ( Cu ) Screening ( If applicable)

Characteristics
Anti termite coating on wooden drums

Hot Set Test/ Eccentricity & Ovality
Thermal seability on outer sheath
ifi ti
Make, Type, Rating & T.C
Spark Test(as applicable)
outer sheath & insulation

Lay length & Sequence

gap between two wire

Mechanial properties
NTPC specification
t d d & NTPC
Curing Properties
Item /
Components /
FRLS Test
Sub System
Assembly
length
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)
FRLS PVC Compound Y Y Y Y Y
(IS-5831, ASTM-
D2843, IS10810( Part
58)
,IEC-60754 Part-1)
Triple Extrusion & Y Y Y Y
curing /Manufacturing
of Core
Copper Tape Y Y Y Y
Polyster tape Y Y
Armour wire/strip Y Y Y
Copper tapping Y Y Y
Inner sheath Y Y
Armouring Y Y
Outer Sheathing Y Y Y Y Y Y
Power Cable Y Y Y Y Y Y Y Y Y
(Finished)
(IS : 7098 Part II,
IEC : 60332 (Part 3
Cat. B), IS-5831,
ASTM-D2843,
IS10810(Part 58) ,
IEC-60754 Part-1)
Wooden drum(IS- Y Y
10418) /Steel Drum
COAL CONVEYING PLANT PACKAGE SECTION-VI, H.T CABLES 1 OF 3
PART-B
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.
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished

cables for all types & sizes.
2) High voltage test
3) Partial discharge test ( for Screened cables only )
ACCEPTANCE TESTS
sampling plan mentioned in IS: 7098 Part 1I
A) For Conductor
1) Tensile Test
2) Wrapping Test
3) Resistance test

2) Tensile Tests
3) Elongation Test
5) Wrapping Test
6) Resistance Test
only
only
only
C) For XLPE insulation & PVC Sheath

PART-B

3) Hot set test (For XLPE insulation)

2) High voltage test
3 Partial discharge test ( for Screened cables only )
1) Tensile strength & elongation after ageing on XLPE insulation and PVC
outer sheath
2) Thermal stability test on outer sheath

cable

offered lot:
2) Measurement of Eccentricity & Ovality

PART-B
HT SWITCHGEAR SQE_5
ATTRIBUTES /
per NTPC spec. (By physical

Degree of Protection Routine test as
relevant
verification of gasketting arrangement
Paint shade, thickness, adhesion &
CHARACTERISTICS
Make, Type, Model, Rating & TC
and by paper insertion method)

CB Operation timing check

All Routine Tests as per
Mechanical properties
Dimensions & Finish

Chemical Properties
Functional Checks
per NTPC Spec.
HV & IR Test
standard
ITEMS, COMPONENTS,
SUB-SYSTEM ASSEMBLY
Aluminum Bus bar material Y Y Y Y Y Y
( IS : 5082 )
Copper Bus bar material Y Y Y Y Y Y
( IS : 613 )
Bus bar Support Insulator Y Y Y Y Y Y
(IS : 9431 )
HT Circuit Breaker (IEC : 56 ) Y Y Y Y Y Y Y
HT Contactors ( IS : 9046 ) Y Y Y Y Y Y
Protection & Auxilliary Relays Y Y Y Y Y Y
( IS : 3231 / 8686 )
HT CT’s & PT’s Y Y Y Y
( IS : 2705 / 3156 )
HT Fuses ( IS : 9385 ) Y Y Y Y
Surge Arrester ( IEC : 99 –4 ) Y Y Y Y
LT Contactors ( IS : 13947) Y Y Y Y Y
Control & Selector Switches Y Y Y Y Y
( IS : 6875 )
Indicating Meters ( IS : 1248) Y Y Y Y Y Y
Indicating Lamps ( IS : 13947) Y Y Y Y Y
Push Buttons ( IS : 4794) Y Y Y Y Y
Control Transformer Y Y Y Y Y Y
( IS : 12021 )
LT Fuses ( IS : 13703) Y Y Y Y
Energy Meters ( IS : 722 ) Y Y Y Y Y Y
Transducers ( IEC : 60688) Y Y Y Y Y Y
Diodes Y Y Y Y Y
Terminal Blocks Y Y Y Y
Synthetic Rubber Gasket Y Y Y Y
( IS : 11149 / 3400 )
Breaker Handling Trolley Y Y Y Y Y
HT Switchgear Panel Y Y Y Y Y Y Y Y Y Y Y
( IS : 3427)

COAL CONVEYING PLANT PACKAGE SECTION-VI, HT SWITCHGEAR 1 OF 2
PART-B
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality

COAL CONVEYING PLANT PACKAGE SECTION-VI, HT SWITCHGEAR 2 OF 2
PART-B
HT Capacitor Bank
ATTRIBUTES /
relevant
CHARACTERISTICS
Make, Type, Model, Rating & TC
All Routine Tests as per

Dimensions & Finish

Chemical Properties
per NTPC Spec.
standard
ITEMS, COMPONENTS,
SUB-SYSTEM
ASSEMBLY
Enclosure Y Y Y
Oil / Paper Y Y Y Y
Insulator Y Y Y Y
Accessories Y Y Y Y Y Y
Supporting Structure Y Y Y
(Galvanized)
Complete Capacitor Y Y Y Y
Notes:
1. This is an indicative list of tests / checks. The manufacturer is

to furnish a detailed Quality Plan indicating the practice and
procedure along with relevant supporting documents.
2. Make of all major Bought Out Items will be subject to NTPC
approval.

PROJECT HT Capacitor Bank
SECTION-VI, 1 OF 1
MEASURING INSTRUMENTS (PRIMARY AND SECONDARY)

TESTS
Process / Electrical connection (R)
IBR Certification (if applicable )(R)

Make, Model, Type, Rating (R)
Material Test certificate ®

ITEMS
Insulation Resistance (R)

Test as per standard(R)
Dimensions (R)
Calibration (R)
Hydro Test(R)
1. PR Gauge (IS-3624) Y Y Y Y Y
2. Temp. Gauge (BS-5235) Y Y Y Y Y
3. Pr./D.P.Switch(BS-6134) Y Y Y Y Y Y
4. Electronic Y Y Y Y Y Y
Transmitter(BS-6447 / IEC-
60770)
5. Temp. Switch Y Y Y Y Y Y
6. Recorder(IS-9319/ANSI Y Y Y Y Y Y
C-39.4)
7. Vertical indicators Y Y Y Y Y
8. Digital Indicators Y Y Y Y Y
9. Integrators Y Y Y Y
10. Electrical Metering Y Y Y Y Y Y
Instrument (IS-1248)
11. Transducer (IEC-688) Y Y Y Y Y Y
12. Thermocouples (ANSI- Y Y Y Y Y Y
MC-96.1)
13. RTD(IEC-751) Y Y Y Y Y Y
14. Thermowell Y Y Y Y Y
R-Routine Test A- Acceptance Test Y – Test applicable
: Note: 1) Detailed procedure of Environmental Stress Screening
Test shall be as per Quality Assurance Programme in
General Technical Conditions
2) This is an indicative list of tests/checks. The
manufacturer is to furnish a detailed quality plan
indicating the Practices and Procedure adopted
alongwith relevant supporting documents.
MEASURING
INSTRUMENTS
PART-B
TESTS
Process / Electrical connection (R)
IBR Certification as applicable (R)

Requirement as per standard (R)
Make, Model, Type, Rating (R)
Calculation for accuracy (R)

Non-destructive testing (R)
Material test certificate (A)

Insulation Resistance (R)
ITEMS
WPS approval (A)

Dimensions (R)
Calibration (R)
Hydro test (R)

15. Cold junction Y Y Y Y Y
compensation box
16. Orifice plate(BS-1042) Y Y Y Y Y Y Y Y Y Y
* ** ** **
17. Flow nozzle(BS-1042) Y Y Y Y Y Y Y Y Y Y
*
18. Impact head type element Y Y Y Y Y
19. Level transmitter/float Y Y Y Y Y Y Y Y
type switch
20. Flue Gas analyser Y Y Y Y
21. Dust emission monitors Y Y Y Y
*Calibration to be carried out
on one flow element of each
type and size if calibration
carried out as type test same
shall not be repeated.
** If applicable
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as
per Quality Assurance Programme in General Technical Conditions
2) This is an indicative list of tests/checks. The manufacturer is to furnish a
detailed quality plan indicating the Practices and Procedure adopted

MEASURING
INSTRUMENTS
PART-B
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 (IEC-
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
146 PT-4)
VOLTAGE STABILISER Y Y Y Y Y Y Y Y
LEAD ACID
BATTERY(TUBLAR)-IS- Y
1651
LEAD ACID BATTERY
Y
(PLANTE)-IS-1652
NICKEL CADMIUM
BATTERY(IS-10918/IEC- Y
623)
SMF BATTERY Y
ACDB/DCDB Y Y Y Y
BATTERY CHARGER Y Y Y Y Y Y Y Y Y Y
* Transfer time and Over shoot /under shoot during load & system transfer shall be
recorded .
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality
Assurance Programme in General Technical Conditions
2) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed
quality plan indicating the Practices and Procedure adopted alongwith relevant
supporting documents.

POWER SUPPLY FOR
C&I SYSTEMS
PART-B
CLAUSE NO. Quality Assurance
AUX. TRANSFORMER
Attributes /
&
Make / Type / Rating / Model / TC /

Characteristics
Voltage Ratio, Vector Group
Routine Test as per relevant test

Polarity, Magnetic Balance Test
Visual & Dimensional Checks
General Physical Inspection.

NDT / DPT / MPI / UT

Core Loss*, Hot Spot
Items/Components
Compatibility with oil

Thermal properties
Sub Systems
Electrical strength
WPS & PQR
Routine Test
Ageing Test.
Tank, H.V. & L.V. Cable Box / Flange
throat Y Y Y
Conservator / Radiator / Cooler / Pipes

Y Y Y
Copper Conductor (IS:191) Y Y Y Y

Insulating Material Y Y Y Y Y Y
CRGO Lamination & Built Core Y Y Y Y Y Y
Bushing / Insulator
( IS:2544 / 5621) Y Y Y Y
Gasket Y Y Y Y Y
Transformer Oil ( IS:335) Y
Off-Circuit Tap Changer Y Y
Core Coil Assembly & Pre-tanking Y Y
Marshalling Box Y Y Y Y
Attributes /
Polarity,
Make / Type / Rating / Model / TC / General

Characteristics
&
Group
Routine Test as per relevant test

Items/Components
Visual & Dimensional Checks
Sub Systems
Vacuum & Pressure Test

Voltage Ratio, Vector
Magnetic Balance Test
NDT / DPT / MPI / UT

Core Loss*, Hot Spot
Compatibility with oil
Physical Inspection.
Thermal properties
Electrical strength
WPS & PQR
Routine Test
Ageing Test.
WTI, OTI, MOG, PRD, Breather,

Terminal Connector, Bucholz Relay,
Globe & Gate Valve,
Y Y
Welding (ASME Sect-IX) Y Y
Complete Transformer
(IS:2026)
Y Y
* Core Loss on first Job
Note: 1) This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the
practice and procedure along with relevant supporting documents.
2) All major Bought Out Items will be subject to NTPC approval.
FARAKKA SUPER THERMAL POWER TECHNICAL SPECIFICATIONS Sub-Section - IIIE-15 Page 1 of 1

PROJECT SECTION VI, PART-B Aux. Transformer
LEAD ACID BATTERY

ATTRIBUTES /
Conformance to relevant part drg. &
discharge rate along with the test for

Conformance to CPWD Spec. for Teak
Constructional requirements as per

microns, IS: 6848 App.F) & Adhesion
Paint Process checks, Paint Shade,
Checking of Polarity & absence of short

Lead Coating Thickness (min. 25
Test for Capacities for 10 hrs.
voltage during discharge ( Acceptance

Marking ( Routine & Acceptance Test)
CHARACTERISTICS
circuit (Routine & Acceptance Test)

Thickness, Adhesion & Finish
Manufacturer’s standards
Chemical composition
Insulation Resistance
Dimensions & Finish
ITEMS, COMPONENTS,
SUB SYSTEM
ASSEMBLY
NTPC S
Test)
Container & Lids ( IS : Y Y
1146)
Vent Plugs Y Y
Sealing Compound Y Y
( IS : 3116 )
Positive & Negative Y Y
Plates
Separators ( IS : 6071 ) Y Y
Electrolyte Y Y
( Water / Sulphuric Acid )
( IS : 1069 / 266 )
Inter-cell Connectors & Y Y Y
Fasteners
Battery Stand Y Y Y Y
Cell Insulators Y Y Y
Stack Assembly Y Y
Lead Acid Battery Y Y Y Y Y
( IS : 1652 )
Note: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed
Quality
Plan indicating the practice and procedure along with relevant supporting
documents.

COAL CONVEYING PLANT PACKAGE SECTION-VI, BATTERY 1 OF 2
PART-B
Ni- Cd BATTERY
ATTRIBUTES /
&
Polarity & absence of short circuit (Routine &

CHARACTERISTICS
Marking & Mass (Routine & Acceptance Test)
Retention of Charge Test ( Acceptance Test)

drg.
Paint Shade, Thickness, Adhesion & Finish

part
Air Pressure Test (Acceptance Test)

Air Pressure Test after heat sealing
Conformance to relevant
AH Test (Acceptance Test)

ITEMS,
Manufacturer’s standards
COMPONENTS, SUB
Nickel Plating thickness

Chemical composition
Insulation Resistance
SYSTEM ASSEMBLY
Dimensions & Finish
Resistance to Alkali
(Acceptance Test)
Acceptance Test)
Impact Strength
Container & Lids Y Y Y Y

Vent Plugs Y Y Y
Perforated Steel Strips Y Y Y Y
Active Material for Y Y
Positive & Negative
Plates
Separators Y Y Y
Electrolyte Y Y
Inter-cell Connectors & Y Y Y Y
Fasteners
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:
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.

COAL CONVEYING PLANT PACKAGE SECTION-VI, BATTERY 2 OF 2
PART-B
BATTERY CHARGER (220 / 110 V)
Verification of Routine test reports as per
for
Temperature Rise Test on one unit of each
Ripple Content Test, Load Limiter & AVR

constructional features as per NTPC
Degree of Protection Test as per NTCP

Dimensional check and Paint shade,
Sheet Steel Pretreatment & Painting
Burn-In Test at 50^C for 48 hrs in energised
Spec. (By physical verification of gasketting

Conform to relevant Standard & NTPC spec
Attributes / Characteristics
ti
examination
Alternating current measurement test

thickness, adhesion & Finish checks
i
Make, Model, Type, Rating & Finish
rating if Type testing is waived off
Operational & Functional Checks

Dynamic Response Test
d b
physical
Items / Components /
Operation Test
h k
Sub- assembly
HV & IR Test
t
relevant IS
Complete
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: 13947) Y Y Y
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:
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.

COAL CONVEYING PLANT PACKAGE SECTION-VI, BATTERY CHARGER 1 OF 1
PART-B
CONTROL PANEL ( AHP & CHP) SQE_25
Make,
Attributes
Degree of Protection Test (By
arrangement and by paper

shade/thickness
Interlock Functional & Operation
physical verification of gasketting

Routine test as per relevant std.
Characteristics
Type/ Rating/Functional check
IS:6005 ,Seven tank process
Testing / Simulation check
Specification requirement
Constructional Features
BOM/
Chemical Properties
Dimensions / Finish
Item Components
finish/
Mountings /
Completeness
Sub System
Assembly
HV/IR
Paint
Sheet Steel (IS-513) Y Y Y
Aluminum / Copper Y Y Y Y
Bus-bar(IS-5082/IS-
613/IS-1987)
Support Insulator Y Y Y Y
(BS-2782/IEC-
660/IS-10912)
Control / Selector Y Y Y
Switch(IS-6875)
Contractor/ MCB(IS- Y Y Y
13947)
O/L Protection Y Y
relays(IS-3231)
C.T /V.T/ Indicating Y Y Y
Meter(IS-
2705/3156/1248)
Fuse/ Fuse carrier(IS- Y Y Y
13703)
Terminals/lugs/pvc Y Y Y Y Y
wires(IS-13947//IS-
694)
Timers(IS-3231) Y Y Y
LVS, Mosaics Y
Push Button/ Lamp/ Y Y Y
(IS-6875)
Control Transformer Y Y Y
(IS-12021)
Mimic, Annunciater Y Y
GASKET(IS-11149) Y Y Y Y Y
Fabrication Y
Pretreatment & Y Y
Painting
Control panel Y Y Y Y Y

CONTROL PANEL
( AHP & CHP)
PART-B
NOTE:
1. This is an indicative list of Test/ Checks. The manufacturer to furnish a detailed Quality Plan indicating
the practice and procedure along with relevant supporting documents.
2. All major Bought Out Items will be subject to NTPC approval.

CONTROL PANEL
( AHP & CHP)
PART-B
CONTROL DESK, PLC PANEL, SMOKE DETECTOR, FIRE ALARM &

CONTROL SYSTEM
TESTS
,
Review of TC for instruments/ Devices/ Recorders,
Element
Indicators/ osaic Items/ Transducers ®
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. Annunciation/ Y Y Y Y Y Y Y Y Y Y Y Y
Control/ PLC Panel
3.Smoke Detectors 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) Detailed procedure of Environmental Stress Screening test shall be
as per Quality Assurance Programme in General Technical
Conditions
2) This is an indicative list of test/ checks. The manufacturer is to
furnish a detailed quality plan indicating the Practice and Procedure
• *Applicable for PLC
• Y - Test Applicable , ® - Routine Test (A) - Acceptance Test

COAL CONVEYING PLANT PACKAGE SECTION-VI, CONTROL SYSTEM 1 OF 1
PART-B
CLAUSE NO. QUALITY ASSURANCE
CHP System - Civil Works
1.00.00 SAMPLING, TESTING AND QUALITY ASSURANCE
1.01.00 GENERAL REQUIREMENT

1.01.01 This part of the specification covers the sampling, testing and quality assurance
requirement ( including construction tolerances and acceptance criteria for all works
and structures covered in this specification i.e. excavation and filling, cast in situ
concrete and allied works, fabrication and erection of structural steel works, masonry
/ sheeting and allied works, finishing items, water supply and sanitation, modular
aerated concrete panel, pre-engineered building, special items of works, and piling.
1.01.02 This part of the technical specification shall be read in conjunction with other Parts of
the technical specification.
1.01.03 All tests required for all materials ( bought by Contractor ) and workmanship shall be
done / got done by the contractor at his own cost. The unit rate for respective items
of the schedule of items 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.
1.01.04 The Contractor shall provide the facilities whatsoever required and also bear all cost
for all sampling, testing and quality assurance in the field and in the laboratory. The
Contractor shall carry out all sampling and testing in accordance with the relevant
Indian standards and / or international standards and this technical specification.
Where no specific testing procedure is mentioned, the tests shall be carried out as
per the best prevalent engineering practices and to the directions of the Engineer. All
sampling shall be done in the presence of the Engineer or his authorised
representative. The Contractor shall establish the Field Quality Assurance ( F. Q. A. )
laboratory and field tests shall be done in the presence of the Engineer and / or his
authorised representative. The tests which cannot be carried out in the field
laboratory shall be done at a laboratory of repute ( CSMRS, NCBM, IITs, Shriram
Test House, New Delhi / National Test House, New Delhi etc. ), as agreed by the
Engineer, If the Engineer desires to witness such tests at laboratory, Contractor shall
arrange to conduct the test in his presence.
1.01.05 The recommendations and suitability of material including petrographic examination
of fine and coarse aggregates shall be sought from the testing agency. The
Contractor shall submit the test results to the Engineer in triplicate, within three (03)
days after completion of any test.
1.01.06 The Contractor shall maintain Records of all Inspection and Testing, which shall be
made available to the Engineer.
1.01.07 All records shall be submitted, unless specified otherwise, as per the format
developed by the Contractor and approved by the Engineer.
1.01.08 Work found unsuitable for acceptance shall be removed and replaced by the
Contractor, as per Technical Specification requirements and to the satisfaction of the
Engineer.
1.01.09 Representative samples shall be procured by the Contractor (from approved
vendors) and submitted to the Engineer for his approval before bulk procurement.
Approval of material / sample by the Engineer shall not relieve the Contractor of his

PROJECT SECTION VI, PART-B CHP System
BID DOC. NO.: CS-2140-157-2
responsibility, for their conformance to the specification, the requisite quality and
performance of material.
1.01.10 All Equipment and Instruments shall be calibrated before the commencement of
Tests and then at regular intervals, as directed by the Engineer. If the Engineer so
desires, the Contractor shall arrange for having the Instruments / Equipment get
Tested for their calibration, at an Approved Laboratory and the Test report shall be
submitted to the Engineer.
1.01.11 The F. Q. A. laboratory shall have all necessary equipment and instruments and shall
be managed by a qualified / experienced person. F. Q. A. laboratory shall be
equipped with minimum equipment, as appended at Appendix – I to these technical
Specifications.
1.01.12 The F. Q. A laboratory shall be managed by personnel specially trained for such job
and approved by the Engineer. The personnel who have been trained for carrying out
the relevant tests shall do all testing. The Contractor shall engage all such personnel
for the duration of the Contract.
1.01.13 The F. Q. A laboratory building shall be constructed by the Contractor at his own
cost. The laboratory building shall be constructed and installed with the appropriate
facilities. Temperature and humidity controls shall be available wherever necessary
during testing of samples.
1.01.14 Indicative (not exhaustive) list of typical F. Q. A. laboratory equipment shall be as
specified elsewhere in this specification. The contractor at his owns cost shall provide
all these equipment. The contractor shall maintain the equipment in good working
condition for the duration of the contract. Any other equipment though required for
testing but not listed in the equipment list shall be provided / arranged by the
contractor at his own cost.
1.01.15 If any facility for testing or the trained personnel for conducting test is not available
with the Contractor then the Contractor may get the test done from reputed /
approved laboratory or out source the personnel as approved by the Engineer.
1.01.16 An indicative (not exhaustive) Field Quality Assurance organisational set up is placed
at Appendix - II. The set up shall be suitably augmented as and when directed by the
Engineer to cope with the work demand. Based on the schedule of work and the
approved Field Quality Plan (F. Q. P.). The Contractor shall prepare a schedule of F.
Q. A. tests and shall submit to the owner and shall organise the tests as scheduled.
1.01.17 The contractor shall prepare and obtain the approval of the Owner of the F. Q. P.
before the award of the work. This F. Q. P. shall cover for all the items / activities
covered in the schedule of items and required for the completion of the work.
1.01.18 Owner at their discretion shall also carry out quality audit and quality surveillance of
systems and procedures of contractor’s quality control activities. However generally
the field quality audit shall take place at an interval of three months all through the
construction stage.
1.01.19 The contractor shall store and handle the materials as per the requirements of the
relevant standards at his own cost.
2.00.00 CONSTRUCTION TOLERANCE AND ACCEPTANCE CRITERIA
2.01.00 EXCAVATION AND FILLING
2.01.01 Tolerance
Finished surface level shall be within 20 mm of the level shown in the drawing.

BID DOC. NO.: CS-2140-157-2

Following Acceptance Criteria shall be followed.
(a.) When only one set of sample is tested, then all individual samples collected and
tested should pass without any deviation
(b.) For retest of any sample two additional samples shall be collected and tested,
and both should pass without any deviation.
(c.) Where a large number of samples are tested for a particular test than 9
samples out of every 10 consecutive samples tested shall meet the
specification Requirement.
(d.) Tolerance on finished levels for important filling areas at approved interval shall
be + 20 mm. However, for an unimportant area, tolerance upto +75 mm shall be
acceptable at the discretion of the Engineer. However, these tolerances shall
be applicable for localised areas only.
2.02.00 CAST-IN-SITU CONCRETE AND ALLIED WORKS

2.02.01 Tolerances
(a.) CAST-IN-SITU CONCRETE
Unless otherwise specified, the dimensions of concrete as cast when compared with
those on the drawings i. e. the tolerance in construction shall be as given hereunder :
DESCRIPTION OF ITEM / PERMISSIBLE DEVIATION

STRUCTURAL ELEMENT IN MM (MAX)
Faces of concrete in foundations and structural + 25 - 10

members against which backfill is placed
Location of footing (for RCC framed structures +25 - 25

only)
Eccentricity of footing 2% of footing width in
direction of misplace - ment
but limiting to 50mm
Top surfaces of slabs and of concrete to +5 -5
receive base plates to be grouted
Alignment of beams, lintels, columns, walls, +5 -5
slabs and similar structural elements
Cross sectional dimensions of walls, slabs and +5 -5
similar structural elements
Deviation from specified dimensions of cross - +12 -6
section of columns and beams.
Alignment of holding down bolts without +1.5 - 1.5
sleeves
Alignment of holding down bolts with sleeves. +5 -5
Level of holding down bolt assemblies. +10 - 10
Embedded parts (in any direction) +5 -5
Centres of pockets or holes with greatest +10 - 10
lateral dimension not exceeding 150mm

BID DOC. NO.: CS-2140-157-2
Variation in steps :
Riser +1.5 - 1.5
Tread +3.0 - 3.0
Plumb 3mm for every meter
subject to a maximum of
10mm.
(b.) Reinforcement
Tolerance on placing of reinforcement and for cover shall be as per clause number
12.3 of IS : 456.
Reinforcement shall be placed within the following tolerances:
Sl. Description Tolerance limits
No.
a) For effective depth 200 mm or less ± 10 mm
b) For effective depth more than 200 mm ± 15 mm
(c.) Cover
Actual concrete cover should not deviate from the required nominal cover by + 10
mm
(d.) Pre cast concrete
Tolerance on dimensions of pre-cast units shall be as follows:
(1.) Length : +/- 0.1 percent subject to minimum of +/- 5 mm and maximum of
+ 10 mm.
(2.) Cross-sectional dimensions : +/- 3 mm or +/- 0.1 percent whichever is
greater.
(3.) Straightness or Bow : 1/750 of the length subject to minimum of +/- 5 mm
and maximum of +/- 10 mm.
(4.) Squareness : When considering the squareness of the corner the length
of the two adjacent sides being checked shall be taken as the base line.
The shorter side shall not vary in length from the perpendicular by more
than 5 mm.
(5.) Flatness : The maximum deviation from a 1.5m straight edge placed in
any position on a nominal plant surface shall not exceed 5 mm.
(e.) FORMWORK AND STAGING
(1.) Staging shall be checked for its soundness as a whole and for adequacy
of the joints and its foundations. Formwork joints shall be inspected for
soundness of connections. All joints shall be either vertical or horizontal
and shall be such as to avoid loss of liquid through the FormWork.
(2.) Dimensional tolerance for formwork shall be as per Clause 9.6 of IS :
14687 and 11.1 of IS : 456 and as given below :

BID DOC. NO.: CS-2140-157-2
Description Tolerances
Levels and heights +6mm
Plumb 3mm for every meter subject to a

maximum of 10mm.
Unevenness of any surfaces +3mm
Length or breadth +12mm
Diagonals +15mm
In case of inclined surfaces like folded

plates etc., the deviation in the
alignment of inclined surfaces, shall not
exceed 3mm with reference to the
theoretical alignment, for a length of
1000 mm measured vertically, subject to
a maximum of 10mm.
Deviation from specified +12 mm / - 6 mm

dimensions of cross section of
columns and beams
Deviation from dimensions of footings
1 ) Dimensions in plan + 50 / - 12 mm
2 ) Eccentricity 0.02 times the width of the footing in

the direction of deviation but not more
than 50 mm
3 ) Thickness ± 0.05 times the specified thickness
The above tolerances apply to concrete dimensions only, and not to positioning
of vertical reinforcing steel or dowels
(3.) Checklist for formwork shall be as per Clause 9.9 of IS : 14687. Format as
per Annexure - C of IS : 14687 shall necessarily be made for all important
structures including all machine foundations.
(a.) The acceptance criteria of concrete shall be in accordance with clause no. 16 of
IS : 456. However in exceptional circumstances, and that too in non-critical
areas, the Engineer may accept concrete work which is marginally
unacceptable as per the criteria laid down in IS : 456. For such accepted work,
payment shall be made at a reduced rate pro rate to the concrete cube strength
obtained, against that stipulated.

BID DOC. NO.: CS-2140-157-2
(b.) Unacceptable Concrete Work shall be dismantled by the Contractor and

replaced by fresh Work, meeting the specification Requirements. In the course
of dismantling, if any damage is done to the Embedded items or adjacent
structures, the same shall be made good, by the Contractor, to the satisfaction
of the Engineer, at no extra cost to the Owner.
(c.) Test shall be conducted for the Water tightness of the liquid retaining structures
as per IS : 3370 and IS : 6494.
2.03.00 FABRICATION AND ERECTION OF STRUCTURAL STEEL WORK
2.03.01 Fillet Welds
(a.) Check for size and visual examination.
(b.) Macroetch examination on production test coupons for main fillet welds with
minimum one joint per built up beams, columns and crane girder etc.
(c.) 25% weld length of tension member of crane girder shall be subjected to Dye
Penetration Test ( D. P. T. )
(d.) On all other fillet welds, D. P. T. on 5% of weld length with minimum 300 mm at
each location shall be carried out.
2.03.02 Butt Welds
(a.) 100% visual examination
(b.) D. P. T. on all butt welds after back gouging
(c.) Mechanical testing of production test coupons with minimum one joint per built
up beam, column and crane girder.
(d.) 100% radiography test on butt welds of tension flange ( bottom flange ) of crane
girder. All other butt welds shall be subjected to Radiography Test ( R. T. ) on
10% weld length of each welder. Wherever R. T. is not feasible, U. T. shall be
carried out.
(e.) Full penetration welds ( other than butt welds ) shall be subjected to Ultrasonic
Testing in following quantum :
(1.) 100% U. T. on web to flange joint of crane girder.
(2.) 10% U. T. on other full penetration joints.
(f.) In case of failure of any welds in 10% R. T. / U. T., the %age for retesting shall
be doubled at that particular location. Acceptance criteria of Non Destructive
Tests ( N. D. T. ) on welds shall be as per AWS D1.1.
2.03.03 All structure components / members shall be checked for following dimensional
tolerances during fabrication and erection.
(a.) Fabrication tolerances
(1.) maximum permissible gap in built up members.
(2.) maximum permissible deviation in depth and / or width of girder at the
joints.
(3.) maximum permissible out-of-square of flanges in built-up girders.
(4.) length of beams and girders and their components.
(5.) permissible deviation in column heights.
All tolerances for above shall be as per drawings / IS : 7215.

BID DOC. NO.: CS-2140-157-2
(b.) Erection tolerances

(1.) permissible tolerances in erected steel columns.
(2.) permissible tolerances in erected steel trusses.
(3.) permissible tolerances in crane girder and rails.
All tolerances for above shall be as per approved drawings / IS : 12843.
(c.) Requirement of pre-heating
Thickness of thickest part at the Welding using Welding using low

point of welding electrodes other than low hydrogen welding
hydrogen welding electrodes or
electrodes IS : submerged arc
2062 welding IS:2062
Upto 20 mm ( including ) None None
Over 20 mm to 40 mm ( including ) 66o C 20o C
Over 20 mm to 63 mm (including) Not allowed 66o C
Over 63 mm Not allowed 110o C

(a.) The acceptance criteria of Non Destructive Testing ( N. D. T. ) on welds shall
be as per AWS D1.1 ( Dynamically Loaded Structures - tension welds ). In case
of failure of any of the tests, the Contractor at his own cost shall also carry out
rectification of such defective welds. The Contractor, at his own cost shall also
carry out re-testing of the rectified joint.
(b.) Every 1st and further every 10th set of identical structure shall be checked for
control assembly in shop before erection.
2.04.00 Embedded Parts
2.04.01 Tolerances
Tolerances shall be as specified under concrete works.
2.05.00 Masonry, Sheeting, and Allied works
2.05.01 Tolerances
(a.) All masonry shall be built true and plumb within the tolerances prescribed as
below. Care shall be taken to keep perpends properly aligned. Unless specified
otherwise the tolerances in construction of masonry shall be as below :
(1.) Deviation in verticality in total height of any wall of a building more than
one storey in height shall not exceed ( 12.5 mm.

BID DOC. NO.: CS-2140-157-2
(2.) Deviation from vertical within a storey shall not exceed ( 6 mm per 3m
height.
(3.) Deviation from the position shown on the plan of any brickwork more than
one storey in height shall not exceed 12.5 mm.
(4.) Relative displacement between load bearing walls in adjacent storey
intended to be in vertical alignment shall not exceed 6 mm.
(5.) Deviation of bed joint from horizontal in any length upto 12m shall not
exceed 6 mm, and in any length over 12m it shall not exceed 12.5 mm
total.
(6.) Deviation from the specified thickness of bed-joints, cross-joints or
perpends shall not exceed ( 3 mm.
(b.) The plastered surface shall be checked for
(1.) Blistering, bond failure or loss of adhesion, cracking, crazing,
efflorescence, grinning, irregularity of surface texture, popping or blowing,
recurrent surface dampness, softness or chalkiness defects and the
remedial measures for the same shall be adopted as per IS: 1661.
(2.) The finished plastered surface shall not show any deviation more than 4
mm when checked with a straight edge of 2 metre length placed against
the surface.
(3.) The thickness of the plaster shall be measured exclusive of the thickness
of key i.e., grooves or open joints in brickwork. The average thickness of
plaster shall not be less than the specified thickness. The minimum
thickness over any portion of the surface shall not be less than the
specified thickness by more than 3 mm for plaster thickness above 12 mm
and 1 mm for ceiling plaster. Extra thickness required in dubbing, behind
rounding of the corners, at junctions of wall or in plastering of masonry
cornices etc. shall be ignored.
(c.) Sheeting works shall be checked for the following
(1.) Material Test Certificate ( M. T. C. ) for structural steel submitted by the
contractor shall be checked for compliance with the applicable IS code.
(2.) Material test certificate for coated sheet ( issued by an approved
laboratory ) submitted by the contractor for each supply of batch.
(3.) At least three random samples of sheet, from three different batches of
supply, shall be selected by the Engineer, which shall be got tested by the
Contractor, for salt spray test for 1000 hrs, type of coating, physical
properties, thickness of coating at an approved laboratory.
(4.) Constructional tolerances for sheeting works shall be similar to those
allowed for masonry works
Following acceptance criteria shall be followed:
(a.) General workmanship is being good and as recommended by the manufacturer
and approved by the Engineer.
(b.) Tolerances are within the specified limits.
(c.) Material test certificate is in compliance with the applicable codes/standards.
(d.) Bought out material is from the approved manufacturer / vendor.

BID DOC. NO.: CS-2140-157-2
(e.) Bought out material is matching with the approved sample.

2.06.00 FINISHING AND ALLIED WORKS
2.06.01 Floor Finish
The tolerances shall be checked specially for the following :
(a.) Level, slope, plumb as the case may be
(b.) Pattern and symmetry
(c.) Alignment of joints, dividing strips etc.
(d.) Colour, texture
(e.) Surface finish
(f.) Thickness of joints
(g.) Details of edges, junction etc.
(h.) PERFORMANCE
(i.) Precautions specified for durability
Local depressions on account of faulty workmanship shall not be acceptable. Tiles /
natural stones with cracked or broken / chipped edges shall not be acceptable.
2.06.02 Door, Window, Ventilator, Partitions
(a.) Before fitting and fixing in position following shall be checked :
(1.) Overall dimensions shall be within + 1.5 mm of the size shown on
drawing.
(2.) Mullions, transoms etc. shall be in one length and permissible deviations
from straightness shall be limited to + 1.5 mm from the axis of the
member.
iii ). Door leaves shall be undercut where shown on drawings.
(3.) Doors, windows, ventilators, partition frames, etc., shall be on a true
plane, free from warp or buckle.
(4.) All welds shall be dressed flush on exposed and contact surfaces.
(5.) Correctness of location and smoothness of operation of all shop installed
hardware and fixtures.
(6.) Provision for hardware and fixtures to be installed at site and compliance
with relevant IS codes.
(7.) Glazing beads shall be cut with mitered corners.
(8.) Glazing clips, fixing devices etc. shall be supplied in adequate numbers.
(9.) Shop coats shall be properly applied.
(10.) Exposed aluminium surface shall be free from scratches, stains and
discoloration. Anodised surfaces shall present a uniform and pleasant
look.
(11.) Correlating the material with the test certificate ( M. T. C. )
(12.) Matching the material supplied with the approved sample
(13.) Thickness of paint / anodized coating

BID DOC. NO.: CS-2140-157-2
(14.) All welds shall be dressed flush on exposed and contact surfaces.
(b.) During and after fitting and fixing in position following shall be checked.
(1.) Installation shall be at correct locations, elevations and in general on a
true vertical plane.
(2.) Fixing details shall be strictly as shown on drawings.
(3.) Assembly of composite units shall be strictly as per drawing, with mastic
caulking at transoms and mullions, gaskets, weather strips etc. complete.
(4.) All frames on external wall shall be mastic caulked to prevent leakage
through joint between frames and masonry.
(5.) All openable sections shall operate smoothly without jamming. Lock,
fasteners, etc, shall engage positively. Keys shall be non-interchangeable.
(6.) Cutting to concrete or masonry shall be made good and all abrasions to
shop paint shall be touched up with paint or same quality as shop paint.
(7.) Aluminium doors, windows, ventilators, partitions etc., shall be free from
scratches, stains or discoloration.
(8.) 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.
2.06.03 Fire Proof Doors
(a.) Fire Proof doors shall be tested for the requirements mentioned in IS-3614
Part-II. The doors shall have minimum 2 hours fire rating.
(b.) D. F. T. and fire retardancy of paint of fireproof doors shall be checked.
2.06.04 Rolling Shutters / Grills / Sliding doors
(a.) After installing the shutters, the contractor shall test the performance of the
shutter in the presence of the engineer. The shutter shall be smoothly operable
under all ambient conditions. All controls and locking devices shall give fault
free performance.
(b.) Sliding doors : The sliding mechanism shall provide for smoothly operable by
gentle push / pull of a single person.
2.06.05 GLASS AND GLAZING
Following shall be checked for :
(a.) All Glazing is free from cracked, broken or damaged glass.
(b.) Edges of large panes of glass shall be inspected carefully for chipped, cracked
or ungrounded edges.
(c.) At completion, the panes shall be free from dirt, stains, excess putty, etc., to the
complete satisfaction of the Engineer.
(d.) All glasses shall be embedded in martie or fixed by neoprene gaskets to give a
leak proof installation.
2.06.06 False Ceiling System
(a.) Following shall be checked for :
(1.) as installed shall be true to shape, level.

BID DOC. NO.: CS-2140-157-2
(2.) correctness for the opening for the fixtures, colour and shade.
(3.) All joints shall be in the same line and cross-joints shall be securely fixed
to walls.
(4.) There shall not be any sagging and / or unevenness in the surface
(b.) Acceptance Criteria
Ceiling panels shall be best quality material in thickness and properties called for in
the schedule of items. Material Test Certificate to be submitted before bulk supply.
Finished ceiling shall be at the correct plane and prevent an aesthetically pleasing
and uniform appearance, free from sags and warps. Joints and exposed grids shall
be in true lines and symmetrically placed in manner as shown in drawings. Cut outs
for light fixtures, diffusers and other relevant services shall be of exact dimensions
and in exact locations.
2.06.07 Water proofing
Water proofing shall be tested for water tightness by creating a pond of water
minimum 25 mm height on area of 6 m x 6 m, for the period of 48 hrs on fully dried
elastomeric membrane surfaces. Minimum 5% area of the roof shall be subjected to
water tightness test. Such test necessarily be conducted on vulnerable areas like
drain channel/ drain head. No dampness shall be visible on the underneath side of
roof ( i.e. ceiling ), parapet and well junctions etc. which have been subjected for
testing. The above testing shall be carried out prior to application of wearing course.
2.07.00 PAINTING AND ALLIED WORKS
2.07.01 Various materials used shall conform and tested for the requirements of
Indian/International Codes specified in the technical specification.
2.07.02 Surface to receive paint shall be made smooth.
2.07.03 Painting shall be checked for thickness and or number of different coats as specified
in schedule of items/drawing.
(b.) Tolerances are within the specified limit.
(c.) Material test certificate is in compliance with the applicable codes/standards.
2.08.00 WATER SUPPLY, DRAINAGE AND SANITATION
2.08.01 Tolerances
(a.) All soil pipes, waste pipes, ventilating pipes and all other pipes, when above
ground, shall be gas tight. All sewers and drain laid below ground shall be
watertight.

BID DOC. NO.: CS-2140-157-2
(b.) Obstruction / Straightness Test

The obstructions shall be checked by inserting a smooth ball, of diameter 13 mm less
than the pipe bore at the high end of the sewer or drain. If absence of any
obstructions, such as yarn or mortar projecting through the joints, ball shall roll down
the invert of the pipe and emerge at the lower end. The straightness shall be checked
by means of a mirror at one end of the line and lamp at the other. If the pipeline is
straight, the full circle of the light may be observed. The mirror will also indicate
obstruction in the barrel, if the pipeline is not straight.
(c.) Service Pipes Testing with Water
The service Pipes shall be slowly and carefully charged with Water, allowing all air to
escape avoiding all shock or Water hammer. The service Pipe shall then be
inspected under Working condition of Pressure and flow, when all draw off Taps are
closed. The service Pipes shall be checked for satisfactorily support and protection
from damage corrosion and frost.
(d.) Fixtures etc.
Watertight joints shall connect all fixtures and fittings. No dripping of water shall be
acceptable.
(a.) General workmanship is being good and is recommend by the manufacturer
and approved by the engineer.
(c.) Material test certificate is in compliance with the applicable IS Codes.
2.09.00 Bored Cast - in - Situ Piles
2.09.01 Tolerances
(a.) Founding level of the piles shall be checked as per the criteria given elsewhere
in the Technical specifications and Standard Penetration Test ( S. P. T. ), core
recovery of rock, as applicable.
(b.) The permissible limits for deviation with respect to position and ( inclination )
alignment shall conform to IS : 2911 Part - I and as given below.
(1.) The maximum deviation of vertical piles shall not exceed 1.5 per cent in
alignment.
(2.) Piles shall not deviate more than 75 mm or D / 10 whichever is higher
from their designed position at cut-off-level.
(c.) Limits for Bentonite for piling work shall satisfy the following requirements
(1.) Liquid limit of bentonite when tested in accordance with IS : 2720 ( Part -
V ) shall be more than 300 percent and less than 450 percent.
(2.) Sand content of the bentonite powder shall not be greater than 7 percent.
(3.) Bentonite solution should be made by mixing it with fresh water using
pump for circulation. The density of the freshly prepared bentonite
suspension shall be between 1.034 and 1.10 gm/ml depending upon the

BID DOC. NO.: CS-2140-157-2
pile dimensions and type of soil in which the pile is to be installed.

However, the density of bentonite suspension after getting mixed with
deleterious materials in the pile bore may be upto 1.25 gm / ml.
(4.) The Marsh viscosity when tested by a Marsh cone shall be between 30 to
60 seconds.
(5.) The differential free swell shall be more than 540 percent.
(6.) The pH value of the bentonite suspension shall be between 9 and 11.5.
(d.) Check for pile bore: on completion of boring and cleaning, the bottom of each
pile bore shall be checked from the samples of the contaminated drilling mud
collected from near the bottom of pile bore.
(e.) Slump of concrete shall be 150 - 180 mm
(f.) Cover to reinforcement shall be as per technical specifications.
(g.) Concrete above Cut-off-Level ( C. O. L. ) shall be 1.0 m.
(a.) The founding level shall be as per technical specification.
(b.) Density of drilling mud from pile bore bottom shall not be more than 1.25 T / m3
before concreting.
(c.) Tolerances are in the specified limits.
2.10.00 SPECIAL ITEMS
2.10.01 Vibration Isolation System ( V. I. S. )
Stiffness values shall be checked. The permissible deviations shall be as per DIN
2096.
For accepting, following acceptance criteria shall be followed:
(c.) Material test certificate ( M. T. C. ) is in compliance with the applicable codes /
standards.

BID DOC. NO.: CS-2140-157-2
ANNEXURE – I
TYPICAL FIELD QUALITY LAB EQUIPMENT
Sl. Equipment Minimum Nos.

No.
1 Vicat Apparatus with deskpot 2
2 Le chatelier flask 2
3 Le chatelier Mould 2
4 Cube Moulds for cement testing 6
5 Vibration Machine 1
6 Laboratory cement autoclave 2
7 Length comparator 2
8 Shrinkage Bar mould 2
9 Sieve shaker 1
10 Sieves for sand, coarse and fine aggregate 1 set for each
11 Sieves for coarse aggregate for Road 1 set
12 Proctor testing equipment 1 sets + 9 cores
13 Slump testing equipment 3 sets
14 Oven 1
15 Physical balance 1
16 Rapid moisture meter 2
17 Thermometer 2
18 Burret 1
19 Measuring cylinders 5
20 Measuring flasks 2
21 Compression testing machine 1 sets of 200 kN

capacity each

22 Cube moulds 15
23 Electronic balance 1 (12 kg capacity ),

2 (200 mg
capacity)
24 pH balance 1
25 Radiographic facilities Party should

deploy BARC
approved agency
for carrying out R.
T.
26 Mechanical weighing machine 1 (100 kg capacity)
27 Ultrasonic testing machine As per requirement
28 D. P. Test kit 5
29 Vernier 300 mm, 600 mm 2
30 Micrometer ( 0.25 mm ) out side ( 25.00 ) 2
31 Radiography film viewer 1
32 Inside Micrometer 25-750 dia 2
33 Digital elcometer for paint thickness 2
34 Baking oven for electrode 2
35 Portable ovens As per requirement
Note : The list of equipment above is only indicative and shall be suitably
modified depending upon the size and capacity of package and project.

ANNEXURE - II
Notes :
(i.) All test reports / inspection reports have to be computerized and maintained
on LAN with an access to the owner.
(ii.) Computers - 2 Nos shall be deployed with Windows operating system and
connected to the NTPC server.
(iii.) Based on the schedule (L2 Network), Quality control and Quality Assurance
work plan including the schedule of tests shall be generated on the computer
which shall be accessed by the owner for database and day to day
monitoring.
(iv.) The above organisation setup is indicative only. The contractor shall mobilize
required number of skilled and supporting staff and additional resources, if
any to meet the work schedule.

PROJECT
SECTION VI, PART-B CHP System
BID DOC. NO.:CS-9558-156-2
APPENDIX – II
FQA ORGANISATION SET UP
Project Manager
Manager (Quality)
CIVIL ENGINEER FOR ENGINEER (NDT)

CONCRETING WORK CUM STRUCTURE
EARTH WORK & LAB
INCHARGE
Lab Assistance & Qualified Manpower

Sufficient skilled manpower RT Level II
UT Level II
NOTE :
1. All test reports/inspection reports have to be computerized and maintained on

LAN with an access to the Employer.
2. Computers – 2 Nos. shall be deployed with Windows operating system and

connected to the NTPC server.
3. Based on the schedule (L2 Network), Quality Control & Assurance work plan
shall be generated on the computer to be accessed by the Employer for
database and day to day monitoring.
4. The above organisation setup is indicative only. The contractor shall mobilise
required number of skilled & supporting staff and additional resources, if any
to meet the work schedule.

PROJECT
SECTION VI, PART-B CHP System
BID DOC. NO.:CS-9558-156-2
CLAUSE NO.
LIST OF TENDER DRAWINGS
----------------------------------------------------------------------------------------------------------------
S.NO. DRG. NO. TITLE
----------------------------------------------------------------------------------------------------------------
A MECHANICAL
1. 4140-999-POM-A-001 General Layout Plan
2. 4140-999-POM-A-002 GA of Junction Houses
3. 4140-999-POM-A-003 Single Line Diagram for DS, SW, CW &

Potable Water System
B ELECTRICAL
1. 4140-999-POE-A-001 Coal Conveyors Plant Single Line Diagram

(Two sheets)
SECTION-VI LIST OF TENDER PAGE
PROJECT
PART - E DRAWINGS 1 OF 1

ScheduleETechnicalSpecificationHQ120111 PDF

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NTPC Limited

(A Government of India Enterprise)

FARAKKA SUPER THERMAL POWER PROJECT

COAL CONVEYING PLANT PACKAGE

BIDDING DOCUMENT NO. :

FARAKKA SUPER THERMAL POWER PROJECT

COAL CONVEYING PLANT PACKAGE

BIDDING DOCUMENT NO. :

PART SECTION NO TITLE

PART-B III-B ELECTRICAL

PART-B III-D CIVIL

PART-B III-E QA & I SECTION

PART-E List of Tender Drawings

1.00.00 INTENT OF SPECIFICATION

(ii) Complete manufacture including shop testing/ type testing.

(iii) Providing engineering data, drawings, Commissioning procedures

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

(v) Receipt, unloading, storage, preservation, conservation and

(vii) Associated civil, structural, architectural and electrical works.

(viii) Commissioning and completion of facilities and Performance

(x) Reconciliation with custom authorities, if applicable.

(xi) Satisfactory completion of the contract.

respects to high standards of engineering, design and workmanship and

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

(g.) The sizes of various buildings/conveyor galleries indicated in the tender

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

III-A-02 : Brakes and Clamps

III-A-03 : Monorails and Hoists

III-A-04 : Chutes and Hoppers

III-A-05 : Belt Conveyor System

III-A-06 : Drive Equipment

III-A-07 : Belt Scales

III-A-08 : Dust Control & Miscellaneous Systems

III-A-09 : Ventilation System

III-A-10 : CHP Buildings

III-A-11 : Inline Magnetic Separator

III-A-12 : Metal Detector

III-A-13 : Coal Sampling Unit

IIIA-14: Vibrating Feeder

IIIB-02 : LT Switchgear & Bus Duct

IIIB-03 : LT Power Cables

IIIB-05 : Control Cables

IIIB-06 : Instrumentation cables

IIIB-07 : Illumination System

IIIB-08 : Cabling, Earthing & Lightning Protection

IIIB-11 : PLC CONTROL PANEL

IIIB-13 : Battery Charger

IIIIB-14 : MEASURING INSTRUMENTS

III-D-01 : CHP System – Civil and Structural Works

III-D-02 : Foundation System and Geotechnical Data

E-01 : Coal Conveyors Belt

E-05 : LT Power Cables

E-06 : LT Control Cables

E-07 : Instrumentation Cables

E-08 : Station Lighting

E-09 : Cabling, Earthing & Lightning Protection

E-12 : HT Capacitor Bank

E-13 : Measuring Instruments

E-14 : Power Supply For C&I System

E-17: Battery Charger

E-18 : Control Panels

E-19 : Control System

E-20 : CHP System - Civil Works