FGD Tendor For Refrence

AN ISO 9001 & 14001 COMPANY
TENDER DOCUMENT
NIT No: SRO/CON/ETS/079 dtd 15.04.2021
Tender for “Design Supply, Fabrication, Erection and Commissioning of

ABSORBER of FGD in all respects at NTPC RAMAGUNDUM SUPER THERMAL
POWER STATION, STAGE III (1X500 MW) under LOT-5” -PACKAGE-E -
SECOND CALL
VOLUME – II
Technical Specifications, construction schedule and Drawings
ENGINEERING PROJECTS (INDIA) LIMITED

(A GOVT. OF INDIA ENTERPRISE)
Southern Regional Office, Chennai
Signature of the Bidder with seal Page 1 of 2 EPI

Index
Sl. Page No. No. of

Description
No. Pages
Technical Specifications, NTPC Tender Documents and

Drawings.
1 03-396 394
(Volume 2 part 1 of 5 to Volume part 5 of 5)
Signature of the Bidder with seal Page 2 of 2 EPI

TENDER DOCUMENT
(Tender Doc No.:SRO/CON/ETS/079)
VOLUME- II - TECHNICAL SPECIFICATIONS
FOR
ABSORBER PACKAGE
(FGD SYSTEM)
PREPARED BY
POWERTEC ENGINEERING PVT LTD.

New No. 4, Old No. 8, 5th Main Road
Vijayanagar Velachery
Chennai - 600 042, India
TEL NO: 044-22591731/22593572 FAX NO. 044 - 22591726
RSTPP
ABSORBER PACKAGE (FGD SYSTEM )
STAGE - III
CONTENTS
TOTAL
S.No SECTION NO DESCRIPTION NO. OF
PAGES
1 SECTION – I SCOPE OF SUPPLY & SERVICES (GENERAL) 16
2 SECTION – II PROJECT INFORMATION 22
SCOPE OF WORK, EXCLUIONS & TERMINAL

3 SECTION – III 10
POINTS
4 SECTION – IV A TECHNICAL REQUIREMENTS - MECHANICAL 38
5 SECTION – IV B TECHNICAL REQUIREMENTS - ELECTRICAL 29
6 SECTION – IV C NOT USED ---
TECHNICAL REQUIRMENTS – CIVIL &

7 SECTION – IV D 34
STRUCTURAL WORKS
TECHNICAL REQUIREMENTS – QA &

8 SECTION – IV E 55
INSPECTION
9 SECTION – V FUNCTIONAL GUARANTEES & LD 8
10 SECTION – VI MANDATORY SPARES 7
11 SECTION – VII GENERAL TECHNICAL REQUIREMENTS 86
12 SECTION – VIII ERECTION CONDITIONS OF CONTRACT 64
PRE-COMMISSIONING, COMMISSIONING &

13 SECTION – IX 16
INITIAL OPERATIONS
14 SECTION – X TENDER DRAWINGS ---
TENDER DOC NO.:SRO/CON/ETS/079 VOLUME - II Page 2 of 2

RSTPP ABSORBER PACKAGE SCOPE OF SUPPLY & SERVICES
STAGE - III (FGD SYSTEM ) (GENERAL)
Index
1. PREAMBLE: .............................................................................................................................. 2
2. PROJECT INFORMATION ..................................................................................................... 2
3. INTENT OF SPECIFICATION ................................................................................................ 2
4. TENDER DRAWINGS.............................................................................................................. 8
5. SYSTEM DESCRIPTION ......................................................................................................... 9
6. GENERAL LAYOUT ASPECTS ............................................................................................ 10
7. CONTROL & OPEARTION PHILOSOPHY ........................................................................ 11
8. SCOPE OF SUPPLY & SERVICES (General) ....................................................................... 11
9. QUALIFYING REQUIREMENTS FOR EQUIPMENTS / SYSTEMS ............................... 16
10. PROVENNESS CRITERIA FOR VARIOUS EQUIPMENTS .............................................. 16
Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION - I Page 1 of 16

1. PREAMBLE:
1.1. Supply and Installation contract of Flue Gas Desulphurisation (FGD) system package for
RAMAGUNDAM SUPER THERMAL POWER STATION - Stage III (Unit # 7) of NTPC
Ltd (OWNER) is entrusted to ENGINEERING PROJECTS (INDIA) Ltd (EPIL- Client) by
NTPC Ltd.
1.2. The scope of the contract includes Engineering, Supply, Construction, Erection, Testing
and Commissioning of Flue Gas Desulphurisation (FGD) of System.
1.3. FGD technology for the contract is being provided to EPIL by their collaborator / JV Partner
(Technology Partner), M/s WUHAN KAIDI ELECTRIC POWER ENVIRONMENAL, CO,
LTD – CHINA (KDPE).
1.4. KDPE shall provide the FGD Technology, Basic Engineering, Overall System Guarantee and
supply of some critical equipments and commissioning /advisory services.
1.5. EPIL has appointed M/s Powertec Engineering Pvt. Ltd. (PEPL) as their Associate
Consultant for Post award engineering work of FGD work.
1.6. The entire FGD Work is split into various packages and EPIL shall tender and award the
packages to reputed, qualified, technically competent, Vendors / Suppliers / Manufacturers
/ Sub-contractor as the case may be.
1.7. The Vendors/ Suppliers / Manufacturers Sub-contractors shall supply /execute the work /
as per the requirements spelt out in the Technical Specifications.
2. PROJECT INFORMATION
Project Information of RAMAGUNDAM STPP is enclosed in Section – II of this Technical

Specification (Volume –II of Bid Document).
3. INTENT OF SPECIFICATION
3.1. The scope of the proposal covered in this tender document shall be on the basis of a single
point responsibility, completely covering the following activities and services in respect of
all the equipment specified and covered under the specifications and read in conjunction
with “Scope of Supply & Services, Exclusions and Terminal Points”, in Section- III of this
Technical Specification.
a) Detailed design of equipment and system(s) included under Bidder’s scope.
b) Providing engineering drawings, equipment sizing as required, & applicable

performance data , instruction manuals and as built drawings (wherever required)
and other information ;
c) Providing training of Owner’s personnel if any mentioned in General Technical

Requirements (i.e) GTR in Section –VII of this Technical Specification.

d) Compliance with statutory requirements and obtaining clearances from statutory

authorities, wherever required;
e) Finalization of sub-vendors, manufacturing quality plans and Field quality plans;
f) Complete manufacturing including shop testing/type testing;
g) Civil, and Structural works to the extent applicable, construction facilities,

providing construction offices, field laboratory, construction power distribution
and construction equipments;
h) Packing and transportation from the manufacturer’s works to the site including
customs clearance & port clearance, port charges, if any.
i) Receipt, storage, preservation, handling and conservation of equipment and other

materials at the site;
j) Pre-fabrication /Fabrication , pre-assembly, as specified elsewhere
k) Erection / Installation, testing, commissioning and completion of facilities

including putting into satisfactory operation of identified equipment(s) including
successful completion of initial operation;
l) Furnishing of spares on FOR site basis.
m) Reconciliation with customs authorities, as required,
n) Satisfactory conclusion/ closure of the contract.
o) Insurance and other requirements for the complete package in accordance with the
provisions of General Conditions of Contract (GCC), /Additional Condition of
Contract (ACC) is enclosed in Volume-I of Bid Document.
p) The contractor shall be responsible for supplying any necessary jointing material,
connectors, electrodes, nuts, bolts (including anchor/foundation bolts, accessories),
etc.
q) All the first fill and one year's topping requirement of consumables such as oil,
lubricants, greases etc. which will be required to put the equipment covered under
the scope of specifications, into successful commissioning/ initial operation and to
establish completion of facilities shall be furnished by the contractor. Suitable
standard lubricants as available in India are desired. Effort should be made to limit
the variety of lubricants to minimum.
r) Special tools and tackles if any required for erection and commissioning of
Absorber tower and Elevator which is included in Bidder’s scope.
3.2. The work to be carried out as per the above scope shall be all in accordance with the
requirements, conditions, appendices etc. given in Technical Specifications (Volume-II of the

Bid Document) together with those stated in other Chapters, Annexure, Appendices stated
in other Volumes of the Bid Document completely as if bound herewith.
3.3. It is not the intent to specify herein all aspects of design and construction nevertheless, the
Absorber tower along with internal lining and Lift includes all necessary Electrical &
Instrumentation shall conform in all aspects to high standard of engineering, design and
workmanship and shall be capable of performing in continuous commercial operation in a
manner acceptable to the Client (EPIL) who will interpret the meaning of the specification &
drawings and shall have a right to reject or accept any work or material which in his
assessment is not complete to meet the requirements of this specification and/or applicable
Indian / International standards mentioned elsewhere in this specification.
3.4. The Bidder shall be responsible for providing all materials, equipment and services,
specified or otherwise (unless specifically excluded) which are required to fulfill the intent of
ensuring operability, maintainability and the reliability of the complete system covered
under this specification.
3.5. Bidders are requested to carefully examine and understand the specifications and seek
clarifications, if required, to ensure that they have understood the specification. Before,
submitting their offer, Bidder is required to visit the Project site for assessing the feasibility
and layout for FGD System. The Bidder’s offer should not carry any sections like
clarifications, interpretations and/or assumptions. However, if the Bidder feels that, in his
opinion, certain features brought out in his offer are superior to what has been specified,
those may be highlighted separately.
3.6. In the event of conflict between the Technical Specifications and the GCC, SCC & ACC, the
requirements as indicated in the Technical Specification shall govern, unless confirmed
otherwise by the Client (EPIL) in writing before the award of this contract, based on a
written request from the Bidder for such a clarification.
3.7. Wherever a material or article is specified or described by the name of a particular brand,
manufacturer or vendor, the specific items mentioned shall be understood to be descriptive
only and not restrictive. Such description indicates the equipment type, function and quality
desired. Other manufacturer’s products may be considered provided sufficient information
so as to enable the Client (EPIL) to determine that the products proposed are equivalent to
those named.
3.8. Main and Alternate Proposals
a) Bidder shall quote for the main proposal strictly as per the Technical Specification for
all the equipments and systems covered herein. However, if the Bidder wishes to
propose any other type/material of Equipments/Systems, the same shall be quoted
as an Alternate Proposal. For bids comparison during evaluation, only the Main
Proposal shall be considered.

b) If the Bidder feels that, in his opinion, certain features brought out in his offer are
superior to what has been specified, those shall be highlighted separately.
c) For all such alternatives, the Bidder shall furnish all details similar to those asked for
in the base offer and his reasons for recommending them. Adequate technical
information, operating feedback, etc. including list of installations, year of
commissioning, availability of data etc. which by itself will establish the proven
nature, intent of the specification and the qualifying requirement shall be enclosed
with the offer to enable the Client (EPIL) to assess the superiority and reliability of
the alternatives offered.
d) In case of each alternative proposal, its implications on the performance, guaranteed

efficiency, auxiliary power consumption etc. shall be clearly brought out for the
Client (EPIL) to make an overall assessment. However, no extra credits would be
given to any claims of superiority during bid evaluation. Client (EPIL) reserves the
right to reject or accept any of the Alternate Proposal.
e) However, if any alternate type of equipments or systems are sought/ specified in

Technical Specification both the type of Equipments or Systems shall be evaluated at
par separately. Bidder may offer/quote for any one of the type or all the types of
Equipments/Systems specified.
f) Under no circumstances the specified equipment etc. shall be brought out as an

alternative offer.
3.9. Technical Deviations
a) Any deviation or variation from the scope, requirement and/or intent of this
specification shall be clearly defined under Deviation Schedules of the relevant Bid
forms irrespective of the fact that such deviations/variations may be standard
practice or a possible interpretation of the specification by the Bidder.
b) Any other remarks/deviations/clarifications/exceptions variations in any other part

of the offer/bid other than in the "Technical Deviation Schedules" if any under the
captions, "Technical Specifications/clarifications on the offer/Assumptions etc." shall
not be considered for bid evaluation and these remarks / deviations will have to be
withdrawn by the bidder without any cost implication to Client (EPIL).
c) Except for those deviations/ variations covered under Deviation Schedules which
are accepted by the Client (EPIL) before the award of the Contract, it will be the
responsibility of the bidder to fully meet the intent and the requirements of the
specification within the quoted price.
d) No other deviation whatsoever from this specification, except for the declared
deviations submitted by the bidder with his proposal under “Deviations Schedule”

shall be considered for Evaluation. Bids not complying with this requirement shall be
treated as non-responsive and hence liable for rejection.
e) The interpretation of the Client (EPIL) in respect of the scope, details and services to
be performed by the Bidder shall be binding unless specifically clarified otherwise by
the Client (EPIL) in writing before the Award of the Contract.
3.10. Additional Requirements
a) Before submitting his bid, the Bidder should inspect and examine the site and its
surroundings and should satisfy himself as to the nature of the ground and subsoil,
the quantities and nature of work, materials necessary for completion of the work
and their availability, means of access to site and in general shall himself obtain all
necessary information as to risks, contingencies and other circumstances which may
influence or affect his offer. No consequent extra claims on any misunderstanding
or otherwise shall be allowed by the Client (EPIL).
b) The works under the scope of this contract are to be executed within the power plant
which is under operation. The contractor shall take all necessary precautions to
protect all the existing equipment, structures, facilities and buildings etc. from
damage. In case any damage occurs due to the activities of the contractor on account
of negligence, ignorance, accidental or any other reason whatsoever, the damage
shall be immediately made good by the contractor at his own cost to the satisfaction
of the Client /NTPC. The contractor shall also take all necessary safety measures at
his own cost, to avoid any harm or injury to his workers and staff from the
equipment and facilities of the power station and as well as other facilities
/properties of others.
c) Bidder should note that the existing rail lines, if any within the plant area may be
operational with rail traffic of equipments, coal and liquid fuel rakes. He shall take
all precautions to ensure the safety of existing rail tracks and other associated
facilities as well as the safety of his men, material and equipment from the operating
rail traffic. He shall plan and make all arrangements to ensure that disruption to the
existing rail traffic is minimum and he shall follow the instructions of the Client
/Engineer-in-Charge in this regard. Further he shall plan and coordinate all his
activities considering restrictions, if any, on free access to his work areas due to the
rail traffic.
d) For his site office and covered store buildings, the contractor shall adopt pre-
engineered / pre-fabricated constructions made of steel with single / double skin,
insulated or uninsulated roof and wall coverings (fabricated out of permanently
colour coated metal sheets). Alternatively, contractor can adopt readymade ‘Porta

cabin’ or similar construction. Contractor shall ensure that all such construction is
well engineered, neatly constructed and overall present a pleasing look.
e) In line with Gazette Notification on Ash Utilization issued by MOEF and its
amendment thereafter, contractor shall use ash and ash based products in works as
specified in these specifications, drawings and as per instructions of the Engineer.
He shall also use ash and ash based products in construction of his offices, stores,
staff quarters and labour huts etc. He shall furnish a compliance report along with all
details of use of ash and ash based products along with each bill.
f) In case of any conflicts /contradiction among various volumes / sections / annexure

/chapters/appendices/tender drawings of bid documents, the same shall be referred
to the Client for clarifications whose decision shall be final and binding. No extra
claims shall be allowed on this account.
g) In addition to the specifications of equipment /system indicated in various sections

and General Technical (Section-VII) Requirements and Erection Conditions of
(Section-VII) Contract shall also form part of this Technical specification and shall be
referred by the Bidder.
h) Construction Power
i) One Construction power supply feeder will be provided at zero Meter level of
Absorber to meet the construction power requirements of Absorber on
chargeable basis. If any additional feeders are required the same shall have to
be distributed by the bidder from the above source. However required
load/power requirement of construction power shall be furnished by the
bidder in his tender, which will be mutually agreed during execution.
ii) Suitable metering arrangement along with associated Instrument transformers

and Metering Cubicles meeting the DISCOM requirements shall be provided
by the Contractor at each Construction power feeders provided by the Client,
for the measurement of actual energy consumed by the Contractor for billing
and payment.
iii) The charges for the actual energy consumed by the Contractor shall be
recovered by the Client based on prevalent rate of DISCOM for type of
connection (HT/LT as applicable).
iv) Complete construction power arrangement along with power drawl limits shall
comply with respective DISCOM service rules..

v) Supply, erection, testing and commissioning of all equipments as required for

further distribution for meeting the construction power requirements shall be
in the Contractor's scope. All necessary statutory requirements for charging
construction power of Contractor’s network shall be in the Contractor’s scope.
vi) Construction power supply network is a temporary arrangement which shall

be used during the project construction phase. To meet this requirement, the
equipments may be arranged by Contractor either by shifting their existing
equipments at other installation or by fresh procurement, which may be taken
back after commissioning of the project.
vii) Even though the Client (EPIL) shall make all efforts to maintain a continuous
supply of construction power, the same is not guaranteed and the Client (EPIL)
shall not be responsible for any loss or delays which the contractor may suffer
on this account. Also the Client shall not entertain any claim for
exemption/reduction of liquidated damages for delay in execution of the
contract due to irregular power supply. Contractor shall arrange/provide
necessary backup arrangement on his own for uninterrupted power supply.
viii) The Contractor shall maintain a minimum drawl power factor as per DISCOM
regulations for their substations, and all such devices for maintaining power
factor shall be under the scope of contractor. All temporary wiring must
comply with local regulations and will be subject to Client (EPIL)/NTPC’s
inspection and approval before connection to supply. Power supply shall not
be provided for use in labor and staff colony.
i) Construction water shall be provided free of cost for the within the plant at a single
point.
4. TENDER DRAWINGS
4.1. The tender of drawings listed in Section –X of the Technical Specification shall form part of
the specification and shall supplement the requirements specified in these Technical
specifications. The scope and terminal points of the equipment to be furnished under this
Package shall be as identified in these drawings read in conjunction with text of the
specification.
4.2. These drawings are preliminary drawings for bidding purpose only and subject to changes
that may be necessary during the detailed engineering keeping the basic parameters as
specified. Various parameters for building and other equipment specified in the tender
drawing are the minimum required & any increase in these parameters if required to meet
the system requirement shall be made by the Bidder without any additional cost implication
to Client (EPIL).

5. SYSTEM DESCRIPTION
a) The FGD system shall be based on Wet Limestone Forced Oxidation process. Flue gas
from the discharge duct of ID (Induced Draft) fans duct shall be led through Flue Gas
Ducting System directly to an Absorber Vessel by means of a set of Booster Fans.
Motorized Guillotine type gates/dampers with seal air fans shall be provided at
suction and discharge of each Booster Fan.
b) Expansion Joints (EJ) shall be designed and provided in the FLUE GAS DUCTS at
appropriate locations
c) In the absorber, Sulphur-di Oxide (SO2) in flue gas shall be removed by a spray of
re-circulating lime-slurry; which shall be pumped by Slurry-Recirculation Pumps.
d) A set of Blowers shall blow compressed oxidation air through the slurry in the
oxidation tank, to oxidize the Calcium sulphite to gypsum.
e) Clean Flue gas after stripping pollutant (SO2 gas), through three stage mist-
eliminators (provided inside the Absorber unit) is conveyed through a duct to a new
Steel lined RCC wet chimney of 150 m height with 38mm thick Borosilcate blocks
lining on Steel flue liner of 150 m height
f) Provision shall be made for facilitating operation of the unit by bypassing the FGD
system and letting the flue gas through existing stack from ID Fan Discharge by
providing a By-pass Duct and associated Damper.
g) The Axial type Booster Fans located at the downstream of the ID Fans shall be
capable of handling the pressure drop in the FGD system (ducting, dampers and
Absorber etc) upto the inlet of new wet stack over the entire load range; with any one
or both Booster fans in operation in conjunction with one or both ID fans while firing
the specified range of fuels.
h) The fan control system shall be designed to achieve stable and satisfactory operation
with flow control and pressure controls. Fan flow control shall be by blade pitch
control. Motorized Guillotine type gates with sealing air supply from external seal air
fans shall provided at suction and discharge of both the Booster Fans.
i) Limestone to the absorbers shall be supplied by a wet limestone grinding system.

Limestone shall be fed to the Limestone day silos which in turn will feed Limestone
to wet ball mill(s) through a gravimetric feeder. The classified limestone slurry from
the mills shall be stored in two numbers of limestone slurry storage tanks, from
where the slurry shall be pumped to the individual absorbers by dedicated (for each
Unit) limestone slurry pumps.
j) The Gypsum produced through this process, from the Absorber, shall be pumped by
dedicated gypsum bleed pumps to a common Gypsum Dewatering system

consisting of two streams of primary and secondary hydro-cyclones and vacuum

belt filters for de-watering.
k) After de-watering, water shall be recycled back to the absorber. Waste water from the
system shall be collected and neutralized using lime and neutralized effluent shall be
pumped at required pressure to waste water terminal point.
l) An emergency cooling system for automatic spray of quenching water for a sufficient
time (minimum 15 min) at the inlet to the absorber, in case the gas temperature
exceeds the design temperature due to failure of upstream equipment’s shall be
provided to protect the FGD and all other sensitive downstream equipment against
high flue gas temperatures. The water shall be supplied from an elevated tank
(emergency quench water tank) to be mounted near the absorber tower and shall be
led inti the absorber through a pipe array at the upstream of Absrober.
m) The FGD system is completed with various tanks, pumps, piping etc, Equipment
Cooling Water system, Compressed Air system, Fire protection system, required
Ducts, Isolation dampers & Expansion Joints in the Flue Gas duct, associated
Electrical Equipments such as Transformers, Switchgears etc and associated Control
and Instrumentation System.
6. GENERAL LAYOUT ASPECTS
a) The Absorber is located outdoor.
b) Location of Absorber and Elevator be referred in Layout drawing of FGD Plant

which is enclosed as a part of Tender Drawings. Other Equipments associated with
FGD System is also shown in the Layout drawing.
c) Elevator :
The elevator is located at a distance of about 6 to 8 meters from the absorber. The
landing /operating platform (s) of absorber shall be interconnected with the
corresponding landing level(s) of Elevator by means of Walkway /platform.
e) Walkway & platforms shown around the elevator and the nearby Steel staircase
(provided to approach various levels of the Absorber) shall be provided by the Client
through another agency. However the structural load on account of these platforms,
walkways, stairs etc around the elevator shall be included in the structural design of
the Elevator supporting structure by the Bidder. Design input on account of this shall
be furnished to the Bidder during detailed engineering.
e) Instruments, junctions boxes etc (if any under the Scope of Bidder) associated with
equipments shall be provided with local canopy cover to avoid direct exposure to
sunlight and rain.

7. CONTROL & OPEARTION PHILOSOPHY
Brief Control philosophy of the FGD system shall be provided (if required by Bidder) after
award. Control Panel (PLC based system) for the FGD System shall be provided by Client.
8. SCOPE OF SUPPLY & SERVICES (General)
8.1. A) The scope of work for the equipment and accessories to be furnished in accordance
with this specification shall include design, manufacture, engineering, inspection and
testing at supplier’s works, packing, forwarding to site, unloading, supervision of
commissioning of the equipment / system and works indicated in the Section - III of
Technical specification. Any items or works though not specifically mentioned in this
specification but needed to complete the equipment & systems to meet the Intent of
the Specification shall also be furnished, unless specifically mentioned under
"Exclusions" in Section - III of Technical specification.
B) Systems / Equipments Covered In this Specification
i) Complete Absorber Vessel : Preparation of Fabrication drawings, Supply (of

plates / liners material and other raw materials),
fabrication, installation, testing and
commissioning.
ii) Internals Absorber Vessel : Erection / Installation and Commissioning of
required internal accessories of Absorber.
iii) Inlet Duct of Absorber : Supply, Fabrication and Installation of Inlet (a
small portion) flue gas duct from the terminal
point upto the final point of delivery of flue gas
into the Absorber Vessel .
iv) Outlet Duct of Absorber : Supply, Fabrication and Installation &
Commissioning of outlet clean flue gas duct
from the absorber upto the final point of
delivery of clean flue gas into the Chimney.
[EXCLUDING Complete Structural material for
four legged duct structure between Absorber
Outlet and New Wet Chimney Inlet, associated
platforms / walkways and adjoining structural
steel staircase near the elevator and associated
approach walkway/platforms to Absorber &
elevator from the stairs as required (which is to
be supplied by other Ducting package
contractor).]

v) Internals of Absorber : Erection / Installation and Commissioning of

Absorber SO2 removal System Equipments such
as Spray Headers, Nozzles, Mist Eliminators,
ME Wash System, Flushing nozzle , Tray,
agitators, Lances , Instruments etc. (to be
supplied by the Technology Partner KDPE).
vi) Emergency Quench Water : Erection / Installation and Commissioning of
required emergency quench water supply pipe
array (inside the inlet duct to absorber which is
to be supplied by the other agency).
vii) Expansion Joints : Erection of specified expansion joints (one at the
inlet duct of Absorber & two at the discharge
ducts of absorber), which are to be supplied by
the other agency.
viii) Elevator (for Absorber) : Design, Testing, Supply, Installation, and
commissioning of elevator; Execution of Civil,
Structural and architectural works of elevator
shaft and machine room etc.
Detailed Scope of Supply, terminal points and Exclusions are described in Section- III
(titled Scope of Supply, Exclusions and Terminal Points) of this Technical
Specification.
8.2. Electrical
AC power supply to the Elevator shall be provided to the bidder near the Elevator at Zero
meter Level.
8.3. Spares
Scope of supply of the Bidder includes Mandatory spares, Start-up and Commissioning
spares. General description in respect of spares and the list of Mandatory Spares is given in
Section - VI of Technical specification..
8.4. The detailed TECHNICAL REQUIREMENTS for Mechanical equipment/Systems,

Electrical Systems/ Equipments, and Civil and Structural Works are elaborated in relevant
SECTION-IV A to IV D of Technical Specification.
8.5. Scope of the Bidder also includes all shop tests, type tests, site tests, and Routine tests etc.
for fulfillment of complete quality assurance & inspection requirements for the
equipments included in the scope of Bidder as per the stipulations of Technical
Specifications.

8.6. Paints / Painting
A) Contractor shall provide Corrosion protection painting for structures & equipments as
described in the specification.
B) The Scope of work includes supply of paints and painting of all equipments as per the
Client / NTPC’s Standard colour coding scheme which shall be furnished to the
Contractor during detail engineering stage. The quality and finish of paints shall be as
per standards of BIS or approved equivalent. The painting of various components
shall comply with the requirements stipulated in different part of this specification.
However, for components where no specific requirement is stipulated, the painting
conforming to the requirements stipulated below shall be provided :
(i) Surface preparation shall be blast cleaned conforming to Sa 2-1/2 Swiss

Standard.
(ii) Primer coat shall consist of epoxy resin based zinc phosphate primer having
minimum DFT of 100 microns.
(iii) Intermediate coat (or under coat) shall consist of epoxy resin based paint
pigmented with Titanium dioxide with minimum DFT of 100 microns.
(iv) Top coat shall consist of one coat of epoxy paint suitable pigmented of approved
shade and colour with glossy finish and DFT of 75 microns.
(v) Additionally finishing coat of polyurethane of minimum DFT of 25 microns shall

be provided.
B) The flue gas swept surface of Absorber inlet ducting (excluding wet dry interface section)
shall be blast cleaned conforming to Sa 2-1/2 Swiss Standard and applied with of 50 microns
of ethyl silicate zinc primer (suitable upto minimum 400 degree Celsius).
C) Painting of Structural members may be referred in Section IV-D (Technical Requirements of

Civil Works) of the Technical Specification.
8.7. Pre-commissioning and Commissioning Activities
a) Requirement of pre-commissioning and commissioning activities (if any) is specified

in Subsection –III. (Scope of Works. Exclusions & Terminal Points). The bidder's scope
shall include provision of materials and services as detailed in Section- VII of
Technical Specifications (Erection Conditions of Contract) including supply of all
consumables temporary equipments and pipings, instruments, labour/ skilled
manpower etc
b) Contractor's scope shall also include supply of all materials and services including the
following for successful conductance of pre-commissioning and commissioning
activities:

c) Complete pre-commissioning work including tests of facilities and all other tests as
mutually agreed in the Contractor’s quality assurance program as well as those
identified in the specification.
d) Commissioning and initial operation of the facilities.
e) Supply of all consumables as may be required for above pre-commissioning/

commissioning activities.
f) Supply of all temporary equipment such as piping including supports, valves, blowers
and all necessary instrumentation for successful conductance of pre-commissioning
and commissioning activities.
g) All temporary equipments, blowers, valves etc. brought to sites, by the Contractor for
pre-commissioning/commissioning purpose shall be in good working condition to
ensure its safe and reliable operation at site. All such temporary equipments/
components shall be made available at site at least three (3) months prior to
commencement of relevant pre-commissioning/commissioning activities.
h) On receipt of the temporary equipments/components at site, the same shall be

inspected by the Client to ensure its safe and reliable operation and if in the opinion of
the Client the temporary equipments/components are not in satisfactory conditions to
ensure it's safe and reliable operation the same shall be immediately replaced by the
Contractor.
i) The temporary equipments specifically brought solely for the pre-commissioning and
commissioning work shall on completion of these activities, remain the property of the
Contractor. The selection of material of all the temporary equipments/ instruments
shall be compatible with the service conditions expected during pre-commissioning /
j) All temporary equipments and instruments shall be clearly listed out in the bid.
k) Supply of all labour, skilled/semi skilled supervisors, engineers and any other
manpower.
l) The scope of Contractor shall also include necessary approach & platforms for all the
instruments, if applicable and if required during commissioning and testing. These
approach platforms shall be provided to meet all required safety norms and these shall
be permanent nature.
8.8. First Fill of Consumables, Oils & Lubricants
All the first fill and One year's topping requirements of consumable such as greases, oil,
lubricants, servo fluids etc. which will be required to put the equipments covered under the
scope of specifications, into successful commissioning/ initial operation and to establish

completion of facilities shall be furnished by the bidder, unless specifically excluded under
the Exclusions in these specifications and documents.
8.9. Guarantee Tests
The guarantee tests for various equipment and systems shall be carried out as specified in
SECTION –V (Functional guarantee and LD) and in Section – VII (GTR) of Technical
Specification. All special equipment, tools and tackles instruments, measuring devices
required for the successful conductance of Guarantee Tests shall be provided by the bidder,
free of cost. All costs associated with the tests shall be included in bid price.
8.10. Special Tools & Tackles and Test/ Measuring Equipments
One set of all special tools and tackles including testing, calibrating and measuring
instruments required for erection, assembly, disassembly and maintenance of all
equipments/ systems covered under the scope of the Bidder shall be supplied by the Bidder
if any (as per relevant clauses of SECTION III, SECTION – IV-A to IV-D) and SECTON-
VII) Technical Specifications.
These shall not be used for erection/ commissioning purposes and shall be in an unused and
new condition, when they are handed over to the Owner. A list of all such special tools and
tackles shall be submitted along with the offer.
8.11. Detailed Engineering, Documentation and Technical co-ordination
i) Scope of the bidder includes complete design and engineering, finalization of specified
drawings, design calculations, documents etc, submission of these documents and
processing of their approvals from NTPC/Owner as per relevant clauses of Section –
VII (GTR) of Technical Specification and other relevant clauses given elsewhere in the
Technical Specifications.
ii) Further scope of services shall also include submission, in proper shape & format, of all
types of manuals, handbooks & documents in requisite numbers to the Client / NTPC
at different phases of the project as per the requirement.
iii) The Contractor shall furnish all relevant data required by the Client / NTPC, at
interface points within schedule as agreed to prior to award of contract.
8.12. Type Tests and Type test Charges
a) Bidder shall include under his scope all type tests to be conducted on various
equipments as envisaged in Technical Specifications. Bidder shall include in the total
Bid Price the cost of carrying out all such type tests.
b) Further in relevant price Schedule(s), of the bid documents, bidder shall furnish the
breakup of the type test charges indicating charges of each type and rating of various

equipments. Client (EPIL) at his discretion during the execution of the work may
delete any or all type tests from the Bidder’s scope and the contract price shall be
adjusted as per the breakup of type test charges indicated in the schedule for such
type tests.
8.13. Noise Level
The noise level to be maintained by all the equipment & systems supplied and erected by
the bidder as per relevant clause of General Technical Requirements (GTR) in Section VII
and in Sections IV A to IV D
9. QUALIFYING REQUIREMENTS FOR EQUIPMENTS / SYSTEMS
The Bidder / Bidder's sub-vendor(s) is required to meet the provenness criteria and/or
qualification requirement for the items/ as per the stipulated criteria indicated in the
respective clauses. For the purpose of qualification of Bidders / Sub-vendor(s), experience
shall be reckoned as on the date stipulated in Bid Forms.
10. PROVENNESS CRITERIA FOR VARIOUS EQUIPMENTS
The Bidder at his option can source the equipments /systems . However for such plant
equipment/systems, the Client (EPIL) / NTPC Employer reserves the rights to satisfy
himself on the provenness of the equipment and capability and capacity of the
manufacturers. The Client (EPIL) / NTPC reserves the right to assess the capabilities and
capacity of the Bidder/his collaborators/ licenser/ his subcontractors to perform the
contract, should the circumstances warrant such assessment in the overall interest of the
Client (EPIL)/NTPC/ Project. To enable the approval of sub-vendors, the Bidder shall
provide all necessary data such as type, design, make, capacity, duty conditions, date of
Commissioning/operation etc.

RSTPP ABSORBER PACKAGE
PROJECT INFORMATION
STAGE - III (FGD SYSTEM )
INDEX
1. PROJECT INFORMATION: ................................................................................................... 2
1.1. BACKGROUND ................................................................................................................. 2
1.2. LOCATION AND APPROACH ....................................................................................... 2
1.3. LAND REQUIREMENT .................................................................................................... 2
1.4. COAL QUALITY PARAMETERS.................................................................................... 2
1.5. FUEL OIL CHARACTERISTICS ..................................................................................... 3
1.6. STEAM GENERATOR AND ESP DATA: ..................................................................... 4
1.7. PLANT WATER DETAILS:............................................................................................... 5
2. METEOROLOGICAL DATA ................................................................................................. 7
3. CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND

EQUIPMENT ............................................................................................................................. 7
4. CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND

EQUIPMENT ........................................................................................................................... 13
5. FOUNDATION SYSTEM AND GEOTECHNICAL DATA ........................................... 14
Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION - II Page 1 of 22

PROJECT INFORMATION
1. PROJECT INFORMATION:
1.1. BACKGROUND
NTPC Ramagundam (RSTPS) is a pit-head thermal power station based on the coal supplied
from the nearby Singareni Mines of M/s. SCCL and water from Pochampad Dam.
The power station today has seven coal fired units having a total installed capacity of 2600
MW consisting of 3 units of 200 MW capacity in stage-I, three units of 500 MW in stage-II
and one unit of 500 MW capacity in stage-III.
1.2. LOCATION AND APPROACH
The station is located in the Karimnagar district of Telangana State about 60 kms from
Karimnagar town and 100 kms from Warangal. The coordinates of plant are 18.7519° N,
79.5134° E. Ramagundam Railway station is on the Delhi - Chennai main line. Ramagundam
is well connected to Hyderabad by Rajiv Rahadari state highway. The plant site is
approximately at a height of 156m from the mean sea level.
1.3. LAND REQUIREMENT
Land required for the ultimate stage of project i.e. 2600 MW is acquired.
1.4. COAL QUALITY PARAMETERS
Design Worst Range of

S.No. Description Symbol Best Coal
Coal Coal Adequacy Coal
A. Proximate Analysis (As Received basis)
1. Total Moisture % 13.00 15.00 10.00 10.00 - 16.00
2. Ash % 41.00 45.00 30.00 29.00 - 47.00
3. Volatile Matter % 21.00 18.00 26.00 26.00 - 17.00
4. Fixed Carbon % 25.00 22.00 34.00 35.00 - 20.00
B. Ultimate Analysis (As Received basis)
1. Carbon C% 34.05 30.15 46.2 46.85 - 47.8
2. Hydrogen H2% 3.05 2.9 3.2 2.8 - 3.3
3. Nitrogen N2% 1.4 0.6 1.7 4.0 - 1.8
Oxygen
4. O2% 6.05 5.25 7.3 5.5 - 7.35
(By Difference)
5. Sulphur S% 0.3 0.5 0.36 0.30 - 0.50
6. Carbonates CO3% 0.85 0.5 1.02 0.35 - 0.50
7. Phosphorus P2% 0.3 0.1 0.22 0.1 - 0.3
8. Total Moisture H2O% 13.00 15.00 10.00 10.00 - 16.00
9. Ash % 41.00 45.00 30.00 29.00 - 47.00
Gross Calorific
10. Kcal/Kg 3500 3200 4500 3000 - 4600
Value
11. Hard Grove Index 55 50 60 45 – 65

PROJECT INFORMATION
Design Worst Range of

S.No. Description Symbol Best Coal
Coal Coal Adequacy Coal
C Ash Analysis
1. Silica (SiO2)% 58.85 59.00 58.2 59.9 - 59.2
2. Alumina (AI2O3)% 28.8 28.0 29.5 27.7 - 30
3. Iron Oxide (Fe2O3)% 5.5 6.00 4.7 4.5 - 6.5
4. Titania (TiO2)% 1.8 2 1.7 1.5 - 2.1
Phosphoric
5. (P2O5)% 0.7 0.6 0.9 0.4 - 0.95
Anhydride
6. Lime (CaO)% 1.5 1.2 1.9 1.0 - 2.1
7. Magnesia (MgO)% 1.3 1.5 1.2 1.5 - 2.1
Sulphuric
8. (SO3)% 0.5 0.6 0.4 0.6 - 0.4
Anhydride
Alkalies (By
9. (Na2O+K2O)% 1.15 1.02 1.2 09 - 1.2
Difference)
D Ash Fusion Range (under Reducing atmosphere)

Initial Deformation
a) °C 1150 1100 1200 1100 - 1200
Temperature (IDT)
Hemispherical
b) °C 1350 1300 1400 1300 - 1400
Temperature
c) Flow Temperature °C 1400 1350 1400 1350 - 1400
1.5. FUEL OIL CHARACTERISTICS
Low Sulphur Heavy

Heavy Furnace Oil
Heavy Stock Petroleum stock
S.No. Characteristics grade HV (HFO)
(LSHS) (HPS)
IS-1593-1982
IS-11489-1985 IS-11489-1985
1. Total sulphur content 4.5% Max. 1.0% Max. 4.5% Max.
Gross calorific value of the order of of the order of of the order of
2.
(KCal/kg) 10,000 10,000 10,000
3. Flash Point (Min) 66 deg C 76 deg C 66 deg C
Water content by volume
4. 1.0% 1.0% 1.0%
(Max)
5. Sediment by weight (Max) 0.25% 0.25% 0.25%
Asphaltene content by weight
6. 2.5% 2.5% 2.5%
(Max.)
Kinematic viscosity in
7. 370 at 50deg C 100 at 100deg C 100 at 100deg C
Centistokes
Ash Content by weight
8. 0.1% 0.1% 0.1%
(Max.)
9. Acidity (inorganic) Nil Nil Nil
10. Pour Point (Max.) 57 deg C 66 deg C 72 deg C
11. Sodium content - - 100 ppm

PROJECT INFORMATION
Low Sulphur Heavy

Heavy Furnace Oil
Heavy Stock Petroleum stock
S.No. Characteristics grade HV (HFO)
(LSHS) (HPS)
IS-1593-1982
IS-11489-1985 IS-11489-1985
12. Vanadium content 25 ppm 25ppm 25 ppm
Specific heat below pour
13. 0.65
point (KCal/Kg °C)
LIGHT DIESEL OIL CHARACTERISTICS (As per IS 1460 - 2000)
S.No. Characteristics LDO

21 deg.C & 12°C for Summer and Winter
1. Pour Point (max)
respectively
2. Kinematic viscosity in centistokes at 40 deg.C 2.5 to 15.7
3. Sediment percent by mass (max) 0.10
4. Total sulphur percent by mass (max) 1.8
5. Ash percentage by mass (max) 0.02
6. Carbon residue (Rans bottom) percent by pass (max.) 1.50
7. Acidity in organic Nil
8. Flash point(Min.) - Pensky Martens 66 deg.C
9. Copper strip corrosion for 3 hours at 100°C Not worse than No. 2
10. Water content, % by volume(max) 0.25
11. GCV (Kcal/kg) 10,000
1.6. STEAM GENERATOR AND ESP DATA:
S.NO. CHARACTERISTICS DETAILS
1. Location Outdoor
2. Operation Base load
3. Type Pulverised coal fired
4. Maximum Continuous Rating 1625 Tonns/hr.
5. Steam pressure at SH outlet 179 Kg/cm²(a)
6. Steam temperature at SH outlet 540°C
7. Oil for start up and flame stabilisation LDO + HFO/LSHS/HPS
8. Fuel oil system sizing 30% of Boiler MCR for HFO/LSHS/HPS
9. Pulverised coal size Minimum 70% through 200 Mesh

PROJECT INFORMATION
10. Type of pulveriser Bowl Mills XRP-1003

Air atomized for LDO Steam atomized
11. Type of oil burners
for HFO/LSHS/HP
Steam atomised for HFO/LSHS/HP
12. No. of air heaters
Two (2) for the primary air side
13. No. of ID Fans Two (both working)
S.NO. DESCRIPTION DETAILS

1. Location Downstream side of Air preheaters
2. Operation Base load
3. Type Rigid Discharge frame
4. Rapping Intermittent
1.7. PLANT WATER DETAILS:
a) Cooling Water Analysis/CW Blow Down water Analysis
S.NO. Parameters CW
1. pH 8.1
2. Cond us/cm 1270
3. Turb (NTU) 14
4. Calcium (ppm as Ca Co3) 182
5. Magnesium (ppm as Ca Co3) 150
6. Iron (ppb as Fe ) 100
7. P-Alkalinity (ppm as Ca Co3) Nil
8. M-Alkalinity(ppm as Ca Co3) 148
9. Chloride(ppm as Ca Co3) 140
10. Sulphate (ppm as Ca Co3) 320
11. Silica (ppm ) 42
12. Temp : ( Deg/c)
13. TDS (ppm) 595
14. TSS (ppm) 25
15. Organic Matter ( ppm) Nil
16. Residual.Chlorine (ppm) 0.2

PROJECT INFORMATION
b) Clarified water quality/Raw Water Analysis
S.NO. Parameters CW
1. pH 8.2
2. Cond us/cm 430
3. Turb (NTU) 7
4. Calcium (ppm as Ca Co3) 70
5. Magnesium (ppm as Ca Co3) 65
6. Iron (ppb as Fe ) 80
7. P-Alkalinity (ppm as Ca Co3) 2
8. M-Alkalinity(ppm as Ca Co3) 165
9. Chloride(ppm as Ca Co3) 50
10. Sulphate (ppm as Ca Co3) 24
11. Silica (ppm ) 17
12. Temp : ( Deg/c) 30
13. TDS (ppm) 250
14. TSS (ppm) 8
15. Organic Matter ( ppm) 2
16. Residual.Chlorine (ppm) -
c) DM water quality
S.NO. Constituent As Mg per liter

1. Silca SiO2 0.2 ppm
2. Iron Fe Nil
3. Total Hardness Nil
4. pH Value 6.8 - 7.2

Not More than 0.1
5. Conductivity
Excluding
The effects of Free
6. Bicarbonates
CO2

PROJECT INFORMATION
2. METEOROLOGICAL DATA
Important meteorological data from nearest observatory at Ramagundam is placed at

ANNEXURE- A I.
3. CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND

EQUIPMENT
All structures and equipment shall be designed for seismic forces adopting the site specific
seismic information provided in this document and using the other provisions in
accordance with IS:1893 (Part 1 to Part 4). Pending finalization of Part 5 of IS:1893,
provisions of part 1 shall be read along with the relevant clauses of IS:1893:1984, for
embankments.
A site specific seismic study has been conducted for the project site. The peak ground
horizontal acceleration for the project site, the site specific acceleration spectral
coefficients (in units of gravity acceleration ‘g’) in the horizontal direction for the various
damping values and the multiplying factor (to be used over the spectral coefficients) for
evaluating the design acceleration spectra are as given at Appendix- I.
Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding

horizontal values.
The site specific design acceleration spectra shall be used in place of the response
acceleration spectra, given at figure-2 in IS:1893 (Part 1) and Annex B of IS:1893 (Part
4). The site specific acceleration spectra along with multiplying factors specified in
Appendix-I includes the effect of the seismic environment of the site, the importance
factor related to the structures and the response reduction factor. Hence, the design spectra
do not require any further consideration of the zone factor (Z), the importance factor (I) and
response reduction factor (R) as used in the IS:1893 (Part 1 to Part 4).
Damping in Structures
The damping factor (as a percentage of critical damping) to be adopted shall not be more
than as indicated below for:
a) Steel structures : 2%
b) Reinforced Concrete structures : 5%
c) Reinforced Concrete Stacks : 3%
d) Steel stacks : 2%
Method of Analysis
Since most structures in a power plant are irregular in shape and have irregular
distribution of mass and stiffness, dynamic analysis for obtaining the design seismic forces
shall be carried out using the response spectrum method. The number of vibration
modes used in the analysis should be such that the sum total of modal masses of all
modes considered is at least 90 percent of the total seismic mass and shall also meet
requirements of IS:1893 (Part 1). Modal combination of the peak response quantities shall
be performed as per Complete Quadratic Combination (CQC) method or by an
acceptable alternative as per IS:1893 (Part 1).

PROJECT INFORMATION
In general, seismic analysis shall be performed for the three orthogonal (two principal
horizontal and one vertical) components of earthquake motion. The seismic response from
the three components shall be combined as specified in IS:1893 (Part 1).
The spectral acceleration coefficient shall get restricted to the peak spectral value if the
fundamental natural period of the structure falls to the left of the peak in the spectral
acceleration curve.
For buildings, if the design base shear (VB) obtained from modal combination is less than
the base shear (VB) computed using the approximate fundamental period (Ta) given in
IS:1893:Part 1 and using site specific acceleration spectra with appropriate multiplying
factor, the response quantities (e.g. member forces, displacements, storey forces, storey
shears and base reactions) shall be enhanced in the ratio of VB/ VB. However, no reduction
is permitted if VB is less than VB.
Design/Detailing for Ductility for Structures
The site specific design acceleration spectra is a reduced spectra and has an in-built
allowance for ductility. Structures shall be engineered and detailed in accordance with
relevant Indian/International standards to achieve ductility.

PROJECT INFORMATION
Appendix- I
SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES AND

EQUIPMENT
The various site specific seismic parameters for the project site shall be as follows:
1) Peak ground horizontal acceleration (MCE) : 0.28 g
2) Multiplying factor to be applied to the site specific horizontal acceleration spectral

coefficients (in units of gravity acceleration ‘g’) to obtain the design acceleration
spectra
a) For special moment resisting steel frames designed and : 0.07

detailed as per IS:800
b) For special concentrically braced steel frames designed and : 0.053

detailed as per IS:800
c) For special moment resisting RC frames designed and : 0.042

detailed as per IS:456 and IS:13920
d) For RCC Chimney : 0.14
e) For Liquid retaining tanks : 0.084
f) For Steel chimney, Absorber tower, Vessels : 0.11
g) For design of structures not covered under 2 (a) to 2 (f) : 0.07

above and under 3 below in general (excluding
special structure/ configuration/materials)
3) Multiplying factor to be applied to the site specific horizontal : 0.14

acceleration spectral coefficients (in units of gravity acceleration
‘g’) for design of equipment and structures where inelastic
action is not relevant or not permitted
Note:
1) g = Acceleration due to gravity
2) For industrial structures, analysis for verification of mechanism shall be carried out
as per IS:1893 (Part 4):2015.
The horizontal seismic acceleration spectral coefficients are furnished in subsequent

pages.

PROJECT INFORMATION
HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS

(In units of ‘g’)
Time Period Damping Factor (as a percentage of critical damping)

(Sec) 2% 3% 5%
0.000 1.000 1.000 1.000
0.030 1.000 1.842 1.450
0.040 1.355 2.032 1.600
0.050 1.716 2.223 1.750
0.060 2.081 2.413 1.900
0.070 2.449 2.604 2.050
0.080 2.820 2.794 2.200
0.090 3.194 2.985 2.350
0.100 3.570 3.175 2.500
0.105 3.759 3.175 2.500
0.106 3.760 3.175 2.500
0.110 3.760 3.175 2.500
0.115 3.760 3.175 2.500
0.120 3.760 3.175 2.500
0.125 3.760 3.175 2.500
0.130 3.760 3.175 2.500
0.135 3.760 3.175 2.500
0.140 3.760 3.175 2.500
0.145 3.760 3.175 2.500
0.150 3.760 3.175 2.500
0.200 3.760 3.175 2.500
0.250 3.760 3.175 2.500
0.270 3.760 3.175 2.500
0.300 3.760 3.175 2.500
0.320 3.760 3.175 2.500
0.350 3.760 3.175 2.500
0.372 3.760 3.175 2.500
0.400 3.500 3.175 2.500
0.402 3.483 3.175 2.500
0.405 3.457 3.136 2.469
0.410 3.415 3.098 2.439
0.425 3.294 2.988 2.353
0.450 3.111 2.822 2.222
0.500 2.800 2.540 2.000
0.550 2.545 2.309 1.818

PROJECT INFORMATION
0.600 2.333 2.117 1.667

0.650 2.154 1.954 1.538
0.700 2.000 1.814 1.429
0.750 1.867 1.693 1.333
0.800 1.750 1.588 1.250
0.850 1.647 1.494 1.176
0.900 1.556 1.411 1.111
0.950 1.474 1.337 1.053
1.000 1.400 1.270 1.000
1.050 1.333 1.210 0.952
1.100 1.273 1.155 0.909
1.150 1.217 1.104 0.870
1.200 1.167 1.058 0.833
1.250 1.120 1.016 0.800
1.300 1.077 0.977 0.769
1.350 1.037 0.941 0.741
1.400 1.000 0.907 0.714
1.450 0.966 0.876 0.690
1.500 0.933 0.847 0.667
1.550 0.903 0.819 0.645
1.600 0.875 0.794 0.625
1.650 0.848 0.770 0.606
1.700 0.824 0.747 0.588
1.750 0.800 0.726 0.571
1.800 0.778 0.706 0.556
1.850 0.757 0.686 0.541
1.900 0.737 0.668 0.526
1.950 0.718 0.651 0.510
2.000 0.700 0.635 0.500
2.050 0.683 0.620 0.488
2.100 0.667 0.605 0.476
2.150 0.651 0.591 0.465
2.200 0.636 0.577 0.455
2.250 0.622 0.564 0.444
2.300 0.609 0.552 0.435
2.350 0.596 0.540 0.426
2.400 0.583 0.529 0.417
2.450 0.571 0.518 0.408
2.500 0.560 0.508 0.400

PROJECT INFORMATION
2.550 0.549 0.498 0.392

2.600 0.538 0.488 0.385
2.650 0.528 0.479 0.377
2.700 0.519 0.470 0.370
2.740 0.511 0.464 0.365
2.800 0.500 0.454 0.357
2.850 0.491 0.446 0.351
2.880 0.486 0.441 0.347
2.900 0.483 0.438 0.345
2.950 0.475 0.431 0.339
3.000 0.467 0.423 0.333
3.050 0.459 0.416 0.328
3.100 0.452 0.410 0.323
3.150 0.444 0.403 0.317
3.200 0.438 0.397 0.313
3.250 0.431 0.391 0.308
3.300 0.424 0.385 0.303
3.350 0.418 0.379 0.299
3.400 0.412 0.374 0.294
3.450 0.406 0.368 0.290
3.500 0.400 0.363 0.286

PROJECT INFORMATION
4. CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT
All structures shall be designed for wind forces in accordance with IS: 875 (Part-3) and as
specified in this document. Refer Appendix – II (below) of this document for site specific
information.
Along wind forces shall generally be computed by the Peak (i.e. 3 second gust) Wind Speed
method as defined in the standard.
Along wind forces on slender and wind sensitive structures and structural elements shall
also be computed, for dynamic effects, using the Gust Factor or Gust Effectiveness Factor
Method as defined in the standard. The structures shall be designed for the higher of
the forces obtained from Gust Factor method and the Peak Wind Speed method.
Analysis for dynamic effects of wind must be undertaken for any structure which has a
height to minimum lateral dimension ratio greater than “5” and/or if the fundamental
frequency of the structure is less than 1 Hz.
Susceptibility of structures to across-wind forces, galloping, flutter, ovalling etc.

should be examined and designed/detailed accordingly following the recommendations of
IS:875(Part-3) and other relevant Indian standards.
It should be estimated if size and relative position of other structures are likely to enhance
the wind loading on the structure under consideration. Enhancement factor, if
necessary, shall suitably be estimated and applied to the wind loading to account for the
interference effects.
Damping in Structures
The damping factor (as a percentage of critical damping) to be adopted shall not be
more than as indicated below for:
a) Welded steel structures : 1.0%

b) Bolted steel structures : 2.0%
c) Reinforced concrete structures : 1.6%
d) Steel stacks : As per IS:6533 & CICIND Model
Code whichever is more critical.
Appendix-II
SITE SPECIFIC DESIGN PARAMETERS
The various design parameters, as defined in IS: 875 (Part-3), to be adopted for the project
site shall be as follows:
a) The basic wind speed “Vb” at ten metres above the mean ground level: 44
meters/second
b) The risk coefficient “K1” : 1.07
c) Category of terrain : Category-2

PROJECT INFORMATION
5. FOUNDATION SYSTEM AND GEOTECHNICAL DATA
5.1. SOIL DATA
Client (EPIL) has carried out geotechnical investigation in the proposed area of
Ramagundam STPP. Bearing capacity for design of foundations and Bore logs data are
furnished at Annexure - I of this specification. The geotechnical investigation report
comprising of Boreholes, Laboratory tests, Chemical analysis, etc. in respect of the sub-strata
prevailing at site will be made available for the Bidder's study at the Client’s office, if
required. The onus of correct assessment / interpretation and understanding of the
existing subsoil condition / data is on the Bidder. The geotechnical investigation
report will be made available for the Bidder’s study at the Client (EPIL)’s office, if required.
In case, bidder feels that the available data is inadequate, he may carry out his own
geotechnical investigation. Geotechnical Investigation layout/location of borehole/field
test where investigation has been carried out is enclosed at Annexure-II. Further, if any
change in layout or area not covered as per enclosed Geotechnical Investigation layout,
Contractor shall carry out geotechnical investigation in the area at no cost to
Client (EPIL). The scheme for geotechnical investigation shall be approved by
Client (EPIL) before execution. Geotechnical investigation work shall got executed by
the contractor through the agencies as mentioned in Clause No. 7.07.00. However, no
time extension shall be given on account of soil investigation carried out by the Bidder.
The geotechnical investigation report shall be prepared with detailed recommendations
regarding type of foundation and allowable bearing pressure for various structures/
facilities and other soil parameters. The report shall be submitted for Client
(EPIL)’s approval prior to commencement of design of foundation.
Site levelling & grading had been carried out and achieved finished ground level
(FGL). Bidder may refer topographical survey drawing for variation in existing/ natural
ground level (NGL) and FGL.
Ground water table is varying from 2.0m to 5.0m at the time of geotechnical
investigation and may fluctuate with seasonal variation
5.1.1. The furnished borelog details are specific to the co-ordinates where the boreholes have been
carried out and are provided for bidder’s information only. Soil profile in the proposed
area may vary with respect to the borelogs enclosed for bidder’s information. Bidder
has to consider all such variations in his estimation, over the extent of the work to
be carried out. The Bidder should note that nothing extra whatsoever on account of
variation between soil data collected by Client (EPIL) and that found by the Bidder during
geotechnical investigation by him or during execution of works, shall be payable.
5.1.2. Tank Foundations
a) The tanks shall rest on flexible tank pad foundation, resting on sand with
concrete ring wall to retain sand. Base of the concrete ring wall shall not rest on the
expansive soil, if any.
b) Entire loose/ soft soil inside the concrete ring wall shall be removed and shall be
filled with sand. Sand for filling shall be clean and well graded conforming to IS 383
with grading Zone I to III.

PROJECT INFORMATION
c) Sand shall be spread in layers not exceeding 30cm compacted thickness over the
area. Each layer shall be uniformly compacted by mechanical means like plate
vibrators, small vibratory rollers, etc to achieve a relative density of not less than
80%.
d) Other requirements of tank foundations shall be as per IS 803 and as specified

elsewhere in the specifications.
5.2. FOUNDATION SYSTEM
The requirements for the foundation system to be adopted are as given in

subsequent clauses.
5.2.1. GENERAL REQUIREMENTS
a) All structures/equipment shall be supported on suitable open foundations

(isolated, combined, raft) depending on type of structures/facilities, sub-strata,
topography etc.
b) The roads, ground floor slabs, trenches, pipe pedestals, channels/drains and
staircase foundation with foundation loading intensity less than 4 T / M2 may be
supported on open / shallow foundations resting on virgin / controlled
compacted filled up soil. If the encountered sub-strata is black cotton soil, the same
shall be either replaced upto the full depth or black cotton soil shall be stabilized by
suitable treatment.
c) No other foundation (other than as mentioned in (b) above and (i) below) shall rest
on the filled up ground / soil.
d) Before execution of work, the bidder shall ensure that there is no obstruction to
underground/over ground facilities like sewer lines, pipe lines etc. Any such
damage and remedial/ rectification measures shall be at the contractors cost.
e) Bidder shall also ensure that there is no damage to existing nearby

foundations and the foundations pertaining to this package are not placed at
shallower depth than the nearby foundations. If required depth of foundation is
deeper than the existing foundations, proper protection shall be provided to existing
foundations. If required bidder may carry out GPR survey to locate existing
underground facilities at no extra cost to Client (EPIL).
f) All foundations shall be designed in accordance with relevant parts of the

latest revisions of Indian Standards.
g) The water table for design purpose shall be considered at Finished Ground Level.
h) A combination of open and pile foundations shall not be permitted under the same
equipment / structure / building.
i) Foundation for equipment on ground floor
For equipment of static weight up to 1.5 T, the equipment may be supported on the

PROJECT INFORMATION
ground floor slab by locally thickening the slab. Thickening of the ground floor slab
shall be done up to an extent of about 0.6 m beyond the plan area of the equipment
on all the sides. Further, the load intensity below the equipment shall be limited to
4T/m2. Other requirements of floor slab and compaction below the floor slab
shall be adhered, as specified elsewhere in the specifications.
For equipment’s of static weight between 1.5 T and 20 T, the equipment may be
supported on compacted sand filling with the load intensity below the
equipment limited to 4T/m2. The minimum depth of foundation is 1.0m below FFL.
Other requirements of sand compaction below the foundation shall be adhered,
as specified elsewhere in the specifications.
For equipment of static weight more than 20 T, the equipment foundation shall be
taken to the founding level or shall be built up with PCC from the level as mentioned
in the Table 2. The pedestal of equipment foundation or the foundation Block
shall be isolated from the adjoining floor slab by providing bitumen
impregnated fiber board of minimum 50 mm thick, conforming to IS: 1838 all
around the equipment pedestal for the full depth of the floor slab.
5.2.2. OPEN FOUNDATIONS
In case open foundations are adopted, following shall be adhered to. a) The minimum
width of foundation shall be 1.0 m.
a) Minimum depth of foundation shall be 1.0m below Ground Level.
b) It shall be ensured that all foundations of a particular structure/

buildings/facility shall rest on one bearing stratum.
c) Wherever the intended bearing sub-strata is virgin soil stratum but the actual
stratum encountered during foundation excavation consists of filled up soil at
founding level, under such cases either the foundation shall be lowered
completely into the virgin stratum or the filled up soil upto the virgin layers
shall be removed and built up through PCC (1:4:8) up to designed foundation level.
d) Wherever the intended bearing stratum is weathered rock, but the actual strata
encountered during excavation consists of both overburden soil and weathered
rock at founding level, under such cases, the overburden upto the weathered rock
level including 0.5 m into the weathered rock shall be removed and built up
through PCC (1:3:6) upto the designed founding level. Thus, maintaining the same
founding level for all the footings of a structure. The treatment at the base of
foundation before laying the PCC shall be carried out as per IS: 12070.
e) The last layer of about 300 mm before reaching the founding level shall be excavated
carefully by such equipment so that soil / rock at the required level will be left in its
natural condition.
f) If joints, fissures or other discontinuities in rock are encountered at founding level,

then treatment of such rock defects shall be carried out as per IS: 13063-1991 in
consultation with the Engineer.

PROJECT INFORMATION
5.3. SPECIAL REQUIREMENTS
Details of treatment for foundations / underground structures required to counteract soil /

water chemical environment, cement type, grade of concrete, type of reinforcement,
cover to reinforcement and protective coating to foundations, etc. shall be as mentioned in
Appendix -III of this document.
5.4. EXCAVATION, FILLING AND DEWATERING
5.4.1. For excavation works, comprehensive dewatering with well point or deep wells
arrangement, if required, shall be adopted. Scheme for dewatering and design with all
computations and back up data for dewatering shall be submitted for the Client (EPIL)’s
information. The water table shall be maintained at 0.5m below the founding depth.
5.4.2. Excavation for shallow foundations shall be covered with PCC immediately after
reaching the founding level. In case of any local loosening of soil or any loose
pockets are encountered at founding level during excavation the same shall be
removed and compensated by PCC M7.5. The final layer of about 300 mm thickness above
the founding level shall be excavated by suitable means, so as to avoid disturbance to
founding stratum.
5.4.3. Backfilling around foundations, pipes, trenches, sumps, pits, plinths, etc. shall be
carried out with approved material in layers not exceeding 300 mm compacted
thickness (higher thickness of layers upto 500mm with heavy mechanical compacting
equipment) and each layer shall be compacted to 90% of standard proctor density for
cohesive soils and to 80% of relative density for non cohesive soils. In any case, black
cotton soil shall not be used in back filling without providing cusion of 1m of non expansive
cohesive soil/moorum around the footings. In case of roads in the area of black cotton soil,
minimum 0.4m moorum shall be provided.
5.4.4. Rock pieces having size less than 150 mm and interstices filled with soil may be used
for backfilling around foundation, plinths etc. and shall be compacted to minimum of
85% of original stack of material after filling the interstices.
5.4.5. Founding level for trenches/channels shall be decided as per functional requirement. The
bottom of excavation shall be properly compacted prior to casting of bottom slab of trenches
/ channels.
5.4.6. CBR tests for pavement/road design shall be carried out by the Contractor after earth filling
(if applicable) has been completed upto the formation level.
5.4.7. The contractor shall take all necessary measures during excavation to prevent the
hazards of falling or sliding of material or article from any bank or side of such
excavation which is more than one and a half meter above the footing by providing
adequate piling, shoring, bracing etc. against such bank or sides.
5.4.8. Adequate and suitable warning signs shall be put up at conspicuous places at the
excavation work to prevent any persons or vehicles falling into the excavation trench. No
worker should be allowed to work where he may be stuck or endangered by
excavation machinery or collapse of excavations or trenches.

PROJECT INFORMATION
5.5. EXCAVATION IN ROCK
5.5.1. Excavation in rock shall be carried out by mechanical means and if blasting is
required for founding of some of the structures under this package, control blasting only
shall be carried out.
5.5.2. Controlled blasting shall be done by a specialised agency duly approved by Engineer.
All controlled blasting shall be done by using time delay detonators (i.e. excel type).
a) Contractor shall engage an agency expert in blasting such as, NIRM (National
Institute of Rock Mechanics), CMPDIL, Central Institute of Mining and Fuel
Research Dhanbad, Dept. of Mining of Govt. Institutions etc. to design detailed
blasting scheme and get the same approved from Engineer before carrying out the
blasting operation. All blasting shall be done as per the approved blasting scheme &
initial blasting operations shall be done under the supervision & guidance of the
representative of the blasting expert.
b) All the statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards, etc.
pertaining to the acquisition, transport, storage, handling and use of
explosives, etc. shall be strictly followed.
c) The Contractor shall obtain Licenses from Competent Authorities for undertaking
blasting work as well as for procuring, transporting to site and storing the
explosives as per explosives act. The Contractor shall be responsible for the safe
transport, use, custody and proper accounting of the explosive Materials.
d) The Contractor shall be responsible and liable for any accident and injury/
damage which may occur to any person or property of the project or public on
account of any operations connected with the storage, transportation, handling or use
of explosive and blasting operations.
5.6. SHEETING & SHORING
The contractor shall ascertain for himself the nature of materials to be excavated and
difficulties, if any, likely to be encountered in excavation while executing the work.
Sheet piling, sheeting and shoring, bracing and maintaining suitable slopes,
drainage, etc. shall be provided and installed by the Contractor, to the satisfaction of the
Engineer.
5.7. Geotechnical investigation work shall be got executed by the Contractor through the following
agencies.
1. C.E.TESTING COMPANY Pvt. Ltd, Kolkata

2. Cengrs Geotechnica Pvt. Ltd, New Delhi
3. KCT Consultancy Services, Ahemdabad
4. M.K. Soil Testing Laboratory, Ahemdabad

PROJECT INFORMATION
Appendix-III
SOIL DATA AND FOUNDATION SYSTEM
NTPC has carried out geotechnical investigation in the proposed area. Logs of boreholes of
proposed area are enclosed with this Annexure.
a) The foundation system to be adopted for different structures shall be as given in

Table – 1 below
Table : 1
Type of Foundation to
Structure
be adopted
Chimney, Absorber, Gypsum Dewatering facilities, FGD
Open
Control Room, Compressor Building and Other Structures
b) The minimum founding level and the corresponding net allowable bearing pressure
shall be as given in Table – 2 below.
Table : 2 - Net Allowable Bearing Pressure
Founding Depth/
Net Allowable Bearing Pressure T/m2
Stratum
Isolated and combined
footings for 40mm Rafts (width>6m) for 75mm
permissible settlement permissible settlement in
in case of soil and 12mm case of soil and 12mm in
in case of rocky case of rocky strata
Width upto 6.0m
In case of Soil
1.0m below NGL 10 12
In case of rocky strata

0.6m Embedment in
40 40
fractured rock
1.0m Embedment in
45 45
fractured rock.
For NGL, topographical survey drawing along with borehole details shall be
referred.
The net allowable bearing pressure higher than above mentioned values shall not be
permitted. At intermediate levels the bearing capacity shall be same as the net
allowable bearing pressure corresponding to the immediate shallower level
mentioned above.

PROJECT INFORMATION
In case any loose/soft pockets in rocky strata is encountered at founding level, the
same shall be removed completely upto the hard strata and filled up with
PCC (1:4:8).
c) Permissible Settlement of Foundations:
For open foundations, the total permissible settlement and differential settlement
shall be governed by IS: 1904 and from functional requirements whichever is more
stringent. However, total settlement shall be restricted to the following:
Isolated & Strip 40 mm
Raft (Width greater than 6 m) 75 mm
Foundation in rock 12 mm
In case the total permissible settlement is to be restricted to less than as above

specified from functional requirements, then the net allowable bearing pressure shall
be reduced after review in consultation with Engineer

PROJECT INFORMATION
ANNEXURE - A I

PROJECT INFORMATION

RSTPP ABSORBER PACKAGE SCOPE OF WORK, EXCLUSIONS &
STAGE - III (FGD SYSTEM ) TERMINAL POINTS
INDEX
1. GENERAL ............................................................................................................. 2
2. SCOPE OF WORK & SERVICES .......................................................................... 2
3. EXCLUSIONS........................................................................................................ 7
4. TERMINAL POINTS ............................................................................................ 8
ANNEXURE -1 .............................................................................................................. 9
ANNEXURE -2 ............................................................................................................ 10
Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION - III Page 1 of 10

1. GENERAL
1.1. Scope of work described below shall be read in conjunction with the Technical Requirements
(Sections – IV- A/ IV- B / IV-C / IV-D) and relevant Tender drawings wherein Technical
Parameters and Specifications are described.
1.2. NTPC envisages to carry out the capital overhaul of units once in three (3) years. The design
and materials for various equipments/auxiliaries etc. shall be selected by the Contractor
keeping in view the above requirement, such that no major repairs/replacements, requiring
shutdown of the unit, are needed in between the capital overhauls.
1.3. The Contractor shall provide adequate handling facilities & approach as for carrying out on-
line and off-line maintenance of the FGD system and its auxiliaries. In order to carry out on-
line maintenance, it shall be possible to readily disassemble, repair and reassemble the
equipment supplied in the shortest period,
2. SCOPE OF WORK & SERVICES
2.1. Mechanical
A) Detailed Engineering :
a) Preparation of Civil Input drawing with Civil Load Data.
b) Preparation of Mechanical General Arrangement of the Absorber Vessel.
c) Design of Fabrication Drawing of the Absorber Vessel, various Appurtenances,

nozzles, supporting structure, beams, columns etc.
d) Approval of the design calculations, design documents, drawings, fabrication

drawings etc from Client (EPIL)/ NTPC.
B) Supply
a) Supply of Absorber Shell Plate and Clad Material as per requirement as per
design / fabrication drawing and supply of base metal bonded with clad material
shall be supplied.
b) Supply of tested structural steel components for supporting structures, staircases,

operating platforms, walkway, etc.
c) Supply of Foundation Base Plate, foundation bolts, anchor etc.
d) Supply material for support brackets/ stools for internal supporting beams etc.

e) Inlet Duct portion(near Absorber)
i) Supply of a portion of Absorber Inlet Duct from downstream of expansion

joint (at the absorber inlet) upto the final point of delivery of flue gas into the
Absorber Vessel. This Absorber wet-dry interface duct shall be of solid C276
material (minimum 6m thick).
ii) Supply of balance absorber inlet duct portion from the expansion joint upto
the terminal point [“Refer Tender drawing of FGD Plant Layout”]; This shall
be carbon steel construction (without C276 lining)
f) Outlet Duct portion (from Absorber to Wet Chimney)
Supply of Absorber discharge duct from absorber upto the Transition Piece of
Chimney flue-can. This shall be made out of Carbon steel material of minimum
thickness of 7mm bonded with clad material of 2 mm thick Alloy C276.
g) Supply of all metallic fasteners of C276 material which are provided inside the
absorber/absorber wet-dry interface ducting.
h) Supply of Structures members, colour coated sheet steel enclosures for the
enclosure of elevator and its Machine room.
i) Supply and provision of all necessary instrument tapping points, along with
required stubs, nipple and first root valve/flange as per the design
drawings/documents
Note : All these Supply raw materials shall be of tested quality as per Design
Standard, material standard and Design Codes with certificates /
documents and these shall be reviewed and approved by Client before
Dispatch.
C) Fabrication and Erection
a) Fabrication of the Vessel from bonded material (Base metal with clad liner) suiting
the erection sequence.
b) Assembly of Vessel
c) Placement of Foundation Bolts, grouting to complete the Base plate and bottom
shell plate erection.

d) Installation / Erection of Complete Vessel by adopting “normal assembly method”

or “Inverted assembly method”.
e) Installation/ Erection of supporting structures, staircases, operating platforms of

absorber , brackets/ stools, other accessories etc
f) Painting of Complete Vessels, structural members etc
g) Commissioning of the Absorber Vessel as per the recommendation / requirement

of EPIL (Client) and their Technology Partner (KDPE).
h) Installation of part of Inlet and Discharge Duct
i) Erection of Absorber Inlet Duct from terminal point upto the final point of
delivery of flue gas into the Absorber Vessel.
ii) Erection of Absorber discharge duct from absorber upto the Transition Piece
of Chimney flue of STEEEL CAN.
iii) Welding / Jointing of Inlet duct at the terminal point at one end and at
Absorber vessel shall be carried out by the Bidder.
i) Erection of Expansion Joints at following location (to be Supplied by other

agency):
i) One number in the inlet duct to Absorber (between the duct terminal point
and Absorber).
ii) Two numbers in the discharge duct from Absorber( between absorber and
terminal point at Chimney end);
iii) Welding of the all these three Expansion Joints with the duct portion /
Transition Piece of new wet Chimney flue-Can shall be carried out by the
Bidder.
j) Erection / Installation of Absorber SO2 removal System Equipments (to be

supplied by the Technology Partner KDPE):
Spray Headers, Nozzles, Mist Eliminators, ME Wash System, Flushing nozzle ,

Tray, agitators, Lances , Instruments etc These equipments which are supplied by
Technology partner (KDPE) shall be installed by Bidder in presence of Client
/KDPE. During the Installation, issue if any arises in the fixtures, brackets /
supporting frames etc shall be attended / rectified/ repaired by the Bidder.

k) Emergency quench water supply system (to be supplied by other agency):
In the inlet duct to Absorber (Between the terminal point the Expansion joint) an
array of pipe header, pipe network shall be erected /installed by the Bidder. This
pipe work is used for Emergency quench water supply from an Overhead Tank to
the absorber as and when required. This pipe array shall be supplied by
Technology partner (KDPE) and Bidder shall install in presence of Client /KDPE.
2.2. Electrical
A) Elevator
a) Supply and installation of one (1) number passenger cum goods elevator of
minimum capacity of 1000 kgs easy access and movement of man/materials.
b) The scope shall include all items / accessories, service along with all electrical
equipment etc. required to meet all design, installation, operation, safety,
protection and other requirements of IS: 14665 (latest edition) (all parts), 'Lift'
and service lifts. The scope shall include all items / devices needed to comply
with the requirements indicated elsewhere in the specification. The scope shall
include provision of fireman's switch.
c) One (1) number adequately sized, Air conditioners having minimum cooling
capacity of 2.5 Ton for elevator machine room to make it dust proof.
d) Complete erection, testing and commissioning including all testing and

commissioning materials, consumables and other tools and tackles required for
erection.
e) The elevator work shall include getting necessary local administration permits /
approvals and make arrangements for inspection and tests required thereby.
f) Supply of Cables, laying and Termination along with all required cable support
system, trays, conduits etc
g) The Bidder shall furnish the complete and consolidated feeder list for all loads
and drives under the scope of supply of contractor to Client (EPIL) as per the
format enclosed at Annexure to this Section.

B) Painting for Electrical Equipment
The painting of all electrical equipment shall be epoxy based with suitable additives.
The thickness of finish coat shall be minimum 50 microns (minimum total DFT shall be
100 microns). However in case electrostatic process of painting is offered for any
electrical equipment, minimum paint thickness of 50 microns shall be acceptable for
finish coat. The Contractor shall furnish the complete painting details during detailed
engineering stage.
C) Construction Power
Scope of provision Construction Power and Charges for the same shall be as
mentioned in Section –I of this Technical Specification.
2.3. Civil & Structural Work
a) Complete Structural work for Absorber
b) Structural work for the Elevator its enclosure. Required Steel structures, cladding sheet
etc for the elevator enclosure, machine room floor & roof shall be supplied and
installed as a part of elevator by Bidder.
2.4. Supply of Spares as per Section –VI of Technical Specifications.
2.5. Supply of all the Special Tools and Tackles for the Equipments under the Scope of Bidder.
2.6. Carrying out specified Type Tests if any for various equipments apart from all Routine
Tests.
2.7. Other Services
i) All Engineering Services/Documentation as elaborated in Section–I and in Section-

VII (GTR). The total documentation list shall be finalized before award of contract.
However partial/Typical list of documents is enclosed in Annexure to this Section
for Bidder’s information.
ii) Submission of Manuals/Field quality Plans for Receipt and Storage for all the
equipments and accessories included in Bidder’s Scope as per requirement.
iii) Bidder shall obtain necessary local administration permits / approvals for
installation and operation of Elevator and shall make arrangements for inspection
and tests required thereby.

iv) Submission of Erection, Commissioning, Operation and Maintenance Manuals as

required for all the items included in Bidder’s Scope of Supply.
v) Supervision of Erection & Commissioning for all the items included in Bidder’s
Scope of Supply.
vi) Review of Foundation drawings, and other civil construction drawings. The
construction /foundation drawings related to the Bidder’s Equipments shall be
reviewed /checked and vetted by the Supplier (s) so that the details are in line with
their civil input data.
vii) Clearance of Civil Foundation at the time of Casting. Civil Foundation shall be
provided by Client and prior to casting; Bidder shall inspect and clear the
arrangement /dimensions etc.
viii) Bidder’s team (design / construction) shall be present during the erection and
commissioning of Internal Equipments of Absorber by Client. While carrying out
erection of internal equipments, if any issue/problem arises in the Internal structural
members, stools, support, platforms, brackets etc the same shall be rectified /made
good by Bidder’s team so that erection and commissioning is not kept under HOLD
for want of repair/ re-work. Bidder to note that such issues /failures happens due
to poor workmanship of the Bidder, the Client shall not compensate for additional
manpower/ re-work.
Note : Advance intimation shall be sent to the Contractor by client for 2.6(vii) so that the
contractor may deploy their experts at site prior to the activity.
3. EXCLUSIONS
a) Foundations for Absorber Vessel is excluded from Bidder’s Scope.
However Foundation Bolts/Fasteners etc shall be supplied by Bidder along with the
main Equipment. Foundations shall be designed/ provided by Client (EPIL) as per the
Design Input to be provided by Technology Provider.
b) RCC Pit of Elevator and concrete roof are excluded from Bidder’s Scope..
However anchoring / mounting / fixing of Elevator components in the pit shall be

supplied and executed by Bidder. The elevator pit shall be provided as per the Design
Input to be provided by Bidder.

d) The interconnecting platform from each landing of the elevator upto the operating
platform level of absorber shall be provided by Client. However the Staircase around
the absorber (which shall be a independent structure) shall be provided by the Bidder
and the walkway from elevator shall be interconnected with staircase as per Absorber
drawings.
4. TERMINAL POINTS
a) One No. 415 V, 3 phase, 4 wire, AC Power Supply to the Elevator will be provided
near the absorber at zero meter level. Bidder shall receive the power supply in a DB
with an isolator located in zero meter level . DC power supply as required to be
provided by the Bidder.
b) One Telephone cable of 12 pair will be provided in a JB located the near the absorber
at zero meter level . Further cabling and wiring through conduits for the telephone
instruments in the lift cabin and in the machine room shall be in the scope of the
Bidder.
c) Upto the first Root valve/Flange for all instrument tapping/connection to be

provided by the Bidder
d) Flue Gas Inlet /Outlet Connections as shown in the Tender Drawing (FGD plant
Layout)

ANNEXURE -1
TYPICAL ENGINEERING DOCUMENTATION LIST
Sl.
Title of Drawings
No.
1. Electrical Feeder List of the Package
Terminal Points List [its location & Details (Mechanical Piping, Electrical Cables,
2.
Instrumentation JB etc]
3. Proposed List of Tools and Tackles (for Assembly of Absorber)
4. MQP of Absorber Plates including procedure of Cladding
5. FQP for Receipt and Storage of material of Absorber and Elevator
6. FQP for Fabrication of Absorber and Flue Gas duct (included in Scope)
7. Procedure of Erection / Assembly of Absorber Vessel
8. FQP for Erection / Assembly of Absorber
9. Fabrication drawings of Absorber
10. Load data of Absorber tower
11. Erection procedure for Internal equipments (for SO2 removal) of Absorber
12. Erection procedure of emergency quenching sysem pipes
13. Erection and Testing methodology of Absorber Tower
14. GA and Data Sheet of Elevator
15. MQP of Elevator
16. FQP of Elevator
Foundation Load Data of Elevator supporting structures with structural design
17.
Calculation.
18. General Arrangement & Data sheet of Elevator
19. GA and Architectual details elevator enclosure (Housing)
20. Type test & Routine test procedure of Elevator
21. GA and Load data of Elevator Pit
22. GA OF Machine Room
23. Architectural details of doors, windows of Machine room & Elevator Car
24. Erection procedure of Elevator
25. Testing and Commissioning procedure of Elevator
26. O&M Manual of Elevator

ANNEXURE -2
STANDRAD FORMAT FOR ELECTRICAL FEEDER LOAD LIST
1 2 3 4 5 6 7 8 9 10 11 12
KKS code
as in Recom -
Vendor Description Rating Supply Unitised Normal / Feeder Running mended Location
S.NO drawing of tender (KW/A) type / Station Emergency type Mode Cable Size Coordinate Remarks
GUIDELINES TO FILL THE FORMAT
Col Legend Designation Description
1 S.NO 1, 2,3 Serial Number
2 KKS code as in Vendor ---- Unit kks of the Equipment
drawing
3 Description ---- Description of the Bidder’s equipment
4 Rating Name Plate Rating in KW or Amps at 50 deg C
5 Supply type 11 KV 3ph AC/3.3 KV 3ph AC/415V 3ph AC /220 V DC /240 V ACUPS/240 V AC Non-UPS
6 Unitised / Station U Unit (U) is applied for each unit
S STN (S) is applied for common equipment Load
7 Normal / Emergency N Normal Supply
E Emergency Supply (i.e DG Supply)
8 Feeder type U Unit-directional motor feeder
B Bi-directional motor feeder
H Heater Feeder
S SFU(Switch fuse feeder)
9 Running Mode W Working
S Standby
10 Recommended Cable Size -/--/--/-- Recommended Incoming Cable Size in :No of runs/ no of cores/ Size in
sqmm/Al or Cu/PVC/XLPE
11 Location Location of the equipment in co-ordinates row & column as per layout
12 Remarks Any other relevant information
Notes 1)Electrical Load List shall be submitted as “MS Excel” sheet also in addition to that in pdf as per the format given above
2)Each Row shall contain data of only one equipment /load: i.e if there are two numbers of the same equipment they shall be indicated in
two different rows with unique description & tag number

RSTPP
ABSORBER PACKAGE TECHNICAL REQUIREMENTS
STAGE - (FGD SYSTEM ) (MECHANICAL SYSTEM & EQUIPMENTS)
III
INDEX
1. GENERAL ............................................................................................................. 2
2. ABSORBER – PROCESS DESCRIPTION ............................................................ 2
3. ABSORBER – TECHNICAL DATA ...................................................................... 4
4. SEQUENCE OF SUPPLY & INSTALLATON OF ABSORBER ........................... 6
5. DESIGN ................................................................................................................. 7
6. ABSORBER FABRICATION & INSTALLATION ............................................... 9
7. INSTRUCTIONS FOR FABRICATION & INSTALLATION ............................. 11
8. ELEVATORS ....................................................................................................... 18
9. OTHER MISCELLAOUS WORK ........................................................................ 21
10. QUALITY ASSURANCE, INSPECTION / TESTING ......................................... 22
Annexure 1 .................................................................................................................... 23
Annexure 2 .................................................................................................................... 28
Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION – IV A Page 1 of 38

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1. GENERAL
This specification defines the requirements of system design, engineering,
installation, testing and commissioning of various Equipments covered in this
Technical Specification. This specification also includes basic guidelines to design,
manufacture and supply the equipments included in this Specification. This Section
Covers Mechanical System Equipment.
2. ABSORBER – PROCESS DESCRIPTION

a) Brief Description of FGD System is mentioned in Section-I of the Technical
Specification.
b) Absorber which is a critical equipment of FGD system is described below.

Description covers the General Arrangement, Technical Parameters, Functions,
Material of Construction, construction features etc of Absorber.
c) The Tender drawing (Drg no GA 3140-1095-PVM-B-044) titled Plant Layout

FGD system shows the overall layout of FGD system, duct layout from existing
chimney etc. GA drawing of the absorber ( Drg no : 3140-1095-PVM-B-010) and
P&I Diagram (Drg no : 3140-1095-PVM-F-001) shows the arrangement and
overall scheme of Absorber.
d) Detailed Drawings of Absorber attached with this Technical Specification (a

set of thirty one (31) sheets including an Index Sheet along with other Tender
Drawings) shall be referred by Bidder to prepare Fabrication Drawings by
Bidder. These are preliminary drawings.
e) Bidder shall also prepare “Sheet Development (Unfolded drawings for each
plate width)drawing so that nozzle opening/holes for fittings etc is clearly
identified and fabricated / made accurately.
f) The Absorber utilize a wet limestone process with in-situ forced oxidation to
remove SO2 (Sulphur di Oxide) from flue gas and produce Gypsum as
byproduct.
g) A perforated Tray and four (4) lime slurry spray levels above Tray are
provided inside the Absorber. Lime slurry is fed to each spray level by a
dedicated slurry re-circulation pump for SO2 removal.
h) The hot flue gas entering the absorber is cooled and saturated by the slurry
falling from the absorption zone and flows through the absorber tray.
i) The gas passes through the layer of absorber slurry on the tray, thereby
assuring intimate SO2 mixing between the liquid and the gas passes through

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the absorber spray zones. The slurry spraying countercurrent to the flue gas
flow completes the sulfur dioxide removal process.
j) The gas flows upward to the first stage mist (ME) eliminator which is sprayed
with raw water (by means of series of headers with water spray nozzles) onto
the first stage mist eliminator from below and above the ME.
k) These sprays keep the surface of the mist eliminator wet and wash away slurry
solids reaching the mist eliminator. The gas then enters the second stage and
third stage mist eliminators and thereafter the flue gas exits the absorber
through the outlet hood.
l) The slurry and mist eliminator wash water that is sprayed into the absorber
passes down through the absorber and is collected in the lower section of the
absorber i.e “the absorber reaction tank”.
m) Five numbers of side entry type agitators are provided to keep the absorber
slurry solids in suspension in the tank portion. Each absorber reaction tank is
designed with an absorber overflow such as way absorber & inlet duct is
protected from flooding and prevent the flue gas from escaping through the
overflow.
n) The process is controlled by established control & instrumentation system

using measurement of pH and Density of the slurry, liquid level (s)in the tank
etc.
o) The sulfur dioxide removal process forms solid products. The absorber
reaction tank includes an in-situ forced oxidation system through Oxidation
Air Blowers through air lance which enables conversion of Calcium Sulphite to
Calcium Sulphate. This final semi solid, product, gypsum is bled periodically
by gypsum bleed pumps.
p) An emergency cooling system for automatic spray of quenching water for a

sufficient time (minimum 15 min) at the inlet to the absorber, in case the gas
temperature exceeds the design temperature due to failure of upstream
equipment’s shall be provided to protect the FGD and all other sensitive
downstream equipment against high flue gas temperatures. The water shall be
supplied from an elevated tank (emergency quench water tank) to be mounted
near the absorber tower and shall be led into the absorber through a pipe array
at the upstream of Absrober.

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3. ABSORBER – TECHNICAL DATA

(i) Number & Type of Absorber : One (1) number spray type
(ii) Size of absorber : (Φ (diameter) 16.5 m and 40.91 m

Height )
(iii) Ambient Conditions : 45 deg C / 60 % RH
(iv) Number of Trays : One
(v) Number of Spray Banks : Four (4)
(vi) Type of Nozzles : Hollow cone nozzles
(vii) Type & number of Agitators : Sid-entry type ; 5 numbers.
(viii) Mist Eliminator : Three Stages
(ix) Design pressure : -150 to + 660 mm wg or

maximum conceivable pressure of
the Booster Fan, whichever is
higher, at 67% of yield strength of
material.
(x) Max working pressure : 3203 Pascal
(xi) Design inlet gas temperature : 150 deg C
(xii) Flue gas flow rate at Inlet : 642 Nm3/sec (wet, design
condition)
(xiii) Gas velocity through Absorber : : ≤ 4 m/sec
(xiv) Slurry residence time : 4.0 minutes
(xv) Oxygen air distribution type : Lance
(xvi) Number of tray : 1
(xvii) Height between top of inlet duct to the tray : 1.5 m
(xviii) Height between tray to 1st spray levels : 2.0 m
(xix) Height between individual spray levels : 2.0 m
(xx) Diameter of absorber : 16.5 M
(xxi) Diameter of reaction tank : 16.5 M
(xxii) Height of absorber : 40.91M

(xxiii) Number of spray bank : 4 (3 + 1 Standby)

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(xxiv) Liquid level
a) Design level : 8.12 m
b) High level : 8.8 m
c) Lower level : 8.28 m
(xxv) Specific gravity of Slurry : 1140 kg/ m3
(xxvi) Slurry : pH 5.5 - 6
(xxvii) Slurry solids concentration : 20 %
(xxviii) Insulation for absorber : No
(xxix) Absorber supporting method : self-supported
(xxx) Materials of Absorber Construction
a) Complete absorber vessel (**) : Clad sheet of C276 (minimum

2mm thickness) by explosion
bonding with Carbon Steel as
Base material which shall be of
varying thickness (minimum 7
mm thick) as per tender drawing.
(This material is applicable for
absorber oxidation tank, absorber
tower & absorber outlet duct up
to absorber outlet flange)
b) Wet Dry Interface and lining : C276 of minimum 6mm thickness.

(length is 2.0m measured
horizontally from the center of
inlet nozzle flange to the absorber
shell).
c) Metallic fasteners : C276 inside the

absorber/absorber wet-dry
interface ducting
d) Bridges (supports) : Lined with minimum 2 mm C276
e) Suction screens : C276 (to protect the Slurry

recirculation pumps)

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f) Mist Eliminators (ME) /Type : Polysulfone or stainless steel /

CHEVON type.
g) ME Wash Water Header & Nozzles : Polypropylene
h) Spray Headers : FRP (corrosions and erosion

resistant in the inner and outer
side) Silicon Carbide coating on
FRP surface exposed to slurry.
i) Spray Nozzles : Silicon carbide.
j) Oxidation lances : Duplex stainless steel DIN 1.4529
k) Tray : Duplex stainless steel UNS

S32205 in accordance with ASTM
A240.
l) Agitator : Duplex stainless steel DIN 1.4529
(xxxi) Structural Design Standard : As per API STANDARD 650

of the Absorber by Technology provider
(xxxii) Dimensions & details of Absorber : Refer enclosed Tender Drawings.
4. SEQUENCE OF SUPPLY & INSTALLATON OF ABSORBER

4.1 Absorber vessel supply & installation generally involves the following stages
to be carried out by the Bidder
 Absorber design (i.e) Preparation of detailed design and GA drawings

which is already carried out by KDPE (Technology provider) and
enclosed as Tender drawings.
 Bidder to break the drawing up into parts for fabrication and shall
develop detailed fabrication drawings and as well as Development
drawing for each sheet along with Bill of Materials.
 Procurement of clad sheet of C276 (minimum 2 mm thickness).
 Bonding of clad sheet with Carbon Steel as Base material which shall be
of varying thickness (minimum 7 mm thick) as per tender drawing by
“Explosion bonding” or by “Hot rolling”.
 Fabrication of Sheets; This can be carried out either at “Site” or in the

“Factory”.

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 Absorber vessel installation either by “Normal assembly method” or by

“Inverted assembly method”
 Testing of the Vessel
Requirements of each of above steps, which are included in this contract

(Bidder’s scope) are described.
4.2 The Bill of Material from the detailed drawings of Absorber Vessel (referred
in Clause 2.0(d)) above is compiled and enclosed in Annexure -2. This data is
presented only for quick reference for Bidder and Bidder to procure required
material, fabricate and erect /install the same as per the Absorber drawing.
Bidder may review and cross check the Compiled Data themselves and client
shall not be responsible for any discrepancy between the BOM and the
drawings.
5. DESIGN
a) Detailed (structural) design of Absorber had been carried out by KDPE
(Technology Provider) as per API Standard 650. Preliminary Input and detailed
Design drawings are enclosed as Tender drawing. After award, (before
ordering of materials and development of fabrication drawings by Bidder)
revised design drawings if applicable shall be made available to the Bidder.
b) The absorber shell shall be designed for pressure loads, piping forces and
moments, wind and seismic loads and all other loads imposed on the absorber.
Bracing and reinforcement shall be adequate to prevent deflection and
vibration.
c) Internal supports for mist eliminator sections, etc. shall be designed to

withstand the flooded weight of the supported section. The absorber and its
structural supports shall be designed for the maximum operating loads
including design positive & negative internal pressure, static head, external
attachment loads (such as piping loads etc) wind load using the allowable
stresses permitted by the applied standards.
d) The absorber shall be self-supported from the bottom to suit site conditions.
The absorber shall have adequate stiffening arrangement on the external side.
Internal stiffeners shall be used only where it is not possible to provide proper
external stiffening with approval of Client/ NTPC.
e) Structural GA drawing shall be split into various portions for preparation of

Fabrication drawings by the Bidder through experienced personal.
Development of Fabrication drawings shall take into account sheet width,

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length, erection tools proposed to be employed, method of Assembly of Shell

plates, connection details etc.
f) Fabrication drawings shall be submitted for approval of Client/NTPC and final

approved Fabrication drawing shall be release by Client for Fabrication and
Installation.
g) The fabrication of the absorber vessel shall follow common practice as there
shall be no longitudinal seams located behind any attachment or obstruction
which would prevent inspection of the welds. Nozzles, access ways, and their
reinforcements shall not be located in or on any seam. Inaccessible gaps or
hollow beams shall be avoided.
h) Walkways shall be arranged and also measures shall be taken as appropriate to

permit the internal components to be disassembled and reassembled during
repairs without the necessity for time-consuming preparatory work. The
headroom shall have a height of more than 2200 mm. The mist eliminator
support beams shall be designed to act as maintenance walkways
approximately 300 mm wide and shall allow for a minimum 500 Kg/m2 load.
The support beam/walkways shall provide personnel access to all mist
eliminator modules, wash headers and wash nozzles.
i) All equipment located in the gas path or connected to such equipment shall be
designed to withstand the maximum inlet gas temperature fluctuations. There
shall be no damage whatsoever to any equipment as a result of these
fluctuations.
j) All internal members shall be lined with minimum 2 mm C276. All metallic
fasteners which are provided inside the absorber/absorber wet-dry interface
ducting shall be of C276.
k) The absorber wet-dry interface shall be made of solid C276 of minimum 6 mm

thickness.
l) The other bridges (supports) shall be lined with minimum 2 mm C276. It

should be possible to build platforms inside the absorber for access to all parts
of the absorber during maintenance. Arrangement shall be properly designed
to facilitate access for maintenance and replacement of spray nozzles.The spray
piping, mist eliminators and its supporting structure shall be designed to carry
sufficient load during maintenance.

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6. ABSORBER FABRICATION & INSTALLATION

6.1. The sequences of Fabrication and options adopted :
a) Fabrication at site (Option :1)
 Composite C276 plates are (sizes as per requirement / drawing)

procured and brought to site .
 With pre-fabrication tools such as plasma cutter, rolling machine and

crane, plate cutting, groove making and plate rolling are carried out at
site as per drawings.
 Then installation of absorber tower is taken up.
b) Factory Mode (Option :2) .
 The manufacturer purchases the composite plates
 carries out pre-fabrication as per drawings in their factory
 transport the same to site and install the absorber tower.
Each method has its own merits and demerits. The Bidder can adopt either of
the above options considering the aspects such as:
(i) Bidder’s experience in their past jobs,
(ii) Availability of skilled fabricating personal at site
(iii) Availability of quality manufacturers who can fabricate and Supply pre-
fabricated composite plates from their factory etc.
Bidder shall submit their proposed method / option with details /data in the
Bid. This shall be discussed and finalized before award.
6.2. The method for Installation of Absorber Vessel (with Options) :
a) Construction procedure of the absorber tower , installation of the absorber

tower (including the fabrication and installation of the absorber tower shell,
installation of the inner parts of the tower, internal lining, external paint )
and installation of ancillary equipments.
b) Commonly two methods are used for installation of Absorber Towers. (viz)
“Normal assembly” method and “Inverted Assembly Method”.
c) The normal assembly method is to install the shell plates from the bottom
plate to the cone after installing the absorber bottom plate; on the contrary,
the inverted assembly method is to install the shell plates from cone to
bottom plate.

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d) Construction tools required for Normal assembly method are Crane or

tower crane, welding machine, other auxiliary tools etc. For Inverted
Assembly, Crane or tower crane, hydraulic lifting device or motor hoist,
welding machine, other auxiliary tools etc are used.
e) The Construction Process /sequence of Normal assembly method is as

follows:
 Prefabrication of absorber tower shells and structural parts (hollow

beams, Shell ring )
 Inspection and acceptance of civil foundation
 Floor beam installation
 Grouting
 Bottom Plates Installation
 Floor elevation review and Floor welding
 Weld inspection followed up with Absorber shell installation from

bottom to top
 Cone roof installation
 Shell ring installation followed with Installation of ladder platform
 Installation of hollow beams & pipes interface
 Testing such as UT/RT etc
 Settlement observation, Paintwork, Internal Inspection of tower
 Equipment installation and Scaffolding removal
 Absorber tower final inspection and acceptance
f) The Construction Process /sequence of Inverted assembly method is as

follow:
 Prefabrication of absorber tower shells and structural parts (hollow

beams, Shell ring )
 Inspection and acceptance of civil foundation
 Floor beam installation
 Grouting
 Bottom Plates Installation

 Floor elevation review and Floor welding

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 Weld inspection
 Top of absorber shell and cone roof installation
 Installation and commissioning of hydraulic lifting device
 Shell ring installation
 Installation of ladder platform
 Successive lifting of each shell of the absorber tower
 Complete the inspection work until the vessel is installed
 Installation of Shell ring and Installation of hollow beams
 Installation of pipes interface
 Testing such as UT/RT etc
 Settlement observation, Paintwork, Internal Inspection of tower
 Equipment installation and Scaffolding removal
 Absorber tower final inspection and acceptance
6.3. Bidder shall submit their proposed method of installation i.e “Normal
Assembly Method” or “Inverted Assembly Method” with the experience
details /data in the Bid. This shall be discussed and finalized before award.
7. INSTRUCTIONS FOR FABRICATION & INSTALLATION
7.1. The complete bonding /installation of liners shall be as per the liner
supplier guidelines or under their supervision. In the execution of the
welds, contractor must ensure that welding material has same corrosion
resistance as the actual plate surface.
7.2. All the erection tools, machineries such as bending / rolling machine,
testing equipments (for UT, RT, other NDTs, Vacuum Box, hydraulic) etc
which are being referred in this Section are to be deployed by Bidder /
Contractor.
The total population of these tools and tackles to be deployed shall be

discussed and finalized before award. During the course of Site work,
augmentation and substitution of these equipments if required to meet the
project schedule shall be agreed to by the Bidder no additional cost to the
Client.
7.3. Bidder’s QA programme & System manuals shall cover all the activities.
Manufacturing Quality Plans shall include the QA, Inspection and Testing

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of all Raw materials and Shop fabrication.(Bidder to refer Section VII of the
Technical Specification)
7.4. Bidder shall furnish Field Quality Plans for all site activities such as :-
(i) Procedure for Receipt, Unloading of Materials and/or prefabricated

items (as applicable),
(ii) Storage procedure of Materials / pre-fabricated items,
(iii) Receipt & storage procedure of erection tools (Cranes, hydraulic jacks.
Hoists etc) and appliances such as weld electrodes, testing appliance
etc.
(iv) Site Fabrication (if adopted) procedure with testing and inspection
details.
(v) Installation of Complete Absorber Vessel, Inspections and testing,
(vi) Forms/Templates for various inspections identified in the above

procedures so that these are filled and Quality Records are maintained
for each activity.
7.5. At every stage of site activity, checking, inspection, review & corrections in
presence of Client’s representative shall be carried out by contractor before
proceeding to the next step.
7.6. Each Piece of Plates, fittings or any other component of absorber system
shall be clearly identified by marking heat number on the parts marking by
painting or hard punching with the confirmation of QC. And every weld
joint shall be marked with joint Number with Welder Number.
7.7. All fabrication work involving material identification, marking, cutting,

rolling and Welding shall be done in accordance as per drawing dimensions.
7.8. The workmanship shall be good in every respect meeting all safety, QC &
NDT requirements, with the coordination. All Shell plate handling with dog
clamp along with proper packing to avoid C276 materials damage while
shifting & lifting of Cladded plates.
7.9. Temporary Stiffeners shall be welded directly on clad plates in between and
if C276 clad is removed for welding temporary supports, then it shall be
removed and after removal temporary support, the area shall be repaired
with overlay as per overlay procedure. Strip back for edge preparation etc.,
where ever applicable shall be done as per drawing for fabrication and
erection work.

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7.10. In site fabrication, cutting of CS plate and Liner plate C276 has to be done by
Plasma cutting machine. The plate edges have to be prepared as per the
details mentioned in the fabrication drawings. The plates shall be feed to
rolling machine & SS rolled shell plate to be kept on top roller of the rolling
machine by using crane, Nylon Belt & proper lifting Clamps. The rolling
radius to be maintained and checked as per the drawing.
7.11. Before starting the erection of Shell assembly, the contractor must
Inspect/ensure himself for trueness/leveling of absorber foundation.
7.12. Qualified welder should be engaged for welding. Welder Qualification has
to be submitted to Client/NTPC for approval before start of welding works.
7.13. Normal Assembly of Absorber
a) As said above, in normal assembly the installation of absorber tower

shall be starts from bottom plate to cone. Hence the floor beam has to be
installed as per the drawings/instructions.
b) The fabricated floor beam has to be installed above the embedment plate
as per the drawing. Once the level of floor has been verified, grouting of
floor has to be done. After curing of floor beam grout, the Absorber
bottom plates installation may be started.
c) The Absorber bottom plate elevation/leveling has to be checked and

confirmed before starting of bottom plate welding. After completion,
UT/RT test has to be done for welding as per the approved FQP. The
prefabricated absorber shell plate installation has to be started from
Bottom to top. The necessary supporting structures such as scaffolding,
structural members etc has to be arranged by bidder. While erecting the
Absorber shell assembly, the cone roof fabrication work may be started
simultaneously in the ground level.
d) After completion of shell assembly, the pre fabricated cone can be

installed with the help of Crane/Tower Crane. Required sufficient safety
measures have to be taken up prior to start of cone installation.
e) The shell ring support and box beam support has to be along absorber
shell erection. The walkway/plat form has to be erected along with
staircase as per the drawings. After completion of absorber shell
installation, UT/RT has to be conducted for confirming the healthiness
of weld. The internal beam supporting brackets/stool and internal beam
have to be installed as per the drawings.

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7.14. Inverted Assembly of Absorber
a) In case Inverted Assembly method adopted, total lifting capacity of the

hydraulic Jacks should have adequate margin not less than 1.5 times of
the Absorber Tower Weight.
b) In inverted assembly methodology, the top most shell course/segment

has to erected along with the cone. After shell plate erection, temporary
arrangements make for vertical joint fit- up be made. During shell plate
fit-up, sufficient number of stiffeners to be ensured to control profile and
avoid distortion.
c) Meanwhile peaking points in all vertical joints to be checked by using

template gauge.
d) After completion of plate fit-up, inspection calls to be raised to client to

obtain welding clearance. In the same way balance Shell
course/Segment has to be erected.
e) After completion of top two shell erection the conical part have to be
erected by segment wise on the top most shell course. Proper temporary
support arrangements have to be provided to avoid cone part coalition
and outside permanent stiffener supports to be provided before erection.
During shell course erection the support beams & support brackets have
to be erected along with shell course as mentioned in the drawings.
f) The second set of shell courses have to be positioned below the first shell
course. During shell course erection, temporary lifting arrangements
have to provided to avoid shell course distortion.
g) Root gap be ensured and horizontal alignment be made and fit-up

throughout shell circumference and shell plate verticality be checked.
Sufficient stiffeners as required to be provided. After fit-up completion
the alignment inspection have to be offered to client/NTPC to get
welding clearance.
h) Longitudinal welding shall be completed first and later circumference

joint with Upper shell. Touch up painting shall be made for all weld
joints. C276 welds shall be cleaned by pickling/passivation.
i) The number of shell course welding to be completed before cutting of

opening shall be decided depending upon size of opening, doors, RF
pads, pipe supports, and stiffeners. Staircase shall be erected along with
shell course elevation wise.

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j) NDT including RT shall be done progressively with weld completion.

All temporary stiffeners shall be welded on clad plate as per following
weld details using suitable WPS & PQR wherever required.
k) Nozzle orientation of pipe with flanges on the shell and entire openings
will be cut by plasma method. Mark the orientation of the spray headers
pipe support on the inside the shell wall and ensure the elevation and
levelness of the all support during support fit up & welding. The access
door & its pad with flanges have to be erected parallel with shell
elevation as mentioned in drawings. All above works will be done along
with shell course erection level by level as mentioned in drawings.
l) In order to avoid the damage of bottom plate cladding (C276), the same
has to be erected after completion of all shell coarse, Cone & Absorber
internals completion. Short seam welding have to be carried out
alternatively to avoid distortion. Bottom plate Butt joint minimum root
gaps has to be maintained while the fit-up of long-seam as per approved
fabrication drawing. After Completion of welding the bottom plate joints
has to be thoroughly cleaned by using wire Brushing and grinding.
m) The designer of absorber (KDPE) had prepared suggestive Installation

steps for Inverted Assembly of Absorber which is enclosed in Annexure 1
to this Section. The same is enclosed for guidance only and Bidder’s to
execute the installation as per their experience. Bidder to note that the
steps are presented considering an assumed plate width. However actual
plate /liner width to be adopted by Bidder may be different and erection
sequence /weld length shall be different compared to the sketch enclosed
in Annexure 1 and no additional payment shall be payable on this
account to Bidder.
7.15. After completion of erection the Absorber Tower has to be in observation for
settlement test. The painting of absorber has to be done as per the details
mentioned in Section – I & III of the Technical Specification.
7.16. After completion of Absorber tower erection, the Bidder has to conduct the
vacuum box testing. 100 % NDT test has to be conducted for all the field
joints.
7.17. Alloy to carbon steel welds must either be hidden behind a covering strip
alloy material, or be executed by a special welding procedure ensuring the
same quality at the weld surface as the alloy lining. All welding which shall

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be in the contact with process fluids shall be executed under the supervision
of the designer/manufacturer.
7.18. All the tasks /Activities need to be accomplished with at most care with
good workmanship and in accordance with the specifications to achieve
satisfactory completion of the whole activities.
7.19. All tools, cranes, hydraulic jacks, hoist and other temporary equipments
brought to site for erection of Absorber tower by the Contractor shall be in
good working condition to ensure its safe and reliable operation at site. On
receipt of the temporary equipments/components at site, the same shall be
inspected by Client/NTPC to ensure its safe and reliable operation and if in
the opinion of the Employer the temporary equipments/ components are
not in satisfactory conditions to ensure its safe and reliable operation the
same shall be immediately replaced by the Contractor. The temporary
equipments specifically brought by the Contractor remain the property of
the Contractor.
7.20. Contractor shall establish/set up at site suitable repair facilities for

construction/erection plant, equipment and machinery. He will also make
arrangements/tie up with equipment manufacturers /suppliers for periodic
overhaul/maintenance and for major breakdown, if any. He shall also keep
adequate stock of spares at site for various plant, equipment and machinery
to meet day to day requirements as recommended by the equipment
manufacturer/suppliers or as instructed by the Engineer-in Charge.
Contractor shall deploy dedicated qualified, full time mechanical/electrical
foreman/supervisors for operating the equipments and repairing facilities as
specified above.
7.21. Inlet Duct and Discharge Duct portion of Absorber & associated Expansion
Joints :
a) The terminal points of inlet duct to the absorber and discharge duct from
absorber be referred in Tender Drawing (Drg no GA 3140-1095-PVM-B-
044) titled Plant Layout FGD system.
b) In the inlet duct, a portion of duct shall be of carbon steel construction

(without C276 lining) from terminal point to the expansion joint and the
portion from the downstream of expansion joint upto the final point of
delivery of flue gas into the Absorber shall be of solid C276 material
(minimum 6m thick) as this being Absorber wet-dry interface duct.

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c) The outlet portion of duct from absorber upto the transition piece of
Chimney flue-can shall be made out of Carbon steel material of
minimum thickness of 7mm bonded with clad material of 2 mm thick
Alloy C276. In the portion, two expansions joints are to be provided as
shown in the Tender drawing.
d) The transition piece of the new wet Chimney flue-can and the main
Chimney flue-can is provided with 38 mm borosilicate glass block lining.
d) All the expansion joints including its Flanges, Gaskets, Counter flanges
and the fasteners shall be supplied by Client (EPIL) from an another
agency. Three expansion joints (one in the Inlet duct to absorber & two
in discharge duct portion) shown in the Bidder’s duct portion shall be
installed in the respective duct portion by the Bidder as per the
instruction of Expansion Joint Suppler and under their supervision.
These flanges of Expansion Joints are proposed to be made of solid C276
material.
e) The dimensions of Expansion Joints which are to be installed by the

Bidder be referred in the Tender Drawing. Other details like weight,
erection instructions etc shall be furnished later to the Bidder.
f) The agency who would be supplying expansion joints is entrusted with

complete Ducting system design , fabrication, supply and installation
from chimney to the above terminal points. Bidder may note that this
agency shall also design (structural) this duct portion also (which are
included in this package) and Bidder shall supply and install as per the
design. The structural supports of these part portions of the duct shall
also be provided by that agency along with complete ducting system.
g) At the respective terminal points, the jointing (welding) of Absorber

Inlet duct and Absorber discharge duct (which are installed by the
Bidder) shall be carried out by the Bidder with the main duct and
transition piece of Chimney respectively. Similarly welding of the three
expansion joints with the duct shall also be carried out by the Bidder. In
this regard following point shall be kept in mind:-
 at the transition piece end of Chimney, lining of borosilicate glass

block is provided.
 The Absorber inlet duct (portion at the downstream of Expansion

joint) shall be solid C276 construction of minimum 7mm thickness

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III
 The Flanges & counter flanges and fasteners of these three expansion
joints are of C276 construction.
 Absorber discharge duct is of carbon steel (of minimum 7 mm thick)

cladded with C276 (2 mm thick)
h) Close co-ordination is expected from the Bidder while executing this

work as more than one agency is involves in this area (viz)duct
contractor, Bidder and Chimney Flue Liner contractor.
i) The complete bonding /installation of liners shall be as per the liner

supplier guidelines or under their supervision. In the execution of the
welds, contractor must ensure that welding material has same
corrosion resistance as the actual plate surface.
8. ELEVATORS
8.1. Elevators shall be designed based on following criteria :
S.No. Details Remarks

A. Type of service : One (1) no. Passenger cum goods
elevator
B. Design/construction/installation : a) Latest edition of IS:14665 (All
codes
parts)AND also meeting any
additional requirements of
IS:4666, IS:1860 and IS:3534.
b) Any other equivalent code,
subject to Client’s / NTPC s
approval.
C. Capacity : 1000 kg (minimum).
D. Rated speed : 1.0 m/s.
E. Total Travel : As per GA drawing
F. Number of floors to be served : Five Levels other than Ground level ;
Tentative Landing Levels are : 30.4
M, 27.6M, 23.2, 19.2 M and 16.8 M
G. Entrance : As per requirement and subject
Client’s / NTPC s approval
H. Entrance and platform size : As per design/installation codes at
(B)
Above
I. Drive/motor : As per Electrical Specifications.

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III

J. Method of control : As per Electrical Specifications.
K. Machine room and lift Shaft : Pressurized dust proof or
Air-conditioned machine room as per
the
requirement
L. Position of machine room : Directly above the lift shaft.
M. Power Supply : As detailed in Electrical Specification
8.2. Landing doors of the elevators shall have fire resistance of at least one hour. These
doors shall also be smoke tight as far as possible.
8.3. Construction of the elevators shall specifically meet all requirements of the codes
indicated at Cl. 8.1 (B) and shall have following additional features:

1. Flooring of Cabin : 6 mm thick Checkered Plate flooring.
2. Design, Construction and finish : Car inside enclosure including inner
of car & car door side of door shall be of stainless steel
plate of grade SS:304 of bright finish.
3. Car entrance and landing doors : As per BS:476 (Part 20 & 22)
4. Door construction : Hollow metal construction from 16
guage thick steel sheet spray painted.
5. Signals : Car position informer in car both
visual and audio, hall position
indicator at all floors, telltale lights at
all floors, battery operated alarm bell
and emergency light with suitable
battery, charger & controls.
6. Type of Indicators : Soft touch keys and digital luminous
display in car operating panel and on
all floors landings.
(All fixtures in stainless steel face
plates).
8.4. Technical requirements of Electrical items shall be as per details given in IV –B

(Technical Requirements –Electrical System)
8.5. Construction Details /Data

i) Elevator shall be covered by Colour Coated sheet steel enclosure over
Structural steel frame work including for the portions of Machine Room.

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ii) Roof and Side enclosure of Machine Room shall be provided with Prefabricated
Insulated Metal sandwich panels. Composition of Insulated Metal Sandwich
Panels shall be as described in Section IV D (Technical Requirements of Civil &
Structural Works)
iii) Doors of Machine Room shall be Double Plate Steel flush doors of thickness 45
mm with steel sheets of 18 gauge with necessary stiffeners. Space between two
sheets shall be filled with mineral wool insulation. Frame of doors shall be
pressed steel sheets of 16 gauge. All necessary fittings for the doors shall be
provided by the Bidder. Rubber sealing, for making the Doors airtight shall
also be provided.
iv) Windows/ventilators shall be of standard extruded Anodised Aluminium

Sections of minimum 2 mm thickness with 24 mm hermitically sealed double
glazing consisting of two 6 mm thick toughened glass separated by 12 mm gap.
v) Technical requirements of Prefabricated Insulated Metal Sandwich

Panels/decking sheets shall be as given elsewhere in this specification.
vi) Floor of the Cabin shall also provided with Checkered Plate flooring.
vii) Floor of Machine Room shall be provided with profiled metal decking sheet.
Trough shall be filled with Insulating Material (glass wool or rock wool) and
thereafter finished with Minimum 50 mm thick wooded flooring, consisting of
37 mm thick hardwood planks, finished with 11 mm thick laminated wooden
flooring (of ‘pergo’ or equivalent) with plank size 193X1195mm (material class
shall be 34 as per EN13329), over 2 mm expanded polystyrene foam and
polythene sheet under laying.
viii) Machine room of elevator (lift) shall be dust free air tight with Air Conditioner
which shall be designed as per the guidelines given in Clause 8.10 below.
8.6. Provide sound reducing material below machines in machine room.
8.7. Provide special corrosion resistant treatment on all elevator components. The
protective treatment shall be subject to Client/NTPC’s approval.
8.8. Elevators shall have provisions to meet following operational requirements:
i. Selective collective, automatic operation with or without operator through

illuminated push button station located inside the lift car.
ii. Power operated with automatic opening/closing car and landing doors.

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iii. Two push buttons, one for upward movement and the other for downward
movement at each intermediate landing, and one push button at each terminal
landing shall be provided in order to call the car.
iv. Push buttons shall be fixed in the car for holding the doors open for any
length of the time required.
8.9. Fireman's switch shall be provided for each elevator.
8.10. Design guideline for Air Conditioner :
(i) For areas where air conditioning requirement is 5-15 TR ductable

split/packaged A/C shall be provided. If the air conditioning load is less
than 5TR, then Hi-wall Split/Cassette air conditioner shall be provided.
(ii) Design ambient conditions for air conditioning shall be as given below:
Season Dry Bulb Temp (deg C) Wet Bulb Temp (deg C)

Summer 45 27.5
Monsoon 35.8 28.3
Winter 12.8 8.9
(ii) Air-Conditioner shall be designed for continuous duty.
(iii) Air conditioned areas shall be maintained at 24 deg. C ± (plus or minus) 1

deg. C..
9. OTHER MISCELLAOUS WORK

9.1. Apart from supply and installation of Absorber, Bidder’s Scope of work also
includes the following :
a) Installation of Absorber SO2 removal System Equipments (to be supplied by

the Technology Partner KDPE).
b) Installation of Emergency quenching water system spray piping (to be

Supplied by other agency)
c) Installation of specified expansion joints (to be Supplied by other agency)
9.2. Absorber SO2 removal System Equipments:
a) All the SO2 removal system equipments such as Spray Banks/Headers,

Nozzles, Mist Eliminators, Flushing Nozzles, Tray, Agitators, Oxidation Air
Lances, Sieves, instruments etc shall be supplied by Technology Provider
(KDPE) .

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b) Bidder shall install the internals and commission the same as per the sequence
guided by instructions of the Client /Technology Provider and their instruction
manuals.
c) Tentative weight and details of these Items are mentioned in the Table in
Annexure-2.
9.3. Emergency quenching water system spray piping:
The tentative layout and arrangement of the Piping is exhibited in the Absorber
Detailed drawings which is referred in Clause no 2.0(d) above (In sheet no 30).
9.4. Expansion Joints:
Specified expansion joints (one at the inlet duct of Absorber & two at the discharge
ducts of absorber)
10. QUALITY ASSURANCE, INSPECTION / TESTING

Brief inspection and Testing aspects of the Equipments are tabulated in Section-IV-E
of the Technical Specification. Section- VII (GTR) be referred regarding Quality
Assurance Programme, Quality Assurance Documents etc.

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III
Annexure 1
SUGGESTIVE STEPS FOR INVERTED ASSMEBLY
A. Considering the integrity of the alloy lining and the safety during the whole
lifting process, lifting devices be mounted on the outer of the shell walls ;
B. Suggested that Absorber be lifted in two successive stages i.e. first stage of
lifting from level 0 meter to level 18 meters (the level of tray beam); second
stage of lifting from level 18 meters to level 41 meters. (The schematic diagram of
the absorber be referred at the end of this steps /write up)
C. Considering the cone of the Absorber as a nonstandard piece and installation

from height will be difficult, it is suggested to prefabricate the cone first and
use temporary measures to fix it on the shell of tray beam level.
D. After the first stage of lifting is completed and the lifting devices are prepared
for the second stage, sever the temporary connection between the cone and
the tray level shell wall; redistribute the weight of the cone on the lifting
devices that are prepared for the second stage, and begin the second stage of
inverted lifting for Absorber.
E. The detailed steps are as following:
1) Installation of Absorber bottom plate be completed, , complete the

installation of foundation bolt and secondary grouting;
2) Prefabricate the Absorber wall plates (plate rolling) and cone roof wall;
3) Install and weld the lowest shell wall (#1) and finish the fixation on the
bottom plate; Manufacture the support corbel brackets, lifting bearing
plate and other temporary accessories (support, lifting lug, limiting
stopper, jack rod clamp and wall plate slide rail, etc.)
4) Reinforce the lowest shell wall from the outer rim (mount temporary
reinforcement bar and reinforcement strip), weld the support corbel
brackets, slide rail, stoppers and other accessories;
5) After finishing the installation of the lowest shell wall (#1), a 4-meter
operation platform (full scaffold and steel scaffold board) shall be set up
inside the tower as the lifting operation platform and internal welding
assembly platform for the following work; an external operation platform
shall be set up around the outer wall of Absorber tower as lifting and
welding platform for wall plate installation;

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III
6) Install the hydraulic lifting devices, which shall be welded above the
supporting accessories and reinforce the jack rod;
7) Commission the lifting devices, make sure no leakage in the oil tubes or
connection fittings, and each individual rod is synchronized stable and
reliable;
8) Use the truck crane to lift the top shell wall (#17) of the Absorber tower
above the lowest shell wall (#1). Each wall plate is arranged to the
position of the Absorber tower rim through the slide rail outside the shell
wall and the corresponding manual hoist. After the wall plates are
calibrated in place (consistent with the arc degree of the lower wall
plate),the vertical weld of the wall plates of this layer shall be fully
welded;
9) Locate and weld lifting bearing plates at the proper position around the
assembled shell wall (consistent with the number of jack rods)
10) Start the lifting devices to lift the lifting rods to the bottom of the lifting
bearing plates, and initially bear the weight of the top shell wall (#17) of
the Absorber tower assembled in step 9;
11) On the operation platform at the bottom of the Absorber tower, the cone
roof combination (#18) at the top of the Absorber tower is installed above
the top shell wall (#17) of the Absorber tower; after assembling, the lifting
weight of the lifting device is about 70 tons;
12) Start the lifting devices to lift the top combination above to suitable
height, ensuring space for the installation of next layer of wall plates;
13) Use the truck crane to install the tray level shell wall (#9) on the reserved
space. Each wall plate is arranged to the position of the Absorber tower
rim through the slide rail outside the shell wall and the corresponding
manual hoist. After the wall plates are calibrated in place, operate the
lifting device to place the upper shell (#17 & #18 in this step) on this layer
of shell wall and intermittent welding is carried out. After the two layers
of shells are combined, the pressure of the lifting devices can be released,
and the two layer wall plates can be fully welded on the internal and
external operation platforms. However, it is emphasized that the top
combination of the Absorber tower (#17 & #18) and the wall plates of the
tray level (#9) cannot be fully welded, and only to hold the position with
the internal and external limiting parts, temporary intermittent welding
can be carried out outside the shell wall, so that the top combination can

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be severed from the tray level shell wall (#9) during the second stage of
lifting;
14) The sequence of shells installation for first stage of lifting is: #9 (with
17&18)→8→7→6→5→4→3→2
15) Repeat above step 9,10,12,13 for the installation of each layer of shell wall.
After assembling each layer, lifting bearing plates (consistent with the
number of jack rods) shall be located and welded at the proper position;
except for the temporary measures stated above, all other wall plates shall
be fully welded;
16) After the completion of the first stage of lifting, the lifting device is
dropped, and the combination welding of the lowest layer shell wall (#1)
plates of the Absorber tower and the lifted combination is completed. So
far, the first stage of lifting is completed, and the Absorber tower is
erected to the level of 18 meters;
17) Remove the lifting devices and corresponding reinforcement fittings;
18) At the level of tray beam (#9) of Absorber (about 17.2 meters) locate and
cut the opening for tray beam, lift the prefabricated tray beam to the
opening and insert the tray beam, when the position is calibrated to the
specifications of the drawings, start welding.
19) After finishing the installation of tray beam, set up internal and external
operation platforms above the tray beam, the principle is the same as that
of step 5;
20) Repeat step 4 (reinforce the tray beam level shell wall and set up
temporary measures for lifting devices), install the lifting devices on the
outer of tray beam level;
21) The sequence of shells for the second stage of lifting is: #16 (second from
the top of Absorber, around the level of 34 meters) →
15→14→13→12→11→10 (the shell wall level above tray beam, around 18
meters)
22) Locate and weld lifting bearing plates at the proper position around the
outside of assembled Absorber top combination (consistent with the
number of jack rods);
23) Start the lifting devices to lift the lifting rods to the bottom of bearing
plates, (sever the connection between top combination and tray level shell

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III
#9), continue lifting to secure enough height for the installation of next
layer of wall plates;
24) Use truck crane to lift the second shell wall (#16) from the top of Absorber
to the reserved space. Each wall plate is arranged to the position of the
Absorber tower rim through the slide rail outside the shell wall and the
corresponding manual hoist. After the wall plates are calibrated in place,
operate the lifting device to place the upper shell on this layer of shell
wall and intermittent welding is carried out. After the two layers of shells
are combined, the pressure of the lifting device can be released, and the
two layer wall plates can be fully welded on the internal and external
operation platforms.
25) Repeat the procedures of above steps 22 → 24 for the installation of each
layer shell, after the connection of each layer shell, the lifting bearing
plates around the outside of shell walls shall be located and mounted
(consistent with the number of jack rods);
26) After finishing the installation of the last layer of shell walls, the second
stage of lifting is finished. Drop the lifting devices, finish the welding and
connection between the first stage and the second stage, the whole
erection process of Absorber tower is completed;
27) The installation of the internal support beams of Absorber tower shall be
consistent with that of the wall plates, that is, the corresponding support
beam should be installed in place in time wherever the wall plate has
reached;
28) The installation of ladder platform outside of the Absorber tower is

recommended to be carried out at synchronized pace depending the site
situation; during the lifting process, continuously watch out for the
verticality and levelness of the tower body.

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RSTPP STAGE - ABSORBER PACKAGE TECHNICAL REQUIREMENTS (MECHANICAL SYSTEM &
III (FGD SYSTEM ) EQUIPMENTS)
Annexure 2
ABSORBER BILL OF MATERIAL
TOTAL
DRAWING
NO. NAME DESCRIPTION MATERIAL UNIT QUANTITY WEIGHT RAMARK SUPPLIER
NUMBER
(kg)
1 ABSORBER TOWER SHELL
ABSORBER TOWER
1.1 STEEL PLATE δ=18 E250B m² 744 105127.2 BIDDER
SHELL
ABSORBER TOWER
1.2 STEEL PLATE δ=16 E250B m² 523.3 65726.5 BIDDER
SHELL
ABSORBER TOWER
SHELL
ABSORBER TOWER
1.4 ALLOY PLATE δ=2 C276 m² 1609.3 28613.4 BIDDER
SHELL
STRUCTURE ABSORBER RING
1.5 T250X200X10X12 E250B m 161 6041.2 BIDDER
STEEL STIFFENER
ABSORBER RING
STRUCTURE
1.6 T250X200X10X12 E250B m 107 4265.8 STIFFENER，INCLU BIDDER
STEEL T858S-J0106-01
DE DILATED PARTS
ABSORBER RING
STIFFENER GUSSETS
ABSORBER RING
STRUCTURE
1.8 T300X200X10X16 E250B m 108 5320.7 STIFFENER，INCLU BIDDER
STEEL
DE DILATED PARTS
ABSORBER RING
STIFFENER GUSSETS
ABSORBER
STRUCTURE WB600X250X11.2
1.10 E250B m 34.6 4631.0 VERTICAL BIDDER
STEEL X21.3
STIFFENER
1.11 ALLOY PLATE δ=10 C276 m² 0.04 3.6 EARTH PLATE BIDDER

TOTAL
DRAWING
NUMBER
(kg)
2 ABSORBER TOWER FLOOR
ABSORBER FLOOR
PLATE
ABSORBER FLOOR
2.2 ALLOY PLATE δ=2 C276 m² 223 3964.9 BIDDER
PLATE
2.3 STEEL PLATE δ=32 E250B m² 10.4 2602.4 CHAIR STIFFENER BIDDER
2.4 STEEL PLATE δ=48 E250B m² 2.9 1091.6 CHAIR TOP PLATE BIDDER
2.5 STEEL PLATE δ=40 E250B m² 6.7 2103.8 REINFORCED PLATE BIDDER T858S-J0106-07
2.6 STEEL PLATE δ=20 E250B m² 0.5 81.4 WASHER BIDDER
2.7 STEEL PLATE δ=40 E250B m² 4.4 1384.7 REINFORCED PLATE BIDDER
2.8 BOLT M80*6 E250B m 110.5 4357.9 ANCHOR BOLT BIDDER
2.9 NUT M80 E250B PIECE 72 295.0 HEAVY HEX NUT BIDDER
2.10 STEEL BEAM MB100 E250B m 166 1474.7 BOTTOM BEAM BIDDER
3 ABSORBER TOWER INLET

3.1 ALLOY PLATE δ=6 C276 m² 161 8587.7 INLET SHELL BIDDER
3.2 PIPE ∅88.9x3.05 C276 m 29.2 213.5 HANDRAIL BIDDER
3.3 STEEL PLATE δ=10 E250B m² 9.23 724.6 CONNECT PLATE BIDDER
BOTTOM PLATE
3.4 BEAM MB550 E250B m 50.2 5220.8 BIDDER
STIFFENER
SIDE PLATE
3.5 BEAM LB250 E250B m 64.8 1807.9 BIDDER T858S-J0106-
STIFFENER
TOP PLATE 08~09
3.6 BEAM LB450 E250B m 26.7 1743.5 BIDDER
STIFFENER
3.7 PIPE ∅12 E250B PIECE 1 0.5 90° ELBOW BIDDER
EXPANSION JOINT EXPANSION

3.8 CHANNEL MC150 C276 m 36 684.0
FLANGE JOINT
SUPPLIER

TOTAL
DRAWING
NUMBER
(kg)
4 ABSORBER TOWER OUTLET
4.1 STEEL PLATE δ=12 E250B m² 187 17615.4 OUTLET PLATE BIDDER
4.2 STEEL PLATE δ=10 E250B m² 119.8 9404.3 OUTLET PLATE BIDDER
4.3 STEEL PLATE δ=8 E250B m² 190.8 11982.2 OUTLET PLATE BIDDER
4.4 ALLOY PLATE δ=2 C276 m² 448.2 7969.0 OUTLET PLATE BIDDER
STRUCTURE RIB
4.5 T250X200X10X1 E250B m 24 900.6 BIDDER
STEEL REINFORCEMENT
2
SLOPPING ROOF
STIFFENER
OUTLET SIDE PLATE T858S-J0106-
4.7 BEAM SC250 E250B m 13.3 1138.5 BIDDER
STIFFENER 08~09
OUTLET SIDE PLATE
4.8 BEAM LB250 E250B m 105 2929.5 BIDDER
STIFFENER
OUTLET BOTTOM
PLATE STIFFENER
CONNECT ANGLE
4.10 ANGLE STEEL L75X75X6 C276 m 23.5 181.0 BIDDER
STEEL
4.11 PIPE ∅88.9x3.05 C276 m 22.2 162.3 HANDRAIL BIDDER
EXPANSION
EXPANSION JOINT
4.12 CHANNEL MC150 C276 m 31.4 596.6 JOINT
FLANGE
SUPPLIER
5 ABSORBER TOWER TRAY

5.1 PLATE δ=3 UNS S32205 m² 416.67 10000.1 TRAY KDPE
BOLT
5.2 M12 C276 SET 1003 110.0 TRAY FASTENERS KDPE T858S-J0106-
COMBINATION
12~13
5.3 PLATE δ=3 UNS S32205 m² 12.22 293.3 PRESSING PLATE KDPE
5.4 PLATE δ=3 UNS S32205 m² 1.45 34.8 SQUARE WASHER KDPE

TOTAL
DRAWING
NUMBER
(kg)
5.5 PLATE δ=6 UNS S32205 m² 0.32 15.4 BAR KDPE
5.6 PIPE ∅18x2 UNS S32205 m 2 1.6 SPACER KDPE
5.7 ALLOY PLATE δ=4 EPDM m² 32 KDPE
5.8 ALLOY PLATE δ=10 C276 m² 4.73 420.5 SEAL PLATE BIDDER
SUPPORT BEAM
LINING
5.10 ANGLE STEEL L75X75X6 C276 m 51.81 398.9 RING ANGLE STEEL BIDDER
5.11 PIPE Φ60X5 C276 m 15.3 117.5 SUPPORT PIPE BIDDER T858S-J0106-
12~13
5.12 TUBE Φ27X2 C276 m 3.6 5.0 LEAK CHECK TUBE BIDDER
5.13 PLATE δ=10 E250B m² 0.9 70.7 END PLATE BIDDER
5.14 BOX BEAM HSS 550X120X12 E250B m 65.1 7922.7 SUPPORT BEAM BIDDER
5.18 ALLOY PLATE δ=2 C276 m² 4.85 86.2 CLAD PLATE BIDDER
6 ABSORBER TOWER AGITATOR

STRUCTURE
6.1 H200X100X6X8 E250B m 37 785.5 STIFFENER BIDDER
STEEL
6.2 PLATE δ=10 E250B m² 4.66 365.8 REINFORCED PLATE BIDDER
6.4 PLATE δ=20 E250B m² 7.8 1224.6 REINFORCED PLATE BIDDER
6.5 PIPE Φ60X2.8 C276 m 3.6 14.4 WATER LANCE KDPE
WATER LANCE T858S-J0106-14
6.6 FLANGE DN50 C276 PIECE 5 10.6 KDPE
FLANGE
6.7 ALLOY PLATE δ=6 C276 m² 0.26 13.9 SUPPORT PLATE KDPE
6.8 AGITATOR & SIDE ENTRY SET 5 ASSEMBLY KDPE
MOTOR

TOTAL
DRAWING
NUMBER
(kg)
7 ABSORBER TOWER OXIDATION LANCE
OXIDATION
7.1 PIPE Φ219.08X6.35 DIN1.4529 m 23.1 797.0 KDPE
SEAMLESS PIPE
45°CLASS 150
7.2 45°ELBOW Φ219.08X6.35 DIN1.4529 PIECE 5 60.0 KDPE
ELBOW
SLIP-ON FLANGE
7.3 FLANGE DN200 DIN1.4529 PIECE 5 72.5 KDPE
CLASS 150 RF
7.4 ANGLE STEEL L75X75X6 C276 m 29.2 227.5 SUPPORT KDPE
7.5 PLATE δ=6 C276 m² 1.5 80.0 FIXED RING KDPE
7.6 BOLT 3/4 INX90mm C276 PIECE 40 13.2 KDPE
7.7 NUT 3/4 IN C276 PIECE 40 2.5 KDPE
7.8 FLAT WASHER 3/4 IN δ=3mm C276 PIECE 80 2.0 KDPE
T858S-J0106-15
7.9 BOLT 1/2 INX45 C276 PIECE 20 1.4 KDPE
7.10 NUT 1/2 IN C276 PIECE 20 0.4 KDPE
RETAINING
7.11 1/2 IN C276 PIECE 20 0.4 KDPE
NUT
7.12 FLAT WASHER 1/2 IN δ=2mm C276 PIECE 40 0.4 KDPE
B16.5 CLASS 150 PIPE Klingersil
7.13 GASKET PIECE 5 KDPE
FLANGE δ=3mm C-4401
RING 344mmX152mm Klingersil
7.14 GASKET PIECE 10 KDPE
δ=3mm C-4401
7.15 PLATE δ=20 E250B m² 0.57 89.5 BIDDER
8 ABSORBER TOWER MIST ELIMINATOR

8.2 ALLOY PLATE δ=12 C276 m² 46 4907.3 RING PLATE BIDDER T858S-J0106-
16~17
8.3 ALLOY PLATE δ=16 C276 m² 3.64 517.8 RING PLATE BIDDER
SUPPORT BEAM
LINING

TOTAL
DRAWING
NUMBER
(kg)
8.6 TUBE Φ20X3 E250B m 3.6 4.5 LEAK CHECK TUBE BIDDER
T858S-J0106-
8.11 BOX BEAM HSS 500X300X10 E250B m 31.774 3891.0 SUPPORT BEAM BIDDER 16~17
MIST
ELIMINATOR
THREE-STAGE
8.14 (INCLUDING SET 1 ASSEMBLY KDPE
CHEVRON TYPE
WASHING
SYSTEM)
9 ABSORBER TOWER SPRAY SYSTEM
SUPPORT BEAM
LINING
9.3 PIPE C276 SET 4 2540.0 SUPPORT PIPE BIDDER
9.5 TUBE Φ20X3 E250B m 4.4 5.5 LEAK CHECK TUBE BIDDER
9.6 BOX BEAM HSS 650X300X16 E250B m 66.4 15311.8 SUPPORT BEAM BIDDER T858S-J0106-
9.7 BOX BEAM HSS 300X250X12 E250B m 124.76 12363.7 SUPPORT BEAM BIDDER 18~19
9.10 SPRAY HEADER FRP SET 4 ASSEMBLY KDPE
9.11 SPRAY NOZZLE SiC SET 4 BOLTED KDPE
CONNECTION

TOTAL
DRAWING
NUMBER
(kg)
10 ABSORBER TOWER ROUNDED ACCESS DOOR
REINFORCING
PLATE
10.2 ROD STEEL ∅14 E250B 0.8 BAR BIDDER
10.3 PLATE δ=18 E250B m² 0.085 12.0 DAVIT BRACKET BIDDER
10.4 PIPE ∅83X4 E250B 12.0 SLEEVING BIDDER
10.5 PLATE δ=20 E250B m² 0.038 6.0 GUSSET PLATE BIDDER
10.7 ROD STEEL ∅60 E250B 38.3 SUSPENDER BIDDER
10.8 ROD STEEL ∅14 E250B 0.2 EYE BOLT HOOK BIDDER
10.9 BOLT M22 E250B PIECE 9.4 CLOSED EYE BOLT BIDDER
10.10 HEX NUT M22 E250B PIECE 2 0.02 BIDDER
PLAIN
10.11 ∅22 E250B PIECE 1 0.03 BIDDER
WASHER
T858S-J0106-20
10.12 PLATE δ=6 E250B m² 0.006 0.3 ∅75MMX6MM BIDDER
10.13 HEX BOLT M20X100 E250B PIECE 60 22.0 ASTM B18.2.1 BIDDER
10.14 HEX NUT M20 E250B PIECE 60 3.72 ASTM B18.2.2 BIDDER
10.15 WASHER ∅20 E250B PIECE 60 1.20 BIDDER
10.16 LOCK WASHER ∅20 E250B PIECE 60 0.30 BIDDER
10.17 PLATE δ=48 E250B m² 1.82 685.8 DOOR COVER BIDDER
10.18 PLATE δ=2 C276 m² 1.82 32.4 DOOR COVER BIDDER
10.19 PLATE δ=48 E250B m² 1.82 685.8 DOOR FLANGE BIDDER
10.20 PLATE δ=2 C276 m² 1.82 32.4 DOOR FLANGE BIDDER
10.21 GASKET EPDM PIECE 1 BIDDER
10.22 PLATE δ=12 E250B m² 1.14 107.4 DOOR NECK BIDDER
10.23 PLATE δ=2 C276 m² 1.14 20.3 DOOR NECK BIDDER

TOTAL
DRAWING
NUMBER
(kg)
11 ABSORBER TOWER FLUSH CLEANOUT DOOR
DOOR FLOOR
PLATE
DOOR FLOOR
11.2 PLATE δ=2 C276 m² 1.64 29.2 BIDDER
PLATE
11.3 PLATE δ=18 E250B m² 2.6 367.4 DOOR SHELL PLATE BIDDER
11.4 PLATE δ=2 C276 m² 2.6 46.2 DOOR SHELL PLATE BIDDER
DOOR
11.5 PLATE δ=18 E250B m² 1 141.3 REINFORCING BIDDER
PLATE
11.6 PLATE δ=16 E250B m² 0.28 35.2 DOOR NECK BIDDER
11.7 PLATE δ=2 C276 m² 0.28 5.0 DOOR NECK BIDDER
11.8 PLATE δ=18 E250B m² 0.468 66.1 DOOR FLANGE BIDDER T858S-J0106-21
11.9 PLATE δ=2 C276 m² 0.468 8.3 DOOR FLANGE BIDDER
DOOR COVER
PLATE
DOOR COVER
11.11 PLATE δ=2 C276 m² 0.54 9.6 BIDDER
PLATE
11.12 GASKET δ=6 EPDM PIECE 2 BIDDER
11.13 HEX BOLT M20X85 E250B PIECE 44 5.7 ASTM B18.2.1 BIDDER
11.14 HEX NUT M20 E250B PIECE 44 1.37 ASTM B18.2.2 BIDDER
11.15 LOCK WASHER ∅20 E250B PIECE 44 0.55 BIDDER
11.16 PLATE δ=18 E250B m² 0.04 5.7 LIFTING LUG BIDDER
12 ABSORBER TOWER OVERFLOW BOX
12.1 PLATE δ=6 C276 m² 17.56 936.7 OVERFLOW BOX BIDDER
12.2 PIPE ∅406.4X12.7 E250B m² 0.24 23.9 BIDDER
12.3 PLATE δ=2 C276 m² 0.24 4.3 PIPE LINING BIDDER T858S-J0106-22
12.4 FLANGE DN400 E250B PIECE 1 26.6 BIDDER
12.5 PLATE δ=2 C276 m² 0.12 2.1 FLANGE LINING BIDDER

TOTAL
DRAWING
NUMBER
(kg)
13 ABSORBER TOWER RECTANGLE ACCESS DOOR

13.1 PLATE δ=16 E250B m² 15.12 1899.1 COVER PLATE BIDDER
13.2 PLATE δ=2 C276 m² 15.12 268.8 COVER PLATE BIDDER
13.3 PLATE δ=14 E250B m² 2.87 315.4 UPPER PLATE BIDDER
13.4 PLATE δ=2 C276 m² 2.87 51.0 UPPER PLATE BIDDER
13.5 PLATE δ=14 E250B m² 3.5 384.7 SIDE PLATE BIDDER
13.6 PLATE δ=2 C276 m² 3.5 62.2 SIDE PLATE BIDDER
13.7 PLATE δ=14 E250B m² 2.87 315.4 BOTTOM PLATE BIDDER
13.8 PLATE δ=2 C276 m² 2.87 51.0 BOTTOM PLATE BIDDER
CHANNEL
13.9 MB150 E250B m 15.064 253.08 BIDDER
STEEL
13.10 PLATE δ=14 E250B m² 4.27 469.3 RIBBED PLATE BIDDER
13.12 PLATE δ=14 E250B m² 0.7 76.9 BIDDER T858S-J0106-23
13.13 HEX BOLT M20X63 E250B PIECE 224 9.0 BIDDER
13.16 GASKET δ=4 EPDM PIECE 7 BIDDER
THIN HEX
13.19 M27 E250B PIECE 28 0.28 BIDDER
NUTS
13.21 ROD STEEL ∅16 E250B PIECE 7 3.85 HANDLE BIDDER
13.23 PLATE δ=2 C276 m² 3.402 60.5 BIDDER

TOTAL
DRAWING
NUMBER
(kg)
14 ABSORBER TOWER PLATFORM

14.1 PIPE ∅42.4X3.2 E250B m 524.7 1626.00 BIDDER
14.2 FLAT STEEL 100X6 E250B m 165 777.2 BIDDER
14.3 CHANNEL MC250 E250B m 12 365.4 BIDDER
ANSI NAAMM
14.4 GRATING W-30-100(32x5) E250B PIECE 21 355.0 GALVANIZED BIDDER
GRATING
14.5 GRATING W-30-100(32x5) E250B PIECE 1 11.0 -- do --- BIDDER
14.6 GRATING W-30-100(32x5) E250B PIECE 1 12.3 -- do --- BIDDER
14.9 WASHER ∅12 E250B PIECE 184 2.03 BIDDER
SPRING
14.10 ∅12 E250B PIECE 92 0.19 BIDDER T858S-J0106-
WASHER
14.11 ANGLE STEEL 100X75X10 E250B m 231 3003.0 BIDDER 24~26
14.12 CHANNEL MC225 E250B m 130.5 3406.1 BIDDER

14.13 GRATING W-30-100(32x5) E250B m² 206 9064.0 -- do --- BIDDER
SPRING
14.20 ∅12 E250B PIECE 1118 5.59 BIDDER
WASHER

TOTAL
DRAWING
NUMBER
(kg)
15 ABSORBER TOWER WET-DRY INTERFACE FLUSHING
15.1 PIPE ∅141.3X3.5 C276 m 3.8 51.3 BIDDER
ASME B16.5,CLASS
15.2 FLANGE DN125 C276 PIECE 2 137.60 BIDDER
150LB
BOLT
15.3 M20X110 C276 SET 80 34.40 KDPE
COMPONENTS
ASME B16.5,CLASS
15.4 FLANGE DN20 C276 PIECE 10 9.60 KDPE T858S-J0106-27
150LB
15.5 PIPE ∅26.75X2.75 C276 m 1 1.8 KDPE
BOLT
15.6 M12X50 C276 SET 40 4.42 KDPE
COMPONENTS
FLUSHING
15.7 DIN1.4529 SET 10 KDPE
NOZZLE
16 ABSORBER TOWER FILTER SCREEN OF SLURRY RECIRCULATION PUMPS
16.1 PLATE δ=4 C276 m² 45.36 1613.0 KDPE
16.2 BOLT M16X60 C276 PIECE 64 2.72 KDPE
BOLT T858S-J0106-28
16.3 M12X45 C276 SET 64 1.12 KDPE
COMPONENTS
16.4 PLATE δ=20 C276 m² 0.268 47.7 KDPE
17 ABSORBER TOWER FILTER SCREEN OF GYPSUM BLEED PUMPS
17.1 PLATE δ=4 C276 m² 2.04 72.5 KDPE
17.2 BOLT M16X60 C276 PIECE 8 0.68 KDPE
T858S-J0106-29
17.3 PLATE δ=20 C276 m² 0.034 6.0 KDPE
18 EMERGENCY QUENCH PIPING LAYOUT
QUENCH
18.1 PIPING & DIN1.4529 SET 1 1122.1 KDPE T858S-J0106-30
NOZZLE
NOTE: 1. Reinforcing plates for connecting nozzles on absorber shell are not included above.
2. Welding allowance and unfold margin of absorber are not included above.

TECHNICAL REQUIREMENTS
(ELECTRICAL SYSTEM &
EQUIPMENTS)
INDEX
1. GENERAL .................................................................................................................................. 2
2. QUALITY ASSURANCE, INSPECTION / TESTING ........................................................... 2
3. GENERAL REQUIREMENTS OF ELECTRICAL SYSTEM DESIGN .............................. 3
4. MOTORS ..................................................................................................................................... 5
5. L.T POWER CABLES ............................................................................................................. 14
6. L.T CONTROL CABLES ........................................................................................................ 21
7. ELEVATORS (ELECTRICALS)............................................................................................. 27
Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION – IV B Page 1 of 29

EQUIPMENTS)
1. GENERAL
This specification defines the requirements of system design, engineering, installation,

testing and commissioning of various Equipments covered in this Technical Specification.
This specification also includes basic guidelines to design, manufacture and supply the
equipments included in this Specification. This Section Covers following Electrical System/
Equipments.
A) GENERAL REQUIREMENTS OF ELECTRICAL SYSTEM DESIGN
B) MOTORS
C) L .T POWER CABLES
D) L.T CONTROL CABLES
E) ELEVATOR (Electrical)
2. QUALITY ASSURANCE, INSPECTION / TESTING
Brief inspection and testing aspects of the Electrical Equipments are tabulated in Section-IV-
E of the Technical Specification. Section- VII (GTR) be referred regarding Quality Assurance
Programme, Quality Assurance Documents etc.

EQUIPMENTS)
3. GENERAL REQUIREMENTS OF ELECTRICAL SYSTEM DESIGN
3.1. For the purpose of design of equipment/systems, an ambient temperature of 50 deg.

Centigrade and relative humidity of 95% shall be considered. The equipment shall operate
in a highly polluted environment. However, for equipment in air conditioned areas, design
ambient temperature shall be 35 deg.C, if 2x100% air conditioning system is provided unless
specified specifically in relevant sections.
3.2. All equipment shall be suitable for rated frequency of 50Hz with a variation of +3% & -5%,
and 10% combined variation of voltage and frequency unless specifically brought out in the
specification.
3.3. Contractor shall provide fully compatible electrical system, equipment, accessories and
services for the entire station/plant in his scope as well as those specifically required by the
Client (EPIL).
3.4. All the equipment, material and systems shall, in general, conform to the latest edition of
relevant National and International Codes and Standards, especially the Indian Statutory
Regulations.
3.5. The auxiliary AC voltage supply arrangement shall have 33kV,11 kV/3.3kV or 6.6KV and
415V systems. It shall be designed to limit voltage variations as given below under worst
operating condition:
1) 33 kV (MV) (+/-) 5%
2) 11KV/3.3KV/6.6KV (MV) (+/-) 6%
3) 415 V/240 V (+/-)10%
4) 220V/110V DC (-)15% to (+)10%
3.6. The voltage level for motors shall be as follows:
1) Upto 0.2 KW : Single phase 240V AC / 3 phase 415V AC
2) Above 0.2 KW and upto 200 KW : 3 phase, 415V AC
3) Above 200 KW and upto 1500 KW : 3 phase, 3.3kV or 6.6kV AC
4) Above 1500 KW : 11 kV/6.6kV AC*
 *Wherever only 6.6 kV & 415V is indicated in Electrical SLD, all motors above
200kW shall be 6.6 kV. Final selection of voltage levels shall be as per relevant
tender SLD.

EQUIPMENTS)
 The bidder may adopt 415V/3.3 KV or 6.6kV for the drives rated in the range of
160-210 KW.
 Voltage rating for special purpose motors viz, VFD shall be as per manufacturer’s
standard.
3.7. The preferred AC control supply voltage shall be 110V for all 415 V non breaker controlled
feeders. Control supply voltages other than above may be offered by Bidder based on the
Bidder’s standard proven practice.
3.8. The designed fault levels for various voltage levels shall be restricted to the following
values:
11 kV - 40 kArms for 1 sec
3.3kV/6.6kV - 40 kA rms for 1 sec
415 V - 50kA rmsfor 1 sec
The 33kV system electrical equipments shall have designed short circuit fault current rating
as per relevant Tender SLD/system requirement except for switchgears which shall be rated
for SC current of 21kA rms for 1 sec (minimum). Bidder shall submit suitable system studies
and calculations to this effect during detailed engineering.
3.9. The Contractor shall furnish calculations of maximum loading and fault levels under the
most onerous conditions for the various equipment/systems as defined elsewhere in the
specification to prove adequacy of their parameters. In case any equipment or system is
found to be inadequate, it shall be changed/ modified without any additional liability to the
Client (EPIL).
3.10. Transformer voltage ratios, taps, impedances and tolerances thereon, shall be so optimized
so that the auxiliary system voltages under various loading conditions are always within
permissible limits and equipment are not subjected to unacceptable voltages during
operation and starting of motors. The vector groups of the transformers shall be so selected
that all the buses of particular voltage level have same vector within the plant.
3.11. In fire hazardous areas like gas/ liquid fuel storage/ handling areas, lighting fixtures,
switchgears shall be flame proof.
3.12. The responsibility of coordination with electrical agencies /TAC/Pollution control board
and obtaining all necessary clearances shall be of the contractor.

EQUIPMENTS)
4. MOTORS
4.1. GENERAL REQUIREMENTS
4.1.1. For the purpose of design of equipment/systems, an ambient temperature of 50 deg.

Centigrade and relative humidity of 95% (at 40 deg C) shall be considered. The equipment
shall operate in a highly polluted environment.
4.1.2. All equipment’s shall be suitable for rated frequency of 50 Hz with a variation of (+) 3% and
(-) 5%, and 10% combined variation of voltage and frequency unless specifically brought out
in the specification.
4.1.3. Contactor shall provide fully compatible electrical system, equipment’s, accessories and
services.
4.1.4. All the equipment, material and systems shall, in general, conform to the latest edition of
relevant National and international Codes & Standards, especially the Indian Statutory
Regulations.
4.1.5. Paint shade shall be as per RAL 5012 (Blue) for indoor and outdoor equipment.
4.1.6. The responsibility of coordination with electrical agencies and obtaining all necessary
clearances for Contactors equipment and systems shall be under the Contactor scope.
4.1.7. Degree of Protection
Degree of protection for various enclosures as per IEC60034-05 shall be as follows :-
I) Indoor motors - IP 54
II) Outdoor motors - IP 55
III) Cable box-indoor area - IP 54
IV) Cable box-Outdoor area - IP 55
4.2. CODES AND STANDARDS
1) Three phase induction motors : IS/IEC:60034
2) Single phase AC motors : IS/ IEC:60034
3) Crane duty motors : IS:3177, IS/IEC:60034
4) DC motors/generators : IS:4722, IS/IEC:60034
4.3. Type
4.3.1. AC Motors:
a) Squirrel cage induction motor suitable for direct-on-line starting.

EQUIPMENTS)
b) Continuous duty LT motors upto 200 KW Output rating (at 50 deg.C ambient
temperature), shall be Premium Efficiency class-IE3, conforming to IS 12615, or
IEC:60034-30. HT motors shall have minimum design efficiency of 95 %.
However, tolerance on this efficiency value shall be applicable as per IEC 60034.
c) Crane duty motors shall be slip ring/ squirrel cage Induction motor as per
the requirement.
d) Motor operating through variable frequency drives shall be suitable for inverter
duty with VPI insulation. Also these motors shall comply the requirements
stipulated in IEC: 60034-18-41 and IEC: 60034-18-42 as applicable.
e) Motors operating through variable frequency drives shall also meet the
requirements specified under title “VFD”
4.3.2. DC Motors Shunt wound.
4.4. Rating
a) Continuously rated (S1). However, crane motors shall be rated for S4 duty, 40%
cyclic duration factor.
b) Whenever the basis for motor or driven equipment ratings are not specified in the
corresponding mechanical specification sub-sections, maximum continuous motor
ratings shall be at least 10% above the maximum load demand of the driven
equipment under entire operating range including voltage and frequency variations.
4.5. Temperature Rise
Air cooled motors : 70 deg. C by resistance method for both thermal class
130(B) & 155 (F) insulation.
Water cooled motors : 80 deg. C over inlet cooling water temperature

mentioned elsewhere, by resistance method for both
thermal class 130(B) & 155 (F) insulation.
4.6. Operational Requirements
4.6.1. Starting Time
a) For motors with starting time upto 20 secs. at minimum permissible voltage during
starting, the locked rotor withstand time under hot condition at highest voltage limit
shall be at least 2.5 secs. more than starting time.
b) For motors with starting time more than 20 secs. and upto 45 secs. at minimum
permissible voltage during starting, the locked rotor withstand time under hot
condition at highest voltage limit shall be at least 5 secs. more than starting time.

EQUIPMENTS)
c) For motors with starting time more than 45 secs. at minimum permissible voltage
during starting, the locked rotor withstand time under hot condition at highest
voltage limit shall be more than starting time by at least 10% of the starting time.
d) Speed switches mounted on the motor shaft shall be provided in cases where above
requirements are not met.
4.6.2. Torque Requirements
a) Accelerating torque at any speed with the lowest permissible starting voltage shall be
at least 10% motor rated torque.
b) Pull out torque at rated voltage shall not be less than 205% of rated torque. It shall be
275% for crane duty motors.
4.6.3. Starting voltage requirement
a) Up to 85% of rated voltage for ratings below 110 KW
b) Up to 80% of rated voltage for ratings from 110 KW to 200 KW
c) Up to 85% of rated voltage for ratings from 201 KW to 1000 KW
d) Up to 80% of rated voltage for ratings from 1001 KW to 4000 KW
e) Up to 75 % of rated voltage for ratings above 4000KW
4.7. Design and Constructional Features
4.7.1. Suitable single phase space heaters shall be provided on motors rated 30KW and above to
maintain windings in dry condition when motor is standstill. Separate terminal box for
space heaters & RTDs shall be provided. However for flame proof motors, space heater
terminals inside the main terminal box may be acceptable.
4.7.2. All motors shall be either Totally enclosed fan cooled (TEFC) or totally enclosed tube
ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors rated
3000KW or above can be Closed air circuit water cooled (CACW).
The method of movement of primary and secondary coolant shall be self circulated by fan
or pump directly mounted on the rotor of the main motor as per IEC 60034-6.
However VFD driven motors can be offered with forced cooling type with machine
mounted fan or pump driven by separate electric motor. Motors and EPB located in
hazardous areas shall have flame proof enclosures conforming to IS:2148 as detailed below
4.7.3. Winding and Insulation
a) Type : Non-hygroscopic, oil resistant, flame

resistant.

EQUIPMENTS)
b) Starting duty : Two hot starts in succession, with

motor initially at normal running
temperature.
c) 11kV, 6.6 KV & 3.3 kV AC motors : Thermal class 155 (F) insulation. The
winding insulation process shall be
total Vacuum Pressure Impregnated i.e
resin poor method. The lightning
Impulse & interturn insulation surge
withstand level shall be as per
IEC-60034 part-15.
d) 240VAC, 415V AC & 220V DC motors : Thermal Class ( B ) or better
4.7.4. Motors rated above 1000KW shall have insulated bearings/housing to prevent flow of
shaft currents.
4.7.5. Motors with heat exchangers shall have dial type thermometer with adjustable alarm
contacts to indicate inlet and outlet primary air temperature.
4.7.6. Noise level for all the motors shall be limited to 85 dB(A) except for BFP motor for which
the maximum limit shall be 90dB(A). Vibration shall be limited within the limits
prescribed in IS:12075 / IEC 60034-14. Motors shall withstand vibrations produced by
driven equipment. HT motor bearing housings shall have flat surfaces, in both X and Y
directions, suitable for mounting 80mmX80mm vibration pads.
4.7.7. In HT motors, at least four numbers simplex / two numbers duplex platinum resistance
type temperature detectors shall be provided in each phase stator winding. Each bearing of
HT motor shall be provided with dial type thermometer and minimum 2 numbers duplex
platinum resistance type temperature detectors.
4.7.8. Motor body shall have two earthing points on opposite sides.
4.7.9. 11 KV motors shall be offered with Separable Insulated Connector (SIC) as per IEEE 386.
The offered SIC terminations shall be provided with protective cover and trifurcating
sleeves. SIC termination kit shall be suitable for fault level of 25 KA for 0.17 seconds.
4.7.10. 3.3/6.6 KV motors shall be offered with dust tight phase separated double walled (metallic
as well as insulated barrier) Terminal box. Contractor shall provide termination kit for the
offered Terminal box. The offered Terminal Box shall be suitable for fault level of 250 MVA
for 0.12 sec. Removable gland plates of thickness 3 mm (hot/cold rolled sheet steel) or 4
mm (non magnetic material for single core cables) shall be provided.

EQUIPMENTS)
4.7.11. The spacing between gland plate & centre of bottom terminal stud shall be as per Table-I
below:-
TABLE - I
DIMENSIONS OF TERMINAL BOXES FOR LV MOTORS
Minimum distance between centre of bottom

Motor MCR in KW
terminal stud and gland plate in mm
1 UP to 3 KW As per manufacturer's practice
2 Above 3 KW - upto 7 KW 85
9 Above 125 KW-upto 200 KW 385 / 203 (For Single core cables only)
For HT motors the distance between gland plate and the terminal studs shall not be
less than 500 mm
PHASE TO PHASE/ PHASE TO EARTH AIR CLEARANCE:
Minimum inter-phase and phase-earth air

NOTE: clearances for LT motors with lugs installed
shall be as follows:
Motor MCR in KW Clearance
UP to 110 KW 10 mm
Above 110 KW and upto 150 KW 12.5 mm
Above 150 KW 19 mm

EQUIPMENTS)
4.7.12. All motors shall be so designed that maximum inrush currents and locked rotor and
pullout torque developed by them at extreme voltage and frequency variations do not
endanger the motor and driven equipment.
4.7.13. The motors shall be suitable for bus transfer schemes provided on the 11kV, 6.6 KV, 3.3 kV
/415V systems without any injurious effect on its life.
4.7.14. For motors rated 2000 KW & above, neutral current transformers of PS class shall be
provided on each phase in a separate neutral terminal box.
4.7.15. The size and number of cables (for HT motors) to be intimated to the successful Contactor
during detailed engineering and the Contactor shall provide terminal box suitable for the
same.
4.7.16. The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the following
(without any further tolerance):
a) From 50KW & upto 110KW : 11.0
b) From 110 KW & upto 200 KW : 9.0
c) Above 200 KW & upto 1000KW : 10.0
d) From 1001KW & upto 4000KW : 9.0
e) Above 4000KW : 6 to 6.5
4.8. Type Tests
4.8.1. HT Motors
a) The Contactor shall carry out the type tests as listed in this specification on the
equipment to be supplied under this contract. The Contactor shall indicate the charges
for each of these type tests separately in the relevant price schedule and the same shall
be considered for the evaluation of the bids. The type tests charges shall be paid only
for the test(s) actually conducted successfully under this contract and upon
certification by the Client (EPIL)’s engineer.
b) The type tests shall be carried out in presence of the Client (EPIL)/NTPC’s
representative, for which minimum 15 days notice shall be given by the Contactor. The
Contactor shall obtain the Client (EPIL)/NTPC’s approval for the type test procedure
before conducting the type test. The type test procedure shall clearly specify the test
set–up, instruments to be used, procedure, acceptance norms, recording of different
parameters, interval of recording, precautions to be taken etc. for the type test(s) to be
carried out.

EQUIPMENTS)
c) In case the Contactor has conducted such specified type test(s) within last ten years as
on the date of bid opening, he may submit during detailed engineering the type test
reports to the Client (EPIL) for waival of conductance of such test(s). These reports
should be for the tests conducted on the equipment similar to those proposed to be
supplied under this contract and test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client. The Client (EPIL)
reserves the right to waive conducting of any or all the specified type test(s) under this
contract. In case type tests are waived, the type test charges shall not be payable to the
Contactor.
d) Further the Contactor shall only submit the reports of the type tests as listed in "LIST
OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED" and carried out within
last ten years from the date of bid opening. These reports should be for the test
conducted on the equipment similar to those proposed to be supplied under this
contract and the test(s) should have been either conducted at an independent
laboratory or should have been witnessed by a client. However if the Contactor is not
able to submit report of the type test(s) conducted within last ten years from the date
of bid opening, or in the case of type test report(s) are not found to be meeting the
specification requirements, the Contactor shall conduct all such tests under this
contract at no additional cost to the Client (EPIL) either at third party lab or in
presence of client/ Client (EPIL)’s representative and submit the reports for approval.
e) List of Type Tests To Be Conducted
The following type tests shall be conducted on each type and rating of HT motor.
(i) No load saturation and loss curves upto approximately 115% of rated voltage.
(ii) Measurement of noise at no load.
(iii) Momentary excess torque test (subject to test bed constraint).
(iv) Full load test (subject to test bed constraint).
(v) Temperature rise test at rated conditions. During heat run test, bearing temp.,
winding temperature, coolant flow and its temperature shall also be measured.
In case the temperature rise test is carried at load other than rated load, specific
approval for the test method and procedure is required to be obtained. Wherever
ETD's are provided, the temperature shall be measured by ETD's also for the
record purpose.

EQUIPMENTS)
f) List of Tests For Which Reports Have To Be Submitted
The following type test reports shall be submitted for each type and rating of HT
motor.
1) Degree of protection test for the enclosure followed by IR, HV and no load run
test.
2) Terminal box-fault level withstand test for each type of terminal box of HT
motors only.
3) Lightning Impulse withstand test on the sample coil shall be as per clause no. 4.3
IEC-60034, part-15.
4) Surge-withstand test on inter-turn insulation shall be as per clause no. 4.2 of IEC
60034, part-15.
4.8.2. LT Motors
a) LT Motors supplied shall be of type tested design. During detailed engineering, the
Contactor shall submit for Client (EPIL)’s approval the reports of all the type tests as
listed in this specification and carried out within last ten years from the date of bid
opening. These reports should be for the test conducted on the equipment similar to
those proposed to be supplied under this contract and the test(s) should have been
either conducted at an independent laboratory or should have been witnessed by a
client.
b) However if the Contactor is not able to submit report of the type test(s) conducted
within last ten years from the date of bid opening, or in the case of type test report(s)
are not found to be meeting the specification requirements, the Contactor shall
conduct all such tests under this contract at no additional cost to the Client (EPIL)
either at third party lab or in presence of client/Client (EPIL)s representative and
submit the reports for approval.
c) List of Tests For Which Reports Have To Be Submitted
The following type test reports shall be submitted for each type and rating of LT
motor of above 100 KW only.
1) Measurement of resistance of windings of stator and wound rotor.
2) No load test at rated voltage to determine input current power and speed.
3) Open circuit voltage ratio of wound rotor motors ( in case of Slip ring motors).
4) Full load test to determine efficiency power factor and slip.
5) Temperature rise test.

EQUIPMENTS)
6) Momentary excess torque test.
7) High voltage test.
8) Test for vibration severity of motor.
9) Test for noise levels of motor (Shall be limited as per clause no 2.07.06 of this
section).
10) Test for degree of protection
11) Over speed test.
12) Type test reports for motors located in fuel oil area having flame proof
enclosures as per IS 2148 / IEC 60079-1
4.8.3. All acceptance and routine tests as per the specification and relevant standards shall be
carried out. Charges for these shall be deemed to be included in the equipment price.
4.8.4. The type test reports once approved for any projects shall be treated as reference. For
subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer
confirming similarity and “No design Change”. Minor changes if any shall be highlighted
on the endorsement sheet.

EQUIPMENTS)
5. L.T POWER CABLES
5.1. CODES & STANDARDS
5.1.1. All standards, specifications and codes of practice referred to herein shall be the latest
editions including all applicable official amendments and revisions as on date of opening
of bid. In case of conflict between this specification and those (IS, codes, standards, etc.)
referred to herein, the former shall prevail. All the cables shall conform to the requirements
of the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto
and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanized steel wires, formed wires and tapes for
armouring of cables.
IS : 5831 PVC insulation and sheath of electrical cables.
IS:7098(Part -I) Cross linked polyethylene insulated PVC sheathed cables for working
voltages upto and including 1100V.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D -2843 Standard test method for density of smoke from the burning or
decomposition of plastics.
IEC-754 (Part-I) Tests on gases evolved during combustion of electric cables.
IEC-332 Tests on electric cables under fire conditions. Part-3: Tests on bunched
wires or cables (Category-B).
5.2. TECHNICAL REQUIREMENTS
5.2.1. The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under
ground buried installation with chances of flooding by water.
5.2.2. All cables including EPR cables shall be flame retardant, low smoke (FRLS) type designed
to withstand all mechanical, electrical and thermal stresses developed under steady state
and transient operating conditions as specified elsewhere in this specification.
5.2.3. Aluminium conductor used in power cables shall have tensile strength of more than 100
N/ sq.mm. Conductors shall be stranded.

EQUIPMENTS)
5.2.4. XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg. C and
short circuit conductor temperature of 250 deg C. PVC insulation shall be suitable for
continuous conductor temperature of 70 deg C and short circuit conductor temperature of
160 deg. C.
5.2.5. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall
not stick to insulation and inner sheath. All the cables, other than single core unarmoured
cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831.
5.2.6. For single core armoured cables, armouring shall be of aluminium wires/ formed wires.
For multicore armoured cables, armouring shall be of galvanized steel as follows:
Calculated nominal dia.of Size and Type of armour

cable under armour
Upto 13 mm 1.4mm dia GS wire
Above 13 & upto 25mm 0.8 mm thick GS formed wire /1.6 mm dia GS wire
25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia GS wire
40 & upto 55mm 1.4 mm thick GS formed wire /2.5mm dia GS wire
55 & upto 70 mm 1.4mm thick GS formed wire /3.15mm dia GS wire
Above 70mm 1.4 mm thick GS formed wire /4.0 mm dia GS wire
5.2.7. The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum
resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of aluminium armouring
shall be same as indicated above for galvanized steel.
5.2.8. The gap between armour wires / formed wires shall not exceed one armour wire /formed
wire space and there shall be no cross over / over-riding of armour wire /formed wire.
The minimum area of coverage of armouring shall be 90%. The breaking load of armour
joint shall not be less than 95% of that of armour wire /formed wire. Zinc rich paint shall
be applied on armour joint surface of G.S.wires/ formed wires.
5.2.9. Outer sheath shall be of PVC as per IS: 5831 & black in colour. In addition to meeting all
the requirements of Indian standards referred to, outer sheath of all the cables shall have
the following FRLS properties.
a) Oxygen index of min. 29 (as per IS 10810 Part-58).
b) Acid gas emission of max. 20% (as per IEC-754-I).
c) Smoke density rating shall not be more than 60 % (as per ASTMD-2843).

EQUIPMENTS)
5.2.10. Cores of the cables shall be identified by colouring of insulation. Following colour scheme
shall be adopted:
1 core - Red, Black, Yellow or Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
5.2.11. For reduced neutral conductors, the core shall be black.
5.2.12. In addition to manufacturer's identification on cables as per IS, following marking shall
also be provided over outer sheath.
a) Cable size and voltage grade - To be embossed
b) Word 'FRLS' at every 5 metre - To be embossed
c) Sequential marking of length of the cable in metres at every one metre - To be

embossed / printed.
The embossing shall be progressive, automatic, in line and marking shall be legible and
indelible. For EPR cables identification shall be printed on outer sheath.
5.2.13. All cables shall meet the fire resistance requirement as per Category-B of IEC 332 Part-3.
5.2.14. Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum,
over the declared value in the technical data sheets.
5.2.15. In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not
acceptable.
5.2.16. Cable selection & sizing
5.2.16.1. Cables shall be sized based on the following considerations:
a) Rated current of the equipment
b) The voltage drop in the cable, during motor starting condition, shall be limited to
10% and during full load running condition, shall be limited to 3% of the rated
voltage
c) Short circuit withstand capability
d) This will depend on the feeder type. For a fuse protected circuit, cable should be
sized to withstand the let-out energy of the fuse. For breaker controlled feeder,
cable shall be capable of withstanding the system fault current level for total
breaker tripping time inclusive of relay pickup time.

EQUIPMENTS)
5.2.16.2. Derating Factors
a) Derating factors for various conditions of installations including the following shall
be considered while selecting the cable sizes:
b) Variation in ambient temperature for cables laid in air.
c) Grouping of cables
d) Variation in ground temperature and soil resistivity for buried cables.
5.2.16.3. Cable lengths shall be considered in such a way that straight through cable joints are
avoided
5.2.16.4. All Cables shall be of armoured type.
5.2.16.5. All LT power cables of sizes more than 120 sq.mm. shall be XLPE insulated and sizes
shall be of 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm. However for cable sizes
upto 120 sq.mm. both XLPE insulated & PVC insulated LT power cables are acceptable.
5.2.16.6. Same cable sizes to be used for same type & rating of motor i.e if there are three pumps
for one application, all three pumps motor should be provided with same cables sizes.
5.3. CONSTRUCTIONAL FEATURES
5.3.1. 1.1 KV Grade Power Cables
a) 1.1 KV grade XLPE power cables shall have compacted aluminium conductor, XLPE
insulated, PVC inner-sheathed (as applicable), armoured,PVC outer-sheathed
conforming to IS:7098. (Part-I).
b) 1.1KV grade PVC power cables shall have aluminium conductor(compacted type for
sizes above 10 sq.mm), PVC Insulated, PVC inner sheathed (as applicable) armoured,
PVC outer-sheathed conforming to IS:1554 (Part-I).
c) 1.1 KV grade Trailing cables shall have tinned copper (class 5 )conductor, insulated
with heat resistant elastomeric compound based on Ethylene Propyline Rubber(EPR)
suitable for withstanding 90 deg.C continuous conductor temperature and 250deg C
during short circuit, inner-sheathed with heat resistant elastomeric compound, nylon
cord reinforced, outersheathed with heat resistant, oil resistant and flame retardant
heavy duty elastomeric compound conforming to IS 9968.
5.4. CABLE DRUMS
a) Cables shall be supplied in non returnable wooden or steel drums of heavy

construction. The surface of the drum and the outer most cable layer shall be covered
with water proof cover. Both the ends of the cables shall be properly sealed with heat
shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water

EQUIPMENTS)
during transportation, storage and erection. Wood preservative anti-termite

treatment shall be applied to the entire drum. Wooden drums shall comply with IS:
10418.
b) Each drum shall carry manufacturer's name, purchaser’s name, address and contract
number, item number and type, size and length of cable and net gross weight
stencilled on both sides of the drum. A tag containing same information shall be
attached to the leading end of the cable. An arrow and suitable accompanying
wording shall be marked on one end of the reel indicating the direction in which it
should be rolled.
c) The standard drum length of LT power cable with a maximum tolerance of +/- 5%
may be decided by the bidder subject to condition that there shall not be any joint in
cable, where application length of cable is up to & including 1000 meter for single
core cable excluding 630 sqmm size, and 750 meter for multicore cable & single core
630 sqmm. One drum length of each cable size can be of non-standard length (not
less than 250 meter) so as to match the ordered quantity Subject to condition that
there shall not be any joint in cable.
5.5. TESTS
a) All equipments to be supplied shall be of type tested design. During detailed

engineering, the contractor shall submit for Client (EPIL)’s approval the reports of all
the type tests as listed in this specification and carried out within last ten years from
the date of bid opening. These reports should be for the test conducted on the
equipment similar to those proposed to be supplied under this contract and the
test(s) should have been either conducted at an independent laboratory or should
have been witnessed by a client.
b) However if the contractor is not able to submit report of the type test(s) conducted
are not found to be meeting the specification requirements, the contractor shall
either at third party lab or in presence of client /Client (EPIL)s representative and
c) All acceptance and routine tests as per the specification and relevant standards shall
be carried out. Charges for these shall be deemed to be included in the equipment
price.
d) The type test reports once approved for any projects shall be treated as reference. For
subsequent projects of NTPC, an endorsement sheet will be furnished by the

EQUIPMENTS)
manufacturer confirming similarity and “No design Change”. Minor changes if any
shall be highlighted on the endorsement sheet.
6.5.1. Type Tests
The reports for the following type tests shall be submitted for one size each of LT XLPE
and LT PVC Power cables. Size shall be decided by the Client (EPIL) during detailed
engineering:
S.No. Type test Remarks
For Conductor
1. Resistance test
2. Tensile test For circular non-compacted conductors only
3. Wrapping test For circular non-compacted only
For Armour Wires/ Formed Wires
4. Measurement of Dimensions
5. Tensile Test
6. Elongation test
7. Torsion test For round wires only
8. Wrapping test For aluminium wires/formed wires only.
9. Resistance test
10(a) Mass of zinc coating test For GS Formed wires/wires only
10(b) Uniformity of zinc coating For GS Formed wires /wires only
11. Adhesion test For GS Formed wires/wires only
For PVC/XLPE insulation & PVC Sheath
12. Test for thickness
13. Tensile strength & elongation test Before ageing and after ageing
14. Ageing in air oven
15. Loss of mass test For PVC insulation and sheath only
16. Hot deformation test For PVC insulation and sheath only
17. Heat shock test For PVC insulation and sheath only
18. Shrinkage test
19. Thermal stability test For PVC insulation and sheath only

EQUIPMENTS)
20. Hot set test For XLPE insulation only
21. Water absorption test For XLPE insulation only
22. Oxygen index test For outer sheath only
23. Smoke density test For outer sheath only
24. Acid gas generation test For outer sheath only
For completed cables
25. Insulation resistance test (Volume resistivity method)
26. High voltage test
27. Flammability test as per IEC-332 Part-3 (Category-B)
Indicative list of tests/checks, Routine and Acceptance tests shall be as per Quality
Assurance & Inspection table of LT power cables enclosed.

EQUIPMENTS)
6. L.T CONTROL CABLES
6.1. CODES & STANDARDS
6.1.1. All standards, specifications and codes of practice referred to herein shall be the latest
editions including all applicable official amendments and revisions as on date of
opening of bid. In case of conflict between this specification and those (IS : codes,
standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to
the requirements of the following standards and codes:
IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto
and including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanized steel wires, formed wires and tapes for
armouring of cables.
IS : 5831 PVC insulation and sheath of electrical cables.
IS:7098(Part -I) Cross linked polyethylene insulated PVC sheathed cables for
working voltages upto and including 1100V.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D -2843 Standard test method for density of smoke from the burning or
decomposition of plastics.
IEC-754 (Part-I) Tests on gases evolved during combustion of electric cables.
IEC-332 Tests on electric cables under fire conditions. Part-3: Tests on

bunched wires or cables (Category-B).
IS :1554 - I PVC insulated (heavy duty) electric cables for working

voltages up to and including 1100V.
IS : 8130 Conductors for insulated electrical cables and flexible

cords.
6.2. TECHNICAL REQUIREMENTS
6.2.1. The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under
ground buried installation with chances of flooding by water.

EQUIPMENTS)
6.2.2. All cables including EPR cables shall be flame retardant, low smoke (FRLS) type designed
to withstand all mechanical, electrical and thermal stresses developed under steady state
and transient operating conditions as specified elsewhere in this specification.
6.2.3. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall
not stick to insulation and inner sheath. All the cables, other than single core unarmoured
cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831.
6.2.4. For multicore armoured cables, armouring shall be of aluminium wires/ formed wires. For
multicore armoured cables, armouring shall be of galvanized steel as follows:
Calculated nominal dia Size and Type of armour

of cable under armour
Upto 13 mm 1.4mm dia GS wire
Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm dia GSwire Above
25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia GS wire Above
40 & upto 55mm 1.4 mm thick GS formed wire /2.5mm dia GS wire Above
55 & upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia GS wire Above
Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire
The gap between armour wires / formed wires shall not exceed one armour wire
/formed wire space and there shall be no cross over / over-riding of armour wire
/formed wire. The minimum area of coverage of armouring shall be 90%. The breaking
load of armour joint shall not be less than 95% of that of armour wire /formed wire. Zinc
rich paint shall be applied on armour joint surface of G.S.wires/ formed wires.
6.2.5. Outer sheath shall be of PVC as per IS: 5831 & black in colour. In addition to meeting all
the requirements of Indian standards referred to, outer sheath of all the cables shall have
the following FRLS properties.
a) Oxygen index of min. 29 (as per IS 10810 Part-58).
c) Smoke density rating shall not be more than 60 % (as per ASTMD-2843).
6.2.6. Cores of the cables of upto 5 cores shall be identified by colouring of insulation. Following
colour scheme shall be adopted
1 core - Red, Black, Yellow or Blue
2 core - Red & Black
3 core - Red, Yellow & Blue

EQUIPMENTS)
4 core - Red, Yellow, Blue and Black
5 core - Red, Yellow, Blue, Black and Grey
6.2.7. For cables having more than 5 cores, core identification shall be done by numbering the
insulation of cores sequentially, starting by number 1 in the inner layer (e.g. say for 10
core cable, core numbering shall be from 1 to 10). The number shall be printed in Hindu-
Arabic numerals on the outer surfaces of the cores. All the numbers shall be of the same
colour, which shall contrast with the colour of insulation. The colour of insulation for all
the cores shall be grey only. The numerals shall be legible and indelible. The numbers shall
be repeated at regular intervals along the core, consecutive numbers being inverted in
relation to each other. When the number is a single numeral, a dash shall be placed
underneath it. If the number consists of two numerals, these shall be disposed one below
the other and a dash placed below the lower numeral. The spacing between consecutive
numbers shall not exceed 50 mm.
6.2.8. In addition to manufacturer's identification on cables as per IS, following marking shall
also be provided over outer sheath:
a) Cable size and voltage grade - To be embossed
b) Word 'FRLS' at every 5 metre - To be embossed
c) Sequential marking of length of the cable in metres at every one metre - To be

embossed / printed.
The embossing/printing shall be progressive, automatic, in line and marking shall be

legible and indelible. For EPR cables identification shall be printed on outer sheath.
6.2.9. All cables shall meet the fire resistance requirement as per Category-B of IEC-332 Part-3.
6.2.10. Allowable tolerances on the overall diameter of the cables shall be +\-2 mm
maximum over the declared value in the technical data sheets.
6.2.11. In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not
acceptable.
6.2.12. Cable selection and sizing
6.2.12.1. Control cables shall be sized based on the following considerations:
a) The minimum conductor cross-section shall be 1.5 sq.mm.
b) The minimum number of spare cores in control cables shall be as follows:
No. of cores in cable Min. No. of spare cores
2C, 3C NIL
5C 1

EQUIPMENTS)
7C-12C 2
14C & above 3
6.2.12.2. Cable lengths shall be considered in such a way that straight through cable joints are
avoided.
6.2.12.3. All Cables shall be of armoured type.
6.3. CONSTRUCTIONAL FEATURES
6.3.1. 1.1 KV Grade Control Cables shall have stranded copper conductor and shall be multicore
PVC insulated, PVC inner sheathed, armoured, FRLS PVC outer sheathed conforming
to IS: 1554. (Part-I).
6.3.2. 1.1 KV grade Trailing cables shall have tinned copper(class 5)conductor, insulated with
heat resistant elastomeric compound based on Ethylene Propyline Rubber (EPR) suitable
for withstanding 90 deg.C continuous conductor temperature and 250degC during short
circuit, inner-sheathed with heat resistant elastomeric compound, nylon cord reinforced,
outer-sheathed with heat resistant, oil resistant and flame retardant heavy duty
elastomeric compound conforming to IS 9968. Minimum conductor size shall be 2.5 sqmm.
6.4. CABLE DRUMS
a) Cables shall be supplied in non returnable wooden or steel drums of heavy

construction. The surface of the drum and the outer most cable layer shall be covered
with water proof cover. Both the ends of the cables shall be properly sealed with heat
shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water
during transportation, storage and erection. Wood preservative anti-termite
treatment shall be applied to the entire drum. Wooden drums shall comply with IS:
10418.
b) Each drum shall carry manufacturer's name, purchaser’s name, address and contract
number, item number and type, size and length of cable and net gross weight
stencilled on both sides of the drum. A tag containing same information shall be
attached to the leading end of the cable. An arrow and suitable accompanying
wording shall be marked on one end of the reel indicating the direction in which it
should be rolled.
c) The standard drum length of control cable with a maximum tolerance of +/- 5% may
be decided by the bidder subject to condition that there shall not be any joint in cable,
where application length of cable is up to & including 1000 meter. One drum length
of each cable size can be of non-standard length (not less than 250 meter) so as to
match the ordered quantity Subject to condition that there shall not be any joint in
cable.

EQUIPMENTS)
6.5. TESTS
a) All equipments to be supplied shall be of type tested design. During detailed

engineering, the contractor shall submit for Client (EPIL)’s approval the reports of all
the type tests as listed in this specification and carried out within last ten years from
the date of bid opening. These reports should be for the test conducted on the
equipment similar to those proposed to be supplied under this contract and the
test(s) should have been either conducted at an independent laboratory or should
have been witnessed by a client.
b) However if the contractor is not able to submit report of the type test(s) conducted
are not found to be meeting the specification requirements, the contractor shall
either at third party lab or in presence of client /Client (EPIL)s representative and
c) All acceptance and routine tests as per the specification and relevant standards shall
be carried out. Charges for these shall be deemed to be included in the equipment
price.
d) The type test reports once approved for any projects shall be treated as reference. For
subsequent projects of NTPC, an endorsement sheet will be furnished by the
manufacturer confirming similarity and “No design Change”. Minor changes if any
shall be highlighted on the endorsement sheet.
6.5.1. Type Tests
The reports for the following type tests shall be submitted for one size of control cables.
Size shall be decided by the Client (EPIL) during detailed engineering:
S.No. Type test Remarks
For Conductor
1. Resistance test
For Armour Wires/ Formed Wires
3. Tensile Test
4. Elongation test
5. Torsion test For round wires only

EQUIPMENTS)
6. Wrapping test For aluminium wires / formed wires only.

7. Resistance test
8(a) Mass of zinc coating test For GS Formed wires/wires only
8(b) Uniformity of zinc coating For GS Formed wires /wires only
9. Adhesion test For GS Formed wires/wires only
For PVC insulation & PVC Sheath
11. Tensile strength & elongation test Before ageing and after ageing
12. Ageing in air oven
13. Loss of mass test For PVC insulation and sheath only
14. Hot deformation test For PVC insulation and sheath only
15. Heat shock test For PVC insulation and sheath only
16. Shrinkage test
17. Thermal stability test For PVC insulation and sheath only
18 Oxygen index test For outer sheath only
19. Smoke density test For outer sheath only
20. Acid gas generation test For outer sheath only
For completed cables
21. Insulation resistance test (Volume resistivity method)
23. Flammability test as per IEC-332 Part-3 (Category-B)
6.5.2. Indicative list of tests/checks, Routine and Acceptance tests shall be as per Quality
Assurance & Inspection table of LT control cables enclosed.

EQUIPMENTS)
7. ELEVATORS (ELECTRICALS)
7.1. Codes And Standards
All standards, specifications and codes of practice referred to herein shall be the latest
editions including all applicable official amendments and revisions. In case of conflict
between this specification and those (IS codes, standards, etc.) referred to herein, the former
shall prevail. All work shall be carried out as per the standards/ codes as applicable.
7.2. Electric motor:
The driving motors shall conform to IEC 60034 and suitable for the Variable Voltage
Variable Frequency (VVVF) application. All motors shall be squirrel cage induction type,
suitable for operation at 415V (+/- 10% variation) , 3 phase, 3 wire, 50HZ (+3% to -5%
variation) supply. Motors shall be provided with thermal class 130(B) or better insulation.
7.3. Car Electrical Accessories
The following accessories shall be provided :
a) LED light fittings for illumination level of 100 lux on car floor.
b) Portable light and alarm bell with battery and charger ventilation fan with control.
c) Car control station with position indicator inside the car and at landing platforms
(both visual and audio).
d) Emergency stop switch.
e) 5/15A, 3 pin plug socket with switch on top of lift car.
f) Hand free speaker telephone set connected to plant network.
g) Automatic Rescue Device (ARD)-(Battery Drive) :
Contractor to provide a modern Advanced electronic drive system of “Rescuing

Passenger Trapped in an Elevator”.
h) Emergency Safety Devices :
The lift shall be provided with safety Device attached to the lift car frame and placed
beneath the car. The safety device shall be capable of stopping and sustaining the lift
car up at governor tripping speed with full rated load in car.
7.4. Operational Requirements:
a) Contractor shall provide car operating panel with luminous buttons, car position
indication in car (both visual and audio) combined with direction arrows, overload
warning indicator, battery operated alarm bell and emergency light and fan & hands
free speaker telephone set with suitable battery, charger & controls.

EQUIPMENTS)
b) Contractor shall provide emergency indicator to indicate the location of elevator in

case of elevator being stuck up between the floors through automatic flashers (both
audio & visual).
c) Contractor shall provide electronic door detector ( Infra red curtain type).
d) Digital hall position indicator at all floors, tell lights at all floors shall also be
provided by the Contractor.
e) For facilitating the movement of visually & hearing impaired persons, hall lantern
and car arrival chimes shall be provided
f) All fixtures shall be in stainless steel face plates.
g) Push buttons shall be fixed in the car for holding the doors open for any length of the
time required.
h) All other safety/protection/operation interlocks as required by IS:14665 (latest

edition).
7.5. Power Supply
Each elevator shall be provided with a separate three phase, three wire 415V feeder of
adequate rating
7.6. Controls:
The controls shall be Variable Voltage and Variable frequency type and shall provide
smooth and constant acceleration and retardation under all conditions of operation. Suitable
control panel shall be provided in the machine room.
7.7. Cables and wiring:
All the cables except trailing cables shall be as per IS:1554-1 or IS-7098-I. the PVC outer
sheath of these cables shall be flame retardant, low smoke (FRLS) type with the following
FRLS properties.
a) Oxygen index of min. 29 (as per IS:10810 Part-58)
c) Smoke density rating shall not be more than 60% (as per ASTMD-2843).
The circular trailing cables shall be either in accordance with IS 4289 Part-I (Elastomer
insulated ) or IS-4289 Part-II (PVC insulated). The flat type trailing cables if offered shall be
in accordance with IEC-60227-6.

EQUIPMENTS)
All wiring / cabling between the equipments in the lift machine room and that between the
machine room and equipments in the lift well and at the landings shall be wired in HDP
conduits/ galvanized steel conduits to be supplied by the contractor. Alternatively armored
cables may be used.
7.8. Earthing:
The elevator structures and all Electrical equipment, including metal conduits shall be
effectively earthed with the earth conductors provided in the machine room as per IS: 3043.

RSTPP ABSORBER PACKAGE TECHNICAL REQUIREMENTS
STAGE - III (FGD SYSTEM ) (CIVIL & STRUCTURAL WORKS)
SECTION-IV D – INDEX
TECHNICA REQUIRMENTS – Civil & Structural Works
1.0 GENERAL .................................................................................................................................. 3
2.0 DELETED................................................................................................................................... 3
3.0 WORK DESCRIPTION............................................................................................................. 3
4.0 DELETED................................................................................................................................... 4
5.0 COLOUR COATED AND OTHER SHEETING WORK ....................................................... 4
6.0 CLAUSE DELETED .................................................................................................................. 9
7.0 CLAUSE DELETED .................................................................................................................. 9
8.0 CLAUSE DELETED .................................................................................................................. 9
9.0 CLAUSE DELETED .................................................................................................................. 9
10.0 CLAUSE DELETED .................................................................................................................. 9
11.0 CLAUSE DELETED .................................................................................................................. 9
12.0 CLAUSE DELETED .................................................................................................................. 9
13.0 CLAUSE DELETED .................................................................................................................. 9
14.0 CLAUSE DELETED .................................................................................................................. 9
15.0 CLAUSE DELETED .................................................................................................................. 9
16.0 LOADING ................................................................................................................................... 9
17.0 DESIGN CRITERIA .............................................................................................................. 12
18.0 CLAUSE DELETED ................................................................................................................ 17
19.0 FABRICATION ....................................................................................................................... 17
20.0 ELECTRODES ........................................................................................................................ 17
21.0 CLAUSE DELETED ................................................................................................................ 19
22.0 STATUTORY REQUIREMENTS ....................................................................................... 19
23.0 INSPECTION, TESTING AND QUALITY CONTROL.................................................. 20
24.0 CLAUSE DELETED ................................................................................................................ 20
Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION – IV D Page 1 of 34

25.0 CLAUSE DELETED ................................................................................................................ 20
26.0 GALVANISING ...................................................................................................................... 20
27.0 CLAUSE DELETED ................................................................................................................ 21
28.0 CLAUSE DELETED ................................................................................................................ 21
29.0 ARCHITECTURAL CONCEPTS ......................................................................................... 21
30.0 CLAUSE DELETED ................................................................................................................ 23
31.0 CORROSION PROTECTION ............................................................................................... 24
32.0 MISCELLANEOUS ................................................................................................................ 27
33.0 CLAUSE DELETED ................................................................................................................ 27
34.0 CLAUSE DELETED ................................................................................................................ 27
35.0 PACKAGINGAND TRANSPORTATION ......................................................................... 27
36.0 PLANT LIFE ........................................................................................................................... 28
37.0 PTFE (POLY TETRA FLUOROETHYLENE) BEARING ........................................... 28
38.0 TESTS FOR MATERIAL / WORKMANSHIP ................................................................. 28
39.0 MATERIALS ........................................................................................................................... 28
40.0 CODES AND STANDARDS ................................................................................................. 31

1.0 GENERAL
a) This section of the bidding document deals mainly with the technical specification for
the design and preparation of detailed drawings, getting the design and drawings
approved by the Client / NTPC, fabrication, erection and construction of the necessary
civil, structural and architectural works associated with the Flue Gas Desulphurization
system package. The work shall have to be carried out both below and above ground
level and shall be involving, basements, equipment foundations, slabs, beams,
columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, access
roads, culverts, trestles, silos, sumps, Limestone storage hopper & sheds, all buildings,
Chimney, all equipment Foundations, finishes, complete architectural aspects,
drainage, sanitation, water supply (from terminal points to various
buildings/facilities) and all other civil, structural and architectural works associated
with the complete FGD package.
b) The specifications are intended for the general description of the work, quality and
workmanship. The specifications are not, however, intended to cover minutest details
and the work shall be executed according to the relevant latest Indian Standard Codes
/ I. R. S. / I. R. C. specifications. Where provisions are not covered in Indian
Standards, reference shall be made to ACI, AISC, ASCE, EN, CICIND and other
international standards or to the best prevailing local Public Works Department
practices or to the instructions of the Engineer. Some of the relevant I. S. Codes to be
followed are mentioned in the Technical Specifications. The Contractor is expected to
get clarified on any doubts about the specifications, etc. before bidding, in writing with
the Employer in respect of interpretation of any portions of this document.
c) Bidder or his agencies engaged as detailer for fabrication drawings should have the
experience of detailing for power plant structures or steel plant or Industrial structures
like Petro/ Chemical/ Refinery/ Cement/FGD Plant/Coal Handling Plant/Ash
Handling Plant etc.
d) The designer responsible for preparation of scope drawings shall review and approve
the fabrication drawings prepared by the detailer before releasing them for fabrication.
2.0 DELETED
3.0 WORK DESCRIPTION
3.1. Staircases, Gratings, Handrails
a) All floors of transfer points/crusher houses and other facility buildings shall be
accessible through staircase. All staircases of Transfer points and crusher house
shall be of steel. Cage ladders (min. 450mm wide) shall be provided for access to

roof of penthouses, single storey mcc rooms& mumty. All Stairs shall be minimum
1200 mm wide, maximum rise should not be more than 180 mm and minimum
tread with 250 mm. Numbers and arrangement (including enclosures etc.) of stair
cases shall be such as to meet the fire safety requirement as per guide lines of
statutory regulatory bodies. For steel staircases, Stringers shall be of rolled steel
channel ( minimum ISMC 250) and tread shall be of steel gratings. Outside stairs
to transfer points/crusher house shall be open type. However sheeting shall be
provided at the top. Minimum 50 x 50 x 6 mm size angles with lugs shall be
provided as edge protection for treads of stairs in underground TP's
b) All gratings shall be electro forged types. Minimum thickness of the grating shall
be 40 mm for indoor installation and 32 mm for outdoor installation. However, at
entry or road crossing point’s minimum thickness of grating shall be 40 mm The
opening size shall not be more than 30mmx100mm. The minimum thickness of the
main bearing bar shall be 6 mm or as per design requirement whichever is higher.
All gratings shall be designed for minimum imposed load of 500Kgs. / Sq. M. If
actual expected load is more than the specified load, then actual load is to be
considered. All gratings shall be hot dip galvanized at the rate of 610 g. per sq.m.
after surface preparation by means of blast cleaning/ acid pickling.
c) Minimum 1000 mm high hand railing shall be provided around all openings,
projections / balconies, walkways, platforms, Stairs, etc. All handrails and ladder
Pipes shall be 32 mm nominal bore MS Pipes (medium class) as per IS: 1161.
Handrails shall have top and middle rails at a height of 1000 mm and 500 mm and
the vertical post spacing shall not exceed 1.50 M, with provision of kick Plates (100
mm high and 6 mm thick). All handrails and ladders shall be galvanised at the rate of
610 Gms / Sq. M as per IS: 4736.
4.0 DELETED
5.0 COLOUR COATED AND OTHER SHEETING WORK
5.1. Material
a) Wall Cladding & Roofing Material
Troughed permanently colour coated sheet of approved shade and colour shall be:
i) either of steel with minimum 0.6mm bare metal thickness (i.e. excluding
the thickness of galvanizing/aluminium-zinc coating and painting) of
grade G250 as per AS1397 / grade SS255 as per ASTM A653M / grade
S250GD as per EN 10326 with zinc coating to class Z275 / aluminium-zinc
alloy coating to class AZ150.

ii) or of minimum 0.5mm BMT (i.e. excluding the thickness of

galvanizing/aluminium-zinc coating and painting) of grade G350 as per
AS1397 / grade SS340 class 4 as per ASTM A792M / grade S350GD as per
EN 10326 with zinc coating to class Z275 / aluminium-zinc alloy coating to
class AZ150
iii) or of steel of minimum 0.4mm BMT (i.e. excluding the thickness of

galvanizing/aluminum-zinc coating and painting) of grade G550 as per
AS1397 / grade SS550 as per ASTM A792M / grade S550GD as per EN
10326 with zinc coating to class Z275 / aluminum-zinc alloy coating to
class AZ150.
Alternatively aluminum feed material of minimum bare metal thickness of 0.7

mm of aluminum alloy of Series 31000 and above as per IS 737 and IS 1254.
b) Metal Deck Roof Material
Troughed permanently colour coated metal decking sheets shall be:
i either of steel with minimum 0.8mm bare metal thickness (i.e. excluding
the thickness of galvanizing/aluminum-zinc coating and painting) of grade
G250 as per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as
per EN 10326 with zinc coating to class Z275.
ii or of minimum 0.6mm BMT (i.e. excluding the thickness of

AS1397 / grade SS340 class 4 as per ASTM A792M / grade S350GD as per
EN 10326 with zinc coating to class Z275.
iii or of steel of minimum 0.6mm BMT (i.e. excluding the thickness

AS1397 / grade SS550 as per ASTM A792M / grade S550GD as per EN
10326 with zinc coating to class Z275.
Alternatively aluminum feed material of minimum bare metal thickness of 0.9

mm of aluminum alloy of Series 31000 and above as per IS 737 and IS 1254 can
also be used for metal decking.
Thickness tolerance of (+/-) 0.04mm is permissible. However, all design

calculations shall be carried out on the basis of lowest value of sheet thickness
provided.

5.2. Colour Coating
Steel shall be colour coated with total coating thickness of at least 40 microns (nominal)
comprising of silicon modified polyester (SMP with silicon content of 30% to 50%) paint or
Super Polyester paint, of minimum 20 microns (nominal) dry film thickness (DFT) on
external face over primer coat of minimum 5 microns (nominal) and minimum 10 microns
(nominal) SMP or super polyester paint over primer coat of minimum 5 microns (nominal)
on internal face. SMP and Super polyester paint systems shall be of industrial finish of
product type 4 of AS/NZ2728.
5.3. Design Criteria
For wall cladding insulated / uninsulated sides and roof, permanently colour coated sheet
of troughed profile shall be used. The nominal depth of trough shall be 30 mm.
For profiled metal decking sheets (to be used for RCC floor slab or roof slab) the sectional
modulus and moment of inertia of troughed profile per meter width shall be so as to limit
the deflection of sheets to span/250 under total super imposed loading (DL +LL) comprising
the self-weight of metal deck sheet, dead weight of green concrete and an additional
construction load 100kg per sq.m for two span condition. The section modulus and moment
of inertia of troughed profile shall be computed as per the provisions of IS 801 for satisfying
the deflection and strength requirements.
For metal deck sheets used for roofing ( with or without RCC) and side cladding, the
sectional modulus and moment of inertia of troughed profile per metre width shall be such
that the deflection of sheets is limited to span/250 under design wind pressure for two span
condition. The sectional modulus and moment of inertia of troughed profile shall be
computed as per the provisions of IS 801 for satisfying the deflection and strength
requirements. No increase in allowable stress is permissible under wind load condition.
5.4. Fasteners
a) Side cladding/roofing/decking sheets shall be fixed to the runner/purlins using self-

drilling special coated fasteners confirming to corrosion resistant class 3 of AS3566 and
tested for 1000 hours salt spray test. Spacing of Self-drilling fasteners in transverse
direction (along runners/purlin) shall be equal to the pitch of trough or 250(+/-100)
mm, whichever is lesser and in longitudinal direction at every runner/purlin location.
b) Shear anchor studs shall also be provided through troughed permanently colour
coated metal decking sheets metal deck, which are to be used as permanent shuttering,
at regular interval on all top flange / flange plate of structural beams.
c) The shear anchor studs for fixing metal deck sheet to floor structural beams shall
conform to Type-B studs specified in AWS D1.1/D1.1M or equivalent as shear

connector of 19mm diameter and 100mm length manufactured from cold drawn round
steel bars conforming to the requirement of ASTM A 29, of grade designation 1010
through 1020, of standard quality with either semi-killed or killed, welded by Drawn
Arc Stud Welding through metal deck sheet.
d) The shear anchor studs for fixing metal deck sheet to roof structural purlins shall
conform to Type-B studs specified in AWS D1.1/D1.1M or equivalent as shear
connector of 16mm diameter and 65mm length manufactured from cold drawn round
steel bars conforming to the requirement of ASTM A 29, of grade designation 1010
through 1020, of standard quality with either semi-killed or killed, welded by Draw
Arc Stud Welding through metal deck sheet.
e) Alternatively, J/U type hooks shall be used in roofing which shall be provided in
transverse direction (along runners/purlin) at a spacing equal to the pitch of trough or
250(+/-100) mm, whichever is lesser and in longitudinal direction at every
runner/purlin location.
5.5. Miscellaneous Details
a) To minimize the number of joints, the length of the sheet shall preferably be not less
than 4.5m, cut pieces shall not be used, unless specifically approved by the Engineer.
However, the actual length shall be such so as to suit the purlin / runner spacing.
b) Lap between the sheets shall be at least 150mm in the longitudinal direction and at
least one crest wide in the transverse direction which shall be properly anchored /
fixed with fasteners.
c) Z spacers if required shall be made of at least 2 mm thick galvanised steel sheet of

grade 350 as per IS 277Sealant used for cladding shall be butyl based, two parts poly
sulphide or equivalent approved, non stainless material and be flexible enough not to
interface with fit of the sheets
d) Filler blocks as a trough filler shall be used to seal cavities formed between the profiled
sheet and the support or flashing. The filler blocks shall be manufactured from black
synthetic rubber or any other material approved by the Engineer.
e) All flashings, trim closures, caps etc. required for the metal cladding system shall be
made out of plain sheets having same material and any weather/moisture sealants
with appropriate material and coating specification as mentioned above for the outer
face of the metal cladding. Overlap shall be min. 150 mm or as specified by
manufacturer.

5.6. Pre-Fabricated Insulated Metal Sandwich Panels
For structures where Pre-Fabricated Insulated Metal Sandwich Panels shall be used for
Roofing, the sandwich panels shall comprise top sheet as troughed permanently colour
coated sheet & bottom sheet as plain permanently colour coated with 50mm thick insulation
sandwiched between the two sheets. Each sheet shall be:
a) either of steel with minimum 0.6mm bare metal thickness (i.e. excluding the thickness
of galvanizing/aluminum-zinc coating and painting) of grade G250 as per AS1397 /
grade SS255 as per ASTM A653M / grade S250GD as per EN 10326 with zinc coating
to class Z275 / aluminum-zinc alloy coating to class AZ150.
b) or of minimum 0.5mm BMT (i.e. excluding the thickness of galvanizing/

aluminum-zinc coating and painting) of grade G350 as per AS1397 / grade SS340 class
4 as per ASTM A792M / grade S350GD as per EN 10326 with zinc coating to class
Z275 / aluminum-zinc alloy coating to class AZ150.
c) or of steel of minimum 0.4 mm BMT (i.e. excluding the thickness of

galvanizing/aluminum-zinc coating and painting) of grade G550 as per AS1397
/grade SS550 as per ASTM A792M / grade S550GD as per EN 10326 with zinc coating
to class Z275 / aluminum-zinc alloy coating to class AZ150.
Alternatively aluminum feed material of minimum bare metal thickness of 0.7 mm of

aluminum alloy of Series 31000 and above as per IS 737 and IS 1254.
Metal sheets (steel or aluminum) shall be colour coated with total coating thickness of at
least 40 microns (nominal) dry film thickness (DFT) comprising of Silicon Modified
Polyester (SMP with silicon content of 30% to 50%) paint or Polyester paint, of minimum 20
microns (nominal) SMP or polyester paint on one side (exposed face), over minimum 5
micron (nominal) primer coat and minimum 10 micron (nominal) SMP or Polyester paint
over minimum 5 micron (nominal) primer coat on other side. SMP and Super Polyester paint
shall conform to product type 4 of AS/NZS 2728. Troughed sheet shall be of approved
profile, sectional properties, (suitable for the specified loading / deflection and purlins /
runners spacing), colour and shade.
Special coated fastener conforming to corrosion resistant Class 3 of AS3566 and tested for
1000 hours salt spray test shall be used for fixing Pre-Fabricated Insulated Metal Sandwich
Panels with the structural members below.
The contractor shall prepare working drawings of sheeting system including end and side
laps, fixing details etc. before starting sheeting work at site.

5.7. Polycarbonate Sheets
The polycarbonate sheet to be used for cladding and glazing purpose in conveyor galleries,
Transfer points & pump houses shall have toughed profile to match with the metal cladding
profile. Minimum 3.0mm thick fire retardant and UV resistant polycarbonate clean sheet of
approved make shall be used. The polycarbonate sheet shall be installed along with the
metal cladding so as to have a watertight lapping arrangement. Suitable detailing shall be
made to cater for the thermal expansion. IS 14434 to be referred for other details.
6.0 CLAUSE DELETED
7.0 CLAUSE DELETED
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16.0 LOADING
For consideration of loads on structures IS : 875 - ‘Code of practice for structural safety of
buildings’ shall be followed. In addition to the dead load, live load, equipment load
(including impact / vibration). Temperature loads etc. various loading conditions arising
due to operation and maintenance of equipment shall be considered in the design. The
structure and equipment shall also be designed for seismic loads as per the “Criteria for
Earthquake Resistant Design of Structures and equipment" and the “Criteria for Wind
Resistant Design of Structures and equipment" specified in the “Project Information
section”of technical specification. Wind and seismic forces shall not be considered to act

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

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

300 Kgs. / Sq. M.
galleries )
In addition to the live loads, loads

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

water pressure, etc. additional earth
Channels / trenches
pressure due to surcharge of 2T/Sq.
M. shall also be considered for design
Covers for channels & trenches,

shall be designed for a live load of
0.4T Sq.M. and loading as mentioned
Covers for trenches / channels under clause in trenches, whichever is
critical.

1. Water / liquid inside and no

earth outside (applicable only to
such structures which are liable
to be filled up with water or any
Sumps and tanks and other In addition liquid).
to earth pressure with a underground basement
2. Earth with surcharge outside
type surcharge of 2T / Sq. M. (or surcharge
and no water / liquid inside
structures due to Railway loading whichever is
critical for Railway load bearing structures etc.) 3. For underground (basement)
and sub - soil water pressure etc. These are also structures protection against
to be designed for the following conditions : buoyancy during execution and
after execution shall be ensured
without superimposed loadings
with minimum factor of safety
of 1.2 against buoyancy.
Grating covers/ Precast RCC covers 2500kgs. / sqm for drains, trench, sump pit in As
per IRC standard (at road crossing ground floor/paving area. for vehicular traffic.)
If the erection load is higher than the specified live loads on any floor or part thereof,
then the erection loads are to be considered for the design.
Permissible increase in stresses of materials and bearing pressure of soil due to wind
load or seismic load shall be as per relevant I. R. S. and I. S. code.
16.1 Crane load
For crane loads, an impact factor of 25% and lateral crane surge of 10% (of lifted weight +
trolley weight) shall be considered in the analysis of frame according to the provisions of
IS:875. The longitudinal crane surge shall be 5% of the static wheel load. Longitudinal surge
and lateral surge shall not be considered to act simultaneously.
16.2 Temperature load
For temperature loading, the total temperature variation shall be considered as 2/3 of the
average maximum annual variation in temperature. The average maximum annual variation
in temperature for this purpose shall be taken as the difference between the mean of the
daily minimum ambient temperature during the coldest month of the year and mean of
daily maximum ambient temperature during the hottest month of the year. The structure
shall be designed to withstand stresses due to 50% of the total temperature variation.
Suitable expansion joints shall be provided in the longitudinal direction wherever necessary

with provision of twin columns. The maximum distance of the expansion joint shall be as
per the provisions of IS: 800 and IS: 456 for steel and concrete structures respectively.
17.0 DESIGN CRITERIA
a) The design of all R. C. C. structures shall be carried out as per ‘code of practice for
plain and reinforced concrete for general building construction’, IS: 456.
b) Design of steel structures shall be done as per provisions of IS:800:2007 (Limit state
design) and other relevant IS standards.
c) Minimum size of the angle section to be used as structural members shall be 50 X
50 X 6. Minimum weld size shall be 6 mm. Connections shall be designed for 70 %
of shear capacity of the member or the actual shear force, whichever is higher.The
steel structures using tubular sections shall be designed and fabricated as per
IS:806 – “Code of Practice for use of steel tubes in general building construction.”
and EN 1993-1-8:2005. Minimum grade of steel & thickness of Tubular/Hollow
sections shall be Yst 240 Mpa & 4.0mm respectively.
d) The building shall conform to local bye - laws, rules and regulations for industrial
buildings and also B. I. S. publications, SP 32 and 41.
e) Slotted holes shall not be assumed to act as expansion joint for relieving of stresses
and suitable bearings shall be provided at the supports.
f) Stresses for all structures shall be checked for the higher of the forces obtained
from gust factor method and the peak wind speed method.
g) Horizontal bracing system shall be provided at floor levels around the openings.
h) Shear force in steel columns shall be transferred to the pedestals / foundations
exclusively either through foundation bolts or the shear key arrangement.
i) For design of liquid retaining structures, IS : 3370 ( Part - I to IV ) ( latest ) shall be
followed. Face of the structure in contact with liquid shall be designed as un -
cracked section. For design of R. C. C. pipes for culverts, latest editions of IS : 458,
IS : 783 should be followed.
j) For design of all underground structures / foundations, ground water table shall
be assumed at the formation level ( i. e. the adjoining ground level ). For all
underground structures like tunnel, underground transfer point and underground
hopper etc. crack width shall be limited to 0.2mm.
k) The loads for all railway load bearing structures e. g. tunnel, culverts and
underground transfer houses etc. and the analysis and the design of these
structures shall be made strictly in accordance with the provisions of Indian
Railway Bridge rules (latest edition), and Indian Railway Codes of practice (latest
edition) with all amendments up to the date of opening of bids. The analysis,
design and detailed drawing for tunnel, underground transfer houses, culverts etc.
coming directly below the railway track shall be got approved by the contractor

from the concerned railway authorities. All necessary payment for the above work
shall be made by the bidder to the railway authority.
l) Minimum clearance of 8.5m above the road crest / rail top shall be maintained at
the location where the overhead conveyor gallery/cable gallery crosses road / rail
line. The horizontal distance between Centre line of rail track and edge of any
nearby building/structure shall not be less than 3.0m.
m) Design of masonry walls shall be made as per IS : 1905.
n) Civil task drawing indicating various equipment loading and supporting
arrangement and floor loads to be submitted along with the design calculation.
o) Minimum 0.12% of reinforcement shall be provided on the top face of the
foundation concrete on either direction and minimum percentage of reinforcement
at bottom face of foundation shall be same as that stipulated for beam as per
IS:456.
p) Foundations for all tanks shall be designed for as per IS: 803.
q) Footings shall be so proportioned to as to minimise the differential settlement.
r) All gallery supporting trestles shall be so proportioned that the transverse
deflection of gallery due to wind / seismic load should not exceed trestle height /
1000 as stipulated in IS: 11592. This deflection condition shall be strictly followed.
Peak wind speed method shall be considered for checking the transverse
deflection.
s) The crusher and transfer house structures shall be so designed that transverse
deflection at places where conveyor galleries meet, should be equal to the
respective transverse deflection of conveyor supporting trestles.
t) Deflection criteria
u) The maximum Horizontal Deflection for various structures shall not exceed and be
limited to the following:
Sl.
Description Maximum value
No
1 Height/1000(Transverse For Trestles and transfer points

deflection at Conveyor (For Wind load by Peak Wind gallery Speed
supporting level) Method / Seismic Load)
2 Height/325 For other Buildings
i Permissible deflection (unless specified otherwise in this specification) for latticed

framework and beams of floors other than drive floor shall be span/325.
ii The allowable deflection for beams directly supporting drive machinery shall be
restricted to span/500 unless specified otherwise in this specification.
iii The deflection for manually operated cranes & monorail supporting beams shall
not exceed span/500.

For electric overhead cranes :

 upto 50 t capacity : span/750
 over 50 t capacity : span/1000
iv The vertical deflection of metal deck sheet for roofing and side cladding shall be
limited to span/250
v The permissible vertical deflection for beams supporting drive machinery shall be
restricted to span / 500 and for other beams it shall be within span / 325.
vi Permissible deflection for all purlins, cladding runners, roofing/cladding sheets

and grating / chequered plates shall be span/250. However, the maximum
vertical deflection of Grating/ Chequered plate shall be limited to 6 mm.
v) Dispersion of load in any direction through soil shall be as per IS: 8009 (relevant
part).
Dispersion of load through concrete shall be considered at an angle of 45 degrees

with horizontal from the edge of contact area.
w) The design and construction of RCC structures shall be carried out as per IS 456.
Working stress method shall be adopted for the design wherever specifically
mentioned in this specification.
i. For design and construction of steel-concrete composite members, IS: 11384

shall be followed.
ii. For reinforcement detailing, IS: 5525 and SP: 34 shall be followed.
iii. Two layers of reinforcement (on both inner and outer faces) shall be provided
for RCC wall sections having thickness 150 mm or more
x) All RCC liquid retaining/conveying shall be designed by working stress method

as outlined in clause no. 4.5 of IS 3370 (Part-2) 2009 unless specified otherwise.
i. Water proofing treatment shall be provided for liquid retaining/ carrying

structures and basement type structures (requiring dry working condition).
Dense and durable concrete with water cement ratio not more than 0.45 shall
be used. Plasticiser /super-plasticiser cum water proofing compound shall
be added to the concrete. All the construction/expansion joints shall be
provided with PVC water bar and/or chemical injection grouting as per

IS:6494. As applicable internal/external surface of such structures shall be

provided with acrylic based polymer modified cementitious composite
coating system for critical structures. For liquid carrying/retaining
structures, minimum two coats of such coating shall be applied. For external
application wherever the surface is in contact with the earth, fine
silica/quartz sand of 0.6 mm nominal size shall be added in the coating mix
for better abrasion resistance and total nominal thickness of such coating
shall be minimum 1.5 mm. For non critical structures minimum two coats of
bitumen grade 85/25 as per IS: 702, mixed with 1% of anti-stripping
compound meeting the requirement of IS:6241, shall be applied. The total
application of bitumen shall not be less than 1.7 kg/sq.m.
ii. Bidder shall submit a comprehensive scheme for water proofing treatment
based on above or any other alternative scheme, internationally accepted for
Employer's approval prior to commencement of work.
iii. All liquid retaining/carrying structures shall be tested for water tightness as
per the provisions of IS: 3370 and IS: 6494 and in case of leakage, the same
shall be rectified by chemical injection grouting through nozzles.
y) Earth pressure for all underground structures shall be calculated using coefficient
of earth pressure at rest or co-efficient of active earth pressure, whichever is
applicable, depending upon the structural configuration. However, for the design
of substructure of pump houses, earth pressure at rest shall be considered. Co-
efficient of passive earth pressure shall be used only in design of shear keys for
stability against sliding.
Following loading conditions shall be considered in addition to the loading from

super structure for the design of substructure of pump house, channels, sumps,
tanks, trenches and other underground structures containing liquid
i. Water pressure from inside and no outside pressure, like earth pressure,
ground water and surcharge pressure (applicable only to structures, which
are liable to be filled up with water or any other liquid.).
ii. Earth pressure, surcharge pressure and ground water pressure from outside
and no water pressure from inside.
iii. Design shall also be checked against buoyancy due to the ground water
during construction as well as after construction stages. Minimum factor of
safety of 1.2 against buoyancy shall be ensured considering empty condition

inside and ignoring the superimposed loadings. Provision of pressure relief

valves/flap valves, etc., shall not be permitted to counter the buoyancy
unless specified otherwise.
iv. Base slab and piers of the pump houses shall also be designed for the
condition of different combination of pump sumps being empty during
maintenance stages with maximum ground water level.
v. Intermediate dividing pier of pump sumps and partition wall (if applicable)
in channel shall be designed considering water on one side only and other
side being empty for maintenance.
vi. All pump houses and other substructures (wherever applicable) shall be
checked for stability against sliding and overturning during construction as
well as operating conditions for various combinations of loads.
z) Design of Block Foundation
i Block foundation resting on soil shall be analyzed using elastic half space
theory. In case the foundation is supported over piles, Novak’s
approximation shall be used for determining the spring constant and
damping ratio of pile groups. The mass of the RCC block shall be at least
three times the mass of machine. Free vibration analysis of the foundation
shall be carried out to evaluate the natural frequencies. The fundamental
natural frequency shall be kept at least 20% away from the operating
frequency (speed). Forced vibration analysis shall be carried out if the
dynamic forces are made available by the machine supplier in which case the
amplitude limits stipulated by the machine supplier and ISO 10816,
whichever is lower, shall be satisfied.
ii Reinforcement design shall be done by working stress method as per IS:456-

2000 and IS:2974 (Part-IV).
iii For the foundations supporting minor rotating equipment weighing less
than one ton or if the mass of the rotating parts is less than one hundredth of
the mass of the foundation, no dynamic analysis is necessary. However, if
such minor equipment is to be supported on building structure, floors, etc.,
suitable vibration isolation shall be provided by means of springs, neoprene
pads, etc., and such vibration isolation system shall be designed suitably.

aa) Design drawings of steel structures shall include the connection, joint & fastener
details for Main columns, Beams & Bracings.
bb) Unless specified all sand filling shall be compacted to minimum 80% of the
relative density and backfilled earth shall be compacted to minimum 90% of the
Standard proctor density at OMC.
18.0 CLAUSE DELETED
19.0 FABRICATION
All steel structures shall be fabricated in factor, transported and erected at site. All factory
fabricated structure shall have bolted filed connections.
Tanks, Silo with hopper &Chimney flue liners can either be fabricated at factory in segments,
transported and welded at site before erection or fabricated at site. For Chimney flue liners, to
prevent flue gas leakages, the applicable field joints shall necessarily be welded.
20.0 ELECTRODES
a) The electrodes used for welding shall be of suitable type and size depending upon
specifications of the parent material, the method of welding, the position of welding and
quality of welds desired. Only low hydrogen electrodes shall be used for welding of
medium / high tensile steel and for mild steel plate thickness above 20 mm.
b) All low hydrogen electrodes shall be baked and stored before use as per manufacturer's
recommendation. The electrodes shall be re-baked at 250oC - 300oC for one hour and
later on cooled in the same oven to 100o C. It shall be transferred to a holding oven
maintained at 60oC - 70oC. The electrodes shall be drawn from this oven for use.
c) Where coated electrodes are used they shall meet the requirements of IS: 814 and
relevant ASME - Sec. II. Covering shall be heavy to withstand normal conditions of
handling and storage.
d) Only those electrodes that give radiographic quality welds shall be used for welds,
which are subjected to radiographic testing.
e) Where bare electrodes are used these shall correspond to specification of the parent
material. The type of flux-wire combination for submerged arc welding shall conform to
the requirements of F-60 class of AWSA-5-17-69 and IS: 3613. The electrodes shall be
stored properly and the flux shall be baked before use in an oven in accordance with the
manufacturer's requirements as stipulated.
f) The contractor shall take specific approval of the weld for the various electrodes
proposed to be used on the works before any welding is started.

g) Edge Preparation for Welding

Suitable edge as per weld joint detail shall be prepared either by machines or by
automatic gas cutting. All edges cut by flame shall be ground before they are welded.
h) Pre Heating and Post Heating
Mild steel and medium / high tensile steel plates thicker than 20mm, will require Pre-
Heating of the parent plate prior to welding as mentioned in Table - 1 for mild steel and
Table - 2 for medium / high tensile steel, however, higher pre heat temperature may be
required as per approved welding procedure and it shall be followed. In welding
materials of unequal thickness, the thicker part shall be taken for this purpose.
Base metal shall be preheated, not withstanding provisions of IS: 9595 to the
temperature given in Table - 1 for mild steel and Table - 2 for medium / high tensile
steel, prior to welding or tack welding. When base metal not otherwise required to be
pre heated is at a temperature below 0°C it shall be pre heated to atleast 20°C., prior to
tack welding or welding. Pre heating shall bring the surface of the base metal to the
specified pre heat and this temperature shall be maintained as minimum inter-pass
temperature welding is in progress.
TABLE – 1
MINIMUM PREHEAT AND INTERPASS TEMPERATURE

FOR WELDING MILD STEEL
Welding Using
Thickness of thicker part at Low hydrogen electrode or Other than low hydrogen
Point of welding submerged arc welding electrode
Upto and including 20mm None None
Over 20mm and up to and 20°C Not allowed

including 40mm
Over 40mm and up to and 66°C Not allowed

including 63mm
Over 63mm 110°C Not allowed
Note: Type of electrode and the preheating requirements for welding shall be as per
approved welding procedure.

TABLE – 2
MINIMUM PREHEAT AND INTERPASS TEMPERATURE

FOR
WELDING MEDIUM / HIGH TENSILE STEEL
Welding Using
Thickness of thicker part at Low hydrogen electrode or Other than low hydrogen
Point of welding submerged arc welding electrode
Upto and including 20mm None Not Allowed
Over 20mm 120°C - 140°C Not Allowed
Note: Type of electrode and the preheating requirements for welding of medium and high
tensile steel shall be as per approved welding procedure.
i) Pre heating may be applied by external flame which is non-carbonizing like LPG, by electric
resistance or electric induction process such that uniform heating of the surface extending
up to a distance of four times the thickness of the plate on either side of the welded joint is
obtained.
j) Thermo-chalk, thermo-couple or other approved methods shall be used for measuring the
plate temperature.
k)All butt welds with plates thicker than 50mm and all site butt welds of main framing beam
supporting the bunker shall require post weld heat treatment as per procedure given in
AWS D-1.1. Post heating shall be done up to 600oC and rate of application shall be 200oC
per hour.
l) The post heat temperature shall be maintained for 60 minutes per 2.5cm thickness. For
maintaining slow and uniform cooling, asbestos pads shall be used for covering the heated
areas.
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22.0 STATUTORY REQUIREMENTS

Bidder shall comply with all the applicable statutory rules pertaining to Factories Act, Fire
Safety Rules at Tariff Advisory Committee. Water Act for pollution control, Explosives Act,
etc.
Provisions of safety, health and welfare according to Factories Act shall be complied with.

These shall include provision of continuous walkways along the crane - girder level on both
sides of building, comfortable approach to EOT crane cabin, railing, fire escape, locker room
for workmen, pantry, toilets, rest room etc.
Provisions for fire proof doors, number of staircases, fire separation wall, lath
plastering/encasing the structural members (in fire prone areas), type of glazing etc. shall be
made according to the recommendations of Tarrif Advisory Committee.
Statutory clearances and norms of State Pollution Control Board shall be followed.
Bidder shall obtain approval of Civil/Architectural drawings from concerned authorities
before taking up the construction work.
23.0 INSPECTION, TESTING AND QUALITY CONTROL
Sampling and testing of major items of civil works viz. earthwork, concreting, structural
steel work (including welding), piling, sheeting, etc. shall be carried out in accordance with
the requirements of this specification. Wherever nothing is specified relevant Indian
Standards shall be followed. In absence of Indian Standard equivalent International
Standards may be used.
The Bidder shall submit and finalise a detailed field Quality Assurance Programme before
starting of the construction work according to the requirement of this specification. This
shall include frequency of sampling and testing, nature/type of test, method of test, setting
of a testing laboratory, arrangement of testing apparatus/equipment, deployment of
qualified / experienced manpower, preparation of format for record, Field Quality Plan, etc.
Tests shall be done in the field and/or at a laboratory approved by the Engineer. The Bidder
shall furnish the test certificate from the manufacturer’s of various materials to be used in
the construction.
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26.0 GALVANISING
All burrs and irregular edges of the structural steel members to be galvanised shall be
ground smooth before galvanising.
Purity of Zinc to be used for galvanising shall be 99.5 % as per IS : 209 ( latest edition).
The weight of the zinc coating shall be at least 610 Gms. / m2 unless noted otherwise.

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29.0 ARCHITECTURAL CONCEPTS
Buildings shall be architecturally treated in such a way that it presents a pleasing

composition of mass and void with suitable and functionally designed projections and
recesses. The overall impact of the building shall be one of aesthetically unified
architectural composition having a comprehensive scale, blending with the
surroundings and taking full consideration of the climatic conditions and the building
orientation. All the buildings shall be architecturally treated in such a way so as to be in
harmony with the surroundings. The over all composition may have straight or
curvilinear profiles.
Necessary projections, fins, parapets, chajjas etc. in addition to the minimum area
specified elsewhere in this specification shall be provided as required.
Nothing extra shall be payable for any changes required while getting the drawings /
scheme approved and for executing the same.
All structures, buildings and facilities shall be designed as per provisions of National
Building Code 2016 and Local building by - laws as applicable including provisions of
the Factories Act of the State concerned, with regard to requirement of free access, stairs,
minimum head room, walkways, ventilation, toilets etc. and safety requirements like
railings, fire escapes etc. Further all layouts and detailed drawings shall meet th relevant
statutory requirements specified in recommendations of Petroleum act, Explosives act
and Indian Electricity rules’ as applicable.
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29.12 Doors, Windows, Ventilators, Louvers, Rolling Shutters & Glazing

Adequate Doors, Windows, Louvers and Ventilators shall be provided for proper
lighting and ventilation of all buildings. The area of windows shall be at least 10% of the
floor area of the respective building. In addition to the above, wherever room height is
more than 3.5 m, a band of ventilators of 600 mm height (minimum) shall be provided at
the top.
Unless specified all doors, of air conditioned areas, entrance door of air locklobby of all
buildings shall have electro colour coated (anodised) aluminium frame work with8 mm
thick toughened glass glazing. All doors of toilet, kitchen, pantry & store areas shall be
of factory made pre - laminated solid core flush door shutters, as per IS: 2202 (Part-I)
with pressed steel door frame. Control room shall have Aluminium glazed door &
partitions. All other doors (unless otherwise specified) shall be of steel.
All steel doors shall consist of double plate flush door shutters. The door shutter shall be
45 mm thick with two outer sheets of 18 G rigidly connected with continuous
vertical 20 G stiffeners at the rate of 150 mm centre to centre. Side, top and bottom
edges of shutters shall be reinforced by continuous pressed steel channel with
minimum 18 G. The door shall be sound deadened by filling the inside void with
mineral wool. Doors shall be complete with all hardware and fixtures like door closer,
tower bolts, handles, stoppers, aldrops, etc.
Wherever functionally required, rolling shutters of suitable size approved by the

Owner, with suitable operating arrangement manual/ electric shall be provided to
facilitate smooth operations. Rolling shutters shall conform to IS: 6248.

All windows and ventilators at ground floor level shall be provided with suitable
anodised aluminum grill.
Fire proof doors with panic devices shall be provided at all fire exit points as per the
requirements. However minimum Fire rating shall be 2 hours. These doors shall
generally be as per IS 3614 (Part 2).Vision Panel in minimum 11 mm thick inter layered
fire resistant glass shall be provided in Fire Doors.
Hollow excluded Section of minimum 2 mm wall thickness as manufactured by

INDAL, Jindal, Hindalco or equivalent shall be used for all Aluminium doors,
windows, ventilators and Partitions.
The doors, Windows & ventilators frame shall be of suitable size & thickness for fixing
the glazing. The Glazing thickness shall be minimum 6 mm thk clear toughened glass for
all glazed doors, windows, ventilators & partitions. Windows in air conditioned areas
shall be provided with 24mm thick hermetically sealed composite double glazing.
Composite double glazing shall be 24mm thick consisting of 6mm thick clear float glass
on inner side and 6mm thick reflective toughened glass on outer side. The two glasses
shall be separated by 12mm air-gap and hermetically sealed by beading of anodized
aluminium with outer edge sealed with silicon sealant. Outer glass of 6mm thickness
shall have following technical characteristics: Solar factor 25% or less, Maximum U-
value 3.3 W/ SQMK, VLT min 30%: Light reflection internal 10 to 15%, light reflection
external 10 to 20 %, shading coefficient (0.25-
0.28).
Doors and windows on external walls shall be provided with sunshade over the
openings with width 600 mm more than the opening width. The projection from the
finished face of the wall for sunshade shall generally be 450 mm over window
openings, 750 mm over door openings and 900 over Rolling shutters, or as decided and
approved by the Engineer.
All glazing work shall conform to IS: 3548.
Windows in conveyor gallery shall be provided with welded wire fabric of 1.6mm thick
wire as per IS: 4948 and 12mm x 30mm mesh size.
30.0 CLAUSE DELETED

31.0 CORROSION PROTECTION
31.1 GENERAL
All Steel structures shall be provided with painting as given in the specification.
Further, painting system shall also meet the requirements of Corrosivity category C3
(durability High) as per ISO 12944.
a. Painting system for steel surfaces embedded in Concrete is given separately.

b. All Painting shall be done as per technical specification. Painting scheme shall
be submitted by the bidder for approval of employer.
c. All steel structures shall be designed by following basic design criteria in ISO
12944 Part 3.However, where it is not feasible to follow the design criteria given in
ISO 12944 Part 3 where the steel surface are inaccessible for application of
protective coating, corrosion allowance of 1.5 mm shall be kept in thickness(over
the design thickness) of structural steel members.
31.2 PAINTING OF STEEL SURFACES EMBEDDED IN CONCRETE:
a. For the portion of Steel surfaces embedded in Concrete, the surface shall be
prepared by Manual Cleaning and provided with Primer Coat of Chlorinated
Rubber based Zinc Phosphate Primer of Minimum 50 Micron Dry Film Thickness
(DFT).
b. All threaded and other surfaces of foundation bolts and its materials, insulation
pins, Anchor channels, sleeves, etc. shall be coated with temporary rust preventive
fluid and during execution of civil works, the dried film of coating shall be
removed using organic solvents.
31.3 PAINTING OF STEEL SURFACES (OTHER THAN THOSE EMBEDDED IN

CONCRETE)
a. All steel surfaces shall be provided with two component moisture curing zinc
(ethyl) silicate primer coat (having minimum 80% of metallic Zinc content in dry
film, solid by volume minimum 60% ±2%) of minimum 70 micron DFT to be
applied over blast cleaned surface conforming to Sa 2 ½ finish of ISO 8501-1 with
surface profile 40-60 Micron. The primer coat shall be applied in shop immediately
after blast cleaning by airless spray technique. Zinc dust composition and
properties shall be Type-II as per ASTM D520-00.

b. Primer coat shall be followed with the application of Intermediate coat of two
component polyamide cured epoxy with MIO Content (containing lamellar MIO
minimum 30% on pigment, solid by volume minimum 80% ±2%) of minimum 100
micron DFT. This coat shall be applied in shop after an interval of minimum 24
hours (from the application of primer coat) by airless spray technique.
c. Intermediate coat shall be followed with the application of finish coat of two- pack
aliphatic Isocyanate cured acrylic finish paint (solid by volume minimum 55%
±2%) with Gloss retention (SSPC Paint Spec No 36, ASTM D 4587, D 2244, D 523) of
Level 2 (after minimum 1000 hours exposure, Gloss loss less than 30 and colour
change less than 2.0 ∆E) and minimum 70 micron DFT. This coat shall be applied
shop after an interval of minimum 10 hours and within six (6) months (from the
completion of Intermediate coat), Colour and shade of the coat shall be as
approved by the Employer.
Notes:
1. For Primer, high quality surface preparation is necessary and good amount
of moisture is required for proper curing. Below 70 % relative humidity,
curing time may go up to 7 days or more. In such a case additional water
sprinkling may be ensured for completion of curing. Additionally Inorganic
zinc silicate cannot be recoated; even with itself. Typically it should be used
when coating bare steel surface for first time.
2. The most frequent problem associated when top coating Primer is

bubbling/pin holing especially with non-weathered zinc silicate coatings. To
a great extent, this bubbling of finish paint can be eliminated by applying a
mist coat of intermediate/topcoat as the first pass of the product, allow the
bubbles to subside and then apply a full coat, as required.
3. In case top coating of zinc silicate with epoxy/polyurethane coatings, is

expected to be delayed, it is advisable to use a suitable tie coat to avoid
formation of white rust. However, if white rust forms then clean the surface
with high pressure water, dry and apply the subsequent coats as required.
4. Touch up paintings on damaged areas: Surface preparation by manual

tools, wire brush/ emery paper etc. Minimum 6 inches peripheral area,
adjoining to damaged area to be covered. If metal surface is exposed, it is to
be painted with Zinc rich epoxy (70 micron) or suitable primer with existing
paint scheme. If primer is intact, intermediate & top coat to be done with
specified DFT in scheme.

31.4 COATING FOR MILD STEEL PARTS IN CONTACT WITH WATER.
a. All mild Steel parts coming in contact with water or water vapour shall be hot dip
galvanised. The Minimum Coating of Zinc shall be 610 Gms / Sq. M. for
galvanised Structures and shall comply with IS: 4759 and other relevant Codes.
Galvanising shall be checked and tested in accordance with IS: 2629.
b. The galvanising shall be followed by the application of an etching Primer and

dipping in black bitumen in accordance with BS: 3416, unless otherwise specified.
31.5 Gratings
All gratings shall be blast cleaned to Sa 2 ½ finish or cleaned by acid pickling as per
ISO 8501-1 and shall be hot dip galvanized at the rate of 610 Gms / Sq. M.
31.6 Hand Railings and Ladders
All Mild steel handrails and ladders shall be galvanised at the rate of 610Gms / Sq. as
per IS: 4736. 31.07.00
31.7 Sea Worthiness
All Steel Sections and fabricated Structures, which are required to be transported on sea,
shall be provided with anti corrosive Paint before shipment to take care of sea
worthiness.
31.8 For Reinforced Concrete Work.

a. The protection for concrete sub-structure shall be provided based on
aggressiveness of the soil, chemical analysis of soil/sub-soil water and presence of
harmful chemicals/salts.
b. The protection to super structure shall depend on exposure condition and

degree of atmospheric corrosion.
This shall require use of dense and durable concrete, control of water cement ratio,
increase in clear cover, use of special type of cement and reinforcement, etc., coating of
concrete surface, etc.,
Bidder shall furnish the details of corrosion protection measures.

32.0 MISCELLANEOUS
32.1 Ordinary form work shall be used in roofs and floor slabs in transfer houses, footings,
pedestals, cable trenches, pits etc., Plywood form work shall be used for all over ground
exposed work like columns, beams, floors and ceilings in control room and M. C. C.
buildings.
32.2 Monorail girders and fixtures shall be provided for monorails at the locations as required
and as described elsewhere in these specifications or drawings. Monorail openings in the
walls shall be provided with steel frame doors preferably sliding type or otherwise open
able inside, access platforms and ladders.
32.3 Steel frame around openings in roof and on external walls for mounting of exhaust fans
shall be provided.
32.4 Ready mix non - shrink cementitious grout of reputed manufacturer as approved by the
Employer shall be used for grouting of block outs and foundation bolts, underpinning of
base plates and machine bases. Crushing strength of grout shall be one grade higher than
the foundation concrete. Minimum crushing strength shall be 30 N / mm2 unless higher
strength requirement is specified by the equipment supplier or the grout manufacturers.
32.5 The bottom of steel in case of cable / pipe galleries and trestles shall be generally 3m above
the ground except for rail / road crossing where it shall be 8m above the rail top / road
crest/ground. Further in bunker areas it shall be 8 m above the ground.
32.6 Polysulphide Sealing Compound shall be two-part polysulphide sealant and shall be from
approved manufacturer, conforming to IS : 12118. Materials shall consist of polysulphide
polymer and a curing agent. Gun grade material shall be used unless otherwise specified.
The application of the sealant shall be strictly followed as per manufacturer’s guidelines.
33.0 CLAUSE DELETED

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35.0 PACKAGINGAND TRANSPORTATION

All the equipment shall be suitably protected coated, covered or boxed and crated to
prevent damage or deterioration during transit, handling and storage at site till the time
of erection. While packing all the materials the limitations from the point of view of
availability of railway wagon sizes in India should be taken into account. The contractor
shall be responsible for any loss or damage during transportation, handling and storage
due to improper packing.

36.0 PLANT LIFE

The plant shall be designed for a minimum operating life of 30 years under the
conditions of operation. Assurance shall be given that plant components are adequate
for this lifetime. If there are any exceptional items of the plant on which an assurance of
meeting this clause cannot be given, life of such components and the difficulties
associated with them shall be stated.
37.0 PTFE (POLY TETRA FLUOROETHYLENE) BEARING

The bearing shall be of reputed make and manufacturer as approved by the Engineer,
for required vertical load and end displacement/rotation. PTFE bearing shall be sliding
against highly polished stainless steel and the coefficient of friction between them shall
be less than 0.06 at 55 kg/sq.cm. In order to prevent cold flow in PTFE surface it shall be
rigidly bonded by a special high temperature resistance adhesive to the stainless steel
substrata. The stainless steel surface that slides against the PTFE is mirror polished. The
stainless steel shall be bonded to the top plate by special high strength adhesive. The
thickness of stainless steel plate shall be between 1.0 mm to 1.5 mm.
38.0 TESTS FOR MATERIAL / WORKMANSHIP

All tests required for all materials, quality of workmanship or any other tests as desired
by the Engineer shall be at contractor’s cost.
39.0 MATERIALS
39.1 For Civil, Structural and Architectural works

Employer will not supply any material. All materials including cement, reinforcement
steel and structural steel, whatsoever required for execution and completion of the
entire scope of work covered under this specification shall be arranged by the
contractor at his own cost. All materials procured by the contractor shall meet the
quality requirements specified in this specification.
The contractor shall keep sufficient stock of cement and steel at site at any point of time
when the work is in progress excluding what has been already incorporated in the
works, so that any disruption / delay in availability of these materials during
procurement will not affect the progress of work at site. The minimum quantity of such
materials in stock at site shall not be less then the Requirement of one ( 1 ) month in case
of Cement and Requirement of two ( 2 ) Consecutive months in case of Steel.
39.2 Structural steel
Structural Steel (including embedded Steel) shall be straight, sound, free from twists,
cracks, flaw, laminations and all other defects. Structural steel shall comprise of mild
steel, medium strength steel and high tensile steel as specified below.

39.3 Mild Steel
a) Rolled sections shall be of grade designation E250, Quality A/BR, Semi-killed/

killed conforming to IS 2062. All steel plates shall be of Grade designation E250,
Quality BR (fully killed), conforming to IS 2062 and shall be tested for impact
resistance at room temperature. Plates beyond 12mm thickness and up to 40mm
thickness shall be normalized rolled. Plates beyond 40mm thickness shall be
vacuum degassed & furnace normalised and shall also be 100% ultrasonically
tested as per ASTM –A578 level B-S2.
b) Pipes shall conform to IS 1161.
c) Hollow (square and rectangular) steel sections shall be hot formed conforming to
IS: 4923 and shall be of minimum Grade Yst 240.
d) Chequered plate shall conform to IS 3502 and shall be minimum 6 mm thick
excluding projection. Steel for chequered plate shall conform to grade E250A semi
killed of IS: 2062 or equivalent grade conforming to ASTM & BS standards only.
39.4 Medium and High Tensile Steel
Rolled Sections and plates shall be of grade designation E350 or higher, Quality B0
(Fully killed), conforming to IS 2062. Plates beyond 12mm thickness and up to 40mm
thickness shall be normalized rolled. Plates beyond 40mm thickness shall be vacuum
degassed & furnace normalised and shall also be 100% ultrasonically tested as per
ASTM –A578 level B-S2.
39.5 Cement
a) Fly ash based portland pozzolana cement conforming to IS:1489 (Part-1) shall be
used for all areas other than for the critical structures identified below. Other
properties shall be as per IS code.
b) Ordinary Portland Cement (OPC) shall necessarily be used for the following
structures.
i Spring supported decks of limestone crusher

ii RCC for Chimney shell.
The grade of cement shall be Grade 43 for OPC conforming to IS:269.
c) In place of fly ash based portland pozzolana cement, OPC mixed with Fly Ash can
be used. Batching plant shall have facility for mixing fly ash. Fly ash shall conform

to IS:3812(Part I & Part II). Percentage of fly ash to be mixed in concrete shall be
based on trial mix. Mix design shall be done with varying percentage of fly ash
mix with cement.
d) Reinforcement steel shall conform to:
i Mild steel bars of grade I of IS: 432 Part – I or grade A of IS: 2062.
ii High yield strength deformed TMT steel bars of grade Fe-500 having
minimum elongation of 14.5 % or Fe-500D, and conforming to other
requirements of IS 1786.
39.6 Aggregates
a) Coarse Aggregate
Coarse aggregate for concrete shall be crushed stones chemically inert, hard,
strong, durable against weathering of limited porosity and free from deleterious
materials. It shall be properly graded. It shall meet the requirements of IS: 383.
b) Fine Aggregate
Fine aggregate shall consist of natural sand/ crushed sand and shall be hard,
durable, clean and free from adherent coatings of organic matter and clay balls or
pellets. Fine aggregate in concrete shall conform to IS: 383. For plaster, it shall
conform to IS: 1542 and for masonrywork to IS: 2116.However, in case of chimney
shellconstruction, natural sand conformingto IS: 383 shall only be used.
b) Petrographic examination of aggregate shall be carried out by the contractor at

National Council for Cement and Building Materials (NCB), Ballabgarh, or any
other approved laboratory to ascertain the structure and rock type including
presence of strained quartz and other reactive minerals. In case, the coarse
aggregate sample is of composite nature, the proportions (by weight) of different
rock types in the composite sample and petrographic evaluation of each rock
should also be ascertained. While determining the rock type, special emphasis
should be given on identification of known reactive rocks like chalcedony, opal
etc. The procedure laid down in IS 2430 for sampling of aggregates may be
followed.
The laboratory shall determine potential reactivity of the aggregate, which may lead to
reaction of silica in aggregate with the alkalis of cement and / or potential of some
aggregates like limestone to cause residual expansion due to repeated temperature

cycle. If the same is established, the contractor shall further carry out alkali aggregates
reactivity test as per IS 2386 (Pt.VII) and / or repeated temperature cycle test to establish
the suitability of the aggregates for the concrete work. The test results, with the final
recommendations of the laboratory, as to a suitability of the aggregate, for use in the
concrete work for various structures and suggested measures, in case of results are not
satisfactory, shall be submitted to the Engineer for his review, in a report form.
In case in the report, it is established, that the aggregates contain reactive silica, which
would react with alkalis of the cement, the contractor shall change the source of supply
of the aggregate or use low alkali cement as per recommendation or take measures as
recommended in the report as instructed by Engineer.
In case aggregates indicate residual expansion, under repeated temperature cycle test
(from 10o Celsius to 65o Celsius and for 60 temperature cycles) the material shall not be
used for concreting of Lime stone crusher decks, Mills, Fans and other equipment
foundations which are likely to be subjected to repeated temperature cycle. The
contractor shall use aggregates free from residual expansion under repeated
temperatures cycle test.
39.6 NUTS AND BOLTS
M.S. Nuts and Bolts shall conform to IS:1363,IS:1364, IS:1367.
Hightensile fixing with bolts and nuts shall respectively be as per IS:3757 and IS:6623.
Washers shall conform to IS:5369, IS:5370, IS:5372, IS:5374, IS:6610, IS:6649, as

appropriate.
40.0 CODES AND STANDARDS

All standards, specifications, acts and code of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions. Other Indian,
foreign Codes and Standards not listed here but referred to elsewhere within this
specification shall also be deemed to be part of this list.
In case of conflict between this specification and those (IS standards, codes etc.) referred
to herein, the former shall prevail.
Some of the relevant Indian standards, Acts and Codes applicable to this section of the
specification are listed below

IS : 383 Specification for coarse and fine aggregates from natural

sources for Concrete.
IS : 432 Specification for mild steel and medium tensile steel bars
and hard drawn steel wire for concrete reinforcement.
IS : 456 Code of practice for plain and reinforced concrete.
IS : 458 Specification for concrete pipes.
IS : 516 Method of test for strength of concrete.
IS : 800 Code of practice for use of structural steel in general
building construction.
IS : 814 Specification for covered electrodes for metal arc welding
for weld steel.
IS : 816 Code of practice for use of metal arc welding for general
construction.
IS : 817 Code of practice for training and testing of metal arc
welders.
IS : 875 (Pt.I toV) Code of practice for design loads other than
earthquake) for buildings and structures.
IS : 1038 Steel doors, windows and ventilators
IS : 1172 Basic requirements for water supply, drainage and
sanitation.
IS : 1361 Steel windows for industrial buildings.
IS : 1786 Specification for high strength deformed steel bars and
wires for concrete reinforcement.
IS : 1892 Code of practice for subsurface investigation for
foundation.
IS : 1893 Criteria for earthquake resistant design of structures.
IS : 1904 Code of practice for design and construction of
foundations in soils; general requirements.
IS : 1905 Code of practice for structural safety of buildings -
Masonry walls.
IS : 1948 Specification for aluminium doors, windowsand
ventilators.
IS : 2062 Steel for general structural purposes.
IS : 2131 Method of standard penetration test for soils.
IS : 2212 Code of practice for brickwork.
IS : 2645 Specification for Integral cement water proofing

compounds.
IS:2720 (Part-II, Methods of test for soils - determination for water

IV TO VIII, XIV , content etc code of practice for earth work on canals.
XXI, XXIII, XXIV,
XXVII TO XXIX, XL)
IS : 2911 Code of practice for design and construction of pile
foundations.
(Part-1/Sec.1) Driven cast in situ concrete piles.
(Part-1/Sec.2) Bored cast-in-situ concrete piles.
(Part-IV) Load test on piles
IS : 2974 (Part - I Code of practice for design and construction of machine
foundations
IS : 3370(Part I Code of practice for concrete structures for the storage of

to IV) liquids.
IS : 3658 Code of practice for liquid penetrant flaw detection.
IS : 3664 Code of practice for ultra sonic testing by pulse echo method.
IS : 4326 Code of practice for earthquake resistant design and

construction of buildings.
IS : 4990 Specification for plywood for concrete shuttering work.
IS : 5624 Specification for foundation bolts.
IS : 7215 Tolerances for fabrication steel structures.

IS : 8112 Specification for 43 grade Ordinary Portland Cement.
IS : 9103 Specification for admixtures for concrete.

IS : 9595 Code of procedure of manual metal arc welding of mild
steel.
IS : 10262 Recommended guidelines for concrete mix design.
IS : 13311 Method of non - destructive testing of concrete.

IS : 13755 Dust pressed ceramic tiles with water absorption of 3%,
E6% (Group B11a)
ASTM 898 -89 Standard guide for use of high solid content, cold liquid-
applied elastomeric water proofing membrane for use with
separate wearing course.

AS/NZS 2728 Pre finished / pre painted sheet metal product for interior /
exterior building applications – Performance requirements.
AS : 1365 Standards for steel manufacturing.
AS : 1397 A steel sheet & strip – hot – dipped-zinc-coated or
Aluminium-Zinc coated.
AS : 3566 Self drilling screws for building and construction industry.
IRC : 37 Guidelines for the design of flexible pavements.

- Manual on sewerage and sewage treatment (Published by
CPH & EEO) As updated.
Indian Explosives Act. 1940 as updated.
For “Foundation System and Geotechnical Data” refer “Project Information

section” of Technical specification.

STAGE – III (FGD SYSTEM ) (QA & INSPECTION)
SECTION- IVE - INDEX
TECHNICAL REQUIREMENTS – QA & INSPECTION
1.0 INTRODUCTION TO THE QUALITY ASSURANCE SPECIFICATION.......................... 2

2.0 QUALITY ASSURANCE – MECHANICAL EQUIPMENTS................................................ 3
3.0 QUALITY ASSURANCE – ELECTRICAL EQUIPMENTS ................................................. 6
4.0 QUALITY ASSURANCE - CIVIL & STRUCTUTAL WORKS......................................... 23
A. INTRODUCTION ............................................................................................................. 24
B. QUALITY ASSURANCE PROGRAMME ..................................................................... 24
C. QA AND QC MANPOWER ............................................................................................. 25
D. SAMPLING AND TESTING OF CONSTRUCTION MATERIALS ........................... 26
E. LABORATORY AND FIELD TESTING ...................................................................... 26
F. PURCHASE AND SERVICE .......................................................................................... 27
G. MANUFACTURING QUALITY PLAN AND FIELD QUALITY PLAN .................. 29
H. DISPOSITIONING OF NON CONFORMITIES .......................................................... 31
I. QUALITY AUDIT ............................................................................................................ 31
J. QA DOCUMENTATION PACKAGE.............................................................................. 31
K. GENERAL QA REQUIREMENTS ................................................................................ 31
5.0 APPENDIX AND ANNEXURES.......................................................................................... 32
Tender Doc No.:SRO/CON/ETS/079 VOLUME-II SECTION-IV E Page 1 of 55

STAGE – III (FGD SYSTEM) (QA & INSPECTION)
1.0 INTRODUCTION TO THE QUALITY ASSURANCE SPECIFICATION
For fulfillment of the relevant clauses (regarding Testing, Inspection etc.) of the General
Conditions of Contract (GCC) and General Technical Requirements (GTR in Section
VII) of Contract , the Quality Assurance Specification acts as a part of the Technical
Specification and is included in the Contract.
This part of the Technical Specification shall be read in conjunction with other parts of the
Technical Specifications, General Technical Requirements and Erection Conditions of the
Contract (ECC- Section VIII).
This document specifies the quality requirements, to be detailed in terms of

Tests/Checks/Procedures to be followed at the times of manufacturing, Testing,
Inspection and also during installation of various Equipment / Components at the place of
manufacturer and /or on the site. Various standards referred in this document shall be the
latest revisions.
The quality requirements are spelt out in the following ways;
1) Through description
2) In tabular form
In either of the above two formats the tests/checks/procedures that are required to be
performed are mentioned against particular item/ equipment/component/system etc.
This specification also contains the NTPC’s Indicative vendor list (with disclaimer)
mentioned against particular item/equipment/component/system etc and enclosed as
Annexure-1 to this Section –IV E. The quality requirements specified in this document and
also the vendor list are only indicative and not exhaustive.

2.0 QUALITY ASSURANCE – MECHANICAL EQUIPMENTS

2.1. TANKS / VESSELS
2.1.1 Atmospheric tanks:
i) All welds joints shall be DP tested and complete tanks shall be water fill tested.
ii) All atmospheric storage tanks fabricated and erected at site shall be subjected to tests
(Hydro, NDT and Vacuum) according to design code/standard as applicable.
iii) Lining of the tanks/vessels shall be tested for hardness and spark test etc, as per
applicable standard.
2.1.2 Pressure vessels:
1) NDT on weld joint shall be as per respective code requirements or the minimum as
specified as below:
i) 100% DPT on root run of butt weld, nozzle welds and finished fillet welds.
ii) 10% DPT on all finished butt welds.
iii) 10% RT (covering all ‘T’/cross joints) of butt welds.
2) Butt welds of dished ends shall be stress relieved and subjected to 100% RT.
3) Each finished vessels shall be hydraulically tested to 150% of the design pressure for a
duration of 30 minutes.
2.2. ABSORBER
A. All weld joints shall be tested to suitable NDT techniques as applicable to the
materials being welded, joint design & weld profile etc. according to design code/
standard as applicable
B. Cladding / Bonding material and its application shall be tested as per applicable
standard.
C. Absorber fabricated and erected at site shall be subjected to all tests according to
design code/ standard as applicable.
2.3. Thermal Insulation, Lagging & Cladding:
A. Lightly resin bonded mineral wool:
LRB mattresses/sections of Rockwool/ Glasswool shall conform to & tested as per

relevant clauses of Indian Standards and shall meet the requirements of NTPC
data sheet. Type tests except Thermal Conductivity shall be regularly carried out
once in three months, Thermal Conductivity Type Test shall be carried out
minimum once in twelve months by the manufacturer. Requirements of various
components like Binding wires, Lacing wires, Wire mesh, etc. shall be as per

NTPC approved data sheet /as given in respective Sub-Section of Technical

Requirements of Steam Generator & Auxiliaries.
B. Lagging & Cladding:
All insulation shall be protected by means of an outer covering of Aluminium

sheeting confirming to ASTM B-209-1060 temper H14 from reputed manufacturer
meeting the requirements of NTPC data sheet.
2.4. OTHER CRITICAL EQUIPMENTS:
a) Checks/ NDTs shall be done as per relevant Indian Standards or equivalent

International Standards..

3.0 QUALITY ASSURANCE – ELECTRICAL EQUIPMENTS

Shaft
SC Ring
Stator copper
Tubes, for Cooler

Magnetic Material
Insulating Material
Tems/Components
Rotor Copper/Aluminium
Test/Checks
Tender Doc No.:SRO/CON/ETS/079

RSTPP STAGE - III
Plates for stator frame, end shield, spider etc.
Y
Y
Y
Y
Y
Y
Y
Y
Visual
3.1. QUALITY ASSURANCE FOR MOTORS
Y
Y
Y
Y
Y
Y
Y
Dimensional
Dimensional Make/ Type/ Rating /
Y
Y
Y
Y
Y
Y
Y
Y
General Physical Inspection
Y
Y
Y
Y
Y
Y
Y
Y
Mech / Chem. Properties
Y
Y
Y
Y
NDT /DP/MPI/UT
(FGD SYSTEM )
Metallography
ABSORBER PACKAGE
Y
Y
Y
Y
Y
Electrical Characteristics
Y
Welding/Brazing(WPS/PQR)
Y
Y
Y
Y
Y
Y
Heat Treatment
Y
Magnetic Characteristics
VOLUME - II : SECTION – IV E
Y
Hydraulic/ Leak/ Pressure Test

Y
Y
Y
Thermal Characteristics
Run out
Dynamic Balancing
Routine & Acceptance tests as per IS-
325/ IS-4722 / IS- 283 / IS2148/
IEC60034\IEC 60079-I/ IS-12615
Vibration
Page 7 of 34
Over speed
(QUALITY ASSURANCE & INSPECTION)
Tan delta, shaft voltage &

polarization index test
Paint shade, thickness & adhesion

RSTPP STAGE - III
(FGD SYSTEM ) (QUALITY ASSURANCE & INSPECTION)
Routine & Acceptance tests as per IS-

Dimensional Make/ Type/ Rating /
Hydraulic/ Leak/ Pressure Test
Paint shade, thickness & adhesion

Welding/Brazing(WPS/PQR)
IEC60034\IEC 60079-I/ IS-12615

Mech / Chem. Properties
Magnetic Characteristics
Electrical Characteristics
Thermal Characteristics
325/ IS-4722 / IS- 283 / IS2148/

Test/Checks
Dynamic Balancing
General Physical Inspection
NDT /DP/MPI/UT
Heat Treatment
Metallography
Tan delta, shaft voltage &

Dimensional
Over speed
Vibration
Run out
polarization index test

Visual
Tems/Components
Sleeve Bearing Y Y Y Y Y Y Y
Stator/Rotor, Exciter Coils Y Y Y Y Y

Castings, stator frame, terminal box and
Y Y Y Y Y Y
bearing housing etc.
Fabrication & machining of stator, rotor,
Y Y Y Y Y
terminal box
Wound stator Y Y Y Y
Wound Exciter Y Y Y Y
Rotor complete Y Y Y Y Y
Exciter, Stator, Rotor, Terminal Box assembly Y Y Y

Accessories, RTD, BTD,CT, Space heater,
Y Y Y
antifriction bearing, gaskets etc.
Complete Motor Y Y Y Y Y Y Y1 Y
Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION – IV E Page 8 of 55

RSTPP STAGE - III
Note:
1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality Plan indicating the practices & Procedure
followed along with relevant supporting documents during QP finalization. However, following methodology to be followed for
Inspection Categorisation:
a) Up to 50 KW: Cat-III: Acceptance of Motor up to 50 KW is based on COC of the manufacturer & the Main Contractor confir
specifications.
b.i) Above 50 KW and up to 75KW: Cat-III : For manufacturers who have already supplied this range of motors to NTPC which
have be no adverse feedback has been reported from RIO/project-site AND for skid mounted motor supplied with the driven
equipment. Acce of Routine Test Inspection report as per IS-325 along with COC of the Manufacturer and Main Contractor
confirming NTPC's technical Specification.
b.ii) Above 50 KW and up to 75KW: Cat-I: For Other Manufacturers, as per NTPC approved Quality Plan
c) Above 75 KW: Cat-I: as per NTPC approved Quality Plan
2. Additional routine tests for Flame proof motors shall be applicable as per relevant standard
3. Makes of major bought out items for HT motors will be subject to NTPC approval.
4. Y1 = for HT Motor / Machines only.

RSTPP STAGE - III
3.2. QUALITY ASSURANCE FOR LT POWER CABLES

Attributes /Characteristics
Armour coverage, cross over,
Constructional requirements
Routine & Acceptance Tests

after ageing on outer sheath
looseness, gap between two
Hot Set Test/ Eccentricity &
feature as per specification

Sequential marking/ Batch
T.S & elongation before &
as per relevant standard &

Dimension/surface finish
Spark Test(as applicable)

Make, Type & T.C as per
marking/ surface finish/

Lay length & Sequence
Anti termite coating on

Chemical Composition
Mechanical properties
Electrical properties
relevant standard
Thermal stability
wooden drums
specification
& insulation
cable length
FRLS Tests
Ovality
wires
Item / Components /
Sub System Assembly
Aluminum ( IEC 60228) Y Y Y Y Y
XLPE Compound ( IEC 60502-2 (2005)) Y Y Y Y Y
PVC insulation Compound ( IEC 60502) Y Y Y Y Y
FRLS PVC Compound (IEC-60754 Part-1) Y Y Y Y Y

Extrusion & curing /Manufacturing of Core
Y Y Y Y
( PVC / XLPE)
Core Laying Y
Armour wire/strip Y Y Y
Inner sheath Y Y
Armouring Y Y
Outer Sheathing Y Y
Power Cable (Finished) (IEC-60754 Part-1,
Y Y Y Y Y Y Y Y
IEC 60332 part III cat B/ relevant Std
Wooden drum( relevant standard )
Y Y Y
/SteelDrum

RSTPP STAGE - III
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and
procedure along with relevant supporting documents.
2. Make of all major Bought out items will be subject to Owner’s approval.
ROUTINE TESTS Following routine tests shall be carried out on each drum of finished cables for all types (PVC / XLPE insulated) & sizes.
1. Conductor Resistance test
ACCEPTANCE TESTS Following Acceptance tests shall be carried out on each size of each type (PVC / XLPE insulated) of cables, in the offered lot.
A. For Conductor (as per sampling plan mentioned in IEC Pub 502 (1983)/ BS 6346:1969/ IEC 60502-2 (2005) )
1. Annealing test (Copper)
2. Tensile Test ( Aluminum)
3. Wrapping Test ( Aluminum)
4. Resistance test
B. For Armour Wires / Formed Wires ( If applicable ) (as per sampling plan mentioned in IEC Pub 502 (1983)/ BS 6346:1969/ IEC 60502-2
(2005))
2. Tensile Tests
3. Elongation Test
4. Torsion Test For Round wires only
5. Wrapping Test

RSTPP STAGE - III
6. Resistance Test
7. Mass of Zinc coating test For G S wires / Formed wires only
8. Uniformity of Zinc coating For G S wires / Formed wires only
9. Adhesion test For G S wires / Formed wires only
10. Freedom from surface defects
C. For PVC / XLPE insulation & PVC Sheath (as per sampling plan mentioned in IEC Pub 502 (1983)/ BS 6346:1969/IEC 60502-2 (2005))
2. Tensile strength & Elongation before ageing(for tests after ageing see “D”)
3. Hot set test (For XLPE insulation)
D. Ageing test:
If the compound manufacturer is carrying out Ageing test, test report of compound manufacturer is to be reviewed. If the compound
manufacturer is not carrying out ageing test, then cable manufacturer will carry out ageing test & the test report will be reviewed by owner
(quantum of ageing test sample shall be one sample /batch)
E. Following tests will be carried out on completed cables as per relevant standard on each size of each type (PVC /XLPE insulated)
1. Insulation resistance test ( Volume resistivity method )
F. Following tests shall be carried out on only one size of offered lot (comprising of all sizes & types)
1. Thermal stability test on PVC insulation and outer sheath
2. Oxygen index test on outer sheath
3. Smoke density rating test on outer sheath

RSTPP STAGE - III
4. Acid gas generation test on outer sheath
G. Flammability test as per IEC 60332 - Part- 3 (Category- B) on completed cables as per following sampling plan
This test will be carried out using composite sampling i.e. irrespective of size; cables of one particular type (i.e.
armoured PVC insulated, unarmoured PVC insulated, armoured XLPE insulated, unarmoured XLPE insulated) will
be bunched together, as per calculations in line with the IEC. All sizes of PVC & XLPE insulated, armoured &
unarmoured cables shall be covered. For one particular type, cables with OD less than or equal to 30 mm shall be
clubbed together in touching formation while cables with OD greater than 30 mm shall be clubbed together leaving a
gap equal to OD of cable having least diameter. Cable OD shall be taken as nominal overall diameter as per approved
datasheet.
H. Following tests shall be carried on one length of each size of each type (PVC / XLPE insulated) of offered lot:
Constructional / dimensional check, surface finish, length measurement, sequence of cores, armour coverage, Gap
1. between two consecutive armour wires / formed wires, Sequential marking, drum / Batch (outer sheath extrusion
batch )number marking on sheath
2. Measurement of Eccentricity & Ovality
GENERAL NOTE:
a) In case of manufacturers / supplier who have supplied cables in the past through Corporate Centre:- Routine Test of manufacturer internal test
report are to be verified by owner and Main Contractor at the time of final inspection. Owner and Main Contractor will also witness routine tests on
cables on 10% sample basis.
b) In case of manufacturers / supplier WHO HAVE NOT SUPPLIED cables in the past through Corporate Centre:- Routine Test of manufacturer
internal test report are to be verified by Owner at the time of final inspection. Owner will witness routine tests on cables for the first order on 10%
sample basis and Main Contractor will witness routine tests on cables for the first order on 100% basis.
1) For Smoke Density rating test: if the test result without conditioning is within (-)10% of the maximum specified value, then, retesting is to be carried
out with conditioning of samples as per standard and the test results after conditioning shall be final for acceptance/rejection.
2) For Acid Gas Generation test: if the test result without conditioning is within (-)10% of the maximum specified value, then, retesting is to be carried
3) For Oxygen Index test: if the test result without conditioning is within (+)7% of the minimum specified value, then, retesting is to be carried out with

RSTPP STAGE - III
conditioning of samples as per standard and the test results after conditioning shall be final for acceptance/rejection.
4) In case the test results without conditioning do not meet the maximum/minimum specified value, the manufacturer may exercise the option of
retesting the samples after conditioning as per standard.

RSTPP STAGE - III
3.3. QUALITY ASSURANCE FOR LT CONTROL CABLES

Routine & Acceptance Tests

after ageing on outer sheath
requirements feature as per

Sequential marking/ Batch
T.S & elongation before &
as per relevant standard &

Dimension/surface finish
Spark Test(as applicable)

Make, Type & T.C as per
marking/ surface finish/

Armour coverage, cross
Lay length & Sequence
Anti termite coating on

Chemical Composition
Mechanical properties
Electrical properties
over, looseness, gap

between two wires
relevant standard
Thermal stability
wooden drums
Constructional
specification
specification
& insulation
cable length
FRLS Tests
Item / Components /
Sub System Assembly
Copper (IEC 60228) Y Y Y Y Y
PVC insulation Compound ( IEC 60502) Y Y Y Y Y
FRLS PVC Compound (IEC-60754 Part-1) Y Y Y Y

Extrusion & curing /Manufacturing of Core
Y Y Y
( PVC / XLPE)
Core Laying Y
Armour wire/strip Y Y Y
Inner sheath Y Y
Armouring Y Y
Outer Sheathing Y Y
Finished cable (IEC-60754 Part-1, IEC 60332
Y Y Y Y Y Y Y Y
part III cat B/relevant standard)

RSTPP STAGE - III
Wooden drum( relevant standard ) /Steel

Y Y Y
Drum
Notes:
ROUTINE TESTS Following routine tests shall be carried out on each drum of finished cables for all sizes.
1. Conductor Resistance test
ACCEPTANCE TESTS Following Acceptance tests shall be carried out on each size of cables, in the offered lot.
A. For Conductor (as per sampling plan mentioned in IEC Pub 502 (1983)/ BS 6346:1969)
1. Annealing test (Copper)
2. Resistance test
B. For Armour Wires / Formed Wires ( If applicable ) (as per sampling plan mentioned in IEC Pub 502 (1983)/ BS 6346:1969)
2. Tensile Tests
3. Elongation Test
4. Torsion Test For Round wires only
5. Wrapping Test
6. Resistance Test

RSTPP STAGE - III
7. Mass of Zinc coating test For G S wires / Formed wires only
8. Uniformity of Zinc coating For G S wires / Formed wires only
9. Adhesion test For G S wires / Formed wires only
10. Freedom from surface defects
C. For PVC / XLPE insulation & PVC Sheath (as per sampling plan mentioned in IEC Pub 502 (1983)/ BS 6346:1969)
2. Tensile strength & Elongation before ageing(for tests after ageing see “D”)
D. Ageing test:
If the compound manufacturer is carrying out Ageing test, test report of compound manufacturer is to be reviewed. If the compound
manufacturer is not carrying out ageing test, then cable manufacturer will carry out ageing test & the test report will be reviewed by owner
(quantum of ageing test sample shall be one sample /batch)
E. Following tests will be carried out on completed cables as per relevant standard on each size
1. Insulation resistance test ( Volume resistivity method )
F. Following tests shall be carried out on only one size of offered lot (comprising of all sizes & types)
1. Thermal stability test on PVC insulation and outer sheath
2. Oxygen index test on outer sheath
3. Smoke density rating test on outer sheath
4. Acid gas generation test on outer sheath
G. Flammability test as per IEC 60332 - Part- 3 (Category- B) on completed cables as per following sampling plan

RSTPP STAGE - III
This test will be carried out using composite sampling i.e. irrespective of size; cables of one particular type (i.e.
armoured, unarmoured) will be bunched together, as per calculations in line with the IEC. All sizes of armoured &
unarmoured cables shall be covered.
H. Following tests shall be carried on one length of each size of (armoured & unarmoured) of offered lot:
Constructional / dimensional check, surface finish, length measurement, sequence of cores, armour coverage, Gap
1. between two consecutive armour wires / formed wires, Sequential marking, drum / Batch (outer sheath extrusion
batch )number marking on sheath
2. Measurement of Eccentricity & Ovality
GENERAL NOTE:
a) In case of manufacturers / supplier who have supplied cables in the past through Corporate Centre:- Routine Test of manufacturer internal test
report are to be verified by owner and Main Contractor at the time of final inspection. Owner and Main Contractor will also witness routine tests on
cables on 10% sample basis.
b) In case of manufacturers / supplier WHO HAVE NOT SUPPLIED cables in the past through Corporate Centre:- Routine Test of manufacturer
internal test report are to be verified by Owner at the time of final inspection. Owner will witness routine tests on cables for the first order on 10%
sample basis and Main Contractor will witness routine tests on cables for the first order on 100% basis.
1) For Smoke Density rating test: if the test result without conditioning is within (-)10% of the maximum specified value, then, retesting is to be carried
2) For Acid Gas Generation test: if the test result without conditioning is within (-)10% of the maximum specified value, then, retesting is to be carried
3) For Oxygen Index test: if the test result without conditioning is within (+)7% of the minimum specified value, then, retesting is to be carried out with
conditioning of samples as per standard and the test results after conditioning shall be final for acceptance/rejection.
4) In case the test results without conditioning do not meet the maximum/minimum specified value, the manufacturer may exercise the option of
retesting the samples after conditioning as per standard.

RSTPP STAGE - III
3.4. QUALITY ASSURANCE FOR CABLING EARTHING & LIGHTNING PROTECTION
Acceptance tests as per relevant standard &

Paint shade, paint thickness, adhesion
Constructional feature as per NTPC

Routine tests as per relevant standard &

Bought out items/Bill of material
Galvanise Test (If Applicable)
Pre-treatment of sheet
Deflection test*
Surface finish
IP protection
specification
specification
Proof load*
Dimension
Functional
HV & IR
Item / Components /
Sub System Assembly
Wall Mounted-Lighting Panel (IS-513, IS:5,

Y Y Y Y Y Y Y Y Y Y Y
IS:2629, 2633, 6745)
Switch box/junction box/Receptacles Panel
Y Y Y Y Y Y Y Y Y Y Y Y
(IS-513, IS:5, IS:2629, 2633, 6745)
Cable glands(BS-6121) Y Y
Cable lug Y Y
Lighting wire (IS-694) Y Y
Flexible conduits Y Y Y
Conduits (Galvanise & Epoxy) IS-9537 & IS-
Y Y Y Y Y
2629, 2633, 6745
RCC Hume Pipe (IS-458) Y
Cable termination & straight through joint (IS
Y Y Y
13573)

RSTPP STAGE - III
Acceptance tests as per relevant standard &

Paint shade, paint thickness, adhesion
Constructional feature as per NTPC

Routine tests as per relevant standard &

Bought out items/Bill of material
Galvanise Test (If Applicable)
Pre-treatment of sheet
Deflection test*
Surface finish
IP protection
specification
specification
Proof load*
Dimension
Functional
HV & IR
Item / Components /
Sub System Assembly
Cable Trays, bends, tees, crosses, Flexible

supports system & accessories IS-513, Y Y Y Y Y Y Y Y Y
2629,2633,6745
Trefoil clamp Y Y
GI flats for earthing & lighting protection (IS
Y Y Y Y Y
2062, 2629, 6745,2633
GI wire (IS-280) Y Y
Fire Sealing System ( BS –476) Y Y Y
Notes:

RSTPP STAGE - III
3.5. QUALITY ASSURANCE FOR ELEVATOR
All routine tests as

Dimensions/Physi
Operational Test/
Performance Test
Assembly/fit up
Ultrasonic Test
per applicable
Material Test
Plain shade,
thickness &
Other Tests
TEST /CHECK
Functional/
adhesion
DPI/MPI
Run Test
standard
cal
ITEM
Shaft/ /Gears/Pinion/Pulley/Sheave Y Y Y Y
Spring Y Y Y Y Y
Plates Y Y
Wire rope Y Y5
Safety device Y
Geared Machine Y
VVVF Drive Y Y
Power, Control & Trailing Cables Y4
Control Panel Y Y
ARD System Y Y
Electrical motor Y
Controller assembly with VVVF drive Y Y3
Complete Elevator Y Y Y1 Y1 Y2 Y

RSTPP STAGE - III
Y1 –Test to Be Done At Site

Y2 - Load/Overload Test to Be Done At Site as Applicable.
Y3 – Burn in test on electronic card
Y4 – Routine tests including FRLS tests as per Tech. Spec.
Y5- Test report as per relevant std.
Notes:

RSTPP FLUE GAS DUCT PACKAGE TECHNICAL REQUIREMENTS
STAGE - III (FGD SYSTEM) (QA & INSPECTION)
4.0 QUALITY ASSURANCE - CIVIL & STRUCTUTAL WORKS

RSTPP FLUE GAS DUCT PACKAGE TECHNICAL REQUIREMENTS
A. INTRODUCTION
a) This section of the specification covers the sampling, testing and quality assurance
requirement for civil and structural works covered in this specification.
b) This section of the technical specification shall be read in conjunction with other
parts of the technical specifications, general technical requirements & erection
conditions of the contract. Wherever IS code or standards have been referred they
shall be the latest revisions.
c) The rate for respective items of work or price shall include the cost for all works,
activities, equipment, instrument, personnel, material etc. whatsoever associated
to comply with sampling, testing and quality assurance requirement including
construction tolerances and acceptance criteria and as specified in subsequent
clauses of this part of the technical specifications. The QA and QC activities in all
respects as specified in the technical specifications/ drawings / data sheets /
quality plans / contract documents shall be carried out at no extra cost to the
NTPC.
The contractor shall prepare detailed construction and erection methodology
scheme which shall be compatible to the requirements of the desired progress of
work execution, quality measures, prior approvals if any and the same shall be got
approved by the NTPC. If required, work methodology may be revised/ reviewed
at every stage of execution of work at site, to suit the site conditions by the
contractor at no extra cost to the NTPC.
B. QUALITY ASSURANCE PROGRAMME

a) The contractor shall adopt suitable Quality Assurance Programme (QAP) to ensure that
the equipments and services under the scope of contract whether manufactured or
performed within contractor’s works or at his sub-contractor’s premises or at the NTPC’s
site or at any other place of work are in accordance with the specifications. Such QAP
shall be outlined by the contractor and shall be finally accepted by the NTPC or their
authorized representative after discussions before the start of work. The QAP shall be
generally in line with IS/ISO Systems.
The contractor shall furnish complete QA & QC programme for the work envisaged which
may include the following.
i) Organization structure for the management and implementation of the proposed
quality assurance programme.
ii) Quality System Manual.
iii) Design Control System
iv) Documentation and Data Control System
v) Qualification data / details for Contractor’s key personnel

vi) The procedure for purchase of materials, parts, components and selection of
subcontractor’s services including vendor analysis, source inspection, incoming
raw material inspection, verification of materials purchased, etc.
vii) System for shop manufacturing and site erection controls including process,
fabrication and assembly
viii) Control of non-conforming items and system for corrective actions and resolution
of Deviations.
ix) Inspection and test procedure both for manufacture and field activities
x) Control of calibration and testing of measuring testing equipment
xi) System for Quality Audits
xii) System for identification and appraisal of inspection status
xiii) System for authorizing release of manufactured product to the NTPC.
xiv) System for handling, storage and delivery
xv) System for maintenance of records
xvi) Quality plans for manufacturing and field activities detailing out the specific
quality control procedure adopted for controlling the quality characteristics
relevant to each item of work/ equipment/component.
C. QA AND QC MANPOWER
a) The contractor shall nominate one overall QA coordinator for the contract
detailing the name, designation, contact details and address at the time of post bid
discussions. All correspondence related to Quality Assurance shall be addressed
by the contractor’s QA coordinator to NTPC. NTPC shall address all
correspondence related to Quality issues to the contractor’s QA coordinator. The
contractor’s QA coordinator shall be responsible for co-ordination of Quality
activities between various divisions of the contractor and their sub-vendors on one
hand & with NTPC on the other hand.
b) The contractor shall appoint a dedicated, experienced and competent QA&QC in-
charge at site, preferably directly reporting to the Project Manager, supported as
necessary by experienced personnel, to ensure the effective implementation of the
approved QAP. An indicative structure of contractor’s QA&QC manpower
required to be deployed at site is enclosed at Annexure -I. Based on the finalized
L-2 network and the approved Field Quality plan, the contractor shall finalize and
submit a deployment schedule of QA&QC personnel along with their details to
NTPC for approval/ acceptance and further shall ensure their availability well
before the start of the concern activity.
c) The QA&QC in-charge shall have the organizational freedom and authority to
implement the requirements of these quality assurance arrangements, free from
commercial and programme restraints. The QA&QC setup of the contractor shall

consist of qualified and experienced Civil, Electrical, Mechanical Engineers and

Laboratory assistants with their supporting staff both at their works and site.
d) The deployment of man power for QA & QC set up shall be affected on the basis
of agreed manpower deployment schedule, which shall be prepared by the
contractor based on the L-2 network and the same shall be submitted to the NTPC
for acceptance.
D. SAMPLING AND TESTING OF CONSTRUCTION MATERIALS

a) The method of sampling for testing of construction materials and work / job samples
shall be as per the relevant IS / standards / codes and in line with the requirements of the
technical specifications / quality plans. All samples shall be jointly drawn, signed and
sealed wherever required, by the contractor and the NTPC or his authorized
representative.
b) The contractor shall carry out testing in accordance with the relevant IS / standards /
codes and in line with the requirements of the technical specifications / quality plans.
Where no specific testing procedure is mentioned, the tests shall be carried out as per the
best prevalent engineering practices and to the directions of the NTPC. All testing shall be
done in the presence of the NTPC or his authorized representative.
E. LABORATORY AND FIELD TESTING

a) The field laboratory for QA and QC activities shall be constructed and set-up by the
contractor in line with the indicative field QA&QC laboratory set-up enclosed at
Annexure -IV. The Laboratory building shall be constructed and installed with the
adequate facilities to meet the requirement of envisaged test setup. Temperature and
humidity controls shall be available wherever necessary during testing of samples. The
quality plan shall identify the testing equipments/ instrument, which the contractor shall
deploy and equip the field quality laboratory for meeting the field quality plan
requirements. The contractor shall furnish a comprehensive list of testing equipments/
instrument required to meet the planned/scheduled tests for the execution of works for
NTPC acceptance/ approval. The contractor shall mobilize the requisite laboratory
equipment and QA&QC manpower at least 15 days prior to the planned test activity as
per the schedule of tests.
b) All equipments and instruments in the field shall be calibrated before the commencement
of tests and then at regular intervals, as per the manufacturer’s recommendation and as
directed by the NTPC. The calibration certificates shall specify the fitness of the
equipments and instruments within the limit of tolerance for use. Contractor shall arrange
for calibration of equipments and instruments by an NABL / NPL accredited agency and
the calibration report shall be submitted to NTPC.

c) Based on the schedule of work agreed with the NTPC and the approved FQP, the
contractor shall prepare a schedule of tests and submit them to the NTPC and organize to
carry out the tests as scheduled / agreed.
F. PURCHASE AND SERVICE

a) The major items/ equipments/ components to be manufactured in the shop of the
contractor i.e. in-house items and those procured from sub-vendors / sub-manufacturer /
sub-contractors i.e. bought out items (BOIs) shall be listed out by the contractor in their
bid proposal.
b) The list of manufacturers/ sub-vendors for all the BOIs envisaged in contract shall be
included in the bid proposal by the contractor which shall be discussed / reviewed by the
NTPC during post bid discussions and the list of proposed manufacturers / sub-vendors
for each of the BOIs shall be agreed/ approved. If any item is left out or gets included
during detailed engineering, the contractor shall propose the manufacturer’s /
subvendor’s details for review / approval of NTPC, prior to initiating the procurement of
such materials.
c) To facilitate advance planning of material testing/ approval of bought out items, well
before the start of activity as per L-2 network, representative samples shall be procured
by the contractor from approved sub-vendors and submitted to the NTPC for his
approval before bulk procurement at least two months prior to start of works. In case of
manufacturers test certificate (MTC) is submitted for acceptance, it shall be clearly
traceable and correlated with the consignment received at site. MTC of all bought out
items shall essentially contain all the test parameters / characteristics specified in the
technical specifications / standards / codes. In case the manufacturer’s test certificate
does not mention these details, sample from each lot shall be tested for these properties at
the third party lab acceptable to NTPC. Approval of material / sample by the NTPC shall
not relieve the contractor of his responsibility, for their conformance to the specification,
as well as the requisite performance and quality of material.
d) Monthly progress reports on sub-contractor detail submission / approval shall be

furnished as per Engineering Co-ordination Procedure. Such vendor approval shall not
relieve the contractor from any obligation, duty or responsibility under the contract.
Subvendor whose details are not submitted within the agreed cut-off date, shall be
deemed to be withdrawn by the contractor.
e) Structural steel (plates and rolled sections i.e. channels, beams & angles) and
Reinforcement steel supply if in the scope of the contractor shall be procured from
Primary Steel Producers (Refer NOTE below). Currently, Primary Steel Producers
acceptable are SAIL, JSW Steel Ltd, Jindal Steel & Power, Tata steel Ltd. (for
Reinforcement steel/TMT bars), RINL (for long products/Rolled sections and
Reinforcement steel/TMT bars), Essar Steel India Ltd. (for Flat products/ Steel Plates),

Electrosteel steel Ltd. (for Reinforcement steel/TMT bars) and Monnet Ispat and Energy
Ltd. (for long products/Rolled sections and Reinforcement steel/TMT bars).
Subsequently, if any new Primary Steel Producer/s are proposed during execution of
contract, the same may be considered for acceptance subject to meeting the following
qualifying requirements:
i. The proposed supplier should be a Primary Steel Producer, having a minimum

production capacity of one million tons per annum (MTPA).
ii. The proposed supplier should be a regular manufacturer of Steel Plates and / or
Rolled Sections and / or Reinforcement Steel for the last two years as on date of
submission of proposal.
iii. The proposed supplier should also be a registered licensee with Bureau of Indian
Standards for BIS:1786/2062 at the time of submission of proposal.
NOTE: The “Primary Steel Producer” shall mean Steel Producer of any capacity,
irrespective of process route, starting their operations from iron making using iron ore,
virgin or processed, with necessary refining facilities and rolling/processing facilities, at a
single location or else in multiple locations provided that the entire gamut of iron & steel
production, from iron making to finished steel production, is owned by the same
company or its subsidiary company(ies). Provided that the iron making capacity is
sufficiently matching the steel making capacity. Further, downstream units should use
material from the upstream units of the same company or its subsidiaries.
In case of non-availability of certain steel section/s i.e. Angle smaller than 100x100x10
mm, MS flats, rounds, square bars and chequered plate from primary steel producers, an
option is given to the Main contractor to source these sections directly from SAIL
Conversion/Wet Leasing agent subject to the conditions given at point no. i) below:
i. Approval conditions for procurement of structural steel sections through SAIL
Conversion/Wet Leasing agent:
 Main Contractor to ensure continuity of BIS license of the manufacturer for

the sections being manufactured for NTPC supply.
 Billets shall be procured from NTPC approved Main Steel Producers. Proper
records for traceability from raw material to final product shall be
maintained.
 100% chemical analysis of the raw material (Billets) shall be carried out as
per IS: 2830. Testing of one sample per 40 MT for each type of section or part
thereof shall be carried out as per IS: 2062 on finished product.
 Each lot of delivery of finished product shall be accompanied with co-
relatable Manufacturer’s Test Certificate (MTC). MTC of finished sections
shall be correlated with original MTC for Billets received from Main Steel
Producer and Manufacturer Test Report of chemical analysis of Billets

mentioned at point no.3. MTC of finished sections shall include the reference
of MTC for Billets from Main Steel Producer.
 NTPC will have access to carry out the surveillance checks for in-process
stage.
 In case of any defects are seen in the material, Main Contractor will replace
the material without any cost implication to NTPC.
In case of non-availability of certain size/s of steel tubes conforming to IS:1161 and

Hollow (square and rectangular) steel sections conforming to IS: 4923 from primary steel
producers, the same may be sourced from BIS approved sources having valid BIS license
subject to the conditions given at point no.ii) below:
ii. Approval conditions for procurement of Steel tubes conforming to IS: 1161 and
Hollow (square and rectangular) steel sections conforming to IS: 4923 from BIS
approved sources:
 Main Contractor to ensure continuity of BIS license of the manufacturer for

the sections being manufactured for NTPC supply.
 Raw materials shall be procured from NTPC approved Main Steel
Producers.
 100% chemical analysis of the raw material (steel) shall be carried out as per
IS: 228. Testing of samples of steel tubes and hollow sections from each lot
shall be carried out as per IS: 1161 & IS: 4923 respectively on finished
product.
 Each lot of delivery of finished product shall be accompanied with co-
relatable Manufacturer’s Test Certificate (MTC).
 NTPC will have access to carry out the surveillance checks for in-process
stage.
 In case of any defects are seen in the material, Main Contractor will replace
the material without any cost implication to NTPC.
The specific methodology to be followed for procurement of Structural Steel and
Reinforcement Bars through conversion route/BIS approved sources route shall be
subject to approval by NTPC in advance.
G. MANUFACTURING QUALITY PLAN AND FIELD QUALITY PLAN

a) All materials / components and equipment covered under the scope of work, shall be
procured by the contractor for the purpose of the contract, after obtaining the written
approval of the NTPC, which are to be manufactured at shop/ factory of the vendor/sub
vendor shall be covered under a comprehensive quality assurance programme. The
contractor’s purchase specifications and inquiries shall call for Manufacturing Quality
Plans (MQP) to be submitted by the sub-contractor/ sub-supplier/ sub-vendor. The MQP
called for from the sub-contractor shall detail out for all the components and equipment,

various tests / inspection, to be carried out as per the requirements of this specification
and standards mentioned therein, quality practices and procedures followed by
contractor’s / sub-contractor’s / sub-supplier's quality control organization, the relevant
reference documents and standards, acceptance norms, inspection documents raised etc.,
during all stages of materials procurement, manufacture, assembly and final testing/
performance testing. Such quality plans of the vendors / sub-vendors shall be submitted
to the NTPC for approval in the prescribed format enclosed at Annexure- VI and such
approved quality plans shall form a part of the purchase order / contract between the
contractor and sub-contractor. The quality plans shall be submitted on electronic form e.g.
CD or E-mail in addition to hard copy, for review and approval of NTPC. After approval
the same shall be submitted in compiled form on CD in addition to hard copy.
b) The contractor shall furnish copies of the reference documents/ plant standards /
acceptance norms/ tests and inspection procedure etc., as referred in quality plans. These
quality plans and reference documents/standards etc. will be subject to NTPC approval
without which manufacturer shall not proceed. These approved documents shall form a
part of the contract. In these approved quality plans, NTPC shall identify customer hold
points (CHP), i.e. test/ checks which shall be carried out in presence of the NTPC
engineer or his authorized representative and beyond which the work shall not proceed
without consent of NTPC in writing. All deviations to this specification, approved quality
plans and applicable standards must be documented and referred to NTPC along with
technical justification for approval and dispositioning.
c) Within three weeks of the release of the purchase orders /contracts for such bought out
items /components, a copy of the same without price details but together with the
detailed purchase specifications, quality plans and delivery conditions shall be furnished
to the NTPC for reference / record by the contractor along with a report of the purchase
orders placed so far for the contract.
d) Well before the start of the work, the contractor shall prepare and submit the Field
Quality Plans (FQP) on the format Annexure-VII enclosed at elsewhere, and obtain
approval of NTPC, which shall detail out for all the works, equipments, services, quality
practices and procedures etc in line with the requirement of the technical specifications to
be followed by the contractor at site. This FQP shall cover for all the items / activities
covered in the contract / schedule of items required, right from material procurement to
completion of the work at site. An Indicative Field Quality Plan for civil works is enclosed
at Annexure – V-B (Indicative FQP for structural steel works).
e) Monthly progress reports on MQP / FQP submission / approval shall be furnished by

the contractor. List of items requiring quality plans and sub-supplier approval shall be
finalized with the contractor during the post bid discussions.

H. DISPOSITIONING OF NON CONFORMITIES

The non-conformity for the site works on being detected / noted shall be reported by
the contractor as per NTPC procedure. The dispositioning of the NCR relating to
equipment, assemblies, materials condition or process during construction / erection
shall describe the proposed correction and also include the preventive / corrective
action plan for future.
I. QUALITY AUDIT
NTPC reserves the right to carry out quality audit and quality surveillance of the
quality management and control activities, systems and procedures of the contractor
or their sub-contractor. The contractor shall provide all necessary assistance to enable
the NTPC carry out such audit and surveillance. The contractor shall also take
necessary measures, raise NCRs wherever required based on the audit findings /
observations.
J. QA DOCUMENTATION PACKAGE
The contractor shall be required to submit the QA documentation in two hard copies
and two CD ROMs, as identified in respective quality plan with tick (√) mark. Typical
contents of QA documentation pertaining to field activities as per approved MQP,
FQP and other agreed manuals / procedures, prior to commissioning of individual
system shall generally contain the Quality Plan, Material mill test reports, Non-
destructive examination results/reports, Heat Treatment Certificate/Record, Non-
conformance Reports, CHP, Certificate of Conformance (COC) and MDCC.
K. GENERAL QA REQUIREMENTS
The contractor shall ensure that the works, BOIs and services under the scope of
contract whether manufactured or performed within contractor’s works or at his
subcontractor’s premises or at the NTPC’s site or at any other place of work are in
accordance with the NTPC technical specification, applicable standards / codes,
approved drawings / data sheets / quality plans and BOQ. All the works, BOIs and
services shall be carried out as per the best prevalent engineering practices and to the
directions of the NTPC.

5.0 APPENDIX AND ANNEXURES
5.1. Appendix -1 - Indicative Vendor List ------------------------------ Page 37

5.2 Annexure-I - QA & QC Organization Setup (Civil works) -------------- Page 67
5.3 Annexure – II – Deleted -------------------------------------- Page 68
5.4 Annexure- III – Deleted -------------------------------------------------------- Page 69
5.5 Annexure- IV – Typical QA/ QC Lab Equipment (Civil Works) ----------- Page 70
5.6 Annexure – V-B - Indicative FQP for structural steel works -------------- Page 71
5.7 Annexure- VI - MQP Format ------------------------------------------------------ Page 77
5.8 Annexure- VII - FQP Format --------------------------------------------------- Page 78

Appendix - I
DISCLAIMER FOR INDICATIVE VENDOR LIST

1.1 Reasonable efforts have been made to collate the sub-vendors proposed by the
various main contractors from time to time against different Projects/Packages and
accepted by NTPC for various items. However, in case of error/omission, if any, and
represented by the successful bidder this will be addressed during the execution of the
contract based on the material evidence available with NTPC / Main Contractor.
1.2 The approved sub-vendor list drawn is not based on NTPC driven enlistment process
but based on the sub- vendors proposed by various Main Contractors. As such, it is
possible that some of the Suppliers/Manufacturers who may be involved in similar
work/process may not be appearing in the list as such sub-vendors may not have been
proposed by Main Contractors against NTPC Contracts.
1.3 In case the successful bidder chooses to propose additional sub-vendors with relevant
experience after the award of the contract such sub-vendors will be considered in
terms of Clause no: 19.1 of GCC, provided the proposals are received sufficiently in
time: 90 days prior to ordering date of a Bought Out Items/Start of Manufacturing so
as not to impede the progress of the contract.
1.4 Sub-vendors have been grouped under different categories of items. It is possible that
an item characterized by certain specific features such as range and type required as
per Main Contractor’s design requirements may not be in the range of the listed sub-
vendor’s manufacturing process/capability. As such the main contractor to ascertain
the vendor’s capability to meet his specific requirements before considering a sub-
vendor.
1.5 It is to be noted by the bidders that any shortfall in contract performance attributable to
the sub-vendor listed will not absolve the contractor from his contractual obligations
in any manner.
1.6 The approval was granted based on the evaluation of relevant capabilities and
facilities possessed by the sub-vendor at the time of evaluation. Also, some of the sub-
vendors may not be active. As such, the successful bidder is to carry out his own due
diligence before considering the listed sub-vendor for subletting: the current
status of the sub-vendor, the continued availability of productive resources including
Human Resources.

1.7 The list of sub-vendors is periodically revised to include new sub-vendors. Such a
revision may also see a deletion of certain sub-vendors who may have been
disqualified on grounds of inadequate performance or banned in line with NTPC’s
banning policy. The then current list will be shared with the successful bidder
immediately on award.

:n--,
PACKAGE: NTPC DOC NO
INDICATIVE SUB VENDOR LIST
,�,aitl REVISION NO
DATE ,;
v
SI Item QP/ ACCEPTABLE SUPPLIER AS PER DATABASE PLACE OF MANUFACTURING APPROVAL
No. lnsp. STA S
Cat. : ,
33 MISC. FABRICATED ITEMS,

TECHNOLOGICAL STRUCTURE PHYSICAL ASSESSMENT SHALL BE DONE
MAIN CONTRACTOR APPROVED
BY THE MAIN CONTRACTOR BASED ON
SOURCES
CRITERINCHECKLIST PROVIDED BY NTPC
�
r\'
34 BELT CLEANER & SKIRT BOARD SEALING
(BACKING PLATE, RUBBER BLOCKS), MAIN CONT. APPROVED SOURCES
FESTOON TROLLEY
35 SCRAPPER,SHEAVES,T AKEUP
TROLLEY,TAKEUP COMPONENTS
(THIMBLE,BULL DOG GRIP,TURN MAIN CONTRACTOR APPRD
.-
BUCKLE,COUNTER WEIGHTS), SCREW SOURCES
TAKEUP, RAIL, MANUAL RAIL CLAMP ��
36 WIRE ROPE BOMBAY WIRE ROPES � � �at A
'
t'
BHARAT WIRE ROPE �ll�R>AI A
USHA MARTIN �CHI A
,,
.-.
37 PAC VOLTAS � THANE/SILVASSA A
v
CARRIER AIRCON GURGAON A
38 SPLIT/WINDOW AC
BLUESTAR
MAIN CONTRACTO ..
<I SILVASSA A
,
SOURCES -..
39 QUICK RELEASE COUPLING, SHRINK
DISC COUPLINGS, SLIP RING , CLUTCH MAIN c,��PRD
COUPLING, COMPRESSION SOURC ·
COUPLINGS .-.
40 AIR RELEASE VALVE, FLOAT VALVES
v
MAIN��ACTOR APPRD
$0UR s
41 DUST SUPPRESSION SYSTEM
(PLAIN WATER & DRY FOG) BOls (Pump,Strainer,Pipes, Nozzle,
-�
� Gate,Globe,Check valve, Butterfly valve,
� Actuator,Motors,Control Panel, Pressure
MAIN CONTRACTOR APPRD
Reducing valve ,Solenoid valve, Pressure
SOURCES
� Gauge and Temperature Gauge, Pressure
switch, Level switch, Flow switch, Transmitter )
from NTPC approved sources
�
42 BELT VULCAN ISER NILOS CHENNAI A
THEJO ENGG CHENNAI A
43 CAST IRON CASTING MAIN CONT. APPRD SOURCES
44 PLUMMER BLOCK MAIN CONT. APPRD SOURCES
Page 11 of 18
PROJECT : INDICATIVE VENDOR LIST(MECHANICAL) DOC. No.
PACKAGE: FGD SUB SYSTEM: AC & VENTILATION,CAS & ECW
SUPPLIER :
BID DOC. NO:-
S ffEM ACCEPTABLE SUPPLIER AS PER DATA PLACE

N BASE
CENTRIFUGAL PUMPS
UP TO lOOCMH
34 HOSES
35 PIPES-MS- (BLACK/ GI) AS PER IS IS:3589 A CO-RELATED MIC
>lOOONB SAIL SHALL BE REVIEWED.
WELSPUN A SAW UPTO 2600NB
WELSPUN A SAW UPTO 1300NB
MAN INDUSTRIES A SAW UPTO 1400NB
SAMSHI PIPE INDUSTRIES LTD A SAW 450TO 2540NB
MUKAI TANKS & VESSELS A SAW 200TO 1200NB
MUKAT PIPES A SAW UPTO 1800NB
LALIT PIPES AND PIPES LTD A SAW 350TO 1400NB
RATNAMANI CHATRAL A SAW 600 TO 2600NB
RATNAMANI KUTCH A SAW 400TO 3600NB
PSL HOLDINGS LIMJ,TED DAMAN A SAW 450TO 1600NB
PSL INTERNATIONfilt:t:f CHENNAI A SAW 450TO 3000NB
PSL LIMITED KUTCH A SAW 700TO 2200NB
VISAKHAPAT A
NAM SAW UP TO 3200NB
CHHINDWAR A
A SAW UPTO 1600NB
TEEL TUBE LTD AN JAR A SAW UP TO 2300NB
UCURES PVT LTD (EARLIER A ROLLERD & WELDED
A PIPES & STRUCTURES PVT. LTD. THANE 406.4MM TO 3874MM
36 MS PIPE (BLACK/GI) TRACTOR APPROVED SOURCES A (BIS MARKED,
(IS 1239 /IS 3589) MANUFACTURERS WITH
( UPTO lOOO NB) VALID BIS LICENSE)
37 PIPE-CS SEAMLESS ASTM A 106 AHMADNAGA A UPTO 150NB &
R
BARAMATI A UPT0200NB
UPTO 177.8MM OD, HOT
REMI BHARUCH A FINISHED
PROJECT : INDICATIVE VENDOR LIST(MECHANICAL) DOC. No.
PACKAGE: FGD SUB SYSTEM: AC & VENTILATION,CAS & ECW
SUPPLIER :
BID DOC. NO:-
S ffEM ACCEPTABLE SUPPLIER AS PER DATA PLACE

N BASE
MAHARASHTRA SEEMLESS CS SEAMLESS PIPES

UPT0350 NB
38 PIPES & FITTINGS-CI & DI

39 PIPE-SS ASTM A 312 UP TO 100 NB REMI A ERW UPTO 400 NB
RATNAMANI ERW UPTO 500 NB,
A SEAMLESS UPTO 50 NB
ONLY
RATNAMANI ERW UPTO 400 NB,
SEAMLESS UPTO 50 NB
A
ONLY, ARC WELDED UP
T0450NB
SUMITOMO JAPAN A
SOSTA GERMANY A
SWEDEN A
ONLY FOR SEAMLESS
UPTO 50NB AND ERW UP
VALSAD A T0400NB
DEWAS A ERW UP T0300NB
BEHRORE A ERW UPTO 400 NB,
SEAMLESS UPTO 50 NB.
40 PIPING FABRICATION AND FABRICATED MAIN CONTRACTOR APPROVED SOURCES

FITTINGS-LP UP TO 300PSI
41 PLATE HEAT EXCHANGER TER INDIA(FORMERLY INDWEEP) PUNE A HT PLATES & GASKETS
FROM TRANTER
SWIDEN/USA.HT PLATES
FROM HISKA JAPAN
KELVION INDIA PVT LTD ( FORMLY GEA PUNE A
ECOFLEX INDIA
:,
DATE
No. lnsp. STA S
Cat. : ,
"M"ETAL SEATED, TRIPLE ECCENTRIC, SS

ADVANCE GREATER NOIDA BFV OF SIZE UPTO 100NB, AND
v PRESSURE RATING UPTO CLASS #300.
A
�
BRAY CONTROLS INDIA PVT LTD VADODARA <...;1 � UP TO 400NB CLASS 150 I PN16
CHINA UP TO 400 NB CLASS#600
u,v I \JV" I "VLv \LnCvl ,,....,) \JV.
"'"''A
J
ITn
L&T KANCHIPURA� A UPTO 400NB, CLASS #150
INSTRUMENTATION LTD. PALAK� ,� A UPTO 2200NB CLASS # 75
HAWA ENGINEERS A'

-� Y
---- A
Cl/ CS & FABRICATED UPTO 1200MM,
CLASS #150, SS UPTO 250MM,
..ij, � CLASS#150
\� (/..
48 MS FITTINGS (BLACK I GI) AS PER MAIN CONTRACTOR APPRD
IS 1239 PART-2 SOURCES
49 MS ERW PIPES AS PER IS 1239 / IS
3589 ( UPTO 600 NB)
SAIL
MAHARASHTRA SEA�,
--
............_, R�URKELA
RA IGAD
A
A
200 NB TO 500 NB ERW PIPES AS PER IS
3589
INDUS TUBES
\� G.B.NAGAR A UPTO 300 NB AS PER IS 1239/3589
SURYA R��
JIND12L
�D�
#"' �
BAHADURGARH
GHAZIABAD
JANGALPUR
A
A
UPTO 400 NB ERW PIPES AS PER IS 1239/3589
UPTO 350 NB ERW PIPES AS PER IS 1239/3589
UPTO 500 NB FOR BLACK PIPE
--
UP TO 300 NB ERW BLACK PIPE AS PER IS
..1NDJlJDUSTRIES LTD. HISSAR A
1239/3589
-�-s
41,.. �
MS pipes ( Black & GI) as per IS 1239 & MS
� pipes ( Black & GI) as per IS 3589 up to 250
APL APOLLO TUBES LTD. SIKANDRABAD A
NB size, 8 mm thickness and Grade up to Fe
410.
MS pipes ( Black & GI) as per IS 1239 & MS

�- LLYODS LINE PIPES LTD. THANE A pipes ( Black ) as per IS 3589 up to 350 NB
size, 8 mm thickness and Grade up to Fe 410.
DADU PIPES SIKANDRABAD A UPTO 300 NB ERW BLACK PIPES
Page 13 of 18
:,
DATE ,;
No. lnsp. STA S
Cat. : ,
-
TATA JAMSHEDPUR '-. A ' UPTO 150 NB ERW PIPES AS PER IS 1239
_v
RATNAMANI KUTCH ERW PIPES AS PER IS 3589 UPTO 400 NB
�
( "'�
WELPSUN AN JAR ._. A UPTO 400 NB ERW PIPES AS PER IS 1239/3589
50 FORGED/FORMED FITTINGS GUJARAT INFRA PIPES BARODA A

EBY UMBAI �'-' A
N.L.HAZRA KOLK41.� ) A
MS FITTINGS KQL_KA�V A
TRUE FORGE .,. �ARL!iABAB A
TUBE PRODUCTS ..< �q,PA A
PIPEFIT ENGINEERS
\ ft'�DA A
SIDDARTH & GAUTAM """"'-' FARIDABAD A
51 MATERIAL FOR DUCTING, DUCTING
SUPPORT, GRILLS, LOUVRE,
DAMPERS, PRE & FINE FILTERS (no of MAIN CONTRAC s RCES
�""
filters< 100 each), EARTHING MATERIAL �
(MS ROUND BAR)
52 Cl PRESSURE RELEIF/REDUCING
VALVE
DARLING�ES�
LEAD ER
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...,.
FISCFtf'�MAR
' AHMEDABAD
JULLUNDHAR
PLINE
A
A
A
jfflR�MARSHALL PLINE A
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........."'
f.AINfER LESSER AURANGABAD A
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53 HYDRAULIC POWER PACK EA,ON POWER PLINE A
,,--�
B'"OSCH-REXROTH AHMEDABAD A
....� HAGGLUNDS SWEDEN A
T
MAHA HYDRAULICS CHENNAI A
L & T HYDRAULICS BANGALORE A EXCEPT FOR STACKER RECLAIMER
54 HYDRAULIC CYLINDER � VELJAN HYDERABAD A
WIPRO BANGALORE A
EATON POWER PLINE A
L & T HYDRAULICS BANGALORE A
Page 14 of 18
:-,
REVISION NO
,�,aitl DATE
No. lnsp. STA S
Cat. :,
64 PLAIN WATER SPRAY SPRAYING SYSTEM BANGALORE ..._ "

NOZZLE/SPRINKLERS FOR OS
A
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F.HARLEY KOLKATA �,;
SYSTEM
EAGLE AGRO RAJKOT
{ ,�
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PLINE ....,_ A
INDIANA GRATINGS PVT. LTD.
RAIGARH A
JINDAL STEEL & POWER LTD.
TRICHY� A
BABY ENGG. PVT. LTD.
T�V A
REGIONAL ENGG. WORKS
---
AJANTHA FABS �
t� � A
A
-....
CAPACITE STRUCTURES LTD. \ �
MIURA INFRASTRUCTURE
� BHILAI A
LTD. i
BHILAI A
SHIVAM HITECH Sl<.EUvbLTD
TECHNOFAB MANU C'��1\JG
' CHENNAI A
LTD. ...............-
JSW SE l TRl:.JCTURES
SHOP FABRICATED STRUCTURE �., � BELLARY A
LTD!JSS �
65
ALLIANCE l GRATED METALIKS
� RAJPURA A
LTD!�L..l
�AlpvT LTD DURGAPUR A
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�OREFAB PROJECTS PVT LTD
KOTHARI CHEMICALS
NAGPUR
BHILAI
BHILAI
A
A
FEDDERS LLOYD CORPORATION
SIKANDRABAD A
�- LTD
ARCELOR MITTAL DHAMM
PROCESSING PVT LTD
RANIPET A
ARTSON ENGINEERING NASIK A
Page 17 of 18
Project : ELECTRICAL ITEMS Doc No :
Package : Rev No :
INDICATIVE VENDOR LIST FOR ITEMS REQUIRING QUALITY PLAN AND SUB-
Supplier : Date : 14.06.2019
VENDOR APPROVAL
Contract No.: Page :
ITEM DESCRIPTION Sub-Supplier Sub-supplier
QP / QP QP
approval Details
Sl No Insp. QP No: Sub. approval Proposed sub-supplier Place Remark
status / submission
Cat. Sch. Sch.
category sch
Sri ram Cables Bhiwadi A upto 11kV only
Sterlite Haridwar A
ST
14 H.T. CABLE Grade- upto 33kV Tirupati Plastomatics Jaipur A upto 11kV only
Torrent Cable Ltd Nadaid A
Universal Cable Ltd. Satna A
Chabbi India Ltdi Electricals Jalgaon A
LI
HBL Power Hyderabad A
Battery Charger Dubas Engineering Bangalore A
15
( 48V/110V/220V) Chloride Power Kolkatta A
R
Statcon Hapur A
Masstech Jalgaon A
O
Exide Kolkata A* * For lead acid plante type only
Hoppekkee Brilon, Germany A* * For lead acid plante type only
16 Battery
HBL Power Systesm Hyderabad A# # For Ni-cd type only
D
Amcosaft Bangalore A# # For Ni-cd type only
ECE GHAZIABAD A
N
TECHNO AHMEDABAD A
OTIS MUMBAI A
17 ELEVATOR
VE
KONE CHENNAI A
OMEGA AHMEDABAD A
SAMIL ELTEC KOREA A
TIL Ghaziabad A UP TO 1500KVA
Powerica Silvasa A UP TO 500KVA
E
Jakson Kathua A
18 DG Set
Sterling Generators Pvt Ltd Silvasa A
IV
Supernova Rajpur A
Kohler Singapore A
AT
BHEL Rudrapur A
C&S G.Noida/Haridwar A
19 HV Busduct ( SPBD)
KGS Engg Chennai A Upto 11KV only
Powergear Chennai/Bangalore A
IC
Inar Profiles Ltd Ankapally (Vizag) A

Vatco Mumbai A Galvanization at Sigma Mumbai
Indiana cable trays Mumbai A Galvanization at Karamtara galvaniser
D
Industrial Perforation Kolkata A

Ratan Projects Howrah A Galvanization at DMP Projects
IN
20 GI CABLE TRAYS India Electric Syndicate Kolkata A Galvanization at BMW Industries/B.P Projects
Steelite engg. Mumbai A
Premier Power Products Kolkata A Galvanising at Neha Galvaniser
Indiana Gratings Pune A Galvanization at Poona Galvanizer

ANNEXURE -I - QA & QC ORGANISATION SETUP
Project Manager
Manager (Quality)
Geotechnical
Civil Engineer
Civil Engineer Engineer Engineer (NDT)
Engineer (welding
(lab incharge) ( I/c Earth (Mech)
(Field 1*) & fitup)
work)
Qualified
Manpower
RT level II - 1No
UT level II - 2 No
NOTE:
1. The above organization setup is minimum however their deployment shall be as per
the agreed deployment schedule. The contractor shall prepare a manpower
deployment schedule in line with the finalized work plan and the same shall be
submitted to the engineer-in charge for acceptance/ approval.
2. The contractor shall mobilize the QA& QC manpower in line with the finalized
manpower deployment schedule and shall ensure their availability well in advance
(15 days approx.) of the beginning of the concerned activity/ work.
3. The contractor shall further mobilize required number of skilled & supporting staff
and additional resources, if any to meet the work schedule.
ANNEXURE II - DELETD
ANNEXURE – III - DELETED
ANNEXURE- IV - TYPICAL QA/ QC LAB EQUIPMENT
Project: Package:
S. No. Equipment Nos.

1 Oven 2
2 Physical balance 1
3 Rapid moisture meter 2
4 Thermometer 4
5 Burret 2
6 Measuring cylinders 9
7 Measuring flasks 3
2 sets of 2000 kN
8 Compression testing machine
capacity each
2 (12 kg capacity), 2
9 Electronic balance
(200 mg capacity)
10 pH balance As per requirement
As per requirement,
Party should deploy
11 Radiographic facilities BARC approved
agency for carrying
out RT
12 Mechanical weighing machine 1 (100 kg capacity)
13 Ultrasonic testing machine As per requirement
14 D.P. Test kit 10
15 Vernier 300 mm, 600 mm 2
16 Micrometer (0.25 mm) out side (25.00) 2
17 Radiography film viewer 2
18 Inside Micrometer 25-750 dia 2
19 Digital elcometer for paint thickness 2
20 Baking oven for electrode 3
21 Portable ovens 2
ANNEXURE-VB
PAGE 74OF 6
INDICATIVE FIELD QUALITY PLAN

SUPPLIERS NAME AND
QP NO. : 2 PROJECT: LOT-5 PROJECTS
ITEM : STRUCTURAL STEEL WORK
LOGO REV. NO .: 0 PACKAGE: Flue Gas Desulphurization (FGD) System Package
ADDRESS:
SUB-SYSTEM : FABRICATION & ERECTION DATE : CONTRACT NO.
PAGE : MAIN CONTRACTOR
Class of Acceptance
Sl. No Activity and operation Characteristics / instruments Type of Check Quantum Of check Reference Document Format of Record Remarks
check Norms
1 2 3 4 5 6 7 8 9 D* 10
1.00 MATERIALS
Structural steel procured from

Correlated MTC shall be verified. In
NTPC approved sources- For each batch of
Review of Technical Specification and Construction the event of non submission of MTC ,
i Mechanical (YS, UTS, Elg, UT if A each section delivered SR/MTC 
MTC Drawings, IS 2062 sample shall be selected by FQA for
specified),,and Chemical at site
testing as per specification.
properties (CE as per IS)
2.00 FIT-UP
As agreed / Visual & Tech Specs and Const. Drawings/
i Marking and Cutting B Each plate/ Section SR
required Measurement Approved cutting plan
Match markings for trial As agreed /
ii B Physical Each fit-up Tech Specs and Const. Drawings SR
assembled components required
As agreed /
iii Weld Fit Up B Physical Each fit-up Tech Specs and Const. Drawings SR  Edge Preparation/ Gap/ Alignment
required
3.00 PRE HEATING (wherever applicable)

As agreed / Tech Specs and Const. Drawings,
i Pre-Heating Temperature B Measurement Each pre-heating SR 
required Approved WPS
Post Weld Heat Treatment As agreed / Time & Tech Specs and Const. Drawings,
ii A Each PWHT SR 
(PWHT), if required required Temperature Approved WPS
4.00 WELDING REQUIREMENTS

Approved WPS/ PQR, AWS-D1.1/ASME-
As agreed / Test Main contractor approved WPS to be
i PQR and Welder's Qualification A Physical Each welder IX, Tech Specs and Const. Drawings 
required Report used.
As agreed / electrodes used shall be as specified in
ii Welding consumables B Physical Random in each shift SR 
required Approved WPS
As agreed /
iii Sequence of welding B Physical Random in each shift Tech Specs and Const. Drawings SR
required
Removal/ grinding of temporary As agreed / All cleats/ Tech Specs and Const. Drawings, IS-
iv B Measurement SR
attachments required attachments 7215
Completeness after welding- As agreed / Each structure
v B Visual Tech Specs and Const. Drawings SR
Dimensions/ distortion required component
5.00 NON DESTRUCTIVE AND DESTRUCTIVE TESTING

5.01 Fillet Welds
As required/ Visual/ As per technical specifications and
i Visual B Each welded joint SR As per requirement of NTPC Engineer
agreed Measurement construction drawings
Main fillet weld with

As required/ min one joint per built As per technical specifications and
ii Macro-Etch Examination B Physical SR 
agreed up beam, columns construction drawings
and crane girders
25% weld length of

tension member of
crane girder- For
crane girder
As required/ As per technical specifications and
iii Dye Penetration Test (DPT) B Physical SR 
agreed 5% of Weld length construction drawings
with min. 300mm at
each location - Except
Crane Girder, for all
other Fillet Welds
ANNEXURE-VB
PAGE 75OF 6

SUPPLIERS NAME AND
ADDRESS:
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
5.02 Butt Welds
i Visual B Visual Each welded joint SR
agreed construction drawings
100% DPT after back
gouging on all butt
welds except for coal
As required/ bunker bins As per technical specifications and All butt welds to be back gouged
ii Dye Penetration Test B Physical SR
agreed construction drawings before DPT
10% DPT after back
gouging-For coal
bunker bins
Min. one joint per built

Mechanical testing on As required/ As per technical specifications and
iii A Physical up beams, columns SR  Test on production test coupons
production test coupons agreed construction drawings
and crane girder.
100% RT on butt In case of failure of any welds in

welds of tension SPOT/RT or UT the % of retesting
flange (bottom flange) shall be doubled. Acceptance criteria
of crane girders of NDT on welds shall be as per AWS
iv Radiography Test (RT) A Physical SR  D1.1.
10% RT weld length
of each welder on butt Wherever RT is not feasible UT to be
welds, except for carried out with the approval of the
crane girders Engineer-in-charge.
5.03 Full Penetration Welds (Other than butt welds)
100% UT on the web
to flange joint of crane In case of failure of any welds in
girder SPOT/RT or UT the % of retesting
i Ultrasonic Testing (UT) A Physical IR  shall be doubled. Acceptance criteria
10% UT on other full of NDT on welds shall be as per AWS
penetration joints D1.1.
5.04 NON DESTRUCTIVE AND DESTRUCTIVE TESTING FOR CHIMNEY STEEL LINER
As per technical specifications and

i Visual examination As required/ agreed B Visual 100% SR  As per requirement of NTPC Engineer
construction drawings, IS 822, AWS D 1.1

ii DPT As required/ agreed B Physical 100% IR 
10% FOR SHOP BUTT

iii RT As required/ agreed A Physical WELD AND 15% FOR
SITE BUTT WELDS
6.00 FOUNDATION CHECKS
As agreed / Physical/ Shape, lines (including diagonal

i Dimensions and levels B Each Foundation Tech Specs and Const. Drawings SR 
required Measurement checks)
Foundation bolts shall be conforming

As agreed / Physical and Once for each lot of
ii Foundation Bolts (materials) A Tech Specs and Const. Drawings SR/MTC  to relevant IS as given in the Tech.
required MTC Review delivery
Spec./ Construction Drawing
ANNEXURE-VB
PAGE 76OF 6

SUPPLIERS NAME AND
ADDRESS:
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
Foundation Bolts and As agreed / Physical/ Measurement of Verticality, Levels,
ii B Each Foundation Tech Specs and Const. Drawings SR 
Embedment's required Measurement pitch distance
Receipt of shop Visual/

As agreed / Physical & Each structural Checks for visual defects and
7.0 fabricated steel Material A Tech Specs and Const. Drawings SR 
required Review of member completeness of painting as per CHP
structure at site
CHP/MDCC
Submission of Erection
sequence/ methodology Once prior to erection of Approved drawings and Technical
8.0 - A Approval
each structure Specifications
SR √
of erection for all
structures
ANNEXURE-VB
PAGE 77OF 6

SUPPLIERS NAME AND
ADDRESS:
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
9.00 PRE-ASSEMBLY CHECKS
Markings for -
Punch Erection marks and As agreed / Visual/ Each structural Assembly designation, Part number,
i B Tech Specs and Const. Drawings
match marks on members required Physical member Weight, Any other important
identifications.
Pre-assembly as per match As agreed / Visual/ Each structural
ii B Tech Specs and Const. Drawings
mark required Physical member
Camber, sweep and total length As agreed / Visual/ Each structural
iii B Tech Specs and Const. Drawings SR 
after trial assembly of structure. required Physical member
Every first and tenth
As agreed / Visual/
iv Control assembly check at shop B set of identical Tech Specs and Const. Drawings
required Physical
structure
10.00 ERECTION CHECKS
Alignment, slopes, level, As agreed / Each structural

i B Measurement Tech Specs and Const. Drawings SR 
tolerances of erected member required member
Tightening of bolts including As agreed / Visual/ Each structural

ii B Tech Specs and Const.
Const Drawings SR 
foundation bolts with lock nuts required Physical member
To be verified w.r.t. approved

As agreed / Visual/ Each erected Tech Specs and Const. Drawings, IS
iii Acceptance of erected structure A SR  methodology for erection / erection
required Physical structure 7215 and IS 12843
sequence
11.00 INSTALLATION AND ALIGNMENT OF STEEL LINER
Approved drawings and Technical
Submission of Installation/ Erection
Once prior to erection of Specifications
i sequence/ methodology of erection - A Approval SR √
each structure
for all structures

ii Check for Erection Marks - B Visual 100% SR
Specifications
Check for Installation of Steel Visual/ Approved drawings and Technical
iii As required B 100% Specifications SR
Liners Acceptance
Visual/ Approved drawings and Technical
iv Check for Site Joints As required B 100% SR
Acceptance Specifications
Check for Installation of Inlet Visual/ Approved drawings and Technical
v As required B 100% SR
Transition Ducts Acceptance Specifications
Each layer of expansion Compensator to

Visual, be checked at shop for thickness, unit
Check for Installation of Insulations Approved drawings and Technical
vi As required B Physical, 100% SR weight, tensile strength & elongation along
and Expansion Compensators Specifications
Acceptance with temp. withstand ability for composite
joints
Ensure the Erection of all steel

Visual/ Approved drawings and Technical
vii structures along with permissible As required B 100% SR
Acceptance Specifications
tolerances and their acceptance

Check and approval for Specifications
Visual/
viii Dismantling, Modification and Re- As required B 100% SR
Acceptance
erection, if required for any reason
ANNEXURE-VB
PAGE 78OF 6

SUPPLIERS NAME AND
ADDRESS:
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
12.00 PAINTING SYSTEM
Painting Materials and As agreed / Review of
i A Each batch of delivery Tech Specs and Const. Drawings SR/MTC 
accessories required MTC
As agreed / Physical Tech Specs and Const. Drawings,
ii Surface preparation B Random in each shift SR 
required /visual Relevant code/ standards
As agreed / Each surface at
iii DFT of paint - Over steel surface A Physical Tech Specs and Const. Drawings SR 
required random
As agreed / Each surface at
iv Acceptance of painted surfaces B Physical Tech Specs and Const. Drawings SR
required random
13.00 PERMANENT BOLTS AND NUTS AND WASHERS

All bolts , nuts and washers for
As agreed / Physical and Once for each lot of connections shall be conforming to
i Material A Tech Specs and Const. Drawings SR/MTC 
required MTC Review delivery relevant IS as given in the Tech.
Spec./ Construction Drawing
As agreed / Random before Tech Specs and Const. Drawings, IS
ii Contact surfaces before bolting B Physical SR
required assembly for bolting 4000
Randomly in each
Inspection of the assembled As agreed / Tech Specs and Const. Drawings, IS
iii B Physical shift for assembled SR
bolts required 4000
bolts
Randomlyy during g
As agreed / Tech Specs and Const.
Const Drawings
Drawings, IS
iv Tensioning B Physical snug tight test and SR 
required 4000
after full tensioning
As agreed /
v Acceptance of installed bolts B Physical Each bolt Tech Specs and Const. Drawings SR
required
14.00 ELECTROFORGED GRATINGS
Material A Physical and for each lot of delivery Tech Specs and Const. Drawings SR/MTC
i As agreed / required CHP/MDCC 
Review
Acceptance of Erection, alignment B Physical 100% Tech Specs and Const. Drawings SR
ii and each Installation
As agreed / required
15.00 STAINLESS STEEL HAND RAILS
As agreed / Physical/MTC Once for each lot of

i Material A Tech Specs and Const. Drawings SR/MTC  Also check grade of steel
required Review delivery
Main contractor approved WPS shall

As agreed / Random for each AWS D1.1 / 'Tech Specs and Const.
ii DPT for welding A Physical SR/LB  be used, electrodes used shall be as
required fabrication Drawings
specified in WPS
Acceptance of stainless steel As agreed /
iii B Physical Each installation Tech Specs and Const. Drawings SR
hand rails required
16.00 PTFE SLIDING BEARINGS AND ELASTOMERIC BEARINGS

As agreed / Physical and Once for each lot of Tech Specs and Const. Drawings
i Material A SR/MTC 
required MTC Review delivery
Acceptance of installation of As agreed / Tech Specs and Const. Drawings
ii B Physical Each installation SR
bearings required
LEGEND: D * Records, identified with “Tick” () shall be essentially included by supplier in QA DOC. NO.: REV: 0
documentation.
Legend to be used: Class # : A = Critical, B=Major, C=Minor; SR, TR, MTC, LB
ANNEXURE-VB
PAGE 79OF 6

SUPPLIERS NAME AND
ADDRESS:
Class of Acceptance
check Norms
1 2 3 4 5 6 7 8 9 D* 10
Categorization Witnessing & Accepting (As per NTPC QA&I System)
Manufactu Category ‘A’ FQA Engineer in association with Executing Engineer, Category ‘B’ Executing Engineer, Category ‘C’
rer/ Sub- Main-supplier Main contractor's Engineer; For NTPC USE
supplier SR = Site Register , TR= Test Report, Mfr TC = Manufacturer's Test Certificate
Signature This document shall be read in conjunction with NTPC Tech. Specifications, BOQ, Drawings REVIEWED BY APPROVED BY APPROVAL SEAL
Annexure VI
MANUFACTURER’S NAME AND

ADDRESS MANUFACTURING QUALITY PLAN PROJECT :
ITEM : QP NO.: PACKAGE :
MFGR.’s REV.NO.:
LOGO CONTRACT NO. :
SUB-SYSTEM: DATE:
PAGE: …. OF…. MAIN-SUPPLIER:
SL. COMPONENT & CHARACTERISTICS CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
NO OPERATIONS CHECK OF CHECK DOCUMENT NORMS RECORD
M C/N M C N
1. 2. 3. 4. 5. 6. 7. 8. 9. D* ** 10. 11.
LEGEND: * RECORDS, INDENTIFIED WITH “TICK” (  ) SHALL BE DOC. NO.: REV…… CAT…..
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
** M: MANUFACTURER/SUB-SUPPLIER C: MAIN SUPPLIER, N: NTPC
P: PERFORM W: WITNESS AND V: VERIFICATION. AS APPROPRIATE,
MANUFACTURER/ MAIN-SUPPLIER CHP: NTPC SHALL IDENTIFY IN COLUM “N” AS ‘ W” FOR
SUB-SUPPLIER NTPC
SIGNATURE USE REVIEWED BY APPROVED BY APPROVAL
SEAL
FORMAT NO.: QS-01-QAI-P-03/F1 1/1 ENGG. DIV./QA&I
Annexure VII
SUPPLIER’S NAME AND ADDRESS

FIELD QUALITY PLAN PROJECT :
ITEM : QP NO.: PACKAGE :
SUPPLIER’S REV. NO.:
LOGO CONTRACT NO. :
SUB-SYSTEM: DATE:
PAGE: …. OF…. MAIN-SUPPLIER:
SL. ACTIVITY AND CHARACTERISTICS / INSTRUMENTS CLASS OF TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF REMARKS
NO OPERATION CHECK # CHECK OF CHECK DOCUMENT NORMS RECORD
1. 2. 3. 4. 5. 6. 7. 8. 9. D* 10.
DOC. NO.: REV……

LEGEND: * RECORDS, INDENTIFIED WITH “TICK” () SHALL BE
ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION.
LEGEND TO BE USED: CLASS # : A = CRITICAL, B=MAJOR, C=MINOR;
MANUFACTURER/ MAIN-SUPPLIER ‘A’ SHALL BE WITNESSED BY NTPC FQA, ‘B’ SHALL BE WITNESSED BY FOR
SUB-SUPPLIER NTPC ERECTION / CONSTRUCTION DEPTT. AND ‘C’ SHALL BE WITNESSED NTPC
BY MAIN SUPPLIER (A & B CHECK SHALL BE NTPC CHP STAGE) USE
SIGNATURE REVIEWED BY APPROVED BY APPROVAL SEAL
FORMAT NO.: QS-01-QAI-P-03/F2 1/1 ENGG. DIV./QA&I
RSTPP ABSORBER PACKAGE FUNCTIONAL GUARNTEES AND
STAGE - III (FGD SYSTEM ) LIQUIDATED DAMAGES
SECTION–V – INDEX
(FUNCTIONAL GUARANTEES & LD)
1. GENERAL: ................................................................................................................................. 2
2. PERFORMANCE GUARANTEES / PERFORMANCE TESTS ........................................... 2
3. AMOUNT OF LIQUIDATED DAMAGES (LD) APPLICABLE FOR GUARANTEES .... 6
4. GUARANTEE PARAMETERS................................................................................................ 6
5. AUXILIARY POWER CONSUMPTION................................................................................ 7
6. METHOD OF COMPUTING AVAILABILITY ...................................................................... 7
Tender Doc No.:SRO/CON/ETS/079 VOLUME-II SECTION-V Page 1 of 8

FUNCTIONAL GUARANTEES, LIQUIDATED DAMAGES FOR SHORTFALL IN

PERFORMANCE AND PERFORMANCE GUARANTEE TESTS
1. GENERAL:
The term “Performance Guarantees” wherever appears in the Technical

Specifications shall have the same meaning and shall be synonymous to “Functional
Guarantees”. Similarly the term “Performance Tests” wherever appears in the Technical
Specifications shall have the same meaning and shall be synonymous to “Guarantee
Test(s)”.
2. PERFORMANCE GUARANTEES / PERFORMANCE TESTS
2.1. General Requirements
a) The Contractor shall guarantee that the equipment offered shall meet the ratings and
performance requirements stipulated for various equipment covered in
these specifications.
b) The guaranteed performance parameters furnished by the Bidder in his offer, shall be
without any tolerance values whatsoever. All margins required for instrument
inaccuracies and other uncertainties shall be deemed to have been included in the
guaranteed figures. No tolerance or allowance on the test result will be permitted for
instrument errors or inaccuracy, the method of testing or any other causes.
c) The Contractor shall conduct performance test and demonstrate all the guarantees
covered herein. The various tests which are to be carried out during
performance guarantee tests are listed in this Section. The guarantee tests
shall be conducted by the Contractor at site in presence of Client (EPIL) &
NTPC on each unit individually.
d) All costs associated with the tests including cost associated with the supply,
calibration, installation and removal of the test instrumentation shall be included in
the contract price.
e) The performance tests shall be performed using only the normal number of
NTPC supplied operating staff. Contractor, vendor or other subcontractor
personnel shall be used only for instructional purposes or data collection. At all times
during the Performance Tests the emissions and effluents from the Plant shall not
exceed the Guaranteed Emission and Effluent Limits as applicable.

f) It shall be responsibility of the Contractor to make the plant ready for

the performance guarantee tests.
2.2. Test Instrumentation, Flow Measurement and their Calibration
a) All instruments required for performance testing shall be of the type and accuracy
required by the code and prior to the test, the Contractor shall get these instruments
calibrated in an independent test Institute approved by the Client (EPIL) / NTPC
and submit the same to Client (EPIL) prior to commencement of test.
All test instrumentation required for performance tests shall be supplied by the
Contractor and shall be retained by him upon satisfactory completion of all such tests
at site. All calibration procedures and standards shall be subject to the
approval of the Client (EPIL) prior to commencement of test. The protecting
tubes, pressure connections and other test connections required for conducting
guarantee test shall conform to the relevant codes.
Tools and tackles, thermowells (both screwed and welded) instruments/devices

including flow devices, matching flanges, impulse piping & valves etc. and any
special equipment, required for the successful completion of the tests, shall be
provided by the Contractor free of cost.
The Performance test shall be carried out as per the agreed procedure. The detailed
PG test procedure shall be submitted and finalised within schedule identified in
Notification of Award.
All test instrumentation, Personal computer(s), necessary server and required

interface, software for on line computation of test results and report as required for
performance guarantee tests shall be supplied by the Bidder and shall be retained by
the Client.
b) The P&G test procedures shall be submitted for equipments/system &

subsystem under Contractor's scope for all Guarantees as mentioned below, as
per latest International codes / standard including correction curves, meeting the
specification requirements along with sample calculations & detailed activity plan of
preparation (including test instrumentation), conductance and evaluation of
Guarantees.

c) The Contractor shall submit for Client (EPIL) approval the detailed Performance Test
procedure containing the following:
i) Object of the test.
ii) Various guaranteed parameters & tests as per contract.
iii) Method of conductance of test and test code.
iv) Duration of test, frequency of readings & number of test runs.
v) Method of calculation.
vi) Correction calculations & curves.
vii) Instrument list consisting of range, accuracy, least count, and location of
instruments.
viii) Scheme showing measurement points.
ix) Sample calculation.
x) Acceptance criteria.
xi) Any other information required for conducting the test.
2.3. Test Reports
After the conductance of Performance test, the Contractor shall submit the test
evaluation report of Performance test results to Client (EPIL) & NTPC promptly but not later
than one month from the date of conductance of Performance test. Preliminary test
reports shall be submitted to the Client (EPIL) after completing each test run. Four (4) hard
copies and two (2) soft copies on CD-ROM of each test report of final conducted test
on each equipment/plant/system shall be submitted to Client (EPIL) & NTPC for approval.
2.4 Performance Guarantee Tests on the equipments/systems not covered in this Section shall be
carried out as per the procedure/test codes specified in respective detailed specifications.
2.5 Acceptance of Guarantee Test Results
a) For Category-I Guarantees
In case during performance guarantee test(s) it is found that the

equipment/system has failed to meet the guarantees, the Contractor shall carry
out all necessary modifications and/or replacements to make the
equipment/system comply with the guaranteed requirements at no extra cost to the

Client (EPIL) and re-conduct the performance guarantee test(s) with Client
(EPIL)’s consent. In case the specified performance guarantee(s) are still not met but
are achieved within the Acceptable Shortfall Limit as specified at Clause 3 of this
Section, Client (EPIL) will accept the equipment/system/ plant after
levying liquidated damages as per clause 3.00.00 of this Section. However, if,
the demonstrated performance guarantee(s) continue to be beyond the stipulated
Acceptable Shortfall Limit, even after the above modifications/replacements within
ninety (90) days or a reasonable period allowed by the Client (EPIL)/NTPC, after
the tests have been completed, the Client (EPIL) / NTPC will have the right to:
(i) Reject the equipment / system / plant and recover from the Contractor the
payments already made,
OR
(ii) Accept the equipment /system/ plant after levying Liquidated Damages.
The liquidated damages for shortfall in performance indicated in Clause 3 of this
Section shall be levied separately for each unit. The rates indicated in Clause 3 of this
Section are on per unit basis. The liquidated damages shall be pro-rated for the
fractional parts of the deficiencies.
b) For Category-II Guarantees:
In case during performance guarantee test(s) it is found that the equipment/ system
has failed to meet the guarantees, the Contractor shall carry out all necessary
modifications and/or replacements to make the equipment/system comply with the
guaranteed requirements at no extra cost to the Client (EPIL) and re-conduct the
performance guarantee test(s) with Client (EPIL)'s consent. In case the specified
performance guarantee(s) are still not met even after the above
modifications/replacements with in ninety (90) days or a reasonable period
allowed by the Client (EPIL) / NTPC, after the tests have been completed, the
Client (EPIL) / NTPC will have the right to:
Reject the equipment /system / plant and recover from the Contractor the payments
already made.
OR
Accept the equipment/system after assessing the deficiency in respect of the various ratings,
performance parameters and capabilities and recover from the contract price an amount
equivalent to the damages as determined by the Client (EPIL).

Such damages shall, however be limited to the cost of replacement of the

equipment(s)/system(s), replacement of which shall remove the deficiency so as to
achieve the guaranteed performance. These parameters/capacities shall be termed as
“Category-II” Guarantees.
3. AMOUNT OF LIQUIDATED DAMAGES (LD) APPLICABLE FOR GUARANTEES
The rate of liquidated damages and acceptable shortfall limits for different
guarantees shall be as under and such liquidated damages shall be deducted from the
Contract Price of the project.
Sl.No Guarantee Rate of Liquidated Acceptable Shortfall Limit

Damage (LD) with LD
1 Auxiliary Power INR 191,800/- (INR One (+) 1% of the guaranteed

Consumption For Hundred Ninety One auxiliary power
increase in the Thousand Eight hundred consumption.
auxiliary power only) for every KW
consumption in KW increase in Auxiliary
guaranteed as per the
power consumption from
requirements of clause
the guaranteed value.
4. 1 (i), of this Section.
(i) Each of the liquidated damages specified above shall be independent and these
liquidated damages shall be levied concurrently as applicable.
(ii) All these liquidated damages for short fall in performance shall be deducted from the
contract price as detailed in General Conditions of Contract (GCC)/ Special
Conditions of Contract (SCC)
(iii) Contractor’s aggregate liability to pay Liquidated Damages (LD) for failure to attain
the functional guarantee shall not exceed twenty five percent (25%) of the Contract
Price.
(iv) The LD values are applicable on per unit basis.
4. GUARANTEE PARAMETERS
4.1 Guarantees Under Category-I :
The Performance Guarantees which attract Liquidated Damages (LD) are as follows:

The following shall be guaranteed by the Bidder under guarantee point condition.
(i) Auxiliary Power Consumption
The Contractor shall guarantee auxiliary power consumption of the drives stipulated
in Clause 5 of this Sub-Section.
4.2 Guarantees Under Category-II
The parameters/capabilities shall be demonstrated for various systems/ equipments shall

include but not limited to the following:-
a) Passenger cum Goods Elevator for FGD absorber :
a) Over load tests, travel and hoist speed checks.
b) Availability of Elevator:
The Contractor shall guarantee and demonstrate the availability of Elevator. This
shall not be less than 98% and the same shall be computed as mentioned in Clause
6.0 this Section.
5. AUXILIARY POWER CONSUMPTION
i) The bidder shall include all continuously operating auxiliaries under this package
while guaranteeing the auxiliary power consumption. The auxiliaries to be considered
shall include but not be limited to the following:
a) Elevator
6. METHOD OF COMPUTING AVAILABILITY
6.1 The Contractor shall guarantee 98 % availability of Elevator so that the Client can realize
overall FGD plant availability of 98%. This shall be demonstrated for a continuous period of
120 days. An availability guarantee test shall be conducted to assure this level of availability
for a period of 240 days as per the procedure indicated below:
Availability 'A' in %:
A = Tc x 100%
Tk
Where, Tc – recorded time of FGD plant (along with the Bidder’s supplied equipments)
Booster operation, expressed in hours ;
Tk – recorded time of boiler operation, expressed in hours;

However, it is required that:
(i) In order to calculate the availability, operation hours will be counted except boiler
start-ups when the operation hours counting will start on the moment of shut down
of all oil burners.
(ii) FGD Plant will be regarded as a FGD in operation, when by-pass damper is closed
and total flow of flue gas from boiler goes via FGD, and SO2 content is as below in
cleaned flue gas for the range of specified coals & loads:
a) 200 mg/Nm3 (6% O2 dry) for units having capacity of 500 MW
If FGD is out of operation during the boiler operation time as a result of the Client’s
/NTPC’s decision, this time will not be counted as boiler operation time for
calculating the FGD availability,
(iii) Boiler operation hours will be counted based on the recorded boiler operation
hours and the recorded data will be made available to the Contractor by Client
(EPIL)/NTPC.
Mandatory spares for the Bidder’s supplied Equipments have been identified in the
Contract. Bidder/Contractor can use the mandatory spares supplied under the
contract during this period in agreement with the Client. However, if other
additional spares are required for demonstration of availability of demonstration
guarantee, Bidder to should clearly indicate along with their offer.
6.2 If the calculated availability after 120 days availability test is lower than the guaranteed
value, the Contractor will undertake actions as per Clause 2.5 (b) of this Section to achieve
the guaranteed availability.

MANDATORY SPARES
INDEX
MANDATORY SPARES
1. GENERAL .................................................................................................................................. 2
2. DESCRIPTION OF VARIOUS TYPE OF SPARES .............................................................. 2
3. LIST OF MANDATORY SPARES ........................................................................................... 6
Tender Doc No.: SRO/CON/ETS/079 VOLUME - II : SECTION – VI Page 1 of 7

MANDATORY SPARES
1. GENERAL
The Bidder shall include in his scope of supply all the necessary Mandatory spares, Start-up
and commissioning spares and recommended spares. These shall be indicated in the
relevant schedules of the Bid Forms & Price Schedules. The general requirements pertaining
to Mandatory spares, Start-up and commissioning spares and Recommended spares is given
in this Section.
2. DESCRIPTION OF VARIOUS TYPE OF SPARES
2.1. MANDATORY SPARES
a) The list of mandatory spares considered essential by the Client(EPIL)/NTPC is

indicated in the list enclosed to this Section.
b) The bidder shall indicate the prices for each and every item (except for items not
applicable to the bidders design) in the ‘Price Schedule of Mandatory Spares’ whether
or not he considers it necessary for the Client(EPIL)/NTPC to procure such spares.
c) If the bidder fails to comply with the above or fails to quote the price of any spare
item, the cost of such spares shall be deemed to be included in the contract price. The
bidder shall furnish total population of each item in the Bid Forms & Price Schedules.
Whenever the quantity is mentioned in “sets” the bidder has to give the item details
and prices of each item.
d) Whenever the quantity is indicated as a percentage, it shall mean percentage of total

population of that item in the station (project), unless specified otherwise, and the
fraction will be rounded off to the next higher whole number.
e) Wherever the requirement has been specified as a ‘set’ (marked by **) it will include
the total requirement of the item for a unit, module or the station as specified.
f) Where it is specified as ‘set’ (marked by*) it would mean the requirement for the single
equipment/system as the case may be. Also one set for the particular equipment. e.g.
‘set’ of bearings for a pump would include the total number of bearings in a pump.
Also the ‘set’ would include all components required to replace the item; for example,
a set of bearings shall include all hardware normally required while replacing the
bearings.
Tender Doc No.: SRO/CON/ETS/079 VOLUME - II : SECTION – VI Page 2 of 7

MANDATORY SPARES
g) The assembly/sub assembly which have different orientation (like left hand, right
hand, top or bottom), different direction of rotation or mirror image positioning or any
other regions which result in maintaining two different sets of spares to be used for
subject assembly/sub-assembly shall be considered as different type of assembly/sub-
assembly.
h) The Client(EPIL)/NTPC reserves the right to buy any or all the mandatory spare parts.
i) The prices of mandatory spares indicated by the Bidder in the Bid Proposal/ Bid forms
sheets shall be used for bid evaluation purposes.
j) All mandatory spares shall be delivered at site at least two months before scheduled
date of initial operation of the first unit. However, spares shall not be dispatched
before dispatch of corresponding main equipments.
k) Wherever quantity is specified both as a percentage and a value, the Bidder has to
supply the higher quantity until & unless specified otherwise.
2.2. RECOMMENDED SPARES
a) In addition to the spare parts mentioned above, the Contractor shall also provide a list
of recommended spares for 3 years of normal operation of the plant/equipment and
indicate the list and total prices in relevant schedule of the Bid Forms/Price
Schedules.
b) This list shall take into consideration the mandatory spares specified in this Section
and should be independent of the list of the mandatory spares. The Client (EPIL)/
NTPC reserves the right to buy any or all of the recommended spares.
c) The recommended spares shall be delivered at project site at least two months before
the scheduled date of initial operation of first unit. However, the spares shall not be
dispatched before the dispatch of the main equipment.
d) Prices of recommended spares will not be used for evaluation of the bids.
e) The price of these spares will remain valid up to 6 months after placement of
Notification of Award for the main equipment. However, the Contractor shall be
liable to provide necessary justification for the quoted prices for these spares as
desired by the Client(EPIL)/NTPC.
Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION – VI Page 3 of 7

MANDATORY SPARES
2.3. START-UP & COMMISSIONING SPARES
a) Start-up & commissioning spares are those spares which may be required during the
start-up and commissioning of the equipment/system. All spares used till the Plant is
handed over to the Client(EPIL)/NTPC shall come under this category.
b) The Contractor shall provide for an adequate stock of such start up and
commissioning spares to be brought by him to the site for the plant erection and
commissioning. They must be available at site before the equipments are energized.
The unused spares, if any, should be removed from site only after the issue of "Taking
Over certificate” by Client(EPIL)/NTPC. All start up spares which remain unused at
the time shall remain the property of the Contractor.
2.4. The Bidder shall include in his scope of supply all the necessary Mandatory spares, Start-up
and commissioning spares and indicate these in the relevant schedules of the Bid
forms/Price Schedules.
2.5. The general requirements pertaining to supply of these spares is given below.
a) The Contractor shall indicate the service expectancy period for the spare parts (both
mandatory and recommended) under normal operating conditions before replacement
is necessary.
b) All spares supplied under this contract shall be strictly inter-changeable with the
parts for which they are intended for replacements. The spares shall be treated and
packed for long storage under the climatic conditions prevailing at the site e.g. small
items shall be packed in sealed transparent plastic with desiccators packs as
necessary.
c) All the spares (both recommended and mandatory) shall be manufactured along
with the main equipment components as a continuous operation as per same
specification and quality plan.
d) The Contractor will provide Client (EPIL) with cross-sectional drawings, catalogues,
assembly drawings and other relevant documents so as to enable the Client to identify
and finalize order for recommended spares.

MANDATORY SPARES
e) Each spare part shall be clearly marked or labeled on the outside of the packing with
its description. When more than one spare part is packed in a single case, a general
description of the content shall be shown on the outside of such case and a detailed list
enclosed. All cases, containers and other packages must be suitably marked and
numbered for the purposes of identification.
f) All cases, containers or other packages are to be opened for such examination as may
be considered necessary by the Client (EPIL)/NTPC.
g) The Contractor will provide the Client (EPIL)/NTPC with all the addresses and
particulars of his sub-suppliers while placing the order on vendors for items/
components/ equipments covered under the Contract and will further ensure with his
vendors that the Client (EPIL)/NTPC, if so desires, will have the right to place order
for spares directly on them on mutually agreed terms based on offers of such vendors.
h) The Contractor shall warrant that all spares supplied will be new and in accordance
with the Contract Documents and will be free from defects in design, material and
workmanship.
i) In addition to the recommended spares listed by the Contractor, if the Client (EPIL)/
NTPC further identifies certain particular items of spares, the Contractor shall submit
the prices and delivery quotation for such spares within 30 days of receipt of such
request with a validity period of 6 months for consideration by the Client (EPIL)/
NTPC and placement of order for additional spares if the Client (EPIL)/NTPC so
desires.
j) Long term Availability:
i) The Contractor shall guarantee the long term availability of spares to the Client
(EPIL)/NTPC for the full life of the equipment covered under the Contract.
ii) The Contractor shall guarantee that before going out of production of spare
parts of the equipment covered under the Contract, he shall give the Client
(EPIL)/NTPC at least 2 years advance notice so that the latter may order his bulk
requirement of spares, if he so desires. The same provision will also be
applicable to Sub-contractors.
iii) Further, in case of discontinuance of manufacture of any spares by the
Contractor and/or his Sub- Contractors, Contractor will provide the Client
(EPIL)/NTPC, two years in advance, with full manufacturing drawings,

MANDATORY SPARES
material specifications and technical information including information on

alternative equivalent makes required by the Client (EPIL)/NTPC for the
purpose of manufacture/procurement of such items.
3. LIST OF MANDATORY SPARES
S.No. Description Quantity
1. Friction block 2 Nos.

20% of total population or 3 Nos. of
2. Guide roller of each type
type whichever is higher
3. Contactors of each type 2 nos
4. Control Transformer 1 no. of each type
5. Time device 2 nos. of each type
6. Rectifiers 4 nos. of each type
7. Over-current relay 2 nos. of each type
8. Auxiliary relay 3 nos. of each type
9. Resistor 3 nos. of each type
10. Fuses of each rating 20% of the total population
11. Limit switches of each type 3 nos.
12. Push button 3 nos. of each type
13. Contact device (if applicable) 3 nos. of each type
14. Brake motor 2 nos. of each type
15. Transmitters 2 nos. of each type
16. Switches of each type 3 nos.
17. Receiver 2 nos. of each type
18. Bearings of each type & size 2 nos.
19. Roller of each type 3 nos.
20. Worm gear spares
a) O' rings 3 sets *
b) Sealing ring of each type 3 sets *
21. Spares for brake
a) Fan 2 nos. of each type

MANDATORY SPARES
S.No. Description Quantity
b) Magnetic coil 3 nos. of each type
c) Brake disc 2 sets *
d) Brake pad 2 sets *
22. Bushing (for door front) 2 sets *
23. Pinion 2 nos. of each type
24. Elevator Motor with VVVF drive 1 no of each type
* Unless otherwise stated, a set shall mean complete replacement for one equipment.

RSTPP ABSORBER PACKAGE GENERAL TECHNICAL
STAGE - III (FGD SYSTEM ) REQUIREMENTS (GTR)
SECTION – VII -- INDEX

GENERAL TECHNICAL REQUIREMENTS
1.00.00 INTRODUCTION ............................................................................................................ 3
2.00.00 BRAND NAME ................................................................................................................ 3
3.00.00 BASE OFFER & ALTERNATE PROPOSALS ............................................................... 3
4.00.00 COMPLETENESS OF FACILITIES ................................................................................ 3
5.00.00 RULES, REGULATIONS, CODES & STANDARDS ................................................... 4
6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE ............................................................. 6
7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY
CONSIDERATIONS........................................................................................................ 7
8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY
CONTRACTOR ............................................................................................................... 8
9.00.00 TECHNICAL CO-ORDINATION MEETING............................................................ 25
10.00.00 DESIGN IMPROVEMENTS........................................................................................... 26
11.00.00 EQUIPMENT BASES ..................................................................................................... 26
12.00.00 PROTECTIVE GUARDS ............................................................................................... 26
13.00.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS............................................... 26
14.00.00 LUBRICATION .............................................................................................................. 27
15.00.00 TERIAL OF CONSTRUCTION .................................................................................... 27
16.00.00 RATING PLATES, NAME PLATES & LABELS ........................................................ 27
17.00.00 TOOLS AND TACKLES................................................................................................ 28
18.00.00 WELDING ........................................................................................................................ 29
19.00.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES ............ 29
20.00.00 PROTECTION AND PRESERVATIVE SHOP COATING ....................................... 29
21.00.00 QUALITY ASSURANCE PROGRAMME................................................................... 31
22.00.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE ....................................... 32
23.00.00 QUALITY ASSURANCE DOCUMENTS ................................................................... 37
24.00.00 PROJECT MANAGER’S SUPERVISION ..................................................................... 39
25.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES ............................. 40
26.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES........................... 43
27.00.00 TAKING OVER .............................................................................................................. 46
28.00.00 TRAINING OF NTPC'S PERSONNEL ....................................................................... 47
29.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION ....................... 48
Tender Doc No.:SRO/CON/ETS/079 VOLUME-II SECTION-VII Page 1 of 86

30.00.00 NOISE LEVEL................................................................................................................. 48

31.00.00 PACKAGING AND TRANSPORTATION ................................................................ 48
32.00.00 ELECTRICAL EQUIPMENTS/ENCLOSURES ......................................................... 49
33.00.00 INSTRUMENTATION AND CONTROL ................................................................... 49
34.00.00 ELECTRICAL NOISE CONTROL ................................................................................ 50
35.00.00 SURGE PROTECTION FOR SOLID STATE EQUIPMENT ..................................... 50
36.00.00 INSTRUMENT AIR SYSTEM ....................................................................................... 50
37.00.00 TAPPING POINTS FOR MEASUREMENTS ............................................................. 50
38.00.00 SYSTEM DOCUMENTATION..................................................................................... 51
39.00.00 MAINTENANCE MANUALS OF ELECTRONIC MODULES ................................. 51
ANNEXURE- I .................................................................................................................................... 79
ANNEXURE- II .................................................................................................................................. 80
ANNEXURE- III ................................................................................................................................. 81
ANNEXURE- IV ................................................................................................................................. 82
ANNEXURE- V .................................................................................................................................. 83
ANNEXURE- VI ................................................................................................................................. 84
ANNEXURE- VII................................................................................................................................ 86

1.00.00 INTRODUCTION
This part covers technical requirements which will form an integral part of the
Contract. The following provisions shall supplement all the detailed
technical specifications and requirements brought out in the Technical
Specification and the Technical Data Sheets.
2.00.00 BRAND NAME
Whenever a material or article is specified or described by the name of a particular

brand, manufacturer or vendor, the specific item mentioned shall be understood to be
indicative of the function and quality desired, and not restrictive; other
manufacturer's products may be considered provided sufficient information
is furnished to enable the Client (EPIL) / NTPC to determine that the products
proposed are equivalent to those named.
3.00.00 BASE OFFER & ALTERNATE PROPOSALS
The Bidder's proposal shall be based upon the use of equipment and material
complying fully with the requirements specified herein. It is recognised that the
Contractor may have standardized on the use of certain components, materials,
processes or procedures different than those specified herein. Alternate proposals
offering similar equipment based on the manufacturer's standard practice will also be
considered, provided the base offer is in line with technical specifications and such
proposals meet the specified design standards and performance requirement and
are acceptable to the Client (EPIL) / NTPC. Sufficient amount of information for
justifying such proposals shall be furnished to Client (EPIL) / NTPC along with the
bid to enable the Client (EPIL) / NTPC to determine the acceptability of these
proposals.
4.00.00 COMPLETENESS OF FACILITIES

4.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant shall be engineered and designed in
accordance with the specification requirement. All engineering and associated
services are required to ensure a completely engineered plant shall be provided.
4.02.00 All equipments furnished by the Contractor shall be complete in every respect, with all
mountings, fittings, fixtures and standard accessories normally provided with such

equipment and/or those needed for erection, completion and safe operation of
the equipment and for the safety of the operating personnel, as required by applicable
codes, though they may not have been specifically detailed in the respective
specifications, unless included in the list of exclusions.
All same standard components/ parts of same equipment provided, shall

be interchangeable with one another.
For the C&I systems, the Contractor shall be required to provide regular information
about future upgrades and migration paths to the Client (EPIL) / NTPC.
5.00.00 RULES, REGULATIONS, CODES & STANDARDS

5.01.00 In addition to the codes and standards specifically mentioned in the relevant
technical specifications for the equipment / plant / system, all equipment parts,
systems and works covered under this specification shall comply with all
currently applicable statutory regulations and safety codes of the Republic of
India, NTPC rules/codes of practices as well as of the locality where they will
be installed, including the following:
a) Indian Electricity Act
b) Indian Electricity Rules
c) Indian Explosives Act
d) Indian Factories Act and State Factories Act
e) Indian Boiler Regulations (IBR)
f) Regulations of the Central Pollution Control Board, India
g) Regulations of the Ministry of Environment & Forest (MoEF), Government of

India
h) Pollution Control Regulations of Department of Environment, Government of

India
i) State Pollution Control Board.
(j.) Rules for Electrical installation by Tariff Advisory Committee (TAC).
(k.) Building and other construction workers (Regulation of Employment and

Conditions of services) Act, 1996

(l.) Building and other construction workers (Regulation of Employment and

Conditions of services) Central Rules, 1998 (m.) Explosive Rules, 1983
(n.) Petroleum Act, 1984
(o.) Petroleum Rules, 1976,
(p.) Gas Cylinder Rules, 1981
(q.) Static and Mobile Pressure Vessels (Unified) Rules, 1981
(r.) Workmen's Compensation Act, 1923
(s.) Workmen's Compensation Rules, 1924
(t.) NTPC Safety Rules for Construction and Erection
(u.) NTPC Safety Policy
(v.) Any other statutory codes / standards / regulations, as may be applicable.
5.02.00 Unless covered otherwise in the specifications, the latest editions (as applicable as on
date of bid opening), of the codes and standards given below shall also apply:
a) Bureau of Indian standards (BIS)
b) Japanese Industrial Standards (JIS)
c) American National Standards Institute (ANSI)
d) American Society of Testing and Materials (ASTM)
e) American Society of Mechanical Engineers (ASME)
f) American Petroleum Institute (API)
g) Standards of the Hydraulic Institute, U.S.A.
h) International Organisation for Standardisation (ISO)
i) Tubular Exchanger Manufacturer's Association (TEMA)
j) American Welding Society (AWS)
k) National Electrical Manufacturers Association (NEMA)
l) National Fire Protection Association (NFPA)
m) International Electro-Technical Commission (IEC)/European Norm (EN)
n) Expansion Joint Manufacturers Association (EJMA)

o) Heat Exchange Institute (HEI)
p) IEEE standard
q) JEC standard
5.03.00 Other International/ National standards such as DIN, JIS, VDI, EN, BS, GOST etc. shall
also be accepted for only material codes and manufacturing standards, subject to the
Client (EPIL) / NTPC's approval, for which the Bidder shall furnish, adequate
information to justify that these standards are equivalent or superior to the standards
mentioned above. In all such cases the Bidder shall furnish specifically the
variations and deviations from the standards mentioned elsewhere in the specification
together with the complete word to word translation of the standard that is normally
not published in English.
5.04.00 Not used.
5.05.00 In the event of any conflict between the codes and standards referred to in the
above clauses and the requirement of this specification, the requirement of
Technical Specification shall govern.
5.06.00 Two (2) English language copies of all national and international codes and/or
standards used in the design of the plant, equipment, civil, structural and
architectural works shall be provided by the Contractor to the Client (EPIL) / NTPC
within two calendar months from the date of the Notification of Award.
5.07.00 In case of any change in codes, standards & regulations between the date of bid
opening and the date when vendors proceed with fabrication, the Client (EPIL) /
NTPC shall have the option to incorporate the changed requirements or to retain
the original standard. It shall be the responsibility of the Contractor to bring to the
notice of the Client (EPIL) / NTPC such changes and advise Client (EPIL) / NTPC of
the resulting effect.
5.08.00 A detailed list of standards apart from those mentioned in the respective
detailed specifications in other parts of Section-VI to which all
equipment/systems/civil works should conform as indicated in this Part C and
elsewhere in the specification.
6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE

6.01.00 The functional guarantees of the equipment under the scope of the Contract is given in
Section-V of Technical Specifications. These guarantees shall supplement the

general functional guarantee provisions covered under Defect liabilities Section-IV,

General Conditions of Contract.
6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during the
performance and guarantee tests shall be assessed and recovered from the
Contractor as specified elsewhere in this specification.
7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY

CONSIDERATIONS
7.01.00 DESIGN OF FACILITIES
All the design procedures, systems and components proposed shall have already
been adequately developed and shall have demonstrated good reliability under
similar conditions elsewhere.
The Contractor shall be responsible for the selection and design of appropriate
equipments to provide the best co-ordinated performance of the entire system. The
basic requirements are detailed out in various clauses of the Technical
Specifications. The design of various components, assemblies and subassemblies
shall be done so that it facilitates easy field assembly and dismantling. All the
rotating components shall be so selected that the natural frequency of the complete
unit is not critical or close to the operating range of the unit.
7.02.00 MAINTENANCE AND AVILABILITY CONSIDERATIONS
Equipment/works offered shall be designed for high availability, low

maintenance and ease of maintenance. The Bidder shall specifically state the design
features incorporated to achieve high degree of reliability/ availability and
ease of maintenance. The Bidder shall also furnish details of availability records
in the reference plants stated in his experience list.
Bidder shall state in his offer the various maintenance intervals, spare parts and
man-hour requirement during such operation. The intervals for each type
of maintenance namely inspection of the furnace, inspection of the entire hot gas path
and the minor and major overhauls shall be specified in terms of fired hours , clearly
defining the spare parts and man-hour requirement for each stage.
Lifting devices i.e. hoists and chain pulley jacks ,etc. shall be provided by the
contractor for handling of any equipment or any of its part having weight in excess of
500 Kgs during erection and maintenance activities.

Lifting devices like lifting tackles, slings, etc. to be connected to hook of the hoist /
crane shall be provided by the contractor for lifting the equipment and accessories
covered under the specification.
8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY

CONTRACTOR
8.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant and equipment shall be fully
integrated, engineered and designed to perform in accordance with the technical
specification. All engineering and technical services required to ensure a completely
engineered plant shall be provided in respect of mechanical, electrical, control &
instrumentation, civil & structural works as per the scope.
Each main and auxiliary equipment/item of the plant including instruments shall be
assigned a unique tag number. The assignment of tag numbers shall be in
accordance with KKS system. In all drawings/documents/data heet etc. KKS tag
number of the equipment/item/instrument etc. shall be indicated.
The Contractor shall furnish engineering data /drawings in accordance with the
schedule of information as specified in Technical Data Sheets and Technical
Specification.
A comprehensive engineering and quality coordination procedure shall be

finalized with the successful bidder covering salient features as described in this
section of specifications.
8.02.00 The number of copies/prints/CD-ROMs/manuals to be furnished for various types of

document is given in Annexure-VI to this Part-C, Section-VI of the Technical
Specification.
8.03.00 The documentation that shall be provided by the Contractor is indicated in the
various sections of specification. This documentation shall include but not be limited
to the following:
8.03.01 A) BASIC ENGINEERING DOCUMENTATION
Prior to commencement of the detailed engineering work, the Contractor

shall furnish a Plant Definition Manual within 12 weeks from the date of the
Notification of Award. This manual shall contain the following as a minimum:

i) System description of all the mechanical, electrical, control &

instrumentation & civil systems.
ii) Technology scan for each system / sub-system & equipment.
ii) Selection of appropriate technology / schemes for various systems/

subsystems including techno-economic studies between various
options.
iv) Optimisation studies including thermal cycle optimisation.
v) Sizing criteria of all the systems, sub-systems/ equipments/

structures/ equipment foundations along with all calculations justifying and
identifying the sizing and the design margins.
vi) Schemes and Process & Instrumentation diagrams for the various
systems/ sub-systems with functional write-ups.
vii) Operation Philosophy and the control philosophy of the

equipments/system covered under the scope.
ix) General Layout plan of the FGD System incorporating all facilities in
Bidder's as well as those in the Client (EPIL) / NTPC's scope.
x) Basic layouts and cross sections of the main plant building (various
floor elevations), boiler, fuel oil area and other areas included in the scope of
the bidder.
xi) Documentation in respect of Quality Assurance System as listed out

elsewhere in this specification.
The successful bidder shall furnish within three (3) weeks from the date of
Notification of Award, a list of contents of the Plant Definition Manual (PDMs)
including techno-economic studies, which shall then be mutually discussed &
finalised with the Client (EPIL) / NTPC.
8.03.01 B) DETAILED ENGINEERING DOCUMENTS
i) General layout plan of the FGD System.
ii) Layouts, general arrangements, elevations and cross-sections

drawings for all the equipment and facilities of the plant.

iii) Flow diagram, process and instrumentation diagrams along with write
up and system description.
iv) Performance curves for Absorber
v) Piping isometric, composite layout and fabrication drawings.
vi) Piping engineering diagrams, pipe and fittings schedules, valve
schedules, hanger and support schedules, insulation schedules.
vii) Technical data sheets for all bought out and manufactured items.
Contractor shall use the Client (EPIL) / NTPC’s specifications as a base
for placement of orders on their sub vendors.
viii) Detailed design calculations for components, system, piping etc.,
wherever applicable including sizing calculations for all auxiliaries like
mills, fans etc. as per criteria specified elsewhere in specification.
ix) Absorber sizing calculations. Absorber performance data.
x) Mass Balance Diagram
xi) Characteristic Curves/ Performance Correction Curves.
xii) Comprehensive list of all terminal points which interface with Client
(EPIL) / NTPC's facilities, giving details of location, terminal pressure,
temperature, fluid handled, end connection details, forces, moments etc.
xiii) Power supply single line diagram, block logics, control schematics,
electrical schematics, etc.
xiv) Protection systems diagrams and relay settings.
xv) Cables schedules and interconnection diagrams.
xvi) Cable routing plan.
xvii) Instrument schedule, measuring point list, I/O list, Interconnection
& wiring diagram, functional write-ups, and installation drawings for
field mounted instruments, logic diagrams, control schematics, wiring
and tubing diagrams of panels and enclosures etc. Drawings for open
loop and close loop controls (both hardware and software). Motor list
and valve schedule including type of actuator etc.
xviii) Alarm and annunciation/ Sequence of Event (SOE) list and alarms & trip
set points.
xix) Sequence and protection interlock schemes.
xx) Type test reports, insulation co-ordination study report

xxi) Control system configuration diagrams and card circuit diagrams and
maintenance details.
xxii) Detailed Control system manuals.
xxiii) Detailed flow chart for digital control system.
xxiv) Mimic diagram layout, Assignment for other application
engineering .drawings and documents.
xxv) Civil and Structural works drawings and documents for all structures,
facilities, architectural works, foundations underground and
over ground works and super-structural works as included in the
scope of the bidder civil calculation sheets including structural
analysis and design along with output results.
xxvi) Underground facilities, leveling, sanitary, land-scaping drawings
xxvii) Geotechnical investigation and site survey reports (if and as
applicable).
xxviii) Model study reports wherever applicable
xxix) Functional & guarantee test procedures and test reports.
xxx) Documentation in respect of Quality Assurance System and
Documentation in respect of Commissioning, as listed out elsewhere in
this specification.
xxxi) Maintenance schedule for Absorber & auxiliaries clearly indicating
interval, duration if shutdown required, man-hours required and tools &
tackles required for maintenance.
The Contractor's while submitting the above documents/ drawings for

approval/ reference as the case may be, shall mark on each copy of submission
the reference letter along with the date vide which the submissions are made.
8.03.02 INSTRUCTION MANUALS
The Contractor shall make first submission of instruction manual for all
the equipments covered under the Contract as per agreed engineering information
schedule. The Instruction manuals shall contain full details required for erection,
commissioning, operation and maintenance of each equipment. The manual shall be
specifically compiled for this project. After finalisation and approval of the Client
(EPIL) / NTPC the Instruction Manuals shall be submitted as indicated in
Annexure-IV. The Contract shall not be considered to be completed for purposes of

taking over until the final Instructions manuals have been supplied to the Client
(EPIL) / NTPC. The Instruction Manuals shall comprise of the following.
A ERECTION MANUALS
The erection manuals shall be submitted atleast three (3) months prior to the
commencement of erection activities of particular equipment/system. The
erection manual should contain the following as a minimum.
a) Erection strategy.
b) Sequence of erection
c) Erection instructions
d) Critical checks and permissible deviation/tolerances
e) List of tool, tackles, heavy equipments like cranes, dozers, etc.
f) Bill of Materials
g) Procedure for erection and general Safety procedures to followed during

erection/installation.
h) Procedure for initial checking after erection.
i) Procedure for testing and acceptance norms.
j) Procedure / Check list for pre-commissioning activities.
k) Procedure / Check list for commissioning of the system.
l) Safety precautions to be followed in electrical supply distribution during

erection.
B) OPERATION & MAINTENANCE MANUALS
a) The manual shall be a two rim PVC bound stiff sided binder able to
withstand constant usage or where a thicker type is required it shall have
locking steel pins, the size of the manual shall not be larger than
international size A3. The cover shall be printed with the Project
Name, Services covered and Volume / Book number Each section of the
manual shall be divided by a stiff divider of the same size as the holder.
The dividers shall clearly state the section number and title. All written

instructions within the manual not provided by the manufacturers

shall be typewritten with a margin on the left hand side.
b) The arrangement and contents of O & M manuals shall be as follows:
1) Chapter 1 - Plant Description:
To contain the following sections specific to the equipment/system

supplied : -
a) Description of operating principle of equipment / system

with schematic drawing / layouts.
b) Functional description of associated accessories / controls.
Control interlock protection write up.
c) Integrated operation of the equipment alongwith the intended
system. (This is to be given by the supplier of the Main equipment
by taking into account the operating instruction given by
the associated suppliers).
d) Exploded view of the main equipment, associated accessories
and auxiliaries with description. Schematic drawing of the
equipment along with its accessories and auxiliaries.
e) Design data against which the plant performance will be
compared.
f) Master list of equipments, Technical specification of the
equipment/system and approved data sheets.
g) Identification system adopted for the various components, (it will
be of a simple process linked tagging system).
Master list of drawings (as built drawing - Drawings to be enclosed in a
separate volume).
2) Chapter 2.0 - Plant Operation:
To contain the following sections specific to the equipment supplied :-
a) Protection logics provided for the equipment along with

brief philosophy behind the logic, Drawings etc.
b) Limiting values of all protection settings.
c) Various settings of annunciation/interlocks provided.

d) Startup and shut down procedure for equipment along

with the associated systems in step mode.
e) Do's and Don'ts related to operation of the equipment.
f) Safety precautions to be take during normal operation.
Emergency instruction on total power failure
condition/lubrication failure/any other conditions
g) Parameters to be monitored with normal value and limiting
values.
h) Equipment isolating procedures.
i) Trouble shooting with causes and remedial measures.
j) Routine testing procedure to ascertain healthiness of the safety
devices along with schedule of testing.
k) Routine Operational Checks, Recommended Logs and Records
l) Change over schedule if more than one auxiliary for the
same purpose is given.
m) Preservation procedure on long shut down.
n) System/plant commissioning procedure.
3) Chapter 3.0 - Plant Maintenance:
To contain the following sections specific to the equipment supplied:-
a) Exploded view of each of the equipments. Drawings along with

bill of materials including name, code no. & population
b) Exploded view of the spare parts and critical
components with dimensional drawings (In case of Electronic
cards, the circuit diagram to be given) and spare parts catalogue
for each equipment.
c) List of Special T/P required for Overhauling /Trouble
shooting including special testing equipment required for
calibration etc.
d) Stepwise dismantling and assembly procedure clearly specifying
the tools to be used, checks to be made, records to be maintained,
Clearance to be maintained etc.
e) Preventive Maintenance schedules linked with running hours/
calendar period along with checks to be carried out.

f) Overhauling schedules linked with running hours/calendar

period along with checks to be done.
g) Long term maintenance schedules
h) Consumables list along with the estimated quantity required
during normal running and during maintenance like Preventive
Maintenance and Overhauling.
i) List of lubricants with their Indian equivalent, Lubrication
Schedule including charts showing lubrication checking,
testing and replacement procedure to be carried daily, weekly,
monthly & at longer intervals to ensure trouble free operation
and quantity required for complete replacement.
j) Tolerance for fitment of various components.
k) Details of sub vendors with their part no. in case of bought out
items.
l) List of spare parts with their Part No, total population, life
expediency & their interchangeability with already supplied
spares to NTPC.
m) List of mandatory and recommended spare list along with
manufacturing drawings, material specification & quality plan for
fast moving consumable spares.
n) Lead time required for ordering of spares from the equipment
supplier, instructions for storage and preservation of spares.
o) General information on the equipment such as modification
carried out in the equipment from its inception, equipment
population in the country / foreign country and list of utilities
where similar equipments have been supplied.
C) After finalization and approval of the Client (EPIL) / NTPC, the O & M Manuals
shall be submitted as indicated in Annexure-VI. The Contract shall not be
considered to be completed for purposes of taking over until the final
Instructions manuals (both erection and O & M manuals have been supplied to
the Client (EPIL) / NTPC.
If after the commissioning and initial operation of the plant, the

instruction manuals (Erection and /or O &M manuals) require

modifications/additions/ changes, the same shall be incorporated and the

updated final instruction manuals shall be submitted by the Contractor to
the Client (EPIL) / NTPC for records and number of copies shall be as
mentioned in Annexure-VI.
8.03.03 PLANT HANDBOOK AND PROJECT COMPLETION REPORT
8.03.03.01 PLANT HANDBOOK
The Contractor shall submit to the Client (EPIL) / NTPC a preliminary plant
hand book preferably in A-4 size sheets which shall contain the design and
performance data of various plants, equipments and systems covering the complete
project including;
i) Design and performance data.
ii) Process & Instrumentation diagrams.
iii) Single line diagrams.
iv) Sequence & Protection Interlock Schemes.
v) Alarm and trip values.
vi) Performance Curves.
vii) General layout plan and layout of main plant building and auxiliary buildings
viii) Important Do's & Don't's
The plant handbook shall be submitted within twelve (12) months from the date of
award of contract. After the incorporation of Client (EPIL) / NTPC's comments,
the final plant handbook complete in all respects shall be submitted three (3) months
before start- up and commissioning activities.
8.03.03.02 PROJECT COMPLETION REPORT
The Contractor shall submit a Project Completion Report at the time of handing over
the plant.
8.03.04 DRAWINGS
a) i) All the FGD plant layouts shall be made in computerised 3D

modelling system. The Client (EPIL) / NTPC reserves the right to review the
3D model at different stages during the progress of engineering. The

layout drawings submitted for Client (EPIL) / NTPC's review shall be

fully dimensioned and extracted from 3D model after interference check.
ii) All documents submitted by the Contractor for Client (EPIL) / NTPC's
review shall be in electronic form (soft copies) along with the desired number
of hard copies as per Annexure-VI of Part-C. The soft copies shall be
uploaded by the vendors in C-folders, a Web-based system of NTPC ERP, for
which a username and password will be allotted to the new vendor by NTPC.
Similarly, the vendor can download the drawings/documents,

approved/ commented by NTPC, through above site.
The soft copies of identified drawings/documents shall be in pdf format,

whereas the attachments/reply to the submitted document(s) can be in .doc,
.xls, .pdf, .dwg or .std formats.
iii) Final copies of the approved drawings along with requisite number of hard
copies shall be submitted as per Annexure-VI of this Section.
iv) Contractor shall prepare the model of all the facilities located in FLUE GAS
DESULPHURISATION (FGD) SYSTEM PACKAGE (including all facilities),
and any other facility in an integrated & intelligent 3D software solution
using rule-based, data centric 3D Design software with equipment
drawings, data sheets, intelligent P&ID correlated with intelligent 3D
Model, BOQ, schematics and logic diagrams etc. attached to the
respective equipment / systems in the aforesaid 3D model. Contractor
shall make a presentation on 3D model every 3 months from LOA to
enable NTPC to review the progress of engineering. After the
completion of engineering the corresponding complete 3D review model shall
be handed over to the Client (EPIL) / NTPC for its reference.
Contractor shall provide 3D model (which shall include visual

interference check, walk-through animation, video simulation for
major equipment placement and removal, visual effect, photo realism etc),
which is extracted from intelligent 3D model, for Client (EPIL) / NTPC’s
review as & when desired by Client (EPIL) / NTPC. However, all piping
layouts, equipment layouts, floor plans, ducting layout (Air/flue gas,
A/C, Ventilation etc.), General Arrangement drawings of major

buildings, structural arrangement drawings and RCC layout drawings

shall necessarily be extracted from the aforesaid 3D model and submitted for
Client (EPIL) / NTPC’s review along with the 3D review model to
enable NTPC to review and approve these drawings.
b) All documents/text information shall be in latest version of MS Office / MS Excel

/PDF FORMAT as applicable.
c) All drawings submitted by the Contractor including those submitted at the

time of bid shall be in sufficient detail indicating the type, size, arrangement,
weight of each component for packing and shipment, the external
connection, fixing arrangement required, the dimensions required for
installation and interconnections with other equipments and materials,
clearance and spaces required between various portions of equipment and
any other information specifically requested in the drawing schedules.
d) Each drawing submitted by the Contractor (including those of sub-vendors)

shall bear a title block at the right hand bottom corner with clear mention of the
name of the Client (EPIL) / NTPC, the system designation, the specifications
title, the specification number, the name of the Project, drawing number and
revisions. If standard catalogue pages are submitted the applicable items
shall be indicated therein. All titles, noting, markings and writings on the
drawing shall be in English. All the dimensions should be in metric units.
e) The drawings submitted by the Contractor (or their sub-vendors) shall bear
Client (EPIL) / NTPC's drawing number in addition to contractor's (their sub-
vendor's) own drawing number. Client (EPIL) / NTPC's drawing numbering
system shall be made available to the successful bidder so as to enable him to
assign Client (EPIL) / NTPC's drawing numbers to the drawings to be submitted
by him during the course of execution of the Contract.
The Contractor shall also furnish a "Master Drawing List" which shall be a
comprehensive list of all drawings/ documents/ calculations envisaged to be
furnished by him during the detailed engineering to the Client (EPIL) / NTPC.
Such list should clearly indicate the purpose of submission of these drawings
i.e. "FOR APPROVAL" or "FOR INFORMATION ONLY".

Similarly, all the drawings/ documents submitted by the Contractor during

detailed engineering stage shall be marked "FOR APPROVAL" or "FOR
INFORMATION" prior to submission. Further, space shall be identified on each
drawing for Approval stamp and electronic signature.
f) The furnishing of detailed engineering data and drawings by the Contractor shall
be in accordance with the time schedule for the project. The review of these
documents/ data/ drawings by the Client (EPIL) / NTPC will cover only
general conformance of the data/ drawings/ documents to the specifications
and contract, interfaces with the equipments provided by others and external
connections & dimensions which might affect plant layout. The review by the
Client (EPIL) / NTPC should not be construed to be a thorough review of all
dimensions, quantities and details of the equipments, materials, any devices
or items indicated or the accuracy of the information submitted. The review
and/ or approval by the Client (EPIL) / NTPC/ Project Manager shall not relieve
the Contractor of any of his responsibilities and liabilities under this contract.
g) After the approval of the drawings, further work by the Contractor shall be in
strict accordance with these approved drawings and no deviation shall be
permitted without the written approval of the Client (EPIL) / NTPC.
h) All manufacturing, fabrication and execution of work in connection with the

equipment / system, prior to the approval of the drawings, shall be at the
Contractor's risk. The Contractor is expected not to make any changes in the
design of the equipment /system, once they are approved by the Client (EPIL) /
NTPC. However, if some changes are necessitated in the design of the
equipment/system at a later date, the Contractor may do so, but such
changes shall promptly be brought to the notice of the Client (EPIL) / NTPC
indicating the reasons for the change and get the revised drawing approved
again in strict conformance to the provisions of the Technical Specification.
i) Drawings shall include all installations and detailed piping layout drawings.
Layout drawings for all piping of 65 mm and larger diameter shall be
submitted for review/ approval of Client (EPIL) / NTPC prior to erection. Small
diameter pipes shall however be routed as per site conditions in consultation with
site authority/ representative of Client (EPIL) / NTPC based on requirements of
such piping indicated in approved/finalized Flow Scheme/ Process &

Instrumentation Diagrams and/or the requirements cropping up for draining

& venting of larger diameter piping or otherwise after their erection as per actual
physical condition for the entire scope of work of this package.
Assessing & anticipating the requirement and supply of all piping and equipment
shall be done by the contractor well in advance so as not to hinder the
progress of piping & equipment erection, subsequent system charging and
its effective draining & venting arrangement as per site suitability.
j) As Built Drawings
After final acceptance of individual equipment / system by the Client (EPIL) /

NTPC, the Contractor will update all original drawings and documents for the
equipment / system to “As built” conditions and submit no. of copies as per
Annexure VI.
k) Drawings must be checked by the Contractor in terms of its completeness, data

adequacy and relevance with respect to Engineering schedule prior to submission
to the Client (EPIL) / NTPC. In case drawings are found to be submitted
without proper checking by the Contractor, the same shall not be reviewed
and returned to the Contractor for re-submission. The contractor shall make a
visit to site to see the existing facilities and understand the layout
completely and collect all necessary data/ drawings at site which are needed as an
input to the engineering. The contractor shall do the complete engineering
including interfacing and integration of all his equipment, systems &
facilities within his scope of work as well as interface engineering & integration of
systems, facilities, equipment & works under Client (EPIL) / NTPC's scope and
submit all necessary drawings/ documents for the same.
l) The Contractor shall submit adequate prints of drawing /data/ document for
Client (EPIL) / NTPC's review and approval. The Client (EPIL) / NTPC shall
review the drawings and return soft copy to the Contractor authorizing
either to proceed with manufacture or fabrication, or marked to show
changes desired. When changes are required, drawings shall be re-
submitted promptly, with revisions clearly marked, for final review. Any delays
arising out of the failure of the Contractor to submit/rectify and resubmit in time
shall not be accepted as a reason for delay in the contract schedule.

m) All engineering data submitted by the Contractor after final process including
review and approval by the Project Manager/ Client (EPIL) / NTPC shall form
part of the contract documents and the entire works covered under these
specification shall be performed in strict conformity with technical
specifications unless otherwise expressly requested by the Project Manager in
writing.
n) The Contractor shall submit drawings in line with the suggestive MDL which will
be finalised at the time of award finalised covered in Part-B, Section-VI of
Technical Specification and which shall be duly integrated with approved
PERT network.
8.04.00 ENGINEERING INFORMATION SUBMISSION SCHEDULE
Prior to the award of Contract, a Detailed Engineering Information Submission

Scheduler/Master Drawing List duly integrated with approved PERT network shall be
tied up with the Client (EPIL) / NTPC. For this, the bidder shall furnish a detailed
list of engineering information along with the proposed submission schedule. This list
would be a comprehensive one including all engineering data / drawings /
information for all bought out items and manufactured items. The information shall be
categorized into the following parts.
i) Information that shall be submitted for the approval to the Client (EPIL) /
NTPC before proceeding further, and
ii) Information that would be submitted for Client (EPIL) / NTPC's information
only.
The Master Drawing List (MDL) shall be updated periodically and submitted to the
Client (EPIL) / NTPC, highlighting the changes made in MDL.
The schedule should allow adequate time for proper review and incorporation
of changes/ modifications, if any, to meet the contract without affecting the equipment
delivery schedule and overall project schedule. The early submission of
drawings and data is as important as the manufacture and delivery of
equipment and hardware and this shall be duly considered while
determining the overall performance and progress.
8.05.00 ENGINEERING PROGRESS AND EXCEPTION REPORT

8.05.01 The Contractor shall submit every month an Engineering progress and Exception
Report giving the status of each engineering information including
a) A list of drawings/engineering information which remains unapproved for

more than four (4) weeks after the date of first submission.
b) Drawings which were not submitted as per agreed schedule.
8.05.02 The draft format for this report shall be furnished to the Client (EPIL) / NTPC
within four (4) weeks of the award of the contract, which shall then be discussed and
finalised with the Client (EPIL) / NTPC.
8.06.00 Engineering Co-ordination Procedure
8.06.01 The following principal coordinators will be identified by respective organizations at

time of award of contract:
NTPC /EPI Engineering Coordinator (EPI/ NTPC EC):
Name :
Designation :
Address :
a) Postal :
b) Telegraphic / e-Mail :
c) FAX : TELEPHONE :
Contractor’s/ Vendor’s Engineering Coordinator (VENDOR EC):
Name :
Designation :
Address :
a) Postal :
b) Telegraphic / e-Mail :
c) FAX : TELEPHONE :
8.06.02 All engineering correspondence shall be in the name of above coordinators on

behalf of the respective organizations.

8.06.03 Contractor’s/Vendor’s Drawing Submission and Approval Procedure:
a) All data/information furnished by Vendor in the form of drawings/

documents/catalogues or in any other form for NTPC’s information/ interface
and or review and approval are referred by the general term “drawings”.
b) The ‘Master drawings list’ indicating titles, Drawing Number, Date of

submission and approval etc. shall be finalised mutually between Contractor
and Client (EPIL) / NTPC before the award of contract. This list shall be
updated if required at suitable interval during detailed engineering.
c) All drawings (including those of subvendor’s) shall bear at the right hand
bottom corner the ‘title plate’ with all relevant information duly filled in.
The Contractor shall furnish this format to his subvendor along with his
purchase order for subvendor’s compliance.
d) Client (EPIL) / NTPC and contractor shall follow their own numbering
systems for the drawings. However, Client (EPIL) / NTPC shall intimate the
contractor, NTPC drawing number on receipt of the first submission of
each drawing. Vendor, thereafter, shall indicate NTPC’s drawing number in
subsequent Submission, in the space provided for this purpose in title plate,
in addition to his own drawing number.
e) The contractor shall make a visit to site to see the existing facilities and
understand the layout completely and collect all necessary data / drawings at
site which are needed as an input to the engineering. The contractor shall do the
complete engineering including interfacing and integration of all his
equipment, systems & facilities within his scope of work as well as interface
engineering & integration of systems, facilities, equipment & works under
Client (EPIL) / NTPC’s scope and submit all necessary drawings/
documents for the same.
f) Drawings must be checked by the Contractor in terms of its completeness, data

adequacy and relevance with respect to engineering schedule prior to
submission to the Client (EPIL) / NTPC. In case drawings are found to be
submitted without proper endorsement for checking by the Contractor, the same
shall not be reviewed and returned to the Contractor for re-submission.

g) The Contractor shall submit adequate prints of drawing / data / document for
Client (EPIL) / NTPC’s review and approval. The drawings submitted
by the Contractor/vendor shall be reviewed by NTPC and their comments
shall be forwarded within four (4) weeks of receipt of drawings. Upon review of
each drawing, depending on the correctness and completeness of the drawing,
the same will be categorized and approval accorded in one of the
following categories :
CATEGORY- I: Approved
CATEGORY- II: Approved, subject to incorporation of comments/

modification as noted. Resubmit revised drawing
incorporating the comments.
CATEGORY–III: Not approved. Resubmit revised drawings for approval

after incorporating comments/ modification as noted.
CATEGORY –IV: For information and records.
h) Contractor shall resubmit the drawings approved under Category II, III & IVR
within three (3) weeks of receipt of comments on the drawings, incorporating all
comments. Every revision of the drawing shall bear a revision index
wherein such revisions shall be highlighted in the form of description or
marked up in the drawing identifying the same with relevant revision Number
enclosed in a triangle (eg. 1, 2, 3 etc). Contractor shall not make any
changes in the portions of the drawing other than those commented. If
changes are required to be made in the portions already approved, the
Contractor shall resubmit the drawing identifying the changes for Client (EPIL)
/ NTPC’s review and approval. Drawings resubmitted shall show clearly
the portions where the same are revised marking the relevant revision
numbers and Client (EPIL) / NTPC shall review only such revised portion
of documents.
i) In case, the Contractor/ Vendor does not agree with any specific comment, he
shall furnish the explanation for the same to NTPC for consideration. In all such
cases the Contractor shall necessarily enclose explanations along with the
revised drawing (taking care of balance comments) to avoid any delay
and/or duplication in review work.

j) It is responsibility of the Contractor/ Vendor to get all the drawings approved in

the Category I & IV (as the case may be) and complete engineering
activities within the agreed schedule. Any delay arising out of submission and
modification of drawings shall not alter the contract completion schedule.
k) If Contractor/ Vendor fails to resubmit the drawings as per the schedule,

construction work at site will not be held up and work will be carried out on the
basis of comments furnished on previous issues of the drawing.
l) These comments will be taken care by the contractor while submitting the
revised drawing.
The contractor shall use a single transmittal for drawing submission. This shall
include transmittal numbers and date, number of copies being sent, names
of the agencies to whom copies being sent, drawing number and titles,
remarks or special notes if any etc.
9.00.00 TECHNICAL CO-ORDINATION MEETING

9.01.00 The Contractor shall be called upon to organise and attend monthly Design/
Technical Co-ordination Meetings (TCMs) with the Client (EPIL) /
NTPC/Client (EPIL) / NTPC's representatives and other Contractors of the Client
(EPIL) / NTPC during the period of contract. The Contractor shall attend such
meetings at his own cost at NEW DELHI / NOIDA or at mutually agreed venue as
and when required and fully co-operate with such persons and agencies involved
during the discussions.
9.02.00 The Contractor should note that Time is the essence of the contract. In order to
expedite the early completion of engineering activities, the Contractor shall submit all
drawings as per the agreed Engineering Information Submission Schedule. The
drawings submitted by the Contractor will be reviewed by the Client (EPIL) /
NTPC as far as practicable within three (3) weeks from the date of receipt of
the drawing. The comments of the Client (EPIL) / NTPC shall then be discussed
across the table during the above Technical Co-ordination Meeting (s) wherein
best efforts shall be made by both sides to ensure the approval of the drawing.
9.02.01 The Contractor shall ensure availability of the concerned experts / consultants/
personnel who are empowered to take necessary decisions during these meetings. The
Contractor shall be equipped with necessary tools and facilities so that the

drawings/documents can be resubmitted after incorporating necessary changes and

approved during the meeting itself.
9.02.02 Should any drawing remain unapproved for more than six (6) weeks after it's
first submission ,this shall be brought out in the monthly Engineering Progress
and Exception Report with reasons thereof.
9.02.03 Any delays arising out of failure by the Contractor to incorporate Client (EPIL) /
NTPC's comments and resubmit the same during the TCM shall be considered as a
default and in no case shall entitle the Contractor to alter the Contract completion date.
10.00.00 DESIGN IMPROVEMENTS

The Client (EPIL) / NTPC or the Contractor may propose changes in the
specification of the equipment or quality thereof and if the parties agree upon
any such changes the specification shall be modified accordingly.
If any such agreed upon change is such that it affects the price and schedule of
completion, the parties shall agree in writing as to the extent of any changing
the price and/or schedule of completion before the Contractor proceeds with the
change. Following such agreement, the provision thereof, shall be deemed to
have been amended accordingly.
11.00.00 EQUIPMENT BASES

A cast iron or welded steel base plate shall be provided for all rotating
equipment which is to be installed on a concrete base, unless otherwise specifically
agreed to by the Client (EPIL) / NTPC. Each base plate shall support the unit and its
drive assembly, shall be of a neat design with pads for anchoring the units, shall have
a raised lip all around, and shall have threaded drain connections.
12.00.00 PROTECTIVE GUARDS

Suitable guards shall be provided for protection of personnel on all exposed rotating
and/or moving machine parts. All such guards shall be designed for easy installation
and removal for maintenance purpose.
13.00.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS

13.01.00 All the first fills of consumables and one year topping requirement of
consumables such as greases, oil, lubricants, servo fluids / control fluids, gases
and essential chemicals etc. which will be required to put the equipment
covered under the scope of specifications, into successful commissioning /
initial operation and to establish completion of facilities shall be supplied by the

Contractor. Suitable standard lubricants as available in India are desired. Efforts

should be made to limit the variety of lubricants to minimum.
Bidder shall supply a quantity not less than 10 % of the full charge or one (1) year
topping requirement mentioned above (whichever is higher) of each variety of
lubricants, servo fluids, gases, chemicals etc (as detailed above) which is expected to
be utilized during the first year of operation. The additional quantity shall be
supplied in separate container.
13.02.00 As far as possible lubricants marketed by the Indian Oil Corporation shall be used.
The variety of lubricants shall be kept to a minimum possible.
Detailed specifications for the lubricating oil, grease, gases, servo fluids, control
fluids, chemicals etc required for the complete plant covered herein shall be
furnished. On completion of erection, a complete list of bearings/ equipment giving
their location and identification marks shall be furnished to the Client (EPIL) / NTPC
along with lubrication requirements.
14.00.00 LUBRICATION
14.01.00 Equipment shall be lubricated by systems designed for continuous operation.
Lubricant level indicators shall be furnished and marked to indicate proper
levels under both standstill and operating conditions.
15.00.00 TERIAL OF CONSTRUCTION

15.01.00 All materials used for the construction of the equipment shall be new and shall be in
accordance with the requirements of this specification. Materials utilised for various
components shall be those which have established themselves for use in such
applications.
16.00.00 RATING PLATES, NAME PLATES & LABELS

16.01.00 Each main and auxiliary item of plant including instruments shall have permanently
attached to it in a conspicuous position, a rating plate of non-corrosive material upon
which shall be engraved manufacturer’s name, equipment, type or serial number
together with details of the ratings, service conditions under which the item of plant in
question has been designed to operate, and such diagram plates as may be
required by the Client (EPIL) / NTPC.
16.02.00 Each item of plant shall be provided with nameplate or label designating the service of
the particular equipment. The inscriptions shall be approved by the Client (EPIL) /
NTPC or as detailed in appropriate section of the technical specifications.

16.03.00 Such nameplates or labels shall be of white non-hygroscopic material with engraved
black lettering or alternately, in the case of indoor circuit breakers, starters, etc. of
transparent plastic material with suitably coloured lettering engraved on the back.
The name plates shall be suitably fixed on both front and rear side.
16.04.00 Items of plant such as valves, which are subject to handling, shall be provided with an
engraved chromium plated nameplate or label with engraving filled with enamel. The
name plates for valves shall be marked in accordance with MSS standard SP-25 and
ANSI B 16.34 as a minimum.
16.05.00 Hanger/ support numbers shall be marked on all pipe supports, anchors, hangers,
snubbers and restraint assemblies. Each constant and variable spring support shall
also have stamped upon it the designed hot and cold load which it is intended
to support. Suitable scale shall also be provided to indicate load on support or hanger.
16.06.00 Valves, steam traps and strainers shall be identified by Client (EPIL) / NTPC's tag
number of a metal tap permanently attached to non pressure parts such as the
yoke by a stainless steel wire. The direction of flow shall also be marked on the body.
16.07.00 Safety and relief valves shall be provided with the following:
a) Manufacturer's identification.
b) Nominal inlet and outlet sizes in mm.
c) Set pressure in Kg/cm2 (abs).
d) Blow down and accumulation as percentage of set pressure.
e) Certified capacity in Kg of saturated steam per hour or in case of liquid

certified capacity in litres of water per minute.
16.08.00 All such plates, instruction plates, etc. shall be bilingual with Hindi inscription
first, followed by English. Alternatively, two separate plates one with Hindi and the
other with English inscriptions may be provided.
16.09.00 All segregated phases of conductors or bus ducts, indoor or outdoor, shall be
provided with coloured phase plates to clearly identify the phase of the system.
17.00.00 TOOLS AND TACKLES

The Contractor shall supply with the equipment one complete set of all special tools
and tackles and other instruments required and other instruments for the
erection, assembly, disassembly and proper maintenance of the plant and

equipment and systems (including software). These special tools will also include
special material handling equipment, jigs and fixtures for maintenance and calibration
/ re-adjustment, checking and measurement aids etc. A list of such tools and tackles
shall be submitted by the Bidder along with the offer.
The price of each tool / tackle shall be deemed to have been included in the total bid
price. These tools and tackles shall be separately packed and sent to site. The
Contractor shall also ensure that these tools and tackles are not used by him during
erection, commissioning and initial operation. For this period the Contractor should
bring his own tools and tackles. In case these tools and tackles are used by the
Contractor during erection, commissioning or initial operation the same shall be
refurbished repaired/replaced as required to the satisfaction of the Client (EPIL) /
NTPC before handing over to the Client (EPIL) / NTPC. All the tools and tackles
shall be of reputed make acceptable to the Client (EPIL) / NTPC.
18.00.00 WELDING
18.01.00 If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be per formed by others the
requirements shall be submitted to the Client (EPIL) / NTPC in advance of
commencement of erection work.
19.00.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES

19.01.00 All equipment/ piping/ pipe services are to be painted by the Contractor
in accordance with Client (EPIL) / NTPC's standard colour coding scheme, which will
be furnished to the Contractor during detailed engineering stage.
20.00.00 PROTECTION AND PRESERVATIVE SHOP COATING

20.01.00 PROTECTION
All coated surfaces shall be protected against abrasion, impact, discoloration and
any other damages. All exposed threaded portions shall be suitably protected with
either metallic or a non-metallic protection device. All ends of all valves and piping
and conduit equipment connections shall be properly sealed with suitable devices to
protect them from damage. The parts which are likely to get rusted, due to exposure to
weather, should also be properly treated and protected in a suitable manner. All
primers/paints/coatings shall take into account the hot humid, corrosive & alkaline,
subsoil or over ground environment as the case may be. The requirements for

painting specification shall be complied with as detailed out in Part-A & B of

the Technical Specification.
20.02.00 PRESERVATIVE SHOP COATING
All exposed metallic surfaces subject to corrosion shall be protected by shop

application of suitable coatings. All surfaces which will not be easily accessible after
the shop assembly, shall be treated beforehand and protected for the life of the
equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides
and other coatings and prepared in the shop. The surfaces that are to be finish-painted
after installation or require corrosion protection until installation, shall be shop
painted as per the requirements covered in the relevant part of the Technical
Specification.
Transformers and other electrical equipments, if included shall be shop finished with
one or more coats of primer and two coats of high grade resistance enamel.
The finished colors shall be as per manufacturer's standards, to be selected and
specified by the Client (EPIL) / NTPC at a later date.
20.03.00 Shop primer for all steel surfaces which will be exposed to operating
temperature below 95 degrees Celsius shall be selected by the Contractor after
obtaining specific approval of the Client (EPIL) / NTPC regarding the quality of
primer proposed to be applied. Special high temperature primer shall be used on
surfaces exposed to temperature higher than 95 degrees Celsius and such primer shall
also be subject to the approval of the Client (EPIL) / NTPC.
20.04.00 All other steel surfaces which are not to be painted shall be coated with suitable dust
preventive compound subject to the approval of the Client (EPIL) / NTPC.
20.05.00 All piping shall be cleaned after shop assembly by shot blasting or other means
approved by the Client (EPIL) / NTPC. Lube oil piping or carbon steel shall be
pickled.
20.06.00 Painting for Civil structures and equipment/system covered under this package shall
be done as specified under technical requirements on civil works in relevant part of
this specifications.

21.00.00 QUALITY ASSURANCE PROGRAMME

21.01.00 To ensure that the equipment and services under the scope of contract whether
manufactured or performed within the Contractor’s works or at his sub-contractor’s
premises or at the Client (EPIL) / NTPC’s site or at any other place of work are in
accordance with the specifications, the Contractor shall adopt suitable quality
assurance programme to control such activities at all points, as necessary. Such
programmes shall be outlined by the Contractor and shall be finally
accepted by the Client (EPIL) / NTPC/authorised representative after
discussions before the award of the contract. The QA programme shall be
generally in line with ISO-9001/IS-14001. A quality assurance programme of the
contractor shall generally cover the following:
a) His organisation structure for the management and implementation of the

proposed quality assurance programme
b) Quality System Manual
c) Design Control System
d) Documentation Control System
e) Qualification data for Bidder’s key Personnel.
f) The procedure for purchase of materials, parts, components and selection of

sub-contractor’s services including vendor analysis, source inspection,
incoming raw-material inspection, verification of materials purchased etc.
g) System for shop manufacturing and site erection control including process
controls and fabrication and assembly controls.
h) Control of non-conforming items and system for corrective actions.
i) Inspection and test procedure both for manufacture and field activities.
j) Control of calibration and testing of measuring testing equipments.
k) System for Quality Audits.
l) System for indication and appraisal of inspection status.
m) System for authorising release of manufactured product to the Client (EPIL) /

NTPC.
n) System for handling storage and delivery.

o) System for maintenance of records, and
p) Furnishing of quality plans for manufacturing and field activities detailing

out the specific quality control procedure adopted for controlling the
quality characteristics relevant to each item of equipment/component as per
formats enclosed as Annexure-I and Annexure-II respectively.
22.00.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE

22.01.00 All materials, components and equipment covered under this specification shall be
procured, manufactured, erected, commissioned and tested at all the stages, as per a
comprehensive Quality Assurance Programme. An indicative programme of
inspection/tests to be carried out by the contractor for some of the major items
is given in the respective technical specification. This is, however, not intended to
form a comprehensive programme as it is the contractor’s responsibility to draw up
and implement such programme duly approved by the Client (EPIL) / NTPC. The
detailed Quality Plans for manufacturing and field activities shall be drawn up by the
Bidder and will be submitted to Client (EPIL) / NTPC for approval. Schedule of
finalisation of such quality plans will be finalised before award on enclosed
format No. QS-01-QAI-P-1/F3-R0. Monthly progress reports shall be furnished.
22.02.00 Manufacturing Quality Plan will detail out for all the components and
equipment, various tests/inspection, to be carried out as per the
requirements of this specification and standards mentioned therein and quality
practices and procedures followed by Contractor’s/ Sub-contractor’s/ sub-
supplier's Quality Control Organisation, the relevant reference documents and
standards, acceptance norms, inspection documents raised etc., during all stages of
materials procurement, manufacture, assembly and final testing/performance testing.
The Quality Plan shall be submitted on electronic media through C-folders, a web
based system of NTPC ERP in addition to hard copy, for review and approval. After
approval the same shall be submitted in compiled form on CD-ROM (As per format at
Annexure-I).
22.03.00 Field Quality Plans will detail out for all the equipment, the quality practices
and procedures etc. to be followed by the Contractor’s "Site Quality Control
Organisation", during various stages of site activities starting from receipt
of materials/equipment at site (As per format at Annexure – II).

22.04.00 The Bidder shall also furnish copies of the reference documents/plant
standards/acceptance norms/tests and inspection procedure etc., as referred in
Quality Plans along with Quality Plans. These Quality Plans and reference
documents/standards etc. will be subject to Client (EPIL) / NTPC’s approval
without which manufacturer shall not proceed. These approved documents shall
form a part of the contract. In these approved Quality Plans, Client (EPIL) / NTPC
shall identify customer hold points (CHP), i.e. test/checks which shall be
carried out in presence of the Client (EPIL) / NTPC’s Project Manager or his
authorised representative and beyond which the work will not proceed without
consent of Client (EPIL) / NTPC in writing. All deviations to this specification,
approved quality plans and applicable standards must be documented and referred
to Client (EPIL) / NTPC along with technical justification for approval and
dispositioning.
22.05.00 The contractor shall submit to the Client (EPIL) / NTPC Field Welding Schedule for
field welding activities in the format enclosed at Annexure-V. The field welding
schedule shall be submitted to the Client (EPIL) / NTPC along with all
supporting documents, like welding procedures, heat treatment procedures,
NDT procedures etc. at least ninety days before schedule start of erection work at
site.
22.06.00 The contractor shall have suitable Field Quality Organization with adequate
manpower at Client (EPIL) / NTPC's site, to effectively implement the Field Quality
Plan (FQP) and Field Quality Management System for site activities. The contractor
shall submit the details of proposed FQA setup (organizational structure and
manpower) for Client (EPIL) / NTPC's approval. The FQA setup shall be in place at
least one month before the start of site activities.
22.07.00 No material shall be despatched from the manufacturer’s works before the same is
accepted, by Client (EPIL) / NTPC's Project Manager/Authorised representative
and duly authorised for despatch by issuance of Material Despatch Clearance
Certificate (MDCC / CHP Clearance.
22.08.00 All material used for equipment manufacture including casting and forging etc. shall
be of tested quality as per relevant codes/standards. Details of results of the tests
conducted to determine the mechanical properties; chemical analysis and details of
heat treatment procedure recommended and actually followed shall be recorded on

certificates and time temperature chart. Tests shall be carried out as per applicable
material standards and/or agreed details.
22.09.00 All welding and brazing shall be carried out as per procedure drawn and qualified in
accordance with requirements of ASME Section IX/BS-4870 or other International
equivalent standard acceptable to the Client (EPIL) / NTPC.
All welding/brazing procedures shall be submitted to the Client (EPIL) / NTPC or its
authorised representative for approval prior to carrying out the welding/brazing.
22.10.00 All brazers, welders and welding operators employed on any part of the
contract either in Contractor’s/his sub-contractor’s works or at site or elsewhere
shall be qualified as per ASME Section-IX or BS-4871 or other equivalent
International Standards acceptable to the Client (EPIL) / NTPC.
22.11.00 Welder qualification test results shall be furnished to the Client (EPIL) / NTPC
for approval. However, where required by the Client (EPIL) / NTPC, tests shall be
conducted in presence of Client (EPIL) / NTPC/authorized representative.
22.12.00 For all IBR pressure parts and high pressure piping welding, the latest
applicable requirements of the IBR (Indian Boiler Regulations) shall also be
essentially complied with. However, other piping system ASME B31.1 or other
relevant code as applicable shall be followed. Similarly, any other statutory
requirements for the equipment/systems shall also be complied with. On all back-
gauged welds MPI/LPI shall be carried before seal welding.
22.13.00 All the heat treatment results shall be recorded on time temperature charts and
verified with recommended regimes.
22.14.00 No welding shall be carried out on cast iron components for repair.
22.15.00 Unless otherwise proven and specifically agreed with the Client (EPIL) / NTPC,
welding of dissimilar materials and high alloy materials shall be carried out at shop
only.
22.16.00 All non-destructive examination shall be performed in accordance with written

procedures as per International Standards. The NDT operator shall be qualified as per
SNT-TC-IA (of the American Society of non-destructive examination) or
equivalent. NDT shall be recorded in a report, which includes details of

methods and equipment used, result/evaluation, job data and identification of

personnel employed and details of co-relation of the test report with the job.
In general all plates of thickness greater than 40mm & for pressure parts plates of
thickness equal to or greater than 25mm shall be ultrasonically tested otherwise as
specified in respective equipment specification. All bar stock/Forging of diameter
equal to or greater than 40 mm shall be ultrasonically tested.
22.17.00 The Contractor shall list out all major items/ equipment/ components to
be manufactured in house as well as procured from sub-contractors (BOI). All the sub-
contractor proposed by the Contractor for procurement of major bought out
items including castings, forging, semi-finished and finished
components/equipment etc., list of which shall be drawn up by the Contractor
and finalised with the Client (EPIL) / NTPC, shall be subject to Client (EPIL) /
NTPC's approval on enclosed format No. QS-01-QAI-P-01/F3. The contractor’s
proposal shall include vendor’s facilities established at the respective works,
the process capability, process stabilization, QC systems followed, experience list, etc.
along with his own technical evaluation for identified sub- contractors enclosed
and shall be submitted to the Client (EPIL) / NTPC for approval within the period
agreed at the time of pre-awards discussion and identified in "DR" category prior to
any procurement. Monthly progress reports on sub-contractor detail
submission / approval shall be furnished preferably on enclosed format at
Annexure-IV. Such vendor approval shall not relieve the contractor from any
obligation, duty or responsibility under the contract.
22.17.00a An indicative list of sub-vendors accepted by NTPC in the past for Corporate
Awarded similar packages is enclosed for reference purpose as Indicative Sub-
vendors List. The bidders’ specific attention is drawn to the ‘Disclaimer for the
Indicative Vendor List’ placed at the start of the Indicative Sub-vendor List. This is
attached separately with the QA specification.
22.18.00 For components/equipment procured by the contractors for the purpose of the
contract, after obtaining the written approval of the Client (EPIL) / NTPC, the
contractor’s purchase specifications and inquiries shall call for quality plans to be
submitted by the suppliers. The quality plans called for from the sub-contractor
shall set out, during the various stages of manufacture and installation, the quality
practices and procedures followed by the vendor’s quality control organisation,

the relevant reference documents/standards used, acceptance level,

inspection of documentation raised, etc.
Such quality plans of the successful vendors shall be finalised with the Client
(EPIL) / NTPC and such approved Quality Plans shall form a part of the
purchase order/contract between the Contractor and sub-contractor. Within three
weeks of the release of the purchase orders /contracts for such bought out items
/components, a copy of the same without price details but together with the
detailed purchase specifications, quality plans and delivery conditions shall be
furnished to the Client (EPIL) / NTPC on the monthly basis by the Contractor along
with a report of the Purchase Order placed so far for the contract.
22.19.00 Client (EPIL) / NTPC reserves the right to carry out quality audit and quality
surveillance of the systems and procedures of the Contractor’s or their sub-
contractor’s quality management and control activities. The contractor shall provide
all necessary assistance to enable the Client (EPIL) / NTPC carry out such audit and
surveillance.
22.20.00 The contractor shall carry out an inspection and testing programme during
manufacture in his work and that of his sub-contractor’s and at site to ensure
the mechanical accuracy of components, compliance with drawings, conformance
to functional and performance requirements, identity and acceptability of all materials
parts and equipment. Contractor shall carry out all tests/inspection required to
establish that the items/equipment conform to requirements of the specification and
the relevant codes/standards specified in the specification, in addition to carrying out
tests as per the approved quality plan.
22.21.00 Quality audit/surveillance/approval of the results of the tests and inspection will not,
however, prejudice the right of the Client (EPIL) / NTPC to reject the equipment
if it does not comply with the specification when erected or does not give complete
satisfaction in service and the above shall in no way limit the liabilities and
responsibilities of the Contractor in ensuring complete conformance of the
materials/equipment supplied to relevant specification, standard, data sheets,
drawings, etc.
22.22.00 For all spares and replacement items, the quality requirements as agreed for the
main equipment supply shall be applicable.

22.23.00 Repair/rectification procedures to be adopted to make the job acceptable shall

be subject to the approval of the Client (EPIL) / NTPC/authorised representative.
22.24.00 Environmental Stress Screening:
Environmental stress screening test process / procedure for eliminating infant mortile
components for DDCMIS / PLC based system & for other systems having
substantial electronics components (as determined by Client (EPIL) / NTPC) like
Electronic transmitter, CCTV components, PA systems etc. shall be furnished for
Client (EPIL) / NTPC acceptance.
22.25.00 The Contractor/ Sub-contractor shall carry out routine test on 100% item at
contractor/ sub-contractor's works. The quantum of check /test for routine &
acceptance test by Client (EPIL) / NTPC shall be generally as per criteria /
sampling plan defined in referred standards. Wherever standards have not
been mentioned quantum of check / test for routine / acceptance test shall be as
agreed during detailed engineering stage.
22.26.00 Software Reliability / Quality Certification
Certification from OEM’s authorized signatory that software offered with

DDCMIS, PLC, CCTV, PA, Pyrometer, CEMS, AAQMS, EQMS, BHMS etc. declaring
that the all the offered software(s) had gone through the established software quality
test and offered software is not of β-version and offered software is also free from all
known bugs as on date of approval of systems documents by NTPC as a part
of quality documentation review and approval process during detail engineering.
23.00.00 QUALITY ASSURANCE DOCUMENTS

23.01.00 The Contractor shall be required to submit the QA Documentation in two hard copies
and two CD ROMs, as identified in respective quality plan with tick ( ) mark.
23.01.01 Each QA Documentation shall have a project specific Cover Sheet bearing name &
identification number of equipment and including an index of its contents with page
control on each document.
The QA Documentation file shall be progressively completed by the Supplier’s sub-

supplier to allow regular reviews by all parties during the manufacturing.
The final quality document will be compiled and issued at the final assembly place of
equipment before despatch. However CD-Rom may be issued not later than three
weeks.

23.02.00 Typical contents of QA Documentation is as below:-
(a.) Quality Plan
(b.) Material mill test reports on components as specified by the specification and
approved Quality Plans.
(c.) Manufacturer /works test reports/results for testing required as per

applicable codes and standard referred in the specification and approved
Quality Plans.
(d.) Non-destructive examination results /reports including radiography

interpretation reports. Sketches/drawings used for indicating the method of
traceability of the radiographs to the location on the equipment.
(e.) Heat Treatment Certificate/Record (Time- temperature Chart)
(f.) All the accepted Non-conformance Reports (Major/Minor)/deviation, including

complete technical details / repair procedure).
(g.) CHP / Inspection reports duly signed by the Inspector of the Client (EPIL) /
NTPC and Contractor for the agreed Customer Hold Points.
(h.) Certificate of Conformance (COC) wherever applicable.
(i.) MDCC
23.03.00 Similarly, the contractor shall be required to submit two sets (two hard copies and two
CD ROMs), containing QA Documentation pertaining to field activities as per
Approved Field Quality Plans and other agreed manuals/ procedures, prior to
commissioning of individual system.
23.04.00 Before despatch / commissioning of any equipment, the Supplier shall make
sure that the corresponding quality document or in the case of protracted
phased deliveries, the applicable section of the quality document file is
completed. The supplier will then notify the Inspector regarding the
readiness of the quality document (or applicable section) for review.
(a.) If the result of the review carried out by the Inspector is satisfactory, the
Inspector shall stamp the quality document (or applicable section) for
release.

(b.) If the quality document is unsatisfactory, the Supplier shall endeavor to

correct the incompleteness, thus allowing to finalize the quality document (or
applicable section) by time compatible with the requirements as per contract
documents. When it is done, the quality document (or applicable section) is
stamped by the Inspector.
(c.) If a decision is made for despatch, whereas all outstanding actions cannot be
readily cleared for the release of the quality document by that time, the
supplier shall immediately, upon shipment of the equipment, send a copy of the
quality document Review Status signed by the Supplier Representative to the
Inspector and notify of the committed date for the completion of all
outstanding actions & submission. The Inspector shall stamp the quality
document for applicable section when it is effectively completed. The
submission of QA documentation package shall not be later than 3 weeks
after the despatch of equipment.
23.05.00 TRANSMISSION OF QA DOCUMENTATION
On release of QA Documentation by Inspector, one set of quality document shall be

forwarded to Corporate Quality Assurance Department and other set to respective
Project Site of Client (EPIL) / NTPC.
For the particular case of phased deliveries, the complete quality document to the
Client (EPIL) / NTPC shall be issued not later than 3 weeks after the date of the last
delivery of equipment.
24.00.00 PROJECT MANAGER’S SUPERVISION

24.01.00 To eliminate delays and avoid disputes and litigation, it is agreed between the
parties to the Contract that all matters and questions shall be referred to the Project
Manager and without prejudice to the provisions of ‘Arbitration’ clause in
Section GCC, the Contractor shall proceed to comply with the Project Manager's
decision.
24.02.00 The work shall be performed under the supervision of the Project Manager. The scope
of the duties of the Project Manager pursuant to the Contract, will include but not be
limited to the following:
(a.) Interpretation of all the terms and conditions of these documents and
specifications.

(b.) Review and interpretation of all the Contractor’s drawing, engineering data, etc
(c.) Witness or his authorised representative to witness tests and trials either at the
manufacturer’s works or at site, or at any place where work is performed under
the contract.
(d.) Inspect, accept or reject any equipment, material and work under the
contract.
(e.) Issue certificate of acceptance and/or progressive payment and final

payment certificates.
(f.) Review and suggest modifications and improvement in completion schedules

from time to time, and
(g.) Supervise Quality Assurance Programme implementation at all stages of the

works.
25.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES

25.01.00 The word ‘Inspector’ shall mean the Project Manager and/or his authorised
representative and/or an outside inspection agency acting on behalf of the Client
(EPIL) / NTPC to inspect and examine the materials and workmanship of the
works during its manufacture or erection.
25.02.00 The Project Manager or his duly authorised representative and/or an outside
inspection agency acting on behalf of the Client (EPIL) / NTPC shall have access
at all reasonable times to inspect and examine the materials and workmanship
of the works during its manufacture or erection and if part of the works
is being manufactured or assembled on other premises or works, the Contractor shall
obtain for the Project Manager and for his duly authorised representative
permission to inspect as if the works were manufactured or assembled on the
Contractor’s own premises or works.
25.03.00 The Contractor shall give the Project Manager/Inspector fifteen (15) days written
notice of any material being ready for testing. Such tests shall be to the Contractor’s
account except for the expenses of the Inspector’s. The Project Manager/Inspector,
unless the witnessing of the tests is virtually waived and confirmed in writing,
will attend such tests within fifteen (15) days of the date on which the
equipment is noticed as being ready for test/inspection failing which the contractor
may proceed with test which shall be deemed to have been made in the inspector’s

presence and he shall forthwith forward to the inspector duly certified copies of test
reports in two (2) copies.
25.04.00 The Project Manager or Inspector shall within fifteen (15) days from the date of
inspection as defined herein give notice in writing to the Contractor, or any objection
to any drawings and all or any equipment and workmanship which is in his opinion
not in accordance with the contract. The Contractor shall give due consideration to
such objections and shall either make modifications that may be necessary to meet the
said objections or shall inform in writing to the Project Manager/Inspector giving
reasons therein, that no modifications are necessary to comply with the contract.
25.05.00 When the factory tests have been completed at the Contractor’s or sub-contractor’s
works, the Project Manager /Inspector shall issue a certificate to this effect Ten (10)
days after completion of tests but if the tests are not witnessed by the Project
Manager /Inspectors, the certificate shall be issued within Ten (10) days of the
receipt of the Contractor’s test certificate by the Project Manager /Inspector. Failure on
the part of Project Manager /Inspector to issue such a certificate shall not prevent the
Contractor from proceeding with the works. The completion of these tests or the issue
of the certificates shall not bind the Client (EPIL) / NTPC to accept the equipment
should it, on further tests after erection be found not to comply with the contract.
25.06.00 In all cases where the contract provides for tests whether at the premises or works of
the Contractor or any sub-contractor, the Contractor, except where otherwise
specified shall provide free of charge such items as labour, material, electricity, fuel,
water, stores, apparatus and instruments as may be reasonably demanded by the
Project Manager /Inspector or his authorised representatives to carry out effectively
such tests on the equipment in accordance with the Contractor and shall give
facilities to the Project Manager/Inspector or to his authorised representative to
accomplish testing.
25.07.00 The inspection by Project Manager / Inspector and issue of Inspection

Certificate thereon shall in no way limit the liabilities and responsibilities of the
Contractor in respect of the agreed Quality Assurance Programme forming a part of
the contract.
25.08.00 To facilitate advance planning of inspection in addition to giving inspection notice as

specified at clause no 25.03.00 of this chapter, the Contractor shall furnish quarterly

inspection programme indicating schedule dates of inspection at Customer Hold

Point and final inspection stages. Updated quarterly inspection plans will be made
for each three consecutive months and shall be furnished before beginning of each
calendar month.
25.09.00 All inspection, measuring and test equipment used by contractor shall be calibrated
periodically depending on its use and criticality of the test/measurement to be done.
The Contractor shall maintain all the relevant records of periodic calibration and
instrument identification, and shall produce the same for inspection by NTPC.
Wherever asked specifically, the contractor shall re-calibrate the measuring/test
equipment in the presence of Project Manager / Inspector.
25.10.00 Associated document for Quality Assurance programme
25.10.01 Manufacturing Quality Plan Format No. : QS-01-QAI-P-09/F1-R1 enclosed at

Annexure-I.
25.10.02 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R1 enclosed at Annexure-II.
25.10.03 List of items requiring quality plan and sub supplier approval. Format No.: QS-01-
QAI-P-01/F3-R0 (Annexure-III).
25.10.04 Status of items requiring Quality Plan and sub supplier approval. Format enclosed at
Annexure-IV.
25.10.05 Field Welding Schedule Format enclosed at Annexure-V.
25.11.00 Not Used.
25.12.00 DEMONSTRATION OF APPLICATION ENGINEERING
25.12.01 Based on NTPC inputs, the Contractor shall prepare and submit typical implemented
scheme in their system (Control system & HMI) on sample basis. The typical cases to
be covered shall include but not be limited to the following.
(i) Logics/Loops:
a) Drive logics implementation for each type of binary drive along with its
display in HMI.
b) Sequence implementation along with its display in HMI.
c) Single non-cascade controller implementation.
d) Cascade loop implementation.

e) Master slave implementation with different slave combination.
f) Temperature & pressure compensation for flow signals & Pressure

compensation for level signals as applicable.
(ii) HMI Functions:
a) LVS Annunciation.
b) Graphics.
c) HSR
d) Logs/Reports.
e) Calculations (Basic & Performance Calculations).
25.12.02 The above typical cases shall be finalized with the Client (EPIL) / NTPC through
Technical Co- ordination meetings.
After review and finalization of the typical cases, the implementation of each logic &
control loop shall be carried out by the Contractor based on NTPC inputs.
After implementation of these logics & loops, the Contractor shall test each logic /loop
and record the observations in a format to be provided by the Client (EPIL) / NTPC
and demonstrate to Client (EPIL) / NTPC at Client (EPIL) / NTPC premises during
engineering finalization. Any modifications as a result of the demonstration shall be
done and documented as part of the test report along with the final scheme.
Similarly, HMI functions shall also be demonstrated by the Contractor at
Client (EPIL) / NTPC premises & the results shall be documented as part of test
report.
25.12.03 During the integrated testing at the Contractor’s works, only sample checks shall be
done by the Client (EPIL) / NTPC for the items covered in above application
engineering demonstration.
26.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES

26.01.00 (a) As soon as the facilities or part thereof has been completed operationally and
structurally and before start-up, each item of the equipment and systems
forming part of facilities shall be thoroughly cleaned and then inspected
jointly by the Client (EPIL) / NTPC and the Contractor for correctness
of and completeness of facility or part thereof and acceptability for initial
pre- commissioning tests, commissioning and start-up at Site. The list of

pre- commissioning tests to be performed shall be as mutually agreed and

included in the Contractor’s quality assurance programme as well as those
included in Part-D, Section-VI and elsewhere in the Technical Specifications.
(b) The Contractor’s pre-commissioning/commissioning/start-up engineers,

specially identified as far as possible, shall be responsible for carrying out all the
pre-commissioning tests at Site. On completion of inspection, checking and
after the pre-commissioning tests are satisfactorily over, the commissioning of
the complete facilities shall be commenced during which period the
complete facilities, equipments shall be operated integral with sub- systems and
supporting equipment as a complete plant.
(c) All piping system shall be flushed, steam blown, air blown as required and
cleanliness demonstrated using acceptable industry standards. Procedures to
accomplish this work shall be submitted for approval to the Client (EPIL) /
NTPC six months prior to the respective implementations. The Client (EPIL) /
NTPC will approve final verification of cleanliness.
(d) The time consumed in the inspection and checking of the units shall be
considered as a part of the erection and installation period.
(e) The check outs during the pre -commissioning period should be programmed
to follow the construction completion schedule. Each equipment/system, as
it is completed in construction and turned over to Client (EPIL) / NTPC's
commissioning (start-up) Engineer(s), should be checked out and cleaned. The
checking and inspection of individual systems should then follow a prescribed
commissioning documentation [SLs (standard check list)/TS(testing schedule)/
CS(commissioning schedule)] approved by the Client (EPIL) / NTPC.
(f) The Contractor during initial operation and performance testing shall conduct
vibration testing to determine the ‘base line’ of performance of all plant
rotating equipment. These tests shall be conducted when the equipment is
running at the base load, peak load as well as lowest sustained operating
condition as far as practicable.
26.01.01 Contractor shall furnish the commissioning organization chart for review &
acceptance of Client (EPIL) / NTPC at least twelve months prior to the schedule
date of commissioning of 1st unit. The chart should contain:

(1.) Biodata including experience of the Commissioning Engineers.
(2.) Role and responsibilities of the Commissioning Organisation members.
(3.) Expected duration of posting of the above Commissioning Engineers at site.
26.02.00 Initial Operation
(a) On completion of all pre-commissioning activities/ tests and as a part of

commissioning the complete facilities shall be put on 'Initial Operation' during
which period all necessary adjustments shall be made while operating over the
full load range enabling the facilities to be made ready for the Guarantee Tests.
(b) The 'Initial Operation' of the complete facility as an integral unit shall be
conducted for 720 continuous hours. During the period of initial operation of 720
hours, the equipment shall operate continuously at full load for a period
not less than 72 hours.
The Initial Operation shall be considered successful, provided that each item/
part of the facility can operate continuously at the specified operating
characteristics, for the period of Initial Operation with all operating
parameters within the specified limits and at or near the predicted
performance of the equipment/ facility.
The Contractor shall intimate the Client (EPIL) / NTPC about the
commencement of initial operation and shall furnish adequate notice to the
Client (EPIL) / NTPC in this respect.
(c) Any operational interruption in the equipment due to constraints

attributable to the Client (EPIL) / NTPC shall be construed as Deemed
to be in operation.
(d) An Initial Operation report comprising of observations and recordings of

various parameters to be measured in respect of the above Initial Operation shall
be prepared by the Contractor. This report, besides recording the details of
the various observations during initial operation shall also include the dates of
start and finish of the Initial Operation and shall be signed by the representatives
of both the parties. The report shall have sheets, recording all the details of
interruptions occurred, adjustments made and any minor repairs done
during the Initial Operation. Based on the observations, necessary

modifications/repairs to the plant shall be carried out by the Contractor to

the full satisfaction of the Client (EPIL) / NTPC to enable the latter to
accord permission to carry out the Guarantee tests on the facilities.
However, minor defects which do not endanger the safe operation of the
equipment, shall not be considered as reasons for with- holding the aforesaid
permission.
26.03.00 Guarantee Tests
a) The final test as to prove the Functional Guarantees shall be conducted Site
by the Contractor in presence of the Client (EPIL) / NTPC. The
contractor's Commissioning, start-up Engineer shall make the unit ready to
conduct such test before start of initial operation. Such test shall be conducted
along with the Initial Operations.
b) These tests shall be binding on both the parties of the Contract to determine
compliance of the equipment with the functional guarantee.
c) For performance/ demonstration tests instrumentations, of accuracy class

shall be as per specified test codes. The numbers and location of the
instruments shall be as per the specified test codes. In addition the values of
parameters shall be logged from the information system provided under
Client (EPIL) / NTPC's Distributed Digital Control Monitoring and
Information system. Test will be conducted at specified load points.
d) Any special equipment, tools and tackles required for the successful
completion of the Guarantee Tests shall be provided by the Contractor, free of
cost.
e) The Guarantee tests and specific tests to be conducted on equipments have been
brought out in detail elsewhere in the specifications.
27.00.00 TAKING OVER

Upon successful completion of Initial Operations and all the tests conducted to the
Client (EPIL) / NTPC's satisfaction, the Client (EPIL) / NTPC shall issue to the
Contractor a Taking over Certificate as a proof of the final acceptance of the
equipment. Such certificate shall not unreasonably be with held nor will the Client
(EPIL) / NTPC delay the issuance thereof, on account of minor omissions or defects
which do not affect the commercial operation and/or cause any serious risk to the

equipment. Such certificate shall not relieve the Contractor of any of his obligations
which otherwise survive, by the terms and conditions of the Contract after issuance
of such certificate.
28.00.00 TRAINING OF NTPC'S PERSONNEL

28.01.00 Training for NTPCs O&M Personnel
The scope of service under training of NTPC's engineers shall include a training
module covering upto six (6) man months in the areas of Operation & Maintenance.
Such training should enable the personnel to individually take the responsibility
of operating and maintaining the FGD system in a manner acceptable to NTPC.
28.02.00 Training for NTPCs Engineering Personnel
The scope of services under training for NTPC's engineering personnel shall also
necessarily include three (3) man months. This shall cover all disciplines viz,
Mechanical, Electrical, C&I, & QA etc. and shall include all the related areas
like Design familiarization, training on product design features and product
design softwares of major equipment and systems, engineering, manufacturing,
erection, commissioning, training on operating features of equipment, quality
assurance and testing, plant visits and visits to manufacturer's works, exposure to
various kinds of problems which may be encountered in fabrication, manufacturing,
erection, welding etc. An indicative module of the training requirement of /
NTPC's Engineering personnel is attached as Annexure-VII.
28.03.00 Bidder shall furnish in his offer, details of training module(s) covering above
requirements which shall be subject to Client (EPIL) / NTPC's approval.
Consolidated training period included above (i.e. 6 man months and 3 man months
respectively for O&M and Engineering) is indicative only. Client (EPIL) / NTPC
reserves the right to re appropriate the training period between O&M and engineering
depending upon the details of training module proposed by the Bidder.
28.04.00 Exact details, extent of training and the training schedule shall be finalised based on
the Bidder's proposal within two (2) months from placement of award.
28.05.00 In all the above cases, wherever the training of NTPC's personnel is arranged at the
works of the manufacturer's it shall be noted that the lodging and boarding of the
NTPC's personnel shall be at the cost of Contractor. The Contractor shall make all
necessary arrangements towards the same.

28.06.00 Take off prices (product wise) should be indicated by the Bidder in the Bid Proposal
Sheets. Client (EPIL) / NTPC reserves the right to include or exclude these
item(s) during placement of Award.
Note: For training purposes, one (1) man month implies 30 working days (excluding
all intervening holidays) per person.
29.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION

In addition to the requirements given in Erection Conditions of Contract (ECC) the
following shall also cover:
i) Working platforms should be fenced and shall have means of access.
ii) Ladders in accordance with Client (EPIL) / NTPC’s safety rules for
construction and erection shall be used. Rungs shall not be welded on
columns. All the stairs shall be provided with handrails immediately after
its erection.
30.00.00 NOISE LEVEL

The equivalent "A" weighted sound pressure level measured at a height of 1.5 m above
floor level in elevation and at a distance of one (1) meter horizontally from the nearest
surface of any equipment/machine, furnished and installed under these specifications,
expressed in decibels to a reference of 0.0002 microbar, shall not exceed 85 dBA.
However for Ball Mills the noise levels as per following shall also be acceptable:
a) Ball Mill: 90 dBA
31.00.00 PACKAGING AND TRANSPORTATION

All the equipments shall be suitably protected, coated, covered or boxed and crated to
prevent damage or deterioration during transit, handling and storage at Site till the
time of erection. While packing all the materials, the limitation from the point of view
of the sizes of railway wagons available in India should be taken account of.
The Contractor shall be responsible for any loss or damage during
transportation, handling and storage due to improper packing. The Contractor
shall ascertain the availability of Railway wagon sizes from the Indian Railways
or any other agency concerned in India well before effecting despatch of equipment.
Before despatch it shall be ensured that complete processing and manufacturing of the
components is carried out at shop, only restricted by transport limitation, in order to
ensure that site works like grinding, welding, cutting & preassembly to bare

minimum. The Client (EPIL) / NTPC's Inspector shall have right to insist for
completion of works in shops before despatch of materials for transportation.
32.00.00 ELECTRICAL EQUIPMENTS/ENCLOSURES

32.01.00 All electrical equipments and devices, including insulation, heating and
ventilation devices shall be designed for ambient temperature and a maximum relative
humidity as specified elsewhere in the specifications.
33.00.00 INSTRUMENTATION AND CONTROL

All instrumentation and control systems/ equipment/ devices/ components,
furnished under this contract shall be in accordance with the requirements stated
herein, unless otherwise specified in the detailed specifications.
33.01.00 All instrument scales and charts shall be calibrated and printed in metric units and
shall have linear graduation. The ranges shall be selected to have the normal
reading at 75% of full scale.
All scales and charts shall be calibrated and printed in Metric Units as follows:
1 Temperature - Degree centigrade (deg C)
2. Pressure - Kilograms per square centimetre (Kg/cm2).

Pressure instrument shall have the unit suffixed
with 'a' to indicate absolute pressure. If nothing is
there, that will mean that the indicated pressure is
gauge pressure.
3. Draught - Millimetres of water column (mm wc).
4. Vacuum - Millimeters of mercury gauge (mm Hg) or water

column (mm Wcl).
5. Flow (Gas) - Tonnes/ hour
6. Flow (Steam) - Tonnes/ hour
7. Flow (Liquid) - Tonnes / hour
8. Flow base - 760 mm Hg. 0 deg.C
9. Density - Grams per cubic centimetre.

33.02.00 All instruments and control devices provided on panels shall be of miniaturized
design, suitable for modular flush mounting on panels with front draw out facility and
flexible plan-in connection at rear.
33.03.00 All electronic modules shall have gold plated connector fingers and further all input
and output modules shall be short circuit proof. These shall also be tropicalised &
components shall be of industrial grade or better.
34.00.00 ELECTRICAL NOISE CONTROL

The equipment furnished by the Contractor shall incorporate necessary techniques to
eliminate measurement and control problems caused by electrical noise. Areas in
Contractor's equipment which are vulnerable to electrical noise shall be hardened to
eliminate possible problems. Any additional equipment, services required for
effectively eliminating the noise problems shall be included in the proposal. The
equipment shall be protected against ESD as per IEC-61000-2. Radio Frequency
interference (RFI) and Electro Magnetic Interference (EMI) protection against
hardware damage and control system mal-operations/errors shall be provided for all
systems as per EN-50082-2 (1995).
35.00.00 SURGE PROTECTION FOR SOLID STATE EQUIPMENT

All solid state systems /equipment shall be able to withstand the electrical noise and
surge as encountered in actual service conditions and inherent in a power plant and
shall meet the requirements of surge protection as defined in ANSI C37.90.1-1989 on
its suitable equivalent class of IEC 254-4. Details of the features incorporated and
relevant tests carried out. The test certificates. etc. shall be submitted by the Bidder.
36.00.00 INSTRUMENT AIR SYSTEM

The instrument air supply system as supplied by the Bidder for various pneumatic
control & instrumentation devices like pneumatic actuators, power cylinders,
E/P converters, piping / tubing etc.
Each pneumatic instrument shall have an individual air shut - off valve. The pressure
regulating valve shall be equipped with an internal filter, a 50 mm pressure gauge
and a built-in filter housing blow down valve.
37.00.00 TAPPING POINTS FOR MEASUREMENTS

Tapping points shall include probes, wherever applicable, for analytical
measurements and sampling.

For direct temperature measurement of all working media, one stub with
internal threading of approved pattern shall be provided along with suitable plug and
washer. The Contractor will be intimated about thread standard to be adopted.
The following shall be provided on equipment by the Bidder. The standard which is to
be adopted will be intimated to the Contractor.
i) Temperature test pockets with stub and thermowell
ii) Pressure test pockets
38.00.00 SYSTEM DOCUMENTATION

The Bidder shall provide drawings, system overview & description, hardware/
software details, technical literature, functional & hardware schemes, bill of material,
parts list, interconnection diagrams, data sheets, erection/ installation/
commissioning procedures, instruction/ operating manuals, etc. for each of the C& I
system/ sub-systems/ equipment supplied under this package. The documentation
shall include complete details of the C&I systems/ sub-systems/ equipment to enable
review by Client (EPIL) / NTPC during detailed engineering stage and to provide
information to plant personnel for operation & Maintenance (including quick
diagnostics & trouble shooting) of these C&I systems/ sub-systems/ equipment at
site. The minimum documentation requirements for C&I systems shall be as
stipulated under C&I "Technical Data Sheets" Part of specifications. In
addition to this, system documentation for control system shall include as a
minimum to that specified elsewhere in the Technical Specification.
The exact format, submission schedule and contents of various documents shall be as
finalised during detailed engineering stage.
38.01.00 Bill of material (instrument list) for all C&I equipment/ devices shall be furnished by
the bidder in standard formats as approved by the Client (EPIL) / NTPC.
39.00.00 MAINTENANCE MANUALS OF ELECTRONIC MODULES

The Contractor shall have to furnish two (2) sets of all maintenance manual of each
and every electronic card/module as employed on the various systems and
equipment including peripherals etc., offered by him. The Contractor will also have to
furnish the data regarding the expected failure rate of various modules and
other system components. Further , the contractor shall furnish a set of operating
manuals which should include block diagrams ,make, model/type ,details wiring and

external connection drawings etc as required to do the testing and maintenance

of the electronic modules.

LIST OF CODES AND STANDARDS
Indian Title International and Internationally

Standards recognized standards
IS:277 Galvanised steel sheets (plain or
corrugated)
IS:655 Specification for metal air duct
IS:800 Code of practice for use of structural BS 449:1969
steel in general building
BS 5950
construction
ASA A57, 1-1952
IS:807 Code of practice for design, Draft Revision of A.S. NO. CS.2
manufacture, erection and testing SAA Crane and Hoist code Doc:No.
(Structural portion) of cranes and BU/4 Rev
hoists 6588 (Issued by Standards
Association of Australia).
DIN 120:1936 (Sheet 1)
DIN 120:1936 (Sheet 2)
327 part-I, 1951
BS 466 part-II, 1960 BS 644:1960
BS 1757:1951 BS 2573:part-I:1960
IS:875 Code of practice for design loads National Building code of Canada
(other than earthquake) for (1953)-Part-IV Design section 4.1
buildings and structures Leading
standards (issued by Canadian
Standard) DIN-1055-1955 (Issued by
ASA)
IS:1239 Part-I Mild steel tubes (ISO/R 65-1957)
(ISO/R-64-1958)
(ISO/R-65-1958)
(BS 1387 : 1957)
IS:1239 Part-II Mild steel tubulars and other BS 1387 : 1967; BS 1387 :1967
wrought steel pipe fittings
BS 1740 :1965
IS:2825 Code for unfired vessels
IS:1520 Horizontal centrifugal pumps for
clear cold and fresh water


IS:1600 Code for practice for performance of
constant speed IC Engines for
general purpose.
IS:1601 Specification for performance of
constant speed IC Engines for
general Purpose
IS:1893 Criteria for earthquake resistant
design of structures
IS1978-1971 Line Pipe April 1969. API Standards 5L

IS:2254-1970 Dimensions of vertical shaft motor IEC Pub 72-1 part I
for pumps
NEMA Pub MG 1 1954
IS:2266 Steel wire ropes for general BS :302 : 1968
engineering purposes
IS:2312 Propellant type Ventilation fans

IS:2365 Steel wire suspension ropes for lifts BS : 1957
and hoists
IS:3346 Method for the determination DIN 52612 (Deutscher
Thermal conductivity of thermal Normenausschuss)
insulation materials (two slab
ASTM C 163-1964 (American
guarded hot plate method)
Society of Testing and materials)
ASTM C 167-1974
ASTM C 177-1963
IS:3354 Outline dimensions for electric lifts
IS:3401 Silica gel
IS:3588 Specification for electrical axial flow
fans
IS:3589 Electrically welded steel pipes for
water, gas and sewage (200mm to
2000 mm Nominal Diameter)
IS:3677 Un-bonded rock and slag wool for
thermal insulation
IS:3815 Point hook with shank for general BS 482 – 1968 ; Doc.:67/3 1284
engineering purposes (Revision of BS 2903) (Issued BS)


IS:3895 Specification for monocrystallines
Semiconductor rectifier cells and
stacks
IS:3963 Roof extractor unit
IS:3975 Mild steel wires, strips and tapes for
armouring cables
IS:4503 Shell and tube type heat Exchanger
IS:4540 Specification for monorystallines
rectifier assembly equipment
IS:4671 Expanded polystyrene for
thermal insulation purpose
IS:4736 Hot dip zinc coating on steel tubes
IS:4894 Centrifugal fans
IS:5456 Code of practice for testing of
positive displacement type air
compressors and exhauster (For
Test Tolerance Only)
IS:5749 Forged ramshorn hooks Entwurf DIN 15402
Blett 1
Entwurf DIN 15402
BS 3017-1958
IS:6392 Steel pipe flanges BS 4504 : 1969
IS:6524 Code of practice for Part-I design of BS 2799 : 1956
tower cranes Static and rail mounted
IS:7098 Cross linked Polyethylene Standard No. 1 to insulated PVC
sheathed IPCEA (USA) Pub. cables
No. 5-66-524
IS:7373 Specification for wrought
aluminium and aluminium sheet
and strips
IS:7938 Air receivers for compressed air
installation
ISO:1217 Displacement compressor-Acceptance test


ASHRAE-33. Methods of testing for rating of forced circulation air cooling and air
heating coils.
ASHRAE-52-76 Air cleaning device used in general ventilation for removing particle
matter
ASHRAE-22-72 Method of testing for rating of water cooled refrigerant condensers.
ASHRAE 23-67 Methods of testing for rating of positive displacement refrigerant
compressors.
ARI-450-6 Standard for water cooled refrigerant condensers. ARI-550 Standard for
centrifugal water chilling packages.
ARI-410 Standard for forced circulation air cooling and air heating coils
ARI-430/435 Central station AHU/Application of Central Station AHU Fans
BS:848(Part-1,2)
BS:400 Low carbon steel cylinders for the storage & transport of permanent gases.
BS:401 Low carbon steel cylinders for the storage & transport of liquefied gases.
CTI Code . Acceptance test code for Water Cooling Tower.
ACT-105
ANSI-31.5 Refrigerant piping
ASME-PTC- 23- Atmospheric Water Cooling Equipment
1958
AMCA A-21C Test Code for air moving devices
API:618 Reciprocating Compressor for general refinary services.
HYDRAULIC INSTITUTE STANDARDS.
HYDRANT SYSTEM MANUALS OF TAC.
TAC MANUALS OF SPRAY SYSTEM
NFPA USA/ NSC UK/ UL USA/ FM USA STANDARDS.
INDIAN EXPLOSIVES ACT.
INDIAN FACTORIES ACT.
STANDARD OF TUBULAR EXCHANGER MANUFACTURER'S ASSOCIATION.
CODE AND STANDARD FOR CIVIL WORKS

Some of the applicable Standards, Codes and references are as follows:


Excavation &
Filling
IS: 2720 (Part-II, IV TO VIII, XIV, XXI, XXIII, XXIV, XXVII TO XXIX, XL) Methods of test for
soils-determination for water content etc.
IS: 4701 Code of practice for earth work on canals.
IS: 9758 Guide lines for Dewatering during construction.
IS: 10379 Code of practice for field control of moisture and compaction of soils
for embankment and sub-grade.
Properties, Storage and Handling of Common Building Materials

IS: 269 Specification for ordinary Portland cement, 33 grade.
IS: 383 Specification for coarse and fine aggregates from natural sources for
concrete.
IS: 432 Specification for mild steel and (Parts 1&2) medium tensile steel bars and
hard-drawn steel wires for concrete reinforcement.
IS: 455 Specification for Portland slag cement.
IS: 702 Specification for Industrial bitumen.
IS: 712 Specification for building limes
IS: 808 Rolled steel Beam channel and angle sections
IS: 1077 Specification for common burnt clay building bricks.
IS: 1161 Specification of steel tubes for structural purposes
IS: 1363 Hexagon head Bolts, Screws and nuts of production grade C.
IS: 1364 Hexagon head Bolts, Screws and Nuts of Production grade A & B.
IS: 1367 Technical supply conditions for Threaded fasteners.

IS: 1489 Specification for Portland-pozzolana cement.
(Part-I) Fly ash based.
(Part-II) Calcined clay based.
IS: 1542 Specification for sand for plaster.
IS: 1566 Specification for hard-drawn steel wire fabric for concrete reinforcement.
IS: 1786 Specification for high strength deformed bars for concrete reinforcement.
IS: 2062 Specification for steel for general structural purposes.
IS: 2116 Specification for sand for masonry mortars


IS: 2386 Testing of aggregates for concrete.
(Parts-I to VIII)
IS: 3150 Hexagonal wire netting for general purpose.
IS: 3495 Methods of tests of burnt clay building bricks.
(Parts-I to IV)
IS: 3812 Specification for fly ash, for use as pozzolana and admixture.
IS: 4031 Methods of physical tests for hydraulic cement.
IS: 4032 Methods of chemical analysis of hydraulic cement.
IS: 4082 Recommendations on stacking and storage of construction Materials at site.
IS: 8112 Specification for 43 grade ordinary portland cement.
IS: 8500 Medium and high strength structural steel.
IS: 12269 53 grade ordinary portland cement.
IS: 12894 Specification for Fly ash lime bricks. Cast-In-Situ Concrete and Allied
Works
IS: 280 Specification for mild steel wire for general engineering purposes.
IS: 456 Code of practice for plain and reinforced concrete.
IS: 457 Code of practice for general construction of plain & reinforced
concrete for dams & other massive structures.
IS: 516 Method of test for strength of concrete.
IS: 650 Specification for standard sand for testing of cement.
IS: 1199 Methods of sampling and analysis of concrete.
IS: 1791 General requirements for batch type concrete mixers.
IS: 1838 (Part-I) Specification for preformed fillers for expansion joints in
Concrete pavements and structures (non-extruding and resilient
type).
IS: 2204 Code of practice for construction of reinforced concrete shell roof.
IS: 2210 Criteria for the design of reinforced concrete shell structures and
folded plates.
IS: 2438 Specification for roller pan mixer.

IS: 2502 Code of practice for bending and fixing of bars for concrete
reinforcement.
IS: 2505 General requirements for concrete vibrators, immersion type.
IS: 2506 General requirements for concrete vibrators, screed board type.
IS: 2514 Specification for concrete vibrating tables.
IS: 2645 Specification for Integral cement water proofing compounds.
IS: 2722 Specification for portable swing weigh batches for concrete. (single
and double bucket type)
IS: 2750 Specification for Steel scaffolding.
IS: 2751 Code of practice for welding of mild steel plain and deformed bars
for reinforced concrete construction.
IS: 3025 Methods of sampling and test waste water.
IS: 3366 Specification for Pan vibrators.
IS: 3370(Part I to IV) Code of practice for concrete structures for the storage of liquids.
IS: 3414 Code of practice for design and installation of joints in buildings.
IS: 3550 Methods of test for routine control for water used in industry.
IS: 3558 Code of practice for use of immersion vibrators for consolidating
concrete.
IS: 4014(Parts I & II) Code of practice for steel tubular scaffolding.
IS: 4326 Code of practice for earthquake resistant design and construction of
buildings.
IS: 4461 Code of practice for joints in surface hydro-electric power stations.
IS: 4656 Specification for form vibrators for concrete.
IS: 4925 Specification for batching and mixing plant.
IS: 4990 Specification for plywood for concrete shuttering work.
IS: 4995(Parts I & II) Criteria for design of reinforced concrete bins for the storage of
granular and powdery materials.
IS: 5256 Code or practice for sealing joints in concrete lining on canals.
IS: 5525 Recommendations for detailing of reinforcement in reinforced

concrete work.
IS: 5624 Specification for foundation bolts.

IS: 6461 Glossary of terms relating to cement concrete.
IS: 6494 Code of practice for water proofing of underground water reservoirs
and swimming pools.
IS: 6509 Code of practice for installation of joints in concrete pavements.
IS: 7861(Parts I & II) Code of practice for extreme weather concreting.
IS: 9012 Recommended practice for shot concreting.
IS: 9103 Specification for admixtures for concrete.
IS: 9417 Recommendations for welding cold worked steel bars for reinforced
concrete construction.
IS: 10262 Recommended guidelines for concrete mix design.
IS: 11384 Code of practice for composite construction in structural steel and
concrete.
IS: 11504 Criteria for structural design of reinforced concrete natural draught
cooling towers.
IS: 12118 Specification for two-parts poly sulphide.
IS: 12200 Code of practice for provision of water stops at transverse

contraction joints in masonry and concrete dams.
IS: 13311 Method of non-destructive testing of concrete.
Part-1 Ultrasonic pulse velocity.
Part-2 Rebound hammer.
SP:23 Handbook of concrete mixes
SP: 24 Explanatory Handbook on IS: 456-1978
SP: 34 Handbook on concrete reinforcement and detailing.
Precast Concrete Works
SP: 7(PartVI/ National Building Code- Structural design of prefabrication and

Sec.7) systems building.
IS: 10297 Code of practice for design and construction of floors and roofs
using precast reinforced/prestressed concrete ribbed or cored slab
units.
IS: 10505 Code of practice for construction of floors and roofs using pre-cast
reinforced concrete units.

Masonary and Allied Works
IS: 1905 Code of Practice for Structural Safety of Buildings-Masonry walls.
IS: 2212 Code of Practice for Brickwork.
IS: 2250 Code of Practice for Preparation and use of Masonry Mortar.
SP: 20 Explanatory hand book on masonry code.
Sheeting Works
IS:277 Galvanised steel sheets (plain or corrugated).
IS: 459 Unreinforced corrugated and semi-corrugated asbestos cement

sheets.
IS: 513 Cold-rolled carbon steel sheets.
IS: 730 Specification for fixing accessories for corrugated sheet

roofing.
IS: 1626 Specification for Asbestos cement building pipes and pipe
fittings, gutters and gutter fittings and roofing fittings.
IS: 2527 Code of practice for fixing rain water gutters and down pipe
for roof drainage.
IS: 3007 Code of practice for laying of asbestos cement sheets.
IS: 5913 Methods of test for asbestos cement products.
IS: 7178 Technical supply conditions for tapping screw.
IS: 8183 Bonded mineral wool.
IS: 8869 Washers for corrugated sheet roofing.
IS: 12093 Code of practice for laying and fixing of sloped roof covering using
plain and corrugated galvanised steel sheets.
IS: 12866 Plastic translucent sheets made from thermosetting polyster resin
(glass fibre reinforced).
IS: 14246 Specification for continuously pre-painted galvanised steel sheets

and coils.
Fabrication and Erection of Structural Steel Work
IS: 2016 Specification for plain washers.
IS: 814 Specification for covered Electrodes for Metal Arc Welding for
weld steel.

IS: 1852 Specification for Rolling and Cutting Tolerances for Hot rolled
steel products.
IS: 3502 Specifications for chequered plate.
IS: 6911 Specification for stainless steel plate, sheet and strip.
IS: 3757 Specification for high strength structural bolts.
IS: 6623 Specification for high strength structural nuts.
IS: 6649 High Tensile friction grip washers.
IS: 800 Code of practice for use of structural steel in general building
construction.
IS: 816 Code of practice for use of Metal Arc Welding for General
Construction.
IS: 4000 Code of practice for assembly of structural joints using high
tensile friction grip fasteners.
IS: 9595 Code of procedure of Manual Metal Arc Welding of Mild Steel.
IS: 817 Code of practice for Training and Testing of Metal Arc Welders.
IS: 1811 Qualifying tests for Metal Arc Welders (engaged in welding
structures other than pipes).
IS: 9178 Criteria for Design of steel bins for storage of Bulk Materials.
IS: 9006 Recommended Practice for Welding of Clad Steel.
IS: 7215 Tolerances for fabrication steel structures.
IS: 12843 Tolerance for erection of structural steel.
IS: 4353 Recommendations for submerged arc welding of mild steel and
low alloy steels.
SP: 6 ISI Hand book for structural Engineers. (Part 1 to 7)
IS: 1608 Method of Tensile Testing of Steel products other than sheets,
strip, wire and tube.
IS: 1599 Method of Bend Tests for Steel products other than sheet, strip, wire
and tube.
IS : 228 Methods of chemical Analysis of pig iron, cast iron and plain
carbon and low alloy steel.
IS : 2595 Code of Practice for Radio graphic testing.

IS : 1182 Recommended practice for Radiographic Examination of fusion

welded butt joints in steel plates.
IS : 3664 Code of practice for Ultra sonic Testing by pulse echo method.
IS : 3613 Acceptance tests for wire flux combination for submerged Arc
Welding.
IS : 3658 Code of practice for Liquid penetrant Flaw Detection.
IS : 5334 Code of practice for Magnetic Particle Flaw Detection of Welds.
Plastering and Allied Works
IS : 1635 Code of practice for field slaking of Building lime and preparation of
putty.
IS : 1661 Application of cement and cement lime plaster finishes.
IS : 2333 Plaster-of-paris.
IS : 2402 Code of practice for external rendered finishes.
IS : 2547 Gypsum building plaster.
IS : 3150 Hexagonal wire netting for general purpose.
Acid and Alkali Resistant Lining
IS : 158 Ready mixed paint, brushing, bituminous, black, lead free, acid,
alkali & heat resisting.
IS : 412 Specification for expanded metal steel sheets for general

purpose.
IS : 4441 Code of practice for use of silicate type chemical resistant

mortars.
IS : 4443 Code of practice for use of resin type chemical resistant

mortars.
IS : 4456(Part I & II) Method of test for chemical resistant tiles.
IS : 4457 Specification for ceramic unglazed vitreous acid resistant tiles.
IS : 4832 Specification for chemical resistant mortars.
Part I Silicate type
Part II Resin type
Part III Sulphur type
IS : 4860 Specification for acid resistant bricks.

IS : 9510 Specification for bitumasitc, Acid resisting grade.
Water Supply, Drainage and Sanitation
IS : 458 Specification for concrete pipes.
IS : 554 Dimensions for pipe threads, where pressure tight joints are made on
thread.
IS : 651 Specification for salt glazed stoneware pipes.
IS : 774 Flushing cisterns for water closets and urinals.
IS : 775 Cast iron brackets and supports for wash basins and sinks.
IS : 778 Copper alloy gate, globe and check valves for water works
purposes.
IS : 781 Cast copper alloy screw down bib taps and stop valves for water
services.
IS : 782 Caulking lead.
IS : 783 Code of practice for laying of concrete pipes.
IS : 1172 Basic requirements for water supply, drainage and sanitation.
IS : 1230 Cast iron rain water pipes and fittings.
IS : 1239 Mild steel tubes, tubulars and other wrought steel fittings.
IS : 1536 Centrifugally cast (Spun) iron pressure pipes for water, gas and
sewage.
IS : 1537 Vertically cast iron pressure pipes for water, gas and sewage.
IS : 1538 Cast iron fittings for pressure pipe for water, gas and sewage.
IS : 1703 Ball valves (horizontal plunger type) including float for water
supply purposes.
IS : 1726 Cast iron manhole covers and frames.
IS : 1729 Sand cast iron spigot and socket, soil, water and ventilating pipes,
fittings and accessories.
IS : 1742 Code of practice for building drainage.
IS : 1795 Pillar taps for water supply purposes.
IS : 1879 Malleable cast iron pipe fittings.
IS : 2064 Code of practice for selection, installation and maintenance of

sanitary appliances.

IS : 2065 Code of practice for water supply in building.
IS : 2326 Automatic flushing cisterns for urinals.
IS : 2470 Code of practice for installation of septic tanks. (Part-I & II)
IS : 2501 Copper tubes for general engineering purposes.
IS : 2548 Plastic seat and cover for water-closets.
IS : 2556 Vitreous sanitary appliances (vitreous china). (Part 1 to 15)
IS : 2963 Non-ferrous waste fittings for wash basins and sinks.
IS : 3114 Code of practice for laying of cast iron pipes.
IS : 3311 Waste plug and its accessories for sinks and wash basins.
IS : 3438 Silvered glass mirrors for general purposes.
IS : 3486 Cast iron spigot and socket drain pipes.
IS : 3589 Electrically welded steel pipes for water, gas and

sewage(200mm to 2000mm nominal diameter).
IS : 3989 Centrifugally cast (Spun) iron spigot and socket soil, waste and
ventilating pipes, fittings and accessories.
IS : 4111. (Part I to IV) Code of practice for ancillary structure in sewerage system
IS : 4127 Code of practice for laying of glazed stone-ware pipes.
IS : 4764 Tolerance limits for sewage effluents discharged into inland-

surface waters.
IS : 4827 Electro plated coating of nickel and chromium on copper and

copper alloys.
IS : 5329 Code of practice for sanitary pipe work above ground for
buildings.
IS : 5382 Rubber sealing rings for gas mains, water mains and sewers.
IS : 5822 Code of practice for laying of welded steel pipes for water
supply.
IS : 5961 Cast iron grating for drainage purpose.
IS : 7740 Code of practice for road gullies.
IS : 8931 Cast copper alloy fancy bib taps and stop valves for water
services.
IS : 8934 Cast copper alloy fancy pillar taps for water services.

IS : 9762 Polyethylene floats for ball valves.
IS : 10446 Glossary of terms for water supply and sanitation.
IS : 10592 Industrial emergency showers, eye and face fountains and

combination units.
IS : 12592 Specification for precast concrete manhole covers and frames.
IS : 12701 Rotational moulded polyethylene water storage tanks.
SP: 35 Hand book on water supply and drainage.
---- Manual on Sewerage and sewage treatment (Published by CPH &

EEO) As updated.
Doors, Windows and Allied Works
IS : 204 Tower Bolts
Part-I Ferrous metals.
Part-II Nonferrous metals.
IS : 208 Door Handles.
IS : 281 Mild steel sliding door bolts for use with padlocks.
IS : 362 Parliament Hinges.
IS : 420 Specification for putty, for use on metal frames.
IS : 1003 (Part-I) Specification for timber panelled and glazed shutters-door

shutters.
IS : 1038 Steel doors, windows and ventilators.
IS : 1081 Code of practice for fixing and glazing of metal (steel and
aluminium) doors, windows and ventilators.
IS : 1341 Steel butt hinges.
IS : 1361 Steel windows for industrial buildings.
IS : 1823 Floor door stoppers.
IS : 1868 Anodic coatings on Aluminium and its alloys.
IS : 2202(Part-II) Specification for wooden flush door shutters (solid core type);
particle board face panels and hard board face panels
IS:2209 Mortice locks (vertical type).
IS:2553 Safety glass

IS:2835 Flat transparent sheet glass.
IS:3548 Code of practice for glazing in buildings.
IS:3564 Door closers (Hydraulically regulated).
IS : 3614 Fire check doors; plate, metal covered and rolling type. IS:4351
Steel door frames.
IS:5187 Flush bolts.
IS:5437 Wired and figured glass
IS:6248 Metal rolling shutters and rolling grills.
IS:6315 Floor springs (hydraulically regulated) for heavy doors.
IS:7196 Hold fasts.
IS:7452 Hot rolled steel sections for doors, windows and ventilators.
IS:10019 Mild steel stays and fasteners.
IS:10451 Steel sliding shutters (top hung type).
IS:10521 Collapsible gates.
Roof Water Proofing and Allied Works
IS:1203 Methods of testing tar and bitumen.
IS:1322 Specification for bitumen felts for water proofing and damp
proofing.
IS:1346 Code of practice for water proofing of roofs with bitumen felts.
IS:1580 Specification for bituminous compound for water proofing and

caulking purposes.
IS:3067 Code of practice for general design details and preparatory work for
damp proofing and water proofing of buildings.
IS:3384 Specification for bitumen primer for use in water proofing and
damp proofing.
Floor Finishes and Allied Works
IS:1237 Specification for cement concrete flooring tiles.
IS:1443 Code of practice for laying and finishing of cement concrete

flooring tiles.
IS:2114 Code of practice for laying in-situ terrazzo floor finish.

IS:2571 Code of practice for laying in-situ cement concrete flooring.
IS:3462 Specification for unbacked flexible PVC flooring.
IS:4971 Recommendations for selection of industrial floor finishes.
IS:5318 Code of practice for laying of flexible PVC sheet and tile
flooring.
IS:8042 Specification for white portland cement.
IS:13801 Specification for chequered cement concrete flooring tiles.
Painting and Allied Works
IS:162 Specification for fire resisting silicate type, brushing, for use on
wood, colour as required.
IS:1477 Code of practice for painting of ferrous metals in buildings.
Part-I Pretreatment.
Part-II Painting.
IS:1650 Specification for colours for building and decorative finishes.
IS:2074 Specification for red oxide-zinc chrome, priming, ready mixed

paint air drying.
IS:2338 Code of practice for finishing of wood and wood based

materials.
Part-I Operations and workmanship
Part-II Schedules
IS:2395 Code of practice for painting concrete, masonry and plaster

surfaces.
Part-I Operations and workmanship.
Part-II Schedule.
IS:2524 Code of practice for painting of nonferrous metals in buildings.
Part-I Pretreatment.
Part-II Painting.
IS:2932 Specification of synthetic enamel paint, exterior, under-coating

and finishing.
IS:2933 Specification enamel paint, under coating and finishing.

IS:4759 Code of practice for hot dip zinc coating on structural steel and
other allied products.
IS:5410 Specification for cement paint
IS:5411(Part-I) Specification for plastic emulsion paint-for exterior use.
IS:6278 Code of practices for white washing and colour washing.
IS:10403 Glossary of terms relating to building finishes.
Piling and Foundation
IS:1080 Code of practice for design and construction of simple spread

foundations.
IS:1904 Code of practice for design and construction of foundations in

Soils; General Requirements.
IS:2911 Code of practice for designs and construction of Pile

foundations (Relevant Parts).
IS:2950(Part-I) Code of practice for designs and construction of Raft

foundation.
IS:2974(Part-I TO V) Code of practice for design and construction of machine

foundations.
IS:6403 Code of practice for determination of Allowable Bearing

pressure on Shallow foundation.
IS:8009 Code of practice for calculation of settlement of foundation

subjected to symmetrical vertical loads.
Part-I Shallow foundations.
Part-II Deep foundations.
IS:12070 Code of practice for design and construction of shallow

foundations on rocks.
DIN:4024 Flexible supporting structures for machines with rotating

machines.
VDI:2056 Criteria for assessing mechanical vibrations of machines.
VDI:2060 Criteria for assessing rotating imbalances in machines.
Stop Log and Trash Rack
IS:4622 Recommendations for fixed - wheel gates structural design.

IS:5620 Recommendations for structural design criteria for low head slide
gates.
IS:11388 Recommendations for design of trash rack for intakes.
IS:11855 General requirements for rubber seals for hydraulic gates.
Roads
IRC:5 Standard specifications and Code of practice for road bridges,

section-I general Features of Design.
IRC:14 Recommended practice of 2cm thick bitumen and tar carpets.
IRC:16 Specification for priming of base course with bituminous

primers.
IRC:19 Standard specifications and code of practice for water bound

macadam.
IRC:21 Standard specifications and Code of practice for road bridges,

section-III - Cement concrete (plain and reinforced).
IRC:34 Recommendations for road construction in waterlogged areas.
IRC:36 Recommended practice for the construction of earth

embankments for road works.
IRC:37 Guidelines for the Design of flexible pavements.
IRC:56 Recommended practice for treatment of embankment slopes for

erosion control.
IRC:73 Geometric design standards for rural (non-urban) highways.
IRC:SP:13 Guidelines for the design of small bridges & culverts.
IRC – Publication Ministry of Surface Transport (Roads Wing), Specifications for road
and bridge works.
IS:73 Specification for paving bitumen
Loadings
IS:875(Pt. I to V Code of practice for design loads other than earthquake) for
buildings and structures.
IS:1893 Criteria for earthquake resistant design of structures.
IS:4091 Code of Practice for design and construction of foundation for

transmission line towers & poles.

IRC:6 Standard specifications & code of practice for road bridges,

Section-II Loads and stresses.
M.O.T. Deptt. of railways Bridge Rules.
Safety
IS:3696(Part I & II) Safety code for scaffolds and ladders.
IS:3764 Safety code for excavation work.
IS:4081 Safety code for blasting and related drilling operations.
IS:4130 Safety code for demolition of buildings.
IS:5121 Safety code for piling and other deep foundations.
IS:5916 Safety code for construction involving use of hot bituminous

materials.
IS:7205 Safety code for erection on structural steelwork.
IS:7293 Safety code for working with construction machinery.
IS:7969 Safety code for handling and storage of building materials
IS:11769 Guidelines for safe use of products containing asbestos.
----- Indian Explosives Act. 1940 as updated.
Architectural design of buildings
SP:7 National Building Code of India
SP:41 Hand book on functional requirements of buildings (other than

industrial buildings)
Miscellaneous
IS:802 Code of practice for use of structural steel in (Relevant parts)

overhead transmission line towers.
IS:803 Code of practice for design, fabrication and erection of vertical

mild steel cylindrically welded in storage tanks.
IS:10430 Criteria for design of lined canals and liner for selection of type of
lining.
IS:11592 Code of practice for selection and design of belt conveyors.
IS:12867 PVC handrails covers.
CIRIA Publication Design and construction of buried thin-wall pipes.

REFERENCE CODES AND STANDARDS FOR CONTROL AND

INSTRUMENTATION
The design, manufacture, inspection, testing & installation of all equipment and
system covered under this specification shall conform to the latest editions of codes and
standards mentioned below and all other applicable VDE, IEEE, ANSI, ASME, NEC, NEMA,
ISA AND Indian Standards and their equivalents.
Temperature Measurements
1. Instrument and apparatus for temperature measurement - ASME PTC 19.3 (1974).
2. Temperature measurement - Thermocouples ANSI MC 96.1 - 1982.
3. Temperature measurement by electrical Resistance thermometers - IS:2806.
4. Thermometer - element - Platinum resistance - IS:2848.
Pressure Measurements
1. a) Instruments and apparatus for pressure measurement - ASME PTC 19.2

(1964).
b) Electronic transmitters BS:6447.
2. Bourdon tube pressure and vacuum gauges - IS:3624 - 1966.
3. Process operated switch devices (Pr. Switch) BS-6134.
Flow Measurements
Instruments and apparatus for flow measurements - ASME PTC 19.5 (1972) Interim
supplement, Part-II.
Measurement of fluid flow in closed conduits - BS-1042.
Electronic Measuring Instrument & Control Hardware/ Software
1. Automatic null balancing electrical measuring instruments - ANSI C 39.4 (Rev.

1973): IS:9319.
2. Safety requirements for electrical and electronic measuring and controling

instrument - ANSI C 39.5 - 1974.
3. Compatibility of analogue signals for electronic industrial process instruments - ISA

- S 50.1 (1982) ANSI MC 12.1 - 1975.
4. Dynamic response testing of process control instrumentation ISA - S 26 (1968).

5. Surge Withstand Capability (SWC) tests - ANSI C 37.90 a/IEEE-472 or

suitable class of IEC-255-4 equivalent to ANSI C37.90a/IEEE-472.
6. Printed circuit boards - IPC TM - 650, IEC 326 C.
7. General requirement and tests for printed wiring boards - IS 7405 (Part-I)
1973.
8. Edge socket connectors - IEC 130-11.
9. Requirements and methods of testing of wire wrap terminations DIN 41611 Part-2.
10. Dimensions of attachment plugs & receptacles - ANSI C 73 - 1973

(Supplement ANSI C 73 a - 1980).
11. Direct acting electrical indicating instrument - IS:1248 - 1968 (R).
12. Standard Digital Interface for Programmable Instrumentation - IEEE-488.2 - 1990.
13. Information Processing Systems - Local Area Networks - Part 2 : Logical Link
Control - IEEE-802.2 - 1989.
14. Standard for Local Area Networks : Carrier Sense Multiple Access with
Collision Detection - IEEE-802.3 - 1985.
15. Supplements A, B, C and E to Carrier Sense Multiple Access with Collision

Detection - IEEE-802.3 - 1988.
16. Standard for Local Area Networks : Token - Passing Bus Access Method - IEEE-
802.4 - 1985.
17. Standard for Local Area Networks : Token - Ring Access Method and
Physical Layer Specification - IEEE-802.5 - 1985.
18. IEEE Guide to Software Requirements Specifications - IEEE-830 - 1984.
19. Hardware Testing of Digital Process Computers - ISA RP55.1 - 1983.
20. Electromagnetic Susceptibility of Process Control Instrumentation - SAMA

PMC 33.1 - 1978.
21. Interface Between the Data Terminal Equipment and Data Circuit -
Terminating Equipment Employing Serial Binary Data Interchange - EIA-232- D-
1987.
22. Electromagnetic Compatibility for Industrial Process Measurement and

Control Equipment, Part 3 : Radiated Electromagnetic Field Requirements - IEC
801-3-1984.

Instrument Switches and Contact
1. Contact rating - AC services NEMA ICS 2 - 1978 (with revision through May 1983),
Part - 2-125, A6000.
2. Contact rating - DC services NEMA ICS 2-1978 Part-2 125, N600.
Enclosures
1. Type of Enclosures - NEMA ICS Part - 6 - 1978 (with Rev. 1 4/80) through 110.22
(Type 4 to 13).
2. Racks, panels and associated equipment - EIA : RS - 310 C- 1983 (ANSI C 83.9 -
1972).
3. Protection class for Enclosures, cabinets, control panels & desks - IS:2147 - 1962.
Apparatus, enclosures and installation practices in hazardous area
1. Classification of hazardous area - NFPA 70 - 1984, Article 500.
2. Electrical Instruments in hazardous dust location - ISA - 512.11, 1973.
3. Intrinsically safe apparatus - NFPA 493 1978.
4. Purged and pressurised enclosure for electrical equipment in hazardous

location - NFPA 496-1982.
5. Enclosures for Industrial Controls and Systems - NEMA IS 1.1 - 1977.
Sampling System
1. Stainless steel material of tubing and valves for sampling system - ASTMA 296-82,
Grade 7 P 316.
2. Submerged helical coil heat exchangers for sample coolers ASTM D11 92- 1977.
3. Water and steam in power cycle - ASME PTC 19.11.
4. Standard methods of sampling system - ASTM D 1066-99.
Annunciators
1. Specifications and guides for the use of general purpose annunciators - ISA S 19.1,
1979.
2. Surge withstand capability tests - ANSI C 37.90a - 1989/IEEE-472 or suitable class

of IEC 255-4 equivalent to ANSI C37.90a 1989/IEEE-472
3. Damp heat cycling test - IS:2106
4. Specification for Electromagnetic Susceptibility - SAMA DMC 33, 1/78

Protections
1. Relays and relay system associated with electric power apparatus. ANSI C 37.90, 1 -
1989.
2. General requirements & tests for switching devices for control and auxiliary circuits
including contactor relays - IS:6875 (Part-I) - 1973.
3. Turbine water damage prevention - ASME TDP-1-1980.
4. Boiler safety interlocks - NFPA 85 - 2011 or latest version.
UPS System
1. Practices and requirements for semi-conductor power rectifiers - ANSI C 34.2,

1973.
2. Relays and relays system associated with electrical power apparatus - ANSI C 3.90 -
1983.
3. Surge withstand capability test - ANSI C 37.90 1 -1989.
4. Performance testing of UPS - IEC 146.
5. Stationary cells & Batteries Lead Acid type (with tubular positive
plates)specification IS-1651-1991.
6. Recommended practice for sizing large lead storage batteries for generating stations
& sub-stations - IEEE-485-1985.
7. Printed Circuit Board - IPC TM 650, IEC 326C.
8. General Requirements & tests for printed wiring boards, IS:7405 (Part-I) 1973.
Control Valves
1. Control valve sizing - Compressible & Incompressible fluids - ISA S 75.01-

1985.
2. Face to face dimensions of control valves - ANSI B 16.00 - 1973.
3. ISA Hand Book of Control Valves - (ISBN : B: 1047-087664-234-2).
4. Codes for pressure piping - ANSI B 31.1
5. Control Valve leak class - ISA RP 39.6
Process Connection & Piping
1. Codes for pressure piping "power piping" - ANSI B 31.1.
2. Seamless carbon steel pipe ASTM - A - 106.

3. Forged & Rolled Alloy steel pipe flanges, forged fittings and valves and parts -
ASTM - A - 182.
4. Material for socket welded fittings - ASTM - A - 105.
5. Seamless ferritic alloy steep pipe - ASTM - A - 335.
6. Pipe fittings of wrought carbon steel and alloy steel - ASTM - A - 234.
7. Composition bronze of ounce metal castings - ASTM - B - 62.
8. Seamless Copper tube, bright annealed - ASTM - B - 168.
9. Seamless copper tube - ASTM - B - 75.
10. Dimension of fittings - ANSI - B - 16.11.
11. Valves flanged and butt welding ends - ANSI - B - 16.34.
Instrument Tubing
1. Seamless carbon steel pipe - ASTM - A 106.
2. Material of socket weld fittings - ASTM - A105.
3. Dimensions of fittings - ANSI - B - 16.11.
4. Code for pressure piping, welding, hydrostatic testing - ANSI B 31.1.
Cables
1. Thermocouples extension wires/cables - ANSI MC 96.1 - 1992.
2. Requirements for copper conductor-Wiring cables for telecommunications

&information processing system - VDE:0815.
3. Colour coding of single or multi-pair cables - ICEA - S - 61-402 (third edition)

NEMA WCS - 1979 with revisions thorugh 2/83.
4. Insulation & Sheathing compounds for cables : VDE 0207 (Part-4, 5 & 6).
5. Guide design and installation of cable systems in power generating stations

(insulation, jacket materials) - IEEE Std. 422-1977.
6. Rules for Testing insulated cables and flexible cables : VVDE - 0472
7. Requirements of vertical flame propagation test - IEEE 383 - 1974 (R 1980)
8. Standard specification for tinned soft or annealed copper wire for electrical
purpose - ASTM B-33-81.
9. Oxygen index and temperature index test - ASTM D - 2863.
10. Smoke density measurement test - ASTMD - 2843.

11. Acid gas generation test - IEC - 754 - 1.
12. Swedish Chimney test - SEN - 4241475 (F3).
13. Teflon (FEP) insulation & sheath test - ASTMD - 2116.
14. Thermocouple compensating cables - Testing requirements & sampling plan

IS:8784.
15. PVC insulated electric cables for working voltage upto and including 1100 V -
IS:1554 (Part-I).
Cable Trays, Conduits
1. Guide for design and installation of cable systems in power generating station
(Cable trays, support systems, conduits) - IEEE Std. 422, 1977, NEMA VE-1
1979, NFPA 70-1984.
2. -do- Test Standards. NEMA VE-1-1979.
3. Zinc coating "hot dip" on assembled products for galvanising of carbon steel cable
trays - ASTMA - 386-78.
Public Address System
1. Specifications for loud speakers - IS:7741 (Part-I, II and III)
2. Code of safety requirement for electric mains operated audio amplifiers -

IS:1301
3. Specification for Public Address Amplifiers - IS:10426.
4. Code of practice for outdoor installation of PA system - IS:1982.
5. Code of practice for installation for indoor amplifying and sound distribution
system - IS:1881.
6. Basic environmental testing procedures for electronic and electrical items -

IS:9000.
7. Characteristics and methods of measurements for sound system equipment -

IS:9302
8. Code of practice of electrical wiring installations (System voltage not

exceeding 650 volts) - IS:732
9. Rigid steel conduits for electric wiring - IS:9537 (Part-I and II)
10. Fittings for rigid steel conduits for electrical wiring - IS:2667
11. Degree of protection provided by enclosure for low voltage switchgear and
control gear - IS:2147.

Vibration Monitoring System
1. API 670 - 1994
2. BS : 4675 Part-2

ANNEXURE- I

ANNEXURE- II

ANNEXURE- III

ANNEXURE- IV

ANNEXURE- V

RSTPP ABSORBER PACKAGE GENERAL TEC
STAGE - III (FGD SYSTEM ) REQUIREMENT
ANNEXURE- VI


ANNEXURE- VII

RSTPP ABSORBER PACKAGE ERECTION CONDITIONS OF
STAGE - III (FGD SYSTEM ) CONTRACT (ECC)
SECTION VIII—INDEX
ERECTION CONDITIONS OF CONTRACT
1.00.00 GENERAL ........................................................................................................................ 3

2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES ................................. 3
3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING ....................... 3
4.00.00 HEAT TREATMENT ....................................................................................................... 4
5.00.00 WELD EDGE PREPARATION ...................................................................................... 5
6.00.00 CLEANING AND SERVICING ..................................................................................... 5
7.00.00 FIELD WELDING SCHEDULE...................................................................................... 5
8.00.00 SITE RUN MISCELLANEOUS PIPING ....................................................................... 6
9.00.00 THERMAL EXPANSIONS ............................................................................................. 7
10.00.00 PIPING SUPPORTS ......................................................................................................... 7
11.00.00 PRESSURE TESTING ...................................................................................................... 7
12.00.00 THERMOWELLS AND FLOW NOZZLES .................................................................. 8
13.00.00 INSULATION, LAGGING AND CLADDING ........................................................... 8
14.00.00 CODE REQUIREMENTS.............................................................................................. 10
15.00.00 ELECTRICAL SAFETY REGULATIONS ................................................................... 10
16.00.00 REMOVAL OF MATERIAL ......................................................................................... 11
17.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES ............................. 11
18.00.00 ACCESS TO SITE AND WORKS ON SITE ................................................................ 11
19.00.00 CONTRACTOR'S SITE OFFICE ESTABLISHMENT ............................................... 11
20.00.00 CO-OPERATION WITH OTHER CONTRACTORS ................................................ 11
21.00.00 DISCIPLINE OF WORKMEN ...................................................................................... 12
22.00.00 CONTRACTOR'S FIELD OPERATION ..................................................................... 12
23.00.00 PHOTOGRAPHS AND PROGRESS REPORT .......................................................... 13
24.00.00 MAN-POWER REPORT ............................................................................................... 13
25.00.00 PROTECTION OF WORK ............................................................................................ 13
26.00.00 EMPLOYMENT OF LABOUR ..................................................................................... 14
27.00.00 FACILITIES TO BE PROVIDED BY THE CLIENT (EPIL)/ NTPC ........................ 14
28.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR ....................................... 15
29.00.00 LINES AND GRADES .................................................................................................. 16
30.00.00 FIRE PROTECTION ...................................................................................................... 16
Tender Doc No.:SRO/CON/ETS/079 VOLUME-II SECTION-VIII Page 1 of 64

31.00.00 SECURITY ...................................................................................................................... 17

32.00.00 CONTRACTOR'S AREA LIMITS ................................................................................ 17
33.00.00 CONTRACTOR'S CO-OPERATION WITH THE CLIENT (EPIL)/ NTPC .......... 17
34.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES ......................... 18
35.00.00 MATERIALS HANDLING AND STORAGE ............................................................ 20
36.00.00 CONSTRUCTION MANAGEMENT.......................................................................... 22
37.00.00 FIELD OFFICE RECORDS ........................................................................................... 26
38.00.00 CONTRACTOR'S MATERIALS BROUGHT ON TO SITE...................................... 26
39.00.00 PROTECTION OF PROPERTY AND CONTRACTOR'S LIABILITY .................... 27
40.00.00 PAINTING...................................................................................................................... 27
41.00.00 INSURANCE .................................................................................................................. 27
42.00.00 UNFAVOURABLE WORKING CONDITIONS........................................................ 29
43.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS ........................... 29
44.00.00 WORK & SAFETY REGULATIONS ........................................................................... 29
45.00.00 FOREIGN PERSONNEL............................................................................................... 41
46.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/
EQUIPMENT BASES .................................................................................................... 42
47.00.00 SHAFT ALIGNMENTS ................................................................................................ 44
48.00.00 DOWELLING ................................................................................................................. 44
49.00.00 CHECK OUT OF CONTROL SYSTEMS ..................................................................... 45
50.00.00 COMMISSIONING SPARES........................................................................................ 45
51.00.00 CABLING ....................................................................................................................... 45
52.00.00 EQUIPMENT DELIVERY AND ERECTION............................................................. 46
53.00.00 WELDING - SPECIAL REQUIREMENTS ................................................................. 54
54.00.00 DEVIATIONS DISPOSITIONING .............................................................................. 54
55.00.00 NON-DESTRUCTIVE TESTING (NDT) .................................................................... 55
56.00.00 TESTING EQUIPMENT & FACILITIES ...................................................................... 55
ANNEXURE-I ..................................................................................................................................... 56
ANNEXURE-II ................................................................................................................................... 63
ANNEXURE - III ................................................................................................................................ 64

1.00.00 GENERAL
1.01.00 The following provisions shall supplement the conditions already contained in
the other parts of these specifications and documents and shall govern that portion
of the work of this contract which is to be performed at site. The erection requirements
and procedures not specified in these documents shall be in accordance with the
recommendations of the equipment manufacturer, or as mutually agreed to between
the Client (EPIL) and the Contractor prior to commencement of erection work.
1.02.00 The Contractor upon signing of the Contract shall, in addition to a Project
coordinator, nominate another responsible officer as his representative at Site suitably
designated for the purpose of overall responsibility and co-ordination of the Works to
be performed at Site. Such a person shall function from the Site office of the
Contractor during the pendency of Contract.
2.00.00 REGULATION OF LOCAL AUTHORITIES AND STATUTES
2.01.00 In addition to the local laws and regulations, the Contractor shall also comply with
the Minimum Wages Act and the Payment of Wages Act (both of the Government of
India) and the rules made there under in respect of its labour and the labour of its
sub-contractors currently employed on or connected with the contract.
2.02.00 All registration and statutory inspection fees, if any, in respect of his work pursuant to
this Contract shall be to the account of the Contractor. However, any registration,
statutory inspection fees lawfully pay-able under the provisions of the Indian Boiler
Regulations and any other statutory laws and its amendments from time to time
during erection in respect of the plant equipment ultimately to be owned by
the Client (EPIL)/ NTPC, shall be to the account of the Client (EPIL)/ NTPC. Should
any such inspection or registration need to be re-arranged due to the fault of the
Contractor or his Sub- Contractor, the additional fees for such inspection and/or
registration shall be borne by the Contractor.
3.00.00 WELDING OF PRESSURE PARTS AND HIGH PRESSURE PIPING
The welding of all pressure parts and high pressure piping shall be in accordance with
the following requirements:
3.01.00 Qualification of Weld Procedures
Only qualified welding procedures as per ASME Section IX shall be used by
contractor at site. Procedure qualification records along with WPS shall be submitted
to NTPC for review. Welding procedure shall indicate all essential and non-essential
parameters as per ASME Section IX. Makes of welding consumables shall be subject
to Client (EPIL)/ NTPC's approval.

3.02.00 Welder's Qualification

Only welders, who are qualified in accordance with the latest applicable requirements
of the Indian Boiler Regulations, shall be permitted to perform any welding work on
the pressure parts and its attachment welding. In addition to such statutory
qualification requirements, the welders shall also undergo a pre-
production qualification test to be conducted by the Contractor at site as per
ASME Sec IX in presence of Client (EPIL)/ NTPC's representative(s), prior to
performing work under these specifications. The services of an independent testing
laboratory shall be retained by the Contractor to perform welder qualification tests for
welders. All the welders carrying out welding at site shall carry an identification
badge, which shall indicate the category and the grade of welding for which they have
been tested and authorized to carry out welding.
3.03.00 Records
Welders performance shall be monitored regularly and record of their performance
shall be maintained by contractor in a manner acceptable to the Client
(EPIL)/ NTPC. Contractor shall maintain such records including record of procedure
qualification & welder qualification and hand-over to the Client (EPIL)/ NTPC at the
end of work.
3.04.00 MARKING
On completion of each welded joint, the welder shall mark his regularly
assigned identification mark near the joint. The welder's identification numbers,
inspection stamps or code symbol stamps and any other information shall not be
directly stamped on any alloy steel piping. In alloy steel piping, all such information
shall be stamped on separate marking plate which shall be tack welded on pipe
near the weld.
4.00.00 HEAT TREATMENT
4.01.00 Pre-heating, post-heating and post-weld stress relief operations of all welds, shall be
performed in accordance with the requirements of applicable code. Local post weld
stress relieving heat treatments shall be adopted only in cases where it is normally
impracticable to subject the entire assembly as such for stress relieving operations.
Heating may be by means of electric induction coils or electric resistance coils. Oxy-
acetylene flame heating or exothermic chemical heating methods will not be
permitted. Complete recording of the temperatures throughout the stress relieving
cycle of the material and the weld subjected to heat treatment shall be made by
means of a potentiometric recorder. Recorders other than those of potentiometric
type shall not be used for such temperature recording during stress relieving

operations. The contractor & Client (EPIL)/ NTPC's representative, at start and at the
end of HT Cycle shall sign the time and temperature charts for heat-treatment.
4.02.00 Not Used.
4.03.00 After setting up the weld joint for heat treatment operation, the Client (EPIL)/ NTPC's
signature shall be obtained on the strips chart of the recorder prior to starting of heat
treatment cycle. The right hand corner of the strip chart at the starting point of
the heat treatment cycle shall contain details like the weld number, material,
diameter and thickness, method of heating adopted, prescribed ranges of
heat treatment temperatures, date of heat treatment, reference to item number of the
Field welding Schedule (as specified at clause no 7.00.00- of this Section) etc.
5.00.00 WELD EDGE PREPARATION
Preparation at site of weld joint shall be in accordance with details acceptable to the
Client (EPIL)/ NTPC. Wherever possible, machining or automatic flame cutting shall
be used for edge preparation. Hand flame cutting will be permitted only
where edge preparation otherwise is impractical. All slag shall be removed from cuts
and all the hand cuts shall be ground smooth to the satisfaction of the Client (EPIL)/
NTPC. Flame cutting of alloy steel pipe shall be avoided. Wherever such cutting is
done, a 200mm length at the cut face shall be removed by machining. Pneumatic hand
tools such as edge preparation, tube cutting machine can be used.
6.00.00 CLEANING AND SERVICING
6.01.00 The inside of all tubes, pipes, valves and fittings shall be free from dirt, and loose
scales before being erected. All the pipelines shall be thoroughly blown and/or
flushed. Each steam and water tubes shall be blown with compressed air and shall be
subjected to 'ball test' before erection to ensure that no obstructions exist. A
system for recording of all such operations shall be developed and maintained in a
manner to ensure that no obstructions are left inside the tubes and no tubes are left
uncleaned and untested.
6.02.00 All valves and valve actuators, and dampers and damper actuators, if any, shall be
thoroughly cleaned and serviced prior to pre-commissioning tests and/or Initial
Operations of the plant. A system for recording of such servicing operation shall be
developed and maintained in a manner acceptable to the Client (EPIL)/ NTPC and to
ensure that no valves or dampers including their actuators are left unserviced.
6.03.00 All interior surfaces of the turbine shall be thoroughly cleaned prior to boxing - up to
remove all traces of oil preservations.
7.00.00 FIELD WELDING SCHEDULE
The Contractor shall submit to the Client (EPIL)/ NTPC, a certified and complete field
welding schedule for all the field welding activities to be carried out in respect of the

pressure parts involved in the equipment furnished and erected by him, at least 90
days prior to the scheduled start of erection work at site. Such schedule will be strictly
followed by the Contractor during the process of erection. The above field-welding
schedule to be issued by the Contractor shall contain the following:
(a.) Drawing No (s)
(b.) Location of the weld
(c.) Size of the weld (outside diameter and thickness)
(d.) Type of joints
(e.) Material specifications
(f.) Size of fillet on backing ring, when the type of joint is with backing ring.
(g.) Electrode/ filler metal specifications
(h.) Number of welds per unit
(i.) Quantity of filler metal per weld
(j.) Indication of required Non-destructive Examination (NDE) for each weld.
(k.) Pre-heat temperatures for welding.
(l.) Process of welding.
(m.) Post-welding heat treatment temperature ranges, duration, under as
specified at clause no 4.00.00 of this chapter entitled "Heat Treatment".
(n.) Qualification details of weld procedures to be adopted as specified at clause
no 3.01.00 of this Section entitled 'Qualification of Weld Procedures'.
8.00.00 SITE RUN MISCELLANEOUS PIPING
Sketches or diagrams of the proposed routings of all piping, not already indicated
and routed on the shop drawings which were reviewed by the Client (EPIL)/
NTPC, shall be submitted to the Client (EPIL)/ NTPC for review, Client (EPIL)/
NTPC's acceptance of such site routings shall be obtained before the piping is
erected. All these site run piping shall be installed in such a manner as to present an
orderly and neat installation. They shall be located as to avoid obstruction of access
and passages. Valves, instruments or any other special items shall be located
convenient for operation by the operating personnel. Pipe runs shall be plumb or
level except where pitch for drainage is required. Pipe runs that are not parallel
to the building structure, walls or column rows shall be avoided so that deflection
of pipes between hangers does not exceed 6 mm. No miscellaneous pipe shall be
routed and installed above or adjacent to electrical equipment.

9.00.00 THERMAL EXPANSIONS

All piping installation shall be such that no excessive or destructive expansion forces
exist either in the cold condition or under condition of maximum temperature.
All bends, expansion joints and any other special fittings, necessary to provide proper
expansion, shall be incorporated. During installation of expansion joints and
anchors, care must be taken to make sure that full design movement is available at all
times for maximum to minimum temperature and vice-versa.
10.00.00 PIPING SUPPORTS
10.01.00 Hangers, supports and anchors shall be installed as required to obtain a safe,
reliable and complete pipe installation. All supports shall be properly levelled and
anchored when installed. The anchors shall be so placed that thermal expansion will
be absorbed by bends without subjecting the valves or equipment to excessive
strains.
10.02.00 The hanger assemblies shall not be used for the attachment of rigging to hoist the pipe
into place. Other means shall be used to securely hold the pipe in place till the
structures and spring support is set to accommodate the pipe way. All
temporary rigging shall be removed in such a way that the pipe support is not
subjected to any sudden load. All piping, having variable spring type supports, shall
be held securely in place by temporary means during the hydraulic test of pipe
system. Constant support type spring hangers used during hydraulic test shall be
pinned or blocked solid during the test. After complete installation and insulation of
the piping and filling of the piping with its normal operating medium, the pipe
support springs shall be adjusted to the cold positions. If necessary, the spring
support shall be re-adjusted to the hot positions after the line has been placed for
service at its normal maximum operating temperature conditions. Electric arc welding
only shall be used to weld all pipe supports to structural steel members that form
part of the building supporting structure. The structural beams shall not be heated
more than necessary during welding of supports and such welds shall run parallel to
the axis of the span. All lugs or any other attachments welded to the piping shall be of
the same material as the pipe.
11.00.00 PRESSURE TESTING
11.01.00 On completion of erection of pressure parts, a hydraulic test in accordance with the
requirements of the Indian Boiler Regulations shall be performed by the Contractor.
11.02.00 All the valves, high pressure pipes and inter-connected pipes connecting the
pressure parts shall be tested along with pressure parts. All blank flanges or
any removable plugs required for openings not closed by the valves, and
piping provided, shall be furnished by the Contractor. The pressurization

equipment including water piping from the supply, needed for the above test
shall also be furnished by the Contractor. Any defects noticed during the testing are
to be rectified and the unit re-tested. If any welding is done on the pressure
parts after the Hydraulic test, the Hydraulic test for that portion of pressure parts
shall be repeated. Water as required for such pressure testing shall be provided by the
Client (EPIL)/ NTPC.
11.03.00 The hydraulic test shall be considered successful only on certification to that effect by
the concerned inspecting Authority as per the provisions of the Indian Boiler
Regulations and the Client (EPIL)/ NTPC.
12.00.00 THERMOWELLS AND FLOW NOZZLES
12.01.00 All the thermowells and flow nozzles in the equipment furnished under the technical
specifications shall be installed as a part of this work.
12.02.00 All thermowell connections incorporated in the steam service shall be plugged during
the pressure testing and the blow out of steam piping systems. Upon completion of the
blow out operation, all thermowells shall be installed and seam welded. Similarly, all
flow nozzles in the steam lines shall also be installed only on completion of steam
blowing operations unless otherwise agreed to by the Client (EPIL)/ NTPC,
depending upon the sequence of cleaning and purging operations to be adopted by
the Contractor at the field.
13.00.00 INSULATION, LAGGING AND CLADDING
The provision of insulation, lagging and cladding of the various equipments and
portion of the equipment covered under the Contract, shall be furnished by
Contractor as specified elsewhere or agree to separately in writing. Welds required for
holding insulation on pressure parts shall be carried out by IBR qualified welder.
13.01.00 Piping, Pipe Fittings & Valves
All piping insulation and metal cladding furnished with the equipment to be erected
shall be applied as specified herein.
13.01.01 Piping
The insulation on piping shall be applied using wire loops on 150mm centres. These
wire loops shall be thoroughly embedded into the outer insulation surface and
all cracks, voids and depressions shall be filled with insulating cement suitable for the
piping temperature so as to form a smooth base for application of cladding.
The wires used for piping insulation shall be of 16 SWG. The surface shall be
smooth and uniform before applying the outer covering. All piping insulation ends
shall be terminated at a sufficient distance from flanges to facilitate removal of bolts.

13.01.02 Flanges
Insulation on flanges shall be by means of blocks of insulating material securely
bound to the flange by wire loops. Such blocks of insulation shall be long enough to
overlap the adjacent pipe insulation by an amount equal to the thickness of adjacent
pipe insulation. Smooth finish shall be obtained by the application of insulating
cement. Alternatively, sectional pipe insulation of proper diameter may be used.
Insulation on flanges shall not be done until the pipe and equipment have been in
service during the initial operation and till all the flange bolts have been retightened.
13.01.03 Bends and Elbows
Insulation on bends and elbows shall be cut into sections sufficiently short to form a
reasonable smooth external surface. After the application of insulation material in
place, it shall be smoothly coated with insulating cement. Elbows may be insulated as
above or alternatively by means of specially moulded insulation enclosures.
13.01.04 Cladding
Cladding shall be of aluminium sheet of thickness as per details given in detail
Technical Specification or will be provided during detail engineering shall
be machine rolled and formed to accurately fit insulation curvatures. Cladding shall be
secured using self-tapping screws. Screws shall be adequate number and so
located as to produce tight joints. The spacing of screws shall be as far as possible
uniform and on centres not exceeding 150 mm. For outside diameters less than 230
mm, spacing of screws shall be on centres not exceeding 100 mm. adequate
number of screws shall be provided for fixing the cladding and be so placed in such
locations, as to produce a smooth cladding finish without bellying'. Insulated elbows
having insulated diameters less than 330 mm shall be provided with preformed
smooth aluminium elbow jackets. Wherever possible, all joints should be lapped a
minimum of 50 mm with joints facing downwards and so placed that they are
obscured from normal points of vision. All the joints in the cladding shall be made
with suitable provisions for expansions. All butt joints such as those shall be made
using rolled seams. In addition, to prevent galvanic corrosion, suitable action, as
specified at clause no 13.02.00 of this Section, shall be taken.
13.01.05 Valves and Fittings
All valves and fittings (above valve size of 2 inches) installed in the steam pipelines
shall also be applied with insulation and furnished with suitably shaped boxes so as to
facilitate easy dismantling of the fittings. The insulation thickness for valves, valve
fittings etc shall be same as that used on the line on which they are installed. All
voids shall be properly filled up with insulating material and as per the directions of
the Client (EPIL)/ NTPC.

13.02.00 Protection of Equipment during Insulation Applications

All equipment and structures shall be suitably protected from damage while applying
insulation after completion of insulation. All equipment and structures shall be
thoroughly cleaned and remove insulating materials which might have fallen on
them.
14.00.00 CODE REQUIREMENTS
The erection requirements and procedures to be followed during the installation of
the equipment shall be in accordance with the relevant Indian Electricity Rules
& Codes, Indian Boiler Regulations, ASME codes and accepted good practices,
the Client (EPIL)/ NTPC's Drawings and other applicable Indian recognised codes
and laws and regulations of the Government of India.
15.00.00 ELECTRICAL SAFETY REGULATIONS
15.01.00 In no circumstances will the Contractor interfere with fuses and electrical equipment
belonging to the other Contractor or Client (EPIL)/ NTPC.
15.02.00 Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other Contractor or Client (EPIL)/ NTPC, he shall:
(a) Satisfy the Client (EPIL)/ NTPC that the appliance is in good working
condition.
(b) Inform the Client (EPIL)/ NTPC of the maximum current rating, voltage and
phase of the appliances.
(c) Obtain permission of the Client (EPIL)/ NTPC detailing the socket to
which the appliances may be connected.
The Client (EPIL)/ NTPC will not grant permission to connect unitl he is
satisfied that :-
(d) The appliance is in good condition and is fitted with suitable plug.
(e) The appliance is fitted with a suitable cable having two earth conductors, one
of which shall be an earthened metal sheath surrounding the cores.
15.03.00 No electric cable in use by the other Contractor/Client (EPIL)/ NTPC will be
disturbed without permission. No weight of any description will be imposed on
any such cable and ladder or similar equipment will rest against or to be attached
with it.
15.04.00 No reapir work shall be carried out on any live equipment. The equipment must be
declared safe by the Client (EPIL)/ NTPC and a permit to work issued before
any work is carried out.
15.05.00 The Contractor shall employ the necessary number of qualified, full time electricians
to maintain his temporary electrical installation.

16.00.00 REMOVAL OF MATERIAL

No material brought to the Site shall be removed from the Site by the
Contractor and/or his Sub-Contractors without the prior written approval of the
17.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES
The provisions of the clause entitled Inspection, Testing and Inspection Certificates
given in Section-VII (GTR) of the Technical Specification, shall also be applicable
to the erection portion of the Works. The Client (EPIL)/ NTPC shall have the right
to re-inspect any equipment though previously inspected and approved by him
at the Contractor's works, before and after the same are erected at Site. If by the above
inspection, the Client (EPIL)/ NTPC rejects any equipment, the Contractor shall make
good for such rejections either by replacement or modification/ repairs as may
be necessary to the satisfaction of the Client (EPIL)/ NTPC. Such replacements will
also include the replacements or re-execution of such of those works of other
Contractors and/or agencies, which might have got damaged or affected by the
replacements or re-work done to the Contractor's work.
18.00.00 ACCESS TO SITE AND WORKS ON SITE
18.01.00 Suitable access to site and permission to work at the Site shall be accorded to the
Contractor by the Client (EPIL)/ NTPC in reasonable time.
18.02.00 In the execution of the Works, no person other than the Contractor or his duly
appointed representative, Sub-Contractor and workmen, shall be allowed to do work
on the Site, except by the special permission, in writing by the Client (EPIL)/
NTPC or his representative.
19.00.00 CONTRACTOR'S SITE OFFICE ESTABLISHMENT
The Contractor shall establish a Office at the Site and keep posted an authorized
representative for the purpose of the Contract. Any written order or instruction of the
Client (EPIL)/ NTPC or his duly authorised representative shall be communicated to
the said authorized resident representative of the Contractor and the same shall be
deemed to have been communicated to the Contractor at his legal address.
20.00.00 CO-OPERATION WITH OTHER CONTRACTORS
20.01.00 Client (EPIL)/ NTPC, who may be performing other works on behalf of the
Client (EPIL)/ NTPC and the workmen who may be employed by the Client (EPIL)/
NTPC and doing work in the vicinity of the works under the Contract. The Contractor
shall also arrange to perform his work as to minimise, to the maximum extent possible,
interference with the work of other Contracts and their workmen. Any injury or
damage that may be sustained by the employees of the other Contractors and the
Client (EPIL)/ NTPC, due to the Contractor's work shall promptly be made good at

his own expense. The Client (EPIL)/ NTPC shall determine the resolution of any
difference or conflict that may arise between the Contractor and other
Contractors or between the Contractor and the workmen of the Client (EPIL)/
NTPC in regard to their work. If the work of the Contractor is delayed because of the
any acts of omission of another Contractor, the Contractor shall have no claim
against the Client (EPIL)/ NTPC on that account other than an extension of time for
completing his works. Client (EPIL)/ NTPC shall have full access to visit the
contractor's site at any time for inspection and surveillance checks.
20.02.00 The Client (EPIL)/ NTPC shall be notified promptly by the Contractor of any defects
in the other Contractor’s works that could affect the Contractor's Works. The Client
(EPIL)/ NTPC shall determine the corrective measures if any, required to rectify
this situation after inspection of the works and such decisions by the Client (EPIL)/
NTPC shall be binding on the Contractor.
21.00.00 DISCIPLINE OF WORKMEN
The Contractor shall adhere to the disciplinary procedure set by the Client
(EPIL)/ NTPC in respect of his employees and workmen at Site. The Client (EPIL)/
NTPC shall be at liberty to object to the presence of any representative or
employee of the Contractor at the Site, if in the opinion of the Client (EPIL)/ NTPC
such employee has misconducted himself or is incompetent, negligent or otherwise
undesirable then the Contractor shall remove such a person objected to and provide
in his place a competent replacement.
22.00.00 CONTRACTOR'S FIELD OPERATION
22.01.00 The Contractor shall keep the Client (EPIL)/ NTPC informed in advance
regarding his field activity plans and schedules for carrying out each part of the
works. Any review of such plan or schedule or method of work by the Client
(EPIL)/ NTPC shall not relieve the Contractor of any of his responsibilities
towards the field activities. Such reviews shall also not be considered as an
assumption of any risk or liability by the Client (EPIL)/ NTPC or any of his
representatives and no claim of the Contractor will be entertained because of the
failure or inefficiency of any such plan or schedule or method of work reviewed. The
Contractor shall be solely responsible for the safety, adequacy and efficiency of plant
and equipment and his erection methods.
22.02.00 The Contractor shall have the complete responsibility for the conditions of the Work-
Site including the safety of all persons employed by him or his Sub-Contractor and all
the properties under his custody during the performance of the work. This
requirement shall apply continuously till the completion of the Contract and shall not
be limited to normal working hours. The construction review by the Client (EPIL)/

NTPC is not intended to include review of Contractor's safety measures in, on or near
the Work- Site, and their adequacy or otherwise.
23.00.00 PHOTOGRAPHS AND PROGRESS REPORT
23.01.00 The Contractor shall furnish three (3) prints each to the Client (EPIL)/ NTPC of
progress photographs of the work done at Site. Photographs shall be taken as and
when indicated by the Client (EPIL)/ NTPC or his representative. Photographs shall
be adequate in size and number to indicate various stages of erection. Each
photograph shall contain the date, the name of the Contractor and the title of the
photograph.
23.02.00 The above photographs shall accompany the monthly progress report detailing out
the progress achieved on all erection activities as compared to the schedules. The
report shall also indicate the reasons for the variance between the scheduled and
actual progress and the action proposed for corrective measures, wherever
necessary.
23.03.00 The Contractor shall submit the progress of work in soft and hard form (as decided by
Client (EPIL)/ NTPC) quarterly highlighting the progress and constraints at site.
24.00.00 MAN-POWER REPORT
24.01.00 The Contractor shall submit to the Client (EPIL)/ NTPC, on the first day of every
month, a man hour schedule for the month, detailing the man hours scheduled for the
month, skill- wise and area-wise.
24.02.00 The Contractor shall also submit to the Client (EPIL)/ NTPC on the first day of every
month, a man power report of the previous month detailing the number of persons
scheduled to have been employed and actually employed, skill- wise and the
areas of employment of such labour.
25.00.00 PROTECTION OF WORK
The Contractor shall have total responsibility for protecting his works till it is finally
taken over by the Client (EPIL)/ NTPC. No claim will be entertained by the Client
(EPIL)/ NTPC or the representative of the Client (EPIL)/ NTPC for any damage or
loss to the Contractor's works and the Contractor shall be responsible for complete
restoration of the damaged works to original conditions to comply with the
specification and drawings. Should any such damage to the Contractor's Works occur
because of other party not being under his supervision or control, the Contractor
shall make his claim directly with the party concerned. If disagreement or conflict
or dispute develops between the Contractor and the other party or parties concerned
regarding the responsibility for damage to the Contractor's Works the same shall be
resolved as per the provisions of the as specified at clause no 21.00.00 of this
chapter entitled "Co-operation with other Contractors." The Contractor shall not

cause any delay in the repair of such damaged Works because of any delay in
the resolution of such disputes. The Contractor shall proceed to repair the Work
immediately and no cause thereof will be assigned pending resolution of such
disputes.
26.00.00 EMPLOYMENT OF LABOUR
26.01.00 In addition to all local laws and regulations pertaining to the employment of labour to
be complied with by the Contractor pursuant to GCC, the Contractor will be expected
particular work. No female labour shall be employed after darkness. No person
below the age of eighteen years shall be employed.
26.02.00 All travelling expenses including provisions of all necessary transport to and
from Site, lodging allowances and other payments to the Contractor's employees shall
be the sole responsibility of the Contractor.
26.03.00 The hours of work on the Site shall be decided by the Client (EPIL)/ NTPC and the
Contractor shall adhere to it. Working hours will normally be eight (8) hours per day -
Monday through Saturday.
26.04.00 Contractor's employees shall wear identification badges while on work at Site.
26.05.00 In case the Client (EPIL)/ NTPC becomes liable to pay any wages or dues to the
labour or any Government agency under any of the provisions of the Minimum
Wages Act, Workmen Compensation Act, Contact Labour Regulation Abolition Act or
any other law due to act of omission of the Contractor, the Client (EPIL)/ NTPC
may make such payments and shall recover the same from the Contractor's Bills.
27.00.00 FACILITIES TO BE PROVIDED BY THE CLIENT (EPIL)/ NTPC
27.01.00 Electricity
Refer clause 3.20(d) (Construction Power) in Section –I of Technical Specification.
27.02.00 Water
Contractor shall make all arrangements himself for the supply of construction water as
well as potable water for labour and other personnel at the worksite/colony.
However, drawl of construction/potable water from bore-well shall be permitted
if found suitable. Any statutory clearance required shall be obtained by the contractor.
Assistance, if required shall be provided by the Client (EPIL)/ NTPC.
27.03.00 Communication
The Client (EPIL)/ NTPC will extend the telephone facilities, if available at Site, for
purposes of Contract. The Contractor shall be charged at actual for such facilities.
27.04.00 Railway Siding
Railway siding shall be provided by Client (EPIL)/ NTPC (up to plant entry
point) for coal transportation to site. However the same may not be available to

the bidder for material/supplies transport etc. Bidder has to plan its own
arrangement for movement of ODC consignment to plant site.
28.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR
28.01.00 Contractor's site office Establishment
The Contractor shall establish a site office at the site and keep posted an authorized
representative for the purpose of the contract, pursuant to GCC. The site office will
include one conference meeting room for site meetings between the Contractor and the
28.02.00 Tools, tackles and scaffoldings
The Contractor shall provide all the construction equipments, tools, tackles and
scaffoldings required for pre-assembly, installation, testing, commissioning and
conducting Guarantee tests of the equipments covered under the Contract. He shall
submit a list of all such materials to the Client (EPIL)/ NTPC before the
commencement of pre- assembly at Site. These tools and tackles shall not be removed
from the Site without the written permission of the Client (EPIL)/ NTPC. The
Contractor shall arrange Dozer, Hydra, Cranes, Trailer, etc. for the purpose of
fabrication, erection and commissioning.
28.03.00 Testing Equipment and Facilities:
The contractor shall provide the necessary testing, equipment and facilities.
28.04.00 Site laboratory for civil works
Contractor shall provide and maintain a site laboratory for the testing of construction
material under the direction and general supervision of Client (EPIL)/ NTPC.
28.05.00 First-aid
28.05.01 The Contractor shall provide necessary first-aid facilities for all his employees,
representatives and workmen working at the Site. Enough number of Contractor's
personnel shall be trained in administering first-aid.
28.05.02 The Client (EPIL)/ NTPC will provide the Contractor, in case of any emergency, the
services of an ambulance for transportation to the nearest hospital.
28.06.00 Cleanliness
28.06.01 The Contractor shall be responsible for keeping the entire area allotted to him clean
and free from rubbish, debris etc. during the period of Contract. The Contractor shall
employ enough number of special personnel to thoroughly clean his work-area
at least once in a day. All such rubbish and scrap material shall be stacked or disposed
in a place to be identified by the Client (EPIL)/ NTPC. Materials and stores shall be so
arranged to permit easy cleaning of the area. In areas where equipment might drip oil

and cause damage to the floor surface, a suitable protective cover of a flame resistant,
oil proof sheet shall be provided to protect the floor from such damage.
28.06.02 Similarly the offices shall be kept clean and neat to the entire satisfaction of
the Client (EPIL)/ NTPC. Proper sanitary arrangements shall be provided by the
Contractor, in the work-areas and office areas of the Contractor.
29.00.00 LINES AND GRADES
All the Works shall be performed to the lines, grades and elevations indicated on the
drawings. The Contractor shall be responsible to locate and layout the Works.
Basic horizontal and vertical control points will be established and marked by
the Client (EPIL)/ NTPC at Site at suitable points. These points shall be used as
datum for the works under the Contract. The Contractor shall inform the Client
(EPIL)/ NTPC well in advance of the times and places at which he wishes to do work
in the area allotted to him so that suitable datum points may be established and
checked by the Client (EPIL)/ NTPC to enable the Contractor to proceed with his
works. Any work done without being properly located may be removed and/or
dismantled by the Client (EPIL)/ NTPC at Contractor's expense.
30.00.00 FIRE PROTECTION
30.01.00 The work procedures that are to be used during the erection shall be those which
minimise fire hazards to the extent practicable. Combustible materials, combustible
waste and rubbish shall be collected and removed from the Site at least once each day.
Fuels, oils and volatile or flammable materials shall be stored away from the
construction and equipment and materials storage areas in safe containers.
Untreated canvas, paper, plastic or other flammable flexible materials shall not at all
be used at Site for any other purpose unless otherwise specified. If any such
materials are received with the equipment at the Site, the same shall be removed
and replaced with acceptable material before moving into the construction or storage
area.
30.02.00 Similarly corrugated paper fabricated cartons etc will not be permitted in the
construction area either for storage or for handling of materials. All such materials
used shall be of water proof and flame resistant type. All the other materials such as
working drawings, plans etc. which are combustible but are essential for the works to
be executed shall be protected against combustion resulting from welding
sparks, cutting flames and other similar fire sources.
30.03.00 All the Contractor's supervisory personnel and sufficient number of workers shall be
trained for fire-fighting and shall be assigned specific fire protection duties. Enough of
such trained personnel must be available at the Site during the entire period of the
Contract.

30.04.00 The Contractor shall provide enough fire protection equipment of the types and
number for the warehouses, office, temporary structures, labour colony area etc.
Access to such fire protection equipment, shall be easy and kept open at all time.
31.00.00 SECURITY
The Contractor shall have total responsibility for all equipment and materials in his
custody stores, loose, semi-assembled and/or erected by him at Site. The
Contractor shall make suitable security arrangements including employment of
security personnel to ensure the protection of all materials, equipment and
works from theft, fire, pilferage and any other damages and loss. All materials of
the Contractor shall enter and leave the Client (EPIL)/ NTPC Site only with the
written permission of the Client (EPIL)/ NTPC in the prescribed manner.
32.00.00 CONTRACTOR'S AREA LIMITS
The Client (EPIL)/ NTPC will mark-out the boundary limits of access roads,
parking spaces, storage and construction areas for the Contractor and the
Contractor shall not trespass the areas not so marked out for him. The Contractor
shall be responsible to ensure that none of his personnel move out of the areas
marked out for his operations. In case of such a need for the Contactor's personnel to
work out of the areas marked out for him the same shall be done only with the written
permission of the Client (EPIL)/ NTPC.
33.00.00 CONTRACTOR'S CO-OPERATION WITH THE CLIENT (EPIL)/ NTPC
In case where the performance of the erection work by the Contractor affects
the operation of the system facilities of the Client (EPIL)/ NTPC, such erection
work of the Contractor shall be scheduled to be performed only in the manner
stipulated by the Client (EPIL)/ NTPC and the same shall be acceptable at all
times to the Contractor. The Client (EPIL)/ NTPC may impose such restrictions on
the facilities provided to the Contractor such as electricity, etc. as he may think fit
in the interest of the Client (EPIL)/ NTPC and the Contractor shall strictly adhere
to such restrictions and co-operate with the Client (EPIL)/ NTPC. It will be
the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and operation
of the equipment systems which are erected by him. The Contractor shall also be
responsible for flushing and initial filling of all the oil and lubricants required for the
equipment furnished and installed by him, so as to make such equipment ready
for operation. The Contractor shall be responsible for supplying such flushing oil and
other lubricants unless otherwise specified elsewhere in documents and
specifications.

34.00.00 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES

34.01.00 GENERAL
34.01.01 The Contractor upon completion of installation of equipments and systems, shall
conduct pre-commissioning and commissioning activities, to make the
equipment/systems ready for safe, reliable and efficient operation on sustained
basis. All pre-commissioning/commissioning activities considered essential for such
readiness of the equipment/systems including those mutually agreed and included in
the Contractor’s quality assurance programme as well as those indicated in clauses
elsewhere in the technical specifications shall be performed by the contractor.
34.01.02 The pre-commissioning and commissioning activities including Guarantee/
demonstration/ acceptability tests, checks and trial operations of the
equipment/systems furnished and installed by the contractor shall be the
responsibility of the Contractor as detailed in relevant clauses in Technical
Specification. The Contractor shall provide, in addition, test instruments, calibrating
devices etc. and labour required for successful performance of these operations. If it is
anticipated that the above test may prolong for a long time, the Contractor's
workmen required for the above test shall always be present at site during such
operations.
34.01.03 The following activities shall be carried out by the contractor, 18 month prior to
schedule date of commissioning of the equipment/systems installed by him.
(a.) The contractor shall furnish the organization chart of his operation and
commissioning engineers for the acceptance of Client (EPIL)/ NTPC. Adequate
number of operation and commissioning engineers shall be deployed
by the contractor to effectively meet the requirement of round the clock
operation in shifts also, till the plant is taken over by the Client (EPIL)/ NTPC.
(b.) The contractor shall submit the bio-data containing the details of experience of
his operation and commissioning engineers for the acceptance of Client
(EPIL)/ NTPC.
(c.) The contractor shall furnish the deployment schedule of his operation and
commissioning engineers for the acceptance of the Client (EPIL)/ NTPC.
(d.) Apart from above, contractor shall ensure deployment of sufficient
skilled/semi-skilled/unskilled manpower during pre-commissioning and
34.01.04 It shall be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and initial
operation of the equipment/systems which are installed by him.

34.01.05 The Contractor shall also be responsible for flushing and initial filling of all oils and
lubricants required for the equipment furnished and installed by him so as to make
such equipment ready for operation. The Contractor shall be responsible for
supplying such flushing oil and other lubricants unless otherwise specified elsewhere
in these specifications and documents.
34.02.00 COMMISSIONING DOCUMENTATION
34.02.01 The contractor shall submit the commissioning documentation, comprising of
Standard checklists, pre-commissioning procedures, testing schedules, commissioning
schedules and commissioning networks for various equipment/systems covered
under the contract, for the approval of Client (EPIL)/ NTPC.
34.02.02 Standard checklist, as the name suggests, shall be a fairly general documents,
containing the list of all checks required to be carried out for similar and repetitive
type of equipment to ensure consistent and thorough checking. An indicative list of
such equipment is enclosed as Annexure-I.
34.02.03 The testing schedule is a document, designed for safe and systematic
commissioning of individual equipment/sub-system (for example compressor
etc.) Commissioning schedule is a document envisaged for commissioning of a
system (for example Compressed Air system, Unit commissioning etc.).
The testing/Commissioning schedule shall have a standard format in order to
maintain consistency of presentation, content and reporting. A brief write up on the
contents of the Testing /Commissioning Schedule is enclosed as Annexure-II.
34.02.04 The contractor shall submit the list of commissioning documentation to be submitted
by him, along with their submission schedule for various equipment/systems covered
under the contract, with in 6(six) month from the date of award of contract, for the
acceptance of Client (EPIL)/ NTPC.
34.02.05 The Contractor shall submit the commissioning documentation, for various
equipment/covered under the contract, for the approval of Client (EPIL)/ NTPC,
at least 18 months before the scheduled date of commissioning of the
equipment/systems.
34.03.00 COMMISSIONING ACTIVITIES
34.03.01 Upon completion of pre-commissioning activities/tests, the contractor shall
initiate commissioning of facilities. During commissioning the Contractor shall
carry out system checking and reliability trials on various parts of the facilities.
34.03.02 Contractor shall carry out the checks/tests at site to prove to the Client (EPIL)/ NTPC
that each equipment of the supply complies with requirements stipulated and is
installed in accordance with requirements specified.

34.03.03 Before the plant is put into initial operation the Contractor shall be required
to conduct test to demonstrate to the Client (EPIL)/ NTPC that each item of the plant
is capable of correctly performing the functions for which it was specified and its
performance, parameters etc. are as per the specified/approved values. These
tests may be conducted concurrently with those required under commissioning
sequence.
34.03.04 The Contractor shall also demonstrate the performance of all C&I equipment, the
tests on main equipment of prior to that as the case may be.
34.03.05 Other tests shall be conducted, if required by the Client (EPIL)/ NTPC, to
establish that the plant equipment are in accordance with requirements of the
specifications.
34.03.06 The Contractor shall conduct all the commissioning tests and undertake
commissioning activities pertaining to all other auxiliaries and equipments including
all electrical and C&I equipment/systems not specifically brought out above but are
within the scope of work and facilities being supplied and installed by the Contractor
and follow the guidelines indicated above or elsewhere in these Technical
Specifications.
34.05.00 Initial Operation
Upon completion of system checking/Tests as above and as a part of commissioning
of facilities, complete plant/facilities shall be put on initial operation as stipulated in
General Technical Requirements.
35.00.00 MATERIALS HANDLING AND STORAGE
35.01.00 All the equipments furnished under the Contract and arriving at Site shall be
promptly received, unloaded and transported and stored in the storage spaces by
the Contractor.
35.02.00 Contractor shall be responsible for examining all the shipment and notify the
Client (EPIL)/ NTPC immediately of any damage, shortage, discrepancy etc. for the
purpose of Client (EPIL)/ NTPC's information only. The Contractor shall submit
to the Client (EPIL)/ NTPC every week a report detailing all the receipts during
the week. However, the Contractor shall be solely responsible for any shortages or
damage in transit, handling and / or in storage and erection of the equipment at
Site. Any demurrage, wharf age and other such charges claimed by the transporters,
railways etc. shall be to the account of the Contractor.
35.03.00 The Contractor shall maintain an accurate and exhaustive record detailing out the
list of all equipment received by him for the purpose of erection and keep such
record open for the inspection of the Client (EPIL)/ NTPC.

35.04.00 All equipment shall be handled very carefully to prevent any damage or loss.
No bare wire ropes, slings, etc. shall be used for unloading and/or handling of
the equipment without the specific written permission of the Client (EPIL)/ NTPC.
The equipment stored shall be properly protected to prevent damage either to the
equipment or to the floor where they are stored. The equipment from the store shall be
moved to the actual location at the appropriate time so as to avoid damage of such
equipment at Site.
35.05.00 All electrical panels, controls gear, motors and such other devices shall be properly
dried by heating before they are installed and energised. Motor bearings, slip rings,
commutators and other exposed parts shall be protected against moisture ingress
and corrosion during storage and periodically inspected. Heavy rotating parts in
assembled conditions shall be periodically rotated to prevent corrosion due to
prolonged storage.
35.06.00 All the electrical equipment such as motors, etc shall be tested for insulation
resistance at least once in three months from the date of receipt till the date of
commissioning and a record of such measured insulation values maintained by the
Contractor. Such records shall be open for inspection by the Client (EPIL)/ NTPC.
35.07.00 The Contractor shall ensure that all the packing materials and protection devices
used for the various equipments during transit and storage are removed before the
equipment are installed.
35.08.00 The consumables and other supplies likely to deteriorate due to storage must be
thoroughly protected and stored in a suitable manner to prevent damage or
deterioration in quality by storage.
35.09.00 All the materials stored in the open or dusty location must be covered with suitable
weatherproof and flame-proof covering material wherever applicable.
35.10.00 If the materials belonging to the Contractor are stored in areas other than those
earmarked for him, the Client (EPIL)/ NTPC will have the right to get it moved
to the area earmarked for the Contractor at the Contractor's cost.
35.11.00 The Contractor shall be responsible for making suitable indoor storage facilities to
store all equipment which require indoor storage. Normally, all the
electrical equipments such as motors, control gear, generators, exciters and
consumables like electrodes, lubricants etc shall be stored in the closed
storage space. The Client (EPIL)/ NTPC, in addition, may direct the Contractor
to move certain other materials, which in his opinion will require indoor storage,
to indoor storage areas which the Contractor shall strictly comply with.

36.00.00 CONSTRUCTION MANAGEMENT

36.01.00 The field activities of the Contractors working at Site, will be coordinated by
the Client (EPIL)/ NTPC and the Client (EPIL)/ NTPC decision shall be final in
resolving any disputes or conflicts between the Contractor and other Contractors
and tradesmen of the Client (EPIL)/ NTPC regarding scheduling and co-
ordination of work. Such decision by the Client (EPIL)/ NTPC shall not be a cause
for extra compensation or extension of time for the Contractor.
36.02.00 The Client (EPIL)/ NTPC shall hold weekly meetings of all the Contractors working at
Site, at a time and place to be designated by the Client (EPIL)/ NTPC. The Contractor
shall attend such meetings and take notes of discussions during the meeting and the
decisions of the Client (EPIL)/ NTPC and shall strictly adhere to those decisions
in performing his Works. In addition to the above weekly meeting, the Client
(EPIL)/ NTPC may call for other meeting either with individual Contractors or with
selected number of Contractors and in such a case the Contractor if called, will also
attend such meetings.
36.03.00 Time is the essence of the Contract and the Contractor shall be responsible for
performance of his works in accordance with the specified construction schedule. If at
any time, the Contractor is falling behind the schedule, he shall take necessary
action to make good for such delays by increasing his work force or by
working overtime or otherwise accelerate the progress of the work to comply
with the schedule and shall communicate such actions in writing to the Client (EPIL)/
NTPC, satisfying that his action will compensate for the delay. The Contractor
shall not be allowed any extra compensation for such action.
36.04.00 The Client (EPIL)/ NTPC shall however not be responsible for provision of
additional labour and/or materials or supply or any other services to the Contractor
except for the coordination work between various Contractors as set out earlier.
36.05.00 Site management during construction phase till handing over of plant
Bidder shall ensure that the plant site within the plant boundary is managed in
a coordinated and professional way all through the construction phase till handing
over of plant, ensuring safe, easy & unhindered working conditions and a
healthy & hygienic working environment at site. He shall ensure the following
measures at site while executing the project.

a) Proper housekeeping by systematic and proper disposal of earth from

excavations (separately for usable & surplus earth), muck (from pile bores or
otherwise), wastes (from dismantling of pile tops, concrete works etc),
packing & insulation wastes, steel scrap, cable wastes etc generated during
construction / erection works. Suitable disposal sites for each of above shall be
identified in the layout and at site in the beginning of the project itself. It shall be
ensured that all agencies engaged by the bidder follow the discipline to
dispose off of earth spoils and wastes at the designated places. Preferably
once in a week suitable time slot will be identified for housekeeping by all
agencies and suitable instructions shall be issued in this regard. Bidder may
engage a separate agency or identify a gang for collection of wastes and
disposal to designated places. Suitable arrangement / tie-up will also be made
for periodic disposal of wastes/ scrap from the designated places.
b) All fabrication areas shall be suitably hard crusted to provide a water free and
proper working platforms. Suitable sheds preferably pre engineered
structures to be provided for paint shops, fabrication workshops etc for
ensuring all weather work conditions for onsite structural works. For the
main plant and auxiliary buildings, bidder should preferably plan the works
in such a way that structural fabrication is done in suppliers' offsite works /
workshops and onsite fabrication works are avoided / kept minimum.
c) Suitable onsite maintenance workshop for day to day breakdown

maintenance heavy plant and equipment like batching plants, cranes, earth
moving equipment, poclains, welding equipment etc. The workshop shall
have stock of frequently needed spares and suitable repair facilities with
experienced technicians/mechanics. A central test laboratory equipped with test
equipment for routine tests like tests on soil, concrete, bricks, aggregates,
welds etc with experienced staff shall be established at the start of the
project itself.
d) All office and covered store buildings of the bidder and its agencies shall
be of prefab/ pre-engineered / porta cabin construction. Shabby semi -
finished constructions in brickwork/ GI / asbestos roof etc shall not be
permitted.

e) First aid facilities and amenities like rest rooms, suitable pre engineered
toilets ( separate for men and women), drinking water fountains/tanks,
canteen, crèche for women workers shall be planned and established at the
beginning of the project itself. These facilities shall be located distributed over
the plant area to enable easy access by the construction workers and staff
and shall be marked on the plant layout. Suitable treatment for toilet
discharge, like bio digesters etc shall be planned and conventional septic tanks /
soak pits etc shall be avoided.
f) Proper lighting of all construction/ erection areas:
Bidder shall erect adequate number of high lighting masts in main plant, offsite,
office and store areas for lighting during night. DG sets of adequate capacity
shall be provided for emergency backup. The street lighting along the
roads shall also be prioritised along with road construction. The
construction power ring main shall be planned and erected immediately after
the award.
g) Well planned and coordinated storage and movement of plant, equipment

and construction materials. System wise / agency wise storage / laydown areas
shall be planned and marked on the plant layout at the beginning itself. Bidder
shall ensure that all its agencies comply to the areas allocated to them and follow
the designated storage and movement plans. Adequate covered storage shall
be constructed for storage of critical equipments like switchgears, MCCs,
insulation etc.
h) Proper access control for construction workers, staff and visitors. Bidder shall
ensure that suitable electronic based gate pass system is in place from start of
project itself to keep record and track of all workers, staff and visitors
entering/exiting the plant premises shift wise on daily basis.
i) Compliance to all safety requirements as specified elsewhere in the

tender documents. Bidders shall establish a safety centre at the start of the
project itself. It shall have a 24X7 manned safety control room in addition
to a permanent safety equipment display room, separate training / lecture hall
with AV facilities for safety training, store room with adequate stock of
specified safety equipment, a first aid room and other amenities. Bidder

shall install CCTV cameras at all strategic locations in the plant area which shall
be linked to the safety control room.
j) Compliance to all environment and other conditions stipulated by the

concerned statutory authorities while according clearance / NOC to the
project. Bidder shall ensure adequate sprinkling of water by deploying
water tankers to prevent the fugitive dust nuisance during construction.
k) Development of suitable landscape & green belt areas and rainwater

harvesting within the plant premises. Bidder shall plan to develop the landscape
& green belt areas and rainwater harvesting from the start of the project itself.
The landscape and rainwater harvesting plan shall be finalized immediately
after award of work and suitable work plan with priority and schedule shall
also be finalized thereafter. Top soil before excavation shall be suitably
preserved and stacked for landscape and green belt development.
l) Provision of adequate shelters, water supply, sanitation and lighting in

construction workers and staff camps. No camps for workers and staff shall be
permitted within the plant premises and Bidder shall make separate
arrangement outside the plant premises for locating and development of camps
for construction workers and staff. The designated areas shall be suitably
developed with infrastructure like roads, drains, water supply and sewerage
and shall be free from water logging. Suitable low cost shelters will be
provided for the workers. Complete area shall be secured by fencing and shall be
provided adequate area lighting. Suitable waste disposal, shopping and
recreation facilities will be developed in these camps.
Contractor shall ensure that due importance is given to site management

as discussed above and a detailed work plan considering the above aspects is
finalized immediately after the award. A senior level executive shall be
identified who shall be responsible for implementation of the work plan.
Suitable format for progress reporting on site management plan shall be
developed and made part of the project progress report. The progress on
implementation of above work plan shall be reviewed along with project
progress in the monthly project review meetings with Client (EPIL)/ NTPC.
In case the progress on site management plan is unsatisfactory, Engineer-in
Charge may withhold upto 1% of the monthly running bill for civil and site

erection works) till such time the required progress is demonstrated. In case in
the opinion of Engineer-in-charge, bidder's actions on site management aspects
is not adequate, Engineer-in- charge may get the relevant work executed through
a separate agency and deduct the expenses incurred from Bidder's bill along
with overheads @10 %.
37.00.00 FIELD OFFICE RECORDS

The Contractor shall maintain at his Site Office up-to- date copies of all
drawings, specifications and other Contract Documents and any other
supplementary data complete with all the latest revisions thereto. The Contractor
shall also maintain in addition the continuous record of all changes to the above
Contract Documents, drawings, specifications, supplementary data, etc. effected at
the field and on completion of his total assignment under the Contract shall
incorporate all such changes on the drawings and other Engineering data to
indicate as installed conditions of the equipment furnished and erected under
the Contract. Such drawings and Engineering data shall be submitted to the
Client (EPIL)/ NTPC in required number of copies.
38.00.00 CONTRACTOR'S MATERIALS BROUGHT ON TO SITE

38.01.00 The Contractor shall bring to Site all equipment, components, parts, materials,
including construction equipment, tools and tackles for the purpose of the
Works under intimation to the Client (EPIL)/ NTPC. All such goods shall, from the
time of their being brought vest in the Client (EPIL)/ NTPC, but may be used for the
purpose of the Works only and shall not on any account be removed or taken away
by the Contractor without the written permission of the Client (EPIL)/ NTPC. The
Contractor shall nevertheless be solely liable and responsible for any loss or
destruction thereof and damage thereto.
38.02.00 The Client (EPIL)/ NTPC shall have a lien on such goods for any sum or sums which
may at any time be due or owing to him by the Contractor, under, in respect of
or by reasons of the Contract. After giving a fifteen (15) days notice in writing
of his intention to do so, the Client (EPIL)/ NTPC shall be at liberty to sell and dispose
off any such goods, in such manner as he shall think fit including public auction or
private treaty and to apply the proceeds in or towards the satisfaction of such sum or
sums due as aforesaid.

38.03.00 After the completion of the Works, the Contractor shall remove from the Site under the
direction of the Client (EPIL)/ NTPC the materials such as construction equipment,
erection tools and tackles, scaffolding etc. with the written permission of the Client
(EPIL)/ NTPC. If the Contractor fails to remove such materials, within fifteen (15)
days of issue of a notice by the Client (EPIL)/ NTPC to do so then the Client (EPIL)/
NTPC shall have the liberty to dispose off such materials as detailed under as specified
at clause no 39.02.00 of this Section and credit the proceeds thereto to the account of
the Contractor.
39.00.00 PROTECTION OF PROPERTY AND CONTRACTOR'S LIABILITY

39.01.00 The Contractor shall be responsible for any damage resulting from his operations. He
shall also be responsible for protection of all persons including members of
public and employees of the Client (EPIL)/ NTPC and the employees of other
Contractors and Sub- Contractors and all public and private property including
structures, building, other plants and equipments and utilities either above or below
the ground.
39.02.00 The Contractor will ensure provision of necessary safety equipment such as barriers,
sign- boards, warning lights and alarms, etc. to provide adequate protection to persons
and property. The Contractor shall be responsible to give reasonable notice to the
Client (EPIL)/ NTPC and the Client (EPIL)/ NTPCs of public or private property and
utilities when such property and utilities are likely to get damaged or
injured during the performance of his Works and shall make all necessary
arrangements with such Client (EPIL)/ NTPCs, related to removal and/or
replacement or protection of such property and utilities.
40.00.00 PAINTING
For painting refer Part-A, sub section-III, Section VI of Technical specification.
Painting for structures shall conform to the painting specification specified in Part-B
under Civil. Painting for Electrical equipments/systems shall conform to the painting
specification given in Electrical portion of Part-A and Part-B of technical specifications.
41.00.00 INSURANCE
41.01.00 In addition to the conditions covered under the Clause entitled "Insurance" in Section
General Conditions of Contract (GCC), the following provisions will also apply to the
portion of works to be done beyond the Contractor's own or his Sub-
Contractor's manufacturing Works.

41.02.00 Workmen's Compensation Insurance
This insurance shall protect the Contractor against all claims applicable under
the Workmen's Compensation Act, 1948 (Government of India). This policy shall
also cover the Contractor against claims for injury, disability disease or death of his or
his Sub-Contractor's employees, which for any reason are not covered under the
Workmen’s Compensation Act, 1948. The liabilities shall not be less than the
following:
Workmen's Compensation - As per Statutory Provisions
Employee's Liability - As per Statutory Provisions
41.03.00 Comprehensive Automobile Insurance
This insurance shall be in such a form to protect the Contractor against all claims for
injuries, disability, disease and death to members of public including the Client
(EPIL)/ NTPC's men and damage to the property of other arising from the use
of motor vehicles during on or off the Site operations, irrespective of the Client
(EPIL)/ NTPCship of such vehicles. The liability covered shall be as herein indicated:
Fatal Injury : Rs.100,000 each person
: Rs.200,000 each occurrence
Property Damage : Rs.100,000 each occurrence
41.04.00 Comprehensive General Liability Insurance
41.04.01 The insurance shall protect the Contractor against all claims arising from
injuries, disabilities, disease or death of members of public or damage to property of
others, due to any act or omission on the part of the Contractor, his agents, his
employees, his representatives and Sub-Contractors or from riots, strikes and civil
commotion. This insurance shall also cover all the liabilities of the Contractor arising
out of the Clause entitled "Defence of Suits" in Section “General Conditions of
Contract (GCC).”
41.04.02 The hazards to be covered will pertain to all the Works and areas where the
Contractor, his Sub-Contractors, his agents and his employees have to perform work
pursuant to the Contract.

41.05.00 The above are only illustrative list of insurance covers normally required and it will be
the responsibility of the Contractor to maintain all necessary insurance coverage to the
extent both in time and amount to take care of all his liabilities either direct or indirect,
in pursuance of the Contract.
42.00.00 UNFAVOURABLE WORKING CONDITIONS

The Contractor shall confine all his field operations to those works which can
be performed without subjecting the equipment and materials to adverse effects
during inclement weather conditions, like monsoon, storms, etc. and during
other unfavourable construction conditions. No field activities shall be performed
by the Contractor under conditions which might adversely affect the quality and
efficiency thereof, unless special precautions or measures are taken by the
Contractor in a proper and satisfactory manner in the performance of such
Works and with the concurrence of the Client (EPIL)/ NTPC. Such unfavourable
construction conditions will in no way relieve the Contractor of his responsibility
to perform the Works as per the schedule.
43.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS

The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc.
which he may come across during the course of performance of his Works either
during excavation or elsewhere, are properly protected and handed over to the
Client (EPIL)/ NTPC. Similarly the Contractor shall ensure that the bench marks,
reference points, etc., which are marked either with the help of Client (EPIL)/ NTPC
or by the Client (EPIL)/ NTPC shall not be disturbed in any way during the
performance of his Works. If, any work is to be preformed which disturb such
reference, the same shall be done only after these are transferred to other suitable
locations under the direction of the Client (EPIL)/ NTPC. The Contractor shall
provide all necessary materials and assistance for such relocation of reference points
etc.
44.00.00 WORK & SAFETY REGULATIONS

44.01.00 General
i) The contractor shall comply with all the requirements of "The Building
and Other Construction Workers (Regulation of Employment & Conditions
of Service) Act," 1996 and its Central Rule 1998 / State Rules and any other
statutory requirements as applicable.

ii) The Contractor shall follow NTPC Safety Rules as issued from time to time with
respect to safety in construction & erection.
iii) The contractor shall have the approved Safety, Health and Environment
(SHE) Policy in respect of Safety and health of Building Workers and it shall be
circulated widely and displayed at conspicuous place in Hindi and local
language understood by the majority of the workers. A copy of the safety
policy should be submitted to Engineer in charge.
iv) The contractor shall submit the safety plan comprising of methods to
implement the Safety Policy/ Rules, Risk assessment and ensuring Safety at
work areas, Safety audits, inspections and its compliance, Supervision and
responsibility to ensure Safety at various levels, Safety training to
employees, review of Safety and accident analysis, ensure Health and Safety
Procedures to prevent accidents to Engineer-in Charge for approval as per
the format of Safety plan as annexed at Annexure - III.
v) The Contractors shall ensure proper safety of all the workmen, materials,
plant and equipment belonging to him or to the Client (EPIL)/ NTPC or to
others, working at the Site.
vi) All equipments used in construction and erection by the contractor shall meet
BIS / International Standards and where such standards do not exist, the
Contractor shall ensure these to be absolutely safe. All equipments shall be
strictly operated and maintained by the contractor in accordance with
manufacturer's operation manual. The contractor should also follow
Guidelines / Rules of the Client (EPIL)/ NTPC in this regard.
vii) The Contractors shall provide suitable latest Personal Protective Equipments of
prescribed standard to all their employees and workmen according to the need.
The Engineer-in Charge shall have the right to examine these safety
equipments to determine their suitability, reliability, acceptability and
adaptability. The contractor should also ensure these before their use at
worksite.
viii) The Contractor shall provide safe working conditions to all workmen and
employees at his workplace including safe means of access, railings, stairs, and
ladders, scaffolding, work platforms, toe boards etc. The scaffoldings shall

be erected under the control and supervision of an experienced and

competent person. For erection of scaffolds, access, work platforms etc. shall
be good and the contractor shall use standard quality of material.
ix) The Contractor shall follow and comply with all the Safety Rules, standards,
code of practices of NTPC and relevant provisions of applicable laws
pertaining to the safety of workmen, employees, plant and equipment as may be
prescribed from time to time without any protest or contest or reservation. In
case of any unconformity between statutory requirement and the Safety
Rules of the Client (EPIL)/ NTPC referred above, the latter shall be binding
on the Contractor unless the statutory provisions are more stringent. As and
when required he can refer / obtain copy of NTPC safety documents as
stated above.
x) The contractor shall have his own arrangements with nearby hospitals for
shifting and treatment of sick and injured.
The medical examination of the workers employed in hazardous areas shall be

conducted as per Rule 223 0f The Building and Other Construction Worker
(Regulation of Employment and Condition of Service) Central Rule 1998
Their health records shall be maintained accordingly and to be
submitted to Engineer-in Charge when asked for. If any worker found suffering
from occupational health hazard, the worker should be shifted to suitable place
of working and properly treated under intimation to Engineer-in Charge. The
medical fitness certificate to be submitted to Engineer-in Charge.
xi) First Aid boxes equipped with requisite articles as specified in the Rule 231 of
The Building and Other Construction Worker (Regulation of Employment and
Condition of Service) Central Rule 1998 shall be provided at construction sites
for the use of workers. Training has to be provided on first aid to workmen
& office bearers working at site.
xii) Bidder also requested to refer the safety rules under

http://www.ntpctender.com/ applicable for FGD package. Safety rules shall be
followed as per the safety rules indicated under http://www.ntpctender.com/
44.01.01 Emergency Action Plan

The contractor shall prepare an emergency action plan approved by his competent
authority to handle any emergency occurred during construction work. Regular mock
drills shall be organized to practice this emergency plan. The Emergency Action
Plan should be widely circulated to all the employees and suitable infrastructure
shall be provided to handle the emergencies.
44.01.02 Scaffolding
The contractor shall take all precautions to prevent any accidental collapse of
scaffolding or fall of persons from scaffolding. The contractor should ensure that
scaffolding are designed by a competent person and it erection and repairs should be
done under the expert supervision. The scaffolding shall meet the required
strength and other requirements for the purpose for which the scaffold is
erected. The material used for scaffold should conform to the BIS / International
standards.
44.01.03 Opening
The contractor shall ensure that there is no opening in any working

platform/any floor of the building, which may cause fall of workers or material.
Whenever an opening on a platform/any floor of the building is unavoidable, the
opening should be suitably fenced and necessary measures for protection against
falling objects or building workers from such platform are taken by providing
suitable safety nets, safety belts or other similar means. The contractor shall take
all precautions while handling, using, storing or transporting of all explosives.
Before usage of any explosive necessary warning / danger signals be erected at
conspicuous places to warn the workers and general public. The contractor should
strictly ensure that all measures and precautions required to be complied for
use, handling, storing or transportation of explosives under the rules framed under
the Explosives Act, 1884.
44.02.00 Fencing of Machinery
The contractor shall provide suitable fencing or guard to all dangerous and moving
parts of machinery.
The contractor shall not allow any of the employees to clean, lubricate, repair, adjust or
examine during machinery in motion, which may cause injury to the person.

44.03.00 Carrying of Excessive Weight by a Worker
The worker shall not be allowed to lift by hand or carry over his head, back or
shoulder more than the maximum limit set by the prescribed rules for
the construction Workers.
44.04.00 Dangerous and Harmful Gases / Equipment
The contractor shall ensure that the workers are not exposed to any harmful gases
during any construction activity including excavation, tunnelling, confined spaces etc.
The contractor should not allow any worker to go into the confined space unless it is
certified by Engineer-in Charge to be safe and fit for the entry to such work place.
Proper record and work permits should be followed to carry out such works.
44.05.00 Overhead Protection
The contractor shall ensure that any area exposed to risk of falling materials, articles or
objects is roped off or cordoned off or otherwise suitably guarded from inadvertent
entry of any person.
Wherever there is a possibility of falling of any material, equipment or construction

workers while working at heights, a suitable and adequate safety net should be
provided. The safety net should be in accordance with BIS Standards.
44.06.00 Working at Heights
All working platforms, ways and other places of construction work shall be free from
accumulations of debris or any other material causing obstructions and tripping.
Wherever workers are exposed to the hazard of falling into water, the
contractor shall provide adequate equipment for saving the employees from
drowning and rescuing from such hazards. The contractor shall provide boat or
launch equipped with sufficient number of life buoys, life jackets etc. manned with
trained personnel at the site of such work.
Every opening at elevation from ground level through which a building worker,
vehicle, material equipment etc may fall at a construction work shall be covered
and/or guarded suitably by the contractor to prevent such falls.
Wherever the workers are exposed to the hazards of falling from height, the
contractor shall provide full harness safety belts fitted with fall arresting systems to

all the employees working at higher elevations and life line of 8 mm diameter wire
rope with turn buckles for anchoring the safety belts while working or moving
at higher elevations. Safety nets shall also be provided for saving them from fall from
heights and such equipment should be in accordance with BIS standards.
Wherever there is a possibility of falling of any material, equipment or construction

workers while working at heights, a suitable and adequate safety net should be
provided. The safety net should be in accordance with BIS Standards.
The contractor shall provide standard prefabricated ladders on the columns

where the workers are required to use them as an access for higher elevations
till permanent staircase is provided. The workers shall be provided with safety
belts fitted with suitable fall arresting system (Fall arrestors) for climbing/getting
down through ladders to prevent fall from height.
44.07.00 Handling of Hazardous Chemicals
The Contractor will notify well in advance to the Engineer-in Charge of his intention to
bring to the Site any container filled with liquid or gaseous fuel or explosive or
petroleum substance or such chemicals which may involve hazards. NTPC shall have
the right to prescribe the conditions, under which such container is to be stored,
handled and used during the performance of the works and the Contract shall strictly
adhere to and comply with such instructions. The Engineer I/c shall have the right at
his sole discretion to inspect any such container or such construction plant /
equipment for which material in the container is required to be used and if in his
opinion, its use is not safe; he may forbid its use. No claim due to such prohibition
shall be entertained by NTPC and NTPC shall not entertain any claim of the
Contractor towards additional safety provisions / conditions to be provided for /
constructed.
Further, any such decision of the Engineer-in Charge (Engineer I/c) shall not, in
any way, absolve the Contractor of his responsibilities and in case, use of such
a container or entry thereof into the Site area is forbidden by NTPC, the Contractor
shall use alternative methods with the approval of the NTPC without any cost
implication to the NTPC or extension of work schedule.
Where it is necessary to provide and / or store petroleum products or

petroleum mixtures and explosives, the Contractor shall be responsible for

carrying-out such provision and / or storage in accordance with the rules and
regulations laid down in Petroleum Act 1934, Explosives Act 1948, and Petroleum
and Carbide of Calcium Manual published by the Chief Inspector of Explosives
of India. All such storage shall have prior approval of the Engineer I/c. In case any
approvals are necessary from the Chief Inspector (Explosives) or any statutory
authorities, the Contractor shall be responsible for obtaining the same.
The Contractor shall be fully responsible for the safe storage of his and his
Sub- contractor's radio-active sources in accordance with BARC/DAE (Bhabha
Atomic Research Centre/ Department of Atomic Energy, Govt. of India) Rules
and other applicable provisions. All precautionary measures stipulated by
BARC/DAE in connection with use, the contractor would take storage and
handling of such material.
The contractor shall provide suitable personal protective equipments to the workers
who are handling the hazardous and corrosive substances including alkalis and
acids.
As a precautionary measure the contractor should keep the bottles filled with distilled
water in cupboard / Boxes near work place for emergency eye wash by worker
exposed to such hazardous chemicals.
44.08.00 Eye Protection
The contractor shall provide suitable personal protective equipment to his workmen
depending upon the nature of hazards and ensure their usage by the workers
engaged in operations like welding, cutting, chipping, grinding or similar operations
which may cause injuries to his eyes.
44.09.00 Excavation
The contractor shall take all necessary measures during excavation to prevent the
hazards of falling or sliding material or article from any bank or side of such
excavation which is more than one and a half meter above his footing by providing
adequate piling, shoring, bracing etc. against such bank or sides.
Adequate and suitable warning signs shall be put up at conspicuous places at the
excavation work to prevent any persons or vehicles falling into the excavation
trench. No worker should be allowed to work where he may be stuck or endangered
by excavation machinery or collapse of excavations or trenches.

44.10.00 Electrical Hazards
The contractor should ensure that all electrical installations at the construction work
comply with the requirements of latest electricity acts / rules.
The contractor shall take all adequate measures to prevent any worker from coming
into physical contact with any electrical equipment or apparatus, machines or
live electrical circuits which may cause electrical hazards during the construction
work. The contractor shall provide the sufficient ELCBs / RCCBs for all the
portable equipments, electrical switchboards, distribution panels etc to prevent
electrical shocks.
The contractor should ensure use of single / double insulated hand tools or
low voltage i.e., 110 volts hand tools.
The contractor should also ensure that all temporary electrical installations at
the construction works are provided with earth leakage circuit breakers.
44.11.00 Vehicular Traffic
The contractor should employ vehicle drivers who hold a valid driving license under
the Motor Vehicles Act, 1988.
44.12.00 Lifting Appliances, Tools & Tackles, Lifting Gear and Pressure Plant & Equipment
etc.
The contractor shall ensure all the lifting appliances, tools & tackles including cranes
etc., lifting gear including fixed or movable and any plant or gear, hoists, Pressure
Plant and equipment etc. are in good condition and shall be examined by competent
person and only certified shall be used at sites. Periodical Examination and the
tests for all lifting / hoisting equipment & tackles shall be carried out. A register of
such examinations and tests shall be properly maintained by the Contractor and will
be promptly produced as and when desired by the Engineer I/c or by the
person authorized by him.
44.13.0 Excessive Noise, Vibration
The contractor shall take adequate measures to protect the workers against the
harmful effect of excessive noise or vibration. The noise should not exceed the
limits prescribed under the concerned rules, Noise Pollution (Regulation
and Control) Rules, 2000.

44.14.00 Electrical Installations
44.14.01 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical
equipment belonging to the Client (EPIL)/ NTPC or other contractors under any
circumstances, whatsoever, unless expressly permitted in writing by the Engineer I/c
to handle such fuses, wiring or electrical equipment.
Before the Contractor connects any electrical appliances to any plug or socket
belonging to the other contractor or the NTPC, he shall,
i) Satisfy the Engineer I/C that the appliance is in good working condition;
ii) Inform the Engineer I/C of the maximum current rating, voltage and phases of
the appliances;
iii) Obtain permission of the Engineer I/C detailing the sockets to which the
appliances may be connected.
iv) The Engineer I/C will not grant permission to connect until he is satisfied that:
- The appliance is in good condition and is fitted with suitable plug;

having earth connection with the body.
- Wherever armoured / metallic sheathed multi core cable is used,

the same armoured / sheathed should be connected to earth.
iv) No repair work shall be carried out on any live equipment. The Engineer I/c
must declare the equipment safe and a permit to work shall be issued by the
NTPC / contractor as the case may be to carry out any repair / maintenance
work. While working on electric lines / equipments whether live or
dead, suitable type and sufficient quantity of tools will have to be provided by
the contractor to electricians / workmen / Officers.
v) The contractor shall employ necessary number of qualified, full time

Electricians /Electrical Supervisors to maintain his temporary electrical
installation.
vi) The installations are provided with suitable ELCBs and RCCBs wherever
required.

44.15.00 Safety Organisation
44.15.0 The contractor employing more than 250 workmen whether temporary, casual,
probationary, regular or permanent shall employ at least one full time safety officer
exclusively to supervise safety aspects of the equipments and workmen, who will
coordinate with the NTPC Safety Officer. Further requirement of safety officers, if
any, shall be guided by Rule 209 of The Building and Other Construction
Worker (Regulation of Employment and Conditions of Service) Central Rule 1998. In
case the work is being carried out through subcontractor, the employees / workmen of
the sub contractor shall also be considered as the contractor's employees/workmen for
the above purpose.
In case of contractor deploying less than 250 workmen he should designate one of his
Engineer / supervisor or the contractor himself (if he is directly supervising the work)
as safety officer in addition to his existing responsibilities. The Engineer /
supervisor should get atleast 2days safety training from any reputed organization or
from NTPC before resuming the work. If already trained in past the declaration
along with training certificate to be furnished to NTPC safety officer.
44.15.02 The name and address of such Safety Officer of the Contractor will be promptly
informed in writing to the EIC with a copy to the Project Safety Officer before
he starts work or immediately after any change of the incumbent is made
during currency of the Contract.
44.16.00 Reporting of Accident and Investigation
In case any accident occurs during the construction / erection or other associated
activities undertaken by the Contractor thereby causing any near miss, minor or
major or fatal injury to his employees due to any reason, whatsoever, it shall be the
responsibility of the Contractor to promptly inform the same to the Engineer
I/C, NTPC Safety Officer with a copy to NTPC Head of Project in the prescribed
form and also to all the authorities envisaged under the applicable laws.
44.17.00 Right to stop Work
44.17.01 The Engineer I/C shall have the right at his sole discretion to stop the work, if in his
opinion the work is being carried out in such a way that it may cause accidents and
endanger the safety of the persons and / or property, and / or equipments. In such
cases, the contractor shall be informed in writing about the nature of hazards and

possible injury / accident and he shall comply to remove shortcomings

promptly. The Contractor after stopping the specific work can, if felt necessary appeal
against the order of stoppage of work to the Project Manager within 3 days of such
stoppage of work and decision of the Project Manager in this respect shall be
conclusive and binding on the Contractor.
44.17.02 The Contractor shall not be entitled for any damages / compensation for stoppage of
work, {Sub-Clause 17.01 } due to safety reasons and the period of such stoppage of
work shall not be taken as an extension of time for Completion of the Facilities
and will not be the ground for waiver of levy of liquidated damages.
44.18.00 Fire Protection
The contractor shall provide sufficient fire extinguishers at place /s of work. The fire
extinguishers shall be properly maintained as per relevant BIS Standards. The
employees shall be trained to operate the fire extinguishers / equipment.
44.19.00 Penalties
i) If the Contractor fails in providing safe working environment as per the Safety
Rules of NTPC or continues the work even after being instructed to stop the
work by the Engineer-I/C as provided in Clause 17.01 above, the
Contractor shall be penalized at the rate of Rs. 25,000/- per day or part
thereof till the instructions are complied with and so certified by the Engineer
I/C. However, in case of accident, the provisions contained in Sub-Clause 19(II)
below shall also apply in addition to the penalties mentioned in this sub-clause.
ii) If the Contractor does not take all safety precautions and / or fails to comply
with the Safety Rules as prescribed by the Client (EPIL)/ NTPC or under the
applicable law for the safety of the plant and equipment and for the safety of
personnel and the contractor does not prevent hazardous conditions which
cause injury to this own employees or employees of other contractors, or
NTPC's employees or any other person who are at the Site or adjacent thereto,
the Contractor shall be responsible for payment of penalty to NTPC as per the
following schedule:-
a) Fatal injury or accident causing death:
Penalty @10% of contract value or Rs. 5,00,000/- per person, whichever is

less.

b) Major injuries or accident causing 25% or more permanent

disablement to workmen or employees:
Penalty @2.5% of contract value or Rs. 1,00,000/- per person whichever is

less.
Permanent disablement shall have the same meaning as indicated in The

Workmen's Compensation Act' 1923. The penalty mentioned above
shall be in addition to the compensation payable to the workmen /
employees under the relevant provisions of the Workmen's Compensation
Act' 1923 and rules framed there under or any other applicable laws as
applicable from time to time.
iii) If any contractor worker found working without using the safety
equipment like safety helmet, safety shoes, safety belts, etc. or without
anchoring the safety belts while working at height the Engineer I/c / Safety
Officer of NTPC shall have the right to penalize the contractor for Rs. 200/-
per person per day and such worker shall be sent out of the workplace
immediately and shall not be allowed to work on that day. Engineer I/c /
Safety Officer of NTPC will also issue a notice in this regard to the contractor.
iv) If two or more fatal accidents occur at same NTPC site under the control of
contractor during the period of contract and he has:
(1) not complied with keeping adequate PPEs in stock or
(2) defaulted in providing PPEs to his workmen.
(3) not followed statutory requirements / NTPC safety rules.
(4) been issued warning notice/s by NTPC head of the project on non-
observance of safety norms.
(5) not provided safety training to all his workmen, the contractor can be
debarred from getting tender documents in NTPC for two years from
the date of last accident.
The safety performance will also be one of the overriding criteria for
evaluation of overall performance of the contractors by NTPC. The
contractor shall submit the accident data including fatal / non-fatal accidents for
the last 3 years where he has undertaken the construction activities Projects-

wise along with the tender documents. This will also be considered for
evolution of tender documents. If the information given by the contractor found
incorrect, his contract will be liable to be terminated.
44.20.00 The Contractor will make available minimum quantity of all safety equipments and
safety personal protection equipments (PPEs) of required specifications as per
suggestive list included bidding documents as a part of "List of minimum T &
P". Further Contractor will ensure availability of additional requirement for
individual worker and safety equipment as per site requirement during execution
of the contract till its completion.
44.21.00 Award
If the Contractor's performance on safety front is found satisfactory i.e. without any
fatal/reportable accident in the year of consideration; he may be considered for
suitable award "ACCIDENT FREE SAFETY MERITORIOUS AWARD" as per
scheme of the Client (EPIL)/ NTPC.
44.22.00 The Contractor shall abide by the following during Construction and Erection
activities:
I. Chain pulley block shall not be used for loads more than 2 (Two) tonne.
II. Hydra shall not be used for material transport.
III. Cage shall necessarily be provided to Monkey ladders of height more than 4 m.
IV. Fencing shall be provided to all Electrical Distribution boards and
transformers etc.
45.00.00 FOREIGN PERSONNEL

45.01.00 The Contractor shall submit to the Client (EPIL)/ NTPC data on all personnel he
proposes to bring into India from abroad for the performance of the Works under the
Contract, at least sixty (60) days prior to their departure to India. Such data will
include for each person the name, his present address, his assignment and
responsibility in connection with the works, and a short resume of his qualification,
experience etc. in relation to the work to be performed by him.
45.02.00 Any person unsuitable and unacceptable to the Client (EPIL)/ NTPC shall not be
brought to India. Any person brought to India, if found unsuitable or
unacceptable by the Client (EPIL)/ NTPC, the Contractor shall within a

reasonable time make alternate arrangements for providing a suitable

replacement and repatriation of such unsuitable personnel.
45.03.00 No person brought to India for the purposes of the works shall be repatriated without
the consent of the Client (EPIL)/ NTPC in writing, based on a written request
from the Contractor for such repatriation giving reasons for such an action to the
Client (EPIL)/ NTPC. The Client (EPIL)/ NTPC may give permission for such
repatriation provided he is satisfied that the progress of work will not suffer due to
such repatriation.
45.04.00 The cost of passports, visas and all other travel expenses to and from India, incurred
by the Contractor shall be to his account. The Client (EPIL)/ NTPC will not
provide any residential accommodation and/or furniture for any of the
Contractor's personnel including foreign personnel and Contractor shall make his
own arrangements for such facilities in the area allotted at Site, to him by the Client
(EPIL)/ NTPC for that purpose.
45.05.00 The Contractor and his expatriate personnel shall respect all Indian Acts, Laws,
rules and regulations and shall not in any way interfere with Indian political
and religious affairs and shall conform to any other rules and regulations which
the Government of India and the Client (EPIL)/ NTPC may establish from time to
time, on them. The Contractor's expatriate personnel shall work and live in close co-
operation and coordination with their co-workers and the community and
shall not engage themselves in any other employment neither part-time nor
full-time nor shall they take part in any local politics.
45.06.00 The Client (EPIL)/ NTPC shall assist the Contractor, to the extent possible, in
obtaining necessary permits to travel to India and back, by issue of necessary
certificates and other information needed by the Government agencies.
46.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT

BASES
46.01.00 The surfaces of foundations shall be dressed to bring the top surface of the
foundations to the required level, prior to placement of equipment/equipment bases
on the foundations.
46.02.00 All the equipment/ equipment bases, shall be grouted and finished by bidder as per
these specifications unless otherwise recommended by the equipment
manufacturer.

46.03.00 The concrete foundation surfaces shall be properly prepared by bidder by chipping,
grinding as required to bring the top of such foundation to the required level,
to provide the necessary roughness for bondage and to assure enough bearing
strength.
46.04.00 Grout
The grout for equipment foundation shall be high strength grout having a minimum
characteristic compressive strength of 60 N/mm2 at 28 days. The grout shall be ready
mix non-shrink, chloride - free, cement based, free flowing, non-metallic grout as
recommended by equipment manufacturer. The ready- mix grout shall be of reputed
make as approved by the Client (EPIL)/ NTPC.
The Grout shall have good “flowability” even at very low water/ grout powder ratio.
The Grout shall have characteristics of controlled expansion to be able to occupy its
original volume to fill the voids and to compensate for shrinkage. Grout shall be of
pre-mix variety so that only water needs to be added before use.
The mixing of the Grout shall conform to the recommendations of the manufacturer of
the Grout.
46.05.00 Placing of Grout
46.05.01 After the base has been prepared, its alignment and level has been checked and
approved and before actually placing the grout, a low dam shall be set around the
base at a distance that will permit pouring and manipulation of the grout. The height
of such dam shall be at least 25mm above the bottom of the base. Suitable size and
number of chains shall be introduced under the base before placing the grout,
so that such chains can be moved back & forth to push the grout into every part of the
space under the base.
46.05.02 The grout shall be poured either through grout holes if provided or shall be poured at
one side or at two adjacent sides to make the grout move in a solid mass under the
base and out in the opposite side. Pouring shall be continued until the entire space
below the base is thoroughly filled and the grout stands at least 25 mm higher all
around than the bottom of the base. Enough care should be taken to avoid any air or
water pockets beneath the bases.

46.05.03 In addition to the above, recommendations of Grout manufacturer shall also be

followed.
46.06.00 Finishing of the Edges of the Grout
The poured grout should be allowed to stand undisturbed until it is well set.
Immediately thereafter, the dam shall be removed and grout which extends beyond
the edges of the structural or equipment base plates shall be cut off, flushed and
removed. The edges of the grout shall then be pointed and finished with 1:2 cement
mortar pressed firmly to bond with the body of the grout and smoothened with a tool
to present a smooth vertical surface. The work shall be done in a clean and scientific
manner and the adjacent floor spaces, exposed edges of the foundations, and
structural steel and equipment base plates shall be thoroughly cleaned of any
spillage of the grout.
46.07.00 Checking of Equipment after Grouting
After the grout is set and cured, the Contractor shall check and verify the alignment of
equipments, alignment of shafts of rotating machinery, the slopes of all bearing
pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as
applicable and the like items to ensure that no displacement had taken place
during grouting. The values recorded prior to grouting shall be used during
such post grouting check- up and verifications. Such pre and post grout records
of alignment details shall be maintained by the Contractor in a manner acceptable
to the Client (EPIL)/ NTPC.
47.00.00 SHAFT ALIGNMENTS

All the shafts of rotating equipment shall be properly aligned to those of the matching
equipments to as perfect an accuracy as practicable. The equipment shall be free from
excessive vibration so as to avoid overheating of bearings or other conditions which
may tend to shorten the life of the equipment. The vibration level of rotating
equipments measured at bearing housing shall conform to Zone A of ISO 10816. All
bearings, shafts and other rotating parts shall be thoroughly cleaned and
suitably lubricated before starting.
48.00.00 DOWELLING
All the motors and other equipment shall be suitably doweled after alignment
of shafts with tapered machined dowels as per the direction of the Client (EPIL)/
NTPC.

49.00.00 CHECK OUT OF CONTROL SYSTEMS

After completion of wiring, cabling furnished under separate specification and
laid and terminated by the Client (EPIL)/ NTPC, the Contractor shall check out the
operation of all control systems for the equipment furnished and installed under these
specifications and documents.
50.00.00 COMMISSIONING SPARES

50.01.00 It will be the responsibility of the Contractor to provide all commissioning
spares including consumable spares required for initial operation till the
Completion of Facilities. The Contractor shall furnish a list of all commissioning
spares within 60 days from the date of Notification of Award and such list shall be
reviewed by the Client (EPIL)/ NTPC and mutually agreed to. However. such
review and agreement will not absolve the Contractor of his responsibilities to
supply all commissioning spares so that initial operation do not suffer for
want of commissioning spares. All commissioning spares shall be deemed to be
included in the scope of the Contract at no extra cost to the Client (EPIL)/ NTPC.
50.02.00 These spare will be received and stored by the Contractor atleast 3 months prior to the
schedule date of commencement of initial operation of the respective equipment and
utilised as and when required. The unutilised spares and replaced parts, if any, at the
end of successful completion of guarantee tests shall be the property of the Contractor
and he will be allowed to take these parts back at his own cost with the permission of
51.00.00 CABLING
51.01.00 All cables shall be supported by conduits or cable tray run in air or in cable channels.
These shall be installed in exposed runs parallel or perpendicular to dominant
surfaces with right angle turn made of symmetrical bends or fittings. When cables are
run on cable trays, they shall be clamped at a minimum interval of 2000mm or
otherwise as directed by the Client (EPIL)/ NTPC.
51.02.00 Each cable, whether power or control, shall be provided with a metallic or plastic tag
of an approved type, bearing a cable reference number indicated in the cable and
conduit list (prepared by the Contractor), at every 5 meter run or part thereof and at
both ends of the cable adjacent to the terminations. Cable routing is to be done in
such a way that cables are accessible for any maintenance and for easy
identification.

51.03.00 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC
insulted cables 1100 V grade shall be 15 D where D is the overall diameter of the cable.
Installation of other cables like high voltage, coaxial, screened,
compensating, mineral insulated shall be in accordance with the cable
manufacturer’s recommendations. Wherever cables cross roads and water, oil,
sewage or gaslines, special care should be taken for the protection of the cables in
designing the cable channels.
51.04.00 In each cable run some extra length shall be kept at a suitable point to enable one or
two straight through joints to be made, should the cable develop fault at a later date.
51.05.00 Control cable terminations shall be made in accordance with wiring diagrams, using
identifying codes subject to the Client (EPIL)/ NTPC's approval. Multi-core control
cable jackets shall be removed as required to train and terminate the conductors.
The cable jacket shall be left on the cable, as far as possible, to the point of the first
conductor branch. The insulated conductors from which the jacket is removed shall
be neatly twined in bundles and terminated. The bundles shall be firmly but not
tightly tied utilising plastic or nylon ties or specifically treated fungus protected
cord made for this purpose. Control cable conductor insulation shall be securely and
evenly cut.
51.06.00 The connectors for control cables shall be covered with a transparent insulating
sleeve so as to prevent accidental contact with ground or adjacent shall
preferably terminate in Elmex terminals and washers. The insulating sleeve shall
be fire resistant and shall be long enough to over pass the conductor insulation. All
control cables shall be fanned out and connection made to terminal blocks and test
equipment for proper operation before cables are corded together.
52.00.00 EQUIPMENT DELIVERY AND ERECTION

52.01.00 General Requirements
(a.) This part covers Contractor's responsibilities for packing, shipping, ware-
housing and the installation of all equipment and materials furnished and
installed under this specification.
(b.) The Contractor shall submit for Client (EPIL)/ NTPC's approval draft
manual for Equipment Delivery and Erection (EDE Manual) covering
detailed instructions, write up, technical data, drawings, check-lists,
documentation formats for all activities after equipment manufacture upto

installation of equipment. This manual shall cover general instructions for all
equipment and specific instructions for individual equipment wherever required
and shall include at least the following :
(1.) Instructions for packing, shipping, receiving handling, ware-housing and
storage.
(2.) Instructions for location and installation of equipment furnished by this
specification.
(3.) Installation drawings for field mounted equipment, panels, cubicles and
other equipment covered under this specification.
(4.) Instruction relating installation of piping/ tubing, support and routing
drawings of impulse pipes/signal tubes and tube/cable trays.
(5.) Check lists and quality assurance hold points.
(6.) Format for all related documentation.
(c.) The EDE Manual shall conform to the requirements of this specification, all
applicable codes and standards, recommendations of equipment manufacturers
and accepted good engineering practices and shall be subject to Client (EPIL)/
NTPC approval during detailed engineering.
(d.) The Contractor shall ensure that all work under this part shall be performed as
per the requirements of this specification, Client (EPIL)/ NTPC approved
EDE Manual and drawing/documents approved by the Client (EPIL)/ NTPC
during detailed engineering.
52.02.00 Crating
(a.) All equipment and materials shall be suitably coated, wrapped, or covered
and boxed or crated for moist humid tropical shipment and to prevent
damage or deterioration during handling and storage at the site.
(b.) Equipment shall be packed with suitable desiccants, sealed in water proof
vapour-proof wrapping and packed in lumber of plywood enclosures, suitably
braced, tied and skidded. Lumber enclosures shall be solid, not slatted.
(c.) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to
provide the required surface area and activated prior to placing in the
packaging. Calcium sulphate desiccants shall be of a chemical nature to absorb
moisture. In any case, the desiccant shall not be of a type that will absorb

enough moisture to go into solution. Desiccants shall be packed in porous

containers, strong enough to withstand handling encountered during normal
shipment. Enough desiccants shall be used for the volumes enclosed in
wrapping.
(d.) Review by the Client (EPIL)/ NTPC of the Contractor's proposed packaging
methods shall not relieve the Contractor of responsibility for damage or
deterioration to the equipment and materials specified.
(e.) All accessory items shall be shipped with the equipment. ; Boxes and crates
containing accessory items shall be marked so that they are identified with the
main equipment. The contents of each box and crates shall be indicated by
markings on the exterior.
(f.) All boxes, crates, cases bundles, loose pieces, etc shall be marked
consecutively from No.1 upward throughout all shipments from a given port to
completion of the order without repeating the same number.
(g.) An itemized list of contents shall be enclosed inside each case and one other
copy securely fastened to the outside of the case in a tin or light weight sheet
metal envelope or pocket. The lists shall be plainly marked and placed in
accessible locations to facilitate receipt and inspection. The packing list shall
indicate whether shipment is partial or complete and shall incorporate the
following information on each container, etc., according to its individual
shipping number:
i) Export case markings
ii) Case number
iii) Gross weight and net weight in Kilograms
iv) Dimensions in centimetres
v) Complete description of material
(h.) Packaging or shipping units shall be designed within the limitations of

unloading facilities and the equipment which will be used for transport.
Complications involved with ocean shipment and the limitations of ports,
railways and roads shall be considered. It shall be the responsibility

to investigate these limitations and to provide suitable packaging to

permit safe handling during transit and at the job site.
(i.) Electrical equipment, control and instrumentation shall be protected against

moisture and water damage. All external gasket surfaces and flange faces,
couplings, motor pump shafts, bearing and like items shall be thoroughly
cleaned and coated with rust preventive compound as specified above and
protected with suitable wood, metal or other substantial type covering to
ensure their full protection.
(j.) Equipment having antifriction or sleeve bearings shall be protected by

weather tight enclosures.
(k.) Coated surfaces shall be protected against impact, abrasion, discolouration and
other damage. Surfaces which are damaged shall be repaired.
(l.) All exposed threaded parts shall be greased and protected with metallic or
other substantial type protectors. All female threaded openings shall be
closed with forged steel plugs. All pipings, tubing, and conduit equipment
and other equipment openings shall be sealed with metallic or other rough
usage covers and tapped to seal the interior of the equipment piping, tubing, or
conduit.
(m.) Provisions shall be made to ensure that water does not enter any equipment
during shipment or in storage at the plant site.
(n.) Returnable containers and special shipping devices shall be returned by the
manufacturer's field representative at the Contractor's expense.
(o.) While packaging the material, care shall be taken for the limitation from the
point of view of availability of railway wagon sizes in India.
52.03.00 Factory Assembly
(a.) Instrument enclosures shall be supplied and erected completely in the factory
with instrument, air supply and blow down piping with necessary valves,
fittings, etc. and also all electrical wiring between the instruments and the
enclosure terminal blocks. Control panel and cubicles shall also be fully wired
in the factory. Control panel mounted equipments are to be dismounted from
the panels before shipment and individually packed for shipment. Electronic

control modules of the plug-in type are to be removed from equipment

racks after factory checkout are individually packed for shipment. Other
equipment shall be fully assembled at the factory, except for necessary shipping
splits in panels.
(b.) All separately packaged accessories items and parts shall be shipped with the
equipment. Containers for separately packaged items shall be marked so that
they are identified with the main equipment. An itemized packing slip,
indicating what is in that carton only, shall be attached to the outside and
inside of each container used for packing.
A master packing slip covering all accessories items for a given piece of
equipment which are shipped in separate containers, shall be attached to
one container.
52.04.00 Equipment Installation
(a.) General Requirements
(1.) The Contractor shall furnish all construction materials, tools and
equipment and shall perform all work required for complete
installation of all control and instrument equipment furnished under
this specification.
(2.) Contractor shall prepare detailed installation drawings for each

equipment furnished under this specification for Client (EPIL)/ NTPC’s
approval. Installation of all equipment/systems furnished by this
specification shall be as per Client (EPIL)/ NTPC's approval.
(3.) Erection procedures not specified herein shall be in accordance with the
recommendations of the equipment manufacturers. The procedures
shall be acceptable to the Client (EPIL)/ NTPC.
(4.) The Contractor shall coordinate his work with other suppliers where their
instruments and devices are to be installed under specifications.
(b.) Installation Materials
All materials required for installation, testing and commissioning of the

equipment shall be furnished by the Contractor.
(c.) Regulatory Requirements

All installation procedures shall confirm with the accepted good engineering
practice and with all applicable governmental laws, regulations and codes.
(d.) Cleaning
All equipment shall be cleaned of all sand, dirt and other foreign materials
immediately after removal from storage and before the equipment is brought
inside the power plant building or to other installation sites. All piping
and tubes shall be air blown.
(e.) Equipment Assembly
Equipment installed under these specifications shall be assembled if shipped

unassembled. The equipment shall be dismantled and reassembled as
required to perform the installation and commissioning work described in
these specifications.
(f.) Equipment Setting
Field mounted instruments and accessories shall be bracket or sub panel

mounted on the nearest suitable firm steel work or masonry. The brackets,
stands, supports and other miscellaneous hardware required for mounting
instruments and accessories such as receiver gauge, air set, valve manifold,
purge-meter etc. shall be furnished and installed. No field mounted
instruments shall be installed such that it depends for support or rigidity on the
impulse piping or on electrical connection to it.
Indicating type field mounted instruments shall be installed in such a way that
centre of indicating dial shall be about 1600-1800mm from operating floor
level. Non-indicating type field instruments shall be installed such that
operating handle of manifold block / isolating cock comes within 1600
mm from operating floor level.
(g.) Free-Standing Equipment
Free-standing Cabinets shall be attached to the floor, concrete equipment

bases or supporting steel as indicated on the manufacturer's drawings and
the Client (EPIL)/ NTPC's Plant Arrangement Drawings. The cabinets
shall be shimmed for proper alignment before bolting them to the floor.
Adjacent enclosures shall be shimmed to maintain mutually level appearance

before they are attached to floor. Vibration dampening mounts shall be

installed between supporting structures and panels when specified.
(h.) Non-free Standing Equipment
(1.) Non-free standing local enclosures and cabinets shall be mounted in

accessible locations on columns, walls, or stands in locations as
indicated on the Client (EPIL)/ NTPC's Plant Arrangement Drawings.
Bracket and stands shall be fabricated as required to install the
local enclosures and cabinets in a workman like manner.
(2.) Rough edges and welds on all fabricated supports shall be ground
smooth. The supports shall be finished with two coats of primer and two
coats of paint as specified in this part.
(i.) Equipment Location
(1.) All individual items of equipment not located in cabinets or on panels and
racks are located approximately according to the floor elevation and the
nearest building column designated by the Client (EPIL)/ NTPC.
(2.) Solenoid valves not located in enclosures or mounted on valves shall be

mounted in easily accessible protected locations near the
components with which they are associated.
(3.) All brackets, stands, supports and other miscellaneous hardware required
for mounting devices shall be furnished and installed.
(4.) Thermometers shall be installed in the process lines and ducts as

required and adjusted for ease in reading.
(5.) Permanent temperature wells on the main steam, hot reheat and cold reheat
piping shall not be installed until steam blowing has been completed.
Temporary temperature wells shall be installed in the main and reheat
steam piping during steam blow and discarded after completion.
(6.) Any required adapting hardware such as pipe bushings, nipples, drilled
caps and the like shall be provided for complete installation of control
devices into process connections.
For location of C&I related equipment/devices, the requirement

specified elsewhere in the technical specification may be referred.

(j.) Installation of Field Mounted Instruments and Devices
The Contractor shall submit installation drawings for all field mounted
equipment furnished under this specification for Client (EPIL)/ NTPC's
approval. These drawings shall meet the requirements of this
specification, installation drawings, applicable codes and standards and
recommendations of manufacturers of instruments/devices. All
installation work under this specification shall be strictly as per
installation drawings approved by the Client (EPIL)/ NTPC during detailed
engineering stage.
In addition to above relevant Portion as specified elsewhere in technical

specification may be referred.
(k.) Piping Connections
(1.) All equipment having piping connections shall be levelled, aligned

and wedged in place but shall not be grouted or bolted prior to the
initial fitting and alignment of connecting piping. All equipment shall,
however, be grouted or bolted to its foundation prior to final bolting or
welding of the connection piping.
(2.) All flanged joints shall be checked and retightened after

approximately 10 days of operation at normal operating temperature.
(l.) Equipment Checkout
(1.) All equipment shall be cleaned after installation. Equipment subject to

pressure differentials shall be checked for leakage.
(2.) After erection, all equipment having moving parts, having electrical
apparatus, or subject to pressure differentials shall be trial-operated.
(m.) Defects
(1.) All defects in erection shall be corrected to the satisfaction of the

Client (EPIL)/ NTPC and the Project Manager. The dismantling and
reassembly of Contractor furnished equipment to remove defective parts,
replace parts, or make adjustments shall be included as a part of the
work under these specifications.

(2.) The removal of control and instrument equipment in order to allow

bench calibration, if required, and the re-installation of the said
equipment after calibration shall also be included as a part of the work
under these specifications.
(n.) Equipment Protection
(1.) All equipment to be erected under these specifications shall be

protected from damage of any kind from the time of contract award
until commissioning of each unit.
(2.) The equipment shall be protected during storage as described herein.
(3.) Equipment shall be protected from weld spatter during construction.
(4.) Suitable guards shall be provided for protection of personnel on all

exposed rotating or moving machine parts. All such guards with
necessary spares and accessories shall be designed for easy
removal and maintenance.
(5.) Equipment having glass components such as gauges, or equipment

having other easily breakable components, shall be protected during the
construction period with plywood enclosures or other suitable means.
Broken, stolen, or lost components shall be replaced by the Contractor.
(6.) Machine finished surfaces, polished surfaces, or other bare metal

surfaces which are not to be painted, such as machinery shafts and
couplings shall be provided temporary protection during storage and
constructional periods by a coating of a suitable non- drying, oily type, rust
preventive compound.
53.00.00 WELDING - SPECIAL REQUIREMENTS

If the manufacturer has special requirements relating to the welding procedures for
welds at the terminals of the equipments to be performed under separate
specifications, the requirements shall be submitted to the Project Manager in
advance of commencement of erection work.
54.00.00 DEVIATIONS DISPOSITIONING

Any deviation to the contract and Client (EPIL)/ NTPC approved documents shall be
properly recorded in the format prescribed by NTPC. All the deviations shall be

bought to the knowledge of Client (EPIL)/ NTPC's representative for suitable

dispositioning.
55.00.00 NON-DESTRUCTIVE TESTING (NDT)

The contractor shall record results of NDTs carried out at site in the format
acceptable to Client (EPIL)/ NTPC. All the radiographs & its report duly signed &
correlated to the job shall be handed over to the Client (EPIL)/ NTPC. Sensitivity of
all the test equipment shall be compatible to the job & acceptance norms agreed.
56.00.00 TESTING EQUIPMENT & FACILITIES

Contractor shall provide the testing equipment and facilities necessary to carry out
tests & inspections.

ANNEXURE-I
STANDARD CHECKLIST
This is an indicative list of items. The actual list shall depend on the Equipment / System
being supplied by the contractor.
MECHANICAL
VALVES
1. Manually Operated Valve
2. Electrically Operated Valve
3. Pneumatically Actuated Valve
4. Hydraulically Actuated Valve
5. Safety Valve
6. Electromatic Relief Valve
7. Steam Trap
8. Non Return Valve (including Hydraulic/ Pneumatic QCNRVS)
9. Control Valve
10. Relief Valve
11. Differential Pressure Regulating Valve
12. Pinch valve
TANKS & PRESSURE VESSELS
1. Limestone silos
2. Gypsum storage silos
3. Limestone slurry tanks
4. Filtrate tank
5. Waste water tank
6. Secondary hydrocyclone feed tank
7. Lime dosing tank
8. Process water tank

9. Absorber
10. Auxiliary absorbent tank
11. Mill circuit tank
12. Any other tank not covered above
13. Vacuum tanks
14. Air Receiver(if any)
PUMPS
1. Slurry recirculation pumps
2. Gypsum bleed pumps
3. Limestone slurry pumps
4. Process water pumps
5. All other slurry pumps
6. Vacuum pumps
7. Sump pumps
PIPE WORK SYSTEM
1. Steam services
2. Water services
3. Slurry services
4. Air services
5. Constant load support
6. Spring supports
7. Hangers and other Supports
STRAINER AND FILTER
1. Strainer / Filter Basket Type
2. Strainer Rotary (Low Pressure)
3. Filter & Strainers Centrifugal Separators

4. Filter & Strainer Y-Type
5. Filter & Strainer (Plate Type)
6. Purifier
7. Filter – Compressed Air Line
FANS & COMPRESSORS
1. Booster Fans – Axial Flow pressure Lubricated
2. Oxidation Blowers/Compressors-General
DAMPERS & GATES
1. Manually Operated Damper
2. Pneumatically Operated Damper
3. Electrically Operated Damper
4. Manually Operated Gates
5. Pneumatically Operated Gate
6. Electrically Operated Gate
DUCT WORK
1. Flue Gas Ducting
2. Expansion Joints
3. Observation & Access Door
CRANES AND ELEVATORS
1. Crane
2. Hoists
3. Passenger cum goods elevator
POWER TRANSMISSION
1. Power Transmission Gear Box
2. Bearings
3. Couplings

FGD & AUX.SYSTEM
1. Agitators
2. Air Motor
3. Process trustle
4. Limestone feeder
5. Vacuum belt filter
6. Limestone ball mill
7. Limestone Hydrocyclones
8. Primary Hydrocyclones
9. Secondary Hydrocyclones
10. Absorber internals
11. Absorber Auxiliaries
ELELCTRICAL
1. D.C. Motor
2. HV Squirrel Cage Induction Motor
3. 415 V Squirrel Cage Induction Motor
4. Motor Operated Actuators
5. Soot Blower (GGH)
6. Aux. Control and Relay Panel Desk
7. SWITCHGEARS/MCC
(I) STANDARD CHECLISTS FOR ALL TYPES OF RELAYS USED IN

SWITCHGEARS PROTECTION SYSTEM
(II) PT CARRIAGE AND CUBICLES
(III) CABLE/BUS DUCT/BUS BARS
(IV) CONTRACTOR MODULE
(V) SWITCH FUSE MODULE
(VI) MASTER PANEL OF LUBE OIL PANEL

(VII)FEEDER PANEL OF LUBE OIL PANEL
(VIII)SPACE HEATER AND CABLE MODULE
(IX) HT CIRCUIT BREAKER
(X) 415 V CIRCUIT BREAKER
POWER CABLE
AUXILIARY CABLE
D.C. CABLE
EXPLOSION PROOF ELECTRICAL EQUIPMENT
JUNCTION BOX
CONTROL TRANSFORMER MODULE
BRUSH GEAR ASSEMBLY
AUX. CONTROL AND RELAY PANEL DESK
INDICATING INSTRUMENT
RECORDING INSTRUMENT
INTEGRATING INSTRUMENT
CONTROL & INSTRUMENTATION
1. Conductivity Measuring Equipment Including Test Procedures
2. pH Analyser Including Test procedure
3. Silica Analyser
4. Level Switch (Float Actuated)
5. Level Switch (Electrode Type)
6. Level Switch (Displacer Actuated)
7. Transmitter (Float Operated Pneumatic Output including Testing procedures
8. Level indicator (Float/Pulley Type)
9. Local Temperature Indicator Including Test Procedure
10. Resistance Thermometer Element Including Test procedure

11. Thermocouple Element and Connecting Cable
12. Thermocouple and Resistance Thermometer Convertor/Transmitter Including Test

Procedures
13. Temperature Switch Including Test Procedure
14. Cold Junction Boxes
15. O2Analyser
16. S O2 analyzer
17. 02 in Hydrogen including Test procedures
18. Pressure and Vacuum Gauge
19. Pressure and Vacuum Switch Including Test procedures
20. Differential Pressure Transmitter including Test Procedures
21. Differential pressure switch including Test procedures
22. Flow indicator (Variable Area)
23. Orifice plate
24. Flow Switch
25. Nozzle
26. Flow Integrator (pneumatic input) including test procedure
27. Flow indicator (Float Operated) Including Test Procedure
28. Venturi (Fluid)
29. Flow Switch (Magnetic Type)
30. Limit Switches
31. Turbine Supervisory Measuring System
32. Position Measurement & Indication Including Test procedures
33. Vibration Measurement
34. Digital Indicator
35. Moving Coil Indicator Including Test Procedures
36. Recorder Including Test procedure

37. Flame Scanner
38. Electrical Auto Manual Control Station
39. Push Button Module
40. Test Procedure for Electronic Modules of DDCMIS
41. Alarm Annunciator Equipment Including Test Procedure
42. Test procedure for Adjustment of Modulating Controller-PID Term
43. Test Procedure Indicating Controller-Electrical Input & Pneumatic Output
44. Density monitors
Note: The items which are not part of this specification may be considered as not
applicable.

ANNEXURE-II
BRIEF WRITE UP ON THE CONTENTS OF TESTING SCHEDULE / COMMISSIONING
SCHEDULE
Testing Schedules should be designed to ensure that the plant area, equipment or apparatus
are tested and commissioned and will operate as per the Client (EPIL)/ NTPC's
specifications and good engineering practices.
Testing Schedule/Commissioning Schedule is required to be of a standard format in order

to maintain consistency of presentation, content and reporting.
Testing Schedule/Commissioning Schedule should contain the following sections to make

the document a self contained one:
1. Plant Details/Design data
2. Testing Objective/Proposals
3. State of the Plant
a) Erection Status with respect to Mech. Elect and C&I
b) Availability of the services required
c) Safety requirements as per Manufacturer's
4. Test method including completion/acceptance criteria
5. Results
6. Appendix
a) Testing Programme
b) Mech/Elect/C&I -Plant item completing list
c) List of Drawing/documents required for carrying out the testing.

ANNEXURE - III
SAFETY PLAN
01. Safety Policy of the Contractor to be enclosed:
02. When was the Safety Policy last reviewed:
03. Details of implementation procedure / methods to implement Safety Policy /

Safety Rules:
04. Name, Qualification, experience of Safety Officer
05. Review of Accidents Analysis Method, Methods to ensure Safety and Health:
06. Unit executive responsible to ensure Safety at various levels in work area:
07. List of employees trained in safety employed before execution of the job. Give the
details of training:
08. Safety Training Targets, Schedules, methods Adopting to providing safety training
to all employees:
09. Details of checklist for different jobs / work and responsible person to ensure
compliance (copy of checklist to be enclosed):
10. Regular Safety Inspection Methods and Periodicity and list of members to be
enclosed:
11. Risk Assessment, Safety Audit by Professional Agencies, Periodicity:
12. Implementation of Recommendations of Audit /Inspections. Procedures for

implementation and follow up:
13. Provision for treatment of injured persons at work site:
14. Review of overall safety by top Management and Periodicity:
15. System for Implementation of Statutory legislations:
16. Issue of PPEs to employees, Periodicity / stock on hand etc:
Signature
Head of the Organisation

with date & stamp

RSTPP ABSORBER PACKAGE PRE-COMMISSIONING,
STAGE - III (FGD SYSTEM ) COMMISSIONING & INITIAL
OPERATIONS
SECTION IX—INDEX
PRE-COMMISSIONING, COMMISSIONING & INITIAL
OPERATIONS
INDEX
1. GENERAL .................................................................................................................................. 2
2. TESTING / COMMISSIONING PROCEDURES .................................................................... 2
3. PRE-COMMISSIONING & COMMISSIONING ACTIVITIES ............................................. 3
4. INITIAL OPERATION ............................................................................................................. 6
5. COMMISSIONING SPARES..................................................................................................... 6
ANNEXURE-I .................................................................................................................................... 8
ANNEXURE-II .................................................................................................................................. 14
ANNEXURE-III - . ............................................................................................................................ 15
ANNEXURE-IV-................................................................................................................................ 16
Tender Doc No.:SRO/CON/ETS/079 VOLUME-II SECTION-IX Page 1 of 16

RSTPP ABSORBER PACKAGE PRE-COMMISSIONING,
STAGE - III (FGD SYSTEM ) COMMISSIONING & INITIAL
OPERATIONS
1. GENERAL:
1.1. The pre-commissioning and commissioning activities including Guarantee tests, checks
and initial operations of the equipment furnished and installed by the Contractor shall
be the responsibility of the Contractor as detailed in relevant clauses in Technical
Specification. The Contractor shall provide, in addition test instruments, calibrating devices,
etc. and labour required for successful performance of these operations. If it is anticipated
that the above test may prolong for a long time, the Contractor's workmen required for
the above test shall always be present at Site during such operations.
1.2. It shall be the responsibility of the Contractor to provide all necessary temporary
instrumentation and other measuring devices required during start-up and initial
operation of the equipment systems which are installed by him. The Contractor shall also be
responsible for flushing & initial filling of all oils & lubricants required for the equipment
furnished and installed by him so as to make such equipment ready for operation. The
Contractor shall be responsible for supplying such flushing oil and other lubricants
unless otherwise specified elsewhere in these specifications & documents.
1.3. The Contractor upon completion of installation of equipments and systems, shall
conduct pre-commissioning and commissioning activities, to make the facilities ready
for sustained safe, reliable and efficient operation. All pre-commissioning/
commissioning activities considered essential for such readiness of the facilities
including those mutually agreed and included in the Contractors quality assurance program
as well as those indicated in clauses elsewhere in the technical specifications shall
be performed by the Contractor.
2. TESTING / COMMISSIONING PROCEDURES
The contractor shall submit his testing / commissioning check lists and procedures for
various equipments / systems covered under the contract at least 10 months before
the actual commissioning of the equipments / systems for review and approval of
The testing / commissioning procedures are to be of a standard format in order to maintain

consistency of presentation, content and reporting. The list of commissioning

PRE-COMMISSIONING,
COMMISSIONING & INITIAL
OPERATIONS
check lists and procedures to be submitted and their content details shall be agreed upon
during pre-award discussions.
An indicative list of Testing / Commissioning procedures and Standard Checklists and

the details regarding the contents are enclosed as annexure at the end of this sub-section of
section-VI, Part B. The actual list of such equipments / systems shall depend on the
equipments / systems being supplied by the contractor.
i) Annexure-I : Standard Checklist of items

ii) Annexure-II : Testing / Commissioning Procedure
iii) Annexure-III : Commissioning procedures requiring approval of Client
iv) Annexure- IV : Brief write up on Contents of Testing / Commissioning
Procedures
3. PRE-COMMISSIONING & COMMISSIONING ACTIVITIES
3.1. GENERAL
The pre-commissioning activities including some of the important checks & tests for certain
major equipment/ systems (as a minimum) are described below, although it is the
Contractor's responsibility to draw up a detailed sequential & systematic list of checks /
tests and various activities / procedures connected with pre-commissioning of the complete
facilities with all systems, sub-systems and equipment supplied and installed by him and
get the same approved by the Client (EPIL)/ NTPC.
3.2. PRE-COMMISSIONING ACTIVITIES/TESTS:

Air and Gas Tightness Test
a) After completion of installation of Booster fans, ducts, and absorber and
before commencement of application of thermal insulation a test shall be performed on
the FGD system by the contractor to prove or to establish the tightness of the erected
equipments within the Terminal points. The procedure adopted for such tests shall
have the prior approval of the Client (EPIL)/ NTPC. Normally physical leak detection
method by pressurizing the section under test by running Temporary blower is
adopted. The contractor may adopt any other better method of testing.

PRE-COMMISSIONING,
OPERATIONS
b) All equipments including any temporary blanking, if required, for the above test shall
be provided by the Contractor.
c) The Contractor's air and gas tightness test procedure shall be such that it shall
enable conductance of air/gas tightness test on the ducts in segmented manner (as and
when these duct segments are ready), so that these duct segments can be
immediately released for application of insulation after their gas tightness tests.
Contractor shall made all necessary arrangement for conducting tests in this
manner. Any blanking etc. on the duct side required for testing of duct
segments shall be provided by Contractor. Contractor shall bring fan / blower (s) of
adequate size / capacity and other necessary instruments so that these tests can
be conducted. The above equipment shall be brought to site by the Contractor
on temporary basis and shall be taken back after successful completion of air /
gas tightness test.
d) All pre-commissioning tests & activities as indicated in Annexure-I, II & III and
elsewhere in the technical specification shall be performed by the Contractor.
3.3. COMMISSIONING OF FACILITIES

1) General
a) Upon completion of pre-commissioning activities/test the Contractor shall

initiate commissioning of facilities. During commissioning the Contractor shall
carryout system checking and reliability trials on various parts of the facilities.
b) Contractor shall carry out these checks/tests at site to prove to the Client
(EPIL)/ NTPC that each equipment of the supply complies with requirements
stipulated and is installed in accordance with requirements specified. Before the
plant is put into initial operation the Contractor shall be required to conduct
test to demonstrate to the Client (EPIL)/ NTPC that each item of the plant is
capable of correctly performing the functions for which it was specified and its
performance, parameters etc. are as per the specified/approved values. These
tests may be conducted concurrently with those required under commissioning
sequence.

PRE-COMMISSIONING,
OPERATIONS
c) The Contractor shall finalize the protocol of check lists, after erection of the system
and equipment, as per International Codes/Standard with the Client (EPIL)/ NTPC.
d) The Contractor shall furnish requisite no. of copies of procedures and list of start up,
pre-commissioning, commissioning and initial operation tests for Client
(EPIL)/ NTPC's approval.
e) The Contractor shall also demonstrate the performance of all C&I equipment,
the tests on main equipment or prior to that as the case may be.
f) Other tests shall be conducted, if required by the Client (EPIL)/ NTPC, to

establish that the plant equipments are in accordance with requirements of the
specifications.
g) The Commissioning tests/checks shall specifically include but will not be limited to
following:
1. Checks on the operation of all controls of isolating gas and air dampers
2. Checks on operation of fans to ascertain level of noise and vibration
3. Test running of all pumps, blowers & compressors
4. Checks on operation of Fire Fighting System
5. Checks on operation of all ZLD system (wherever provided).
6. Checks on operation of all rotating equipments to ascertain level of noise and
vibration
7. Standard commissioning tests and procedures as per Contractor's practice
for FGD plant
8. Checks on operation of all individual control loops in the FGD control loops in
the FGD control system.
9. Checks on inter-relation between each control loop in the FGD control
system.
10. Calibration tests of orifice, flow nozzles, instruments and control equipment to
the extent included in these specifications.
11. Checks on operation of all static equipments to ascertain level of noise and
vibration
12. Tests on Control & Instrumentation (C&I) Equipments

PRE-COMMISSIONING,
OPERATIONS
h) The Contractor shall finalise the protocol of check lists, after erection of the system
and equipment, as per International Codes/Standard with the Client (EPIL)/ NTPC.
i) The Contractor shall furnish requisite no. of copies of procedures and list of start up,
pre-commissioning, commissioning and initial operation tests for Client
(EPIL)/ NTPC's approval.
j) The Contractor shall also demonstrate the performance of all C&I equipment,
the tests on main equipment or prior to that as the case may be.
Other tests shall be conducted, if required by the Client (EPIL)/ NTPC, to
establish that the plant equipments are in accordance with requirements of the
specifications.
2) Balance equipment & systems
All pre-commissioning tests &activities as required for successful running of the

equipment or as mentioned in the technical specification elsewhere shall be
performed by the contractor.
4. INITIAL OPERATION
Upon completion of system checking/tests and as a part of commissioning of

facilities, complete FGD plant/facilities shall be put on initial operation for a period of thirty
(30) days or 720 hours as stipulated in General Technical Requirements.
The Contractor shall conduct all the commissioning tests and undertake
commissioning activities pertaining to all other auxiliaries and equipments including all
Electrical & C&I equipment/systems not specifically brought out above but are within
the scope of work and facilities being supplied & installed by the Contractor and follow
the guidelines indicated above or elsewhere in these Technical specifications .
The Contractor shall conduct all the commissioning tests and undertake
commissioning activities pertaining to all other auxiliaries and equipments including all
Electrical & C&I equipment/systems not specifically brought out above but are within
the scope of work and facilities being supplied & installed by the Contractor and follow
the guidelines indicated above or elsewhere in these technical specifications.
5. COMMISSIONING SPARES
(a) It will be the responsibility of the Contractor to provide all commissioning

spares including consumable spares required for initial operation till the

PRE-COMMISSIONING,
OPERATIONS
Completion of Facilities. The Contractor shall furnish a list of all commissioning

spares within 60 days from the date of Notification of Award and such list shall be
reviewed by the Client (EPIL)/ NTPC and mutually agreed to. However, such
review and agreement will not absolve the Contractor of his responsibilities to
supply all commissioning spares so that initial operation do not suffer for
want of commissioning spares. All commissioning spares shall be deemed to be
included in the scope of the Contract at no extra cost to the Client (EPIL)/ NTPC.
(b) These spare will be received and stored by the Contractor at least 3 months prior to
the schedule date of commencement of initial operation of the respective equipment
and utilized as and when required. The unutilized spares and replaced parts, if any,
at the end of successful completion of guarantee tests shall be the property of the
Contractor and he will be allowed to take these parts back at his own cost with the
permission of Client (EPIL)/ NTPC.

PRE-COMMISSIONING,
OPERATIONS
ANNEXURE-I - STANDARD CHECKLIST
This is an indicative list of items. The actual list shall depend on the Equipment / System
being supplied by the contractor.
MECHANICAL
1.0 VALVES
1. Manually Operated Valve

2. Electrically Operated Valve
3. Pneumatically Actuated Valve
4. Hydraulically Actuated Valve
5. Safety Valve
6. Electromatic Relief Valve
7. Steam Trap
8. Non Return Valve (including Hydraulic/ Pneumatic QCNRVS)
9. Control Valve
10. Relief Valve
11. Differential Pressure Regulating Valve
12. Pinch valve
2.0 TANKS & PRESSURE VESSELS
1. Limestone silos
2. Gypsum storage silos
3. Limestone slurry tanks
4. Filtrate tank
5. Waste water tank
6. Secondary hydro cyclone feed tank
7. Lime dosing tank
8. Process water tank
9. Absorber
10. Auxiliary absorbent tank
11. Mill circuit tank
12. Any other tank not covered above
13. Vacuum tanks
14. Air Receiver (if any)

PRE-COMMISSIONING,
OPERATIONS
3.0 PUMPS
1. Slurry recirculation pumps

2. Gypsum bleed pumps
3. Limestone slurry pumps
4. Process water pumps
5. All other slurry pumps
6. Vacuum pumps
7. Sump pumps
4.0 PIPE WORK SYSTEM
1. Steam services
2. Water services
3. Slurry services
4. Air services
5. Constant load support
6. Spring supports
7. Hangers and other Supports
5.0 STRAINER AND FILTER
1. Strainer / Filter Basket Type

2. Strainer Rotary (Low Pressure)
3. Filter & Strainers Centrifugal Separators
4. Filter & Strainer Y-Type
5. Filter & Strainer (Plate Type)
6. Purifier
7. Filter – Compressed Air Line
6.0 FANS & COMPRESSORS
1. Booster Fans– Axial Flow pressure Lubricated

2. Oxidation Blowers
3. Compressors
7.0 DAMPERS & GATES
1. Manually Operated Damper

2. Pneumatically Operated Damper
3. Electrically Operated Damper
4. Manually Operated Gates

PRE-COMMISSIONING,
OPERATIONS
5. Pneumatically Operated Gate

6. Electrically Operated Gate
8.0 DUCT WORK
1. Flue Gas Ducting

2. Expansion Joints
3. Observation & Access Door
9.0 CRANES AND ELEVATORS
1. Crane
2. Hoists
3. Passenger cum goods elevator
10 POWER TRANSMISSION
1. Power Transmission Gear Box

2. Bearings
3. Couplings
11 FGD & AUX.SYSTEM
1. Agitators
2. Air Motor
3. Process trestle
4. Limestone feeder
5. Vacuum belt filter
6. Limestone ball mill
7. Limestone Hydro cyclones
8. Primary Hydro cyclones
9. Secondary Hydro cyclones
10. Absorber internals
11. Absorber Auxiliaries

PRE-COMMISSIONING,
OPERATIONS
ELELCTRICAL
1. D.C. Motor
2. HV Squirrel Cage Induction Motor
3. 415 V Squirrel Cage Induction Motor
4. Motor Operated Actuators
5. Transformers
6. Aux. Control and Relay Panel Desk
7. HT & LT SWITCHGEARS/MCC
(I.) Standard Checklists For All Types Of Relays Used In Switchgears
Protection System
(II.) Pt Carriage And Cubicles
(II.) Cable/Bus Duct/Bus Bars
(IV.) Contractor Module
(V.) Switch Fuse Module
(VI.) Master Panel of Lube Oil Panel
(VII.) Feeder Panel of Lube Oil Panel
(VIII.) Space Heater and Cable Module
(IX.) HT Circuit Breaker
(X.) 415 V Circuit Breaker
8. POWER CABLE
9. AUXILIARY CABLE
10. D.C. CABLE
11. EXPLOSION PROOF ELECTRICAL EQUIPMENT
12. JUNCTION BOX
13. CONTROL TRANSFORMER MODULE
14. BRUSH GEAR ASSEMBLY
15. AUX. CONTROL AND RELAY PANEL DESK
16. INDICATING INSTRUMENT
17. RECORDING INSTRUMENT
18. INTEGRATING INSTRUMENT
19. D.G SET
20. STATION LIGHTING

PRE-COMMISSIONING,
OPERATIONS
CONTROL & INSTRUMENTATION
1. Conductivity Measuring Equipment Including Test Procedures

2. pH Analyser Including Test procedure
3. Silica Analyser
4. Level Switch (Float Actuated)
5. Level Switch (Electrode Type)
6. Level Switch (Displacer Actuated)
7. Transmitter (Float Operated Pneumatic Output including Testing procedures
8. Level indicator (Float/Pulley Type)
9. Local Temperature Indicator Including Test Procedure
10. Resistance Thermometer Element Including Test procedure
11. Thermocouple Element and Connecting Cable
12. Thermocouple and Resistance Thermometer Convertor/Transmitter
Including Test Procedures
13. Temperature Switch Including Test Procedure
14. Cold Junction Boxes
15. 02Analyser
16. SO2 analyzer
17. 02 in Hydrogen including Test procedures
18. Pressure and Vacuum Gauge
19. Pressure and Vacuum Switch Including Test procedures
20. Differential Pressure Transmitter including Test Procedures
21. Differential pressure switch including Test procedures
22. Flow indicator (Variable Area)
23. Orifice plate
24. Flow Switch
25. Nozzle
26. Flow Integrator (pneumatic input) including test procedure
27. Flow indicator (Float Operated) Including Test Procedure
28. Venturi (Fluid)
29. Flow Switch (Magnetic Type)
30. Limit Switches
31. Turbine Supervisory Measuring System

PRE-COMMISSIONING,
OPERATIONS
32. Position Measurement & Indication Including Test procedures

33. Vibration Measurement
34. Digital Indicator
35. Moving Coil Indicator Including Test Procedures
36. Recorder Including Test procedure
37. Flame Scanner
38. Electrical Auto Manual Control Station
39. Push Button Module
40. Test Procedure for Electronic Modules of DDCMIS
41. Alarm Annunciator Equipment Including Test Procedure
42. Test procedure for Adjustment of Modulating Controller-PID Term
43. Test Procedure Indicating Controller-Electrical Input & Pneumatic Output
44. Density monitors
AIR CONDITIONING & VENTILATION SYSTEM
FIRE FIGHTING SYSTEM

PRE-COMMISSIONING,
OPERATIONS
ANNEXURE-II
TESTING / COMMISSIONING PROCEDURES
Following is an indicative list of equipments / systems for which Testing /

Commissioning procedures are to be submitted. The actual list will depend on the
equipment / system being supplied by the Contractor.
S. No. DESCRIPTION
FGD
1 Booster Fan
2 Absorber System
3 Limestone grinding system
4 Absorber System
5 Gypsum dewatering system
6 PT & SWRO system (if provided)

PRE-COMMISSIONING,
OPERATIONS
ANNEXURE-III
COMMISSIONING PROCEDURES REQUIRING APPROVAL OF CLIENT(EPIL) /NTPC
S. No. DESCRIPTION
1 Air and Gas Tightness Test
2 Oil Flushing of Lube oil System of Rotary Equipments
3 Limestone Grinding System
4 Gypsum Dewatering System
5 PT & SWRO System (if provided)

PRE-COMMISSIONING,
OPERATIONS
ANNEXURE-IV
BRIEF WRITE UP ON THE CONTENTS OF TESTING / COMMISSIONING PROCEDURE
Testing / Commissioning Procedure is required to be of a standard format in order to
maintain consistency of presentation, content and reporting. These should contain the
following sections to make the document a self-contained one.
1. Plant Details / Design data
2. Objective
3. Proposal
4. Services Required
5. Safety Precautions
6. Emergency Procedures
7. State of the Plant (Status in respect of erection completion of Mech, Elect and
C&I items)
8. Method
9. Completion / Acceptance Criteria
10. Appendix
• Result
• Log sheet
• Drawing etc.

STAGE - III (FGD SYSTEM ) TENDER DRAWINGS
SECTION-X - INDEX
TENDER DRAWINGS
INDEX
1. APPLICABLE DRAWINGS ..................................................................................................... 2
Tender Doc No.:SRO/CON/ETS-040 VOLUME-II SECTION-X Page 1 of 2

STAGE - III (FGD SYSTEM ) TENDER DRAWINGS
1. APPLICABLE DRAWINGS
The drawings listed below and forming part of the specification shall supplement the
requirements specified herein. The scope and terminal points of the equipment to be
furnished under this package shall be as identified in these drawings and read in
conjunction with text of the specification:
(A) LAYOUTS & GA drawings
Sl. No Drawings Title Drawings No No. of Sheets
1) General Layout Plan 3150-999-POC-F-001/ R -2 1
2) Plant Layout of FGD System – GA 3140-1095-PVM-F-044 / R-5 4

(SHEET NO. 02 to 05)
3) Absorber Tower Design Drawings ---------- 31
(B) SCHEMES
Sl. No Drawings Title Drawings No No. of Sheets
1) Process Flow Diagram of FGD System 3140-1095-PVM-F-047 (Sheet 2)
2) P&ID along with process description 3140-1095-PVM-F-079 (Sht 2 to 4)

- Flue Gas Ducting and Dampers System
3) P&ID of Absorber, Oxidation Blower, Gypsum 3140-1095-PVM-F-001 (15 Sheets)

Bleed pump & Filtrate Water system.
Mist Eliminator.
(C) ELECTRICAL
Sl.No Drawings Title Drawings No. No. Of Sheets
1. Electrical single line diagram for 0011-109(2)-POE-J-001/B 1

FGD Package-RAMAGUNDAM – III
Note : All the above drawings are indicative of Owner’s s requirements to enable the Bidder
to make a suitable offer. All variations/alternations shall be clearly brought out in the technical
deviation schedule with implications, if any.
Tender Doc No.:SRO/CON/ETS-040 VOLUME-II SECTION-X Page 2 of 2

GREEN BELT
GREEN BELT
GREEN BELT
GREEN BELT
160
SPACE FOR FGD

50
WITH NEW CHIMNEY

24
UNIT # 3
BOILER
105
118
14 SLURRY PIPE
EXISTING 30
Lot- 5
CHIMNEY 40
28
27 25
28
BA SLURRY
20 9 20 UNIT #2
L UNIT # 2
C BOILER
6 6
UNIT # 1 UNIT #1
BOILER
PIPE
WT-2
WT-3
WT-11
Lot- 5
OPEN LAND
6A+52.55
05 15B+04.80
B
PIPE RACK
2550
14B+95
7250
(156.55M) (156.612M) 6A+36.25 7A+00.25 (156.676M) 7A+55.00 (156.739M)
5A+79 14B+95.00 14B+95.00 14B+95.00 A
14B+95.00
12.0M WIDE ROAD
9000
6A+84.25 (155.00M) NOTE:
(156.155M) 6A+24.25 14800 3000 5200 25000 16000
1.THE TWO UNITS OF 33/11.5KV FGD AUXILIARY TRANSFORMER SHALL NOT LOCATED IN THE FGD AREA, THEY SHALL BE
12.0M WIDE ROAD

14B+95.00 14B+95.00
6000
FGL 155M PLACED CLOSE TO EXISTING 33KV SWITCHYARD.
6A+36.25
10000 3000 2.FINISHED GROUND ELEVATION +151.5M FOR THE EXISTING CHIMNEY AREA.
6000
3.FINISHED GROUND ELEVATION +155M FOR THE NEW CHIMNEY AREA.
DUCT PORTION WITHIN THE CLOUDED PORTION SHALL BE
CEMS ROOM
4.THE UNIT OF DIMENSION : MM, THE UNIT OF ELEVATION AND COORDINATE : M.
4000
ECW SHED
15000
SUPPLIED AND INSTALLED BY THE BIDDER.
5.THE SIZES OF FGD FACILITIES / BUILDINGS ARE TENTATIVE AND WILL BE PROVIDED AS PER ACTUAL DESIGN.
6000
6A+46.25 6.THE SIZE OF STRUCTURE IS TENTATIVE AND WILL BE UPDATED AFTER DURING DETAILED ENGINEERING.
HOWEVER THE DESIGN SHALL BE CARREIED OUT BY FLUE (156.581M) 5A+94.00 14B+72.00
14B+66.00 7.LEGEND:
GAS DUCTING SYSTEM CONTRACTOR . C 153900
6000
30000 10400 6000 17600
NEW CHIMNEY 7A+90.15
13000
05 MAINTENANCE AREA PLATFORM CABLE TRAY/TRENCH DESIGN TERMINAL REVETMENT
6000
6A+36.25 6A+66.25 14B+50.00
14B+53.00 14B+51.00 7A+00.25 7A+23.00
19 14B+51.00 14B+51.00
00 05 05
Ø76
6000
Ø1 RAIL TRACK ROADS(NTPC) ROADS(EPI) EXISTING FACILITIES
40 15 15 14B+51.00
4500
00
13 4.0M WIDE ROAD
6A+8.45 7A+55.00 23 EMERGENCY SLURRY BLEED PUMP 1
000
00 0
6000
4710X10000
05 FGL 155M
Ø4
14B+37.50
Ø4
15000
14B+51.00
15500
9000
1 7A+33.25
4300 6000 9800 7000 5000 5000 4200 3000 2600 3000 22 GYPSUM SLURRY HYDROCYCLONE 2
5000
9800 14000 7500 2500 9000 14B+39.00
8700X6610 3700 3700 B 7800 4000 3200 3200 7200 3600
21 GYPSUM SLURRY PUMP 2
2500
0
3
80
E
Ø4
4 6
3000
CHIMNEY UNIT #6
Ø5
50
11/0.433kV
10 TR
6000
0
20 14
4500
3.3kV VFD
8000
3500
6800X4950
GYPSUM SLURRY TANK AGITATOR
415V PC
1
9000
11KV MV SWITCHGEAR
4000
18 TR
0
4500
4500
00
6000
415V PC
R2
11/3.3kV
1400
1500
1500
12000
5800X5800 1 20 GYPSUM SLURRY TANK 1
11/0.433kV
3500
TR
3.3kV VFD
5
5000
5000
415V EMCC
BOOSTER FAN ROTOR BOOSTER FAN MOTOR
11 21 7A+55.00
6000
10000
19 CHIMNEY RACK AND PINION ELEVATOR 1
10000
MAINTENANCE SPACE MAINTENANCE SPACE
12 TR
4600
6A+36.25 23
3.3KV MV SWITCHGEAR
14B+26.90
12.0M WIDE ROAD

6500
5000 5000 11/3.3kV
4000
11600X5800
14B+18.00 A
1800
7A+00.25
3500
18 ABSORBER ELEVATOR 1
42000
230V UPS
6000
220V DC
A
EL ±0.00M
2800
3000 2500
4000 6800X4950
7
ELECTRICAL CUM CONTROL ROOM

6500
5000 5000
10000
FGD INLET SO2
AIR DRYER 2
10000
9
4600
ANALYZER ROOM
5A+94.00 BATTERY ROOM
6000
BOOSTER FAN ROTOR BOOSTER FAN MOTOR
(156.634M) 14B+16.00
DG
5000
5000
MAINTENANCE SPACE MAINTENANCE SPACE
17 1 5
3500
0
R250
VMS OWS OWS OWS OWS Server Server

8 17 AIR COMPRESSOR 2
DCS OWS & SERVER TABLE

3000
1500
1500
3500
11800 6000 5800X5800 1
6000
POWER CABINET
4500
14B+01
INSTRUMENT
6800X4950
16 7000 05 3
5800X5800
4500
(156.65M)
Monitor
5A+79 16 COMPRESSED AIR RECEIVER 2
DCS CABINET
VMS CABINET
6A+24.25
FGD COMMON CONTROL ROOM
SLURRY RE-CIRCULATION PUMP 0
00
3000 3500
4500
ENGINEER ROOM
R2
OXIDATION BLOWER
14B+05.00
Motorised Valve
Power Cabinet
6000
DCS EWS TABLE
11000
MAINTENANCE SPACE EWS
4 6 WASH ROOM MIST ELIMINATOR WASH PUMP 4

6800X9900
7550
FGL 155M 13B+94.00
C 4.0M WIDE ROAD B 7A+14.25 PROCESS WATER PUMP 4
13B+97.00 CABLE TARE RACK
15 PROCESS WATER TANK 2
14000
14000
WATER DRAIN 14 EMERGENCY WATER TANK 1
ASH SILOS
13B+80.00
7.0M WIDE ROAD ROAD IN CHP CONTRACTOR'S SCOPE (HOLD) AUXILIARY ABSORBENT TANK PUMP 1
5A+50
13B+72 AUXILIARY ABSORBENT TANK AGITATOR
CEL. 171.850
7A+00.25 7A+23.00 7A+55.00 1
13B+80.00 13B+80.00 13B+80.00
13000
CONV.-30A/30B
13 AUXILIARY ABSORBENT TANK 1
WATER DRAIN
ABSORBER AREA SUMP PUMP 2
ASH WATER REC. PIPE LINE
ASH WATER REC. PIPE LINE ABSORBER AREA SUMP AGITATOR 1
CONV. 31A/B
16000
12 ABSORBER AREA SUMP 1
11 GYPSUM BLEED PUMP 2

ASH WATER REC. PIPE LINE
10 OXIDATION BLOWER 2
16200
9 SLURRY RE-CIRCULATION PUMP 4
8 ABSORBER AGITATOR 5
3M
CEL. 168.625
W IDE
TR
ES
WATER DRAIN 7 ABSORBER 1
TL 13B+26
E
6800X9900 6 BOOSTER FAN 2
18000
13B+20
4100 4100 5 DAMPER SEAL AIR FAN 6
4 BOOSTER FAN OUTLET DAMPER 2

5A+16
13B+10
3 BOOSTER FAN INLET DAMPER 2
12800
ROAD 13B+5.125 2 BYPASS DAMPER 2
05
1 EXPANSION JOINT 12
7A+17
LDO NOTE :- 05
TANK FOPH PRECAUTION / SAFETY TO BE TAKEN AS IT No. DESCRIPTION Q'TY REMARK
15700
155.5M 6A+82.75 6A+90.95 IS CROSSING FOPH AT THE TIME OF ERECTION
12B+88 CL OF LOO PIPES PEDESTAL 12B+85.75 12B+85.75 MAIN EQUIMENT LIST
21600
5A+42.27
12B+78.55 2020-12-14 LIYATAO XUBIN ZHUQING UPDATE FOR COMMENTS
05
12B+82.83 CL OF PEDESTAL STAGE-II
2020-10-27 LIYATAO XUBIN ZHUQING UPDATE FOR COMMENTS
16000
04
12B+76.132 CL OF PEDESTAL STAGE-I
03 2020-09-08 LIYATAO XUBIN ZHUQING UPDATE FOR COMMENTS
5A+78.25
12B+69.75 1
4100 4100 6000 6500 10000 6500 6000 6800X9900 02 2020-08-07 LIYATAO XUBIN ZHUQING UPDATE FOR COMMENTS
5A+70 7A+10 REFFER DRG. NOS:
8500
12B+61.25 1
5000
12B+69.75 1. 3130-109-PVM-F-044 PLANT LAYOUT OF FGD SYSTEM 01 2020-07-10 LIYATAO XUBIN ZHUQING UPDATE FOR COMMENTS
5000X6800
5000X6800
12B+61.250 CEL. 167.075

7000
5000X6800 7A+21
5500
5500
REV. DATE PREPARED CHECKED APPROVED DETAILS OF REVISION

II ) 12B+61.25
R2
E-
50
G WATER DRAIN
3500
3500
0
4100 4100
CEL. 167.075
STA FGL 151.5M

CEL. 167.075
(
L IN
E
CLIENT : NTPC LIMITED
Ø4
0
9000
9000
PE
00
EXISTING CHIMNEY
0
PI 5000X6800 5000X6800
H
Ø2
AS
8
5
00
5800 1 2 1 5800
4000
4000 4000 3000
4000 4000 3000

0
5A+44.5 Y9 Y8 Y7 Y6 Y5 Y4 Y3
2 Y2 Y1
12B+36.0
6050X6050
6050X6050
ASH PIPE LINE (STAGE-I) OTHER

6050X6050 6050X6050 OTHER
5500 5500
D D
2000
2000
X9 X8 X7 X6 X5 X4 X3 X2 X1
E 2500 8400 2500

7600 4600 5400 5400 4600 7600 2500
8400 2500 WUHAN KAIDI ELECTRIC POWER ENVIRONMENTAL CO.,LTD.
21600 21600 05
05 6A+65.25
2.5M WIDE TRESTLE
Ø4
5M WIDE TRESTLE
12B+36.25
00
PROJECT : RAMAGUNDAM STPS, STAGE-III (1×500 MW) FGD SYSTEM

00
ASPH
APPROVER CHECKER
PLANT LAYOUT OF FGD SYSTEM
AUDITOR DESIGNER - GENERAL ARRANGEMENT
ID FAN A ID FAN B
DATE SCALE 1:550 EPI DWG NO. EPI- 001-RA-PVM-F-044 (SHEET NO. 02 OF 05)
KDPE T858S-J0104-01 NTPC DWG NO. 3140-1095-PVM-F-044 (SHEET NO. 02 OF 05) REVISION NO. 05
DWG NO.
SUPPLY AND ERECTION OF THIS DUCT PORTION, THATS IS, 6500 mm FROM
8700x6610
ABSORBER VESSEL (AT ITS UPSTREAM) SHALL BE CARRIED OUT BY THE
BIDDER.
HOWEVER EXPANSION JOINT SHOWN IN THIS DUCT PORTION SHALL BE

SUPPLIED BY FLUE GAS DUCTING SYSTEM CONTRACTOR TO THE BIDDER FOR
ERECTION.
6500
3 6800 14500 14500

4500 2500 3400 3400
1
2475
4950X6800
EL. 170.30
5800X11600
5800X5800
5800X5800
EL. 168.90 EL. 168.90
5800X1
EL. 168.00
2475
15¡ã
1600
R3
EL. 166.30 R4
97
90 0
90
5
EL. 165.30 EL. 165.20 R15 0 EL. 165.20
00 R4
0
0
R2
50
00
00
1 R1 4950X6800
R2
7 1 1
0
5800X5800 5800X5800
0 4 1 5800X5800
90
05 R4 6
EL. 160.30 5800X5800 1
EL. 159.10 EL. 159.10
9
Ø5322
Ø16500 FGD INLET SO2
ANALYTICAL ROOM
VFD ROOM 23
FGL. 155.00 EL. 155.30 EL. 155.30
FGL. 155.00 FGL. 155.00

05
6000 9000 12000 11800 6000 3700 3700 7800 4000 6400 10800 3000 3500 4500 3500 6500 6500 3500 4500 3500 3000
A-A B-B
01 2020-06-10 LIYATAO XUBIN ZHUQING FIRST ISSUE
REV. DATE PREPARED CHECKED APPROVED DETAILS OF REVISION
CLIENT : NTPC LIMITED
WUHAN KAIDI ELECTRIC POWER ENVIRONMENTAL CO.,LTD.

NOTES:
1. FINISHED GROUND LEVEL FGL.+151.7M FOR THE EXISTING CHIMNEY AREA.
PROJECT : RAMAGUNDAM STPS, STAGE-III (1×500 MW) FGD SYSTEM
2.FINISHED GROUND LEVEL FGL.+155.0M FOR THE NEW CHIMNEY AREA.
2. THE UNIT OF DIMENSION:MM,THE UNIT OF ELEVENT AND COORDINATE:M. APPROVER CHECKER
3. ALL THE DUCT SIZES ARE TO INSIDE DIMENSIONS ONLY.
PLANT LAYOUT OF FGD SYSTEM
AUDITOR DESIGNER - FGD A-A / B-B SECTION
DATE SCALE 1:200 EPI DWG NO. EPI- 001-RA-PVM-F-044 (SHEET NO. 03 OF 05)
KDPE T858S-J0104-02 NTPC DWG NO. 3140-1095-PVM-F-044 (SHEET NO. 03 OF 05) REVISION NO. 05
DISCIPLINE COUNTER-SIGN SIGNATURE DATE DWG NO.
THIS DUCT PORTION WITHIN THE CLOUD PORTION (i.e) FROM ABOSRBER VESSEL OULET TO INLET OF
THE NEW WET CHIMNEY SHALL BE SUPPLIED AND INSTALLED BY ABSORBER VESSEL CONTRACTOR.
THE DUCT PACKAGE CONTRACTOR SHALL DESIGN THE DUCTING & ITS SUPPORTING SYSTEM AND
SHALL PROVIDE ONLY DUCT SUPPORTING SYSTEM.
THE DUCT PACKAGE CONTRATOR SHALL ALSO SUPPLY EXPANSION (TWO NOS) IN THIS PORTION OF
DUCT TO THE ABSORBER VESSEL CONTRACTOR AND THEY SHALL ERECT THE SAME ALONG WITH
THE DUCT
DUCT WORK
CHIMNEY WORK
CHIMNEY WORK
FOUR LEGGED STRUCTURE IN

THE SCOPE OF THE DUCT
PACKAGE CONTRACTOR

FGD Tendor For Refrence

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AN ISO 9001 & 14001 COMPANY

NIT No: SRO/CON/ETS/079 dtd 15.04.2021

Tender for “Design Supply, Fabrication, Erection and Commissioning of

Technical Specifications, construction schedule and Drawings

ENGINEERING PROJECTS (INDIA) LIMITED

Signature of the Bidder with seal Page 1 of 2 EPI

Sl. Page No. No. of

Technical Specifications, NTPC Tender Documents and

Signature of the Bidder with seal Page 2 of 2 EPI

VOLUME- II - TECHNICAL SPECIFICATIONS

POWERTEC ENGINEERING PVT LTD.

1 SECTION – I SCOPE OF SUPPLY & SERVICES (GENERAL) 16

2 SECTION – II PROJECT INFORMATION 22

SCOPE OF WORK, EXCLUIONS & TERMINAL

4 SECTION – IV A TECHNICAL REQUIREMENTS - MECHANICAL 38

5 SECTION – IV B TECHNICAL REQUIREMENTS - ELECTRICAL 29

6 SECTION – IV C NOT USED ---

TECHNICAL REQUIRMENTS – CIVIL &

TECHNICAL REQUIREMENTS – QA &

9 SECTION – V FUNCTIONAL GUARANTEES & LD 8

10 SECTION – VI MANDATORY SPARES 7

11 SECTION – VII GENERAL TECHNICAL REQUIREMENTS 86

12 SECTION – VIII ERECTION CONDITIONS OF CONTRACT 64

PRE-COMMISSIONING, COMMISSIONING &

14 SECTION – X TENDER DRAWINGS ---

TENDER DOC NO.:SRO/CON/ETS/079 VOLUME - II Page 2 of 2

2. PROJECT INFORMATION ..................................................................................................... 2

3. INTENT OF SPECIFICATION ................................................................................................ 2

5. SYSTEM DESCRIPTION ......................................................................................................... 9

6. GENERAL LAYOUT ASPECTS ............................................................................................ 10

7. CONTROL & OPEARTION PHILOSOPHY ........................................................................ 11

8. SCOPE OF SUPPLY & SERVICES (General) ....................................................................... 11

9. QUALIFYING REQUIREMENTS FOR EQUIPMENTS / SYSTEMS ............................... 16

10. PROVENNESS CRITERIA FOR VARIOUS EQUIPMENTS .............................................. 16

Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION - I Page 1 of 16

Project Information of RAMAGUNDAM STPP is enclosed in Section – II of this Technical

a) Detailed design of equipment and system(s) included under Bidder’s scope.

b) Providing engineering drawings, equipment sizing as required, & applicable

c) Providing training of Owner’s personnel if any mentioned in General Technical

Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION - I Page 2 of 16

d) Compliance with statutory requirements and obtaining clearances from statutory

e) Finalization of sub-vendors, manufacturing quality plans and Field quality plans;

f) Complete manufacturing including shop testing/type testing;

g) Civil, and Structural works to the extent applicable, construction facilities,

i) Receipt, storage, preservation, handling and conservation of equipment and other

j) Pre-fabrication /Fabrication , pre-assembly, as specified elsewhere

k) Erection / Installation, testing, commissioning and completion of facilities

l) Furnishing of spares on FOR site basis.

m) Reconciliation with customs authorities, as required,

n) Satisfactory conclusion/ closure of the contract.

Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION - I Page 3 of 16

3.8. Main and Alternate Proposals

Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION - I Page 4 of 16

d) In case of each alternative proposal, its implications on the performance, guaranteed

e) However, if any alternate type of equipments or systems are sought/ specified in

f) Under no circumstances the specified equipment etc. shall be brought out as an

3.9. Technical Deviations

b) Any other remarks/deviations/clarifications/exceptions variations in any other part

Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION - I Page 5 of 16

3.10. Additional Requirements

Tender Doc No.:SRO/CON/ETS/079 VOLUME - II : SECTION - I Page 6 of 16

f) In case of any conflicts /contradiction among various volumes / sections / annexure

g) In addition to the specifications of equipment /system indicated in various sections