Technical Specification

SECTION – ‘C’ : TECHNICAL SPECIFICATION OF
STORES
NUCLEAR POWER CORPORATION OF INDIA LIMITED
( A Government of India Enterprise )

RESEARCH AND DEVELOPMENT – NUCLEAR SYSTEMS GROUP

PROCUREMENT SPECIFICATION

ON

DECAY HEAT DC POWER SUPPLY SYSTEM
FOR HEATING
OF RESISTANCE ELEMENTS

SPECIFICATION No.: PB -E-775 March- 2008
NUCLEAR POWER CORPORATION OF INDIA LTD.
(A GOVT. OF INDIA ENTERPRISE)
SPECIFICATION NO. PB-E-775
PROCUREMENT SPECIFICATION
ON
DECAY HEAT DC POWER SUPPLY SYSTEM FOR
HEATING OF RESISTANCE ELEMENTS
REVISION NO. : R0
DATE OF ISSUE : March 2008

(MONTH / YEAR)
TOTAL NO. OF PAGES :
ORIGINAL
PREPARED BY : S.P.GUPTA
DCE (R&D-NS)
CHECKED BY : Dr. R.D.KULKARNI

SO/G, RED, BARC
REVIEWED BY : S C HALDAR
CE (R&D-NS)
APPROVED BY : P.K.BHAUMIK
RED, BARC
(Name & Designation) (Signature) (Date)
(For Revisions See Revision Control Sheet)

REVISION CONTROL SHEET
DOCUMENT TYPE: PROCUREMENT SPECIFICATION
SPECIFICATION NO : PB-E-775 Rev. No.: R-0
TITLE: PROCUREMENT SPECIFICATION ON

DECAY HEAT DC POWER SUPPLY SYSTEM FOR
HEATINGOF RESISTANCE ELEMENTS

REV. DESCRIPTION REVISED BY CHECKED REVIEWED APPROVED
NO. & OF REVISION NAME & BY NAME & BY NAME & BY NAME &
DATE SIGNATURE SIGNATURE SIGNATURE SIGNATURE
RESEARCH AND DEVELOPMENT- NUCLEAR SYSTEMS Section : Contents
PROCUREMENT SPECIFICATION ON DECAY HEAT DC POWER Page : 1 of 1
SUPPLY SYSTEM FOR HEATING OF RESISTANCE ELEMENTS Revision : 0
CONTENTS
SECTION TITLE NO. OF PAGE
C PROCUREMENT SPECIFICATION
C0 GENERAL INFORMATION AND INSTRUCTIONS 44
CC 1 Scope of Supply/Work/Services 2
CC 2 Applicable Codes, Standards and Specifications 2
CC 3 Specification of Main Equipment and Accessories 14
CC 4 Equipment construction and Design Details 3
CC 5 Inspection and Testing 4
CC 6 Quality Assurance Plan(QAP) 1
CC 6.1 Quality Assurance Plan for rectifier 11
CC 6.2 QAP for Dry Auxiliary Transformer 9
CC 6.3 QAP for BUS DUCT 4
CC 7 Tender Evaluation 1
CC 8 Erection, Testing and Commissioning 2
CC 9 Special Tools and Tackles for Erection and Maintenance 1
CC 10 List of Drawings 1+3
D FORMAT FOR SUBMISSION OF PART-I (TECHNICAL)
OF TENDER
D2.1 Technical Data 8
D2.2 Schedule for Tender’s Experience 1
D2.3 Drawings to be Submitted along with the Tender 1
D2.4 Performance Data including Performance Curves etc. to be 1
submitted along with the Tender
D2.5 Schedules for Submission of Drawings, Data, Instruction 2
Manuals, Test Reports etc.
D2.6 Performance Data 1
D2.7 Schedule of Deviation from Technical Specification 1
D2.8 Schedule of Manufacturing, Delivery and other Related 1
Activities
D2.9 Schedule of Personnel for Supervision of Erection and 1
Commissioning
E FORMAT FOR SUBMISSION OF PART-II (PRICE BID)
OF TENDER
E 1.0 Price for Design, Engineering, Manufacture, Supply of 4
Equipment, Spares Maintenance Tools, Inspection, Testing,
Transportation, Insurance, Supervision of Erection, Site Testing
and commissioning
Specification No.: PP-E-775 March,2008

SCETION-C
PROCUREMENT
SPECIFICATION

SECTION C- 0
GENERAL INFORMATION AND
INSTRUCTIONS

PROCUREMENT SPECIFICATION ON DECAY HEAT POWER Section : C
DC POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE Sub Section : C- 0
ELEMENTS Page : 1 of 44
GENERAL INFORMATION AND INSTRUCTIONS Revision : 0
GENERAL INFORMATION AND INSTRUCTIONS
1.0 Project Information
1.1 Location : Tarapur, Dist. Thane, Maharashtra, INDIA
1.2 Elevation : varies from +3 m to +8 m
1.3 Nearest railway station: BOISAR on Mumbai- Vadodara station of western

Railway and road journey from Boiser railway station to Tarapur site is 25
km.
1.4 Ambient air temperature:
a) Maximum dry bulb temp. - 40 O C – 60% With corresponding

humidity
b) Minimum dry bulb temp. - 8.7 OC – 74% with corresponding
humidity
c) Design temperature - 45 OC
2.0 General information and instructions to Tenderer
2.1 It is the intent of the purchaser to incorporate this specification in the

contract or purchase order for supply, material, equipment and services
and supervision of erection and commissioning. The Tenderer are required
to review these documents and clearly state in their proposals their
acceptance of the same. Exceptions and deviations, if any, shall be clearly
stipulated in the appropriate tendering schedule. The final contract
between the purchaser and the contractor shall be subject to such changes,
if any mutually agreed upon between the purchaser and the contractor and
included in the main text of the contract or purchase order. All
requirements as called for by this specification shall be included by the
tenderer and he shall quote accordingly. No extra price shall be payable on
account of tenderer not considering some requirements of this
specification.
2.2 Tenderer is requested to carefully examine and understand the

specifications and seek clarifications, if required, to ensure that they have
understood the specifications. Such clarifications should be sought atleast
30 days before the scheduled date of the opening of the bids. The bid
should not include any sections like clarifications, interpretations and/or
assumptions. If the tenderer feels that, in his opinion, certain features
SPECIFIC AT ION NO: PB-E-775 Ma rch . , 2008

brought out in his offer are superior to what has been specified, these may
be highlighted separately.
2.3 The tenderer shall be deemed to have carefully examined the specification
in its complete form. He is also deemed to have been fully informed and
satisfied himself as to the details, nature, character and qualities of the
work to be carried out, site conditions, seismic requirements, other
pertinent matters and details.
2.4 Any deviation or variation from the scope requirement and/or intent of this
specification shall be clearly mentioned under Schedule of Deviations
irrespective of the fact that such deviations/variations may be standard
practice or a possible interpretation of the specification by the Bidder.
Except for the deviations/variations, which are accepted by the Purchaser
in writing before the award of the contract or in Purchase Order, it will be
the responsibility of the Bidder to fully meet the intent and the
requirements of the specification within the quoted price. No other
departure from the specification except for the declared deviation
indicated by the Bidder in his offer and accepted by Purchaser shall only
be considered. The interpretation of the Purchaser in respect of the scope,
details and services to be performed by the Bidder shall be binding, unless
specifically clarified otherwise by the Purchaser in writing before the
award of contract.
2.5 If there is any discrepancy with regard to the quantity indicated in the
price schedules, bill of material given in the scope and tender drawings,
the bidder shall quote based on the quantity indicated in the price
schedule. The discrepancy shall be separately explained
2.6 As it is the intent of this tender that a complete operational and integrated
rectifier, transformer, bus duct, control panel at local and relevant inputs to
work station through PLC system (PLC, software & work station shall not
be part of this tender) etc shall be supplied, erected and commissioned,
under his supervision and handed over to purchaser by the successful
bidder, the bidders shall satisfy themselves that all items and quantities
required for complete and fully operational system have been quoted for in
the tender where the items and quantities are not covered in the tender
Section E the same shall be indicated as additional items required for
completing the scope of work and unit and total price in format of Section
E shall be quoted by the bidder.

2.7 Tenderer may please note that no claims will be entertained on account of
idle work force, labour, non-utilisation of machinery, stoppage of work,
unprecedented rains, storms or any other unforeseen circumstances.
2.8 The successful bidder is required to maintain a hindrance register in

approved format for reporting hindrances if any, while executing the work.
Such hindrances in the approved format shall be furnished to the
competent authority of NPCIL within 10 days of any hindrance.
2.9 The purchaser shall have full powers to make alterations, omissions from,
addition to, or substitutions for the original specifications, drawings,
designs and instructions that may appear to him to be necessary or
advisable during the progress of the work.
2.10 The successful bidder shall be bound to carryout the works in accordance
with any instructions given to him in writing signed by the purchaser and
such alterations omissions, additions or substitutions shall form part of the
contract as if originally provided there in.
2.11 Bidder shall furnish price-schedule as per the format and for the items
indicated in Section-E. Price schedule should have summary sheet giving
the total price for each module and grand-total for the package.
2.12 Information to be included with the tender
2.12.1 The tenderer shall furnish all the data called for in the schedules in the
standard pro-forma to facilitate correct evaluation of his tender in a most
expeditious manner. It is in the interest of the tenderer to submit the tender
in the above manner failing which it is likely that his tender may not be
considered.
2.12.2 The tenderer shall submit all supporting information, technical data,
catalogues, drawings as stipulate in this tender document. This is to enable
the purchaser to make a detailed comparison and evaluation of tenders,
without the need for further information from the tenderer. The tenderer
shall also submit all information and price schedules as called for in the
price-part of this tender document.
2.12.3 Tenderer shall furnish technical information as per the pro-forma given in
Section-D in a separate folder along with Part-I (Technical).The tenderer
shall furnish all the information called for in Section D
2.13 Data, documents & drawings

2.13.1 The data, documents and drawings to be submitted along with the offer
should be furnished by the tenderer in a separate folder.
2.13.2 The data, documents and drawings to be submitted after placement of

order have been listed in Section D.
2.13.3 Approval of the contractor's drawings and design documents by the

purchaser shall not relieve the contractor from his responsibility for any
error or omission therein or from any obligation or liability under the
contract.
2.13.4 The bidder has to indicate in Section-D the schedule for the submission of
drawings, QAP, manufacturing schedules etc. Considering the date on
which the Purchase Order/letter of intent is placed and commissioning
date as specified for individual items, the contractor has to furnish the
schedule to meet the commissioning date for purchaser’s approval.
2.14 Submission of Documents after Placement of Order/Letter of Intent
2.14.1 Bar Chart
Within two weeks from the date of Letter of Intent/Purchase order the
CONTRACTOR shall prepare and submit to the PURCHASER for his
approval Six (6) sets of his detailed bar chart giving details of
submission/approval of drawings, procurement of materials, manufacture,
assembly, inspection, testing, delivery, erection, etc.
2.14.2 Data, Documents and Drawings
a) The data, documents and drawings to be submitted along with the

tender documents have been listed in Section D.
b) The data, documents and drawings to be submitted after placement

of order along with corresponding schedules have been listed in
Section D.
c) In drawing preparation by Vendor, the device nomenclature as per

IEC shall be followed.
d) Supplier shall submit compliance certificate(s) for items supplied

for each item manufactured, tested, supplied and erected and
commissioned. This certificate is to be given by the vendor for all
items covered in the contract awarded the certificate shall be given

in two stages one when each module of work is completed and the
other when all work for the unit/entire contract is completed.
e) All approved DCR should form a part of end document and shall be
reflected in ‘As built drawings’.
2.14.3 Placement of order’s sub-orders by contractor
Contractor shall place all major orders on his vendors within one month of
placement of purchase order or letter of intent which ever is earlier.
2.14.4 Progress report

Four copies of monthly progress report in a format approved by the
purchaser shall be submitted in the first week of every month. It shall
indicate latest status on the progress achieved during the previous month
and the activity planned for the following month.
3.0 Scope of supply, work and services
3.1 Scope of this specification covers the engineering, manufacturing, supply,

inspection and testing, packing, delivery to site, storage at site, supervision
of erection, commissioning and handing over of the equipment under
supply as detailed in the subsequent section.
3.2 The supplier shall review and approve data, drawings, and O&M manuals
etc. of sub suppliers before submission to Purchaser. Providing
engineering data, drawings and O&M manuals for Purchaser’s review,
approval and records.
3.3 The preparation of ‘As Built’ drawings, cable Schedules, interconnection

cable Schedules, terminal lists and interconnection Schedules for
interconnection between equipment under supply
3.3.1 In the event of order all drawings shall also be submitted by the tenderer in
soft form in two sets on compact disc media.
3.3.2 The bidder to note that drawings enclosed with specifications are
indicative for Tender purpose only. Available Drawings for construction
would be made available to successful bidder.
3.4 Complete fabrication, manufacture and procurement from sub suppliers

and including shop testing of all equipment and material.

3.5 Packing, transportation from the manufacturer’s work to the site. For the
transport of over-dimensional consignment (ODC), it is the responsibility
of the contractor to obtain the clearance from various authorities.
3.6 The Contractor shall supply all information as required for the purchaser to
match with schedule requirement.
3.7 Supervision of Fabrication, pre-assembly (if any), erection, testing and

putting into satisfactory operation of all the equipment/material including
successful commissioning.
3.8 Satisfactory conclusion of the contract and handing over of the completed
and fully functional and operational systems.
3.9 Spare parts and special maintenance tools as required shall be supplied by
the contractor.
3.10 Whether called for specifically or not all accessories required for normal
operation of equipment are to be considered as a part of contractor’s scope
of supply.
3.11 It is not the intent to specify completely herein, all details of design and
construction of the equipment. However, the equipment shall conform in
all respects to high standards of Design, engineering and workmanship. It
shall be capable of performing in continuous commercial operation up to
the contractor’s guarantees in a manner acceptable to the purchaser, who
will interpret the meaning of drawings and specifications. The purchaser
shall be entitled to reject any work or material, which, in his judgement,
does not meet the specifications entirely.
3.12 The bidder shall fully apprise himself of the scope and content of the work,
equipment to be supplied erected and commissioned and other services
that may be required at site for completion of work at site by site visit
before bidding. The bidder shall obtain all necessary and additional
information for bidding and completion of scope of works during the site
visit. The bidder shall note that the availability of work front shall be given
progressively by purchaser and it is the intent that the successful bidder
takes up and plans work accordingly, following all precautions and safety
requirements.
3.13 The available drawings for the existing plant where required and as
available would be furnished to the successful bidder for detailed
engineering. In case of non-availability of drawings/details it shall be the

Contractor’s responsibility to get the information from available site

equipment and details.
3.14 It shall be noted by bidders that any joint in power & control cables is not
permitted and the conductors, cables which are short or inadequate in
length etc shall be provided with required length.
3.15 On award of P.O. Contractor shall furnish the schematics, general

arrangement drawings, cable schedules, interconnection schedules, panel
wiring diagrams etc for panels for Purchaser’s approval.
3.16 The Bidder shall submit erection and commissioning procedure and
drawings along with the bid.
3.17 Immediately on award of P.O. the Contractor shall submit a detailed

erection and commissioning procedure and drawings (six sets) to facilitate
the site activities. Among other details this procedure shall also contain
detailed requirement for handling, check list for assembly and erection,
special instructions, precautions erection drawings, log sheets etc.
3.18 The supplier shall review subcontractor’s drawings, documents, data and
manuals etc before submission to Purchaser. Providing engineering data,
drawings and O&M manuals for Purchaser’s review, approval and records.
4.0 Exclusions
4.1 As identified in Section CC-1.
5.0 Free issue of material
5.1 Nil.
6.0 Option for Placement of Order
6.1 The purchaser reserves the right to place order for complete operational
and integrated phase control rectifier thyristor based, transformer, DC
output bus duct, capacitor banks and control panel at local and work
station through PLC system (PLC, soft ware & work station shall not be
part of this tender) etc all of them or separately items.
7.0 Terminal points
7.1 The terminal points for this package shall be as listed in Section CC-1.

8.0 Drawings
8.1 Refer Section CC-10.
9.0 Applicable codes, standards and specifications
9.1 The design, material, construction, manufacture, inspection, testing,

erection, commissioning and performance of equipment supplied shall
comply with the latest editions of all currently applicable Indian standards,
statues, regulations and safety codes in the locality where the equipment
will be installed. Nothing in this specification shall be construed to relieve
the contractor of his responsibility.
9.2 In case of conflict between the standards, the most stringent specification
out of those standards shall govern.
9.3 In case, relevant Indian standards are not available, applicable IEC
standards shall be applied unless otherwise stated in specifications for
individual equipment
9.4 In case of any conflict between any standard and this tender document,
stipulations in this tender document shall govern.
9.5 Other inter-national standards are acceptable if they are established by the
contractor to be equal to or superior to the listed standards. In all such
cases, however, copies of English translation of such national standards
shall be attached to the tender. The tenders not complying with this
requirement are liable to be rejected.
9.6 Applicable standards for individual equipment are generally listed in

Section CC-2.
9.7 Bidder shall ensure that the Installation conforms and meets all the
stipulated requirements of:
i) Indian electricity rule

ii) National electrical code
iii) This specification
iv) Electricity Supply Act 1910 (as amended)
v) Indian Electricity Rules 1956 (as amended)

10.0 Specification of main equipment and accessories
Specifications for individual equipment please refer relevant sections.
11.0 Inspection and testing
11.1.1 The equipment covered by this Contract shall be subjected to inspection

and testing. The contractor shall provide all services to establish and
maintain quality of workmanship in his works and that of his sub-
contractors to ensure the mechanical and electrical performance of
components, compliance with drawings, identification and acceptability of
all materials, parts and equipment.
11.1.2 The contractor shall perform his internal inspection and testing before
offering the equipment for purchaser's inspection. Only after ensuring that
his inspection and test results are satisfactory, contractor shall offer the
equipment for purchaser's inspection. However, this clause is not
applicable in case of such tests which are required to be done only once in
the lifetime of the equipment.
11.1.3 The minimum inspection requirements for all components and equipment
shall conform to the design and fabrication requirements as defined in the
codes and standards referred to in this document. The type of inspection
shall be as given in quality control plan, which shall be, submitted to
purchaser for approval. It shall include, if applicable, inspection
procedures prescribed by codes and regulations recognised by the
governmental authority having jurisdiction over the installed goods.
11.1.4 Approval or passing of any such inspection by the purchaser or his

authorised representative shall not, however, prejudice the right of the
purchaser to reject the equipment if it does not comply with the
specification when erected or give complete satisfaction in service.
11.1.5 The contractor shall intimate to the purchaser of any material being ready
for testing. Such tests shall be to the contractor's account except for the
purchaser's expenses. The purchaser or his representative, unless the
inspection of the tests is waived, shall witness such tests on a mutually
agreed upon date.
11.1.6 The purchaser shall give notice in writing to the contractor of any
objection to any drawings and, all or any equipment and workmanship
which in his opinion is not in accordance with the 'Contract'. The
contractor shall give due consideration to such objections and shall either

make the modifications that may be necessary to meet the said objections
or shall confirm in writing to the purchaser giving reasons therein that no
modifications are necessary to comply with the 'Contract'. However,
purchaser has the final authority to accept or reject the contractor's views.
The equipment or material after rectification by the contractor shall be
offered to the purchaser for his final inspection and acceptance without
any additional cost to purchaser.
11.1.7 When the factory tests have been completed at the contractor's or his sub-
contractor's works to the satisfaction of the purchaser, the purchaser shall
issue a certificate to this effect within fifteen (15) days after completion of
tests. If the tests are not witnessed by purchaser's representative, the
certificate shall be issued within fifteen (15) days of the receipt of the
contractor's test certificate by the purchaser, provided the test results are
satisfactory and conform to the specified parameters. Failure of the
purchaser to issue such certificate shall not prevent the contractor from
proceeding with the subsequent work. The completion of these tests, or the
issue of the certificate shall not bind the purchaser to accept the equipment
should it, on further tests after erection, be found not to comply with the
'Contract'. It shall be ensured by the Contractor that all documentation,
drawing submission is complete atleast 3 months before the shipment of
equipment.
11.1.8 In all cases where the 'Contract' provides for tests whether at the premises
or at the works of the contractor or of any sub-contractor, the contractor,
except where otherwise specified shall provide free of charge such items
as labour, materials, electricity, fuel, water, stores, apparatus and
instruments as may be reasonably demanded by the purchaser or his
authorised representative to carry out effectively, such tests of the
equipment in accordance with the 'Contract' and shall give facilities to the
purchaser or to his authorised representative to carry out testing.
11.1.9 The inspection by the purchaser and issue of inspection certificate thereon
shall in no way limit the liabilities and responsibilities of the contractor in
respect of agreed quality assurance programme forming a part of the
'Contract'.
11.1.10 In the case of stage inspection, the contractor shall proceed from one stage
to another only after the component is inspected by the purchaser or his
representative and permission given to proceed further. The same
procedure shall be adopted for any rectifications and/or repairs suggested
by the purchaser or his representative. At all customer hold points the
contractor shall compulsorily offer for inspection to purchaser and,

waiver, if any, by purchaser, shall be obtained in writing for record

purposes.
11.1.11 None of the equipment to be furnished or used in connection with the

contract shall be despatched until shop inspection, satisfactory to the
purchaser or his representative has been made and specific despatch
instructions for the equipment are issued by the purchaser. However, such
shop inspection shall not relieve the contractor of his responsibility for
furnishing the equipment conforming to the requirement of the contract
nor prejudice any claim which the purchaser or his representative may
have because of the use of defective or unsatisfactory items of the
equipment. Should the purchaser or his representative waive the right to
inspect any item of the equipment, such waiver shall not relieve the
contractor in any way from his obligation under the Contract. In the event
of the purchaser on inspection revealing poor quality of goods, the
purchaser or his representative shall be at liberty to specify additional
inspection procedures, if required, to ascertain the contractor's compliance
with the equipment specifications.
11.1.12 All principal test certificates and test curves shall be supplied for all tests
carried out including other records such as non-destructive testing records
in accordance with the provisions of the contract. The purchaser or his
representative shall reserve the right to call for certificates of origin and
test certificates for all raw material and equipment at any stage of
manufacture.
11.1.13 Bidders shall only offer equipment, which are fully meeting the current
applicable standards, type testing and field proven. Relevant type test
certificates (not earlier than 2000) to demonstrate the compliance of
equipment proposed to the standards shall be submitted along with the
supply. If on review of the test certificates, either before the placement of
order or after the placement of the order, it is found that some of the type
of tests have not been carried out or tests have been carried out not in
accordance with the standards, charges for those type of tests shall not be
payable and the contractor shall carry out all such type of tests at his own
expense. The bidder shall consider the time required to carry out all type
of tests and indicate the delivery schedules. Non-availability of test
facilities for conducting any of the tests will not be accepted as a reason
for delay in delivery of equipment on schedule. However, bidder shall
indicate charges towards each type test separately in their price bid. The
unit prices quoted for each type test(s) will be considered, when type
test(s) is / are required to be repeated (at the option of the Purchaser)
irrespective of whether the type test(s) have been carried out or not..

11.2 Material tests
11.2.1 In event purchaser being supplied with particulars of tests which have
been carried out for the contractor by the suppliers of material, he may, at
his own discretion, accept the same as proper evidence of compliance with
the requirements of appropriate specifications for the materials.
11.2.2 In case the correlating test certificates are not available the contractor shall
at no extra cost to the purchaser will get all the tests done to establish
conformity of the material to relevant code and/or specification.
11.2.3 Physical and chemical tests for check-test shall be carried out at
laboratories approved by the purchaser.
11.3 Tests at manufacturer’s works
11.3.1 These are specified for each equipment in relevant sections.
12.0 Quality assurance and surveillance
12.1 Quality assurance
12.2 The complete operational and integrated phase control rectifier thyristor
based, cast resign dry type transformer, DC bus duct and local control
panel at local and all input to remote work station through PLC system etc
(PLC, soft ware & work station shall not be part of this tender) which
requires conformance to international and national standards/codes for
assured quality and reliability. In line with these requirements the
contractor shall have documented quality assurance programme to assure
quality at all stages, i.e. design, engineering, procurement, manufacture,
handling, shipment, installation, erection and commissioning.
12.3 The quality assurance programme of the contractor shall be in consonance

with the quality assurance programme of purchasers. Therefore the
contractor’s quality system shall as a minimum address the following:
a) Organisation structure and interfaces between various agencies.

b) Functions and responsibilities of the contractor.
c) Requirements on qualifications and training of personnel in each
area of activity, viz. design, engineering, procurement,
manufacturing, inspection and testing and Quality Assurance
d) Control of design.

e) Control of procurement and manufacturing.

f) Inspection and test control.
g) Calibration and control of measuring, examination and testing
equipment.
h) Manufacturing environment, equipment and special process
control.
i) Handling shipping and storage control.
j) Non-conformance control.
k) Corrective actions.
l) Quality assurance records.
m) Document control, their storage and retrieval.
n) Internal audits.
The QA programme shall be subject to acceptance by purchasers and

changes as necessary to bring it in line with purchasers. QA programme
shall be made by the contractor.
12.4 Purchasers reserve the rights to carryout audit in all phases of the work,
i.e. design, engineering, procurement, manufacturing, installation, erection
and commissioning.
12.5 All work covered by this package shall be subject to quality surveillance
(QS) by purchaser or his authorised representative. All required assistance
to carryout QS shall be rendered by contractor. They are to be allowed free
access to all areas at all reasonable times where works involving the
concerned contract are in progress. This includes access necessary to
verify the implementation of all aspects of the quality assurance
programme as well as access to sub-contractor’s facilities.
12.6 Quality surveillance by the purchaser or his authorised representative

includes, but is not limited to verification, witness and hold points. These
points are identified in quality assurance plan (QAPs) enclosed. Additional
witness and hold points can be established by purchaser if manufacturing
or related activities or inspection test results warrant so.
12.7 Witness points are critical steps in manufacturing, inspection and testing
where the contractor is obliged to notify in sufficient advance of the start
of operation/test so that it may be witnessed by purchaser’s quality
surveillance group. Contractor will intimate in advance their
manufacturing schedule to purchasers for planning the coverage of witness
point.

12.8 The contractor may proceed with the work past a witness point if the
purchaser’s representative is not available at the appointed time.
12.9 Hold points are critical steps in manufacturing, inspection and testing
where the contractor is obliged to notify purchaser’s quality surveillance
group in sufficient advance of the start of operation test. Final release prior
shipment is a mandatory hold point. The contractor is not to proceed with
the work past a hold point except by a witness waiver agreement with the
purchaser.
12.10 The performance of waiver of QA activities by the purchaser or his

authorised representative at any stage of manufacturing does not relieve
the contractor of any obligation to perform in accordance with and meet
all the requirements of the procurement documents and also all the codes
& reference documents mentioned in the procurement document nor shall
it preclude subsequent rejection by the purchaser.
12.11 On completion of manufacture the items can be dispatched only after issue
of shipping release by quality surveyor or authorised representative of
Purchaser.
12.12 On award of the Contract, the CONTRACTOR shall prepare detailed

quality/test procedure as per enclosed quality plan identifying the various
stages of manufacture, quality checks performed at each stage and the
Customer hold points. The document shall also furnish details of method
of checking, inspection and acceptance standards/values and get the
approval of PURCHASER or his representative before proceeding with
manufacturing. However, PURCHASER or his representative shall have
the right to review the inspection reports, quality checks and results of
CONTRACTOR’s in-house inspection department which are not
Customer hold points and the CONTRACTOR shall comply with the
remarks made by PURCHASER or his representative on such reviews
with regards to further testing, rectification or rejection etc.
12.13 The contractor shall submit a detailed quality assurance manual to ensure
that the equipment and services under this contract, are in accordance with
the specified requirements.
The quality assurance manual shall provide-
a) Organisation chart of quality assurance department.
b) Qualification and experience details of the personnel of quality

assurance department.

c) In-house quality control plan.
d) Procedures and standards adopted for designing, manufacturing,

inspection and testing.
e) Facilities available for inspection and testing including NDT.
f) Quality check-points indicating the customer hold points normally

adopted by him for such check-points starting from raw material.
Procurement till final tests to be conducted and accepted at shop
and site.
g) Mock-up test procedures.
h) Defect rectification or deviation acceptance procedure with regard

to approval by design department, by purchaser, by quality
assurance department and by collaborators including the
information flow scheme up to erection and commissioning
department wherever applicable.
i) On line statistical quality control methods adopted to prevent

defects in mass produced items (such as coils and other breaker
components).
12.14 The PURCHASER and or his duly authorized representative shall have at
all reasonable times access to the CONTRACTOR’s premises or works
and shall have the power, at all reasonable times to inspect and examine
the materials and workmanship during manufacture and if part of the
equipment is being manufactured or assembled on other premises or
works, the CONTRACTOR shall obtain for the PURCHASER and or his
duly authorized representative, necessary permission or assembled on the
CONTRACTOR’s own premises or works.
12.15 The PURCHASER or his representative shall have the right to inspect any
machinery, material, structures, equipment or workmanship furnished or
used by the CONTRACTOR and may reject any which is defective or
unsuitable for the use and purpose intended, or which is not in accordance
with the intent of the contract. The CONTRACTOR, upon demand by the
PURCHASER or his representative, shall remedy or replace at the
CONTRACTOR’s expense such defective or unsuitable items of the plant,
or the PURCHASER may, at the expense of the CONTRACTOR, remedy
or replace such defective or unsuitable items of the plant.

12.16 The PURCHASER or his representative shall at all working hours have
access to all parts of the CONTRACTOR’s and his SUB-
CONTRACTOR’s factory where the items of the plant are being prepared
and shall be provided with all reasonable inspection facilities by the
CONTRACTOR. The inspection facilities shall include all necessary
tools, instruments, equipment and qualified operators to facilitate
inspection. A set of latest prints of the relevant approved drawings shall
be made available by the CONTRACTOR to the PURCHASER or his
representative for reference during inspection.
12.17 For the purpose of this clause, inter-work-orders are to be treated as sub-
orders. It is obligatory on the CONTRACTOR that he advises his SUB-
CONTRACTOR of the pertinent clauses in this specification when
ordering bought out equipment or materials. In particular, the
CONTRACTOR is to advise each SUB-CONTRACTOR that he is
required to supply design calculations, drawings, inspection reports and
test certificates strictly in accordance with this specification and technical
information for inclusion in the Instruction Manual as specified in Section-
C. The CONTRACTOR shall make available test report on incoming
material inspection, for verification by PURCHASER’s representative.
12.18 The purchaser and/or his duly authorised representative shall have at all
reasonable times access to the contractor's premises or works and shall
have the power, at all reasonable times to inspect and examine the
materials and workmanship during manufacture and if part of the
equipment is being manufactured or assembled on other premises or
works, the contractor shall obtain for the purchaser and/or his duly
authorised representative, necessary permission to inspect as if the
equipment were manufactured or assembled on the contractor's own
premises or works.
12.19 The purchaser or his representative shall have the right to inspect any
machinery, material, structures, equipment or workmanship furnished or
used by the contractor and may reject any which is defective or unsuitable
for the use and purpose intended, or which is not in accordance with the
intent of the contract. The contractor, upon demand by the purchaser or his
representative, shall remedy or replace at the contractor's expense such
defective or unsuitable items of the plant, or the purchaser may, at the
expense of the contractor, remedy or replace such defective or unsuitable
items of the plant.
12.20 The purchaser or his representative shall at all working hours have access
to all parts of the contractor's and his sub-contractor's factory where the

items of the plant are being prepared, and shall be provided with all
reasonable inspection facilities by the contractor. The inspection facilities
shall include all necessary tools, instruments, equipment and qualified
operators to facilitate inspection. A set of latest prints of the relevant
approved drawings shall be made available by the contractor to the
purchaser or his representative for reference during inspection.
12.21 For the purpose of this clause, inter-works orders are to be treated as sub-
orders. It is obligatory on the contractor that he advises his sub-contractor
of the pertinent clauses in this specification when ordering bought-out
equipment or materials. In particular, the contractor is to advise each sub-
contractor that he is required to supply design calculations, drawings,
inspection reports and test certificates strictly in accordance with this
specification and technical information for inclusion in the instruction
manual.
12.22 The contractor will offer test reports on incoming material inspection, for
verification by purchaser's representative.
12.23 The contractor is to provide test pieces as required by the purchaser's

representative to enable him to determine the quality of material supplied
under this contract. If any test piece fails to comply with the requirements,
the purchaser's representative may reject the whole material represented
by the test piece. The purchaser or his representative shall have the right to
select particular test piece of his choice from the lot in case of sample
testing. In case the results are found to be not satisfactory the purchaser's
representative shall have the right to test more number of pieces or each
piece additionally from the lot for testing or reject whole lot. Contractor
should have QAPs for cleaning, painting, packing, identification and
documentation for which QA will be carried out by his internal
department.
12.24 The representative of prime contractor authorised to witness inspection

and testing at his or at his sub-contractor’s works should the required
experience and knowledge of activities being inspected. He should be an
employee of the prime contractor and inspector shall be subject to
purchaser’s approval. In exceptional cases where such experienced person
is not available and the contractor wishes to employ an external agency,
the same should be subject to purchaser’s approval.
12.25 All test reports, certificates and inspection reports shall be reviewed by the
prime contractor or sub-contractor before submitting the same for
verification by the purchaser.

12.26 History dockets and the end-documentation prepared by the prime

contractor or sub-contractor shall be submitted to the purchaser’s QA
department for verification of its completeness before final submission.
12.27 QA plan for each equipment is indicated in relevant Sections. Stage

inspections have to be carried out either by prime contractor’s internal QA
department for the items manufactured by him or by the prime contractor
at his sub-contractor’s works. Where the inspection has to be carried out
by the purchaser also it has to be necessarily carried out jointly by the
prime contractor’s internal QA department and the purchaser’s
representative. Appropriate agencies for the purpose of stage inspection
are given in the various QAPs.
12.28 Based on the QAPs included in the tender documents, the contractor shall
prepare a detailed QAP covering all activities and submit the same for the
approval of purchaser.
12.29 Calibrated instruments shall be used during inspection, examination and

testing.
12.30 Quality control, inspection, testing, witnessing testing at sub-contractor’s

works/site during manufacture, installation and commissioning is totally
under the scope of the contractor as detailed in the QAPs. Purchaser’s QA
personnel will be verifying and auditing the QA reports duly reviewed and
submitted by the contractor as per the QAPs and shall also witness the
tests at some important, critical and hold points as per the QAPs.
13.0 Guarantees
13.1 The contractor shall guarantee that material and workmanship of all
components and operation of the equipment shall meet the requirements of
the specification for a period of twelve (12) months from the date of
commissioning whichever is earlier.
13.2 The items of performance as stated in "Schedule of performance

guarantee" in Section-D, shall be guaranteed either under penalty or under
rejection. The tolerance limits applicable, if any shall be in accordance
with the standards to which the equipment offered by the contractor
conforms and the tolerance limits shall be clearly indicated in the tender.

13.3 Should the performance results deviate from the guaranteed values
including the specified tolerances, if any, the contractor shall correct his
equipment at no extra cost to the purchaser.
13.4 With respect to the goods covered in the specifications the contractor shall
provide to the purchaser following guarantees:
13.4.1 Title-
The contractor warrants that the goods are not subject to any security
interest, lien or other encumbrance.
13.4.2 Against patent infringements-
Except when the purchaser furnishes design specifications to the

contractor, the contractor shall at his own expense, defend and save the
purchaser harmless from the expenses and consequences of any suit or
procedure brought against the purchaser, so far as said suit or procedure is
based on a claim that the goods furnished constitute an infringement of
any patent in existence on the date of the order. In addition, the contractor
shall secure at his own expense a fully paid up licence or licences that will
permit the purchaser to continue use of the goods furnished free of further
claim for infringement.
13.4.3 Performance-
a) The contractor shall guarantee that the goods furnished by him are
new and of high quality in full accordance with the requirements of
this tender specifications.
b) Irrespective of what is specified in other sections the contractor

guarantees that the equipment offered are guaranteed for
satisfactory performance for a period of 12 months from the date of
commissioning.
13.4.4 Quality-
If within the expiry of the above stipulated guarantee period, the subject
goods or any parts thereof are found defective because of design,
workmanship or materials, the contractor at his own expense, repair or
furnish and install replacement parts of design, workmanship and material
approved by the purchaser. The guarantee period for replaced parts or
repair work shall be the same as above.

13.4.5 The guarantee period shall be extended by the length of time required to
make any adjustments, changes or repairs necessary to fulfil the guarantee.
13.4.6 The contractor shall obtain similar guarantees from each one of his sub-
contractors. However, the overall responsibility shall lie with the
contractor.
14.0 Delivery
14.1 All equipment viz. rectifier of forced air cooled thyristor, transformer, DC
bus duct, capacitor banks, control at local and work station through PLC
system etc shall be supplied on safe delivery to site as per the schedule
indicated below from the date of issue of letter/fax of intent or purchase
order which ever is earlier.
UNITS Delivery Period
Rectifier banks -1 : 8 months from placement of PO

15.0 Tender evaluation
15.1 Tenders will be evaluated for transformers losses ( the copper losses shall
be adjusted to 750C as per IS)as per the loading formula given in Section
CC-7.
15.2 All tests as called for in section CC-5, Inspection and Testing shall be
carried out as a part of scope of supply of equipment under this package
and charges included in the lumpsum supply price in section-E. All
bidders shall indicate a list of all types of tests, for which acceptable test
certificates (based on test conducted earlier for identical equipment) are
not available. Those tests for which test certificates are not available shall
be conducted without extra cost to the PURCHASER.
16.0 Tests at site

16.1 The tests to be carried out on site on various systems shall be furnished by
the Contractor for approval by Purchaser. These tests shall form a
comprehensive commissioning check list as it shall be the
CONTRACTOR'S responsibility to draw up and supervise (if required by
Purchaser) such a program covering all required tests.
16.2 The contractor shall be responsible to provide all necessary testing and
commissioning personnel and if required by Purchaser the tools and plant,
test equipment, etc. at no extra cost to the purchaser.
17.0 Commissioning and taking over
17.1 Commissioning stage extends from the moment of installation completed

and the end of successful completion of 'commissioning tests,
performance tests & operational tests as applicable’ and includes 'trial
operation' at site. During this stage, the system and equipment will be in
the charge of the commissioning group of the purchaser. Commissioning
of each equipment and/or system by the contractor will be carried out
under the overall supervision of the purchaser's commissioning group
strictly in accordance with the manufacturer's written instructions. The
contractor's commissioning engineer shall satisfy himself regarding proper
completion of equipment erection, pre-commissioning, electrical testing,
instrument testing and calibration. He shall satisfy himself regarding
operating tests and settings for various devices and also direct minor
repairs, which may have to be carried out in the field. All data collected by
him during commissioning shall be handed over to the purchaser's
commissioning team. The purchaser’s staff will carry out routine operation
during this stage. However, any repair, modification, adjustment, etc. will
have to be carried out by the contractor’s personnel.
17.2 Pre-commissioning checks, inspections, tests at site
17.2.1 Upon satisfactory completion of erection, in the presence of purchaser's

representative, the contractor(if required by the Purchaser) shall supervise
carrying out the pre-commissioning checks, inspections, tests and
adjustments required to put the equipment into satisfactory, reliable and
unrestricted commercial use.
17.3 Commissioning and load testing
17.3.1 After Pre-commissioning checks, inspections, tests of equipment is ready

for commissioning and full load test, it would be on trial operation during

which period all necessary adjustments shall be made while operating in

the full/partial load range under advice from Contractor as required by
Purchaser.
17.4 Operational guarantee
The operation and maintenance of the plant and equipment during the
guarantee period, as stipulated in the specification after takeover under
guarantee, will be carried out by the purchaser's operation and
‘maintenance staff’ in accordance with the manufacturer's operation and
maintenance instruction manuals and specific instructions laid down by
the contractor's or manufacturer's commissioning engineer or specified by
him from time to time. The contractor shall be responsible for remedying
design, material, fabrication and construction defects. The contractor's
supervision engineers shall also train the purchaser's personnel, act as a
liaison between the purchaser and the contractor and assist the purchaser
in ordering and obtaining spare parts, and supervising repair work during
guarantee period.
18.0 Spares
18.1
18.2
18.3 The TENDERER shall include in his scope of supply, all the
recommended spares, as described below. The PURCHASER reserves the
right to finalise the exact quantities of the spare parts the unit rates quoted
by the TENDERER. The spares, ordered by the PURCHASER, shall be
delivered at site along with the main equipment/plant.
18.4 The recommended spares parts shall be for a period of five (5) years for
satisfactory operation of equipment/system.
18.5 Recommended spares are those spares which the 'TENDERER' considers
necessary for five (5) years of normal plant operation, and which are in
addition to the Essential Spares specified by the PURCHASER. The
TENDERER shall indicate in the schedule of recommended spare Parts,
his recommended list of spares. Their unit prices shall be indicated in the
schedule of prices. The PURCHASER reserves the right to buy any or all
of the Recommended Spare Parts. The total price of Recommended Spares
will not be considered, while evaluating the tender.

18.6 The TENDERER shall take into consideration the shelf life of spares
offered when deciding on the list and quantity of spares. The
TENDERER shall also indicate the service expectancy period for the spare
parts under normal operating conditions before replacement will be
necessary. All spare parts shall be despatched along with the main
equipment concerned.
18.7 All spares supplied under this Contract shall be strictly interchangeable
with the parts for which they are intended to be replacements. The spares
shall be treated and packed for long storage under climatic conditions
prevailing at the site, e.g. small items shall be packed in sealed transparent
plastic bags with desiccator’s packs as necessary.
18.8 Each spare shall be clearly marked or labelled on the outside of its packing
with its description and purpose. When more than one spare part is packed
in a single case, a general description of the contents shall be shown on the
outside of such case and the detailed list enclosed. All cases, containers
and other packages must be suitably marked and numbered for the
purposes of identification. A spare parts list with identification tag nos. for
each spare part shall be furnished by CONTRACTOR for PURCHASER'S
use.
18.9 All cases, containers or other packages are liable to be opened for such
examination as the PURCHASER may reasonably require.
18.10 The CONTRACTOR shall guarantee the PURCHASER that before going
out of production of spare parts, for the equipment furnished, he shall give
at least 12 months advance notice to the PURCHASER, so that the latter
may order his requirement of spares in one lot, if he so desires.
18.11 All spare items shall undergo the same extent of inspection and testing as
of the original component.
19.0 Special tools and tackles for erection and maintenance
Special tools and tackles shall be provided in the scope of supply.
20.0 Rating and name-plates
Rating and nameplate details shall be as given in the specification.
20.1 Each main and auxiliary item of plant shall have permanently attached to
it a rating plate in a conspicuous position. This shall be of anodised

aluminium to stand the prevalent atmospheric conditions as indicated. The

inscription shall be engraved in black on the plate.
20.2 The size of the rating plate shall depend upon space availability but
should be reasonably sized for clarity and clear inscription. The size of
the plates and inscriptions shall be approved by the PURCHASER. The
plates shall be attached to the body of the equipment by screws.
20.3 Such name plates shall be of corrosion-proof material preferably

anodised aluminium having engraved black lettering.
20.4 In case of indoor equipment like circuit breakers, panels, starters etc., the
plate shall be of multilayered laminated plastic material with black
lettering engraved onto a white background. The name plates shall be
screwed to the body of the equipment.
20.5 Each item of plant shall be provided with nameplate and label designating
the service of that particular equipment. The shape size content of this
nameplate shall be submitted by the bidder for approval by purchaser and
only such nameplates as are duly approved by purchaser shall be used.
The contents of this name plate shall be in line with that specified in
relevant IS and shall include as a minimum
a) Manufacturer’s name
b) Type designation
c) Voltage and current rating
d) Frequency
e) Short time rating
f) Degree of protection
g) Country of manufacture
h) Year of manufacture
i) Applicable IS/IEC
21.0 Training of purchaser’s personnel
21.1 The CONTRACTOR shall train the PURCHASER'S operation and

maintenance personnel at site so as to make them proficient in operating
the equipment.
21.2 The PURCHASER'S personnel shall also be trained for routine

maintenance work, adjustments and testing and replacement procedures to
be adopted for the equipment offered.

21.3 The CONTRACTOR shall train the PURCHASER's personnel in

carrying out minor repairs, if need arises, during the operation of the
equipment.
21.4 The CONTRACTOR shall train two engineers the CONTRACTOR's

works so that personnel become adequately acquainted with the design
and proficient in carrying out routine maintenance, overhauls, repairs and
operation.
21.5 The CONTRACTOR shall provide all necessary instruction material for
the training, which shall include manuals, booklets, pamphlets, drawings,
sketches, models, pictures, photos, colour slides, film etc. The training
and instruction material shall become the property of the PURCHASER.
21.6 The charges for training the PURCHASER's personnel and the cost of
training material, if any, shall be indicated by the TENDERER in his
offer SEPERATELY.
21.7 The CONTRACTOR shall provide at no extra cost to the PURCHASER

all necessary facilities and reasonable assistance as deemed necessary for
the training. The travelling and living expenses of such personnel shall
be borne by the PURCHASE
22.0 PAINTING
Class of phosphating shall be class ‘A’ (heavy weight) as per IS 6005,

Code for procedure for phosphating of iron & steel.
22.1 Painting on Steel
22.2 All steel work requiring to be painted shall be phosphated first in

accordance with the following procedure and in accordance with relevant
standards for phosphating iron and steel.
22.3 Each coat of primer and finishing paint shall be of a slightly different
shade to enable inspection of the painting.
22.4 The final finished thickness of paint film on steel shall not be less than 75
microns, and shall not be more than 100 microns.
22.5 Instead of stages specified against above preferably powder coating may
be provided with 45-55 micron thickness measure by Elco meter.

22.6 Pre-treatment /Surface Preparation
22.6.1 All the surfaces of steelwork to be painted shall be thoroughly cleaned of

all loose mill scale, rust, grease, dirt and other foreign matter as per seven
tank process. The workmanship shall generally conform to the
requirements of IS: 1477-Part-I.
22.6.2 Oil and grease removal shall be carried out either by solvent cleaning or
by using alkali type degreasing agents. To remove grease material the
surface shall be cleaned with solvents containing emulsifier. After
cleaning, the surface shall be washed with water. When the surface has
cement pelts or salts, the cleaning shall be done with strong alkali. After
cleaning, water rinsing and subsequent passivation by dilute chromic acid
rinsing shall be carried out to ensure that no traces of alkali are left on the
surface. The procedure for cleaning by above-mentioned methods shall be
as per manufacturer instructions.
22.6.3 De-rusting and de-scaling of steel shall be carried out either chemically.
22.6.4 Loose mill scale, loose rust and loose paint shall be removed by wire
brushing, scrapping, chipping and rubbing with abrasive paper or steel
wool. This method shall not be employed when the surface has firmly
adhering mill scale. After hand tool cleaning, the surface shall be rubbed
with sand paper so as to ensure that no loose material exists and the
surfaces shall be dusted off.
22.6.5 Sand Blasting and Shot Blasting shall be resorted to only after removal of
grease, oil and other contaminants. The work shall be carried out by
impinging under pressure of air, a jet of sharp sand or granulated steel
(steel grits) on to the metal surface. The process shall ensure complete
removal of rust and firmly adhering mill scale. Special care shall be taken
on weld areas to remove flux and spatter. Blasting shall ensure an even
colour of the surface and the surface shall have silver gray colour.
Precautions shall be taken when sand or shot blasting of light gauge steel
surfaces to ensure that buckling does not occur due to continuous
impingement of sand or steel shots under high velocity. Sand/shot
blasting shall be adopted for all structures, which are rusted, or on loose
mill scales. As sand blasting causes dust nuisance necessary clearance
shall be obtained by the CONTRACTOR from competent authorities prior
to commencing sand blasting.
22.6.6 Power Tool Cleaning shall be carried out by employing power operated
wire brushes, power tool cleaning shall be resorted to only if sand/shot

blasting is not possible / permissible. The surface prior to such cleaning

shall be cleaned of dust, grease, etc. and heavier layers of rust shall be
removed by chipping. The power tool cleaning shall remove loose mill
scale and rust by adopting very thorough scraping, grinding and machine
brushing. After the surfaces are cleaned by compressed air, it shall have a
pronounced metallic sheen.
22.6.7 Chemical cleaning (pickling) shall be done by pickling in sulphuric,

hydrochloric or phosphoric acids. Pickling shall be carried out in
accordance with detailed procedure as given in IS:6005. Washing after
pickling shall remove all traces of the acids. All work pieces shall be
thoroughly inspected and in particular the inaccessible corners.
22.7 MATERIAL
22.7.1 Primer Paint
22.7.1.1 Anti-corrosive primers shall be either lead based or lead free types. Red
lead primer shall conform to IS:102 and red oxide zinc chrome primer
shall conform to IS:2074. Other primers for epoxy painting as specified
shall be used
22.8. Finish Paint
22.8.1 Synthetic enamel painting for undercoat and finish coat shall conform to
IS: 2932/IS: 2933.
22.8.2 The paints shall be mixed and applied in accordance with the
manufacturers instructions. The final finish paint should give a dry film
thickness as specified.
22.8.3 No painting shall be done in frosty/foggy weather or when the humidity is

high enough to cause condensation on the surface to be painted. Paint
shall not be applied when the temperature of the surface to be painted is at
5°C or lower.
22.8.4 Primers shall adhere to the surface firmly and offer a key to the
subsequent coats
22.8.5 The application of paint film shall serve the twin purpose of protecting the
steel from corrosion and giving the decorative appearance. A paint which
gives the steel adequate protection over a long period together with good
appearance shall therefore be adopted.

22.8.6 Workmanship shall generally conform to requirements specified in

IS:1477-Part II.
22.8.7 It is essential to ensure that immediately after preparation of the surface;

the first coat of prime paint shall be applied by brushing and working it
well to ensure a continuous film without "holidays". After the first coat
becomes hard dry a second coat f primer shall be applied by brushing to
obtain a film free from holidays.
22.8.8 Structural steel surfaces shall be given the first coat of primer at shop and
the second coat after it is erected in position. Further, any abraised
surfaces of the first coat during transport from shop to site and during
erection shall be provided with a touch-up coat of the primer.
22.8.9 The dry film thickness of each coat of primer shall be not less than 25
microns.
22.8.10 Application of finishing paints shall be carried out within the shortest
possible time interval after primer since the primer coats are too thin to
give adequate corrosion protection to the steel surface over a long
duration.
22.8.11 Painting shall be carried out either by brushing or by spraying.

CONTRACTOR shall procure the appropriate quality of paint for this
purpose as recommended by the manufacturer.
22.8.12 After the second coat of primer is hard dry. The undercoat of paint of
optimum thickness shall be applied by brushing/ spraying with minimum
of brush marks.
22.8.13 The first finishing coat of paint shall be applied by brushing or by

spraying and allowed to hard-dry. The gloss from the entire surface shall
then be gently removed and the surface dusted off. The second finishing
coat shall then be applied by brushing by spraying
22.8.14 At least 24 hours shall elapse between the applications of successive coats.
Each coat shall vary slightly in shade and this shall be got approved by the
PURCHASER.
22.8.15 Minimum dry film thickness of each coat of finish paint of synthetic
enamel shall be 25 microns. Minimum dry film thicknesses of other finish
paints shall be as specified in the respective item of work.

22.8.16 The thickness of film shall be measured by an Elco-meter to be supplied

by the CONTRACTOR. The CONTRACTOR shall calibrate the Elco-
meter frequently for different settings. Necessary calibrating accessories
should be kept ready for calibration/testing of Elco-meter at any time.
22.8.17 Epoxy primer and epoxy paint, synthetic enamel paint and primers shall be
applied within the specified pot life all as per recommendations of the
manufacturer.
22.8.18 Surfaces inaccessible after assembly shall receive two coats of primer
prior to assembly.
22.8.19 Surfaces inaccessible after erection, including top surfaces of floor beams
supporting grating or chequered plate shall receive one additional coat of
finish paint over and above the number of coats specified prior to erection.
22.8.20 Portion of steel members embedded/to be encased in concrete shall not be

painted. Joints to be site welded shall have no shop paint for at lest 50
mm from the welding zone. Similarly, the steel surfaces shall not be
painted in areas where connection is by use of friction grip bolts. On
completion of the joint, the surfaces shall receive the painting as specified.
22.8.21 Maintenance painting of steel structures will become necessary if the

painting already carried out shows signs of chalking, hairline cracking,
deep checking, fine checking, peeling, blistering and rusting. The
breakdown of a paint film is progressive from the top finish paint to the
primer coat and the object of maintenance painting is to renovate
periodically to effectively check the breakdown and protect the steel
surfaces from corrosion. It is essential that same quality of paint as
specified earlier need be adopted to ensure compatibility. The general
workmanship for maintenance painting shall conform as per Clause 7 of
IS:1477-Part-II.
22.8.22 CONTRACTOR shall provide suitable protection as necessary to prevent

paint finishes from splashing on equipment, floors, walls, etc.
23.0 Packing and marking
23.1 The responsibility for properly packing the equipment shall be that of the
CONTRACTOR. The requirements of packing and marking of equipment
are as follows:

23.2 Packing
23.2.1 The equipment, all its accessories and other associated plant equipment
shall be packed and shipped in separate and convenient sections. All
withdrawable equipment shall be packed and shipped separately. All
relays and instruments and modules shall be packed and shipped
separately with their operating mechanisms temporarily arrested from
movement, for transport purposes.
23.2.2 All Equipment/material shall be protected for inland transport, carriage at

Site and outdoor storage during transit and at the Site, strictly according to
the instructions given in this Specification.
23.2.3 The CONTRACTOR shall pack the Equipment at his own cost sufficiently
and properly to ensure that they are free from loss or damage while in
transit to the ultimate destination.
23.2.4 It is likely that the equipment may have to be stored at site for some time
before erection and commissioning. The packing shall be suitable for
storing the equipment for at least six months. CONTRACTOR shall give
procedure for storage and monitoring at site.
23.2.5 Only packages constructed out of sound material and of dimensions

proportional to the size and weight of contents shall be used. Each
package shall be limited to the size and weight that are permissible under
existing rail/road transport limitations as the case may be.
23.2.6 Bundled materials shall be strapped rigidly with steel band over the
protective covering.
23.2.7 Fragile materials shall be securely braced within the containers or

otherwise amply fastened and packed to prevent shifting or rattling. Soft
non-hygroscopic packing materials shall be placed between the hard
packing materials and the fragile Equipment. Articles which do not
completely fill the selected container must be cushioned, braced, fastened
or blocked to prevent damage to the article itself or destruction of the
container. Inner bracing or blocking must be such that the content's weight
is distributed uniformly over the entire interior surfaces rather than
concentrated on one or two critical points.
23.2.8 Loose material, e.g. bolts, nuts, etc. shall be packed in gunny bags sealed
in polythene bags with proper tagging.

23.2.9 Components containing glass shall be carefully covered with shock

absorbing protective material such as expanded polysterene (Thermocole).
23.2.10 All flanges and similar surfaces which are prone to scratching shall be
provided with either metal or wooden caps bolted in place. Metal caps
should have a minimum thickness of 3 mm and wooden caps should be
made from two layers of wood, each of 10 mm thickness, nailed together
with the grain of each layer located at right angles to the other.
23.2.11 All openings in the Equipment shall be tightly covered, plugged or capped
to prevent foreign material from entering.
23.2.12 In the case of large and bulky Equipment, the CONTRACTOR shall be
responsible for ascertaining transport limitations and supply the
Equipment in the minimum number of components or sub-assemblies,
within the frame work of transport limitations.
23.2.13 Wherever necessary, proper arrangement for attaching slings for lifting
shall be provided.
23.2.14 The contents of the packages shall be sealed in thick polythene sheets and
all the inside walls of the packages shall be lined with water proof paper to
protect the Equipment from damage due to dust and moisture. Adequate
precaution shall be taken to protect all insulating materials used in the
equipment during shipment to ensure that they remain in a totally dry
environment.
23.2.15 All Equipment shall be protected for the entire period of despatch, long
time storage and erection, against corrosion, incidental damage due to
vermin, sunlight, rain, high temperature, humid saline atmosphere, rough
handling in transit, and storage in the open including possible delays in
transit. Material and Equipment shipped across the sea shall be packed to
withstand without damage, the effects of salt spray. All machined and
plated parts shall be protected with anti-rust grease. Precautions shall be
taken to protect shafts. and journals where they rest on wooden or other
supports likely to contain moisture. At such points, wrappings
impregnated with antirust composition or vapour phase inhibitors shall be
used. These shall have sufficient strength to resist chafing and indentation
due to the movement, which is likely to occur in transit. The protective
wrappings and impregnation shall last for a minimum period of one year.
23.2.16 Instrument connections shall be plugged with suitable caps to avoid

ingress of dust and moisture during shipment and storage. Silica gel or

approved equivalent moisture absorbing material in small cotton bags

shall be placed and tied at various points on the Equipment, in package
wherever necessary.
23.2.17 Adequate provision of skids or pallets shall be made to keep the packages
above the collecting drainage. Crates and other large containers should
have drain holes in the bottom to prevent collection of water within the
packing. This is especially important where the cargo itself is subject to
condensation (cargo sweat).
23.2.18 All cases, where applicable, shall be provided with suitable cutouts, closed
by bolted wooden planks to facilitate inspection by customs authorities.
Waterproof transparent papers shall be provided at the cutout locations to
prevent water ingress into the casing through the cutout.
23.2.19 Each crate or package shall contain a packing list in a water proof
envelope. Copies of the packing list, in triplicate, shall be forwarded to the
PURCHASER prior to despatch. All items of materials shall be clearly
marked for easy identification against the packing list.
23.2.20 All spare parts shall be packed and treated for long storage conditions at
Site.
23.2.21 The PURCHASER may require to inspect and approve the packing before
the items are despatched. However the CONTRACTOR shall be entirely
responsible for ensuring that the packing is suitable for the mode of
shipment and such inspection will not exonerate the CONTRACTOR from
any loss or damage due to faulty packing.
23.2.22 All packing cover and packing material shall become the property of the
PURCHASER.
23.3 MARKING
23.3.1 All packages shall be clearly, legibly and durably marked with uniform
block letters (preferably with water proof paint) on atleast three sides with:
a) Destination address as communicated
b) Contract No. and Date
c) Dimensions

d) Net and gross weights
e) Sign showing 'side up'
f) Sign showing 'fragile' marks in case of delicate Equipment
g) Sign showing slinging and sling position
h) Any handling and unpacking instructions, if considered necessary
i) Identification marks relating them to the appropriate shipping

documents.
j) In case of spare parts, each spare part shall be clearly marked and
labelled on the outside of its packing with its description and
catalogue/part number.
k) Any other necessary data to identify the Equipment and relate it to

Contract.
23.3.2 Each package shall contain a packing note specifying the name and
address of the CONTRACTOR, the number and date of the
Contract/Purchase Order, name and address of consignee, description of
the material, and the quantity contained in such package.
23.3.3 The contents of the package shall be punched on a non-corrosive metal

plate and nailed to the package in a prominently visible place. If the
number of items in the package is too many, a typed list in transparent
water proof bag shall be kept inside a galvanised steel sheet pocket nailed
on to the outside of package in prominently visible location.
23.4 Erection Marks
23.4.1 All Equipment comprising multipart assemblies, e.g. steel frame works,
piping, etc. shall be marked with identifying numbers and/or letters
corresponding to those of the approved drawings or material lists. These
erection marks shall be clearly readable.
23.4.2 Colour banding to an approved code shall be employed to identify

members of similar shape or type but of different strengths or grades.
24.0 Transportation

24.1 This section covers transportation of equipment to site, receipt at site,

unloading of material from carriers at site, transport to contractor’s stores,
joint inspection of material by the purchaser and contractor, which
includes unloading, unpacking, inspection, re-packing wherever required,
submitting shortage and/or damage reports, lodging insurance claims
against losses and damages, etc. In case there is a time interval between
receipt of material and erection, equipment will be stored in the
contractor’s stores or warehouses at contractor’s cost.
24.2 In the event of the contractor proposing to deliver the equipment in

component or sub-assembly form, he shall furnish full particulars of the
quantity and approximate size of each item. All sub-assemblies shall be
match-marked to facilitate assembly at site.
24.3 Various means of transportation
24.3.1 Transportation by sea in case of foreign supplier
The contractor shall ship the equipment on behalf of the purchaser as far
as possible on board a vessel belonging to an Indian shipping line. In the
event of such a course being likely to lead to serious delay, shipment may
be effected by the first available vessel belonging to any other shipping
line of member countries provided the freight rates charged are not higher
than the conference rates applicable to the shipping route at the time of
shipment and all rebates and refunds available for consignment are duly
shall be responsible for the correct appraisal of freight rates (structural or
machinery as the case may be), weights and Volumes. In no case will the
purchaser, be liable to pay any warehouse or wharfage charges.
24.3.2 Transportation by rail
In case of rail transport the equipment shall be booked by the shortest

route from the nearest station to site, further transportation will be done by
road.
24.3.3 Transportation by road
In case of road transport, there shall be no transshipment. Road transport

agency shall be intimated to the purchaser.
24.3.3.1 Any combination of modes of transport can be used for the transport of the
equipment to site.

24.3.3.2 There should not be any transshipment.
24.4 Receipts
24.4.1 The contractor shall promptly unload the equipment covered under this
contract from such carriers at the point of unloading as directed by the
purchaser with care and in the manner prescribed.
24.4.2 Any demurrage incurred due to delays in unloading from carriers shall be
in the contractor’s scope of supply.
24.4.3 It will be necessary for the contractor to constantly keep in touch with
various agencies to obtain the likely time of arrival of consignment so that
necessary planning for unloading of equipment can be made.
24.4.4 It is the responsibility of the contractor to ensure that he has in possession

all the necessary documents such as invoices and carrier receipts to take
delivery of the equipment.
24.4.5 If applicable, time of placing of wagons at unloading yard as well as time

allowed for clearing the wagons are to be checked with Railways to ensure
that no demurrage is incurred. The procedures to be followed in case of
loss or damage are to be finalised with railways before hand.
24.4.6 For heavy or sophisticated equipment, detailed scheme for unloading from
carriers should be finalised well in advance in consultation with the
purchaser so that necessary tools and tackles can be tested and kept ready
for prompt unloading. It will be necessary for the contractor to scrutinise
the invoices, railway receipts and other available documents to study the
sizes and weights of consignment and arrange for suitable handling
equipment to meet the requirement.
24.4.7 The contractor shall submit to the purchaser a list of equipment he

proposes to use indicating their capacities and quantities as well as the
scheme of handling for approval by the purchaser.
24.4.8 The various lifting, handling and rigging tools proposed to be used by the
contractor shall be tested as per statutory and safety regulations and the
latest test certificates shall be furnished to the satisfaction of the purchaser.
In case the purchaser feels that the tools and tackles are inadequate or
unsuitable, the contractor shall arrange to provide such tools and tackles
considered suitable by the purchaser in sufficient quantities acceptable to
the purchaser.

24.5 Unloading
24.5.1 The packing of equipment on arrival at site shall be inspected on the

carrier itself. In case of closed wagons or containers, the condition of the
seals shall be checked to detect any possible tampering.
24.5.2 Wherever feasible, the equipment should be directly loaded on a lorry or

tractor trailer. Otherwise, packages shall be unloaded on sleepers or
concreted plinths and transported to stores as early as possible.
24.5.3 Unloading of equipment shall be carried out by competent, experienced

personnel using suitable handling equipment and approved safe
procedures.
24.6 Inspection
24.6.1 The equipment on arrival at contractor’s warehouse shall be jointly

inspected and report shall be submitted to the purchaser within a week
from the date of receipt of consignment or as specified.
24.6.2 The contractor shall promptly advise the purchaser the damage, if any
noticed during inspection.
24.6.3 It is the responsibility of the contractor to submit periodical reports on the

equipment received during the period of reporting, as well as those
scheduled to be received but not yet received to enable the purchaser to
take necessary action in time. The proper mode of storage is detailed later
in this Volume.
25.0 Erection Procedure
25.1 Bidder shall furnish detailed procedures for installation covering all the
aspects e.g. handling, check list for assembly & erection, special
instructions, erection drawings, log sheets etc. within one months of
placement of order.
25.2 Programme of work
25.2.1 The contractor shall furnish his own optimum programme of work or
scope of supply.

25.2.2 After the award of contract the contractor shall plan the sequence of work
of manufacture and /or erection to meet the agreed Plant commissioning
date and shall ensure that all work/manufacture, shop testing and shipment
of the equipment in accordance with the required construction and erection
sequence. The contractor shall furnish the dates of manufacture, testing,
despatch, completion of erection and commissioning or stages of work as
called for in the schedules.
25.2.3 Within 15 days of LOI/PO the contractor shall submit two copies (1
reproducible, 1 print) of 'network schedule' to the purchaser showing the
logic and period of the following minimum number of activities for review
and approval:
25.2.4 In case of equipment supply and supervision of erection contract:
a) Design and drawing submission and approval of different

categories of drawings.
b) Submission of QA plan for each equipment and approval of the
same by purchaser.
c) Material procurement of raw materials and bought out items.
d) Manufacturing process (indicating all major stages). Prototype to

be manufactured where required.
e) Prototype testing and extra routine type tests and special tests
where specified.
f) Shipment (indicating each planned shipment).
g) Erection (indicating all major stages for each equipment and

structure).
h) Commissioning (indicating all major systems).
i) The schedule for the submission of drawings, approval, QAP
submission and approval, manufacturing, erection and
commissioning have been indicated for individual equipment.
25.2.5 The time allowed for carrying out the work as entered in the tender shall
be strictly observed by the contractor and shall be deemed to be the
essence of the contract on the part of the contractor and shall be reckoned
from the date on which the work order to commence the work is issued to
the contractor.

25.3 Travel
25.3.1 All the charges relating to the travel of contractor's and sub-contractor's
personnel, labour, etc. shall be borne by the contractor. Also, the incidental
charges incurred thereon shall be paid by the contractor.
25.3.2 Contractor shall arrange his own mode of transport at site for all his and
his sub-contractor's staff, personnel, labour, etc.
25.4 Access to site
25.4.1 Suitable access to and possession of the site shall be afforded to the
contractor by the purchaser in reasonable time.
25.4.2 In the execution of the works, no persons other than the contractor or his
duly appointed representative, sub-contractor and workmen, shall be
allowed to do work on the site, except by special permission, in writing by
the purchaser or his representative.
25.5 List of drawings enclosed with the specification
Enclosed drawings are listed in CC-10. These are for tender purposes. The
contractor shall carry out work as per the construction drawings to be
released by the purchaser after the placement of order.
25.6 Co-ordination procedures
25.6.1 The procedure contained in the following paragraphs are to be followed by

all contracting parties for this contract.
25.7 Identification of key personnel
The names designations, postal addresses, telephone numbers, telex

numbers, fax numbers and telegraphic addresses of the representatives of
the contracting parties shall be as given during the tendering process. Any
subsequent changes will be duly intimated.

25.8 Correspondence procedure
25.8.1 All correspondence between the contracting parties shall be as given later
in this section. The contractor shall address all his correspondence to
purchaser.
25.8.2 All correspondence on purely commercial matters shall be sent to

purchaser only.
25.8.3 All letters from contractor shall bear a reference number which should
contain a continuously running serial number. This would enable the
purchaser to identify if any letter or document is misplaced.
25.8.4 The contractor shall be responsible for coordination of all activities with
his sub-contractors.
25.9 Co-ordination meetings
25.9.1 The contractor shall note that he will be called upon to attend meetings
with purchaser and his representatives, consultant and other contractors
during the execution of the contract. The agenda for co-ordination
meetings shall be issued by contractor or purchaser to the other party at
least three(3) weeks in advance of meeting. The contractor shall attend all
such meetings at his own cost. The venue of the meetings would be
decided in advance to suit the convenience of all parties. The coordination
meetings are held to sort out and resolve the various technical matters and
outstanding issues. In these meetings, manufacturer's progress and overall
project schedule will also be discussed.
25.10 Procedure for submission of contractor’s drawings and documents
25.10.1 The contractor shall prepare a complete list of drawings and documents
and shall submit to purchaser for contract engineering purposes within the
time limit as indicated in Section-D.. This drawing schedule shall indicate
title of the drawing or document, document number, expected date of
submission, actual date of submission and purpose of submission (i.e.,
whether for information or for approval) etc., as per engineering schedule
agreed to with the purchaser.
25.10.2 Subsequent to this, an additional list of assembly and other drawings and
documents shall be submitted which are necessary to facilitate inspection,
erection, testing, commissioning and maintenance of equipment and
systems covered in this contract. This shall be also done within a mutually

agreed period. The drawings and documents under this category may be
subject to approval of purchaser depending upon the requirement.
25.10.3 Each and every drawing or document including write-ups, data sheets, etc.,
shall carry project title, names of purchaser, document number, revision
number, date of revision and brief details of revisions carried out,
appropriate reference number of schedule, distribution and purpose, etc..
Wherever any revision is carried out, correspondingly revision number
must be updated. The revisions carried out on any drawing or document
shall be identified by encirclement and tagging the encirclement with the
revision number.
25.10.4 All documents shall have English version on them.
25.10.5 All dimensions on drawings shall be in metric units, unless otherwise

specified. If any dimension figured on a drawing differ from those
obtained by scaling the drawing, the dimension as figured shall be taken as
correct.
25.10.6 Review of contractor's document and drawings by the purchaser will be on

one-unit basis wherever documentation is identical for all units. However,
for subsequent units, contractor shall certify in the documents drawings
that the information contained in the document or drawings is identical
with the one already reviewed by purchaser.
25.10.7 Depending on the completeness and correctness of contractor's drawings

and documents recommended for approval, the same will be stamped as
below:
Nuclear Power Corporation of India Limited

Contractor Drawings Review Status
( ) Approved
( ) Approved subject to comments as noted; proceed with
fabrication considering comments; submit revised drawings
and reproducible for record
( ) Not approved; revise as per comments and resubmit for
approval
( ) Refer covering letter no. dated
( ) Drawing of this category is not reviewed; drawing received
for information only
Reviewed by: Date:

• Approval herein neither relieves contractor of his contractual

obligations and responsibilities nor does it limit purchaser's rights
under the contract.
• Drawing and documents are to be considered as approved only after

written approval by purchaser.
25.10.8 The contractor shall resubmit those drawings and documents on which
clarifications and/or modifications have been sought. This shall normally
be done within two(2) weeks of receipt of comments, if not otherwise
specified in engineering schedule.
25.10.9 Drawings which are resubmitted by contractor without incorporating all

the comments made by purchaser and without any clarifications for
noncompliance with comments made, will be deemed incomplete and will
neither be reviewed further nor approved.
25.10.10 Any work performed or material ordered by the contractor prior to receipt
of drawings stamped "approved subject to comments as noted" by the
purchaser shall be at the risk of the contractor. After print of any drawing
has been returned 'approved', the contractor may release all parts covered
by the drawings, for production.
25.10.11 One reproducible of finally approved drawing shall be sent to the

purchaser along with six(6) prints.
25.10.12 Drawings prepared by the contractor and approved by the purchaser shall
be considered as a part of the specification. However, examination and
approval of the drawings by the purchaser shall not relieve the contractor
of his responsibility for engineering, design, workmanship and materials,
under the contract.
25.10.13 Any delay in the approval of contractor's drawings and documents by

purchaser due to non-compliance of the above procedural requirements by
contractor shall be entirely to contractor's account.
26.0 Secrecy
a) The technical information, drawings, specifications, and other related

documents forming part of the enquiry or 'contract' are property of the
purchaser and shall not be used for any other purpose, except for execution
of the 'contract'. All rights, including rights in the event of grant of a patent
and registration of designs are reserved. The technical information,
drawings, specifications, records and other documents shall not be copied,

transcribed, traced or reproduced in any other form or otherwise in whole

and/or duplicated, modified, divulged and/or disclosed to a third party nor
misused in any other form whatsoever, without the purchaser's previous
consent in writing, except to the extent required for the execution of this
`contract'. These technical information, drawings, specifications and other
related documents shall be returned to the purchaser with all approved
copies and duplicates, if any, immediately after they have been used for the
agreed purpose.
b) In the event of any breach of this provision, the contractor shall indemnity
the purchaser from any loss, cost or damage or any other claim whatsoever
from any parties claiming from or through them in respect of such breach.
27.0 Planning and scheduling
27.1 After the award of contract the contractor shall plan the sequence of work
of manufacture and/or erection to meet the agreed plant commissioning
date and shall ensure that all work, manufacture, shop testing and shipment
of the equipment proceed in accordance with the required construction and
erection sequence. The contractor shall furnish the dates of manufacture,
testing, despatch, completion of erection and commissioning or stages of
works as called for in the schedules.
27.2 During the execution of the contract, if it is found necessary to change the
schedules, the contractor shall inform the purchaser and submit a modified
network schedule with adequate reasons and evidence to the satisfaction of
the purchaser. Such approval is not to be deemed consent to any
amendment to the completion date as stated in the schedule.
27.3 Within one week of approval of the network schedule, the contractor shall
forward to the purchaser copies of the "computer initial run data". The
type of outputs and number of copies of each type to be supplied by the
contractor shall be determined by the purchaser.
27.4 The network schedule shall be updated every month or at a frequency

mutually agreed upon.
27.5 Access to the contractor's and sub-contractor's works is to be granted to the

purchaser at all reasonable times for the purpose of ascertaining progress.
28.0 Project reports for project monitoring

During the execution of the contract, the contractor shall furnish monthly
progress reports to the purchaser in a format as specified by the purchaser
indicating the progress achieved during the month and total progress up to
the month as against scheduled and anticipated completion dates in respect
of key phases of design and engineering, manufacturing and shipment such
as release of drawings for fabrication, procurement of raw material,
manufacture, inspection, testing and shipment. The progress reports shall
indicate all delays anticipated by contractor along with reasons for the
delays. If called for by the purchaser, the contractor shall also furnish
resource data and any other information in a specified format and
frequency.
29.0 Correspondence, document, drawing distribution schedule
Field
Particulars Purchasers Contractor
Office
Correspondence
Purchasers To 1 (Only if
S 0
Contractor relevant)
Contractor To
O+2 -- S
purchasers
Manufacturing
Test Reports O+4 1 S
Instruction Manuals &
end-documentation
Preliminary 2 - S
Final 10 1 S
Contractor Drawings
Preliminary 4P - S
Final Submission 1R+6P - S
Return Of Finally
S - 1P
Approved Drawings
Legend: O- original
S- Source
P- Print
R- Reproducible
30.0 End documentation
Before each equipment is despatched to site the contractor will furnish ten
(10) copies of the end documents in bound form containing following:

a) Copy of the purchase order

b) Miniature form vendor drawings
c) Test reports
d) Analysis reports
e) Approved DCRs
f) O&M manuals containing storage, erection and commissioning
instructions, recommended spare parts
g) Detailed catalogues of various components
h) Shipping releases
31.0 SECURITY RULES
The contractor shall follow at site all security rules as may be framed by
the Corporation from time to time regarding movement of materials and
equipment to and from site, issue of identity cards, control of entry of
personnel and all similar matters. The contractor and his personnel shall
abide by all security measures imposed by the Engineer or his duly
authorised representative from time to time. Contractor shall also follow all
rules and regulations applicable to the area being declared / pronounced
from time to time by the authorities or authority of existing Nuclear Power
Station in the vicinity or any other statutory orders. Nothing extra will be
payable on account of stoppage / hindrance of the work. The contractor,
his employees and agents shall not disclose any information or drawings
furnished to him by the Corporation. Any drawings, reports and other
information prepared by the Contractor / by the Corporation or jointly by
both for the execution of the contract, shall not be disclosed without prior
written approval of the Engineer. No photographs of the works or plant
within site premises shall be taken, without the prior written permission of
the Engineer.

SECTION C-1
Scope of Supply/Work/Services

PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC SECTION : C
POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE Sub Section : CC1

SCOPE OF SUPPLY/WORKS/SERVICES Revision :0
SCOPE OF SUPPLY/WORKS/SERVICES
1.0 Scope of this tender shall be as follows -
1.1 Design, Material, Constructional features Manufacture, Pre-dispatch inspection &
testing at the factory, packing, delivery and installation. Testing & commissioning
of five nos. each of rated output of 3000A, 85V DC, current/power (selectable)
regulated solid state, variable DC power supply units of thyristor based air cooled
rectifier bridges and rectifier transformer, indications/alarms, protective and
input/output isolating devices, DC current hall sensors (LEM), DC output Bus
duct, local control panel & all digital & analog inputs to remote work station
through PLC etc (PLC, software & work station shall not be part of this
tender, however configuration of SCADA software on exiting PLC &
workstation and as required by purchaser shall be in the scope of
this tender) complete in all respect to meet the specified performance and
operational requirements.
1.2 Design, manufacture, inspection and testing at the factory, installation, testing &
commissioning of DC bus duct from rectifier bank to resistance heating elements.
1.3 Design of civil foundation for rectifier transformers along with supply of
necessary rails, anchor bolts etc.
1.4 Supply of Anchor bolts for installation of rectifier panels and transformers.
1.5 Supply, fabrication and installation of support structure for DC out put bus duct.
1.6 Recommended & maintenance spare parts for 5 years and maintenance tools.
1.7 Whether called for specifically or not all accessories required for normal
operations of equipment are deemed to be considered as a part of the
CONTRACTOR’s scope of supply.
1.8 It is not the intent to specify completely herein, all details of design and
construction of the equipment. However, the equipment shall conform in all
respects to high standards of engineering, design and workmanship and be capable
of performing in continuous commercial operation up to the CONTRACTOR’s
guarantees in a manner acceptable to the PURCHASER, who will interpret the
meaning of drawings and specifications and shall be entitled to reject any work of
material which, in his judgment, is not in full accordance therewith.
1.9 The CONTRACTOR shall not sub-contract any of the work without a written
consent from the PURCHASER.
SPECIFICATION NO: PB-E-775 March-2008
PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC SECTION : C
POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE Sub Section : CC1

SCOPE OF SUPPLY/WORKS/SERVICES Revision :0
2.0 TERMINAL POINTS

2.1 Supply, Installation and termination of suitable size & rated of power and control
cables (Except incoming power cables from 415V switchgear but installation of
power cables at both switchgear & rectifier ends shall be in this contract) from
415V switchgear located at same ground floor houses in electrical annex building
to local control & remote control room.
2.2 +Ve and –Ve DC out put supply through bus duct & Flanges up to the heating.
3.0 EXCLUSION
3.1 Civil works for transformers and panels like EP in concrete are not in this contract
but design detail shall be given to other EPC contractor for construction.
3.2 Control & measurement out put parameters from rectifier module to PLC and than
control room server panel, digital display station etc shall be in this contract but
supply of PLC, software & work station i.e. digital display station shall not be
part of this contract.
SPECIFICATION NO: PB-E-775 March-2008

SECTION C-2
Applicable Codes, Standards and
Specifications

PROCUREMENT SPECIFICATION ON DECAY HEAT POWER Section :C
DC POWER SUPPLY SYSTEM FOR HEATING OF Sub Section : CC2
RESISTANCE ELEMENTS Page : 1 of 2

Revision :0
APPLICABLE CODES, STANDARDS AND SPECIFICATIONS

1.0. Other National Standards are acceptable if they are established to be
equivalent to or superior to the listed standards subject to approval by the
PURCHASER and the CONTRACTOR shall provide English version of
standards and codes applicable.
2.0. The DC power supply system shall conform to the currently applicable
standards and codes of practice and reports currently applicable statues,
regulations and safety codes in the locality where the equipment will be
installed. The equipment shall also conform to the latest editions of the codes
and standards as listed below: as of date of Bidding. Nothing in this
specification shall be construed to relieve the VENDOR of this responsibility.
STANADARD NO. TITLE
IS-5 Colors for ready mixed paints and enamels

IS: 191 Copper for electrical purposes
IS: 335 New insulating oil for transformers
IS: 513 Cold rolled low carbon steel sheets and strips
IS: 613 Copper rods and bars for electrical purposes
IS: 694 PVC insulated cables for working voltages up to and including
1100 V
IS: 1271 Thermal evaluation and classification of electrical insulation
IS: 1477 Code of practice for painting of ferrous metals
IS: 1554 PVC insulated electric cables: For working voltages up to
& including 1100V
IS: 1897 Copper strip for electrical purposes
IS: 2026 (part 1 & 2) – Power transformers
IS: 2062 Steel for general structural purposes
IS: 2147 Degree of protection to enclosure
IS: 2629 Recommended practice for hot dip galvanizing on iron and steel
IS: 2705 Current transformers (CT)
IS: 3136 Semiconductor rectifier equipment
IS: 3156 Potential transformers (PT)
IS: 3231 Electrical relays for power system protection
IS: 5082 High conductivity aluminium alloy of grade WP 63401 for busbars
IS: 5469 Code of practice for use of semiconductor junction devices
IS: 6005 Code of practice for epoxy painting of panels
IS: 6297 Transformers for electronic equipment: Pulse and
switching transformers
IS: 6553 Environmental requirements for semiconductor devices
and integrated circuits
IS: 6619 Safety code for semiconductor rectifier equipment
IS: 8084 Bus duct design
SPECIFICATION NO: PB-E-775 March., 2008

DC POWER SUPPLY SYSTEM FOR HEATING OF Sub Section : CC2

Revision :0
IS: 8588 Thermostatic bimetals, general requirements & methods of

(part 1) tests
IS: 8623 Procedure for short circuit withstand test of power panels
IS: 9000 Basic environmental testing procedures for electronic and
electrical items
IS: 9224 Specification for HRC fuse: Requirement for fuse link for
(part 4) the protection of semiconductor devices
IS: 10118 Code of practice for selection, installation & maintenance
of switchgear & control gear
IS: 13703 Low voltages fuses for voltages not exceeding 1000 V AC
or 1500 V DC
IS: 13947 (part 2) & IEC: 947 (part II) – L.V. switchgear &
control gear: General rules, etc.
IEC: 60146 Semiconductor converters: Semiconductor self
commutated converters
IEC: 60326 Printed circuit boards
IEEE: 428 IEEE standard definitions and requirements for thyristorised
AC power controllers
IEEE: 519 IEEE Recommended Practices and Requirements for
Harmonic Control in Electrical Power Systems
ASME: Welding and brazing qualifications
Section IX
BS: 6493 Recommendation for rectifier diodes
(Section 1.2)
BS: 6493 Recommendation for use of thyristors
(Section 1.6)
Indian Electricity Rules

IS: 3043 Code of Practice for Earthing
IS: 10028 Transformer installation
(part-II), 1981
IS-2062 Specification for structural steel
IS: 1477 Code of practice for painting of ferrous metals.

SECTION C-3
Specification of Main Equipment and
Accessories

PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC Section :C
POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE ELEMENTS Sub Section : CC3

Page : 1 of 13
SPECIFICATION OF MAIN EQUIPMENT AND ACCESSORIES Revision :0
SPECIFICATION OF MAIN EQUIPMENT AND ACCESSORIES
1.0 SYSTEM DESCRIPTION:
Decay Heat DC power supplies systems are required to provide power to

heating of resistance elements at various power levels. The resistance heating
elements shall be horizontal channels. The input power to the all five rectifier
banks shall be from 415V Switchgear. Refer single line diagram for power
supply arrangement as attached drawing. The rectifier banks may operate
independently or they may operate in parallel. The various operating modes
of the rectifier bank are shown schematically in attached drawing.
2.0 TECHNICAL REQUIREMENTS:
2.1 AC Input System Particulars.
2.1.1 Nominal Input supply : 415V, 3 phases 4 wire, 50 Hz,
2.1.2 Steady State Variation :
a) Voltage : ± 10%
b) Frequency : ± 5%
c) Combined Voltage and Frequency : not exceeding ± 10%
2.1.3 Max. input supply voltage unbalance : 3%
2.1.4 Harmonic in input supply: Input waveform distortion as per IEEE – 519.
2.1.5 Input supply & short circuit level at 415V bus, 50 kA
2.1.6 Type of input supply earthing : Solidly earthed
2.1.7 Power factor at the input:

Bidder shall ensure p.f. shall not be less than 0.92 (lag).
2.1.8 Current harmonic injected by the rectifier: Shall be limited to 20% without
filters at the input at 100% full load current.
2.2 DC Output Particulars
2.2.1 Rated output voltage: Maximum up to 85 V.
2.2.2 Continuous/ variable rated output current: Maximum up to 3000 A at 85VDC

and also full current at 45V DC out put.
2.2.3 Stability of output current/power at set point : ± 0.5% at set current


Page : 2 of 13
2.2.4 Regulation of output current/power for ± 10% change in line voltage or load
resistance or combination of line voltage and load resistance: Less than 0.5%
at set power / current.
2.2.5 Total harmonic distortion (THD) : Maximum 4% at rated current.
2.2.6 Response time: 100 milli sec. or better (current from 10% to 100% of set
point) through out the range of operation.
2.2.7 Degree of protection : IP-21
2.3 Type and mode of control:
DC power supply system shall have secondary control with Silicon Controlled
Rectifier (SCR) as a control element in a closed loop manner with true RMS
power/true RMS current (selectable) as a feedback.
2.3.1 Type and mode of control:
DC power supply system shall have secondary control with Silicon Controlled
Rectifier (SCR) as a control element in a closed loop manner with true RMS
power/true RMS current (selectable) as a feedback.
2.3.2 Power control strategy:
The output power of the power supply units shall be raised and lowered in the
desired manner to suit the experimental programme. The programmable ramp
generator (PC based) shall be designed to suit the experimental requirement.
The reference to the DC power supply units shall be applied in the small steps
(very small voltage / step) with the help of programmable ramp generator to
simulate as close as possible the desired output pattern of the power supply
units. The typical linear ramps to be simulated as follows-
1) 0.1%, 0.25%, 0.5% etc. of the power per second during increasing the power.
2) Exponential decay during decreasing the power. Please refer the attached
exponential decay heat curve from 100% to 2% with respect to time.
(Note: Bidder shall note this point carefully and quote accordingly. this is one
of performance / acceptance criteria)
2.3.3 Internal/external reference signal option: PLC shall have option to switchover
reference signal from internal to external or vice versa.
2.4 Duties / overload: 150% for 10 sec.

(IEC-146) 125% for 5 minutes
2.5 Power factor capacitors:
Bidders shall design and supply capacitors banks to maintain min. power
factor of 0.92 lagging from 10% to 100 % loads auto / manual control
provision for each incoming 415V buses.


Page : 3 of 13
2.6 Cooling system:

Forced Air cooled for SCRs Rectifier Bridge & cabinets with suitable
protection and air changes as per standard. Similarly AN (air natural) cooling
arrangement for rectifier input transformer and suitable protection in case
failure/ temperature rises to more than decided/ set temperature.
2.7 Dry cast resin rectifier transformer:
2.7.1 Rectifier transformer shall be of cast resin dry indoor type and housed in the
cubicle of IP-32ventilation protection. It shall be designed for AF cooled.
2.7.2 The input voltage to the rectifier transformer shall be 415V ± 10%, 3 phase
and shall be fed from 415V indoor switchgear having air brake circuit breaker
of adequate current capacity (20% extra than the rated input current of the
rectifier transformer) with over current and earth fault protection relays.
2.7.3 The secondary voltage rating of the rectifier transformer shall be designed
such that, voltage of rectifier output terminal is 50 volts DC output. The
length of bus duct from each rectifer shall be of 20 meters (approximate).
2.7.4 Dry cast resin rectifier transformers shall be installed near rectifier panel. The
area meant for rectifier transformers is indicated in attached layout drawing.
2.7.4 The connection between switchgear and rectifier transformer shall be carried
out by cable of suitable size. Bidder shall install at the both transformer and
switchgear end.
2.7.5 Dry cast resin rectifier transformer shall have class-H insulation or higher and
temperature rise are limited to corresponding to class-F insulation.
2.7.6 Transformer shall be provided with embedded thermisters along with control
circuit for trip. The each winding and core shall have minimum 2 in each wdg
& 2 in transformer core. Bidder shall provide control scheme, make and
specification of components.
2.8 Thyristor Rectifier

2.8.1 Brief technical requirements of Thyristor Bridge are:
a. Rated DC Power : 255KW rating

b. Rated DC Voltage : 85 volts
c. Rated DC Current : 3000 amps (Continuous/ variable)
d. Type of cooling : Air forced cooled
e. No. of pulses :6
2.8.2 Cooling fan of force air-cooling for cabinets should have sufficient capacity to
keep the temperature within limits as per relevant standards. Trip & alarms
shall be provided in case air flow reduces to less than a particular set point
below which it is unsafe to operate the power supply unit. There shall be


Page : 4 of 13
enough over capacity available for the cooling. The thermostats shall be
installed on the thyristor heat sinks to provide the back-up protection for the
system.
2.8.3 The cooling of the semiconductor rectifiers shall be given the utmost attention.
Please note that it is important to provide additional thermal capacity as closed
to the junction as possible to obtain the lowest operating temperature.
2.8.4 In the case of number of devices are used in parallel, high speed semi
conductor current limiting fuse in series with each device shall be used which
offers excellent protection. Each thyristor shall be protected by a semi
conductor current limiting fuse with adequate interrupting capacity and current
limiting ability to isolate faulty thyristor without damage to the other
thyristors. The individual thyristor rectifier shall be protected from the over
voltage surges by connecting RC Snubber across them.
2.8.5 Thyristor shall be provided with the following minimum protections:
a) Over voltage i.e. dv/dt for SCRs (Snubber circuit)

b) Over current i.e. di/dt for SCRs (Snubber circuit)
c) Input short circuit (semi conductor current limiting fuse)
d) Short circuit at out put (semi conductor current limiting fuse)
e) Over temperature (sink temp. high by thermostats)/ low air flow
f) Phase loss
g) Input & out put surge suppression
2.9 DC Current Sensor:
a. Principle of operation: Hall effect based by incorporating compensating

coils (null detector)
b. Rating: 32000 amps
c. Accuracy: ± 0.5 % of set point
d. Linearity: ± 0.25 %
e. Construction: Clamp-on type
f. Window size: Suitable to the output DC copper bus bars.
2.10 Control Panel
2.10.1 The local control panels for all common systems and rectifier operation from
local shall be located first floor rectifier local control room & remote control
panel/ station to be located in control room for each rectifier unit. Approximate
panel size and weight to be specified by bidder. The supplier including supply
of control cables shall engineer all interconnections between the thyristor
rectifier cubicle and the local control panels as well as the internal control
connections of the control panels. The control cable shall be of type 1.1 kV
grades, min. conductor cross section of 2.5 mm2, copper flexible conductor,
PVC insulated & sheathed, galvanized flat steel strip armoured. Necessary
(MCBs) isolators shall be provided in control panel for auxiliary 240 volts AC
power supply. All the control switches shall be rotary, back mounted type.


Page : 5 of 13
Cam switch shall not be acceptable. The local/remote selector switch shall be
rotary type with lockable key and mounted on the front of the local control
panel for selecting the operation either through local or remote as required.
Indication lamps shall be of LED type, low power consumption, complete with
the necessary current limiting resistors and transparent lamp covers to defuse
light. The LEDs assemblies and the lenses shall be easily replaceable from the
front. The push buttons shall be of momentary contact, push to actuate type
and rated for 10 amps at 240 volts AC or 110 volts DC. The push buttons shall
be provided with 2 NO + 2 NC contacts. Control panel of individual rectifier
shall be provided with True rms current, voltage and power transducers and I,
V & P indications. The transducers (V, I & P) shall have isolated analog out of
4-20 milli amps each (optical isolation of 1.5KV) and shall be able to drive
output current into a resistance of maximum 500 ohms. Control panel shall be
also provided with indications & transducers for AC input voltage, frequency,
power factor & input power.
2.10.2 Two nos. remote control panels (work station and server ) in that one unit shall
be fully 100% standby including server shall be PLC (that shall not be part of
this tender but all control & measurement parameters are to be connected to
these exiting panels) base soft logic & display in analogue & digital
input/output. The panel shall comprise of all indications, metering,
annunciations display with remote operation & analysis of stored data both in
analogue & digital input / output. Bidder shall specify in detail the technical
data regarding microprocessor make & functions. The output shall be
displayed on monitor as well as laser printer i.e. ON/OFF control, current /
power set , data logging V , I & P, trend, trip page , event recording etc.
2.10.3 The local control panel shall have the following interlock and subsequent
annunciation in the form of module:
There shall be three groups of interlocks of each rectifier unit and subsequent
trips provided as mentioned below.
1) Rectifier process trip:
a. SCR bridge fuse failure
b. SCR heat sink high temperature
c. SCR Heat sink cooling failed/ forced cooling failed
d. DC overload trip (instantaneous type)
e. Thyristor rectifier cubicle and local control panel door opened
during operation, etc.
f. DC over power trip
2) Loop process Trip (potential free contact will be provided by the user).
3) Electrical trip:
a) Instantaneous O/C, IDMT O/C, inst. E/F, REF, under voltage at
415V or breaker trip
b) Rectifier transformer temperature very high


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c) Rectifier transformer winding temperature very high
2.10.4 The interlock for the above parameters shall be designed in such a way that if
one of the above interlock condition is not cleared, power supply unit shall not
get ‘ON’, and if the power supply is already in operation, any incoming
abnormal condition shall trip the power supply unit. The logic shall be
designed for ‘fail safe mode’. The power supply unit shall get ‘ON’ only after
resetting the interlock. On resetting if all the interlock parameters/conditions
are clear, a ready lamp (amber in colour) shall glow indicating that the power
supply unit can be put ‘ON’.
2.10.5 Common window audio annunciation shall be provided for the above-
mentioned interlocking parameters in addition to the visual indication. Each
parameter mentioned above (the electrical trip shall be combined as one trip)
assigned with one annunciation window. Each window of the annunciation
panel shall have two nos. of indicating lamps and a common buzzer for the
entire annunciation panel. Annunciation panel shall have 20% spare blank
window for future use. The required sequence of annunciation is as follows.
a. No lamp indication: Parameter/condition healthy

b. Flushing indication with sound: Parameter/condition abnormal
c. On pressing ACKNOWLEDGEMENT push button – Buzzer shall
silence and flushing lamp shall be steadily ‘ON’
d. On restoring the abnormal parameter/condition–lamp shall be flushing,
accompanied by buzzer sound
e. On actuation of RESET push button: buzzer shall be ‘OFF’ and flushing
indicating lamp shall be ‘OFF’
The common window annunciation panels shall be supplied as per relevant

DIN standard.
2.10.6 In addition to the window annunciation, the following LEDs indications shall
be provided on the front of the local control panel & control room panel:
a. DC power supply ‘ON’ (Red colour)

b. DC power supply ‘OFF’ (Green colour)
c. Power supply interlocks OK (Amber colour)
d. SCR fuse failure- one for each fuse (Red colour)
e. Ready lamp- to indicate that all the interlocking parameters are healthy
(Amber colour)
f. RTD temperature indicator for indicating the temperature of thyristor
heat sink of Auxiliary power supply failure.
2.10.7 The following operating controls shall be provided on front cover of the local
& remote work station:


Page : 7 of 13
a. Local/Remote selector switch (lockable) – To select the operation of

the power supply unit either from local control panel or from remote
control room.
b. Power supply ‘ON’ push button
c. Power supply ‘OFF’ push button
d. 240 volts, 1 phase AC auxiliary (Control) power supply ‘ON/OFF”
MCB
e. Power control/Current control selection by toggle switch
f. Lockable ten turn potentiometer for power/current control through
close loop system
g. Acknowledge push button – To acknowledge fault in case the power
supply trips due to any abnormal condition/parameter. The buzzer shall
silence by pressing this push button.
h. Lamp & buzzer test push button – To check the healthiness of the
lamps of annunciated windows, as well as other lamps on the front and
the common buzzer.
i. Reset Push Button - To reset the interlock and subsequently
annunciation windows when the abnormal condition/parameter is
cleared. It shall not be possible to put ‘ON’ the power supply unit until
Reset button is pressed.
2.10.8 The power supply shall be designed to be put ‘ON’ and output current/power
shall be controlled only from the selected position of the local/remote selector
switch, whereas power supply ‘OFF’ shall be possible from both local as well
as from remote mimic station irrespective of the position of local/remote
selector switch. (Mimic configuration is not in the scope of the bidders.)
2.10.9 The dual output isolated(one for local panel &other for remote work station
panel), True RMS voltage, current and power transducers along with the
digital display of True RMS voltage, current and power to be provided on the
front of the local control panel, shall be supplied as per the following
specifications for the power supply unit.
The display shall flush mounted on the front of the local control panel. The
terminals of the display shall be shrouded to ensure protection from live parts.
a) Input:
i) Voltage transducer: Voltage- 0 to 85Volts DC
ii) Current transducer: Voltage- corresponds to 0-3000Amps DC
iii) Power transducer: Voltage- 0 to 85Volts DC and corresponds to
0 to 3000Amps DC
(Note: The above input signals are derived from the output of the said
power supply units.)
b) Output:
i) Display:
Voltage- 3 ½ digit 7 segment LED with 12 mm character
height


Page : 8 of 13
Range: 0-100 volts (nominal) with resolution 0.1. Accuracy: ±

0.5 % ± LSD of reading or better
Current- 4 digit, 7 segment LED with 12 mm character height

Range: 0-3000 amp (nominal) with resolution 1 amp
Accuracy: ± 0.5 % ± LSD of reading or better
Power- 4 digit, 7 Segment LED with 12 mm character height

Range: 0- 300kW (nominal) with resolution 0.1 kW
Accuracy: ± 0.5 % ± LSD of reading or better
ii) Dual Analog Output:

Isolated 4 to 20 milli amp DC individually for the following.
Voltage (proportional to 0 to 85Volts),
Current (proportional to 0 to 3000Amps) &
Power (proportional to 0 to300kW)
iii) Accuracy of the analog output : ± 0.5 % of reading or better
iv) Isolation between input & output : Up to 1.5 kV RMS
v) Driving Capability: up to 500 Ω i.e. 10 Volts at 20 milli amps
c) Auxiliary Power Supply: 240 V ± 10 %, 50 Hz ± 3 %, 1Φ, AC with

neutral grounded
2.11 Copper Bus Duct
There shall be output DC supply bus duct of copper. The DC bus bars run from
the rectifier cubicle (located on the ground floor) to the heater banks (located
in the ITF building), but elevation of termination may be at different heights.
All joints on bus bars shall be made from silver coated section in such a way
that the resistance of joint shall be less than the equal length of same bus bar
section. The bus bar part shall be enclosed in aluminum bus duct of suitable
size that shall have IP-21 degree of protection. Bus duct shall be fabricated
using 3.0 mm thick aluminum sheets. The bus bars shall be adequately sized
for the continuous current rating in various series & parallel connections,
considering allowable temperature rise at the given ambient temperature with
due consideration to different de-rating factors and they are made out of
copper conforming to IS: 8084. The bus bars shall be supported with non-
hygroscopic glass fiber reinforced SMC supports. The design of bus bar shall
be type tested design to withstand 3000A continuously rated. The neutral and
earth bars shall also be of type-tested design as per the requirement of IS:
8623. The bus bar joints shall be made properly by application of conductive
grease/paste with a moderate torque to get the joint resistance as minimum as
possible. The bus bars shall be provided with the minimum clearances in air as
per the applicable standards for a 500 volts system. The bus bar connections
and bus bar supports shall have sufficient strength to withstand the thermal and
mechanical stresses and electromagnetic forces during short circuit. The bidder


Page : 9 of 13
shall give details of bus bar size selected and support calculation. The
specifications in brief of the copper bus duct are mentioned below.
a. Materials and type: High conductivity Copper of 100% IACS,

Electrolytic Tough Pitch (ETP) grade as per IS: 191- 1981
b. Size of bus bar: Suitable for the required continuous current carrying
capacity as per the design configuration selected
c. Temperature rise: 350 C over ambient temperature of 450 C
d. Short time thermal rating as per applicable standards.
e. Short circuit withstands current for 1 sec (RMS & Peak): 50 kA/105 kA
f. Clearance in bus bars as per applicable standards.
g. Ground / Earth Bus: Material: Copper with sizes: 50X6 mm.
h. Bus bar Joints: Silver-plated
k. Bus bar support material: SMC
m. Material for the duct: Non-magnetic, preferably aluminum
n. Size of bus duct: To be specified by the bidder.
p. The laminated thermal expansion bus bar joints of copper material shall
be connected in between the bus bar length.
q. Bus duct degree of protection- IP-21
Note: The purchaser shall provide hard part of PLC, work

station & SCADA software that shall not be part of this
tender; however configuration, man power training,
cabling of signal to SCADA software & commissioning
from exiting PLC & workstation and as required by
purchaser shall be in the scope of this tender. The
specification of PLC, software & work station for
reference shall be as follows-
2.12 Workstation
2.12.1 Hardware
Workstation shall be of Industrial grade, connected to the Power Supplies
through PLC on Ethernet TCP/IP
CPU/Clock speed: Pentium IV Dual processor, 4.8 GHz or better

Memory: 2 GB RAM
Hard Disk: 160 GB IDE
Operating System: Windows 2000/ XP
DVD-WR, Keyboard, optical Mouse
27” Industrial Grade LCD Colour Monitor.
2.12.2 Software
The SCADA software should provide the operator with process visualization,
data acquisition and supervisory control capability. The software should be


Page : 10 of 13
based on Windows Operating system. The visualization facilities provided by

the SCADA should consist of graphical mimic pages, providing indication of
sensor values, sensor alarms, sensor limits; alarm limits etc. in form of a clear
and comprehensive hierarchical structure designed to give an end to end
response of 1-2sec. Bidder shall specify the version.
2.12.2 The software should enable the operator to command the performance of the
Power Supply system through easily navigable screens. The main positioning
and input tool to the SCADA software should be the mouse. This enables the
operator to monitor and control all processes in an optimal and ergonomic
manner without having to turn his eyes away from the display. All help
information should be available in the form of menus and dialog boxes on a
dynamic and situation oriented basis.
2.12.3 Functional Features
2.12.3.1 Power Circuit Visualization for overall system consisting of all five power
supplies and individual/ group of power supplies.
2.12.3.2 Display of all electrical and temperature parameters as listed below:
Vac, VDC, F, PF, KW, Transformer Winding Temp, Thyristor Panel
Temperature, Steady state rms currents, etc.
2.12.3.3 Display and selection of “Test Sequences” with down loading of set points &
“Test Profile” to individual power supplies.
2.12.3.4 Display & logging of alarms and events.
2.12.3.5 Display of trends: Power, PF, Transformer winding temperatures, Power
Supply panel temperatures etc.
2.12.3.6 ON/OFF control and set point/test profile control.
2.12.3.7 Necessary sensors and PLC with Input /output modules shall be included for
interfacing with Work station
2.12.4 Programmable Logic Controller(PLC)
General: A Programmable Logic Controller is required for controlling high

current variable DC power supplies, which has 10 loops. These loops are
controlled by the reference signal (0 to –10 VDC) for variation of output
power of variable DC power supply (each unit: 0 to 5300 amps). In addition
to digital 40 inputs, 60 digital outputs are required for trip, indication and
ON/OFF control.
2.12.4.1 PLC Processor:

2.12.4.1.1 Programme capacity: More than 28 K steps.
2.12.4.1.2 No of loops that CPU can handle: Minimum 10 or more.
2.12.4.1.3 Basic instruction processing time: 0.1 µsec or better.
2.12.4.1.4 Communication port:To be specified by the bidder.
2.12.4.2 Isolated Analog Input Module

2.12.4.2.1 Analog input type: DC Current.
2.12.4.2.2 Analog Input ranges:4-20 mA, DC .
2.12.4.2.3 Number of channels per module: 4 or available configuration.


Page : 11 of 13
2.12.4.2.4 Resolution: 12 bits or better.

2.12.4.2.5 Conversion speed: 80 µsec/channel or better.
2.12.4.2.6 Resistive load on current output: 250 Ω.
2.12.4.2.7 Biasing voltage: 24 V DC.
2.12.4.2.8 Isolation: Channel to internal circuit: 1.5 kV optical.
2.12.4.2.9 Overall accuracy: +/-0.2 % of F.S or better at 25 deg. C
2.12.4.2.10 Termination connector: Elmax terminal type for 2.5 sq. mm cable.
2.12.4.3 Isolated Analog Output Module:

2.12.4.3.1 Analog Output type:Voltage.
2.12.4.3.2 Analog Output range: 0 to - 10 VDC configurable.
2.12.4.3.3 Number of channels per module: 4 or available configuration.
2.12.4.3.4 Biasing voltage: 24 V DC.
2.12.4.3.5 Isolation: Channel to internal circuit: 1.5 kV optical.
2.12.4.3.6 Resolution12 bits or better.
2.12.4.3.7 Conversion speed: 80 µsec/channel or better.
2.12.4.3.8 Overall accuracy: +/-0.2 % of F.S or better at 25 deg. C.
2.12.4.4 Base Unit:

2.12.4.4.1 Digital Inputs and Output modules and power supply : If base unit does not
have in built DI module, ` DO module and power supply bidder shall quote
these modules separately. The front panel diagnostic for all modules is
preferred.
2.12.4.4.2 Digital Input module:

2.12.4.4.2.1 Total number of inputs: 40.
2.12.4.4.2.2 Digital input voltage:24 VDC.
2.12.4.4.2.3 Isolation: Channel to internal circuit: 1.5 kV optical.
2.12.4.4.4 Digital Output Module:
2.12.4.4.5 Total number of outputs: 60.
2.12.4.4.6 Digital output type: Relay.
2.12.4.4.7 Isolation method: Relay.
2.12.5 Power supply: The input voltage should be 230 +/- 10% VAC, 50 Hz the power
supply should have enough capability to supply all the modules and CPU.
2.12.6 Graphical MMI:

2.12.6.1 Type: Graphical.
2.12.6.1.1 Keypad: Numeric keypad with function keys and cursor keys.
2.12.6.1.2 Display size: To be specified by the bidder. Minimum 3”.
2.12.6.1.3 Communication port: To be specified by the bidder.
2.12.6.1.4 MMI should be compatible to PLC.
2.12.6.1.5 MMI should have capacity to change the internal PLC data like set points,
alarm values etc.


Page : 12 of 13
2.12.6.1.6 MMI should have built in alarm functionality.

2.12.6.1.7 MMI should have ASCII input and display feature.
2.12.6.1.8 Bidder shall specify the MMI software features.
2.12.7 PLC Programming Software:
2.12.7.1 PLC, SCADA and MMI software shall be Windows based and compatible
with Windows XP professional edition. The software should include all the
drivers for integration with PLC. The SCADA shall have following features.
i.Display of current trend of all parameters.
ii.Historical trend of all parameters.
iii.Display and logging of all trips and alarms.
iv.Acknowledgement and reset facility.
v.Data logging.
vi.Event logging and printing.
vii.Changing of parameters like reference voltage and set points from
SCADA.
viii.Animation of parameters.
ix.The minimum number of tags shall be 1000.
x.Run time key and development key shall be provided.
2.12.7.2 PLC Programming language shall preferably be ladder diagram.
2.12.7.3 The bidder should specify for the programming software of MMI.
2.12.8 Interfacing module for Server, workstation and PLC for SCADA: Bidder
shall specify the protocol and hardware module for SCADA.
2.12.9 Communication cables for Server to PLC, server to workstation and PLC to
MMI: Bidder shall supply the compatible communication cables for Server to
PLC, Server to workstation and PLC to MMI.
2.12.10 Operating and maintenance manuals: All relevant catalogues and instruction
cum user manuals should be supplied along with the system.
2.12.11 Specifications for panel:

• TB for external and internal signals.
• ON/OFF switch for input power supply.
• Installation: Suitable for indoor installation.
• Control cable entry: Through removable plate at bottom.
• Internal Wiring: Duly wired to terminations with ferrules, lugs &
sleeves.
• Panel Structure: Vertical free standing.
• Panel Pre-painting: Seven tank treatment before painting.
• Panel Fabrication: C.R.C.A. Sheet steel, 12/14 gauge.


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2.12.12 Computer for Server: Make and model of the Server shall be specified by the
bidder.
2.12.13 Computer for workstation: Make and model of the workstation shall be
specified by the bidder.
2.12.14 Colour Printer: The bidder shall specify the make and model of the printer.

SECTION C-4
Equipment construction and Design
Details
POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE Sub-Section : CC4
EQUIPMENT, CONSTRUCTION AND DESIGN DETAILS Revision :0
EQUIPMENT, CONSTRUCTION AND DESIGN DETAILS

1.0 Constructional features of panels:
1.1 The rectifier power cubicle and the local control panel shall be of flush front
metal enclosed sheet (CRCA) cubicle, indoor floor mounting, free standing
type and shall be made out of minimum 2 mm thick CRCA sheets. The
design shall be totally dust tight and vermin proof. The cubicle shall be
provided with ventilation louvers on the doors rendered dust proof using
fine brass/stainless steel wire mesh at suitable locations. All the components
inside the cubicle shall be located in such a manner that the maintenance of
any component does not interfere with other component. All power cubicle
and control panel shall be provided with 25 mm × 6 mm copper strip
throughout the length of the panel with two terminals at ends for grounding
purposes. All the metallic, non current carrying components of the panels
shall be connected to the earth by suitable size of copper strip. A base
channel of minimum 5 mm thick hot rolled sheet steel painted black shall be
provided to prevent corrosion of sheet steel cubicles and to facilitate
cleaning of the floors. All the structural steel material like plates, strips,
sections, flats etc. to be used for the fabrication of the cubicles shall
conform to IS: 2062. A standard good engineering practice shall be
followed strictly during the execution of the sheet metal constructional
work.
1.2 Painting:
All steel work shall undergo seven tanks process of degreasing, pickling in
acid, cold rinsing, phosphate, and passivity and then sprayed with high
corrosion resistant primer. The primer shall be baked in oven. The finishing
treatment shall be application of synthetic enamel of approved shade and
stove. Powder coating procedure shall be applied to obtain the final finish in
accordance with IS: 1477.
2.0 Constructional requirements:
2.1 Material: Sheet steel - (i) Hot rolled for channels &
(ii) CRCA for enclosure/doors
2.2 Material thickness - 2.5 mm for hot rolled sheets whereas 2.0 mm for CRCA
2.3 Degree of protection - IP 51
2.4 Minimum clearance in air for live parts - 25 mm
2.5 Painting - Shade no. 693 (Siemens gray finish) of IS:5 for exterior and glossy
white for interior of Epoxy powder coating

3.0 Constructional design details:

3.1 Metal clad unit frame shall compose of folded mild steel sheets of 2.5 mm
(minimum) thick hot rolled. For load bearing applications, internal
partitions and compartment doors minimum thickness of sheet steel shall be
2 mm CRCA. The metal sheets shall be smooth finished, leveled and free
from flaws. All steel parts including enclosure walls, doors and top cover
shall be adequately supported and stiffened to prevent flexing.
3.2 Neoprene rubber gasket shall be provided all around the perimeter of the
removable covers, doors, gland plates, cutouts, etc.
3.3 Panel doors shall be provided with concealed type hinges, with lockable
handles. The panel doors shall be of front as well as back opening type and
the side of the panels shall be covered with steel sheets. Doors shall be
provided with locking facility to prevent unauthorized opening of the door.
Appropriate earthed metal barrier or insulated barrier shall be provided to
ensure that the operator does not accidentally come in contact with the live
parts on opening of doors.
3.4 Florescent tube with switch fuse and 5 amps, three pin receptacle shall be
provided.
3.5 The panel shall have the hooks on the top for easy lifting of the power
supply unit as a whole.
3.6 The entire power supply unit shall be constructed in a manner such that it is
very easy and comfortable to work, operate, maintain, etc. till its service
life.
4.0 Wiring & Termination:
The power supply unit shall be of completely factory wired, ready for
connecting to the input. Power connections of the circuit shall be done by
copper bus bars or PVC insulated cable of adequate size, etc. to suit the
rated current. The copper bus bar joints shall be silver plated for best
performance. Control wiring shall be done by 1100 volts grade, armoured,
PVC insulated single core stranded copper conductor wire of size 2.5 mm2
minimum. All the control circuits shall be properly wired with ferrule
numbered at each terminal. The wiring shall be neatly bunched, adequately
supported, properly routed and finally crimpled to allow for easy access and
maintenance. The numbered ferrules at either end shall identify all the

wires. The terminal block shall be clamp type with barrier terminals and
shall be numbered. More than one wire shall not be terminated on either
side of the terminal block. Whenever termination of more than one wire is
required on the same point, they shall be terminated in adjacent terminal
block with suitable shorting links. All the terminals required for remote
operation shall be terminated to the Elmex type terminal blocks of adequate
capacity and be located at suitable locations. All the spare contacts of
relays, devices, etc. for our use shall be terminated into the terminal blocks.
At least 25 % spare terminals shall be provided. All the inter panel wiring
shall be taken through PVC sleeves with rubber grommets. Slotted type
PVC channels shall be provided for laying the control wiring. The detailed
scheme for interlocking with the process parameter and the remote control
will be furnished to the successful bidders at the later date. The power
supply unit shall be designed for the control cable entry from the top of the
panel.

SECTION C-5
Inspection and Testing
POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE Sub- Section : CC5
INSPECTION & TESTING Revision :0
INSPECTION & TESTING
1.0 TESTS AT MANUFACTURER’S WORKS
1.1 General
The supplier shall carry out all the shop tests and inspections specified in the
following clauses and QAP in addition to those normally carried out by him. The
supplier shall deliver the equipment/components covered in this specification to
site only after satisfactory completion of tests and issue of shipping release by the
Purchaser’s representative.
1.2 The equipment covered by this specification shall be subjected to stage inspection
at supplier’s premise or at sub-contractor’s premise in a planned manner as
mentioned below.
1.2. The basic raw material inspection at supplier’s/sub-contractor’s works.
1.2.2 Inspection during marking, cutting, punching, bending, welding, finishing, powder
coating operations of panels.
1.2.3 Inspections during the fabrication of the tank of rectifier transformer.
1.2.4 Inspection during the fabrication of power components viz. step down rectifier
transformer, inter-phase transformer, thyristor rectifier, etc. as well as control
components e.g. local control panel, DC current sensor, etc.
1.2.5 Inspection of busbars, busbar joints, bus bar supports.
1.2.6 Layout inside the thyristor rectifier power cubicle and local control panel, power
& control component mounting, control wiring.
1.2.7 Each major element shall be tested for its routine tests and heat run tests at the
respective works of the subsystem. These subsystems shall be tested to its full
current capacity at respective works & shall be guaranteed for the entire system
for integrated performance.
1.2.8 Inspection after the entire assembly of power supply unit as per the approved
drawings.
1.2.9 Acceptable limits of all tests shall be applicable as per relevant standard or
purchaser’s approval.
1.3 The purchaser or his authorized representative shall be permitted to witness the
tests and the supplier shall inform the purchaser sufficiently in advance (at least 15
days) so that the purchaser can make arrangement for witnessing the tests.

Purchaser or his authorized representative shall have access to valid calibration

certificates of the test and measuring instruments used for the tests.
1.4 Tests for rectifier transformer: as indicated below.

1.4.1 Routine tests:
a) Visual inspection for quality of workmanship, finish, dimensional checks, etc.
b) Voltage ratio test
c) Measurement of winding resistance of primary and secondary windings
d) Measurement of insulation resistance at 5kV/1kV V DC for the following.
i) Primary winding to earth
ii) Secondary winding to earth
iii) Primary winding to secondary winding
The minimum value for each of the above test shall be 100 MΩ.
e) Vector Group confirmation
f) High voltage withstand test for 1 minute as per relevant standard.
g) Induced over voltage withstand test (Double voltage Double Frequency Test)
h) No load test: To measure no load (core) loss.
i) Short circuit test: To measure copper (load) loss and subsequently to calculate
stray loss, % impedance, efficiency, regulation, etc.( copper losses shall be
normalized to 750C)
1.4.2 Type tests
Heat run (temperature rise) test: The heat run test (back to back method) shall be
carried out on both transformers for minimum period of 2 hours after the
stabilization of temperature (variation within± 10C in one hour rate) at all
measuring locations including hot spots. The locations for the temperature
measurement shall be decided mutually between the supplier and the purchaser.
The temperature at any location shall not exceed the design value.
1.5 Tests for thyristor rectifier cubicle and local control panel:
a) Preliminary checks w.r.t. General Arrangement & Bill of Material,
Accessibility of components, checking of clearances, earthing, proper wiring
of device & line supply surge suppressors, terminations, etc.
b) Visual inspection for quality of workmanship, finish, dimensional checks, etc.
c) Measurement of insulation resistance at 500 V DC

d) High voltage withstand test at 1.6 kV AC for 1 minute
e) Checking of direction of airflow & protection trip of the panel fan
f) Functional tests of the power and control cubicle by connecting hexa phase
transformer at the incoming of thyristor rectifier cubicle, which simulates the
secondary configuration of the step down rectifier transformer. This test
consists of checking ON, OFF, RESET, ACK operations, Trip parameter,
alarm annunciation, LED indications, Local/Remote operation, reference
voltage, etc.
g) Output voltage corresponding to the reference voltage, current feedback loop,

etc.
1.5.2 Type tests:

Temperature rise test shall be carried out in bridge configuration at lower scale
than the rated value. The junction temperature of the devices at the rated current
shall be extrapolated as per IEC: 146 1-1 (4.2.5)
1.6 Tests for copper DC output bus duct:

a) Visual inspection for quality of workmanship, finish, dimensional checks, etc.
b) Measurement of insulation resistance at 500 V DC
c) High voltage withstand test at 1.6 kV AC for 1 minute.
d) Measurement of resistance of the bus bar joints by milli-volt drop test.

Type tests:
Heat run/ short circuit (temperature rise) test: The heat run test of entire length of
bus duct shall be carried out at 110 % of the rated current of the bus duct for
minimum period of 2 hours after stabilization of the temperature (variation within
± 10C in one hour rate) at few locations particularly at joints including hot spots.
The locations for the temperature measurement shall be decided mutually between
the supplier and the purchaser. The temperature at any location shall not exceed
the specified value prescribed in the relevant standard.
1.7 Tests on Purchased items

For the bought out items like DC current sensor, isolated true RMS transducers,
etc. test certificates shall be provided by the supplier.

1.8 Tests on complete assembly
Following tests shall be carried out in the presence of Purchaser’s representative.

If the supplier is not in a position to carry out these tests at his works, he shall give
undertaking that he will arrange to carry out tests at site and in case equipment
fails in any of the test, he will replace the equipment.
a) Measurement of losses and efficiency at full load, 50% and 25% of load.
b) Alternating current measurements on the input side in all phases at rated

load and no load including power factor, wave shape and harmonics
injected to the system.
c) Ripple content of DC output at maximum and minimum DC bus voltage

under specified input voltage range.
d) All alarms and trips to be checked for satisfactory operation at various

loads from zero to full load including specified over load.
e) Measurement of sound level.
f) The complete rectifier units shall be operated at no load under ambient

conditions for not less than 96 hours continuously prior to release for
shipment.
g) The complete rectifier units shall be subjected to 100 hours burn in test at
full load at room temperature.

SECTION C-6
Quality Surveillance Plan
DC POWER SUPPLY SYSTEM FOR HEATING OF Sub-Section : CC6
QUALITY SURVEILLANCE PLAN (QAP) Revision : 0
QUALITY SURVEILLANCE PLAN (QAP)
Equipment/component quality & quality surveillance:
The components used in the power supply units shall be of high quality and their
manufacture and testing shall be done as per relevant standards, which are mentioned
above. The action plan for quality surveillance is as follows.
a) The sample quality control plan for all the equipment covered by this
specification is enclosed as annexure to this Section. The bidder shall
submit a detailed QA plan for approval.
b) The purchaser or his authorized representative shall have at all

reasonable times access to the supplier’s works to inspect and examine
the materials and workmanship during manufacture.
c) The supplier shall provide all reasonable inspection facilities such as

necessary tools, instruments, equipment and qualified operators.
SPE C I FI C AT IO N N O: P B - E - 775 Ma rch ., 2008

PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC POWER SUPPLY SYSTEM FOR Section :C
Sub-Section : CC 6.1
HEATING OF RESISTANCE ELEMENTS Page : 1 of 11
QUALITY SURVEILLANCE PLAN (QAP) ON RECTIFIER Revision : 0
QUALITY CONTROL PLAN FOR RECTIFIER
Scope and Purpose:
This document indicates the requirements expected from the contractor/manufacturer of the above equipment. Subsequent to the placement of
Purchase Order contractor/manufacturer shall submit for purchaser’s approval a quality assurance plan in line with this document incorporating
specific document numbers for “format of records”, “acceptance norms” and “reference documents”.
Abbreviations:
V - Verified by
P - Performed by
W - Witnessed by (After lapse of due notice to NPCIL, manufacturer may proceed with manufacture)
H - Hold (Unless a written clearance is obtained from NPCIL, manufacturer shall not proceed to next stage)
1 - NPC QS
2 - Prime supplier contractor
3 - Approved External Laboratory or Sub Vendor QC (if vendor QC/facility not available)
AD - NPC Approved Document such as Tender Document, Purchase Order, Drawing & Test Procedures
TR - Test Report
PS - Plant Standard
CHP - Customer Hold Point (Customer is NPCIL)
IS - Indian Standards
IEC - International Electro-technical Commission Standards
IEEE - Institute of Electronics and Electrical Engineers Standards
Notes:
• Wherever V & W are both indicated, NPC QS to witness test or review TRs.
• TRs not more than five year old from date of purchase order shall be reviewed for acceptance. Otherwise test shall be carried out.
• Minor: The characteristics of a component, process or operation whose failure neither materially reduce the usability of the product in
operation, not does it affect the aesthetic aspects.

• Major: The characteristic of a component, process or operation whose failure may cause operation failure which cannot be readily corrected
at site or cause substandard performance, increased erection and maintenance cost, reduced life or seriously affect aesthetics or ergonomics.
• Critical: The characteristics of a component, process or operation failure of which will surely cause operating failure or intermittent troubles
which is difficult to rectify at site or render the unit unfit for use or safety hazards.
• “Failure” of a characteristic means failure to meet the ‘acceptance norms’.
• Sampling: Generally in accordance with IS:2500 If 100% “Witness” is carried out by “Prime contractor”. NPCIL will witness on sample
basis, or if 100% “Witness” of tests is carried out by “Sub contractor”, “Prime contractor” will witness on sample basis.
Any deviation to this QAP shall be brought out by Vendor in his offer failing which this QAP shall be complied with fully.

Sl. Component Characteristics Category Method Extent Reference Acceptance Format AGENCY Remark
No. Checked of of document norms of
check check record
V P W H
1.0 Incoming
Material
1A CRCA Material composition Major Chem. Random IS-513 & IS-513 & TR 1.2 3
Sheets Dimension Sample Mfgs. Mfgs. I
Bend test Major Meas. 100% Procedure Inspection TR 1.2 3
Surface finish Major Physical 100% Procedure TR 1.2 3
Major Visual 100% TR 1.2 3
1B Bus bar 1. Dimensions Major Meas. 100% P.S/I.S P.S/I.S TR 1.2 3
Material
2. Surface finish Major Visual 100% P.S/I.S P.S/I.S TR 1.2 3
3. Tensile strength Major Physical Sample P.S/I.S P.S/I.S TR 1.2 3
4. % Elongation Major Physical Sample P.S/I.S P.S/I.S TR 1.2 3
5. Chemical Major Chem. Sample P.S/I.S P.S/I.S TR 1.2 3
composition
6. Electrical Major Elect. Sample P.S/I.S P.S/I.S TR 1.2 3
conductivity
7. Silver plating Major Physical Sample P.S/I.S P.S/I.S TR 1 3 2
thickness for joints (If
applicable)*
1C Support 1. Visual Major Visual 100% IS IS TR 1.2 3
Insulator
2. Dimensions Major Mech. 100% IS IS TR 1.2 3
3. Creepage distance Crit. Mech. Sample IS IS TR 1.2 3
4. Power frequency Crit. Elect. Sample IS IS TR 1.2 3
high voltage test
5. CTI Major Elect. Sample IS/IEC IS/IEC TR 1.2 3

1D Neoprene 1. Polymer Major Chem. Random IS-3400 IS-3400 & TR 1.2 3

Gasket identification Sample & Mfgs. PS
2. Burning test Major Physical - do - Mfgs. Inspection TR 1.2 3
3. Surface finish Major Visual 100% Procedu PS TR TR 3
re Procedure
PS
1E Control Routine tests Major Elect. 100% IS-694 IS-694 TR 1 1.2 2
Cables Type tests Major Elect. Sample IS-694 IS-694 TR 1 3 2
1F Control 1. Dimension Major Meas. 100% PS/IS PS/IS TR 1.2 3
Transformer 2. Insulation Rest. Major Major 100% PS/IS PS/IS TR 1.2 3
3. HV test Major Major 100% PS/IS PS/IS TR 1.2 3
4. Type test Major Major Sample PS/IS PS/IS TR 1 3 2
5. Operation Major Major 100% PS/IS PS/IS TR 1.2 3
6. Temp. rise Crit. Physical Sample PS/IS PS/IS TR 1.2 3
1G Air Break Routine tests Major Elect. 100% IS-2959 IS-2959 & TR 1.2 3
Contractor Type test Reports Crit. Elect. 100% Mfgs. TR 1.2 3
Catalogue
1H Air Break Routine tests Major Elect. 100% IS- IS-13947 TR 1.2 3
C.B Type test Reports Crit. Elect. 100% 13947 TR 1.2 3
1I Fuses Routine tests Major Elect. 100% IS IS TR 1.2 3
Type test Reports Crit. Elect. 100% IS IS TR 1.2 3
1J Indicating Rating Major Physical 100% Mfgs. Mfgs. TR 1.2 3
Lamps Function Elect. Catalog Catalogue TR 1.2 3
ue
1K Terminal Appearance Major Elect. 100% Mfgs. Mfgs. TR 1.2 3
Block HV Major Elect. 5% Catalog Catalogue & TR 1.2 3
samp. ue PS
IR Major Elect. 5% TR 1.2 3
samp.

1L Current 1. Visual Major Physical 100% PS/IS PS/IS TR 1,2 3

Transformer 2. Dimension Major Meas. 100% PS/IS PS/IS TR 1,2 3
3. HV Major Elect. 100% PS/IS PS/IS TR 1,2 3
4. Over voltage Major Elect. 100% PS/IS PS/IS TR 1,2 3
5. Temp. rise test Crit. Physical Sample PS/IS PS/IS TR 1 3 2
6. Marking Major Physical 100% PS/IS PS/IS TR 1,2 3
7. Accuracy Crit. Elect. Sample PS/IS PS/IS TR 1,2 3
1M Potential 8. visual Major Physical 100% PS/IS PS/IS TR 1,2 3
Transformer 9. Dimension Major Meas. 100% PS/IS PS/IS TR 1,2 3
10. HV Major Elect. 100% PS/IS PS/IS TR 1,2 3
11. Over voltage Major Elect. 100% PS/IS PS/IS TR 1,2 3
12. Temp. rise test Crit. Physical Sample PS/IS PS/IS TR 1 3 2
13. Marking Major Physical 100% PS/IS PS/IS TR 1,2 3
14. Accuracy Crit. Elect. Sample PS/IS PS/IS TR 1,2 3
1N Transducers 1. Type tests Crit. Meas. Sample PS/IS PS/IS TR 1,2 3
2. Routine tests Major Meas. 100% PS/IS PS/IS TR 1,2 3
3. Function Major Elect. 100% PS/IS PS/IS TR 1,2 3
4. Accuracy Crit. Elect. Sample PS/IS PS/IS TR 1,2 3 2
5. HV test Major Elect. 100% PS/IS PS/IS TR 1,2 3
6. Calibration Major Elect. 100% AD AD TR 1 3 2
1O Shunts 1. Dimension Major Visual 100% PS/IS PS/IS TR 1,2 3
2. Accuracy Crit. Crit. 100% PS/IS PS/IS TR 1,2 3
1P Resistor 1. material Major Chem. Sample PS/IS PS/IS TR 1,2 3
Element composition
(Power) 2. Dimension Major Meas. 100% PS/IS PS/IS TR 1,2 3
3. Physical Major Visual 100% PS/IS PS/IS TR 1,2 3
verification
4. Resistance Crit. Elect. 100% PS/IS PS/IS TR 1,2 3
value
measurement
5. Surface finish Major Visual 100% PS/IS PS/IS TR 1,2 3
1Q Fans 1. Dimension Major Visual 100% PS/IS PS/IS TR 1,2 3

2. Operation Major Physical 100% PS/IS PS/IS TR 1,2 3
3. HV test Crit. Physical 100% PS/IS PS/IS TR 1,2 3
1R Power SCRs 1. Appearance Major Visual 100% PS/IS PS/IS TR 1,2 3
2. Peak forward Crit. Elect. 100% PS/IS PS/IS TR 1,2 3
voltage/leakage
current
3. Peak reverse Crit. Elect. 100% PS/IS PS/IS TR 1,2 3
voltage/leakage
current
of heat sink
1S Power Diode 1. Appearance Major Visual Visual 100% PS/IS PS/IS TR 1,2 3
2. Peak reverse Crit. Elect. Elect. 100% PS/IS PS/IS TR 1,2 3
voltage/leakage
current
of heat sink
1T Bare PCB 1. PCB Grade Crit. Visual 100% IPC IPC Class-3 TR 1 3 2
Board 2. Thickness of Crit. Meas. 100% IPC IPC Class-3 TR 1 3 2
Board
3. Tolerance in Crit. Meas. 100% IPC IPC Class-3 TR 1 3 2
thickness
4. Thickness of Crit. Meas. 100% IPC IPC Class-3 TR 1 3 2
clad copper
conductor
5. Tolerance on Crit. Meas. 100% IPC IPC Class-3 TR 1 3 2
clad
6. Plating Crit. Meas. 100% IPC IPC Class-3 TR 1 3 2
adhesion
7. Hole pattern Crit. Meas. 100% IPC IPC Class-3 TR 1 3 2
accuracy
8. Hole Crit. Meas. 100% IPC IPC Class-3 TR 1 3 2

size/tolerance
9. PCB Crit. Meas. 100% IPC IPC Class-3 TR 1 3 2
cleanliness
10. Other checks Crit. Meas. 100% IPC IPC Class-3 TR 1 3 2
as per IPC
Standard and
acceptance
1U Electronic Type Major Meas. 100% MIL TR 1 3 2
Components qualification/Scre std./Nati
ening as per onal Std.
Section C-19 of
specification
2.0 In Process
Inspection
2A Panel 1. Appearance Major Visual 100% Mfgs. Mfgs. TR 1 3 2
Fabrication 2. Dimensional Major Meas. 100% Docume Acceptance TR 1 3 2
3. Verticality Major Meas. 100% nt Norms PS TR 1 3 2
4. Waviness Major Meas. 100% TR 1 3 2
5. Trough Major Visual 100% TR 1 3 2
Earthing
2B Panel Seven Tank Hot Crit. Visual 100% IS-6005 IS-6005 TR 1 3 2
Pretreatment Phosphating & Meas.
Process*
2C Panel 1. Surface finish Crit. Visual 100% IS-5 IS-5 TR 1 3 2
Painting 2. Paint shade Crit. Visual On TR 1 3 2
coupn.
3. Paint thickness Crit. Meas. - do - TR 1 3 2
4. Scratch test Crit. Physical - do - TR 1 3 2
5. Adhesion & Crit. Physical - do - TR 1 3 2
Peel off test
2E Chocks 1. Insulation Major Elect. 100% Mfgs. Mfgs. Data TR 1 3 2

Resist. Data Sheet and
2. HV test Major Elect. 100% Sheet Relevant IS TR 1 3 2
3. Temp. Rise Crit. Physical Type and TR 1 3 2
test Relevant
4. Inductance Crit. Elect. Type IS TR 1 3 2
test
2F Assembled 1. Correctness of Major 100% Mfgs. Mfgs. TR 1 3 2 TR
PCB components Assembl Assembly
2. Mech. Major 100% y Instruction TR 1 3 2 TR
Assembly Instructi
3. Mounting Major 100% on TR 1 3 2 TR
4. Orientation Major 100% TR 1 3 2 TR
5. Soldering Major 100% TR 1 3 2 TR
6. Marking Major Visual 100% TR 1 3 2 TR
7. Finish Major Visual 100% TR 1 3 2 TR
8. Other Major Meas. 100% IPC-A- IPC-A-610 TR 3 1,2 CHP
inspections and 610
tests as per IPC
standards and
acceptance of
PCBs
2G PCB a) Soldering Crit. Visual 100% IPC Std. IPC Std.- TR 1 3 2
Soldering & (Visual by Class-3
Cleaning magnifying glass)
b) Cleaning by Crit. Visual 100% IPC Std. IPC Std.- TR 1 3 2
cleaner Class-3
c) Finish (Visual) Major Visual 100% IPC Std. IPC Std.- TR 1 3 2
Class-3
d) Lacquering Major Visual 100% IPC Std. IPC Std.- TR 1 3 2
(Visual) Class-3
2H Assembled Functional test at Major Elect. 100% IPC Std. IPC Std.- TR 3 1,2
PCB room temperature Class-3

(Electrical)
3.0 Final
Inspection
3A Panel Wiring HV Withstand Major Elect. 100% IS-8263 IS-8263 & TR 3 1,2
and Insulation & Mfgs. Mfgs. Data
resistance Data Sheet
Sheet
3B I/O Inter- a) Correctness Major Visual 100% Mfgs. TR 3 1,2 CHP
connecting Std. (PS)
Cables b) Pull test Major Mech. 100% Mfgs. TR 3 1,2 CHP
Std. (PS)
c) Continuity test Major Elect. 100% Mfgs. TR 3 1,2 CHP
Std. (PS)
3C Assembled Functional test at Crit. Elect. 100% Mfgs. Mfgs. Data AD & 3 1,2 CHP
PCB energised Data Sheet TR
condition Sheet
4.0 Special Test
4A Climatic a) Dry heat test* Major Elect. Type IEC-68 IEC-68 TR 1 3 2
Test on test
Assembled b) Cold test* Major Elect. Type IEC-68 IEC-68 TR 1 3 2
PCB test
c) Damp heat Major Elect. Type IEC-68 IEC-68 TR 1 3 2
cycle test* test

4B Assembled a) Vibration Major Mech. Sample IEC- IEC-68/PS TR 1 3 2

PCB 68/PS
b) Major Mech. Sample PS PS TR 1 3 2
Insertion/Withdra
wal of Removable
Units
c) Protective Major Visual 100% IPC Std. IPC Std. TR 1 3 2
4C Final Testing 1. Dimension Major Visual 100% PS PS TR 3 1,2 CHP
on Complete 2. Output step Major Elect. 100% PS PS TR 3 1,2 CHP
Panel load change
3. Stability Crit. Elect. 100% PS PS TR 3 1,2 CHP
4. Regulation Crit. Elect. Sample PS PS TR 3 1,2 CHP
5. Measurement Meas. Elect. Type PS/IS PS/IS TR 3 1,2 CHP
of losses test
6. Temp. rise test Crit. Physical Type AD/IS AD/IS TR 3 1,2 CHP
test
7. Harmonic Crit. Elect. Type AD/IEE AD/IEEE TR 3 1,2 CHP
Injection in the test E
input
8. Output Ripple Crit. Elect. Type PS/IEEE PS/IEEE TR 3 1,2 CHP
Content test
9. Effect of input Major Elect. 100% PS PS TR 3 1,2 CHP
voltage variation
10. Checking of Crit. Elect. 100% PS PS TR 3 1,2 CHP
various voltages
and current
settings and its
accuracy

11. Battery branch Crit. Elect. 100% PS PS TR 3 1,2 CHP

circuit current
limit operation
12. Functional Crit. Elect. 100% PS PS TR 3 1,2 CHP
tests
13. Operation of Major Elect. 100% PS PS TR 3 1,2 CHP
various alarms
and indications
14. Trip point Crit. Elect. 100% PS PS TR 3 1,2 CHP
setting check
15. HV & IR tests Crit. Elect. 100% PS/IS PS/IS TR 3 1,2 CHP
16. Load bank Crit. Elect. 100% PS PS TR 3 1,2 CHP
resistance
measurement

PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC POWER SUPPLY SYSTEM FOR Section : C
Sub- Section : CC6.2
HEATING OF RESISTANCE ELEMENTS Page: 1 of 9
QAP FOR DRY CAST RESIN TRANSFORMER Revision : 0
QUALITY ASSURANCE PLAN FOR TRANSFORMER – Dry Cast Resin
Scope and Purpose:
The purpose of this QAP is to describe general quality practices, resources and sequence of activities (such as inspection, testing,
control etc.) to be performed during the manufacture of the above equipment.
Abbreviations:
R - Reviewed by
P - Performed by.
W - Witnessed by.
1 - NPC QS.
2 - Vendor QC.
3 - External Laboratory or Sub Vendor QC.
AD - NPC Approved Document such as Tender Document, Purchase order, Drawings & Test Procedures.
TR - Test Report.
PS - Plant Standard.
Notes:
∗ Wherever ‘Witness by NPC’ is mentioned, it is customer hold point.
∗ Minor: The characteristic of a component, process or operation whose failure neither materially reduce the usability of the product in
operation, nor does it affect the aesthetic aspects.
∗ Major: The characteristic of a component, process or operation whose failure may cause operation failure which cannot be
readily corrected at site or cause substandard performance, increased erection and maintenance cost, reduced life or seriously
affect aesthetics or ergonomics.
∗ Critical: The characteristics of a component, process or operation failure of which will surely cause operating failure or
intermittent troubles which is difficult to rectify at site or render the unit unfit for use or safety hazards.
∗ “‘Failure” of a characteristic means failure to meet the ‘acceptance norms ‘.
∗ Sampling: Generally in accordance with IS: 2500. Sampling will be used as under:-

If 100% “Witness” of tests is carried out by Vendor QC, NPC QS will witness on sample basis or if 100% “ Witness” of test is carried out
by “Sub Vendor”, “Vendor QC” will witness on sample basis.
Any deviation to this has to be specifically mentioned in remarks column.
1 2 3 4 5 6 7 8 9 10 11
CHARACT- REFERE- ACCEPT- FORMAT AGENCY
SL. METHOD EXTENT
COMPONENT ERISTICS CATEGORY NCE ANCE OF REMARKS
NO. OF CHECK OF CHECK R P W
CHECKED DOCUMENT NORM RECORD
1 CRGO Grade Measurement
Dimensions Major Sampling PS PS TR - 2 2
thickness
Iron Loss Major Measurement Sampling PS PS TR - 2 2
Interlaminar
Major Measurement Sampling PS PS TR - 2 2
resistance
Chemical
analysis
Ageing test Major Measurement Sampling PS PS TR - 2 2
Stacking factor Major Measurement Sampling PS PS TR - 2 2
2 Resin Hardener Shelf life
Accelerator Plasticizer viscosity,
colour
(Appearance)
Density Major Measurement Sampling PS PS TR - 2 2
Epoxy content
for RESIN
3 (a) Copper conductor Tensile
Strength,
Elongation,
Resistivity, Major Measurement Sampling PS PS TR - 2 2
Grade of
Copper &
Dimensions
Dimensions,
(b) (i) FG covered
Flexibility & Major Measurement Sampling PS PS TR - 2 2
Enamel Conductor
BDV

1 2 3 4 5 6 7 8 9 10 11
SL. METHOD EXTENT
Covering,
(ii) Enamel coated
abrasion,
conductor, Major Measurement Sampling IS IS TR - 2 2
flexibility and
(Polyesterimide)
BDV
Weight
4 Glass Mat. Uniformity loss Major Measurement Sampling PS PS TR - 2 2
ignition
Thickness &
5 Fleece Major Measurement Sampling PS PS TR - 2 2
BDV
Thickness,
6 F.G. Tape width, weight/ Major Measurement Sampling IS IS TR 1 2 2
meter length
Dimensions,
hardness,
7 Silicon Rubber elongation & Major Measurement Sampling PS PS TR 1 2 2
tensile
Strength
8 (a) Epoxy post Dimensions,
insulators Cantilever, Major Measurement Sampling PS PS TR 1 2 2
creepage
Type test and
acceptance Major Measurement Sampling PS PS TR 1 2 2
tests
(b) HV bushing Dimensions,
Temp. cycle
test, Elect.
Major Measurement Sampling PS PS TR 1 2 2
Routine &
Porosity test,
Type test
9 M.S. Parts (weldable Dimensions,
quality steel) Galvanising
Tensile
Strength, Major Measurement Sampling PS PS TR 1 2 2
Galvanising

1 2 3 4 5 6 7 8 9 10 11
SL. METHOD EXTENT
10 SRBGF Sheets Epoxy Thickness,
resin Bond glass fibre BDV Visual &
tubes Dimensional
Check
11 Copper Flat Thickness,
width,
Resistivity, Major Measurement Sampling PS PS TR 1 2 2
Chemical
analysis
12 Hardware and Tie Rod:
High tensile for load
bearing tie rods items
Dimensions Major Measurement Sampling IS IS TR 1 2 2
core clamping,
structure, bus bars &
enclosures
13 Thermister Calibration HV
Major Measurement 100% PS PS TR - 2 2
& IR
14 Winding Temperature Functional
Indicator Test, Major Measurement 100% PS PS TR - 2 2
Calibration
15 Push-on type cable
Visual Major Measurement 100% PS PS TR - 2 2
termination kit
16 Cable Gland & Lugs Dimensions Major Measurement Sampling PS PS TR - 2 2
17 Neoprene rubber below Dimensions,
hardness Oil
absorption,
flammability
18 Neutral CTs Including all
Routine Tests
as per IS,
Accuracy, Major Measurement 100% IS IS TR 1 2 2
ratio, voltage,
knee point,
Rct., Type test
19 Limit Switches (Door
Operation Major Measurement Sampling IS IS TR - 2 2
limit switch)

1 2 3 4 5 6 7 8 9 10 11
SL. METHOD EXTENT
20 Space heater Dimensions:
IR, HV Test,
Resistance & Major Measurement Sampling PS PS TR - 2 2
Power as per
BOM
21 Thermostat Calibration Major Measurement Sampling PS PS TR - 2 2
22 Terminal blocks Insulation test Major Measurement Sampling PS PS TR - 2 2
23 Connecting wires Measurement,
BDV Major water Sampling PS PS TR - 2 2
immersion
24 Rollers Dimensions Major Measurement Sampling PS PS TR - 2 2
25 Copper flexible Dimensions,
MV drop
MANUFACTURING
PROCESS &
ASSEMBLY
26 Core Cutting Dimensions Major Measurement Sampling PS PS TR - 2 2
Annealling Iron Loss Critical Epstein Test Sampling PS PS TR - 2 2
Assembled Core Dimensions,
Critical Measurement 100% PS PS TR - 2 2
Hot spot check
Pre-core loss
Major Test 100% PS PS TR - 2 2
HV test
27 Winding assembly Dimensions,
before casting continuity,
examination of
brazed joints &
Critical Measurement 100% PS PS TR - 2 1,2
condition of
insulation.
Location of
RTDs
27a Brazing qualification for
joints in winding & Visual Critical Visual 100% PS PS TR - 2 1,2
termination joints
28 Mould Assembly Proper
Critical Visual 100% PS PS TR - 2 2
Assembly

1 2 3 4 5 6 7 8 9 10 11
SL. METHOD EXTENT
29 Preheating Cycle time &
Temperature
30 Casting Temp. &
Vacuum
31 Curing Cycle time &
Temperature
32 Winding after casting Axial height,
ID, OD, size of
ventilation
duct, location Major Measurement 100% PS PS TR - 2 2
of RTD,
Measurement
of Resistance
33 Fabrication of core Welder
clamping structure & qualification.
enclosure Enclosure Major Measurement 100% PS PS TR - 2 2
dimensions
and verticality
Weld quality Major Measurement 100% PS PS TR - 2 2
Surface
Major Visual 100% PS PS TR - 2 2
treatment
Paint
(thickness,
Shade, finish
& adhesion)
34 Core coil assembly Assembly Bus
formation of
HV & LV, core
earthing coil
and supports.
Support
insulator Major Measurement 100% PS PS TR 1 2 2
rating, size
and mounting.
Core clamp
insulation
ventilation
ducts

1 2 3 4 5 6 7 8 9 10 11
SL. METHOD EXTENT
Brazing Major Visual 100% PS PS TR 1 2 1,2
Clearances Critical Measurement 100% PS PS TR 1 2 1,2
Ratio test Critical Measurement 100% PS PS TR 1 2 1,2
HV Tests Critical Measurement 100% PS PS TR 1 2 1,2
35 Cable Box Dimensions Major Measurement 100% PS PS TR - 2 2
36 Marshalling Box / Dimensions Major Measurement 100% PS PS TR 2 2 2
Junction Box
Protection (IP) Major Measurement 100% PS PS TR 2 2 2
HV & IR Tests Major Measurement 100% PS PS TR 2 2 2
Paint
Thickness & Major Measurement 100% PS PS TR 2 2 2
adhesion
37 TESTING & Clearance Critical Measurement 100% PS PS TR - 2 1,2
INSPECTION:
Dimensions Critical Measurement 100% PS PS TR - 2 1,2
Assembled transformer
Clamping of
in enclosure
CCA in Major Visual 100% PS PS TR - 2 1,2
Enclosure
Functioning of
Limit switches Major Tests 100% PS PS TR - 2 1,2
& interlocks
Visual
inspection,
wiring checks,
fitments,
mountings, Major Tests 100% PS PS TR - 2 1,2
accessories &
paint
38 Testing Routine Tests:

(a) Measure-
ment of
winding Critical Measurement 100% PS PS TR - 2 1,2
resistance on
all taps

1 2 3 4 5 6 7 8 9 10 11
SL. METHOD EXTENT
(b) Measure-
ment of turns
ratio for all
taps & voltage
vector
relationship
(c) Measure-
ment of
impedance
voltage, short
circuit & load
loss on all taps
(d) Separate
source voltage Critical Measurement 100% PS PS TR - 2 1,2
withstand test
(e) Induced
overvoltage Critical Measurement 100% PS PS TR - 2 1,2
test
(f) Measure-
ment of no
load loss and
current
(g) Partial
discharge test
(h) IR & PI
Value
(i) Capaci-
tance and tan Critical Measurement 100% PS PS TR - 2 1,2
delta
39 TYPE TESTS:
(a) Noise level Critical Measurement Sampling PS PS TR - 2 1,2
(b) Short
Critical Measurement Sampling PS PS TR - 2 1,2
circuit test *
(c) Impulse
test *
(d) Heat Run * Critical Measurement Sampling PS PS TR - 2 1,2

1 2 3 4 5 6 7 8 9 10 11
SL. METHOD EXTENT
(e) Zero phase
sequence
(f) Measure-
ment of no
load loss,
current at
different
voltages
*with enclosure.

QAP FOR BUS DUCT (NON SEGRATED) Revision : 0

SPECIFICATION NO: PP-E-775 March , 2008






SECTION C-7
Tender Evaluation
PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC Section : C
TENDER EVALUATION Revision : 0
TENDER EVALUATION
1.0 All prices quoted by the TENDERER shall be firm.
2.0 Deviation from the specification, if acceptable to the PURCHASER, in so far as

practicable, will be converted to a rupee value and added to the tender price to
compensate for the deviation from this specification. In determining the rupee value of
the deviation, the PURCHASER will use parameters consistent with those specified in
the documents and specifications and other information as necessary and available to the
PURCHASER.
3.0 Unit prices quoted by the TENDERER in section-E shall be binding on him and shall be
used for determining the final contract price.
4.0 Formula for Evaluation of Tenders
4.1 The tenders will be evaluated for losses as per the loading formula given below:
L = (A X (D1+D2))
L = Cost of loading for losses in Rupees
A = Difference in KW of losses from base case.
D1 (for iron losses) = Rs. 230880/-Per KW of loss.
D2 (for copper losses) = Rs. 83036/-Per KW of loss.
L = (A X D1) + (A X D2)
4.2 For evaluation, maximum guaranteed losses indicated shall be used.
4.3 The offer with lowest loss will be considered as the 'Base'.
4.4 Penalty for excess loss will be Rs. (D1 + D2) Per KW
Note: The maximum guaranteed losses (copper losses shall be normalized to 750C) shall
include losses of rectifier transformer.

SECTION C- 8
Erection, Testing and Commissioning
DC POWER SUPPLY SYSTEM FOR HEATING OF Sub- Section : CC8
ERECTION,TESTING AND COMMISSIONING Revision :0
ERECTION, TESTING AND COMMISSIONING
1.0 Installation of step down rectifier transformer:
The transformer installation consists of making transformer bay as per site layout
of load & confirming to IS: 10028 (Part II)-1981. Following is the scope of work
at site.
a. EP of suitable size embedded in the foundation
b. Earthing connection to the existing earthing grid by 2 nos. of 50 × 6 mm
copper earth bar
c. Installation of transformer / mountings etc.
d. Pre-commissioning checks
2.0 Installation of Bus Duct:
The installation of bus duct at site (indoor and outdoor) including supply and
fabrication of supports, grouting of the same at ground/ceiling/side wall/roof as
the case may be is in your scope. For entry of bus duct, cutouts of suitable size at
wall and also in ceiling as per site conditions are in your scope. The bus duct shall
be provided with two no. of earth strip along the length on either side. The pre-
commissioning tests like IR value, milli-volt drop test etc. shall be carried after
installation.
Preliminary checks prior to commissioning:

a) Check name plate details
b) Check for physical damage
c) Check tightness of all bolts, clamps and connecting terminals
d) Check cleanliness
e) Check earthing
f) Check for general layout
g) Check for bill of material as per approved drawing
h) Check for proper mounting of power devices like SCRs, Diodes, etc. on
heat sinks

DC POWER SUPPLY SYSTEM FOR HEATING OF Sub- Section : CC8
ERECTION,TESTING AND COMMISSIONING Revision :0
Commissioning checks prior to full load testing:

a) Each wire shall be traced by continuity tests and it should be made sure
that the wiring is as per relevant drawing.
b) All the wired terminals shall be meggered to earth.
c) Megger test between busbars and busbars to earth.
d) Insulation resistance test of all circuits.
e) Setting of relays, other alarm tripping devices and interlocks as per
scheme.
f) Functional checking of all control circuits.
g) Measurement of harmonics injected into the system for different loading
conditions.
h) Measurements of output voltage ripple content.
i) Other routine tests as per the relevant standards.
j) Heat run test for the power supply unit at output current of 3000 amps.
(Note: The rated current of the rectifiers shall be demonstrated by vender at site
after compellation of erection, the rated current shall be done by shorting the
+ve & -ve output of buses on all individual power supply)

SECTION C- 9
Special Tools and Tackles for Erection
and Maintenance

PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC
Section :C
POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE
Sub-Section : CC9
SPECIAL TOOLS AND TACKLES FOR ERECTION AND Revision :0
MAINTENANCE
SPECIAL TOOLS AND TACKLES FOR ERECTION AND

MAINTENANCE
1.0 Special Tools and Tackles
All Special tools and tackles required for successful erection, site testing &
commissioning shall be provided by the Contractor and a list of such items shall be
submitted along with the data sheet.
2.0 Spares
The bidder shall include in his scope of supply, all the necessary recommended spares for
5 years after the expiry of guarantee period. The purchaser reserves the right to finalize
the exact quantities of the spare parts on the basis of the unit rates quoted by the bidder.
The spares ordered shall be delivered to site with the main equipment.

SECTION C- 10
List of Drawings
DC POWER SUPPLY SYSTEM FOR HEATING OF Sub- Section : CC 10
LIST OF DRAWINGS Revision :0
LIST OF DRAWINGS ENCLOSED
SL DRAWING NO. DESCRIPTION

NO
1 NPCIL/54000/0501/ED/R-O Single Line Diagram for Power Supply to Resistance
Heating Element and Various Operating Modes of DC
Power Supply Units
2 NPCIL/54000/0503/GA/R-O Decay power DC supply equipments layout
3 NPCIL/54000/0502/GA/R-O DC output bus bar layout

SECTION -D
FORMAT FOR
SUBMISSION OF PART-I
(TECHNICAL) OF TENDER
SECTION D – 2.1
Technical Data
PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC Section :D
POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE Sub-Section : D 2.1
TECHNICAL DATA Revision :0
TECHNICAL DATA
Sl. Description TECHNICAL DATA
No.
Technical data for 5 nos. of 3000A at 85V, solid state variable DC power supply unit
1.0 Ambient requirements:
a) Climatic condition
b) Ambient temperature
c) Relative humidity
2.0 List of applicable codes, standards, and specifications
3.0 General Description of power supply unit
4.0 Technical requirements:
4.1 a) Rating of power supply unit
b) Output voltage in volt (True RMS)
c) Maximum output current in amps (True RMS)
d) Limit of variation of power/current
e) Duty cycle for the output
f) Minimum output voltage at maximum output current of

3000 Amps. DC
4.2 Type and mode of control
4.3 Reference voltage derived from 0 to 300kW power /3000

amps.
4.4 Input to the unit (available at site):
a) Auxiliary supply available


No.
4.5 Type of load with maximum resistance value
4.6 Regulation (Current/Power)
4.7 Response time
4.8 Output current stability
4.9 Output ripple
4.10 Rectifier transformer
a) Type
b) Winding
c) Cooling
d) Insulation
e) Primary voltage
f) Secondary voltage
g) Rated primary KVA
h) Primary current
i) Type of primary connection
j) Type of secondary connection
k) Temperature rise (As per IS:2026)
l) Installation
m) Size & Weight
n) List of Accessories


No.
4.11.1 Thyristor Rectifier
a) Rated DC Power
b) Rated DC Voltage
c) Rated DC Current
d) Type of Cooling
e) No. of pulses
f) Enclosure & IP
g) Size & Weight
4.11.2 Thyristors
A Make
B Applicable standards
C Circuit configuration and no of pulses
D No of Thyristors (stack/assembly) in pulses
E For each Thyristor
i. Value of di/dt & dv/dt

ii. RMS value of forward current & max. mean current (A)
iii. Max. surge forward current
iv. Max. repetitive peak & surge blocking voltage (V)
v. Turn off-time (S)
vi. Turn on-time (S)
vii. Max. thermal ratings
F Type of cooling


No.
G If forced cooling is used, rating of equipment on failure of on
failure of forced cooling.
H Heat sink material
I Max temperature of heat sink
J Protection provided for:

Power circuit
Control circuit
4.12 Inter phase transformer/ Winding
a) Winding
b) Cooling
c) Inductance
d) Size
e) Rating
4.13 DC Current Sensor
a) Principal of operation
b) Rating
c) Accuracy
d) Linearity
e) Construction
f) Window size
g) Overall size


No.
4.14 Local control panel
a) Size of control panel and control cable
b) List of control components & their make
4.14.1 List of interlock and subsequent annunciation
4.14.2 Provision of Audio annunciation for interlocking parameters
4.14.3 List of additional LED indications
4.14.4 List of operating controls on front cover of the local control

panel
4.14.5 Supply of dual output, isolated, True RMS voltage, current
and power transducers along with the digital display of True
RMS voltage, current and power on the front of the local
control panel
1) Input:
a) Voltage transducer
b) Current transducer
c) Power transducer
2) Output:
a) Display: True RMS Voltage:
True RMS Current:
True RMS Power:
b) Dual analogue Output
c) Accuracy of the analogue output


No.
d) Isolation
e) Driving Capability
3: Auxiliary Power Supply
4: Feature of Provision of remote communication
4.14.6 List of protections
4.15 Description of DC output Copper Bus Duct from rectifier

heater banks
a) Material and type
b) Size of bus bar
c) Temperature rise
d) Short time thermal rating
e) Short circuit withstands current for 1 sec. (RMS & Peak)
f) Clearance in bus bars
g) Material for Ground/Earth Bus
h) Current transformer
i) Bus bar Joints
j) Bus bar support material
k) Material for the duct
l) Size of bus duct
4.16 Description of workstation & soft ware at control room &

Programmable Logic Controller to suit the supplier control
scheme if deviate from purchasers specification in mentioned
section-CC 3 Para 2.12 of this tender.


No.
4.16.1 Software details
4.16.2 Hardware details
4.16.3 Functional feature
4.17 Important Constructional features
4.17.1 Painting
4.17.2 Constructional requirements
a) Material
b) Material thickness
c) Degree of protection
d) Minimum clearance in air for live parts
e) Paining (Shade)
f) Cooling
4.17.3 Constructional design details
4.18 Description of Wiring & Termination
4.19 Details about Equipment/component quality & quality

surveillance
4.20 List of recommended Spares
5.0 Inspection, Testing and Reports
5.1 Stage-I:
a) Routine tests
b) Type tests


No.
5.2 Details of the Tests on Purchased items
6.0 List of submission of Technical Documents
7.0 Details about Supplier’s drawing and schedule
8.0 Details about the Familiarization of Purchaser’s Engineer
9.0 Procedure for the Installation and Commissioning at site
a) Preliminary checks
b) Commissioning checks
10.0 Details about the ventilation arrangement
11.0 Guarantee
12.0 Reports submission
13.0 Delivery schedule

SECTION D – 2.2
Schedule for Tender’s Experience
PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC Section : D
SCHEDULE FOR TENDERER'S EXPERIENCE Revision : 0
SCHEDULE FOR TENDERER'S EXPERIENCE
The TENDERER shall furnish here a list of all similar jobs executed by him to whom a reference
may be made by the PURCHASER in case the PURCHASER considers such a reference
necessary.
Sr. Description of Work Value of Delivery Date Actual Contact

No. work including order or Work as per P.O. date of Address of
quantity of items P.O. No. delivery PURCHASER
& Date
SIGNATURE_______________________
DESIGNATION_____________________
COMPANY_________________________
SEAL OF THE COMPANY DATE_____________________________

SECTION D – 2.3
Drawings to be submitted along with
the Tender
PROCUREMENT SPECIFICATION ON DECAY HEAT POWER DC Section : D
DRAWINGS TO BE SUBMITTED ALONGWITH THE TENDER Revision : 0
DRAWINGS TO BE SUBMITTED ALONGWITH THE TENDER

The following drawings/ documents shall be submitted (in triplicate) for purchaser’s scrutiny
and approval within 3 weeks from the date of release of purchase order.
a. Detail schematic drawing showing power circuit configuration and control strategy along
with the bill of materials indicating the make, model no. and the type of components
used.
a. Outline drawing giving dimensions of all the systems and sub systems installed in
thyristor rectifier power cubicle, local control panel, copper bus duct, ventilation system
and cable lying of the control circuit.
b. The assembled weight of the thyristor rectifier power cubicle, DM water polishing unit,
heat exchanger, PLC panel, work station, local control panel etc.
c. Fabrication drawings indicating detailed constructional features like arrangement of
doors and supporting structures, looking arrangement, louvers along with mesh for
ventilation, bus bar supports and frame work, etc.
d. General Arrangement (GA) drawing of thyristor rectifier cubicle, local control panel,
step down rectifier transformer, AC & DC copper bus duct, hall sensor and its control
panel and ventilation system for power module area indicating the layout as well as the
front view, plan, elevation & typical sectional views of all the power & control
components, wiring layout, layout of indication, meters & controls, etc.
e. Power and control wiring diagram giving detailed wiring sequence including terminal
block nos., wire nos., ferule nos., etc.
f. Design details & notes and technical data sheet.
g. Details of Factory and site test to be carried out on individual and assembled system with
limits and acceptable ranges.
h. Earthing details
SIGNATURE_______________________
DESIGNATION_____________________
COMPANY_________________________

SECTION D – 2.4
Performance Data including
Performance Curves etc. to be submitted
along with the Tender
Section : D
Sub-Section : D 2.4
ELEMENTS
Page : 1 of 1
PERFORMANCE DATA INCLUDING PERFORMANCE CURVES
Revision : 0
ETC. TO BE SUBMITTED ALONG WITH THE TENDER
PERFORMANCE DATA INCLUDING PERFORMANCE CURVES

ETC. TO BE SUBMITTED ALONG WITH THE TENDER
1.0. All type test certificates shall be enclosed.
2.0. Performance reports from previous customers to be furnished.
SIGNATURE_______________________
DESIGNATION_____________________
COMPANY_________________________

SECTION D – 2.5
Schedules for Submission of
Drawings, Data, Instruction Manuals,
Test Reports etc
PROCUREMENT SPECIFICATION ON DECAY HEAT POWER Section : D
DC POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE Sub-Section : D 2.5
SCHEDULES FOR SUBMISSION OF DRAWINGS, DATA,
Revision : 0
INSTRUCTION MANUALS, TEST REPORTS, ETC.

1. DRAWINGS/DOCUMENTS
The CONTRACTOR shall furnish the following drawings/documents
for the equipments covered in this specification within the time
indicated after the issue of letter of intent.
1.1 Engineering schedule indicating list of all drawings ICs, Power and
control cable schedule, ED etc, documents, Q.A Plan data,
performance curves, test certificates, manuals, list of items and their 2 Weeks
rating, makes etc. to be submitted by the CONTRACTOR together
with dates of submission and category of approval i.e. for approval or
for reference.
1.2 General Arrangement drawings for all the equipments e.g. rectifier
power module, DM water polishing unit and heat exchanger,
transformer, busbar layout, power and control cables layout etc. 2 Weeks
including all dimensional details, layout and maintenance
requirements, details of supports required and other accessories, cable
entry details, earthing requirements, Detailed cross-sectional drawings
showing all relevant internal details of equipment/accessories etc.
1.3 Bill of materials including make, months technical specification etc.

for all equipment/accessories covered under item. 2 Weeks
1.4 a) Foundation drawings for all equipment/ accessories indicating the
grouting details, loading data and any insert details for supporting
structures and other equipment being supplied by the CONTRACTOR.
b) Detailed wiring diagram indicating scheme of connection, terminal

numbers, and ferrule numbers etc. of all panels.
c) Design calculations (wherever necessary) to prove the adequacy of 2 Weeks

the equipment offered.
d) Manufacturing plan.
e) Detailed quality assurance plan.
f) Any other drawings/documents considered Necessary.
1.5 Final test procedures (at shop as well as at site) 2 Weeks

PROCUREMENT SPECIFICATION ON DECAY HEAT POWER Section : D
DC POWER SUPPLY SYSTEM FOR HEATING OF RESISTANCE Sub-Section : D 2.5
Revision : 0
2.0 DATA
2.1 All final technical details, parameters, characteristic and performance

data as listed in Section D-1.1 of this specification and any other data 1 Months
required.
2.2 Manufacturer's test certificate for all the equipment/components

mounted on the panels.
2.3 Maximum dimensions and weights of various packages for shipment

under this CONTRACT
3.0 TEST CERTIFICATES
3.1 Type test certificates for all equipment & accessories being supplied
under this CONTRACT.
15 days
3.2 Routine test certificates for all equipment & accessories being supplied before
under this CONTRACT dispatch
of
3.3 Ten nos. bound of copies of the compiled and approved test equipment
certificates. .

SECTION D – 2.6
Performance Data including
Schedule of Performance Guarantee
Section : D
Sub- Section : D 2.6
ELEMENTS
Page : 1 of 1
PERFORMANCE DATA
Revision : 0
PERFORMANCE DATA
The TENDERER shall furnish performance guarantee in respect of the following:
1.0 All equipment & accessories supplied shall conform to the requirements listed in this
specification as well as the requirements of all applicable standards. Not meeting any of
these requirements will result in rejection of the equipment / accessories.
SIGNATURE_______________________
DESIGNATION_____________________
COMPANY_________________________

SECTION D – 2.7
Schedule of Deviation from Technical
Specification
Section : D
ELEMENTS
Page : 1 of 1
SCHEDULE OF DEVIATION FROM TECHNICAL
Revision : 0
SPECIFICATION
SCHEDULE OF DEVIATION FROM TECHNICAL SPECIFICATION
All deviations from the technical specification shall be filled in by the TENDERER clause by
clause in this schedule.
Section Clause No. Deviation
The TENDERER hereby certifies that the above mentioned are the only deviations from
the technical specification of the enquiry.
SIGNATURE_______________________
DESIGNATION_____________________
COMPANY_________________________

SECTION D – 2.8
Schedule of Manufacturing, Delivery
and other Related Activities
Section : D
ELEMENTS
Page : 1 of 1
SCHEDULE OF MANUFACTURING, DELIVERY
Revision : 0
AND OTHER RELATED ACTIVITIES
SCHEDULE OF MANUFACTURING, DELIVERY AND OTHER

RELATED ACTIVITIES
The TENDER shall indicate the time period for manufacture, delivery of each rectifier complete
unit and other activities of equipments as shown below.
Sl. Equipment Time for date of Time for Time required Total time
No. order to works test works test, for shipment from date of
(Months) dismantling, to site. order to
packing and (Months) receipt at site.
ready for (Months)
dispatch from
works.
(Months)
We, the undersigned hereby undertake to meet the above time schedule from the date of order.
SIGNATURE_______________________
DESIGNATION_____________________
COMPANY_________________________

SECTION D – 2.9
Schedule of Personnel for Supervision of
Erection and Commissioning
Section : D
ELEMENTS
Page : 1 of 1
SCHEDULE OF PERSONNEL FOR SUPERVISION OF
Revision : 0
ERECTION AND COMMISSIONING
SCHEDULE OF PERSONNEL FOR SUPERVISION OF ERECTION

AND COMMISSIONING
The TENDERER shall indicate below the number and category of personnel proposed to be
deployed by him for erection, testing and commissioning. TENDERER shall also include in
his offer a site organization chart and furnish the bio-data of key personnel proposed to be
deployed by him at site in the event of award of Contract by PURCHASER.
Sl. Category Number of expatriate Personnel Duration

No
SIGNATURE_______________________
DESIGNATION_____________________
COMPANY_________________________

Technical Specification

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SECTION – ‘C’ : TECHNICAL SPECIFICATION OF

SPECIFICATION NO. PB-E-775

DATE OF ISSUE : March 2008

TOTAL NO. OF PAGES :

CHECKED BY : Dr. R.D.KULKARNI

(Name & Designation) (Signature) (Date)

(For Revisions See Revision Control Sheet)

DOCUMENT TYPE: PROCUREMENT SPECIFICATION

SPECIFICATION NO : PB-E-775 Rev. No.: R-0

TITLE: PROCUREMENT SPECIFICATION ON

Specification No.: PP-E-775 March,2008

1.0 Project Information

1.1 Location : Tarapur, Dist. Thane, Maharashtra, INDIA

1.2 Elevation : varies from +3 m to +8 m

1.3 Nearest railway station: BOISAR on Mumbai- Vadodara station of western

1.4 Ambient air temperature:

a) Maximum dry bulb temp. - 40 O C – 60% With corresponding

2.0 General information and instructions to Tenderer

2.1 It is the intent of the purchaser to incorporate this specification in the

2.2 Tenderer is requested to carefully examine and understand the

SPECIFIC AT ION NO: PB-E-775 Ma rch . , 2008

SPECIFIC AT ION NO: PB-E-775 Ma rch . , 2008

2.8 The successful bidder is required to maintain a hindrance register in

2.12 Information to be included with the tender

2.13 Data, documents & drawings

SPECIFIC AT ION NO: PB-E-775 Ma rch . , 2008

2.13.2 The data, documents and drawings to be submitted after placement of

2.13.3 Approval of the contractor's drawings and design documents by the

2.14 Submission of Documents after Placement of Order/Letter of Intent

2.14.1 Bar Chart

2.14.2 Data, Documents and Drawings

a) The data, documents and drawings to be submitted along with the

b) The data, documents and drawings to be submitted after placement

c) In drawing preparation by Vendor, the device nomenclature as per

d) Supplier shall submit compliance certificate(s) for items supplied

SPECIFIC AT ION NO: PB-E-775 Ma rch . , 2008

2.14.3 Placement of order’s sub-orders by contractor

2.14.4 Progress report

3.0 Scope of supply, work and services

3.1 Scope of this specification covers the engineering, manufacturing, supply,

3.3 The preparation of ‘As Built’ drawings, cable Schedules, interconnection

3.4 Complete fabrication, manufacture and procurement from sub suppliers

SPECIFIC AT ION NO: PB-E-775 Ma rch . , 2008

3.7 Supervision of Fabrication, pre-assembly (if any), erection, testing and

SPECIFIC AT ION NO: PB-E-775 Ma rch . , 2008

Contractor’s responsibility to get the information from available site

3.15 On award of P.O. Contractor shall furnish the schematics, general

3.17 Immediately on award of P.O. the Contractor shall submit a detailed

4.1 As identified in Section CC-1.

5.0 Free issue of material

6.0 Option for Placement of Order

7.0 Terminal points

SPECIFIC AT ION NO: PB-E-775 Ma rch . , 2008

8.1 Refer Section CC-10.

9.0 Applicable codes, standards and specifications

9.1 The design, material, construction, manufacture, inspection, testing,

9.6 Applicable standards for individual equipment are generally listed in

i) Indian electricity rule

SPECIFIC AT ION NO: PB-E-775 Ma rch . , 2008

10.0 Specification of main equipment and accessories

Specifications for individual equipment please refer relevant sections.

11.0 Inspection and testing

11.1.1 The equipment covered by this Contract shall be subjected to inspection

11.1.4 Approval or passing of any such inspection by the purchaser or his