Techspec1 2022 04 08 04 - 50 - 37

WBPDCL
1X660MW SAGARDIGHI THERMAL POWER EXTENSION PROJECT,

PHASE-III, UNIT 5
TECHNICAL SPECIFICATION
FOR
MISCELLANEOUS TANKS- SITE FABRICATED (CONDENSATE STORAGE
TANKS AND FGD TANKS) AND AGITATORS
SPECIFICATION NO.: PE-TS-445-167-A002
BHARAT HEAVY ELECTRICALS LTD

POWER SECTOR
PROJECT ENGINEERIING MANAGEMENT
NOIDA
Page 1 of 348
1X660MW SAGARDIGHI STPP SPECIFICATION No:PE-TS-445-167-A002
TECHNICAL SPECIFICATIONS FOR SECTION
MISC. TANKS (SITE FABRICATED) AND DATE MARCH 2022
AGITATORS
SHEET : 1 OF 2
CONTENTS
SECTION - I
SUB- SECTIONS TITLE Page No.
Sub-Section-A INTENT OF SPECIFICATION 04

Sub-Section-B PROJECT INFORMATION WITH WIND AND SEISMIC DESIGN CRITERIA 07
Sub-Section-C TECHNICAL SPECIFICATIONS
Sub Section-C1 SPECIFIC TECHNICAL REQUIREMENT– MECHANICAL 27
C1-A SPECIFIC TECHNICAL REQUIREMENT-TANKS 30
C1-B SPECIFIC TECHNICAL REQUIREMENT- 41
AGITATOR
C1-C SPECIFIC TECHNICAL REQUIREMENT-GLASS 58
FLAKE LINING
Sub Section-C2 CUSTOMER SPECIFICATION
C2 - A TECHNICAL REQUIREMENT 69
C2 - B GENERAL TECHNICAL REQUIREMENT 91
INCLUDING QUALITY ASSURANCE
REQUIREMENTS
C2 - C PAINTING SPECIFICATION 160
C2 - D HARDCOPY DISTRIBUTION SCHEDULE 172
Sub Section-C3 ELECTRICAL SPECIFICATION 174
Sub Section-D ANNEXURE-I LIST OF MAKES OF SUB-VENDOR ITEMS 226
ANNEXURE-II REFERENCE QUALITY PLANS 235
ANNEXURE-III A)DATASHEET AND SKETCH OF CONDENSATE 252
STORAGE TANKS
B)GA DRAWING FOR AUX. ABSORBENT TANK WITH 256
AGITATOR AND PROCESS WATER TANK
C)TYPICAL DETAILS OF DRAIN SUMPS 260
D)TANK SCHEDULE AND AGITATOR SCHEDULE 262
E) DETAILS OF 500 MM NOZZLE FOR BOTTOM DRAIN 264
ANNEXURE-IV MASTER DRAWING LIST WITH SCHEDULE OF 266

SUBMISSION
ANNEXURE-V PACKING PROCEDURE 271
ANNEXURE-VI DATASHEET FOR BOUGHT OUT ITEMS 303
ANNEXURE-VII MANDATORY SPARES 306
Page 2 of 348
TECHNICAL SPECIFICATIONS FOR SECTION
MISC. TANKS (SITE FABRICATED) AND DATE MARCH 2022
AGITATORS
SHEET : 2 OF 2
SECTION – II
SUB SECTIONS TITLE Page No.

Sub-Section-A STANDARD TECHNICAL SPECIFICATIONS-MECHANICAL 309
1. STANDARD TANK SPECIFICATION
Sub-Section-B FORMAT FOR OPERATION AND MANITENANCE 319
Sub-Section-C SITE STORAGE AND PRESERVATION GUIDELINES 323
SECTION – III
SUB SECTIONS TITLE Page No.
Annexure-1 LIST OF DOCUMENTS TO BE SUBMITTED WITH BID 340
Annexure-2 COMPLIANCE CUM CONFIRMATION CERTIFICATE 341
Annexure-3 PRE BID CLARIFICATION SCHEDULE 343
Annexure-4 DEVIATION SHEET (COST OF WITHDRAWAL) 344
Annexure-5 VOID 345
Annexure-6 LIST OF TOOLS & TACKLES 346
Annexure-7 LIST OF COMMISSIONING SPARES 347
Annexure-8 ELECTRICAL LOAD DATA FILLED UP BY THE BIDDER 348
Page 3 of 348
1X660MW SAGARDIGHI STPP SPECIFICATION No: PE-TS-445-167-A002
TECHNICAL SPECIFICATIONS FOR SECTION-I, SUB-SECTION-A
MISC. TANKS (SITE FABRICATED) AND REV. 00
AGITATORS
Date: MARCH 2022
SECTION-I,
SUB-SECTION-A
INTENT OF SPECIFICATION
Page 4 of 348
MISC. TANKS (SITE FABRICATED) AND REV. 00 DATE: MARCH 2022
AGITATORS
SHEET : 1 OF 2
1.0 INTENT OF SPECIFICATION
1.1 The specification covers Supply part, Services part and Mandatory spares for Miscellaneous
FGD Tanks and Agitators package, comprising of design (i.e. Preparation and submission of
drawing /documents including “As Built” drawings and O&M manuals), engineering,
manufacture, fabrication, assembly, inspection / testing at vendor's & sub-vendor’s works,
painting, maintenance tools & tackles, fill of lubricants & consumables till handing over,
mandatory spares along with spares for erection, start-up and commissioning, forwarding,
proper packing, shipment and delivery at site, erection & commissioning, trial run at site
and carrying out Performance guarantee tests at site, training of customer/ client O&M
staff covering all aspects of the Agitator - Operation & Maintenance, Troubleshooting etc.
& handover in flawless condition of the package to the customer, complete with all
accessories cover under scope of work as per BHEL NIT & tender technical specification,
amendment & agreements till placement of order of the MISCELLANEOUS TANKS - SITE
FABRICATED (CONDENSATE STORAGE TANKS AND FGD TANKS) including Agitators for
tanks along with Glass flake lining for 1X660MW SAGARDIGHI THERMAL POWER
EXTENSION PROJECT.
1.2 The contractor shall be responsible for providing all material, equipment & services, which
are required to fulfil the intent of ensuring operability, maintainability, reliability and
complete safety of the complete work covered under this specification, irrespective of
whether it has been specifically listed herein or not. Omission of specific reference to any
component / accessory necessary for proper performance of the equipment shall not
relieve them of the responsibility of providing such facilities to complete the supply,
erection and commissioning, performance and guarantee/demonstration testing of
MISCELLANEOUS TANKS - SITE FABRICATED (CONDENSATE STORAGE TANKS AND FGD
TANKS) including Agitators for tanks along with Glass flake lining.
1.3 It is not the intent to specify herein all the details of design and manufacture. However, the
equipment / system shall conform in all respects to high standards of design, engineering
and workmanship and shall be capable of performing the required duties in a manner
acceptable to purchaser who will interpret the meaning of drawings and specifications and
shall be entitled to reject any work or material which in Customers judgement is not in full
accordance herewith.
1.4 The extent of supply under the contract includes all items shown in the drawings,
notwithstanding the fact that such items may have been omitted from the specification or
schedules. Similarly, the extent of supply also includes all items mentioned in the
specification and /or schedules, notwithstanding the fact that such items may have been
omitted in the drawing. Similarly, the extent of supply also includes all items required for
completion of the system for its safe, efficient, reliable and trouble free operation.
1.5 Items though not specifically mentioned but needed to make the system complete as
stipulated under these specifications are also to be furnished unless otherwise specifically
excluded.
1.6 The general terms and conditions, instructions to tenderer and other attachment referred
to elsewhere are hereby made part of the tender specifications. The equipment / material
and works covered by this specification is subject to compliance to all the attachments
Page 5 of 348
AGITATORS
SHEET : 2 OF 2
referred in the specification. The tenderer shall be responsible for adherence to all
requirements stipulated herein.
1.7 While all efforts have been made to make the specification requirement complete &
unambiguous, it shall be bidders’ responsibility to ask for missing information, ensure
completeness of specification, to bring out any contradictory / conflicting requirement in
different sections of the specification and within a section itself to the notice of BHEL and
to seek any clarification on specification requirement in the format enclosed under Sec.-III
of the specification within 10 days of receipt of tender documents. In absence of any such
clarifications, in case of any contradictory requirement, the more stringent requirement as
per interpretation of Purchaser/Customer shall prevail and shall be complied by the bidder
without any commercial implication on account of the same. Further in case of any missing
information in the specification not brought out by the prospective bidders as part of pre-
bid clarification, the same shall be furnished by Purchaser/ Customer as and when brought
to their notice either by the bidder or by purchaser/ customer themselves. However, such
requirements shall be binding on the successful bidder without any commercial & delivery
implication.
1.8 Deviations, if any, should be very clearly brought out clause by clause along with cost of
withdrawal in the enclosed schedule (in Section -II); otherwise, it will be presumed that the
vendor's offer is strictly in line with NIT specification. If no cost of withdrawal is given
against the deviation, it will be presumed that deviation can be withdrawn without any
cost to BHEL/it’s customer.
1.9 In the event of any conflict between the requirements of two clauses of this specification &
requirements of different codes/standards and between respective clauses of sub-section
C & sub-section D, more stringent clause as per the interpretation of the owner shall apply.
1.10 In case all above requirements are not complied with, the offer may be considered as
incomplete and would become liable for rejection.
1.11 Unless specified otherwise, all through the specification, the word contractor shall have
same meaning as successful bidder/vendor and Customer/Purchaser/Employer will mean
BHEL and/or Customer as interpreted by BHEL in the relevant context. Please refer
GCC/SCC for better clarity.
1.12 Various codes and standards to be used shall be as indicated in various parts of the
specification. In case bidder uses any standard other than those indicated in the
specification, the onus of establishing equivalence of the same with the specified standards
will rest with the bidder and acceptance of the same shall be sole prerogative of customer.
1.13 All text/ numeric in the document / drawings to be generated by the successful bidder will
be in English language only.
1.14 The bidder’s offer shall not carry any sections like clarification, interpretations and /or
assumptions.
Page 6 of 348
TECHNICAL SPECIFICATIONS FOR SECTION-I, SUB-SECTION-B
MISC. TANKS (SITE FABRICATED) AND
AGITATORS REV. 00 DATE: MARCH 2022
SHEET : 1 OF 1
PROJECT INFORMATION WITH WIND AND

SEISMIC DESIGN CRITERIA
Page 7 of 348
EPC Bid Document
Sagardighi Thermal Power Project
WBPDCL 1x660 MW Unit No. 5, Phase – III
SECTION-III
PROJECT SYNOPSIS AND GENERAL INFORMATION
Volume : II-A
Development Consultants Pvt. Ltd. Section : III
Project Synopsis and General
Information
Page 8 of 348
EPC Bid Document
CONTENTS
CLAUSE NO. DESCRIPTION PAGE NO.
1.00.00 INTRODUCTION 1
2.00.00 APPROACH TO SITE 1
3.00.00 LAND 1
4.00.00 SOURCE OF COAL 2
5.00.00 SOURCE OF WATER 2
6.00.00 ASH DISPOSAL AREA 2
7.00.00 DETAILS OF EXISTING 3

FACILITIES OF PHASE-II
8.00.00 SALIENT DESIGN DATA 16
Volume : II-A
Development Consultants Pvt. Ltd. Section : III
Information
Page 9 of 348
EPC Bid Document
SECTION-III
PROJECT SYNOPSIS AND GENERAL INFORMATION
1.00.00 INTRODUCTION
The West Bengal Power Development Corporation Limited (WBPDCL)

proposes to extend their on-going Phase-II extension project of 2x500 MW at
Sagardighi by adding one super critical unit of 660 MW as Phase-III extension
unit. Sagardighi TPS is located in the village Manigram in Murshidabad
district of West Bengal, India. The West Bengal Power Development
Corporation Limited, a Company fully owned by the Government of West
Bengal formed in the year 1985, have commissioned 2x300 MW Thermal
Power Plant together with all other infrastructure at Sagardighi Thermal
Power Project. Presently WBPDCL is also working on their under-
construction Phase- II extension project of 2x500 MW at Sagardighi.
The Bidder shall acquaint himself, by visiting the site, with the conditions
prevailing at site. The information given here in under is for general guidance
only.
2.00.00 APPROACH TO SITE
Sagardighi Super Thermal Power Station site is located at Manigram village,

13 KM north of Sagardighi town by the side of the SMGR (Sagardighi-
Manigram-Gankar-Raghunathganj) Road at a distance 20 KM from National
Highway 34 in Murshidabad District, West Bengal and around 240 KM from
Kolkata, India. The nearest rail station is Manigram adjacent to the site on
Bandel - Barhawara branch line and 6.5 KM from Sagardighi Railway Station
on Sainthia - Azimgunj line of Eastern Railway. From Sagardighi railway
station a railway line will branch off to the site for material unloading and coal
marshalling. The equipment will be normally transported by rail only and
under exceptional cases by road. The material consignments shall be as per
the restrictions of rail and road transportation prevailing in the country.
Nearest Airport – Kolkata.
Nearest Seaport –Haldia.
3.00.00 LAND
The total land available for the Power Station and Plant auxiliaries will be
generally as per the Site Location Plan (12A05-DWG-M-002) enclosed and
flexibility will remain to make the final equipment layout based on equipment
sizes.
All construction material, heavy equipment, over dimensioned consignments

(ODC) for the station during construction may be transported through road/rail
access. During operation stage, coal would be transported through rail
access.
Volume : II-A
Development Consultants Pvt. Ltd. Page 1 of 17 Section : III
Information
Page 10 of 348
EPC Bid Document
The total land, approximately 706 hectares, has already been acquired for the
present and proposed extension. The locations of various facilities and plant
auxiliaries for Unit 1 & 2 under Phase-I and Units 3 & 4 in Phase-II and the
space provision for extension unit no. 5 (660 MW) will be as per the General
Layout enclosed. About 456 acre of land has been kept for disposal of ash.
The Bidder shall accommodate equipment offered under this specification
generally within the spaces allocated for such equipment in the General
Layout. Specific approval from Owner/Consultant shall be taken by the
contractor prior to any revision or relocation.
Except where stated otherwise, the plinth levels of all buildings shall be 300
mm above the corresponding developed grade level and the road level shall
be 150 mm above the developed grade.
4.00.00 SOURCE OF COAL
The Power plant shall receive coal from ECL mines. Coal is planned to be
transported in rake loads through the existing Pakur- Tildanga-Dhulian-
Monigram broad gauge line or through Pakur- Nalhati (proposed)–Takipara-
Gosaingram-Poradanga-Monigram broad gauge line. The coal would be
carried in rake loads of BOBR/BOX-N wagons.
It is considered that coal would be received from the same source as the
plant under Phase-I and Phase-II station with similar characteristics and a
new mine at Pachwara (north) in Jharkhand being developed by WBPDCL.
These sources being connected by B.G. rail track, coal would be transported
by rail only. For coal unloading, crushing and storage facility it is proposed
that a new Wagon tippler along with crusher houses, conveyors will be
installed in addition to existing coal handling plant of Phase-II station with
suitable extension from the end of Transfer Point (TP-19).
5.00.00 SOURCE OF WATER
The source of water for this project is the River Bhagirathi (5 km) through the
proposed intake pump house under implementation for Phase-II station. The
water from the River Bhagirathi will be transferred and stored in the five (5)
nos. Plant Raw Water Reservoirs by augmentation of the Intake water
transportation system for phase - II for meeting the requirement of Phase-III
Sagardighi TPS.
The Power station will operate on semi open recirculating condenser cooling
system using cooling towers. In addition all water conservation and recycling
measures will be adopted to minimize requirement of make up water. The
proposed project will adopt zero effluent discharge philosophy.
6.00.00 ASH DISPOSAL AREA
Bottom Ash (BA) shall be extraction in wet form and conveyed to the disposal
area in lean slurry form. Whereas Fly Ash (FA) shall be extracted in dry form
and stored in dry form for onward usage. However, arrangement shall be also
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EPC Bid Document
made to dispose fly ash in lean slurry form to ash dump yard located within 1
km from Plant boundary under exigency..
7.00.00 DETAILS OF EXISTING FACILITIES OF PHASE-II
INTRODUCTION
The proposed phase-III, Unit No. 5 is an extension project with many auxiliary
systems being common and shared with the Phase-II units (Unit Nos. 3 & 4). It is
not the intent to describe all systems in details. Facilities being shared by both
Phase-II & Phase-III units and which have a common terminating and control
philosophy are outlined below:
MAIN & AUXILIARY COOLING WATER SYSTEMS & ACCESSORIES
Condenser cooling water and auxiliary cooling water system of Phase-III will be
independent of Phase-II. Separate pump house and pumping system shall be
installed for Phase-III. Only CT make-up system of Phase-II will be shared for
Phase-III. However, DMCW system of boiler of Phase-II has excess capacity,
which can be utilized for phase-III. The detail of excess cooling water capacity is
furnished below:
Provision kept of miscellaneous BOP coolers in DMCW (SG) pump capacity of

Phase-II:
i) AHP compressor coolers – 2X300 = 600 m3/hr (for 2X500 MW units)

ii) MRS compressor coolers - 2X30 = 60 m3/hr (for 2X500 MW units)
iii) Plant air compressor coolers - 2X175 = 350 m3/hr (for 2X500 MW units)
Cooling water consumption for miscellaneous BOP coolers (both working and
standby) of Phase-II:
i) AHP compressor coolers 158 m3/hr (for 2X500 MW units)

ii) Fluid Coupling of Ash slurry pumps = 40 m3/hr (for 2X500 MW units)
iii) BA overflow pumps = 30 m3/hr (for 2X500 MW units)
iv) MRS compressor coolers - 30 m3/hr (for 2X500 MW units)
v) Plant air compressor coolers - = 185 m3/hr (for 2X500 MW units)
The following excess capacity of DMCW(SG) system of Phase-II is available,

which can be shared by miscellaneous BOP coolers of Phase-III (except BAOF
pump and vacuum pumps), by suitable extension of existing supply and return
header of Phase-II :
i) AHP system coolers- 372 m3/hr

ii) MRS compressor coolers - 30 m3/hr
iii) Plant air compressor coolers - = 165 m3/hr
Bidder to check and confirm that excess available capacity of DMCW (SG)
system of Phase-II would be adequate for satisfactory operation of the above
mentioned BOP systems of Phase-III. With this consideration, the capacity of
DMCW (SG) can be optimized for Phase-III.
Volume : II-A
Information
Page 12 of 348
EPC Bid Document
Condensate Storage Tanks & Transfer System:
In addition to two (2) nos. installed Condensate storage tanks of Phase-II, One
(1) no. similar capacity Condensate storage tank (CST) of capacity 750 m3 shall
be installed for Phase-III.
Inside CST pumps, the following horizontal centrifugal pumps are installed for
Phase-II:
a) Three (3) nos. (2W+1S) cycle make-up (DMSW)pumps of capacity 120 m3/hr
and TDH 50.0 MWC at rated capacity
b) Two (2) nos. (1W+1S) boiler fill(SG Fill ) pumps of capacity 190 m3/hr and
TDH 140.0 MWC at rated capacity
c) Two (2) nos. (1W+1S) CPU Regeneration pumps
In addition to these, installed pumps, the CST pump house have the provision
for the following pumps of Phase-III:
a) One (1) no cycle make-up pump
b) One (1) no boiler fill pump (though no additional pump is considered for
Phase-II, as the capacity of boiler fill pumps of Phase-II is envisaged to be
sufficient for requirement of Phase-III).
c) Two (2) nos. (1W+1S) CPU Regeneration pumps
The proposed pumps of Phase-III shall be selected and interconnected such that
the aggregate pumping capacity of Phase-II & III can be shared by all the units of
both Phase-II & III.
WATER & WASTEWATER TREATMENT SYSTEMS
Pre-Treatment System-.
A Pre-Treatment Plant for Phase-II (Unit Nos. 3 & 4) have been envisaged
which shall cater the requirement for Phase-III (Unit 5). As per the WBD
developed for 3,4 & 5 the total clarified water requirement works out as 4789
m^3/hr. therefore the requirement of construction of additional PT Plant is not
called for. However the detail of the Pre-Treatment System is given below.
Raw water will be taken through a flow control station to Aerator where raw
water will be aerated and then led to Stilling Chamber where its turbulence
will be broken.
To inhibit incidental growth of organic matters in raw water, pre chlorination of

raw water in Stilling Chamber shall be carried out by use of gaseous chlorine.
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EPC Bid Document
Water will then flow to three (3) nos. Distribution Chambers through three (3)
nos. Parshall Flumes. From Distribution Chambers, water would be directed
to three (3) nos. proposed High Rate Solids Contact Clarifiers. Chemicals
such as Ferric Chloride, Lime solution & Polyelectrolyte will be added at the
inlet of each of the High Rate Solids Contact Clarifiers.
Clarified water from Clarifiers will flow through channel and be stored in a
Clarified Water Reservoir for further use.
The sludge generated from Clarifiers as addressed above will be collected in

a common Sludge Sump. Sludge will be pumped from Sludge Sump by
means of three (3) nos. Sludge transfer Pumps to the Effluent Treatment
Plant. An arrangement for sludge recirculation to Clarifiers shall be provided
to aid flocculation in case of low turbidity in raw water.
All chemicals required for the entire plant will be stored in the ground floor of
a two-storied Chemical House. Chemicals will be unloaded from the trucks
and thereafter be stacked in the respective storage space at ground floor by
means of an Electrically Operated Monorail Hoist. However, preparation of
chemical solution of Ferric Chloride, lime and polyelectrolyte for injection to
raw water shall be carried out in the first floor of the Chemical House.
Chemicals will be lifted from ground floor to first floor by means of another
Electrically Operated Monorail Hoist. The water required for preparation of
solutions is supplied from Overhead Clarified Water Tank to be located above
Chemical House or directly from the Service Water Line.
The Chlorination System will be complete with Electrically Operated Monorail

Hoist, Chlorine Ton Containers, Booster Pumps, Strainers, Pipe Works and
Diffuser Systems up to points of injection, Emergency Chlorine Leak
Absorption System and all other necessary accessories and auxiliaries.
The Chlorinators will be connected with Chlorine Ton Containers. The water
to the Booster Pumps will be supplied from Overhead Clarified Water Tank
located above Chemical House. All the necessary equipment (Chlorinators,
Chlorine Ton Containers, etc.) will be located indoor at ground floor of the
Chemical House as addressed above.
The water to the booster pumps will be supplied from Overhead Clarified
Water Tank.
De-mineralization System
A De-mineralization Plant for Phase-II (Unit Nos. 3 & 4) have been envisaged
which shall cater the requirement for Phase-III (Unit 5), considering 500 MW
sub-critical unit. In view that Unit #5 is now rated to 660 MW super-critical
technology, the requirement of DM water has been reduced as evident from
attached WBD. Therefore the requirement of construction of additional DM
Plant is not called for. However the detail of the De-mineralization System is
given below.
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EPC Bid Document
Clarified Water will be pumped from Clarified Water Reservoir (located in Raw
Water Treatment Plant area) by three (3) nos. DMF Feed Pumps to UF-RO-
MB Exchanger Plant.
Clarified Water will enter the Dual Media Filters and suspended solids present
in it will be removed.
From the Dual Media Filters, water shall flow to UF Modules through Pre-
Filter. The UF Modules shall be backwashed automatically as per the
requirement. Permeate from UF Modules shall be stored in ‘UF Permeate
Water Storage Tank’ for further treatment by Reverse Osmosis. Reject from
UF Modules shall be collected to Backwash Collection Pit and feed to the
Waste Water Treatment System.
Ultrafiltered water from UF Permeate Storage Tank shall be pumped to

Cartridge Filter for further filtration, prior to RO Modules.
Required quantity of antiscalant shall be dosed before Cartridge Filters in

order to reduce scale formation tendency of feed water on the surface of the
RO Membranes. Sodium Bi Sulphite shall be dosed to de-chlorinate the water
and acid shall be dosed to maintain the pH.
After Dosing, filtered Water from Cartridge Filter shall be passed through RO
High Pressure Pump to deliver water at desired pressure to the inlet on RO
Modules.
The entire RO System shall be designed to achieve minimum 85% recovery.

Permeate shall be passed through Degasser Tower to reduce the dissolved
CO2 content in the water. Water from Degasser Towers shall be collected to
the Degassed Water Storage Tank.
Degassified RO Permeate, finally be pumped to MB Exchanger for further

reduction of TDS, to get desired quality of Water.
For chemical cleaning of UF System, One (1) no..UF Cleaning Solution tank,
two (2) nos. UF Cleaning Chemical Pumps and one (1) no. 5 micron cartridge
filter along with necessary piping and instrumentation as addressed in the P&I
Diagram shall be provided.
A full-fledged chemical cleaning system comprising One (1) no. chemical

cleaning tank, one (1) no. chemical solution circulating pumps and one (1) no.
5 micron cartridge filter along with necessary piping and instrumentation as
addressed in the P&I Diagram shall be provided for RO Skid.
The entire UF-RO-MB Exchanger System along with Chemical Dosing /

Cleaning Systems shall be located indoor within DM Plant Building.
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EPC Bid Document
EFFLUENT TREATMENT SYSTEM
An Effluent Treatment Plant is already under construction for the Treatment of

liquid waste to be generated from Unit# 3, 4 & 5. The wastewater streams
from different sources of the Power Plant will be collected, treated and then
reused to the maximum extent possible within the Plant. Various waste
waters are to be handled and treated for reuse.
However few items have been envisaged for Phase-III (Unit 5) which is
described below.
One (1) no. Retention pit and two (2) nos. transfer pumps for service oily
waste from Power House Area which will pump the effluent from Power
House Area to the existing Waste water Treatment Plant.
One (1) no. Retention pit and two (2) nos. transfer pumps oily effluent from
Transformer Yard area which will pump the effluent from Transformer Yard
area to the existing Waste water Treatment Plant.
COAL HANDLING SYSTEM
The Existing Coal Handling Plant has been designed to cater the requirement
for Phase-II & III stations together. One (1) track hopper for Phase-I, one (1)
additional track hopper (Capacity: 5100T) and one (1) wagon tippler (Rated
capacity 20 Tips/Hour and Design capacity 25 tips/Hour) along with one (1)
side arm charger (Rated / Design capacity 29 Loaded wagons of 140 T) in
Phase-II are provided. These are adequate for Phase-III extension unit#5
also. Further two (2) nos. of stacker-cum-reclaimers having 2000 / 2200 TPH
rated / design capacity for Phase-II station are adequate for both Phase- II &
III units. In the existing crushers, coal would be sized to (-) 20 mm. Crushed
coal would thereafter be led either to the boiler bunkers or to the stack yard.
In the main route, coal will be directly taken to the powerhouse via TP # 19.
Existing four (4) nos. in-line magnetic separators, two (2) nos. metal
detectors, two (2) nos. suspended magnets, four (4) nos. belt weighers, two
(2) nos. coal sampling units will be commonly used for phase-II & phase-III
units.
New set of 2000 / 2200 TPH rated / designed capacity twin stream conveyors
as per the same for existing CHP would be installed under Phase-III beyond
Transfer Point 19 of unit #4 upto unit #5 bunkers.
New set of 1650 / 1500 TPH, 1200 / 1320 TPH (rated / designed) capacity
twin stream conveyors considered from New Wagon Tippler to TP-20. This
conveyor stream will also feed to conveyor 22A & 22B for Stacking on the
Existing Stock Pile.
Existing system facilities to be commonly used for Phase-II & III and
new dedicated system facilities for Phase-III
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EPC Bid Document
The major equipment for the coal handling plant installed for Phase-II & shall
serve Phase III also is listed below :-
1. a) Track Hopper : 5100T with paddle feeders to twin

stream conveyors
b) Wagon Tippler : One (1) no (Rated capacity 20 Tips/ Hr

and Design capacity 25 ips / hr.).
c) Side Arm Charger : One (1) no
2. Conveyors : Twin stream conveyor line of 2000 /

2200 TPH rated / design capacity.
3. Crushers : Type: Ring granulator.

Number: Four (4) (2 working + 2
standby)
Capacity: 1200 TPH (Rated) / 1320
TPH (Design)
Input coal size: (-) 300 mm
Output coal size: (-) 20 mm
4. Vibrating Screen : Type: Roller screen type.
Number: Four (4) (2 working + 2
standby)
Capacity: 1200 TPH (Rated) / 1320
TPH (Design)
5. Paddle Feeder : Capacity 1200 TPH rated / 1320 TPH
design x 2 in each stream of
conveyors.
6. Stacker-cum-reclaimer : Type: Hydraulic motor-driven rail-

mounted unidirectional having slewing
and adequate lifting arrangement.
Stacking Capacity: 2000 TPH

(Rated) / 2200 TPH (Design)
Reclaiming Capacity: 2000 TPH
(Avg.) / 2200 TPH (Peak)
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Quantity: Two (2)

Coal size: (-) 20 mm
7. Apron feeder : 2000 / 2200 TPH rated / design
capacity
ASH HANDLING SYSTEM
BAHP Water System
Six (6) nos. (4W+2S) BAHP water pumps (Make- Flowmore& Model - 5822 (HS) /
350 X 300) with drive, each of capacity 1000 CMH and discharge pressure of 70
MWC, are already installed in existing ash water sump & pump house (common for
Phase-II & III). Space for two (2) nos. BAHP water pumps (one shall cater the HP
water requirement of bottom ash system and the other for wet fly ash system) with
drive for Unit#5, had been kept in the existing ash water sump & pump house.
For details and disposition of existing equipments of Phase-II and space provision
for proposed equipment of phase-III, please refer layout of ash water sump & pump
house (Dwg. No I-5034-M-GA-002).
BALP Water System
Three (3) nos. (2W+1S) BALP water pumps (Make – Flowmore & Model - 5821A /
MWC, are already installed in existing ash water sump & pump house. Space for
one (1) no BALP water pump with drive for Unit#5, had been kept in the existing
ash water sump & pump house.
for proposed equipment of phase-III, please refer layout of ash water sump & pump
house (Dwg No I-5034-M-GA-002).
Eco Water System
Three (3) nos. (2W+1S) Eco water pumps (Make – Flowmore & Model - F5824A /
MWC, are already installed in existing Boiler area for Phase-II i.e. Unit #3 & #4.
Space for one (1) no eco water pump for Unit # 5, had been kept in the existing
Boiler area (Phase-II).
Ash Conditioning Water System
Two (2) nos. (1W+1S) ash conditioning water pumps (Make – Flowmore & Model -
F5824 / 100 X 75) with drive, each of capacity 106 CMH and discharge pressure of
50 MWC, are already installed in existing silo utility building. Space for one (1) no
ash conditioning water pump for the proposed silo of Unit#5, had been kept in the
existing silo utility building.
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For details and disposition of existing equipment of Phase-II and space provision
for proposed equipment of phase-III, please refer layout of silo utility building (Dwg
No I-5034-M-BE-016).
Seal Water System
Two (2) nos. (1W+1S) seal water pumps (Make – Flowmore & Model - M5972 /
150 X 100) with drive, are already installed in existing ash slurry pump house for
Phase-II i.e. Unit #3 & #4. Space for Two (2) nos. (1W+1S) seal water pumps for
Unit # 5, had been kept in the existing ash slurry pump house.
Civil foundations for the proposed pumps have already been constructed in the
existing slurry pump house. The base plate of the proposed pumps shall be
matched with the foundation.
for proposed equipment of phase-III, please refer layout of ash slurry sump & pump
Ash Slurry Disposal System
Four (4) nos. (2W+2S) ash slurry pump (Make – Indure & Model - A-918-401)
chain (each slurry pump chain consists of 2 nos. pumps in series and there is
space provision for future series pump also) with drive, each of capacity 1270
CMH, are already installed in existing ash slurry sump & pump house for Phase-II
i.e. Unit #3 & #4. Space for one (1) no ash slurry pump chain for Unit # 5, had been
kept in the existing ash slurry sump & pump house.
Civil foundations for the proposed pumps have already been constructed in the
existing slurry pump house. The base plate of the proposed pumps shall be
matched with the foundation.
for proposed equipment of phase-III, please refer layout of ash slurry sump & pump
Silo
Three (3) nos silos, each of capacity 2400 Tons, are already installed in existing
silo area for Phase-II i.e. Unit #3 & #4. Space for one (1) no silo for Unit # 5, had
been kept in the existing silo area.
For details and disposition of existing silos of Phase-II and space provision for
proposed silo of phase-III, please refer layout of ash compressor house (Dwg No I-
5034-M-GA-015).
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Silo Fluidizing Air System
Five (5) nos. (3W+2S) water cooled silo aeration blowers (Make - Swam & Model -
RH-250 WC ) with drive and heater, each of capacity 1860 CMH and discharge
pressure of 10 MWC, are already installed in existing silo utility building for Phase-II
i.e. Unit #3 & #4. Space for one (1) no silo aeration blower and heater for Unit # 5,
had been kept in the existing silo utility building.
for proposed equipment of phase-III, please refer layout of silo utility building (Dwg
No I-5034-M-BE-016).
Instrument Air System
Four (4) nos. (2W+2S) oil free, water cooled screw compressor (Make - Atlas
Copco & Model ZR 110) with drive and heat of compression (HOC) dryer (Make -
Atlas Copco), each of capacity 900 CMH (FAD) and discharge pressure of 8
Kg/cm2 (g), are already installed in existing ash compressor house for Phase-II i.e.
Unit #3 & #4. Space for one (1) no instrument air compressor & HOC dryer for Unit
# 5, had been kept in the existing ash compressor building.
for proposed equipment of phase-III, please refer layout of ash compressor house
(Dwg No I-5034-M-GA-018).
Recycle Water System
Space for two (2) nos. (1W+1S) recycle water pump with drive for phase-III, had
been kept in the existing ash clarifier area.
Space for one (1) no ash slurry disposal pipe (450 NB x 9.52 MM Thk.) for Unit #
5, had been kept in the existing slurry piping corridor of Phase-II. Please refer Dwg
No I-5034-M-BE-015 & I-5034-M-BE-025 for layout of existing ash slurry disposal
piping & ash dyke.
MILL REJECT SYSTEM (COMPRESSED AIR SYSTEM)
Two (2) nos. (1W+1S) oil free, water cooled screw compressor (Make - ELGI and
Model No. - EG110 - 5.5 WC) with drive, each of capacity 20 m3/min (FAD) and
discharge pressure of 5.0 Bar (g), are already installed in existing Plant
Compressor House (Common for Phase-II & III) for Phase-II i.e. Unit #3 & #4.
Space for one (1) no conveying air compressor for Unit # 5, had been kept in the
existing plant compressor building.
Civil foundation for the proposed MRS Compressor has already been constructed
in the existing plant compressor house. The base plate of the proposed
compressor shall be matched with the foundation.
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EPC Bid Document
For details and disposition of existing equipments of Phase-II and space

provision for proposed equipment of phase-III, please refer layout compressor
house (Dwg. No.PE-V0-373-160-505).
Cooling water requirements for conveying air compressor shall be met from
existing DMCCW system. The supply and return lines shall be connected at the
tie in points from the existing DMCCW system.
PLANT COMPRESSED AIR SYSTEM
Plant air compressor house will be common for Phase-II & III. Instrument air and
service air compressors, dryer, receivers and interconnecting piping system for
phase-II are installed in the compressor house. Provision of one (1) no.
Instrument air Compressor and one (1) no. Service air Compressor, with dryer,
receivers and interconnecting piping system are kept in the compressor house for
Phase-III. The brief details of existing facilities of Phase-II are indicated below:
a) Instrument Air Compressors- Three (3) nos. (2W+1S) Motor driven oil free
screw compressors with air dryer, each of capacity 36 Nm3/min (FAD-46.53
m3/min) and discharge pressure of 8.0 kg/cm2(g)at after cooler outlet at rated
capacity.
b) Service Air Compressors- Two (2) nos. (2W+0S) Motor driven oil free screw
compressors with air dryer, each of capacity 36 Nm3/min (FAD-46.53 m3/min)
and discharge pressure of 8.0 kg/cm2(g)at after cooler outlet at rated capacity.
c) Air Receivers- Five (5) nos., each of capacity 10m3.
for proposed equipment of phase-III, please refer P&ID & layout Compressor
house of Phase-II (Dwg. no. PE-V0-373-555-A002 & PE-V0-373-555-A001
respectively).
The proposed compressors of Phase-III shall be selected and interconnected

such that the aggregate compressed air capacity of Phase-II & III can be shared
by all the units of both Phase-II & III.
FIRE PROTECTION SYSTEM
Two (02) nos. inter-connections with isolation valves for hydrant system and Two
(02) nos. inter-connections with isolation valves for spray system shall be
considered at site for proposed integration with the hydrant and spray network of
Phase-III with Phase – II. Please refer Composite piping layout of hydrant and
spray network of Phase-II (Dwg. no. PE-V0-373-522-A0013) for locations of inter
connection points.
LP PIPING (PIPE RACK)
Existing pipe rack of Phase-II shall be utilized to carry pipe lines from new
pumps/ compressors of Phase-III to be installed in existing pump/compressors
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EPC Bid Document
houses of Phase-II. Suitable augmentation/ modification/strengthening of existing

pipe racks of Phase-II shall carried out by the bidder.
FUEL OIL HANDLING SYSTEM
No further extension of unloading and storage capacity is envisaged for installed

fuel oil handling system, which is sufficient for requirement of Phase-I, II& III
units.
Pressurizing pumps will supply oil from the HFO/LDO storage tanks to the burner.
Three (3) nos.HFO (2 W+ 1S) & two (2) nos. LDO (1W +1S) pressurizing pumps
(each having capacity equivalent of 2X500 MW units) are installed under Phase-II
system.
There is provision for one additional HFO pressuring pump along with HFO
Heater to be installed in pressurizing pump house to cater the requirement of
Phase-III. Installed LDO forwarding pumps of Phase-II can also cater requirement
of Phase-III. HFO & LDO Pressurizing pump discharge lines, which has been
extended up to Unit #4 of Phase-II, shall be further extended by bidder to feed
Phase-III.
HFO supply and return lines to and from boiler of phase-III to be extended from
existing HFO supply and return header respectively (terminated with isolation
valve) of Phase-II. Similarly, LDO supply line to boiler of phase-III to be extended
from existing LDO supply header (terminated with isolation valve) of phase-II.
The proposed HFO pressurizing pump with heater of Phase-III shall be of

identical capacity with the existing equipment to utilize existing equipment
foundations at site.
ELECTRICAL EQUIPMENT & ACCESSORIES
Necessary power supply for Phase-III Fuel oil pump will be arranged from
existing FO Switchboard. Accordingly existing FO switchboard shall be modified
as specified elsewhere.
If the new equipment of Phase-III 400kV air insulated switchyard can be

accommodated in the existing switchyard control building, same needs to be
modified if required.
For further details regarding the existing facilities of Phase – II, please refer
Volume – II F1 and F2: Technical Specifications for Electrical Equipment and
accessories.
CONTROL & INSTRUMENTATION
The following are the existing Stage-II facilities which shall be used for Unit #5
C&I works.
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EPC Bid Document
System Existing Facilities to be used

a) Fuel Oil Existing spare I/O cards and spare I/O slots of
Pressurizing Unit #3 & Unit #4 DCS [Stage-II] shall be used
& Heating for augmentation of the new Fuel Oil
System Pressurizing & Heating System of Unit#5 of
Stage-III. Relevant control shall be
implemented in the existing DCS processors.
b) Compressed New Instrument Air Compressor and Service

Air System Air Compressor shall share the existing serial
network of Compressors of Unit#3 & Unit#4
DCS [Stage-II] for DCS soft communication.
The new Instrument Air Compressor shall also

be interfaced with the existing electronic
sequencer module (ES-6) provided for the
existing Instrument Air compressors of Unit#3
& Unit#4 DCS [Stage-II] for group interlocks.
c) Mill Reject The control shall be implemented in the

Handling existing MRHS PLC of Unit#3 & Unit#4 [Stage-
System II], located in the existing CPU regeneration
Area control room. The new MRH System shall
use the existing processor of the PLC. New IO
panel for additional IO cards for the new
system shall be installed in the assigned
location of the existing control room for Future
IO Panel.
The UPS for the new MRH system PLC IO

Panel shall be derived from the existing UPS
ACDB located in the existing CPU
Regeneration Building Control Room (Stage-II).
d) Ash The operation and control of new Unit#5 AHP

Handling facilities shall be through the existing PLC of
System Stage-II (located in the Compressor House
Control room).
Existing PLC processor (PLC-1), shall cater to

the control of the common systems including
Ash Water & Ash Slurry System, Fly Ash
Unloading System, Instrument Air System &
various sump draining systems.
Additional IO panels shall be installed in the

locations assigned for future IO panels in the
Compressor House Control Room, Ash Water
Pump House RIO Room and Silo Utility
Building RIO Room of Stage-II units.
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EPC Bid Document
One new redundant processor shall be

installed in the existing Processor Panel
located in the Compressor House Control room
to cater the new Unit#5 Bottom Ash & Fly Ash
Evacuation System. Extended RIO of the new
processor shall be procured for the Unit#5
systems.
For new PLC CPU/ IO at existing (Stage-II)

Compressor House Control Room, existing
UPS system in the Existing [Stage-II]
Compressor House Control Room shall be
considered.
New Energy Meter, Numerical Relays, Air

Compressor etc. shall share the existing serial
network for interface with existing PLC for
Unit#3 & Unit#4 [Stage-II].
e) Coal Spare IOs cards at Remote IO Unit of existing

Handling Stage-II CHP PLC near TP-17 of Stage-II shall
System be used for the augmentation of new CHP
system of Unit#5 (Stage-III). The control shall
be implemented in the existing PLC processor.
However, for Wagon Tippler & Crusher

separate new PLC based system with
connectivity with existing PLC at HMI network
level shall be envisaged.
Existing “3D Level Mapping Software” loaded in

the CHP PLC for Unit#3 & #4 of Stage-II shall
be used for the new Unit#5 Bunker Level
indication System. The existing Fiber Optic
network for CHP PLC interface with Bunker
Level indication System of Stage-II shall also
be used by the new Bunker Level indication
System for CHP PLC interface.
f) GPS Master All the microprocessor based control systems

Clock like DCS, PLC based systems, CCTV, TSI &
System Rotating machine condition monitoring system
etc of unit#5 shall be time synchronized with
the Existing GPS Master clock of Phase-II.
g) Fire Alarm Existing Fire Alarm Panel at Fire Station of

System phase II shall be used to display parameters /
Alarms of new Fire Alarm System of unit#5.
Main FAP of unit#5 shall be connected to the
phase II FAP located at existing fire station.
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EPC Bid Document
CIVIL, STRUCTURAL AND ARCHITECTURAL WORK (BUILDINGS

CONSTRUCTED WITH SPACE FOR PHASE III)
Necessary Walkway connection between operating floors of Power House of

Phase – II (Existing) and Phase – III shall be considered by Bidder.
Few civil foundations have already been constructed for future equipment.
Such existing foundation details including bolts, inserts etc. to be studied in
detail before procurement of specific equipment for respective purposes so
that the same can safely be placed over the existing foundations complying
all technical compatibility. In case this is not at all possible, new foundations
need to be constructed after complete demolition of existing foundations.
For further details regarding the existing facilities of Phase – II, please refer
Volume – II G1, G2 and G2: Technical Specifications for Civil, Structural
and Architectural..
8.00.00 SALIENT DESIGN DATA
8.01.00 For implementation of the project, the Bidder shall consider the following Site
and Meteorological data:-
a) Location : Manigram village, Sagardighi,

Raghunathganj sub-division,
Murshidabad District, West Bengal.
b) Latitude and Longitude : 240 22’ 13.7” N, 880 6’ 15.8” E

(Topo sheet No.78/D/3)
c) Nearest Towns : Ajimganj, Jangipur, Raghunathganj.
d) District Head Quarters : Berhampore - 40 km.
e) Approach Road : 20 km from National Highway (NH-34)
f) Nearest Railhead : Manigram railway station on Bandel-

Barhawara branch line 1 km from site.
g) Source of Water : Bhagirathi River - 5 km
h) Source of Coal : Pachwara (North) mine block in

Jharkhand.
i) Fuel Transportation : By rail in rake loads of BOBR/BOX-N

wagons.
j) Surrounding Habitations : Villages - Manigram, Chhamugram,

Karaia, Thakurpara on the south;
Bhumhar, Khasittor, Ekrakhi on the west;
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EPC Bid Document
Dhalo, Bagpara, Santoshpur on the

north and Harirampur, Chandparam,
Dogachhi on the east.
k) Level : Within 34.5 m contour. Land is above

HFL (highest flood level) of the area.
l) Soil : Less fertile alluvial soil.
m) Land Use : Within existing plant boundary of

WBPDCL.
Meteorological data of site is given below:
a) Design ambient
dry bulb temperature : 50 ºC maximum
5 ºC minimum
b) Highest wet bulb temp : 26.9 ºC
c) Maximum relative humidity : 84%
d) Average relative humidity : 73%
e) Average annual Rainfall : 1389 mm
f) Wind load : In accordance with IS-875 for a basic

wind speed of 47 m/sec, up to a height
of 10 metres above mean ground
level.
g) Seismic Zone : Zone III as per IS: 1893 latest edition.
h) Altitude : 34M above MSL
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TECHNICAL SPECIFICATIONS FOR SECTION-I, SUB-SECTION-C1
REV. 00 DATE: MARCH 2022
AGITATORS
SECTION-I,
SUB-SECTION-C1
SPECIFIC TECHNICAL REQUIREMENT –

MECHANICAL
Page 27 of 348
AGITATORS
SHEET : 1 OF 2
SCOPE OF THE TENDER:
 Supply part, Services part and Mandatory spares (if applicable) of one no.
Condensate storage tank comprising of design (i.e. preparation and submission of
drawing /documents including “As Built” drawings and O&M manuals), engineering,
manufacture, fabrication, assembly, inspection / testing at vendor's & sub-vendor’s
works, painting, maintenance tools & tackles (as applicable), mandatory spares along
with spares for erection, startup and commissioning as required, forwarding, proper
packing, shipment and delivery at site, unloading, handling, transportation & storage
at site, in-site transportation, assembly, erection & commissioning, final painting at
site, minor civil work, preparation of layout drawings 3D (as applicable) and carrying
out Performance guarantee / Functional / Demonstration tests at site (as applicable)
and handover in flawless condition.
 Supply part and Services part comprising of one no. process water tank comprising
of design (i.e. preparation and submission of drawing /documents including “As
Built” drawings and O&M manuals), engineering, manufacture, fabrication,
assembly, inspection / testing at vendor's & sub-vendor’s works, painting,
maintenance tools & tackles, consumables along with spares for erection, startup
and commissioning as required, forwarding, proper packing, shipment and delivery
at site, unloading, handling, transportation & storage at site, in-site transportation,
assembly, erection & commissioning, final painting at site, minor civil work, and
carrying out Performance guarantee / Functional / Demonstration tests at site (as
applicable), training of customer/client O&M staff and final handing over to end
customer in flawless condition.
 Supply part and Services part comprising of one no. Auxiliary Absorbent Tank
comprising of design (i.e. preparation and submission of drawing /documents
including “As Built” drawings and O&M manuals), engineering, manufacture,
fabrication, assembly, inspection / testing at vendor's & sub-vendor’s works,
painting on outside surface & glass flake lining on the interior surface, maintenance
tools & tackles, consumables along with spares for erection, startup and
commissioning as required, forwarding, proper packing, shipment and delivery at
site, unloading, handling, transportation & storage at site, in-site transportation,
assembly, erection & commissioning, final painting at site, minor civil work, and
carrying out Performance guarantee / Functional / Demonstration tests at site (as
applicable), training of customer/client O&M staff and final handing over to end
customer in flawless condition.
 Supply part, service part & mandatory spares of agitators for auxiliary absorbent
tank and absorber area drain pit comprising of design (i.e. preparation and
submission of drawing /documents including “As Built” drawings and O&M manuals),
Page 28 of 348
AGITATORS
SHEET : 2 OF 2
engineering, manufacture, fabrication, assembly, inspection / testing at vendor's &

sub-vendor’s works, painting, maintenance tools & tackles, fill of lubricants &
consumables, mandatory spares along with spares for erection, startup and
commissioning as required, forwarding, proper packing, shipment and delivery at
site, unloading, handling, transportation & storage at site, in-site transportation,
assembly, erection & commissioning, trial run at site and carrying out performance
guarantee tests at site, training of customer/client O&M staff, training at
manufacturer's works & final handing over to end customer in flawless condition.
 SUPPLY PART & SERVICE PART of glass flake lining on the interior surface of one no.
Absorber area drain pit including proper packing, shipment and delivery at site,
unloading, handling, transportation & storage at site, in-site transportation,
application, testing at site & final handing over to end customer in flawless condition
For detailed specification refer “SPECIFIC TECHNICAL REQUIREMENT-TANKS & AGITATORS”

(SECTION-I, SUB SECTION-C1A & C1B) along with the other sections of this specification.
Page 29 of 348
AGITATORS
SECTION-I,
SUB SECTION-C1A
SPECIFIC TECHNICAL REQUIREMENT-TANKS
Page 30 of 348
SPECIFICATION NO. PE-TS-445-167-A002
1X660MW SAGARDIGHI STPP
SECTION –I, SUB SECTION –C1-A
TECHNICAL SPECIFICATIONS FOR
REVISION 00
MISC. TANKS (SITE FABRICATED) AND AGITATORS
Date: MARCH 2022
1.0 SCOPE OF SUPPLY
1.1 Supply of Steel plates and fabrication of tanks at site under this specification for the below
mentioned tanks:
 1 (One) no. of Condensate storage tank (for details refer “DATASHEET AND SKETCH OF
CONDENSATE STORAGE TANKS”- Annexure-III, Sub-Section-D, Section-I)
 1 (One) no. Auxiliary absorbent tank (for details refer “GA DRAWING FOR AUX. ABSORBENT
TANK WITH AGITATOR AND PROCESS WATER TANK & TANK AND AGITATOR SCHEDULE”-
Annexure-III, Sub-Section-D, Section-I)
 1 (One) no. Process Water Tank (for details refer “GA DRAWING FOR AUX. ABSORBENT TANK
WITH AGITATOR AND PROCESS WATER TANK & TANK AND AGITATOR SCHEDULE”- Annexure-
III, Sub-Section-D, Section-I)
Detailed GA & fabrication dwgs. of each type of tank shall be submitted by bidder during detail
engineering to suit good engineering practice to the satisfaction of the customer. Auxiliary Absorbent
tank and Process water tank are tanks for the FGD system and henceforth termed as “FGD tanks” in
the specification.
1.2 General design, selection of Vinyl Ester (VE) Flake glass lining, construction features, manufacturing,
shop inspection, testing at manufacturer’s works, surface preparation, lining, inspection & testing of
the lined surface at 1X660MW SAGARDIGHI STPP FGD site.
Vinyl Ester (VE) Flake glass lining shall be provided for the following tanks/drain Pits:
 Auxiliary Absorbent tank (3 mm Thick glass flake lining)
 Absorber Area Drain Sump (3 mm Thick glass flake lining)
For detail specification of Vinyl Ester Flake glass lining refer Sub Section-C1-B of Section-1.1.3
1.3
a) The connections which are required to be supplied with each tank by the bidder shall be as indicated
in the enclosed FGD Tank schedule & GA Drawing and DATA SHEET‐A & SKETCH of condensate storage
tank for Miscellaneous tanks package (Sub Section‐D, Section‐I, Annexure‐III).
b) For Condensate Storage Tank, the piping material inside the tank shall be supplied by the bidder. All
inlet piping shall be extended up to the bottom of the tank and the clearance between the bottom of
the tank and the edge of the inlet piping shall be kept as 500 mm (maximum).
For FGD tanks (Process water Tank, Auxiliary Absorbent tank & Absorber area Drain pit) the inlet pipes
shall be lined with replaceable wear resistant natural rubber lining of minimum 06 mm thickness from
inside. Additional thickness of 2 mm in rubber lining shall be provided at bends. Pipes and fittings for
the FGD tanks is excluded from the bidder scope. However, tank nozzles with glass flake/rubber lining
shall be in bidder’s scope. Also pipe supports on the inside surfaces of the tank shall be in bidder’s
scope.
c) The inside piping shall be adequately supported and shall be provided with adequately sized vent (anti-
siphoned) connection at pipe top.
d) Weir plates of adequate thickness (minimum 8 mm) shall be provided for all inlet piping.
Page 31 of 348
REVISION 00
Date: MARCH 2022
e) Pad plates along with structure for the tanks for supporting outside piping shall be provided by the
bidder. Details of the pad plates along with supporting structure (sizes, quantity etc.) shall be informed
to bidder during detail engineering.
f) Fabrication and supply of all flanges and counter flanges for all nozzles of tank connections shall be
included in the scope of work of the bidder. Necessary bolts, nuts and gaskets for these connections
shall also be supplied by the bidder. Further rubber lining / VE Flake glass lining of these nozzles
including flanges, counter-flanges shall be in bidder’s scope of work.
g) The manhole shall be of hinged and bolted type with nuts, bolts and gaskets in bidder’s scope of supply.
The size of the manhole shall be minimum 800 mm and subjected to customer approval. Bidder shall
provide two nos. manhole for each tank, i.e. one no. manhole on shell and one no. manhole at roof.
h) For FGD tanks, Supply of vent with suitable bird screen shall be in bidder’s scope. Further minimum
two nos. of 80 Nb Vents shall be considered for each tank. However actual vent size shall be decided
during detail engineering.
i) For Condensate Storage Tank- Pipe inside tank and overflow pipe material outside tank shall be in
bidder’s scope. Discharge of overflow pipe shall have 45 Degree inclination towards flow direction of
trench for smooth flow. Drain pipe shall be terminating at 5.0 m from tank
j) Tank drain nozzle to be provided with drain box 500 mm2, for Auxiliary Absorbent Tank. For details
refer “DETAILS OF 500 MM NOZZLE FOR BOTTOM DRAIN”- Annexure-III, Sub-Section-D, Section-1.
1.4(a) The scope of works shall also include supply of agitator (refer SECTION –I, SUB SECTION –C1-D, for
further details) and installation of agitator including special accessories including agitator supporting
arrangements, agitator platform / bridge, baffle plates, Pad plate for pipe supporting structure and
cable trays for power supply to Agitators, Pad plate for mounting tie rod lug for side entry agitator etc.
as indicated in FGD Tank schedule (Sub Section-D, Section-I, Annexure-III). The necessary fixtures and
other accessories for mounting these special accessories shall be included in the scope of work of the
bidder.
1.4(b) For Condensate Storage Tank, the scope of works shall also include supply and installation of special
accessories as indicated in “DATASHEET AND SKETCH OF CONDENSATE STORAGE TANKS”-Sub Section-
D, Section-I, Annexure-III. The necessary fixtures and other accessories for mounting these special
fittings shall be included in the scope of work of the bidder
1.5 VOID
1.6 (a) For FGD Tanks, Quantity and size of nozzles/spare nozzles shall be as per “GA DRAWING FOR AUX.
ABSORBENT TANK WITH AGITATOR AND PROCESS WATER TANK & TANK AND AGITATOR SCHEDULE”-
Annexure-III, Sub-Section-D, Section-I and shall be in bidder’s scope.
1.6(b) For Condensate Storage Tank, Quantity and size of spare nozzles and valves shall be supplied by the
bidder as indicated in “DATASHEET AND SKETCH OF CONDENSATE STORAGE TANKS”-Sub Section-D,
Section-I, Annexure-III.
1.7 For Condensate Storage Tank, the level gauge / indicator shall be provided by the bidder along with all
fittings & accessories as required for mounting the level gauge / indicator on the tanks. Float and board
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type level gauge / indicator shall be provided unless otherwise specified in “DATASHEET AND SKETCH
OF CONDENSATE STORAGE TANKS”-Sub Section-D, Section-I, Annexure-III.
1.8 For Condensate Storage Tank, required number of tapings with 25NB instrument root valves shall be
provided by the bidder for mounting instruments like level switches, level transmitters etc. The number
of tapings shall be as indicated in the “DATASHEET AND SKETCH OF CONDENSATE STORAGE TANKS”-
Sub Section-D, Section-I, Annexure-III.
1.9 (a) For Condensate Storage Tank, NaOH / KOH breather and seal pot shall be provided with necessary
drain valve of size 25 NB with stainless steel construction unless otherwise specified in the DATA SHEET‐
A and sketch (Sub Section-D, Section-I, Annexure-III). Two (2) nos. NaOH / KOH breather shall be
provided by the bidder for each tank out of which one shall be used for in‐breathing purpose and the
other shall be used for out‐breathing purpose.
1.9(b) For Condensate Storage Tank, NaOH / KOH breather and seal pot shall be located in the bottom /
ground level and necessary connection from tank vent to NaOH / KOH breather shall be provided
through 200 NB SS pipe . The overflow pipe from overflow nozzle to seal pot shall also be in bidder’s
scope of work.
1.10 For Condensate Storage Tank, pipes, fittings, nozzles, flanges and counter flanges shall be supplied by
the bidder. The minimum requirement like quantity, size, type etc. are indicated in the DATA SHEET-A
and sketch (Sub Section-D, Section-I, Annexure-III) and may undergo change during detail engineering
stage and these shall be supplied by the bidder as per the approved drawings / documents for which
no commercial implication shall be entertained by BHEL. Material of construction of all pipes, fittings,
nozzles, flanges and counter flanges shall be as per DATASHEET FOR BOUGHT OUT ITEMS, ANNEXURE-
VI, Sub Section-D, Section-I.
1.11 All valves shall be of stainless steel construction for Condensate Storage Tank.
1.12 (a) For FGD tanks, the minimum number of anchor bolts along with its size shall be subject to customer
approval during detail engineering without any commercial and delivery implication. The material of
construction for anchor bolts shall be as mentioned in “GA DRAWING FOR AUX. ABSORBENT TANK
WITH AGITATOR AND PROCESS WATER TANK & TANK AND AGITATOR SCHEDULE”- Annexure-III, Sub-
Section-D, Section-I).
1.12(b) For Condensate Storage Tank, bidder to provide minimum 24 nos., M30 anchor bolts for Condensate
Storage Tank. However, any additional anchor bolts of higher size if found applicable during detailed
Engineering shall be provided by bidder without any commercial implication
1.13 Bidder to provide minimum one wind girder of size 150 mm×75mm×10mm for Condensate Storage
Tank and FGD tanks. However, any additional wind girder/higher size if found applicable during
detailed Engineering shall be provided by bidder without any commercial implication.
1.14 Painting of the tanks is included in bidder’s scope of work.

 Painting specifications of Condensate storage tank/seal pot/NaOH/ KOH breather are are given under
Painting schedule in Sub Section-C2-C, section-1. Painting requirement specified under Painting
schedule are minimum requirement. Any modification in painting requirement found applicable during
detained engineering, shall be under bidder’s scope without any commercial implication.
 Auxiliary tank shall be provided with vinyl ester glass flake lining on the inside surface and painting on
the outside shall be as per Painting schedule in Sub Section-C2-C, section-1.
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 Painting specifications of Process Water tank shall be as given under Painting schedule in Sub Section-
C2-C, section-1.
1.15 Commissioning spares as required for commissioning of the tanks/NaOH breathers / seal pots are in
bidder’s scope.
1.16 Platforms, inter-connecting platforms, monkey ladder inside tank and staircase (hand railing, knee
guard and toe guard (in stair case and all along the periphery of roof of the tank) etc. as per the relevant
design code / good engineering practice (as indicated in the tank schedule) shall be included in bidder’s
scope of work. All staircase treads and platforms shall be 32 mm steel fabricated gratings. Gratings
shall be galvanized as given for handrails in painting specification. Width of stair shall be 1200mm min.
In case of any contradictory requirement with regard to width of staircase mentioned elsewhere in the
specification, requirement given under this clause will prevail.
1.17 Relevant scope of supply as per GTR, GCC, SCC & ECC
1.18 Any other item required for making the installation complete in all respect and for satisfactory
operation of the tank and items mounted thereon, meet layout and accessibility & operability
requirements for the scope within the terminal points, as well as to meet any statutory requirement
relevant to the package, useless specifically mentioned under EXCLUSION.
2.0 SCOPE OF SERVICES
Services shall include but not be limited to the followings:
2.1 Design, engineering, preparation of detailed fabrication drawings, design calculation, bill of material,
tag and piece numbers, welding procedures etc. Stiffeners and other structural framing for supporting
the tank shall be designed by the fabricator and properly shown in the fabrication drawings.
2.2 Erection & Commissioning of Tanks.
2.3 Erection and commissioning, Performance demonstration of agitators for the auxiliary absorbent tank
and absorber area drain pit.
2.4 Erection & Commissioning of VE Flake glass lining.
2.5 Erection of all foundation bolts / anchor bolts etc. as required for any equipment/ foundation
/concrete.
2.6 Minor civil work like chipping of foundation, grouting below base plate for all structures, equipment,
grouting of pockets, excavation & filling of earth for buried MS pipes if and as required. Supply and
application of grouting is also included in bidder’s scope of work.
2.7 Inspection & testing and carrying out demonstration test.
2.8 Inspection & testing and carrying out demonstration test for the VE Flake glass lining of tanks.
2.9 Painting of tank and other equipment within the battery limit.
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2.10 Any other equipment / material / services as required to make the installation complete in all respects
shall be deemed to be included in bidder’s scope of work whether mentioned above or not.
2.11 Relevant scope of service as per GTR, GCC, SCC & ECC
2.12 Any other service required for making the installation complete in all respect within battery limits and
for satisfactory erection & commissioning of the system as well as to meet any statutory requirement
relevant to the package, unless specifically mentioned under EXCLUSION.
3.0 EXCLUSIONS
1) (a) Tank foundation & associated civil works for all tanks i.e process water tank, auxiliary absorbent
tank and condensate storage tank.
(b) All instruments for FGD tanks only (i.e Auxiliary absorbent tank and Process water tank) like
level gauges, Level Transmitters, etc are excluded from bidder’s scope of work even if such items
are shown standard tank specification. However, supply and erection of the nozzles for the shall be
in bidder’s scope of work.
(c) Absorber area drain pit is excluded from the scope of the bidder. However, supply, E&C of vinyl
ester glass flake lining of the sump shall be in bidder scope. Further, the supply, erection and
commissioning of the agitators along with the mounting arrangements within the sump/drain pits
shall be in bidder’s scope of work.
(d) Level Transmitters are excluded from bidder’s scope of work for Condensate Storage Tank.
2) All valves are excluded from bidder’s scope of work for FGD tanks only (i.e Auxiliary absorbent tank
and Process water tank). However, all valves for condensate storage tank shall be in bidder’s scope
of work.
3) For FGD tanks (i.e. Auxiliary absorbent tank and Process water tank), all external piping from the
counter flange of the nozzles of respective tanks is excluded from bidder’s scope of work. However,
matching counter flanges for all nozzle shall be in bidder’s scope of work.
4.0 TERMINAL POINTS
 Matching counter flanges for all nozzles mounted on the tank and its accessories. However,
counter flanges for all nozzles of tank shall be provided by the bidder.
 Drain pipe of seal pot and NaOH breather pots.
5.0 DESIGN CONSIDERATIONS
5.1 The successful bidder shall furnish design calculations to BHEL during detailed engineering stage for
approval along with the Xerox copies of relevant pages of authentic supporting literature e.g. Code,
Hand book, National / international Standards etc. Calculation shall be necessarily done in SI UNITS
only for the followings: -
a) Tanks shall be designed as per IS – 803 / API – 650 / AWWA – D 100 / IS –2825 / BS – 2594 / Good
engineering practice as applicable and referred code shall be of latest edition.
b) Weight calculation of plates, appurtenances, platforms & structures separately shall be included in the
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Design calculation.
c) Design of roof and roof structures for vertical storage tanks shall be designed based on guidelines given
in the book titled “Process equipment design” by Brownell and Young. Further, roof structure shall
preferably be constructed on external side of roof.
d) Tank stability calculation (wind load / seismic / overturning stability) considering static and dynamic
loads of Agitator and its platforms and supporting arrangement shall be done as per API – 650/IS-803,
latest edition. However, factors / coefficients as required for the design of tank shall be obtained from
BHEL by the bidder after placement of order.
d) Vent sizing calculation shall be done as per API – 2000, latest edition
d) Sizing calculation for vent valve.
e) Sizing calculation of NaOH / KOH breather, seal pot and breather valve.
5.2 The successful bidder shall indicate references of all the clauses indicating their page number from
respective standard in the design calculation during detail engineering stage. All calculations shall
necessarily be done in SI units only. All steps including formulas and abbreviations shall be clearly
shown in the calculation. All inputs / assumptions shall be indicated in the first sheet of the calculation.
5.3
a) Bottom plate shall be 8.0 mm thick (minimum). Minimum 8.0 mm (excluding tolerance on plate as per
relevant IS) thick plates including corrosion allowance shall be provided for shell plates and minimum
8 mm for roof plates for all tanks, unless specified otherwise in tank schedule. Calculation for the plate
thickness shall be got approved from BHEL / Customer during detailed engineering stage. However, if
the addition / summation of calculated value of plate thickness (excluding tolerance on plate as per
relevant IS) / nominal minimum thickness specified in the relevant design code / standard and
corrosion allowance of 2mm for CST, 3 mm for FGD tanks comes out more than 8 mm then the nearest
available (higher side) plate thickness in the market shall be provided for shell and roof plates without
any commercial implication. For calculating shell plate thickness IS 803 to be used.
b) Negative tolerance on plate thickness shall not be considered in the plate thickness calculation and
also shall not be provided in the tank. Only positive tolerance shall be considered.
5.4 All appurtenances and mountings shall also be designed as per relevant clauses of IS: 803 / API – 650.
5.5 Tank shall be suitably constructed for safe, proper and continuous operation under all conditions that
can be expected in a plant life without undue strain, corrosion or other operating difficulties.
5.6 For FGD tanks, while calculating the minimum plate thickness, the specific gravity of the liquid shall be
taken as per “GA DRAWING FOR AUX. ABSORBENT TANK WITH AGITATOR AND PROCESS WATER TANK
& TANK AND AGITATOR SCHEDULE”- Annexure-III, Sub-Section-D, Section-I)
5.7 For cylindrical tanks, the plates shall be cold rolled through plate bending machine by several number
of passes to true curvature.
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5.8 Vessels seams shall be so positioned that they do not pass though vessel connections. For cylindrical
vessels consisting of more than two sections longitudinal seams shall be offset.
5.9 Wherever possible, the inside seam weld shall be ground smooth, suitable for application of corrosion
resistant primer.
5.10 Due consideration shall be given by the supplier for wind load and earthquake effect in the design of
tanks.
5.11 For the tanks being of diameter larger than 3.75 m added structural supports in the form of rafter shall
be provided. Further Centre column shall be provided for CondensateStorage
Condensate storage tank
tank and Process Water
tank.
5.12 Reinforcement in tanks shall be provided as per design code. The reinforced connection shall be
completely pre - assembled into shell plate.
5.13 The joint efficiency factor to be adopted for design calculation of shell thickness shall be as per IS:803.
5.14 All roofs and supporting structures shall be designed to support dead load plus a uniform live load of
not less than 150 kg/m2 of projected area. Further, the static and dynamic loads of the agitator
assembly along with the agitator platform shall be considered over and above the uniform live load.
5.15 Staircase / access ladder and hand railing shall be provided as per the relevant codes and standards.
5.16 -VOID-
5.17 Code conformance for flanges / counter flanges shall be ANSI B 16.5. Code conformance for bolts and
nuts shall be SA 193 & 194 respectively. Further, all fasteners used in wetted condition must be of
Duplex Stainless Steel or better material so that even if it comes in contact with liquid by swelling of
rubber, thread remains unaffected.
5.18 The number & size of nozzles (including flanges, counter flanges and inside piping) indicated in the
Input dwgs (Annexure-III, sub Section-D, Section-I) are tentative and bidder guidance purpose only and
the same may undergo change during detail engineering stage for which no commercial implication
shall be entertained by BHEL.
5.19 Bidder shall furnish the STADD calculation along with the roof structure calculation during detail
engineering for following:
a. Roof structure calculations for checking the stability of roof.
b. Shell buckling under Roof & structure loading.
5.20 The tank shall be designed for filled water head / atmospheric pressure and design temperature for
the tank shall be as specified tank schedule (Annexure-III, sub Section-D, Section-I).
5.21 Bidder to note that surface cleaning shall be of Blast clean type. However, Grit blasting shall be decided
during detail engineering for which no commercial implication shall be entertained by BHEL. Further,
the surface cleaning of the tanks shall be in line with the requirements specified in the specification for
VE Flake glass lining.
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5.22 Bidder to note that foundation drawing along with loading data & anchor bolt details shall be provided
by bidder within two weeks’ time from the LOI.
5.23 All materials, furnished shall conform to the latest editions of America National Standard Code for
Pressure piping, Power piping, ANSI B311.1, ANSI B16.11, ASME Boiler and Pressure Vessel Codes, IBR
and other applicable ASME, ANSI and Indian Standards. Schedule numbers, sizes and dimensions of all
carbon steel, stainless steel and alloy seamless steel pipe shall confirm to ANSI B.36.10 and of stainless
steel pipe shall confirm to ANSI B 36.19 unless otherwise specified.
5.24 Tank design calculation to be done will also address bending of shell plates on account of transfer of
roof load and roof supporting structure on the shell. Any increase in thickness and requirement of
girder to take care of shell bending will be taken care by bidder without any commercial and delivery
implication.
5.25 Bidder will need to use appropriate software for addressing of agitator dynamic load in the tank design
calculation. In this regard, the stress analysis including analysis of agitator mounting, nozzle, platform
etc. The latest version of software accepted internationally. All relevant backups such as load
calculations flow charts, computer datas etc shall be furnished. Computer outputs shall be clear and
easily understanding format.
5.26 Provision shall be made by the bidder to minimise the air ingress in the tank through float & board
type level gauge and details of the same shall be furnished during detail engineering stage for BHEL’s
approval and approved arrangement shall be provided by the bidder without any commercial
implication.
5.27 Tank design calculation to be done will also address bending of shell plates on account of transfer of
roof load and roof supporting structure on the shell. Any increase in thickness and requirement of
girder to take care of shell bending will be taken care by bidder without any commercial and delivery
implication.
5.28 Bidder will need to use appropriate software for addressing of agitator dynamic load in the tank design
calculation. In this regard, the stress analysis including analysis of agitator mounting, nozzle, platform
etc. The latest version of software accepted internationally. All relevant backups such as load
calculations flow charts, computer datas etc shall be furnished. Computer outputs shall be clear and
easily understanding format.
6.0 TEST AND INSPECTION
6.1 The particulars of the proposed tests and the procedure for the tests shall be submitted to the Owner
/ Engineer for approval before conducting the tests. The successful bidder shall submit FQP (field
quality plan) and demonstration test procedure for BHEL / customer / consultant’s approval during
detail engineering stage. In the event of any change in the field quality plan and demonstration test
procedure, the same shall be incorporated by the bidder in the document and approved document
shall be adhered by the bidder without any commercial implication.
6.2 DPT / MPI on all welds (as per relevant code).
6.3 All cross / Tee joints and butt welds to be Radio graphed in line with the joint efficiency as specified in
specification.
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6.4 For the offered tanks, fill test shall be carried out for at least 24 hours. Atmospheric storage tanks on
inside surface shall be leak tested before painting / rubber lining / VE glass flake lining.
6.5 All quality plans / checklists for various items shall be furnished during detail engineering stage for
BHEL / customer’s approval and any changes required by BHEL / customer shall be incorporated in the
documents and adhered without any price implication. However, minimum requirement of MQP as
indicated in the technical specification shall be followed. All necessary items as required for inspection
and testing of the tank including instruments shall be arranged by the bidder.
7.0 WELDING
7.1 Welding shall be in accordance with the requirement of IS: 803, 816, 817 and 823 or equivalent and as
specified in the specification for rubber lining / VE Flake Glass lining.
7.2 Welding sequence shall be adopted in such a way so as to minimize the distortion due to welding
shrinkage. Contractor shall indicate in his drawing the sequence of welding proposed by him, which
should meet prior approval of the Engineer.
7.3 All welders shall be BHEL / customer / consultant qualified as per the approved quality plan / field
quality plan which will be submitted by the successful bidder during detail engineering stage. WPS and
PQR shall be submitted by the successful bidder to BHEL / customer / consultant for review and
approval.
7.4 Type of joint (lap/ butt as per IS 803) for bottom plate and roof plate for rubber lining/ VE Flake glass
lining shall be as per recommendation of lining vendor and subject to customer approval during
detailed engineering without any commercial implication.
8.0 MANDATORY SPARES:
Mandatory spares shall be supplied by bidder as indicated in ANNEXURE-VII, sub Section-D, Section-I
9.0 LIST OF COMMISSIONING SPARES:
Any other item required for successful commissioning of the tanks & agitators including VE Flake Glass lining
(to be specified clearly by bidder)
10.0 DRAWINGS AND DOCUMENTS TO BE SUBMITTED WITH THE BID
The bidder must submit the drawings / documents as mentioned under “CHECK LIST FOR DOCUMENT
TO BE SUBMITTED” (In Section-III, Annexure-1) along with their bid. In absence of any of these
documents, BHEL reserves right not to evaluate the offer of the concerned bidder.
11.0 DRAWINGS/ DOCUMENTS REQUIRED DURING DETAIL ENGINEERING
The successful bidder shall submit the drawing / documents as mentioned under SECTION-I, Sub-
Section-D, Annexure-IV during detail engineering for approval / information / reference (as the case
may be).
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12.0 OTHER TECHNICAL REQUIREMENTS
1) 15 days’ time is required by BHEL to offer their comments on the drawings and documents being
submitted by the bidder (during detailed engineering stage in the event of L.O.I being placed) from the
date of receipt.
2) Bidder to depute competent designer (s) at BHEL’s office during detailed engineering stage to discuss
drawings and other technical documents as and when required by BHEL.
3) Bidder to assess the capability of their sub-vendors in terms of preparation of drawings, calculations,
documents, quality assurance, supply of material etc. as per project schedule before placing the order
on them. No deviations shall be entertained.
4) Commercial implication includes price implication as well as delivery implication.
5) Size of hand rails on stairway and tank roof / top shall be minimum 32 NB and shall conform to IS 1239
(M). Handrails shall be galvanized as per painting specification.
6) Type of roof for vertical cylindrical storage tanks shall be either supported cone roof or self-supporting
cone roof as per latest edition of relevant design code.
7) Commissioning of tanks will consist of installation of all accessories of tanks as per approved
drawing/specification, charging of tank, water-fill test (for minimum 24 hours after complete filling of
tank), satisfactory functioning of all accessories, emptying of tank, subsequent painting of complete
tanks and changing of gaskets as per specification requirement.
8) Bidder to furnish prices and unit price of each item of proposed tanks as per BHEL’s price format only
along with the final price bid.
9) Bidder shall check that specifications of all the items are available in the NIT specification. However, in
the event of absence of specification for any item, bidder will approach BHEL to furnish the
specification of missing items and new specification will be adhered by the bidder for which no
commercial implication shall be entertained by BHEL.
10) All tools and plants including welding machines, crane, hydra, fork lift, batching plant etc. and
instruments as required for construction, erection and commissioning, trial run and functional
demonstration test at site shall be arranged by the bidder.
11) Bidder to furnish list of sub-vendors based on sub-vendor list enclosed with the specification during
detail engineering stage for BHEL’s / Customer review and approval and items shall be procured from
these suppliers only.
12) Dealers are not acceptable for any item of the package. Bidder shall procure all items including plates,
structural, flanges, counter flanges etc. from BHEL approved sub vendor only. No argument on this
account shall be entertained. However, any constraint on account of the same is subject to end
customer approval during detailed engineering without any commercial and delivery implication.
13) All rubber lined pipes shall be provided with flanged type connections only. In other words, Rubber
lined pipes shall be flange joined only.
Page 40 of 348
AGITATORS
SECTION-I,
SUB SECTION-C1B
SPECIFIC TECHNICAL REQUIREMENT-AGITATOR
Page 41 of 348
TITLE: SPECIFICATION No: PE-TS-445-167-A002
1X660MW SAGARDIGHI STPP SECTION-C, SUB-SECTION-C1-B
AGITATORS SHEET : 1
1.0. PROVENNESS CRITERIA/Pre-QUALIFICAITON REQUIREMENT FOR

AGITATORS
Bidder to refer “List of Makes of Sub-Vendor Items” in ANNEXURE-I, Sub Section-D, SECTION - I
2.0. TECHNICAL INFROMATION

3.1 AGITATOR DETAILS:
For agitators refer “Agitator Schedule” in Section-I, Sub Section-D, Annexure-III of the
specification.
3.2 MATERIAL OF CONSTRUCTION

Material of Horizontal agitators (side Vertical Agitators ( Top entry)
construction entry)
i. Duplex stainless steel or Duplex stainless steel or better
Impeller blade
better material material
Duplex stainless steel or Duplex stainless steel or better

Impeller Hub
ii. better material material
Duplex stainless steel or Duplex stainless steel or better

Shaft
iii. better material material
Fasteners in wetted Duplex stainless steel or Duplex stainless steel or better
iv. parts better material material
Fasteners in Non GI fastener (40 μ plated) /
GI fastener (40 μ plated) / SS
v. Wetted SS
Duplex stainless steel or
vi. Mounting base Carbon Steel
better material
vii. VOID VOID VOID
3.3 AGITATOR ARRANGEMENT
a) Auxiliary Absorbent Tank Agitator:
These Agitators will operate continuously when Limestone / Gypsum Slurry is evacuated from
absorber for any Absorber maintenance work.
For Typical arrangement of Arrangement of Auxiliary absorbent tank agitator, please refer Input
drawings furnished with the tender specification.
b) Absorber Drain Pit Tank Agitators:
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AGITATORS SHEET : 2
For details of Auxilliary absorbent tank and Drain Pit agitator please refer “AGITATOR SCHEDULE”
ANNEXURE-III, Sub Section-D Section-I of the specification. These Agitators will operate
continuously for FGD system operation.
4 SCOPE OF SUPPLY & SERVICES FOR AGITATORS

 Various inspections by the BHEL/WBPDCL shall not relieve the Bidder in any way of his
obligation to maintain an adequate test, inspection, and documentation program of his own,
and shall not relieve the Bidder of any other obligation under this specification. Furthermore,
any inadvertent overlook of deviations from some requirements of this specification by the
buyer shall not constitute a waiver of these requirements, or of the Bidder's obligation to
correct the condition when it is discovered, or of any other obligation under this specification.
 This specification only states the lowest technical requirement, neither specifying all technical
details, nor referring the pertaining code and standard fully. It is the Bidder's responsibility to
ensure that the complete delivery complies with all relevant codes, standards and
specifications.
 The Bidder is obliged to supply relevant drawings and documentation to the buyer. All to be
in English language and metric system, if not otherwise agreed in writing.
 Scope for the bidders shall include Design, Manufacturing, Supply, and Erection &
Commissioning.
Design: Broadly includes basic engineering, detail engineering, preparation and submission of
engineering drawings/calculations/datasheets/quality assurance documents/field quality plans, storage
instructions, commissioning procedures, Erection & assembly Drawings, operation & maintenance
manuals, performance guarantee test procedures and assisting BHEL in obtaining time bound approval
from customer.
Supply: The scope includes the following:
 Includes manufacturing/fabrication, shop floor testing, stage inspections, final inspections,
painting & packing.
 Mandatory spares as defined as Section-I, Sub-Section-D, Annexure-VII.
 Recommended spare parts list to be furnished (is not part of scope of supply)
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AGITATORS SHEET : 3
 Any special tools & tackles required for the entire equipment to disassemble assemble or
maintain the units.
 Start-up & Commissioning Spares
 First fill of consumables
Services: Services to be provided by the bidder:
 Erection & Commissioning, trial run at site
 Performance guarantee tests at site & handover in flawless condition of the package to the
customer
 Training of customer/ client O&M staff covering all aspects of the Agitators - Operation &
Maintenance, Trouble-shooting etc. at site
 Training of customer at manufacturer’s works (3 persons for 2 days including lodging and
boarding)
 Visits shall be planned by BHEL site team and prior intimation shall be sent to supplier for
visit to site for supervision services. Bidder shall be informed at least 10 days in advance for
the requirement of visit at site. Visiting team shall consist of one or two expert of bidder as
deemed necessary by them.
The scope of supply for AGITATORS shall include but not limited to the following:
A) For Horizontal (Side Entry) Agitators:
Sl. Scope
No
1. AGITATOR complete with
i. AGITATOR Blades
ii. AGITATOR Shafts
iii. Coupling arrangement (Flexible)
iv. Single Mechanical Seals
v. Shaft Sleeve
vi. Lanterns/ Stools ( Bearing Housing), Safety Guard
vii. Bearings
viii. Agitator Mounting Flanges with gaskets and fasteners
ix. Drive Motor(IE3) with gearbox arrangement
x. Supporting arrangement including tie rods, gusset plates etc. of Side Entry Agitator on the
tank Wall. Vessel Nozzle and mating flange for supporting on the tank wall, gaskets and
fasteners.
xi. VOID.
xii. Foundation plate with foundation bolts, vessel nozzle
xiii. Painting and Rust Prevention during shipment and construction
xiv. Packing and transportation
xv. Supervision of Erection & commissioning at site
xvi. Special tools & tackles as applicable
xvii. Start-up spares, Spare parts for commissioning & erection, Mandatory Spares: As per
Project Specific Requirement
xviii. Installation, operation and maintenance manuals
xix. Any other items required for completeness of the equipment except the items covered in
the exclusions.
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AGITATORS SHEET : 4
B) For Vertical (Top Entry) Agitators:

Sl. Scope
No
2. AGITATOR complete with
i. AGITATOR Blades
ii. AGITATOR Shafts
iii. Coupling arrangement (Flexible)
iv. Gland Packing, Seals, O Rings, Glands
v. Shaft Sleeve
vi. Lanterns/ Stools ( Bearing Housing), Safety Guard
vii. Bearings
viii. AGITATOR Mounting Flanges with gaskets and fasteners
ix. Drive Motor(IE3) with gearbox arrangement
x. Mating Flange for Supporting on Slurry Tank Roof
xi. Shims
xii. Painting and Rust Prevention during shipment and construction
xiii. Packing and transportation
xiv. Supervision of Erection & commissioning at site
xv. Special tools & tackles as applicable
xvi. Start-up spares, Spare parts for commissioning & erection, Mandatory Spares: As per
Project Specific Requirement
xvii. Installation, operation and maintenance manuals
xviii. Any other items required for completeness of the equipment except the items covered
in the exclusions.
The quantity, location of the agitators have been included in the agitator schedule (ANNEXURE-III,
Sub Section-D Section-I)
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1X660MW SAGARDIGHI STPP SECTION-I, SUB-SECTION-C1-B
AGITATORS SHEET : 5
4.1 TECHNICAL REQUIREMENTS

Agitators shall be supplied in tanks and vessels to prevent caking and settlement of particles
I
out of the slurry, e.g. in the Auxiliary Absorbent tank and sumps.
All agitators shall be designed for continuous operation unless otherwise specified. The
II
design of the agitators shall be of proven type.
Standard type agitators with suitable characteristics shall be used wherever practical. The
agitators shall be complete with motor, gearbox, agitator shaft, coupling, safety guards,
III
mechanical seal (for side entry agitators), impeller, support legs, agitator mounting flange
including bolts nuts and gasket etc.
All agitator parts and accessories in contact with the stirred fluid shall be constructed of
IV materials specifically designed for the conditions and nature of the stirred fluid and be
resistant to erosion and corrosion.
The material for the shaft (which is continuously in contact with slurry) and agitator blades
of the Auxiliary Absorbent Tank Agitators shall be made with Duplex Stainless Steel or
V
better material. This does not release the bidder of the responsibility for selecting the
correct materials.
Each agitator and its associated equipment shall be arranged in such a manner as to permit
easy access for operation, maintenance and agitator removal without interrupting plant
VI
operation. It shall be possible to remove the sealing devices of the side mounted agitators
without having to drain completely the slurry inside the tank.
VII
-VOID-
VIII Lifting lugs and eyes and other special tackle shall be provided as necessary to permit easy
handling of the agitators and their components.
Static and dynamic (only for aux. absorbent tank agitator) balancing of all agitators shall be
IX
carried out after assembly.
X VOID
XI All exposed moving parts shall be covered by guards.
The shape of the impeller blades of side entry agitators/top entry agitators shall be designed
to avoid wear on the impellers which will affect the agitator performance as specified for a
XII minimum period of 2 years of continuous operation under design conditions for the range of
slurry specified in the specification. In order to avoid excessive wear impeller tip speeds
must not exceed 12 m/s.
Belt drives (if applied for side entry agitators) shall be properly designed to provide a
XIII
minimum lifetime of 2 years under design conditions
It shall be noted that all Agitators are meant for keeping the solid particles in suspended
XIV mode in liquid with “Full Off-Bottom Suspension” of solid particles to 98% of liquid
column to virtually “Uniform Solid Concentration”. No chemical reaction will take place.
Maintaining a uniform concentration over the 95% of liquid column. Absolute sweeping of
solid particle from tank bottom is a must for all Agitators. If speed is required to be
XV
increased to guarantee the above requirements; the same can be increased by vendor.
Bidder's machines that consume less power will be in an advantageous position.
It is to be noted that in continuous process any deposit at tank bottom is the loss of material
XVI which are not getting converted as per process. Hence, total loss of material by
sedimentation is a loss to FGD Process & determines the “In efficiency of the Agitator”.
Vendor should ensure nil settlement; utilization of solid material shall be a guaranteed
XVII parameter and will be assessed in percentage (%) term to net wet of solid mass of inflow or
out flow. This is one of the guarantee parameter.
Agitator and its driver shall perform on the test stand at shop and on the Agitator’s
XVIII permanent location at site within vibration limit. The vibration of combined unit will be the
responsibility of Agitator manufacturer. Agitator manufacturer is to ensure that Site
Page 46 of 348
AGITATORS SHEET : 6
performance of vibration is one of the “Acceptance Criteria” of the equipment. Please note
that vibration at test stand can only be taken as “for information”.
Every Tank will have a pump whose suction line shall be connected to tank. These pumps
are to operate continuously at the lowest operating level which is decided by Process
requirement. Hence, the minimum operating level of liquid in every tank for every Agitator
XIX is a must to assess the combined operation of Agitator as well as that of pump alone. The
Tank water level is indicated in “SECTION-I, SUB-SECTION-D, Annexure-III”. Any
minor change in liquid level required by Agitator supplier will be accommodated only if it
is acceptable to the pump supplier.
A calculation of power specifying the hydraulic power of Agitator, Seal loss, Gear box and
Motor internal loss must be submitted during detail engineering. A characteristics curve
showing power versus liquid level should be submitted from the lowest liquid level,
XX
required for Agitator to maximum liquid level in the tank. Motor should be selected based
on the highest power demand with a 10%margin at maximum liquid level, taking into
account frequency variation.
The agitator shall be suitably designed for mounting and operation in respective tank/sumps
XXI
whose details are given under input drawings, annexed with the enquiry specification ().
XXII VOID
Unless otherwise specified, for small diameter impeller, it shall be possible to remove
complete agitator assembly without dismantling through the opening provided on the
XXIII tank/sump, and for large diameter impeller, the blade shall be of removable construction for
ease of removal. Bidder shall also provide the headroom required for taking out the agitator
as above.
XXIV VOID
XXV VOID
Bidder shall provide proper dowelling between motor and base plate, gear box and
XXVI
mounting tool/base plate, for ease of assembly of agitator unit. Tapered dowell shall be
provided.
Vendor shall provide suitable arrangement for supporting the agitator shaft with impellers
XXVII
during removal of gear-box for maintenance and details of such arrangements shall be
furnished.
4.2 CONSTRUCTIONAL FEATURES
A) BLADE AND HUB OF PROPELLER
I) The blades of the agitators shall be of Duplex Stainless Steel or better material.
The Blade design of the Agitator to be of most efficient design in order to offer least power
II)
consumption. The Agitator power consumption is part of the guarantee parameters.
III) VOID.
IV) Impeller should be dynamically balanced to Gr: G16: ISO-1940 after rubber lining of shaft.
B) SEAL
1 Horizontal / Side Entry Agitators:
Agitators should be provided with Single Stage mechanical seal. The mechanical seal
I.
should be as per ISO-21049 / API 682.
II.
The Mechanical Seals shall be so arranged that repacking or fitting of replacement seals can
be carried out with the minimum of disruption to plant operation.
Design the mechanical seals chamber to have sufficient room to lubricate and get seal face
III.
cool with its own slurry.
IV. Provide requirements for periodical flushing to rinse the seal face for leaked slurry.
V.
All mechanical seals, regardless of type or arrangement, shall be of the cartridge design.
Hook sleeve cartridge should not be used.
VI. -VOID-
Page 47 of 348
AGITATORS SHEET : 7
Requirement of flushing water, its quantity, and pressure to be indicated in data sheet.
VII. Flushing arrangement is excluded from the scope of the bidder. However, provision for the
same shall be provided.
Zero leakage is the intention of this specification. However, quantity of leakage, if it is
VIII.
unavoidable, it should have a provision of collecting / or discharging back to the tank.
IX.
Mechanical seals shall be fitted and installed in the Agitator before shipment and shall be
clean. Mechanical seals shall be plugged with screw for shipping.
Intention of the specification is not to specify Type of Seal, Seal design, Spring
X
configuration, Seal configuration, Balanced or Unbalance type etc. Agitator manufacturer
to decide the same along with seal manufacturer, the best seal that is suitable for the offered
Agitator
Seal life has to be guaranteed, taking into consideration all its components for 25000 hrs. If
XI the seals fail before the completion of guaranteed period, the same should be replaced free
of cost by the bidder.
XII The sub-vendor of the seal shall be approved by customer during contract execution.
C) SHAFT
MOC of Shaft shall be as per Clause no.3.2 & “Agitator Schedule”, Section-II, Annexure-8.
Use of dissimilar material at flange joint shall be avoided to eliminate any crevice
I. corrosion. Spacing of the shaft joint should not be more than 3.0 m for easy assembly if it is
more than 40kg. If welding is used for joining two tubes, welding joint must be 100% radio
graphed.
D) BEARING & BEARING HOUSING IN GEAR BOX
Bearing shall be of rolling type radial and thrust bearing (FAG/SKF/Timken make only) as
I required. Thrust bearing shall be sized for continuous operation under all specified
condition.
Thrust bearing shall provide full load capability if the Agitator’s normal direction of
II
rotation is reversed. Up-thrust and Down-thrust load must be taken into account in sizing
bearing. Life of the every anti-friction bearing, used in the bearing housing as per
manufacturer’s design, should have L10 of 25000 hr (minimum).
Bearing housing should be grease/oil lubricated. If bearing is oil lubricated, constant–level
sight-feed oiler of 100cc size or bigger capacity is to be provided. Bearing housing should
III have oil drain, constant oil level indicator. A provision of one (1) number G1/2” thread
(ISO-228, Part-1)port is required for remote control of temperature of bearing housing oil
bath through RTD.
If bearing housing requires cooling water, volume and pressure of cooling water is to be
IV
indicated in Technical Data Sheet.
Lubricating oil will be the responsibility of Gear Box manufacturer. Hence, manufacturer
V has to make arrangement of first fill of oil at installation and at commissioning stage.
Quantity of oil and its grade is to be indicated in Drawing and Operation Manual.
E) MATERIALS
Agitator components shall meet the requirements of the industry specification as
I listed for the material in the table as well as in the specification in the respective
section.
II A detail quality plan is to be submitted along with offer for all items.
Final acceptance of the quality plan will be by ultimate user during detailed engineering
III without any commercial implication. QAP should be as per the best practice followed
internationally to avoid any conflict of interest.
F) DRIVER (MOTOR)
I
Driver shall be sized to meet all specified operating conditions including bearing
housing , seal, external gear box and coupling loss( if any).
Page 48 of 348
AGITATORS SHEET : 8
III It should meet the electrical specification (SECTION-I, SUBSECTION-C3).

G) GEAR BOX
Gear box should be vertical flange mounted solid shaft type (Vertical Agitators),
reducing speed type, specially designed for the requirement of Slurry mixing and to
be manufactured by the Agitator supplier. Complete up-thrust and down-thrust,
developed by Agitator shall be taken by thrust bearing housing of Gear Box. An
I. auxiliary slow drive provision shall be provided in the Gear Box so that slurry is
always kept in dynamic condition to avoid settling of slurry at bottom, in the event
of Agitator is not operating at its rated speed. Rating of Gear box shall be at least
1.5 times the rated torque of Agitator. Gear box details are subject to customer
approval during detailed engineering without any commercial implications.
The reduction unit shall be procured from a reputed manufacturer and shall confirm
II. to BS: 721 (latest edition)/AGMA/Equivalent specifications. The sub-vendor of the
gear-box shall be approved by customer during contract execution.
III.
Gear drives shall have splash type oil lubrication. If oil pumps are used, they shall
be removable for maintenance without disturbing the motor or drive housing.
The gear reduction unit shall always be provided with an oil drain, a breather and
IV. oil level gauge. The lubrication to be designed keeping in view that the temperature
within the bearing should not exceed 85 Deg.C.
V. VOID.
VI.
The bidder shall provide an easily accessible oil level gauge and a dipstick that will
indicate oil level under standstill and operating conditions.
H) COUPLING & COUPLING GUARD
I.
Coupling and coupling guard should be supplied between driver and driven
equipment.
II.
Coupling should be designed taking into consideration adequate service factor.
III.
Design rating of the coupling (excluding service factor) should be indicated in data
sheet.
Coupling must be having locking screw so that it does not slide over shaft in due course
IV.
operation.
Vertical Agitators - Coupling between Motor and Gear Box shall be Spacer-type flexible
coupling, made of Cast Iron. Spacer shall be of sufficient length so than Motor and Gear
V.
Box shall be able to run independently at no-load condition by detaching the respective
coupling.
It is desirable that for servicing of seal, coupling half should not be removed. Coupling
should be dynamically balanced to Gr: G6.3, ISO-1940. Any deviation to this requirement
VI.
is subject to customer approval during detailed engineering based on applicable codes and
standards to be furnished by the bidders.
Removable coupling guard shall conform to the requirements of all applicable national,
VII.
industrial or statutory regulations.
I) PLATE AND FASTENING BOLTS
Base plate shall be interpreted as the component of Agitator assembly through
which the whole load will be transmitted to the Sole Plate/Nozzle over which the
I. equipment will be mounted. The Base plate shall be fabricated with mild steel of
structural quality (UTS=42N/sq mm minimum) with anti-corrosive paint of
sufficient dry-film thickness.
II.
Base plate must have provision of leveling on its intended mounting place. It should
be noted that Nozzle will be rubber lined to prevent any leakage of corrosive gases
Page 49 of 348
AGITATORS SHEET : 9
Alignment between Gear Head Shaft and Agitator shaft shall be within the
III. permissible limit of Gear Box. Similarly, misalignment between Motor shaft and
Gear Box Shaft shall be within 0.050 micron (radial) and 2 degree (angular) or
better as per requirement of Motor and Gear Box
Base plate with desired number of hole shall be provided by the bidder, will be machined
IV. on one side. Base Plate shall be welded to the structure after leveling, as recommended by
Agitator manufacturer and rubber lining is completed before placing the equipment in its
desired location.
J) OTHER COMPONENTS
All fasteners used in wetted condition must be of Duplex Stainless Steel or better material
I so that even if it comes in contact with liquid by swelling of rubber, thread remains
unaffected.
II
Mounting flange dimensions shall be as per ASME B16.5 up to 600 Nb, ASME B 16.47 for
more than 600 NB.
Rubber Lining (As Applicable)
a) Rubber lined surfaces shall utilize 6 mm nominal thickness chlorobutyl rubber.
III b) Areas of high wear (e.g. leading edges on impeller blades) shall have an additional
6 mm of rubber for abrasion protection.
c) No field-applied linings are permitted except for file patch kits.
K) GENERAL REQUIREMENT OF SIDE ENTRY AGITATORS:
I. All Agitators shall be designed for continuous operation.
II.
The Material of Construction (MOC) of Agitators shall be as per Cl. No. 3.2 & “Agitator
Schedule” ”, Section-II, Annexure-8.
I
III. It should be of Flange mounted type.
Nozzle Isize, on which Agitator shall be mounted, shall have enough opening to Insert
IV. rotating assembly from side.
V
V. The Bidder to consider Gypsum Sedimentation during stoppage of Agitator.
V
VI. VOID
GENERAL REQUIREMENT OF TOP ENTRY AGITATORS IN OTHER
L)
DRAIN PIT:
I. All Agitators shall be designed for continuous operation.
The Material of Construction (MOC) of Agitators: Agitator blades shall be as per Clause
II.
No.3.2 & “Agitator Schedule” ”, SECTION-I, SUB-SECTION-D, Annexure-III.
III. It should be roof mounted.
Agitators shall be vertical mounted type and shall be driven by motor with reducing speed
gear box of rigid type, solid shaft coupling between gear box and agitator and flexible
IV. coupling of spacer type between Motor and Gear Box. Both Gear Box and Motor should be
vertically/horizontally flange mounted type with a common frame of the whole equipment.
The entire thrust load of agitator should be transmitted to the thrust bearing of Gear box.
Nozzle size, on which Agitator shall be mounted, shall have enough opening to Insert
V.
rotating assembly from top.
Cable entry to the Motor terminal box should preferably be from top when motor is
VI.
vertically mounted at its position and it should be easily accessible.
VII. Impeller should be dynamically balanced to Gr: G16: ISO-1940 after rubber lining of shaft.
VIII -VOID-
IX Operation speed of the Agitator motor shall be at least 25% below the first critical speed.
X -VOID-
XI -VOID-
Page 50 of 348
AGITATORS SHEET : 10
4.3 MOTOR
All AC motor shall be Squirrel cage induction motor and, shall be suitable for direct –on-
line starting. Rating of the motor should of Type S1 (Continuously rated) as per ISO-60034,
Part-1. Rating of motor must be selected with minimum margin (as per the below table)
above the maximum load demand of the driven equipment under entire operating range
including voltage and frequency variation:
Agitator Rated BKW Motor Margin

<22KW 125% of Agitator Rated BKW
22KW-55KW 115% of Agitator Rated BKW
>55KW 110% of Agitator Rated BKW
It should meet the electrical specification (SECTION-I, SUBSECTION-C3).
5 GENERAL REQUIREMENTS
Metric unit shall be used in the drawings and in the any displays on the equipment’s.
1 Special attention should be taken that the unit of pressure shall be in dual scales of kPa and
kg/cm2(G). For instance the pressure gauges should have dual unit’s indication.
2 Descriptions in the drawings, in the documents, and in the displays shall be in English
The equipment shall be designed to withstand the corrosive and moist environment in
4
which these are proposed to operate.
Noise level produced by any rotating equipment individually or collectively shall not
5 exceed 85 dB measured at a distance of 1.0 meters from the source in any direction and
1.5m above operating floor.
6 The overall vibration level shall be as per ISO 10816.
7 Suitable drain connections shall be provided.
8 The equipment shall be suitable for stable operation continuously.
Corrosion allowance: Corrosion allowance for entire equipment shall be in accordance with
latest applicable Indian / International standard. Carbon steel shaft shall have a corrosion
9
allowance of 6mm on its diameter. On other non-pressure carbon steel parts a corrosion of
3mm shall be considered on each surface.
10 Unless otherwise specified , flanges shall be in accordance with ANSI B16.5 Class 150
Name plate: All equipment shall be provided with nameplates indicating the item number
and service name. Name plates shall be of 304 Stainless steel plate and placed at a readily
11 visible location. Nameplate of main equipment shall have enough information, which will
be confirmed during engineering phase. Stainless steel nameplates for all instruments and
valves shall be provided.
Rotation arrows shall be cast in or attached with stainless steel plate on each item of
12
rotation equipment at a readily visible location.
Unless otherwise specified, all equipment items where the weight exceeds 15 kg shall be
provided with suitable lifting lugs, ears or ring bolts or tapped holes for lifting rings. When
13
any spreader bars are required for lifting and laydown, the bidder shall provide spreader bar
with equipment.
If the driver/driven equipment train is in the resonance condition or any vibration problems
15
occur, the bidder shall solve the problems in a timely manner.
16 Bidder shall provide the necessary gaskets.
All the surfaces of the carbon steel should be rust prevented before shipment for the period
17
of at least 12 months for storage and construction.
Bidder to provide capacity of hoist required for material handling and the details of heaviest
18 component to be handled. Bidder shall provide a typical arrangement/drawing of the
handling arrangement.
The list of all Bought out items with makes and country of origin to be mentioned during
19
detail engineering and shall be subjected to BHEL/end customer approval.
Page 51 of 348
20 -VOID-
Material of construction for all equipment/components shall be subject to customer/ BHEL
approval during detail engineering. Accordingly bidder shall consider MOC for all
21
equipment/component (complying tender specifications), as per best engineering practice,
global standard and global references, in case no MOC is available in specs.
Bidder to provide sub vendor list and Bidder shall strictly adhere to customer approved
vendor list (reference list is included in SUB-SECTION-D, Annexure-I). In case bidder
22 proposes an additional vendor for an item or vendor approval is required for any new item,
acceptance shall be subject to approval by customer/ BHEL before placing order and bidder
shall submit relevant documents to take up with customer for approval.
It shall be the complete responsibility of the successful bidder to obtain “Sub Vendor
Approval” from BHEL / customer for all equipment’s & components. Any delay in sub
23 vendor’s approval should not affect the project schedule. If any of the sub vendors does not
have the approval of customer/ BHEL, the same may be replaced with another
customer/BHEL approved sub-vendor only, without any price implications to BHEL.
The modalities of inspection (Stage, Final, In-process) shall be finalized during detail
engineering after submission of quality assurance plan (QAP). It shall be reviewed by the
end customer and BHEL. Bidder shall follow the procedures of inspection as per the
approved QAP. Bidder has to submit the following documents along with inspection call
and if any other documents required as per approved QAP.
- Raw material inspection certificate

24 - Internal test reports
- Statutory certificates as required.
- All inspection & testing shall be carried out based on the following documents:
a. Relevant Standards
b. Specifications
c. Approved drawings
d. Data Sheets
e. Calibration certificate for all the measuring instruments
During detail engineering, bidder to strictly adhere to BHEL drawing formats, document
25
numbering, quality plan & FQP formats
26 -VOID-
Complete detail engineering drawings, calculations, selection of components etc. shall be
27
reviewed & subject to approval of BHEL/end customer during detail engineering
Bidder shall furnish necessary inputs & drawings of all equipment in editable Auto CAD/
28
MS-Word /Excel format.
During detail engineering, successful bidder shall ensure flow of drawings/documents as
29 per schedule. Any comments from BHEL/end customer should be addressed timely by the
bidder.
Bidder to note above mentioned points not exhaustive and any work /items required for
30 completing the smooth operation and ensuring satisfactory running of the machines till final
hand over to the end user shall also be in the scope of the bidder.
Bidder shall provide design support to assist the Purchaser in efficiently integrating the
furnished equipment. Design support specifically includes:
 Bidder shall verify/ validate the number and location of agitators to keep material
31
in suspension.
 Static and dynamic loading information and requirements for agitator support
design (applicable for top & side type)
Any other item required to meet the stipulations mentioned in GTR , GCC and SCC and
32
relevant to Agitator package unless specifically excluded from scope of supply.
Page 52 of 348
6 PACKING AND FORWARDING

Proper packing to be ensured.
Indigenous Supply: Agitator & sub system assembly shall be wrapped in polythene bags
& packed in a strong rigid wooden crate. Rain water should not enter into the Agitator
internals during storage in the outer yard of power plant. Further the packing shall be done
in line with requirements mentioned in point no. 2 to 20 of this section.
1
Imported Supply: All imported supply should be packed as per Sea worthy packing
standards as per Sub-Section D, Annexure-V. All imported items should have Sea worthy
packing. Liberal packing materials and struts shall be provided to arrest rolling and to
protect from transit damages.
8 ERECTION, TESTING AND COMMISSIONING
The erection of Agitators will be done by owner as per Erection Manual and check List to
be provided by the bidder during detail engineering. However, the bidder shall make visit as
1 per enquiry/PO for the supervision of erection, pre-commissioning & post- commissioning
check-up, start-up, testing and trial runs of all the items covered under the scope of supply
& Services.
10 INSPECTION AND TESTING
1 The General inspection requirements to be considered are as below:
Bidder shall furnish written copies of shop production, fabrication and quality test
2 procedures and drawings to be used on the Agitators for review by BHEL/end customer
prior to manufacture.
The Bidder shall furnish performance test procedure along with standard. The test
3
procedure will be reviewed and approved by the BHEL/customer.
Power consumption at motor terminal and vibration of equipment will be conducted at site.
5 Vendor to indicate other material tests that are to be conducted as per their practice in their
Quality plan.
No liquid should enter the tube through any flange joint. “O”-ring used in the flange joint
will deteriorate at a highly chlorinated and acidic environment of medium at a maximum
operating temperature unless right quality of rubber is used. Hydrostatic testing of tube
assembly is required at a pressure of twice that of maximum liquid column in any tank or
6
30m whichever is higher. The hydro test duration will be for a minimum of 1 hr to check
sweating of any flange. Hydrostatic test is meant in part for a check of equipment joint at
new condition only. It is cannot be considered as a guarantee of functional objective of
rubber used.
Mechanical Run Test (in air/water/slurry)
Each Agitator unit shall be given a 4-hour mechanical run test in air at vendor's shop.
Agitator unit shall be mounted in the same manner as it will operate in the field. During this
test the record shall be made of:
a) Shaft run out at free end.
b) Dynamic shaft deflection adjacent to the mechanical seal/packing/vapor seal.
c) Gearbox oil temperature and temperature of bearing housing in stool. The temperature of
7 the gear box oil shall not exceed ambient plus 40 Deg.C and that of bearing housing shall
not exceed from room temperature plus 20 Deg.C after temperatures have stabilized.
d) Bearing Housing vibration checks shall be carried out. Maximum acceptable vibration
velocity shall be 6 mm/sec.
e) Noise level shall be checked and shall be within the specified limits mentioned in the
specification.
f) Agitator shaft RPM and motor RPM.
g) Check of satisfactory operation of shut off and retracting arrangement.
In case of any constraints in carrying out shop tests indicated at S.No. 7 & 8 above, the
9
Mechanical run tests for agitators shall be carried out with air/water at shop along with
Page 53 of 348
other test requirement in line with the QAP to be approved by customer during detail
engineering.
Acceptance Test (at Site)
9A After the agitator has been installed at site and is ready for test, vendor shall arrange his
OEM representative to supervise the site acceptance test
10 DYNAMICS
10.1 CRITICAL SPEED
10.1.1 Operation speed of the Agitator motor shall be at least 25% below the first critical speed
Additional to the requirement of the critical speed of Agitator, as specified above. Agitator
manufacturer is to analyze the torsional critical speed of combined system of Agitator, Gear
10.1.2
Box and Motor to establish there is a separation margin of minimum 20% between the
torsional critical speed (dry/wet) and any operating speed.
10.2 VIBRATION SEVERITY
During performance test, unfiltered vibration measurements shall be made with running of
10.2.1 Agitator in Air. Measurement shall be taken on the Gear Box thrust bearing housings as
well in motor top.
Guaranteed Site vibration of the equipment on its own pedestal, at commissioning with
normal level of liquid and with maximum liquid at respective tank, Vibration limit at site
10.2.2 will be as per ISO-10816 and 1.5-2.3mm/sec even if Motor rating falls below 15kw. Any
deviation to this requirement is subject to customer approval during detailed engineering
based on applicable codes and standards to be furnished by the bidders.
Vibration measurements of bearing housing shall be made in root mean square (RMS)
10.2.3
velocity.
Vibration levels measured on the non-rotating parts shall not exceed the zone limit “B” as
10.2.4 defined in ISO 10816 at steady conditions and shall not exceed the zone limit “C” as
defined in ISO 10816 at transient conditions.
For surfaces with rubber lining, welding shall be visually inspected to verify the absence of
11 rough area and unacceptable transition between surfaces which prevent the adequate
adherence of rubber. The acceptance criteria shall be as per latest standard.
For surfaces with rubber lining, degree of cleaning shall be visually checked before the
12 application of the coating. There must be no area with oxidation, dirt or partially or
generalized corrosion defects.
Test certificates shall be issued for each lot of raw material used in the coating,
13
corresponding to specific weight and traction resistance.
For surfaces with rubber lining, adherence test shall be conducted on production samples.
14 Adherence test shall be conducted on the actual surface through hammering. In order to
verify the absence of air packets (or) surface without adherence.
For surfaces with rubber lining, Coating thickness shall be checked at 100%. A High
15
voltage porosity test will be conducted on 100 % of the coated surface.
Out of all Agitators One Number of each type will be inspected at the Bidder’s works
16
before dispatch or where the test facilities are available.
The Bidder shall conduct performance test for the remaining Agitators and submit the
17
reports.
Contract shaft mechanical seals shall be used during shop tests, unless the seal design is
18
unsuitable for the shop-test condition, if applicable.
Agitators shall not be released for shipment, until shop tests data and performance tests
19
curves have been approved by Owner.
Bidder should furnish performance guarantee as per applicable guarantee for the design,
20
manufacture, material and safe operation of the equipments.
21 Bidder to arrange all calibrated gauges, Instruments during inspection.
Page 54 of 348
Mechanical running and the performance test shall be carried out. Bidder to arrange Motor
22
of same / higher rating for the shop test and inspection.
All testing requirement/certificates shall be in line with QAP to be approved by customer
23
during detailed engineering.
11 PAINTING
Painting details for agitator support: -
1
Please refer painting specification (SECTION-C, SUB-SECTION-C2C).
Corrosion protection, coating and galvanizing, painting shall be taken care by the bidder.
2 Bidder shall submit the painting scheme during detail Engg in line with the specification
and shall be subject to approval of BHEL / End Customer.
12 SPARES,TOOLS & TACKLES
Bidder shall supply a set of special tools and tackles required either for erection or
operation or maintenance of the agitator units. A list of such tools shall be submitted by
bidder along with the offer.
Any special tools & tackles required for the entire equipment to disassemble, assemble or
maintain the units, they shall be included in the quotation and furnished as part of the initial
supply of the machine. List of special tools & tackles shall be decided by bidder as per his
proven practice. When special tools are provided, they shall be packaged in separate, boxes
with lugs and marked as “Special Tools for (tag / item number).” Each tool shall be
stamped or tagged to indicate its intended usage. Levers and eye bolts for the removal of
parts to be serviced shall be submitted with special tools (SECTION-III Annexure-6).
12.1 START UP & COMMISSIONING SPARES
Start-up & Commissioning Spares shall be part of the main supply of the Agitators. Start-up
& commissioning spares are those spares which may be required during the start- up and
commissioning of the equipment/system. All spares required for successful operation till
commissioning of Agitator shall come under this category. Bidder shall provide an
adequate stock of such start up and commissioning spares to be brought by him to the site
for the equipment erection and commissioning. The spares must be available at site before
the equipments are energized. The List of such spares to be provided during bidding stage
(SECTION-II Annexure-9).
12.2 RECOMMENDED SPARES
Bidders shall also furnish the recommended spares list along with the offer required for 3
years of normal operation of the plant and should be independent of the list of the
mandatory spares. Prices of recommended spares will not be used for evaluation of the bids.
12.3 MANDATORY SPARES:
Bidder to quote for the mandatory spares as per the Mandatory Spare list (SECTION-I,
SUB-SECTION-D Annexure-VII).
Bidder shall quote for the “Mandatory Spares Part List”, and it will be considered for L1
evaluation. Mandatory spare parts items shall be handed over separately and shall not be
mixed with the supply of the main equipment parts. Spares shall be sent in pre-decided lots
in containers/secure boxes.
All spares supplied under this contract shall be strictly inter-changeable with the parts for
which they are intended for replacements. All the mandatory spares shall be manufactured
along with the main equipment components as a continuous operation as per same
specification and quality plan.
13.0 FIRST FILL OF CONSUMABLES

Bidder’s scope shall include supply and filling of all chemicals, lubricants, grease, filters
I
and consumable items for operation up to commissioning including top up requirements.
All lubricants proposed for the plant operation shall be suitable for all operating and
environmental conditions that will be met on site consistent with good maintenance
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procedures as instructed in the maintenance manuals.
Bidder shall also supply a quantity not less than 10% of the full charge of each variety of
lubricants, servo fluids, gases, chemicals etc. (as applicable) used which is expected to be
II
utilized during the first year of operation. This additional quantity shall be supplied in
separate containers.
Detailed specifications for the lubricating oil, grease, gases, servo fluids, control fluids,
chemicals including items qualities and quantities required per month of the plant operation
for the end customer/BHEL’s approval herein shall be furnished within 2 months of
placement of Order. On completion of erection, complete list of bearings/equipment giving
III their location and identification marks shall be furnished to BHEL along with lubrication
requirements. All types of chemicals, consumables, lubricants and grease shall be readily
obtainable locally and the number of different types shall be kept to a minimum. For each
type and grade of lubricant recommended, bidder shall list at least three equivalent
lubricants manufactured by alternative companies.
16 PERFORMANCE GUARANTEE
All performance tests for Agitators shall be carried out in accordance with any latest
international codes/standards.
Bidder shall furnish Performance guarantee for the design, manufacture, material, safe and
trouble-free operation of the Agitators and its accessories
The Bidder shall ensure a design of the equipment to achieve an average target availability
of 98% for 120 days and average target availability of 95% for 1 year.
Noise level ≤85 dB (A) at 1m horizontal distance from equipment/enclosures and 1.5m
above operating floor is to be guaranteed.
Vibration levels measured on the non-rotating parts shall not exceed the zone limit “B” as
defined in ISO 10816 at steady conditions and shall not exceed the zone limit “C” as
defined in ISO 10816 at transient conditions.
Life of Agitator components/parts from the date of commissioning for continuous operation
shall be guaranteed for 24 months.
Acceptance tests to be carried out as per the procedure defined by the bidder which shall be
submitted for BHEL/ end customer approval.
In the event that the performance test is unsuccessful, bidder shall take necessary remedial
action at his cost and the performance test shall be repeated.
For additional details of performance guarantee please refer ‘functional guarantee’ under
Sub-section C2, Section-I.
17 DOCUMENTATION
A DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT
The Successful bidder shall submit necessary data, documents and drawings for review,
approval as specified in this specification. Drawings that are reviewed by the end customer/
BHEL, will be returned to bidder with a transmittal letter with any comments and / or
questions marked on the drawings or noted in the letter. All comments and questions must
be resolved before a resubmission of drawings / documents. If the design has not developed
enough to resolve some of the comments or questions, bidder shall place a “hold” on those
items or areas of design. End customer/ BHEL reserves the right to return drawings
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unprocessed to bidder if there exists any evidence that bidder has not acknowledged all
comments and questions.
All necessary GA drawings, sections, sub-assembly drawings, specifications of main and
sub components and necessary set of operation & maintenance manual as asked by end
customer must be furnished by bidder in soft and hard copy forms. For all documents
softcopy format shall be searchable pdf, however in addition all drawings, diagrams shall
be supplied in ACAD or other editable format and all lists in Excel format. Further break up
of technical documents will be discussed during finalization of the purchase contract.
All documents in hard and soft form are to be submitted in the English language. Electronic
Copies shall be submitted in primary original data format (e.g. DOC, XLS, DWG) as well
as in a printable non-proprietary document format (e.g. PDF). Especially P&IDs shall be
submitted as DWG files and PDF files. Bidder to ensure submission of hard copies as per
end customer requirement for all engineering drg/doc and for all subsequent revisions along
with a soft copy through email to concerned project team.
The list of such drawing/documents have been indicated in (SECTION-I, SUB-SECTION-
D Annexure-III).
18 LIST OF REFERENCE DRAWINGS BY BHEL
The document specified in Annexure-III, Sub-Section-D of Section-I are being provided
I
along with the tender specification for estimation and calculation purpose of the bidder.
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TECHNICAL SPECIFICATIONS FOR SECTION –I, SUB SECTION –C1C
MISC. TANKS (SITE FABRICATED) AND AGITATORS REVISION 00
DATE: MARCH 2022
SUB SECTION-C1-C
SPECIFIC TECHNICAL REQUIREMENTS – GLASS FLAKE LINING
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DATE: MARCH 2022
1.0 INTENT OF SPECIFICATION
a) This Specification defines the minimum requirements of glass flake lining of Slurry Tanks/drain
sumps in the Flue Gas Desulphurization (FGD) plant.
b) Tanks/Sumps to be lined contain Limestone Slurry/Gypsum Slurry. Slurry details are given in
Annexure- III, Sub Section-D, Section-I. The glass flake lining shall offer better resistance to
corrosion/erosion and shall be based on Vinyl ester resin. Thickness of glass flake lining required
is 3 mm thk.
c) This specification covers the general design, selection of suitable glass flake material/resin,
manufacture, shop inspection (As per latest applicable statutes, regulation and safety codes in
the locality where the lining is to be carried out) and delivery at site, surface preparation of lining
surface, lining the surface to the satisfaction of the customer, inspection of the lining at site,
handling over to the ultimate customer.
d) Compliance to this specification shall not relieve the vendor of the responsibility of furnishing
glass flake lining materials of proper design, materials and workmanship to meet the specified
requirements.
2.0 CODES AND STANDARDS:

The glass flake lining shall conform to the latest version of Indian/British/American/International
Standards. Nothing in this specification shall construe to relieve the contractor of the required
statutory responsibility. The Glass Flake Lining material shall be designed for the corrosion
protection of the Slurry tank/drain sumps. The lining shall be glass flake filled vinyl ester-based
coating system. Only Proven material has to be offered by the bidder. The reference standard is
given below:
STANDARD DESCRIPTION
ASTM D 4285 Standard Test Method for Indicating Oil or Water in Compressed
Air
ASTM D 4541 Standard Test Method for Pull-Off Strength of Coating Using
Portable Adhesion Testers
ASTM E 337 Standard test Method for Relative Humidity by Wet and Dry Bulb
Psychrometer
ASTM D 4618 Standard Specification for Design and Fabrication of Flue Gas
Desulfurization System Components for Protective Lining
Application
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DATE: MARCH 2022
ASTM D 5162 Practice for Discontinuity (Holiday) Testing of Non-Conductive

Protective Coating on Metallic Substrates
NACE Standard RP0178- Fabrication Details, Surface Finish Requirements, and Proper
2003 Design Considerations for Tanks and Vessels to be lined for
Immersion Service
ISO 8501-1, 1988 Preparation of Steel Substrates Before Application of Paints and
Related Products - Visual Assessment of Surface Cleanliness
SSPC”PA2 Measurement of Dry Paint Thickness with Magnetic Gauges
3.0 SCOPE OF WORKS
a) Supply of Vinyl ester based glass flake lining of minimum 3 mm thickness, storage, preparation
of the surfaces for lining at site. All equipments required for lining shall be arranged by the lining
vendor.
b) Erection and Commissioning of the glass flake lining as per specification. Lining of the internal
surfaces of slurry tanks and drain sumps to the satisfaction of the customer and testing the lined
surface for proper adhesion, complete coverage and intactness with the base material/surface
shall be under bidder's scope.
c) To install the linings, full scaffolding access shall be provided to reach the internal walls and the
entire area. Scaffold shall be properly erected with full planking in all work areas. Scaffolding
shall not contact wall surfaces in work areas during lining application and surface preparation
d) The execution of the surface preparation and lining shall be carefully planned in stages to obtain
optimum lining quality with freedom from contamination and overspray or damage to lined
surfaces from preparation in adjacent areas. Surface preparation will commence from the top
and proceed progressively to the wall base and floor.
e) Lining and preparation works shall be staggered or proceed progressively in order to meet
cleanliness requirements or overcoating times indicated in this specification.
f) Air-Compressor, Airless Spray pumps, hopper, blasting hose, lining hose, spray tip, blasting gun,
spray gun and other equipment for blasting and spray application has to be arranged by lining
vendor. Any scaffolding shall be made of Steel only.
g) 10 copies of Operation and Maintenance Manuals containing all details of reference drawings
and technical data shall be furnished by the Bidder.
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DATE: MARCH 2022
4.0 VINYL ESTER BASED GLASS FLAKE LINING

4.1 For slurry tanks, the lining shall completely cover the roof, shell plates, support angle, Man
Holes, Flanges, internal piping, baffle plates and any other component which is in contact with
slurry. For drain sumps, lining shall cover all internal walls, bottom of sump and any other
component which is in direct contact with slurry.
4.2 The glass flake lining used for the lining of the tanks is given as below:
Sl. Tanks/Sumps Lining details of interior

No surface
1 Auxiliary absorbent tank Vinyl ester-based Glass Flake
lining of min 3 mm thickness.
2 Process water Tank Epoxy lining of minimum 150
micron thickness (3 coats of 50
micron each)
5.0 ATMOSPHERIC CONDITION REQUIREMENTS
This section deals with the atmospheric condition requirement to be checked while undertaking
the Glass Flake Lining at site.
1. Blasting or Coating shall not be applied if following conditions prevail.
 When temperature of the surface to be coated is less than 3°C above the dew point, or the
relative humidity is higher than 85%.
 When the base metal temperature is greater than 60°C.
 When the atmospheric temperature is below 4°C.
 When there is, in the opinion of lining Contractor, the likely hood of an unfavourable change
in the weather condition within 2 hours after coating.
 When there is deposition of moisture in the form of rain or condensation.
2. Humidity shall be calculated by bidder using whirling hygrometer whose thermometers are
calibrated.
3. Surface temperature shall be measured using suitable temperature gauge and calibration
certificate of the same shall be provided by bidder.
4. Record will be maintained throughout the execution period. Readings shall be taken once in
every 4 hours up to the time work is in progress. The frequency of reading should be increased
during adverse weather conditions.
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DATE: MARCH 2022
5. While working in unfavourable weather conditions (like monsoons or winters or if provided for
in the contract or in large confined spaces where blasting and priming of the entire surface
cannot be completed in one-day operation, use of dehumidifier shall be resorted to. The
dehumidification equipment will have to be maintained in such a way that the humidity is
around 65% -75% inside the sump/tank at all times during the work. No flash rusting of the
blast surface should take place till the time it receives a primer coat.
6. Where dehumidification equipment is to be used, the humidity readings are to be taken inside
and outside the equipments to be coated.
7. Dehumidification equipment may not be necessary for contained space working if work is done
at near ideal atmospheric conditions as described above.
8. In cases where dehumidification is not possible, alternate methods of warming up the work
front like use of halogen lights, room heaters are to be adopted.
9. Humidity is to be taken at the location where the blasting coating operations taking place.
6.0 PRELIMINARY CHECK REQUIREMENTS
This section deals with the preliminary check requirements to be done while doing the lining work.
6.1 CHLORIDE CONTAMINATION TEST:
The 2% ferricyanide paper method will generally be used to determine the chloride
contamination as described below:
1. Apply de-mineralized water on approximate 12 cm² area of substrate and wait for 3 to 4
minutes.
2. Remove excess moisture by patting the substrate with clean lint free cloth.
3. Press a ferricyanide paper of approximate 12 cm² area against the substrate for approximately
5 seconds and remove the paper.
4. Total absence of blue spots on paper indicates the substrate is free from soluble salts
5. Light speckling paper indicates the substrate has still contamination but it is under the
acceptance level. The component should be released for further process.
6. Large blue spots on the paper indicate the substrate is heavily contaminated.
7. In this case the following procedure to be done before coating.
7.1.1. Pressures wash the substrate with copious amount of town water.
7.1.2. Dry the substrate completely.
7.1.3. Re-blasts the surface.
7.1.4. Follow the salt contamination checking procedure again till you get the desired results.
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DATE: MARCH 2022
8. The Ferricyanide papers should be stored by vendor in air tight container before and after use
and the shelf life of Ferricyanide paper shall be one month.
6.2 ABRASIVE DRYNESS CHECK:
The abrasive to be used will be checked for dryness by taking a small quantity of abrasive on a filter
/tissue paper and checking of traces of moisture absorbed in the filter/tissue paper. Frequency of
test shall be once in day prior to blasting operation.
6.3 COMPRESSED AIR DRYNESS CHECK:
Compressed air to be used for blasting shall be free from oil & moisture and shall be tested adopting
“Blotter Test” by vendor. A piece of blasting Paper will be held in front of blast hose nozzle to check
for traces of oil/moisture captured by the blotting Paper. Frequency of test shall be once in day
prior to blasting operation.
7.0 SURFACE PREPARATION
This section deals with the methods of surface preparation before coating application
7.1 MASKING:
a. Bidder to ensure that areas not being coated are fully and adequately masked.
b. Bidder to ensure that stud holes, dowel/oil ways etc. are suitably masked or plugged to prevent
ingress of blasting abrasives.
7.2 SURFACE PREPARATION METHODS:
The method of surface preparation dry abrasive manual blasting shall be done as follows:
a. Surface to be coated shall be abrasive blasted. Before this operation, removal of existing
coating to be carried out by chipping, grinding or by other suitable means. The walls of the
tanks are painted with min 60µ DFT of Red Oxide Phosphate (rust proof primer), which is to be
removed by vendor during blasting. Clean & dry Copper Slag Abrasive shall be used for ferrous
base substrate.
b. The minimum recommended compressed air required for Blasting shall be 7.0 m3/min at 6
kg/cm² pressure. NACE No.1/SSPC-SP-5 equivalent to SA 2½ of Swedish Standard blast profile
(75 to 100 Microns) to be followed for cleaning the surface.
c. The blasted surface shall be cleaned with dry compressed air/vacuum cleaner or with clean
brush so that there is no presence of Dust & other foreign material. The surface will be then
checked for chloride contamination (Refer Clause.6.1 for Chloride contamination check
procedure). Vendor to ensure that the blasted surface is free from chloride contamination
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DATE: MARCH 2022
d. When cleanliness and blast profile are acceptable, the masking tape adjacent to the area to be
coated shall be peeled back to prevent overlap and subsequent edge contamination.
e. If the blasted surface has not been primed within specified time or if there is any previous
visible sign of blast condition change then the surface shall be checked for metallic salt
contamination and shall be reblasted. Where large areas are required to be blasted in a day,
blasting shall be carried out from morning to evening ensuring weather condition. This shall be
followed by a light sweep blast of the entire area, before priming. The blast cleaned surface
shall be blown off with dry oil free compressed air or vacuum cleaned. A cell tape shall be
thoroughly pasted to the cleaned surfaces. The tape shall be removed after a minute to check
presence of dust if any. Comparator shall be used by vendor for checking the blast profile.
8.0 COATING APPLICATION
This section deals with the methods & requirements of coating application.
8.1 MIXING
a. All coating material tins shall be individually stirred thoroughly to obtain a homogenous
consistency.
b. While doing spray application, the tins which come in pre-measured kits will be fully mixed
individually using a pneumatic stirrer. While doing hand application only small batches of 1 Kg.
capacity shall be taken. Here the mixing will be done by using a metal spatula.
c. The mixing ratios as specified in the respective data sheet will be strictly adhered to. The base
will be weighed out in kgs using mechanical weighing machines calibrated at site using any
standard factory packed commercial product available freely in the market. The catalyst will be
measured out in ML using marked syringes or measuring cylinders.
8.2 APPLICATION PROCESS
a. The preparation and application of coating is done as per relevant product data sheet. Reference
will be made to product datasheet or where appropriate, contract specifications for carrying out
coating.
b. Coating in confined spaces should be done when the ambient temperature is low to avoid excess
build-up of styrene fumes.
c. The entire thickness will be built in multiple coating.
d. Each coat will consist of minimum two passes of wet on wet in perpendicular directions.
e. The Dry film thickness will have built of each coat will be checked and recorded.
f. All the other people working with the paint will be provided with eye splash goggles and masks.
g. Glass flake lining material shall be chosen considering the slurry conditions given in Annexure-
8 (Tank schedule), Section-III.
h. Minimum and maximum intercoat intervals are as follows.
i. For primer coat -At 20ºC - minimum 2 hours, maximum 14 hours.
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DATE: MARCH 2022
ii. For build-up coats-minimum tack free of previous coat, maximum 3 days.
i. Primer coat shall be of 75-100 μm thickness
j. Built up Coat shall be of 3000-3100 μm in multiple coats.
k. Total System DFT: 3000 microns approx.
l. All weld joints phase transition joints will receive a stripe coat by brush in the same sequence of
coating on the shell.
8.3 CURING & FINISH
a. Curing:
The completed linings shall be allowed to cure for a minimum of 48 hrs at 30°C prior to being
placed in service. However, curing time shall be as per the datasheet provided by vendor for a
proven material.
b. Finish:
It is to be noted that the coating will follow the profile of substrate. Any unevenness or other
defects in the substrate may be reflected in the finish coating also. The finished coating shall have
a matt/semi-glossy finish. A few local paint sag marks will not affect performance of coating and
cannot be completely avoided. Hence this is permitted.
9.0 INSPECTION AND TESTING OF GLASS FLAKE LINING
After the completion of lining, the following tests shall be conducted by the vendor to assess the
quality of glass flake lined surfaces.
a. Lining shall be visually inspected to ensure that it shall be free from poor weed out fibers,
entrapped air and exposed fires. The Glass flake lining shall also be subjected to testing at site
as per relevant standards.
b. Testing of coatings is normally carried out as soon as they are sufficiently cured to give true
thickness & to withstand damage by the test equipment. If defects are found, repair will be
carried out as per clause 10.0
c. Spark test shall be carried out at appropriate areas in the presence of Purchaser. Vendor should
conduct holiday test as per relevant standards. If the performance is found not to meet the
requirements as specified, the Glass flake lining shall be rectified or replaced by the Vendor
without any additional cost to the Purchaser.
d. Proper documentation with details of tests conducted by the vendor for evaluation of glass
flake lining shall be submitted to the purchaser.
e. Detailed QAP of glass flake lining shall be submitted by vendor to BHEL during detailed
engineering for approval. Any comments given by BHEL/Customer shall be
incorporated/complied by vendor without any commercial implication to BHEL.
10.0 REPAIRING PROCEDURE FOR GLASS FLAKE COATING
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DATE: MARCH 2022
a. If the exposed or damaged surface is less than 10cm², then such repair can be carried out
without grit blasting. Any area in excess of this amount should be grit blasted using a vacuum
blaster where possible.
b. In case of damage area less than 10cm², then it can be repaired as following.
i. De-contaminate surrounding area by using a suitable solvent such as methylated spirit,
acetone, xylene etc. After washing clean and allow solvent to evaporate.
ii. Roughen up exposed metal & clean using rotary wire brush or a coarse emery paper with
at least 60 grade grit. Brush away residues then further roughen surface of the existing
coating up to 100 mm away from the damaged area. Brush away residues & ensure the
whole area is clean.
iii. Apply a thin coat of material to the surface of the exposed metal only taking care not to
cover more than a few millimetres of the existing coating. Allow this freshly applied material
to become tack-free.
iv. Brush styrene monomer over the whole surface to be repaired (i.e. the whole area
roughened by emery) & allow to evaporate from the surface.
v. Apply at least 2 main coats material over the treated area taking care not to brush on to any
roughened or contaminated areas. The Glass flake should be allowed to harden sufficiently
to bear the weight of next coat before application of further coats. However, it does not
need to be tack-free between coats.
11.0 PERFORMANCE GUARANTEE
The lining shall be guaranteed for uninterrupted minimum life of 25,000 hrs. Performance
parameters to be guaranteed by the vendor and tolerances permitted shall be as indicated in
the data sheet. Glass Flake lining or any portion thereof is liable for rejection, if it fails to give any
of the guaranteed performance parameters. During Guarantee period any defects noticed due to
faulty material and workmanship, shall be rectified by vendor free of cost.
12.0 PACKING
The packing should be suitable for tropical conditions. Vendor shall make arrangements for
storing the Glass flake lining materials in AC containers at site.
13.0 DOCUMENTATION
DATA TO BE FURNISHED BY THE VENDOR AFTER RECEIPT OF PURCHASE ORDER:
13.1 List of Drawing and documents to be submitted for review, approval and information with
submission dates.
13.2 Catalogue/Datasheets for the Vinyl ester-based Glass Flake Lining material
13.3 Detailed dimensional drawing of the lining surfaces indicating the design data and
information about the material, scope of work and weight of the material supply etc.
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DATE: MARCH 2022
13.4 Surface preparation and Lining procedures

13.5 Manufacturing Quality Assurance Plan for Glass flake material and adhesive to be submitted
for approval.
13.6 Repair and rectification procedure for Glass Flake lining
13.7 Installation, Operation and maintenance manual.
Page 67 of 348
REV. 00
AGITATORS
Date: FEB. 2022
SECTION-I,
SUB-SECTION-C2
CUSTOMER SPECIFICATION
Page 68 of 348
REV. 00
AGITATORS
Date: FEB. 2022
SECTION-I,
Sub Section-C2 - A
CUSTOMER SPECIFICATION: TECHNICAL REQUIREMENT
Page 69 of 348
EPC Bid Document
WBPDCL Sagardighi Thermal Power Project
1x660 MW Unit No. 5, Phase - III
VOLUME : II-B
SECTION-V
FOR
FLUE GAS DESULFURISATION SYSTEM
Volume – IIB
Development Consultants Pvt. Ltd. Section - V
Flue Gas Desulfurisation System
Page 70 of 348
EPC Bid Document
CONTENTS
1.00.00 GENERAL INFORMATION 1
2.00.00 SYSTEM DESCRIPTION 1
3.00.00 SCOPE OF WORK 2
4.00.00 TERMINAL POINTS AND EXCLUSIONS 6
5.00.00 DESIGN AND CONSTRUCTION REQUIREMENT 6
6.00.00 INSTRUMENTATION & CONTROL SYSTEM 15
7.00.00 DRAWING, DATA AND MANUALS 16
ATTACHMENT
ANNEXURE-I SPECIFIC DESIGN CRITERIA FOR FGD SYSTEM 18
Volume – IIB
Development Consultants Pvt. Ltd. Section - V
Page 71 of 348
EPC Bid Document
SECTION – V
FLUE GAS DESULFURISATION SYSTEM
1.00.00 GENERAL INFORMATION
1.01.00 This section presents design, constructional features, operation philosophy,

performance requirement, inspection & testing and detailed scope of work for
Flue Gas Desulphurization (FGD) system to be used for reduction of emission
of sulphur dioxide (SO2) in flue gas through stack to a specified limit.
1.02.00 The FGD plant shall be installed at downstream of Induced draft (ID) fan
discharge wherein necessary treatment in flue gas to be carried out before
the same is finally emitted through stack. The FGD system shall be based on
wet limestone forced oxidation process.
2.00.00 SYSTEM DESCRIPTION
Wet limestone based Flue gas desulphurization plant shall only comprise of
Flue gas & absorption system and FGD auxiliary system under the scope of
this specification. Lime stone handling & crushing, Limestone slurry
preparation system, Gypsum Dewatering System and FGD waste water
treatment systems are to be supplied by separate agency.
2.01.00 Flue gas & absorption system: This system shall consist of
i) Booster fans.
ii) Gas to Gas heater (GGH).
iii) Gates, dampers and interconnecting ducting for raw and treated flue
gas.
iv) Absorber and oxidation system.
Booster fans shall be provided to take care of total flue gas pressure loss
in FGD plant. These fans shall take suction from common ID fan
discharge duct and common discharge of these fans shall be connected
to absorber tower through GGH. The raw flue gas shall be scrubbed in
SO2 absorption tower with the aid of limestone slurry. In the absorber
tower, SO2 present in the raw flue gas comes in contact with the calcium
carbonate (CaCO3) in the limestone slurry producing calcium sulphite
(CaSO3), which shall be further oxidized in oxidization tank (integrated
with the absorber module} and ultimately results in the formation of
gypsum, which crystallizes out under sufficient resident time.
After treatment in absorber tower, the moist and treated flue gas will be
led to stack through GGH so as to ensure minimum stipulated
temperature at stack inlet under design operating condition as mentioned
elsewhere in specification.
Volume – IIB
Development Consultants Pvt. Ltd. Page 1 of 19 Section - V
Page 72 of 348
EPC Bid Document
The FGD Inlet & Outlet Gates and Bypass Dampers shall be provided at
appropriate places to direct the flue gas. A by-pass duct shall be provided
to direct 100% flue gas to stack so that the boiler is not forced to be
shut down due to FGD failure.
An emergency cooling system shall be installed upstream of the absorber

inlet in order to protect the absorber internals of too high temperatures in
case of a blackout or plant malfunctions causing a rise in flue gas
temperature.
2.02.00 FGD Auxiliary System: This system shall consist of
i) Process water system.

ii) Seal air system.
iii) Absorber area Drainage System (including Emergency slurry tank).
Process water tank and pumping system shall be provided to cater

process water demand for absorber make-up, mist eliminator washing
(intermittent),emergency quenching water and GGH washing
(intermittent).
The seal air shall be supplied by the Seal air Fan to the GGH system
and the dampers through the heater by seal air fan. Also it is supplied
as purge air for .GGH during FGD plant stoppage.
Drainage pit and pumping system complete with agitators shall be

provided for absorber area. Drain pit at absorber area shall transfer the
slurry to emergency slurry tank or to the absorber area..
For further details , please refer flow diagram of LSFO wet FGD system
(12A05-DWG-M-00IV).
3.00.00 SCOPE OF WORK
The scope of work as identified for FGD system hereunder are minimum
requirements and unless specifically excluded, any equipment/system not
included in this specification but integral to the system offered by the Bidder
to meet the intent of this specification, shall also be included in the scope of
the Bidder. The scope shall include but will not be limited to the following:
3.01.00 Flue Gas and Absorber System
The Flue gas and absorber system shall be complete with:
1) 2x60% booster fans at ID fan discharge.
2) 1x100% Gas Gas heater (GGH) along with soot blowing arrangement
suitable for handling the entire flue gas generated by Boiler at design
point (BMCR with worst coal).
Volume – IIB
Page 73 of 348
EPC Bid Document
3) Complete ducting system with Thermal insulation, cladding for FGD

plant from tap off for booster fans from ID Fan common discharge duct
upto FGD plant duct to common flue gas duct upto the upstream of
chimney inlet duct expansion joint.
4) Motorized guillotine damper at each booster fan inlet and outlet, at the
inlet to GGH and in the clean flue gas duct at GGH outlet. In the FGD
bypass duct, pneumatic Bi-plane dampers along with motorized guillotine
damper shall be provided.
5) Absorber complete with re-circulating slurry spray header(s) and

nozzles, minimum two (2) stage mist eliminators, wash water nozzles,
oxidation tank integral to tower, oxidation headers and nozzles,
agitators and all internal systems integral to the working of the
absorber.
6) 2x100% slurry recirculation pumps for each level of spray. Alternately,

the Bidder may offer a spare level of spray with each spray level
served by an independent 1x100% pump. In case the Bidder offers a
single level of spray, one number of standby pump of the same
capacity & head as the working slurry recirculation pumps shall be
provided.
7) 2x100% oxidation blowers / compressors with piping, valves and all

necessary instruments as required by the system.
8) 2x100% Gypsum Bleed Pumps.
9) Piping from gypsum bleed pumps to gypsum dewatering system, and

emergency slurry tank along with recirculation lines (if required)
necessary isolation and control valves.
10) An emergency slurry tank with agitator of 100% capacity of absorber

sump volume for emergency storage of absorber slurry of the unit.
11) 2x100% emergency slurry pumps with drive motor in emergency slurry
tank for pumping the slurry back to the absorber. All agitator(s), piping,
valves, fittings and other structures required for the system shall be
included in the scope of the Bidder.
12) 2x100% Mist eliminator wash water pumps and motors, Mist eliminator
washing headers, nozzles etc.
13) 1 no. Absorber drain pit.
14) 1x100% absorber drain pit pump for pumping the slurry back to the
absorber or to transfer the same to Emergency Slurry Tank. All
agitator(s), piping, valves, fittings and other structures required for the
system shall be included in the scope of the Bidder.
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15) All connecting piping and valves required by the system.
16) Duct and piping system complete with supports, structures, trestles as
required shall be in the Bidder’s scope of supply.
17) Absorber drain nozzle and air vent valve, hose connector for flushing
nozzle for absorber agitators.
18) Emergency quenching system with headers and nozzles.
19) Steel supporting structure for Duct.
20) Complete platform and access ways.
3.02.00 Process Water Storage & Pumping System
1) One no. (1) Water storage tank suitable to meet requirement of FGD
plant having capacity minimum one (1) hour of maximum requirement
for FGD plant. Process water will be drawn from the clarified water
storage tank (reservoir) having space for installation of VT pump for
FGD make up water supply. All necessary pumping system of
adequate capacity along with level control station required to bring the
process water to process water storage tank for FGD.
2) 2x100% Process Water Pumps to cater to process water requirement

of Absorber tower.
3) 2x100% Mist Eliminator Wash Water Pumps.
4) 2x100% emergency quenching Water Pumps.
3.03.00 Crane & Hoist
Scope of supply for cranes and hoists includes:
1. Two (2) overhead bridge cranes in the common building for

recirculation pumps and oxidation air compressors.
2. One (1) monorail trolley for mist eliminators
3. One (1) monorail trolley for absorber agitators
4. One (1) monorail trolley for GGH.
3.04.00 Misc. Items
1) One (1) number traction type passenger cum goods elevator of

minimum capacity of 1000 kgs. in absorber area of the unit for easy
access & movement of man/materials.
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2) Thermal Insulation along with aluminum cladding, lagging,

reinforcement wire mesh, cleats and supports, shall be provided for all
the equipments/surfaces having skin temperature more than 60 degree
Celsius. The insulation thickness shall be designed based on criteria
specified in elsewhere in the specification.
3) Corrosion protection painting for structures as per main specification.
4) Platforms, walkways, staircase, safety rails for access of each

equipment, valves, dampers, gates, instruments etc. handling.
5) Trestle near absorber area for routing of air & water lines, slurry lines,
steam line, waste water, etc. required for the complete process
operations.
6) Air conditioning for the FGD control room and Analyzer room and
ventilation system for common building for recirculation pumps and
oxidation air compressors.
7) Fire protection and detection system for the FGD area around
absorber/GGH area.
3.05.00 Electrical
For details on Electrical system/equipment refer Vol II-F1 & F2 of this tender
specification.
3.06.00 Control and Instrumentation System
FGD system automation shall be realized in Unit DCS which shall meet the
requirements of monitoring, sequential starting/stopping of drives, interlock
and protection and all other routine functions with minimum operator’s
intervention. One Remote I/O unit of Unit DCS shall be located in the FGD
control room for signal interfaces.
For other details on C&I requirement V.IIE/ S-V of the specification shall be
referred.
3.07.00 Civil and Structural
Complete civil and structural works for FGD plant including building for
housing the equipment, foundation for equipment, structures and supports.
The scope of work shall include the following within FGD area:
A. Civil, Structural and architectural works for following Buildings:
(i) FGD Control Room (RCC framed)-1 No

(ii) RC pump+Oxidation Blower house(Steel framed)--1 No
(iii) SO2 Analyser room (RCC framed)--1 No
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B. Civil works for all equipment foundations for FGD plant under the
scope of this specification.
For detail scope, design criteria, requirements and specifications of Civil,

Structural & Architectural works, General and Technical Specifications
VOLUME: II-G/1, VOLUME: II-G/2 and VOLUME: II-G/3 shall be referred.
4.00.00 TERMINAL POINTS AND EXCLUSIONS
4.01.00 TERMINAL POINTS
The following facilities shall be terminated with valves at 10m away from
Absorber Tower.
i) Lime slurry piping to Absorber tower make up.
ii) Gypsum Bleed pump discharge to Gypsum Dewatering area.
iii) Filtrate water pump discharge to Absorber tower.
4.02.00 EXCLUSIONS
The following facilities are excluded from Bidder’s scope of supply.
i) Lime stone handling and crushing system.
ii) Wet grinding of Limestone and Lime slurry preparation system.
iii) Lime slurry storage and pumping system. Pump discharge piping to be
terminated as per 4.01.00.
iv) Gypsum dewatering and waste water treatment system. Only Gypsum
bleed pump discharge and Filtrate water pump discharge to be terminated
as per 4.01.00.
v) Process water make up connection for Lime stone slurry preparation area
and Gypsum dewatering system.
5.00.00 DESIGN AND CONSTRUCTION REQUIREMENT
5.01.00 GENERAL
The design/specifications/sizing of various plants/systems/equipment offered

for Flue Gas Desulphurization (FGD) System shall comply with the
requirements detailed hereinafter and Annexure – I of this section. Specified
hereafter are the minimum acceptable functional requirements, and all
components, equipments and systems for the Flue Gas Desulfurisation
System shall be designed to cater to these requirements. Compliance to
various stipulations of the Technical Specifications, functional requirements of
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Employer and utilization of various parameters and their values in the

specification shall in no way relieve the Bidder of his responsibilities to meet
all guarantee requirements or of providing completely safe and reliable
operating equipment/systems.
5.01.01 Basic Design Criteria
5.01.01.01 The Flue Gas Desulphurization (FGD) System shall be designed to comply
with the design and guarantee point conditions mentioned below and should
achieve Sulphur Dioxide (SO2) level of not exceeding 100 mg/Nm3 at 6%
excess oxygen level at the stack outlet under all plant operating conditions.
The SO2 removal efficiency shall not be less than 95 % under all operating
condition. These shall be modified to more conservative values if Bidder’s
experience warrants the same. However, no credit shall be given to the
Bidder for this during evaluation of the bids. Utilization of these values in no
way relieves the Bidder of his responsibility to meet all the guarantee
requirements. The Bidder shall also furnish along with his offer the detailed
calculations and data along with his Bid to establish as to how the efficiency
requirements both at design and guarantee point will be met as specified in
FGD sizing criteria.
a. Design Point : BMCR load with worst coal, 45°C and 60% RH
ambient condition
b. Guarantee Point : TMCR load with worst coal, 27°C and 60% RH
ambient condition
5.01.01.02 The FGD system shall also be capable of operating with partial bypass of flue
gas. Bidder shall submit with the offer a write-up highlighting the capability of
operation of FGD system with partial bypass of flue gas and the range for
operating in partial bypass mode.
5.01.01.03 For system design purpose, analysis of limestone as per Volume-IIA, Sec-XII
may be referred.
5.01.02 Justification of Proposed Design
All the design procedures, systems, and components proposed shall have
already been adequately developed and have demonstrated good reliability
under similar or more arduous conditions elsewhere.
The Bidder shall submit with the offer, comprehensive information how the L/G
ratio, mass balance, spray nozzle cone angle, spray nozzle arrangement,
limestone consumption etc. of the proposed design has been arrived at. The
Bidder shall also submit along with the offer, a detailed write up on the
proposed design features with recent design modifications, if any, and their
specific advantages over the previous designs.
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5.02.00 FLUE GAS SYSTEM
5.02.01 Entire flue gas system including Booster fans,GGH, flue gas ducts, absorber
etc. shall be designed to meet the design internal pressure, maximum inlet gas
temperature including short term excursion temperature of gas and inlet dust
burden in gas coming from ESP. The design shall also meet the following:
a) Pressure drop in flue gas path Total pressure drop in FGD system
shall not exceed 350 mmWC under
all operating conditions..
b) Pressure required at Chimney + 10 mm WC.
inlet with FGD Bypass damper
closed
c) Minimum Stack inlet temperature 100°C (uncorrected, without
with GGH in operation against considering any leakage in GGH)
Guarantee Point (TMCR load
with worst coal under 27°C &
60% R.H ambient condition)
5.02.02 2 nos. axial reaction type constant speed Booster fans with blade pitch control
mechanism shall be provided for normal operation at BMCR at rated steam
parameters with worst coal firing. However, all start ups and a stable
operation at 60% BMCR at rated steam temperatures should be achievable
with one fan in operation.
5.02.03 Each Booster Fan shall be provided with forced oil bearing lubrication and
hydraulic blade pitch control unit(s) consisting of 2x100% oil pumps each
with motor, coupling and coupling guard, 2x100% oil coolers, 2x100% filters
with differential pressure transmitters, One (1) oil storage tank ,necessary
instrumentation, vibration monitoring, inter connected piping, valves and
Electrical actuator with accessories etc.
5.02.04 The flue gas ducts shall be sized and designed to meet all the criteria as
specified in Volume-II-B, Section-I. The duct layout shall ensure that there is
no accumulation of acid mist on the duct floor. The absorber outlet duct shall
not have any horizontal section for this purpose.
5.02.05 The duct from GGH outlet to Absorber inlet as well as the duct from Absorber
outlet to GGH inlet shall be of either carbon steel with Glass Flake lining or
better material.
5.02.06 A damper in the bypass duct shall be provided for quick opening to allow
bypass to come into operation in case of emergency.. Power cylinder
operated biplane damper shall be provided with seal air arrangement.
5.02.07 All gates and biplane dampers shall be designed to withstand the operating
flue gas temperature without distortion. All the gates shall be designed for
tight shut off. The Guillotine gate type dampers mentioned above shall have
guaranteed gas tightness efficiency (on flow) of not less than 99.95%.
5.02.08 The GGH shall be Rotary Regenerative (Ljungstrom type or equivalent) with
rotating matrix with vertical axis of rotation. The design of the GGH shall
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ensure that leakage through the seals does not exceed 1.5% of the hot gas
inlet flow from 50% of Guarantee Point flow to 100% of Design point flow. The
above leakage shall be guaranteed by the Bidder and demonstrated after
3000 hrs of operation. No shut down or internal adjustment of the seals shall
be permitted during the above period.
To reduce fly ash and gas leakage of GGH from raw gas side to treated gas
side, scavenging fans may be provided, if the bidder has previous experience
of the same. In such case, 2x100% scavenging air fans with motorized
isolation gates at the discharge of each fan shall be provided.
5.02.09 Rotary regenerative type GGH, shall be driven by a peripheral A.C. motor
through a reduction gear box. An emergency air motor, with automatic
clutching/de-clutching arrangement shall also be provided. The GGH shall
have sump lubricated, oil cooled bearings. 2x100% oil circulation pump shall
be provided for each bearing. The heating elements shall be arranged in
easily removable groups of baskets. GGH design should be capable of
handling inlet dust burden between 50 to 200 mg/Nm3 at 6% O2 level. The
following shall be provided as minimum requirement:
i) Rotor stand-still device with alarm.

ii) Thermocouples/ RTD for each bearing.
iii) Adequate instrumentation in the lube oil system for detection of any
malfunctioning.
5.02.10 The GGH components shall be made of corrosion resistant materials to

withstand the aggressive atmosphere encountered in FGD application. The
shaft shall be made of corten steel or better material. The heating elements
shall be made of enameled steel or better material. The housing, seal plates
and other components in the gas path shall be carbon steel lined with glass
flaked resin lining, as per the proven practice of the Bidder for similar
application.
5.02.11 The Bidder shall provide suitable arrangement for on load cleaning system for
cleaning the heat transfer elements. The cleaning system shall use high
pressure water washing. The cleaning system shall also contain low pressure
water washing to be used when GGH is not in operation. Apart from that, soot
blowing system shall be provided to dislodge the fly ash from heating
surfaces.
5.03.00 ABSORBER
5.03.01 The Bidder may offer either a spray type absorber, with single or multiple
levels of spray, or an absorber with gas bubbling through the slurry, as per his
proven practice. Only proven system in successful operation in previous
installations supplied by the bidder shall be offered.
A. Spray System (if offered)
(i) The bidder shall provide spray system and minimum spray levels
required to meet the stipulated guarantee and design requirement.
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The spray system (including slurry recirculation pump & nozzles)

shall be sized to achieve a desired L/G ratio required to meet the
guarantees SO2 removal efficiency, with redundancies specified
under this clause.
(ii) In case the bidder offers an absorber with multiple levels of spray
nozzles, each spray level shall be provided with independent
2x100% pumps. Alternatively, the Bidder may offer a spare spray
level with each spray level served by an independent 100% capacity
pump. In case the Bidder offers a single level of spray, one number
of standby pump of the same capacity & head as the working slurry
recirculation pumps shall be provided. The Bidder shall provide
spray system / spray levels only as per his proven practice, which
should be in successful operation elsewhere.
(iii) The slurry recirculation pumps shall have a minimum margin of 10%
of flow and head, over the actual requirement for meeting the
guarantee and design point conditions.
(iv) The slurry pumps shall comply with the requirements stipulated in
this specification.
(v) Sufficient redundancy, as per the proven practice of the Bidder, shall
be provided in the spray nozzles. Minimum 10% spare nozzles shall
be provided at each level.
B. Bubbling Type Absorber (if offered)
(i) In case the Bidder offers a bubbling type absorber, the gas
distribution system shall be sized with sufficient margin against
choking of nozzles/holes.
5.03.02 Provision shall be made for automatic spray of quenching water at the inlet to
the absorber, in case the gas temperature exceeds the design temperature
due to failure of upstream equipments.
5.03.03 The absorber shall be designed to withstand the maximum pressure

developed by the booster fans. Maximum flue gas velocity through the
absorber (m/sec) shall not be more than 4 m/s at Design Point Conditions.
5.03.04 Two stage chevron vane type mist eliminators made of FRP or polypropylene
shall be provided at the exit of the absorber. Provision shall be made for
continuous washing of both ends of the first stage and the front section of the
second stage of mist eliminators. Wash water arrangement shall also be
provided at the back end of the second stage of mist eliminator. If the mist
eliminator washing system is designed for cyclic washing of different sections,
all the valves required for cycling shall be motorized or pneumatically
operated.
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The spray headers and air supply headers shall be made of FRP or rubber
lined Carbon Steel, corrosions and erosion resistant in the inner and outer
side. The spray nozzles shall be of silicon carbide or ceramic or equivalent
having a minimum guaranteed life of 25,000 hours. The spray piping, mist
eliminators and its supporting structure shall be designed to carry sufficient
load during maintenance.
5.03.05 Sufficient number of agitators, as per the proven practice of the bidder, shall
be provided in absorber recirculation tank for thorough mixing of the re-
circulating slurry. Recirculation Slurry pH shall not be less than 5.5 under all
operating conditions. The absorber oxidation tank shall be provided with an
over flow line complete with sealing pot, over flow and drain line. The absorber
over flow shall be taken to a sump in the absorber region, from where the
slurry shall be pumped back to the absorber by a sump pump.
5.03.06 The absorber and oxidation tank shall be made of minimum 7 mm thick carbon
steel. The absorber tower and oxidation tank shall be provided with 2 mm
(minimum) thickness lining / cladding / wall paper of SS 317 LMN / Alloy 31 or
other proven material such as rubber lining (5mm thick minimum)/glass flake
lining as per Bidder's practice. In case of rubber lining, Bidder to ensure
required temperature resistance at absorber inlet by means of special lining as
per bidder’s proven practice. The Absorber wet-dry interface shall be made of
Carbon steel material lined with alloy C 276 / alloy 59 or better material.
The material shall be so selected that the minimum guaranteed life of 25000
hours shall be achieved. Sufficient protection shall be provided for the base of
the tank to prevent mechanical damage, particularly during maintenance. The
material of process equipments of flue gas desulphurization system shall
be appropriate for the chloride content and pH level at which the process
is to operate.
5.03.07 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. All internal members shall be made of Stainless Steel
317LMN.
5.03.08 It should be possible to build platforms inside the absorber for access to all
parts of the absorber during maintenance. In case the Bidder offers a multiple
spray level design, minimum distance of 1.5 m shall be maintained between
individual spray levels. Arrangement shall be properly designed to facilitate
access for maintenance and replacement of spray nozzles.
5.03.09 Absorber Oxidation Systems
The Bidder may offer either a grid type oxidation system or a spare jet
oxidation system or lance type or air rotary spurge system for oxidation of
sulfite sludge to sulfates, as per his proven practice.
The oxygen required for oxidation shall be supplied by 2x100% oxidation air
compressors/blowers for each absorber. The compressor/blower shall be
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sized to supply at least 2.5 times the stoichiometric air requirement or the
actual requirement, whichever is higher, under the following condition, all
occurring simultaneously. The natural oxidation of sulfite by residual oxygen
in flue gas shall not be considered for this purpose. Minimum 10% margin
shall be considered for selection of design head for oxidation air
compressors/blowers.
Oxidation nozzles / spargers shall have a minimum redundancy of 10% or as

per the Bidder’s proven practice whichever is maximum.
The oxidation system shall be complete with a quenching system to cool down
heated oxidation air in order to prevent any scaling buildup that could occur at
the sparger tips due to localized evaporation of recycled slurry.
5.03.10 Gypsum Bleed Pump
Each absorber shall be provided with 2x100% Gypsum Bleed Pumps for
supply of gypsum slurry to Gypsum Dewatering system. Each Gypsum bleed
pump shall be sized to bleed-off the gypsum slurry from the absorber with
slurry solid concentration not exceeding 30% against design point. Design
margin against flow and head shall be minimum 10% and 15% respectively.
5.04.00 EMERGENCY SLURRY TANK
An emergency slurry tank, sized to contain the complete slurry of one absorber
tank at its maximum level shall be provided.
The Bidder shall provide 2x100% horizontal Slurry pumps to back the slurry
from the sump to the absorber in a maximum time of 12 hours.
Sufficient number of agitators shall be provided in the tank by the Bidder to

prevent the solids from settling down. There shall be at least one redundant
agitator for this purpose.
Emergency slurry tank shall be designed, fabricated, erected and tested in

accordance with the IS:803, latest edition. Additional Corrosion allowance of
3mm on the minimum tank shell thickness as calculated by IS:803, latest
edition shall be provided by the Bidder. Tank shall be made from IS:2062
quality mild steel plates of tested quality. The tank shall be of welded
construction. Interior surface of the tank shall be lined with replaceable rubber
lining and the outside surface shall be coated with paint as approved by the
Employer. The Tank shall be provided with drain, manholes, over flow & inlet
level control valves etc
5.05.00 SLURRY PUMPS
This specification covers the design, manufacture and erection of all slurry
pumps for the FGD system including the Absorber slurry recirculation pumps,
Gypsum bleed pumps and Emergency slurry transfer pumps.
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The Bidder shall offer only proven design in successful operation in similar
application at previous installations. The design, manufacture, installation and
testing of the pumps shall follow the latest applicable Indian / International
(ASME / EN / Japanese) Standards.
The pumps shall be designed for continuous operation. The pump shall be
single stage centrifugal type capable of delivering the rated flow at rated head
with margins as specified in the respective clauses. The slurry concentration in
the pump shall not exceed 30% by weight.
All the slurry pumps shall be provided with motorized suction and discharge
valves. In addition, flushing water lines with motorized valves shall be provided
for each pump for automatic flushing of the pump after each shut down. The
flushing water for the pumps shall be taken from the process water supply
tank.
The pump casing should be axially split to allow easy removal of impeller.
All the pump wear parts in contact with the slurry shall be provided with
replaceable rubber/elastomer liners suitable for the fluid handled. The Bidder
can also offer a hi-chrome alloy line pump if he has previous experience of the
same for similar applications. The material used by the Bidder shall be proven
in previous installations.
For absorber recirculation service a Silicon carbide impeller and SiC lining for
casing can also be accepted if the manufacturer has supplied a similar pump
for a previous installation for similar service.
The material and thickness of the liners shall ensure a minimum service life of
2 years before replacement. All the wear parts of the pump shall be
guaranteed for a minimum wear life of not less than 14000 hrs.
The design of the shaft shall ensure that the operating speed is at least 20%
above the critical speed of the shaft.
The pump shall be provided with seals of proven type and shall be designed
for minimization of seal water consumption. The shaft shall be supported on
heavy duty ball/roller bearings.
5.06.00 VERTICAL SUMP PUMP
Bidder shall provide sumps of adequate capacity in the absorber area for
containing the over flow from the respective system. Bidder shall make
arrangements for pumping the drainage water back to the respective system
with vertical sump pumps. Agitators shall also be provided to avoid settling of
solids in the sump. Adequate redundancy in line with the standard practice
adopted by the bidder shall be provided. This specification covers the design,
manufacture and erection of all vertical sump pumps for the FGD system.
The pumps shall be designed for continuous operation. The pump shall be
single stage centrifugal type with semi open or open impeller. The pump
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impeller shall be cantilever type and shall not be supported below the base
plate for easy withdrawal.
The pump shall deliver the rated flow at rated head with margins as specified
in the respective clauses. The pump shall be capable of pumping of filtrate
water with solid concentration upto 10% & particle lumps of 6-7mm. Sump
pumps handling slurry shall be designed with a maximum concentration of
30% solid by weight. The material chosen for the pump components shall be
suitable for the fluid handled and shall be proven in similar application.
5.07.00 AGITATORS
Emergency slurry tank and absorber area drain sumps shall be provided with
adequate number of mechanical agitators specified in the respective clauses.
The design of the agitators shall be of proven type.
The shaft and blades of the agitators shall be of stainless steel or Nickel alloy
suitable to the service condition. Alternatively, the blades can also be provided
with rubber lining with a minimum life of 2 years.
5.08.00 SLURRY LINES AND VALVES
Slurry pipes shall be designed to keep the velocity above the settling velocity
under all operating conditions. The Bidder may provide a recirculation line with
motorized isolation valve for the above purpose.
All the pipes handling slurry shall be provided with replaceable rubber lining of
proven quality. The Bidder can provide slurry pipes of size lower than 3” made
up of FRP material if it has previous experience of providing the same.
The isolation valves provided in all the slurry lines shall be of knife gate
type/butterfly type. Motorized actuators shall be provided for valves requiring
frequent operation as indicated in the relevant scheme.
The valves shall be of proven type and the Bidder shall submit a detailed valve
schedule for employer’s approval. Reference list for previous installations for
similar application shall also be furnished to the employer.
The isolation valves shall be of knife gate type with rubber seats designed to
prevent accumulation of solids on the valve seat.
Bidder shall provide all necessary arrangements for purging & flushing of all
the process pipelines, equipments etc.
5.09.00 PROCESS WATER STORAGE TANKS & PUMPS
The Bidder shall provide process water storage tank designed to store one (1)
hour of total water required for the entire FGD process (including absorber
system and mist eliminator washing system, limestone grinding and slurry
preparation system and gypsum dewatering system, etc.). All the process
water storage tanks shall be designed, fabricated, erected and tested in
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accordance with the IS:803, latest edition. Additional Corrosion allowance of

1.50 mm on the minimum tank shell thickness as calculated by IS:803, latest
edition shall be provided by the bidder. Tanks shall be made from IS:2062
quality mild steel plates of tested quality. The Tanks shall be provided with
drain, manholes, over flow & inlet level control valves etc.
The type of pumps shall be horizontal centrifugal type designed for continuous
operation with semi open or closed impeller. Casing, Gland and Stuffing Box
shall be of 2.5 Ni Cast Iron to IS:210 Grade FG 260 or equivalent. Impeller,
Wearing rings (as applicable) shall be of Stainless Steel -316 grade and Shaft
& Shaft sleeves shall be of SS-410 grade. Pump re-circulation line shall be
provided for pumping system. Pumps shall be provided with accessories such
as Y-type suction strainers, Coupling guard, drain plugs, vent valves etc.
6.00.00 INSTRUMENTATION AND CONTROL SYSTEM
Necessary and suitable instrumentation as required to achieve the operation

philosophy as indicated in this specification and as illustrated in the flow
diagram shall be provided as minimum requirement. The measurement shall
include SO2 at FGD inlet and Outlet, Oxygen Analyser, Flue Gas
Temperature, Flue Gas pressure, Density meters, pH Analyser, Conductivity
Analyser, Electro-Magnetic Flow meter, Radar type level measurements,
Pressure Transmitters, Differential pressure transmitters, RTD, Temperature
elements, Temperature Transmitter, Pressure Switch, Pressure Gauge,
Temperature Gauge, Level Switch ,Vibration Monitoring system etc.
Slurry parameters include slurry pH, Slurry flow rate, pressure, suspended
solid levels in slurry tanks, slurry density, On line SOx analyzer at FGD inlet
and outlet reads the SOx emissions concentration in the flue gas and sends
the value to the control system. In the DCS, where the control logic is stored,
reads the value, compares it with the desired set point (fixed by the operator)
and provides necessary signals to dose the right amount of chemical reactant
from the storage silo.
Local Control Panels (LCP) shall be provided as applicable.
FGD process control shall include control of inputs for the solid concentration
and water balance in the Absorber and Monitoring of key parameters. Process
trends, reports, historical data logging shall be achieved in the unit DCS.
Critical FGD Operation & Control with Boiler and Main Power plants shall be
envisaged.
As a minimum overall controls and monitoring shall include the following:
1) Sox removal efficiency monitoring.

2) Monitoring and control of FGD functioning.
3) Make up water inflow controls.
4) Density control /Gypsum solid concentration level control by regulating
Dewatering line flow.
5) Water spray control (Quench control)
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6) Booster fan control.

7) Leakage monitoring of GGH.
8) Pressure loss monitoring.
9) Oxidation Tank Level Control.
10) Absorber tank and Emergency tank level controls.
11) Vibration monitoring system.
In order to be compatible to all possible modes of operation, the design of the

FGD plant shall enable short start-up times, an uncritical and favorable
characteristic during load modifications and a reliable mode of continuous
operation. The flue gas desulphurization plant (FGD) shall be designed to be
operated with limestone with a purity of 90%-w/w of CaCO3. In particular the
following operation characteristics shall be possible: The FGD and the
ancillary facilities shall be suitable for an unlimited operation with all transients
and at any load point between the minimum and maximum load point of the
SG. Furthermore the FGD plant shall be suitable for an unlimited operation at
any pollutant concentrations between minimum and maximum without
exceeding the required and guaranteed emission values.
In case of a power failure all items of equipment which possibly suffer

irreversible damage (e.g. rubber lining, spray level lances, mist eliminator)
shall be connected to the emergency power supply system (e.g. agitators in
absorber and limestone slurry tanks, flue gas damper upstream of FGD) that
no irreversible damage can occur. In case of significant power consumption of
the equipment an emergency drive should be provided.
In case of failure of the SG and ancillary equipment, the FGD plant shall be
brought automatically to the off-load operation without restriction by the current
load case by suitable measures. In case of shutdown and outage periods of
the plant (except for power failure), draining and flushing of limestone slurry
and gypsum slurry pipe work, lime slurry preparation and supply pipes, bins
and all other items being in contact with limestone slurry or gypsum slurry shall
be possible without restriction and without necessity of extensive or unusual
preparation and activity. Draining and flushing which are required even during
short time outages or an emergency shutdown shall be started automatically
and by remote control from the Control Room.
Sufficient tapping points for sampling and measurements shall be provided at

adequate points in sufficient number in order to be able to carry out all
necessary measurements. Gas sampling and temperature monitoring facility
shall be provided for all main items of equipment.
7.00.00 DRAWINGS, DATA AND MANUALS
7.01.00 Technical information and data to be submitted by the Bidder with the Proposal
shall include the following:
i) P&ID diagram .
ii) Mass balance diagram for flue gas and water & slurry system.
iii) Process and guaranteed parameters.
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iv) Filled in Bidder’s data sheet.

v) Load list of FGD plant.
vi) System write up of offered FGD plant with brief description of equipment.
vii) Brief Control philosophy.
viii) General arrangement drawing of FGD plant.
ix) Electrical Single line diagram.
x) Reference list to establish the provenness of the system and equipment
offered.
7.02.00 Technical Information and Data to be submitted by the Bidder with the Proposal
shall include the following:
i) P&ID diagram.
ii) Mass balance diagram for flue gas and water & slurry system.
iii) Sizing calculation of all major equipment.
iii) Data sheet of all Mechanical Equipment along with GAD & cross sectional
drawing.
iv) Characteristic Curves of all pumps, compressors.
viii) General arrangement drawing of FGD plant.
ix) Electrical Single line diagram.
iii) Data sheet of all Electrical l Equipment along with GAD.
x) Instrument Datasheet and related drawings.
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Annexure-I
SPECIFIC DESIGN CRITERIA FOR FGD SYSTEM
1.0 Flue Gas Desulfurization System
a) Type Wet Lime Stone Based
b) Location In between ID fan and Stack
c) Reagent Lime Stone
d) Crushed Lime Stone analysis Refer Volume – II-A
e) Design Point 100% BMCR, worst Coal. To be reconfirmed by bidder

considering equipment being
f) Critical Parameters Maximum SO2 at stack outlet shall not exceed 100 mg/nm3 offered.
(at 6% O2 level) during the entire operating range of steam
generator for the range of coal specified or latest MOEF &
CC guideline whichever is more stringent.
g) Emergency Limestone Slurry Vertical steel tank internally lined with glass flakes. Shall
Storage Tank be sized to contain the complete slurry of one absorber
tank at its maximum level.
h) Absorber Spray type / Bubbling type
i) Maximum flue gas velocity through Not more than 4 m/s at Design Point Conditions.
the Absorber (M/sec)
i) Recirculation Slurry pH Not less than 5.5 under all operating conditions.
j) Material of absorber Absorber wet-dry interface shall be made of STEN-1 or
Volume – IIB
Development Consultants Pvt. Ltd. Page 18 of 19 Section – V
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Annexure-I
SPECIFIC DESIGN CRITERIA FOR FGD SYSTEM
better material and lined with 4 mm thick Alloy C276 / Alloy

59 or better material.
Outlet duct shall be made of SS 317 LMN/Alloy 31 or

better material. Alternatively, the absorber outlet duct shall
be made of 7 mm thickness carbon steel provided with a
flaked glass lining,
The spray headers and air supply headers shall be made

of FRP. The spray nozzles shall be of silicon carbide or
ceramic or equivalent having a minimum guaranteed life of
25,000 hours.
All internal members -Stainless Steel 317LMN.
k) Booster fan 2X60% booster fan to be provided at downstream of ID fan

discharge to take care of FGD system resistance.
l) Pressure drop Total pressure drop in FGD system shall not exceed 350
mmWC under all operating conditions..
Volume – IIB
Development Consultants Pvt. Ltd. Page 19 of 19 Section – V
Page 90 of 348
REV. 00
AGITATORS
Date: FEB. 2022
SECTION-I,
Sub Section-C2 – B
CUSTOMER SPECIFICATION: GENERAL TECHNICAL

REQUIREMENT INCLUDING QUALITY ASSURANCE
REQUIREMENT
REQUIREMENT
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SECTION-V
GENERAL TECHNICAL REQUIREMENTS
Volume : II-A
Development Consultants Pvt. Ltd. Section : V
General Technical Requirements
Page 92 of 348
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CONTENTS
1.00.00 CODES AND STANDARDS 1

2.00.00 RESPONSIBILITY FOR DESIGN 1
3.00.00 NAME PLATES (RATING PLATES) 2
4.00.00 SAFETY AND SECURITY 2
5.00.00 GUARDS 3
6.00.00 LOCATION AND LAYOUT REQUIREMENTS 3
7.00.00 OPERATION AND MAINTENANCE 5
8.00.00 MATERIALS 5
9.00.00 LUBRICATION 6
10.00.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS 6
11.00.00 PLANT LIFE AND MODE OF OPERATION 7
12.00.00 PACKAGING & MARKING 7
13.00.00 PROTECTION 7
14.00.00 PAINTING 8
15.00.00 COLOUR CO-ORDINATION AND FINISH 12
16.00.00 ENVIRONMENT PROTECTION AND NOISE 13
LEVEL REQUIREMENT
17.00.00 INSPECTION AND TESTING 14
18.00.00 TRAINING OF OWNER’S PERSONNEL 16
ATTACHMENTS
ANNEXURE-I LIST OF STANDARDS FOR REFERENCE 19

ANNEXURE-II CRITERIA FOR LAYOUT 21
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SECTION-V
1.00.00 CODES AND STANDARDS
1.01.00 Except where otherwise specified, the Plant shall comply with the appropriate
Indian Standard or an agreed internationally accepted Standard Specification
as listed in the annexure to this Section and mentioned in detailed
specifications, each incorporating the latest revisions at the time of tendering.
Where no internationally accepted standard is applicable, the Bidder shall give
all particulars and details as necessary; to enable the Owner to identify all of
the Plant in the same detail as would be possible had there been a Standard
Specification.
1.02.00 Where the Bidder proposes alternative codes or standards he shall include in
his tender one copy (in English) of each Standard Specification to which
materials offered shall comply. In such case, the adopted alternative standard
shall be equivalent or superior to the standards mentioned in the specification.
1.03.00 Wherever specified or required the Plant shall conform to various statutory
regulations such as Indian Boiler Regulations, Indian Electricity Rules, Indian
Explosives Act, Factories Act etc. Wherever required, approval for the plant
supplied under the specification from statutory authorities shall be the
responsibility of the Successful Bidder.
1.04.00 In the event of any conflict between the codes and standards referred above,
and the requirements of this specification, the requirements, which are more
stringent, shall govern.
1.05.00 In case of any change of code, standards and regulations between the date of
purchase order and the date the Successful Bidder proceeds with
manufacturing the Owner shall have the option to incorporate the changed
requirements. It shall be the responsibility of the Successful Bidder to advise
Owner of the resulting effect.
2.00.00 RESPONSIBILITY FOR DESIGN
2.01.00 The Bidder shall assume full responsibility for the design of the whole and
every portion of the Plant, whether or not the design work was undertaken
specifically in relation to the Contract and whether or not the Successful Bidder
was directly involved in the design work.
2.02.00 Notwithstanding the Owner's wish to receive the benefits of new, advanced and
improved technologies, a prime requirement is that all the systems and
components proposed shall have been already adequately developed and shall
have demonstrated good reliability under similar, or more arduous conditions
elsewhere, at least for continuous 2 years in two different power station.
2.03.00 The Bidder shall carry out optimization studies for selection of pipe size and
equipment wherever required. The result of such studies shall be included as
part of bid proposal.
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The successful Bidder shall have to carry out surge analysis and other transient
condition studies as may be necessary and as required by the Owner as per
proven engineering practice.
2.04.00 The Bid shall include a detailed discussion on the development status of and
the reasons for any changes made in proposed systems or components for the
Plant, as compared with similar items previously supplied in other installations
cited by the bidder as reference plants.
2.05.00 The Bidder may also make alternate offers, provided such offers are superior in
his opinion in which case adequate technical information, operating feedback,
etc. are to be enclosed with the offer, to enable the Owner to assess the
superiority and reliability of the alternatives offered. In case of each alternative
offer, its implications on the performance, guaranteed efficiency, auxiliary
power consumptions, etc. shall be clearly brought out to the Owner to make an
overall assessment. In any case, the base offer shall necessarily be in line with
the specifications i.e. Base offer shall be as per the technical specifications and
the same will be considered for techno-commercial evaluation.
3.00.00 NAME PLATES (RATING PLATES)
3.01.00 Instruction plates, nameplates or labels shall be permanently attached to each

main and auxiliary item of plant in a conspicuous position. These plates shall
be engraved with the identifying name, type and manufacturers serial number,
together with the loading conditions under which the item of plant has been
designed to operate.
3.02.00 Items such as valves, etc. which are subject to hand operation, shall be
provided with nameplates so constructed as to remain clearly legible
throughout the life of the plant giving due consideration to the difficult climatic
conditions to be encountered. Nameplates shall be securely mounted where
they will not be obscured in service by insulation, cladding, actuators or other
equipment. Direction of flow is also to be engraved.
3.03.00 All trade nameplates and labels shall be in English language. All
measurements shall be in M.K.S. Units.
3.04.00 The size and location of nameplates shall be subject to Approval of the
Owner/Owner’s Engineer.
4.00.00 SAFETY AND SECURITY
4.01.00 The design shall incorporate every reasonable precaution and provision for the
safety of all personnel and for the safety and security of all persons and
property. The design shall comply with all appropriate statutory regulations
relating to safety. All structures and equipment shall be designed and
constructed to withstand every foreseeable static and dynamic loading
condition, including loading under earthquake conditions, with an adequate
margin of safety.
4.02.00 Ready and safe access with clear headroom shall be provided to all parts of the
plant for operation, inspection, cleaning and maintenance.
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4.03.00 Escape routes and clear ways shall be provided to allow speedy evacuation of
the plant in the event of fire or explosion, and the plant layout shall allow for
ease of access to all parts of the Works by rescue and fire fighting teams. The
Plant layout shall be designed to localize and minimise the effects of any fire or
explosion. The recommendations of NFPA, OSHA, and TAC etc. as necessary
shall be followed in all respects.
4.04.00 The use of corrosive, explosive, toxic or otherwise hazardous materials shall be
kept to a minimum during construction and the design of the plant shall
minimise the requirement for such materials during operation and maintenance.
Where such materials must be used, all necessary precautions shall be taken
in the design, manufacture and layout of equipment to minimise the resulting
hazard, and all equipment necessary for the protection and first-aid treatment
of personnel in the event of accidents shall be provided. Particular attention
is drawn to avoid the use of materials containing asbestos in any form.
5.00.00 GUARDS
5.01.00 Effective guards and fences must be provided to prevent injury to operators
through accident or malpractice.
5.02.00 Mesh guards which allow visual inspection of equipment with the guard in place
are generally preferable. The guards shall be constructed of mesh attached to
a rigid framework of mild steel rod, tube, or angle and the whole galvanised to
prevent loss of strength by rusting or corrosion. The guards shall be designed
to facilitate removal and replacement during maintenance.
5.03.00 All drive belts, couplings, gears, sharp metallic edges and chains must be
safely guarded. Any lubricating nipple requiring attention during normal running
must be positioned where they can be reached without moving the guards.
5.04.00 Guards for couplings and rotating shafts shall be in accordance with BS
5304-1975 or similar approved standard. All rotating shafts and parts of shafts
must be covered.
5.05.00 Suitable fencing shall be provided to enclose all openings or doorways used for
the hoisting and lowering of machinery etc. This fencing must be securely fixed
but quickly detachable when required. A secure handhold must be provided
on each side of the opening or doorway.
6.00.00 LOCATION AND LAYOUT REQUIREMENTS
The majority of plant and equipment shall all be of indoor installation. A broad
list of buildings housing such equipment is given In Vol-II-G2 Section I. Layout
shall facilitate access for operation-maintenance and inspection of any one or
more equipment/components at a time without disturbing the operation or
installation of rest of the plant. Further, Bidder should comply with the criteria
given under the various equipment and system specifications as well as those
stipulated in Annexure-II attached to this section.
Enclosed General Layout and other tender layout drawings enclosed in Vol-II-L
show the location of major installations and auxiliary buildings. The Bidder
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shall try to retain these locations as far as practicable. The layout of equipment
within the power house as shown in the tender drawings is indicative. The
Bidder may, subject to Owner's acceptance alter the same to suit the space
requirement of the equipment offered.
While developing the layout of buildings the following criteria shall be given
effect:
a) The minimum width of clear access corridors around equipment shall be

1.2 meters.
b) Each building shall have an identified vacant space for equipment

unloading and maintenance and preferably a separate bay altogether in
buildings housing heavy equipment. Provision for handling equipment
by monorail hoist and/or overhead crane shall be made as required.
c) The plinth level with respect to the existing grade level shall be as
indicated elsewhere in Vol-II-A Section-V/Annexure-II.
d) The minimum clear height available between two consecutive floor

slabs shall not be less than five (5) meters. A clear head room of 2.2
meters shall be maintained between the floor and any overhead
piping/cables or other obstruction. Adequate provision for natural
ventilation and illumination shall be made as per good engineering
practices.
e) There shall be at least two (2) nos. main access doors, one on either
side of each building, of which one shall be minimum 3 meters wide
with rolling shutters for equipment entry. For multistoried buildings, at
least two (2) nos. regular staircases diagonally opposite to each other
shall be provided connecting all the floors and roof. These minimum
requirements shall be augmented as required depending on the floor
area, statutory requirements and TAC recommendations.
f) All buildings shall have provision for toilet and associated effluent
discharge system together with facility for drinking water. The criteria for
ventilation, fire protection and illumination of building spaces shall be as
specified in Vol-II-A Section-V/Annexure-II.
g) All rail/road crossings for pipe/cable racks shall be constructed with

minimum 8 meters headroom from top of rail/road to bottom of rack.
Similarly top cover over underground pipes/cables shall be minimum
one (1) meter. For other detail refer to Annexure-II of this section.
h) Cubicle for operating personnel shall be located at safe place near the
equipment.
i) Pipe rack, cable rack and Pipe cum Cable rack shall have hand railings
( not less than 1200 mm high) in walkways (min. 800 mm wide) on both
sides at appropriate heights.
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7.00.00 OPERATION AND MAINTENANCE CONSIDERATIONS
7.01.00 Space for ease of operation and maintenance including equipment removal,
tube bundle/cartridge/rotor pulling etc. shall be provided. All valves, gates,
dampers and other devices shall be located and oriented in such a way that
they are accessible from operating floor levels. Where this cannot be adhered
to, platforms and walkways with access ladders shall be provided to facilitate
operation and maintenance.
7.02.00 Lifting devices i.e. hoists, chain pulleys, jacks, etc. shall be provided for
handling of any equipment and/or part having weight in excess of 100 Kg
during erection and maintenance activities. Suitable beams, hooks etc. for this
purpose shall be provided in the buildings and clear space provided below to a
platform or floor which will allow normal risk free transport means to be used.
Lifting tackles, slings, etc. to be connected to hook of the hoist/crane shall also
be provided by the Bidder for lifting the various equipments and accessories
covered under this specification.
7.03.00 All similar parts of the equipment shall be made to gauge and shall be
interchangeable with and shall be made of same material and workmanship as
the corresponding parts of the equipment. Where feasible common
components shall be employed in different pieces of equipment in order to
optimize the spares inventory and utilization.
8.00.00 MATERIALS
8.01.00 In selecting materials of construction of equipment, the Bidder shall pay

particular attention to the atmospheric conditions existing at the Site and the
nature of material/fluid handled.
All materials shall be new and shall be of the quality most suited to the
proposed application.
8.02.00 Materials used for various components shall be those which have already
proven operating experience in similar type of applications.
8.03.00 All parts which could deteriorate or corrode under the influence of the
atmospheric, meteorological or soil conditions at the Site, or under the
influence of the working conditions shall be suitably and effectively protected so
that such deterioration or corrosion is a minimum over the life of the plant.
8.04.00 Prohibited Materials
The use of the following materials is prohibited:
a) High alumina cement in structural elements
b) Wood wool slabs in permanent framework to concrete
c) Calcium chloride in mixtures for use in concrete works
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d) Naturally occurring aggregate for use in reinforced concrete that does

not comply with the applicable codes and standards.
e) Cast iron for any oil service
f) Carcinogenic material and suspected carcinogenic materials by World

Health Organization.
g) Asbestos or any other fibrous form of hydrated magnesium silicate
h) Any other material generally known to be deleterious if used or

incorporated in such project like the facility.
9.00.00 LUBRICATION
9.01.00 Provision shall be made for suitable efficient lubrication where necessary to
ensure smooth operation free from undue wear.
9.02.00 Non ferrous capillary tubing shall be used throughout.
9.03.00 Gear boxes and oil baths shall be provided with filling and drain plugs, both of
adequate size. An approved means of oil indication including level switches
and temperature indication shall be provided.
9.04.00 All high speed gears shall be oil bath lubricated. Low speed gears shall be
lubricated by means of soft grease. Removable and accessible drip pans shall
be provided to collect lubricant, which may drop, from operating parts.
9.05.00 All lubrication points shall be conveniently situated for maintenance purposes. It
must be possible to carry out lubrication from a gangway or landing and without
the removal of guarding or having to insert the hand into it. Where accessibility
to a bearing for oiling purposes would be difficult a method of remote lubrication
shall be fitted.
9.06.00 The Bidder shall supply grease gun equipment suitable to service each type of
nipple fitted.
.
10.00.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS
10.01.00 The Bidder shall provide a detailed and comprehensive specification for all
lubricating oils, greases and control fluids required for the entire plant. A
sufficient supply of these shall be provided by the Successful Bidder for initial
commissioning, first fill and till completion of facilities and handing over of
respective units.
10.02.00 The Bidder shall supply a detailed schedule giving the lubricant testing,
cleaning and replacement procedures. All equipment and facilities necessary
for the testing, cleaning and changing of lubricants and control fluids shall be
provided. The Successful Bidder shall endeavor to reduce the verities and
grades of required lubricants and control fluids to a minimum, matching them
where possible to those already in use in the generating station in order to
simplify procurement and minimise storage requirements. All lubricants and
control fluids shall be of internationally recognized standards and shall be easily
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obtainable from a large number of Indian suppliers. Bidder shall also indicate
the equivalent Indian Standard for the above for easy procurement in future.
10.03.00 No lubricant or control fluid shall have toxic or other harmful effects on
personnel or on the environment.
11.00.00 PLANT LIFE AND MODE OF OPERATION
The complete plant including all the equipment and systems individually and
collectively shall be designed for continuous operation for an economic service
life of thirty (30) years under the prevailing site conditions and for the type of
duty as specified in relevant sections of the specification.
The critical components of the Steam Generator, Turbine-Generator and

Auxiliary equipment, the life of which is limited by time and temperature
dependent mechanisms such as thermal stress, creep and low cycle fatigue,
are to be designed considering expected (hot, warm and cold) start-up, shut-
down and cyclic load variations. (Details are specified in the Volume IIB –
Specification of Steam Generator and Auxiliaries and Volume IIC –
Specification of Steam Turbine and Auxiliaries and)
The units would be operated on base load with cyclic load variation. The load
variation is expected to be as per schedule depending on power demand.
12.00.00 PACKAGING & MARKING
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 the materials, the limitations from
the point of view of availability of railway wagon sizes in India should be taken
account of. The details of various wagons normally available with Indian
Railways for transportation of heavy equipment shall be considered by the
Bidder. The Bidder shall be responsible for all loss or damage during
transportation, handling and storage due to improper packing.
Bidder shall conduct his own route survey and transportation logistics for
transportation of the equipments to project site by road/rail/sea and indicate
the same in his proposal.
Each package shall have identification marking indicating the name and
address of the consignee shall be clearly marked in indelible ink on two
opposite sides and top of each of the packages. In addition the Bidder shall
include in the marking gross and net weight, outer dimension and cubic
measurement. Each package shall be accompanied by a packing note (in
weather proof paper) quoting specifically the name of the Bidder, the number
and date of contract and names of the office placing the contract, nomenclature
of contents and Bill of Material.
13.00.00 PROTECTION
Equipment having antifriction or sleeve bearings shall be protected by weather-

tight enclosures. Coated surfaces shall be protected against impact, abrasion,
discoloration and other damages. Surfaces that are damaged shall be
repainted.
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Electrical equipment, controls and insulations shall be protected against

moisture and water damages. All external gasket surfaces and flange faces,
couplings, rotating equipment shafts, bearings and like items shall be
thoroughly cleaned and coated with rust preventive compound as specified
above and protected with suitable wood, metal or other suitable covering to
ensure their full protection. All exposed threaded parts shall be greased and
protected with metallic or other suitable protectors.
All piping, tubing and conduit connections on equipment and other equipment
openings shall be closed with rough usage covers or plugs shall be sealed and
taped. Male threaded openings shall be closed with rough usage covers or
plugs shall be sealed and taped. Female threaded openings shall be closed
with forged steel plugs.
Returnable containers and special shipping devices shall be returned by the

Bidder.
14.00.00 PAINTING
14.01.00 General
All exposed metallic and wooden surfaces subject to corrosion shall be

protected by shop application of suitable coatings. Surfaces not easily
accessible after shop assembly shall be treated before-hand and protected for
life of the equipment. Surfaces to be finish painted after installation shall be
shop painted with at least two (2) coats of primer. Steel surfaces, which are not
to be painted, shall be coated with suitable rust preventive compound subject to
the acceptance of the Owner.
All paints shall be used in accordance with the manufacturer's instructions. No

thinners or other substance shall be added to the coating material without the
prior notification and specific acceptance of the Owner. The quality and vendor
of the paints shall require acceptance of the Owner.
Procedure for painting of any item, if not indicated in the relevant specification,
shall be developed by the Bidder. This procedure and quality of paint shall be
subject to Owner’s acceptance
All paints shall be applied in a normal full coat, shall be free from runs, sags,
wrinkles, patchiness, brush marks or other defects.
All primers shall be properly applied on to the surface and the first priming coat
shall be applied as soon as possible after cleaning, within four hours maximum.
The paint shall be applied by brush, roller or airless spray, according to the
manufacturer's instructions. Spray painting shall be carried out by operators
trained and thoroughly experienced in the use of the spray painting equipment.
If the drying interval between successive coats of paint or primer exceeds the
manufacturer’s recommendations, the paint already applied shall be completely
and uniformly abraded with fine abrasive paper before putting on the next coat.
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Paint spraying on large surfaces shall not be done indoors, without the prior
notification and specific acceptance of the Owner. Spray guns shall not be used
outdoors in windy weather nor near unprotected surfaces of a contrasting
colour and under no circumstances shall spray guns be used where spray may
be carried into or onto exposed electrical equipment or unprotected humans.
The Bidder shall provide suitable protection for adjacent plants from air borne
materials during cleaning and spraying to the satisfaction of Owner
Paint containers shall not be opened until required and the paint shall be
mechanically mixed thoroughly before use, and agitated occasionally during
use.
Electrical equipment shall be shop finished with one or more coats of primer
and two coats of high-grade oil resistant enamel. The interior of all panels’
cabinets and enclosures shall be finished with gloss white enamel. For detail
please refer relevant electrical sub-section Volume II F1 & F2.
The Bidder shall furnish sufficient touch-up paint for one complete finish coat
on all exterior factory surfaces of each item of equipment. The touch-up paint
shall be of the same type and colour as the factory applied paint and shall be
carefully packed to avoid damage during shipment. Complete painting
instructions shall be furnished.
Shop primer for steel and iron surfaces which will have a continuous operating
temperature below 35°C shall be selected by the Bidder, in accordance to the
relevant standard. Special high temperature primer shall be used on surface
exposed to operating temperature above 35°C.
The colour scheme shall be submitted during execution of contract for

acceptance by the Owner.
14.02.00 Surface Preparation
The grade of surface preparation shall be classified as indicated in Annexure-

I of this section.
Sl. No. Type of Preparation Reference Standards

SSPC SIS BS 4232
1. Solvent cleaning SP1 - -
2. Hand Tool Cleaning SP2 St-2 -
3. Power Tool Cleaning SP3 St-3 -
4. Flame cleaning of new steel SP4 - -
5. White metal blast cleaning SP5 Sa-3 First Quality
6. Commercial blast cleaning SP6 Sa-2 Third Quality
7. Brush-off blast cleaning SP7 Sa-1 -
8. Pickling SP8 - -
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9. Weathering followed by SP9 - -
blast cleaning
10. Near white blast cleaning SP10 Sa-2.5 Second
Quality
Oil and grease shall be removed from the surface by washing with a suitable
detergent, rinsing with clean water, and drying.
The abrasive to be used shall be metal grit.
The surface preparation of all steel surfaces to be coated shall be free from
all mill scales, rust corrosion products, oxides, paints, oil or other foreign
matter.
All welded areas and appurtenances shall be given special attention for
removal of welding flux in crevices. Welding splatter, slivers, laminations and
underlying mill scale exposed during shot blasting shall be removed or
repaired.
No acid/solvents/other cleaning solutions shall be used on surfaces after they

have been blasted.
14.03.00 Application of Primer and Paint
Primer shall be applied immediately after surface preparation has been

completed.
Brushing, spraying, roller coating or other suitable method shall be adopted

for application of primer and paint and the work shall be carried out strictly as
per the recommendation given by the paint manufacturer.
Primarized surfaces shall be faultless and shall not have mudcracking,

dripping over thickness and dry sprays.
Before application of paint/primer, the following shall be particularly checked

for conformance to this specification and recommendation of the paint
manufacturer:
a) Surface preparation profile.

b) Catalysis ratio for two component paints.
c) Pot life.
d) Minimum and maximum top coating times.
e) Type and quantity of thinners (if required)
f) Viscosity
g) Soundness of previous coating.
h) Ambient conditions (temperature, humidity, etc)
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Depending on the degree of contamination by foreign matters, the surfaces

primed at shop shall be washed as follows to the satisfaction of the Owner:
a) With clean water under a pressure of a least 7 Kg/cm2 (g) using

suitable nozzles. During washing broom of corn brushes shall be
used.
b) With suitable solvents, (such as Carbon Tetrachloride,

Trichloroethylene etc.) if necessary, to remove traces of grease, oil etc.
Coated parts shall be carefully handled using hemp ropes, cloth belts,
pendulum conveyors or suitable means as instructed by the Owner.
Surfaces which cannot be painted after fabrication shall be primed and

provided with suitable rust preventive oil before boxing up.
Paints shall be stored in well-ventilated rooms, far away from heat sources,
open flames, sparks and protected from sun. Outdoor storage is not
permitted. Storage life shall be clearly indicated on the container. Paints,
which have thickened or gelled or contained in non-original containers or in
unsealed containers shall not be used. Owner’s decision in this regard shall
be final and binding.
The requirements for the dry film thickness (DFT) of paint and the materials to
be used shall be as per Table I & II of this section.
For detail painting on building & structural steel elements refer Section-IIG/1 &
IIG/2 of this specification.
14.04.00 Damaged Paintwork
Any damaged paintwork shall be made good as follows:
a) The damaged area, together with an area extending 25mm around its
boundary, shall be cleaned down to bare metal.
b) A priming coat shall be immediately applied, followed by a full paint
finish equal to that originally applied and extending 50mm around the
perimeter of the original damage.
c) The repainted surface shall present a smooth surface. This shall be

obtained by carefully chamfering the paint edges before and after
priming.
14.05.00 Surface preparation and painting work shall not be carried out under the
following weather conditions:
a) When the surface is wet or expected to become wet before the

paint/primer has dried up due to impending rain, fog or mist.
b) High winds.
c) Ambient temperature below 5deg.C or surface temperature less than 3

deg.C above dew point.
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d) Relative Humidity is more than 85%.
14.06.00 Inspection and Testing of Painting
The following inspection and testing shall be performed during and on

completion of paint systems.
- Shot blasting profile shall be checked using a suitable profile-meter.

Acceptable profile shall be 25-30 microns.
- Check of time of top coating and drying, in accordance with the

recommendation of paint manufacturer.
- Check of Dry Film thickness by suitable Non Destructive Equipment.

The painting shall be rejected if any of the spot measurement shows
thickness to be less than 80% of the specified thickness.
- Check of adhesion of Paint Material by "Chequering" or another

suitable method.
- Check of porosity of coating for internals, by the use of a suitable

instrument.
- Visual inspection of appearance and uniformity of the surfaces

painted.
If during above inspection, painting defects are observed, the Bidder shall
carry out rectification to bring the faulty surface to the acceptable degree.
The areas where defective or damaged coatings have been repaired or

replaced shall be re-inspected to the original requirements.
Surface temperature and humidity readings shall be taken prior to application

of each coat. The work shall not proceed if the ambient temperature
parameters are outside the requirements of this specification. If more
stringent, the coating manufacturer’s requirement shall dictate.
The dry film thickness shall be tested with a micro test film gauge or an
accepted equivalent. The testing method shall be in accordance with SSPC –
PA 2.
15.00.00 COLOUR CO-ORDINATION & FINISH
15.01.00 Exterior surfaces throughout the plant shall be finished in colours and textures
which will blend harmoniously together and with the surrounding landscape.
15.02.00 Interior surfaces throughout the plant shall be finished in colours and textures
which will blend harmoniously together and which will be conducive to; the
comfort, well-being and high productivity of the operators. Operating plant and
services provided shall be colour coded for ease of identification.
15.03.00 All finishes shall be durable and as far as possible maintenance free. Finishes
shall be easily cleaned.
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15.04.00 Final colours and finishes shall be to the acceptance of the Owner.
16.00.00 ENVIRONMENT PROTECTION AND NOISE LEVEL REQUIREMENT
16.01.00 Environment Protection
The plant shall be designed for installation and operation in harmony with the
surrounding environment and all measures of pollution control shall be ensured
by the Bidder to restrict pollution from the liquid effluent and stack emission
within the limits as given below with due consideration of Environment
(Protection) Rules 1986 as amended till date.
The Plant shall be designed meeting the latest environmental requirement

issued by MoEF, GOI. In the event of Ministry of Environment & Forest
stipulate any other conditions not specified hereunder, the Bidder shall comply
with those requirements.
16.01.01 Liquid Effluent Discharge
a) Provision laid down in schedule-I for Thermal Power Plants and also in
Schedule-VI. General Standards for discharge of Environmental
pollutants Part-A: Effects of Environmental (protection) Rules 1986, as
amended till date.
b) Any specific requirement of State Pollution Authorities over and above

the above stipulation.
16.01.02 Air Quality Emissions
a) Suspended Particulate Matter at chimney outlet - Maximum 30 mg/Nm3
b) Oxides of Nitrogen (NOx) - 100 mg/Nm3 .
c) Sulphur di-Oxide(SO2) - 100 mg/Nm3
d) Mercury (Hg) - 0.03 mg/Nm3
e) The Efflux velocity from boiler stack(s) shall not be less than 25 m/sec.
g) Outlet dust emission level of bag filter installed in AHP and CHP shall
be restricted to 30 mg/NM3 .
h) For The Coal Handling Plant, areas covered under Dry Fog Dust
Suppression (DFDS) shall be designed to control the dust emission
level in the working area measured at distance of 2m from the dust
generation sources, over and above the atmosphere background dust
level to shall be within 5 mg/NM3
The Bidder shall include in his scope all necessary equipment and measuring
instruments to comply with above requirements. Location and accessibility of
the instruments shall be properly coordinated.
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16.02.00 Noise Level Requirement
The plant shall be designed, constructed and provided with suitable acoustic
measures to ensure the noise level criteria as per the following stipulations.
a) Maximum noise level shall not exceed 85 dB (A) when measured at

1.0M away from the noise emission source.
b) Maximum noise level from its source within the premises shall not
exceed 70 dB (A) as per Environment (Protection) Rules 1986,
Schedule-III, Àmbient Air Quality Standards’ in respect of noise.
c) Any statutory changes in stipulations regarding noise limitation that may

occur in future according to State Pollution Control Board or Central
pollution Control Board or Ministry of Environment & Forest regulation
during tenure of the contract, the Successful Bidder shall comply with
the requirement.
17.00.00 INSPECTION AND TESTING
17.01.00 Inspection and Tests during Manufacture
17.01.01 The method and techniques to be used by the Successful Bidder for the control
of quality during manufacture of all plant and equipment shall be agreed with
the Owner prior to the Award of Contract.
17.01.02 The Owner’s general requirements with respect to quality control and the
required shop tests are set out elsewhere in this specification.
17.01.03 Before any item of plant or equipment leaves its place of manufacture the
Owner shall be given the option of witnessing inspections and tests for
compliance with the specification and related standards.
17.01.04 Advance notice shall be given to the Owner as agreed in the Contract, prior to
the stage of manufacture being reached, and the piece of plant must be held at
this stage until the Owner has inspected the piece, or has advised in writing
that inspection is waived. If having consulted the Owner and given reasonable
notice in writing of the date on which the piece of plant will be available for
inspection, the Owner does not attend the Successful Bidder may proceed with
manufacture having forwarded to the Owner duly certified copies of his own
inspection and test results.
The Successful Bidder shall forthwith forward to the Owner’s Engineer duly
certified copies of the Test Certificates in Three (3) copies for approval.
17.01.05 Under no circumstances any repair or welding of castings be carried out

without the consent of the Engineer. Proof of the effectiveness of each repair
by radiographic and/or other non-destructive testing technique, shall be
provided to the Engineer.
17.01.06 All the individual and assembled rotating parts shall be statically and
dynamically balanced in the works.
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Where accurate alignment is necessary for component parts of machinery
normally assembled on site, the Successful Bidder shall allow for trial assembly
prior to dispatch from place of manufacture.
17.01.07 All materials used for the manufacture of equipment covered under this
specification shall be of tested quality. Relevant test certificates shall be made
available to the Purchaser. The certificates shall include tests for mechanical
properties and chemical analysis of representative material.
17.01.08 All pressure parts connected to pumping main shall be subjected to hydraulic
testing at a pressure of 150% of shut-off head for a period not less than one
hour. Other parts shall be tested for one and half times the maximum operating
pressure, for a period not less than one hour.
17.01.09 All necessary non-destructive examinations shall be performed to meet the

applicable code requirements.
17.01.10 All welding procedures adopted for performing welding work shall be qualified
in accordance with the requirements of Section-IX of ASME code or IBR as
applicable. All welded joints for pressure parts shall be tested by liquid
penetrant examination according to the method outlined in ASME Boiler and
Pressure Vessel code. Radiography, magnetic particle examination magnuflux
and ultrasonic testing shall be employed wherever necessary/ recommended
by the applicable code. At least 10% of all major butt welding joints shall be
radiographed. Statutory payments in respect of IBR approvals including
inspection shall be made by the Successful Bidder. Successful Bidder’s scope
and responsibility shall also include preparation of all necessary documents in
the specific formats stipulated by the statutory bodies, coordination and follow
up for above approvals.
17.02.00 Performance Tests at Site
17.02.01 The full requirements for testing the system shall be agreed between the
Owner and the Bidder prior to Award of Contract. The completely erected
System shall be tested by the Successful Bidder on site under normal operating
conditions. The Successful Bidder shall also ensure the correct performance of
the System under abnormal conditions, i.e. the correct working of the various
emergency and safety devices, interlocks, etc.
17.02.02 The Bidder shall provide complete details of his normal procedures for testing,
for the quality of erection and for the performance of the erected plant. These
tests shall include site pressure test on all erected pipe work to demonstrate the
quality of the piping and the adequacy of joints made at site.
17.02.03 The Successful Bidder shall furnish the quality procedures to be adopted for
assuring quality from the receipt of material at site, during storage, erection,
pre-commissioning to tests on completion and commissioning of the complete
system/equipment.
17.03.00 For details of specific tests required on individual equipment refers to

respective section of this specification.
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18.00.00 TRAINING OF OWNER'S PERSONNEL
The Successful Bidder shall extend all possible assistance and co-operation to
the Purchaser regarding the transfer of technology and developing expertise in
the area of engineering operation and maintenance of the Plant.
Number of man-days of training as mentioned below shall be included in his

Tender.
18.01.00 Training at Successful Bidder's Premises
The Successful Bidder shall conduct training of Sixty Five (65) engineers of the
Purchaser on engineering, operation and maintenance of the Plant at the
Successful Bidder's or Associates or Sub Vendor's premises where adequate
training facilities are available during the design and manufacturing stage of the
successful Bidder.
The total man-months for training of engineers shall be maximum sixty (60),
having following indicative break-up:
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Discipline No. of Engineers No. of Man-month
Operation 25 heads 25
Maintenance 25 heads 25
Boiler, Turbine,
Electrical Maintenance 5 heads 5
Control & Instrumentation 10 heads 5
------------- --------
65 heads 60
------------- --------
However, the details of the training programme will be discussed and finalised
with the successful Bidder.
The training may also be arranged by the Successful Bidder in any Plant where
the equipment manufactured by the Successful Bidder or his Associates is
under installation, operation or testing to enable the trainees to become familiar
with the equipment being furnished by the Successful Bidder. All expenses
inherently related to the training shall be borne by the Successful Bidder and
shall include but not limited to travel expenses in case of off-shore training
(international and inland fares), lodging and per diem charges as well as
medical insurance, instructors fee, programme and miscellaneous cost to be
incurred during the training.
The training programme shall be adequate for the trainees to acquire the
necessary expertise and competence in the area of engineering, operation and
maintenance and as trainers for in-house technology transfer programme of the
Purchaser.
The Successful Bidder shall be responsible for the development of the Training
Module and Programme Schedule, which shall be submitted to the Purchaser
for approval.
The components of the training modules shall include but not be limited to the
training procedures/methodology, instructional materials such as audio visual
materials, CDs and slides and manuals for each trainee.
Three (3) sets of the materials included in the training modules shall be handed
over to the Purchaser upon completion of the training. An evaluation shall be
jointly undertaken by the Successful Bidder and the Purchaser's representative
on the adequacy, appropriateness and relevance of the training and the
programme effectiveness after the training. The training material shall be in
English language only.
The content of the training programme shall include but not be limited to :
1. Coal fired thermal plant principles in management and practice for

operators, technicians and maintenance personnel.
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2. Plant operation and systems training for operators including simulator
training as applicable.
3. Maintenance training programme covering electrical, mechanical and

instrumentation and control.
Said training programme shall be submitted to the Purchaser for approval.
The timing of the training should be such that the participants will be conversant
with sufficient know-how to participate in the pre-commissioning and
commissioning tests of the Plant.
The Successful Bidder shall provide qualified English speaking instructors and
training coordinator(s) during the tenure of the training programme.
18.02.00 Operation and Maintenance Training at Site
The Successful Bidder shall provide a comprehensive training programme

related to design application, plant management, operation and maintenance,
including trouble shooting, of the Successful Bidder's supplied system and
equipment at the Site starting from Start of Commissioning and thereafter up to
the Final hand over of the Unit..
The following instructors shall be at the Site continuously during the training :
a) One (1) for Steam Generator and Auxiliaries
b) One (1) for Turbine Generator and Auxiliaries
c) One (1) for Electrical Works
d) One (1) for Instrumentation and Control (Boiler and Auxiliaries)
e) One (1) for Instrumentation and Control (Turbine and Auxiliaries)
18.03.00 On-the-Job Training
During the period of pre-commissioning, commissioning and trial operation, the

Purchaser shall provide operation and maintenance personnel to assist the
Successful Bidder in the operation and maintenance of his supply and work
under the direction of the Successful Bidder for the purpose of on-the-job
training.
The Purchaser shall have the right to send to the Site his employees later
intended to operate and maintain the equipment supplied under this Contract.
The successful Bidder shall, without additional cost, use his site staff to instruct
these employees on the operation and maintenance of the equipment. All
instructions shall be in the English language.
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ANNEXURE-I
LIST OF STANDARDS FOR REFERENCE
a) International Standards Organisation (ISO).
b) International Electro-technical Commission (IEC).
c) American Society of Mechanical Engineers (ASME).
d) American National Standards Institute (ANSI).
e) American Society for Testing and Materials (ASTM).
f) American Institute of Steel Construction (AISC).
g) American Welding Society (AWS).
h) Architecture Institute of Japan (AIJ).
i) National Fire Protection Association (NFPA).
j) National Electrical Manufacturer's Association (NEMA).
k) Japanese Electro-technical Committee (JEC).
l) Institute of Electrical and Electronics Engineers (IEEE).
m) Federal Occupational Safety and Health Regulations (OSHA).
n) Instrument Society of America (ISA).
o) National Electric Code (NEC).
p) Heat Exchanger Institute (HEI).
q) Tubular Exchanger Manufacturer's Association (TEMA).
r) Hydraulic Institute (HIS).
s) International Electro-Technical Commission Publications.
t) Performance Test Code (PTC).
u) Applicable German Standards (DIN).
v) Applicable British Standards (BS).
w) Applicable Japanese Standards (JIS).
x) Electric Power Research Institute (EPRI).
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y) Standards of Manufacturer's Standardization Society (MSS).
z) Bureau of Indian Standards Institution (BIS).
aa) Indian Electricity Rules.
bb) Indian Boiler Regulations (IBR).
cc) Indian Explosives Act.
dd) Indian Factories Act.
ee) Tariff Advisory Committee (TAC) rules.
ff) Emission regulation of Central Pollution Control Board (CPCB).
gg) Pollution Control regulations of Ministry of Environment & Forests, Govt. of

India.
hh) Central Board of Irrigation and Power (CBIP) Publications.
ii) National Building Code (NBC).
jj) Indian Road Congress (IRC).
kk) Latest guidelines of Railway Authority.
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ANNEXURE-II
CRITERIA FOR LAYOUT
PLOT PLAN LAYOUT REQUIREMENTS
The guidelines shall be applied in general, unless otherwise stated in other technical
Volumes. In addition to these guidelines, Bidder shall refer the attached Plot Plan, drawing
no. 12A05-DWG-M-003A, for tentative arrangement of the various facilities under this
package.
ITEM SPECIFICATION REQUIREMENT
A. Site conditions to be considered
1. Prevalent wind direction during

summer (for deciding Cooling Refer wind-rose in plot plan.
Tower orientation)
2. Prevalent wind direction(s) during dry

seasons (for deciding the location of
coal stock pile and ash dump/ unloading Refer wind-rose in plot plan
areas, minimising the pollution effect
due to dust)
.
3. Location of:
a) Water intake point. Towards South.
b) Water discharge point. -.
c) Plant drainage outfall point(s). Towards East.
d) Railway entries & exits. Towards South.
e) Road entries & exits. Towards North & North-East.
f) Electrical power transmission grid system. Towards East.
g) selected ash dump area. Towards North.
h) Nearest residential area. Towards South.
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B. Layout Requirements
1. Maximum permissible slope in
a) Rail track 1 in 400
b) Road 1 in 30
c) Sides of unpaved embankment 1 in 2
2. Required road width
a) Main roads 8.0 Metres with 2.5m wide

shoulders on either side.
b) Auxiliary interconnections 4.0 Metres with 1.0m wide

shoulders on either side.
c) Road to the power house unloading bay :
• Only for entry to the unloading bay Yes.

• To pass through the unloading bay No.
3. Required minimum horizontal distance

between the nearest points of
a) Plant boundary and the boundary of (Local municipality/factory rule)

residential area
b) Electrical transformer and any other As per the Tariff Advisory

building/facility Committee Rules.
c) Fire water supply installation and any As per the Tariff Advisory
building/facility subject to fire risk. Committee Rules.
d) Inflammable liquid (fuel oil, etc.) storage Rules of the Indian Explosive
& handling installation and their fencing (Indian Explosives Act) and
and other buildings/facilities. Indian Petroleum Code.
4. Required minimum vertical clearance
a) Under pipes/cable racks at road crossings 8.0 Metres.
b) Soil coverage over underground pipes 1.0 Metre (minimum).
c) Pipe/Cable trench No Trench. Pipe/Cable Racks

shall be used exclusively.
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5. Railway Wagon clearance As per the rules of the Indian

Railways.
6. Minimum Clearance between any road edge 3 Metres.

and building/structure/ any fixed installation.
7. Required level, above the local developed

grade level, of
a) top of all roads 150 mm.
b) all outdoor paved areas 150 mm.
c) Temporary storage areas, workshops,

offices, residence etc. required at the
time of erection work. Yes.
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BUILDING/ EQUIPMENT LAYOUT REQUIREMENTS
A. Minimum clear space required at all working and

walking areas for operating & maintenance personnel
1. Horizontal, in all directions
a) Adjacent to any electrical equipment, electrical

cables, running (rotating/reciprocating) equipment,
safety valve or vent/drain pipe outlet, pipe/
equipment of surface temperature exceeding 60C. 1200 mm.
b) Adjacent to any other plant facilities (including

walls/structures) 1000 mm.
2. Vertical (head-room clearance)
a) Under any pipe/equipment surface

of temperature exceeding 60C and any
electrical cables or other electrical items. 2.2 Meters.
b) Under any other plant facilities (including

structures, pipes etc.) 2.2 Meters.
3. For all areas where any equipment (including Minimum 500 mm

trucks, trolleys and other material handling clear in all direction
equipment) will move or maneuver. from the outer edges
of the equipment.
4. Minimum clear hand space required for
a) The application of thermal insulation 100 mm
b) Welding work 150 mm
c) Bolt tightening 150 mm
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B. Floors, platforms, staircase, ladders, walls, doors

& windows
1. Statutory Requirement As per the regulations of OSHA,

Tariff Advisory Committee, Indian
National Building Code, Indian
Factories Act, Local Municipal
Rules, etc.
2. Operation & Maintenance Requirement
a) Adequate floor space shall be kept to permit

dismantling, temporary storing and in-situ
maintenance of plant & equipment parts, satis-
fying the clear space requirements stated above.
A separate unloading bay for such purpose is
required. Yes
b) Floors or fixed/portable platforms with stairs/

ladders shall be provided for easy approach to
any plant item, including valves, instruments,
etc. to be operated, observed and/or to be
frequently (more than once a month) maintained. Yes
3. Plinth level of all buildings, above 300 mm. However, 500 mm

the Finished Ground Level (FGL) for power house building.
4. Minimum access opening required 3.5 m wide x 4 m high or, more

(with rolling shutter) wherever entry of loaded truck is
envisaged, depending upon the
equipment size to be handled.
C. Other Maintenance Requirement
C. Other Maintenance Requirement
1. Generator stator handling
In case the Generator stator cannot be

handled by the turbine house crane, all
provisions for its overhauling, including the
arrangement to slide the stator on the turbine
house floor, the foundation work for stator jacking
/lowering assembly, dismantling of building end
walls/structures etc. shall be kept. Yes
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2. Maintenance of the internals/impellers of Shall be possible without

all important equipment, like boiler feed pumps, disconnecting or dismant-
feed water heaters, Surface Condenser, fans ling any piping/ducting.
of the boiler draft plant, Intake and circulating
water pumps, cooling water pumps, coal mills, air
compressors, blowers, heat exchangers, fuel
oil pumps, filters etc.
3. Overhauling and handling of the casings for the Shall be possible without
above items disturbing/dismantling any
piping/ducting not directly
connected to them.
4. Crane Approach
Wherever required the unobstructed approach

of the crane hook/other hoisting equipment hook to
various plant & equipment shall be possible. Yes
D. Central Control Room
All electronic equipment other than those directly

associated with control, operation or presentation
of displays shall be mounted external to the control
room in air conditioned control equipment room. Yes
The bidder shall describe in his bid the proposed

layout philosophy of the Central Control Room and
Control Equipment Room and the arrangement of
equipment best suited for the system offered by him
and as per good ergonomically consideration.
However, as a guide line, following features are given :
a) False ceiling and false flooring shall be provided.
b) Uniform height, colouring schemes for cabinets etc.

shall be available.
c) The total area of floor space covered by Control

Consoles/Panels in the Control Room shall not exceed
15% of floor area.
d) No opening shall be provided from Boiler side.
e) Two double leaf doors, suitably located for

entering the Control room shall be provided
with opening towards the turbine floor.
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f) Cable entry for the panels/consoles shall be from

bottom and suitable openings shall be provided.
g) The Control Room lighting shall be designed to

provide a glare free uniform illumination. The level
of illumination shall be minimum 400 LUX.
h) Necessary Air Conditioning shall be provided

for Central Control room, Control Equipment Room
and SWAS room etc.
i) Basic amenities like toilet, Tiffin rooms, wash

basins, rest rooms etc. shall be provided near
the Control Room.
D. Toilet and drinking water facility Required in all buildings and on

all floors wherever operating
personnel are to be deployed.
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SECTION-VI
PROJECT MANAGEMENT AND SITE SERVICES
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CONTENT
1.00.00 PROJECT MANAGEMENT SERVICES 1
2.00.00 SITE SERVICES 9
3.00.00 PROTECTION & CARE 18
ANNEXURE-I LIST OF SUB-VENDORS
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SECTION-VI
PROJECT MANAGEMENT AND SITE SERVICES
1.00.00 PROJECT MANAGEMENT SERVICES
1.01.00 Responsibility
The Bidder shall identify a separate and independent project management

team headed by a Project Manager for the execution of this project.
Responsibilities of this project Management team shall cover the areas listed
below :
a) Planning and Monitoring
b) Owner’s Engineering Management
c) Contracts Management
d) Quality Assurance, Inspection & Expediting
e) Construction Management
f) Spares Management
g) Commissioning Management
Detailed responsibilities in the above areas are discussed below :
1.02.00 Organisation
1.02.01 Headquarters
The project management team shall be stationed at the organizational

headquarter and headed by a senior level executive designated as the
Project Manager who shall be responsible to Owner for the execution of the
project. . He should have adequate financial power and authority to give
decision.
Separately, designated leaders shall be identified for each of the areas

mentioned under 1.01.00, who, in turn, will report to the Project Manager for all
matters related to this contract.
1.02.02 Central Co-ordination Cell
The central coordination/ cell shall be based in Kolkata and shall have sufficient
technical personnel to coordinate technical matters and to quickly resolve day
to day queries or references made by Owner and his Consultants without
having the need to refer to his headquarters each time.
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1.02.03 Site Organisation
The site should have a competent construction manager for all site operations
with adequate financial power and sufficient level of authority to take site
decisions. The organisation chart for site should indicate the various levels of
experts to be posted for supervision in the various fields in civil construction,
erection, commissioning etc.
1.02.04 Organisation Chart
The Bidder shall furnish a detailed organisation chart for the project
management team, clearly identifying the key personnel in each of the areas
mentioned at 1.01.00 above. The expected number of executives at different
levels shall also be indicated, separately for headquarters, central coordination
cell and site organisation.
1.03.00 Implementation Schedule
The following milestones shall be followed by the Contractor against each

activity as detailed below:
1. Letter of Award (LOA) Zero Date

2. Supply Completion 36 months from LOA
3. Synchronization 38 months from LOA
4. Completion of Trial 42 months from LOA
Operation
5. System & Completion 45 months from LOA After rectifying
of all facilities as per all jobs as identified in the Punch List
contract and handing to the satisfaction of the Owner.
over
6. P. G. Test To be completed within three (3)
months after Completion of all
facilities and handling over.
7. Guarantee/Warranty For a period of 18 months from the
Period date of completion of the facilities or
twelve (12) months from the date of
operation acceptance (or any part
thereof), whichever occurs first and
any suitable extension of time for
completion of rectified job granted by
Employer
8. Final Acceptance After the expiry of defect liability
period
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1.03.01 Owner’s Engineering Schedules
These schedules shall cover various design submissions indicating different

Owner’s Engineering activities to be performed. Such schedules shall be
furnished by the Bidder for each and every plant/systems/ equipment/ item
covered in the scope of this specification.
1.03.02 Manufacturing Schedule
The Contractor shall submit to the Owner’s Engineer his manufacturing and
delivery schedules for all equipment within thirty (30) days from the date of
issue of the Letter of Award (LOA). Such schedules shall be in line with the
detailed network for all phases of the work of the Contractor. Such schedules
shall be reviewed, updated and submitted to the Owner’s Engineer, once in
every two months thereafter, by the Contractor. Schedules shall also include
the materials and equipment purchased from outside suppliers.
1.03.03 Erection Schedules
In order to achieve the overall completion schedule, the Contractor shall

provide the Owner all the information covering erection sequence, testing and
commissioning activities. These schedules may be based on the recommended
erection procedures and will be subject to discussions/agreements with the
Owner subsequent to the award of contract.
1.03.04 The successful Bidder shall have to provide all the above schedules (i.e.
1.03.01, 1.03.02 & 1.03.03) in a tabular form in addition to that in the form of L2
& L3 networks and these shall necessarily include information not limited to the
earliest and latest dates for various activities/submissions and also any related
constraints. However, the Bidder shall include in his proposal a Level-1 (L-1)
network showing the major activities and various milestones to achieve the
above mentioned completion schedule.
1.03.05 The Contractor shall provide the Owner the original disc/software for all such
schedules along with requisite no. of copies (as required by the Owner) within
an agreed time schedule. This time schedule will be agreed between
Owner/Bidder at the time of award of Contract. The Contractor's project
management software shall be compatible with that of the Owner and the input
data shall be furnished to the Owner in a manner compatible with Owner's
project management software, Primavera.
1.04.00 Detailed Responsibilities
1.04.01 Planning & Monitoring
a) Planning
The Bidder shall prepare a Master Network Schedule in the form of

PERT network consisting of at least 500 activities.
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The network shall be prepared on a Work Breakdown Structure for the

project which sub-divides the project into a set of manageable
systems/sub-systems. The master network will identify milestones of
key events for each system/package in the areas of Owner’s
Engineering, procurement, manufacture and despatch and erection and
commissioning. The master network shall represent the Level-I plan
and will form the basis for development of detailed second and third tier
execution plans. The master network shall conform to the overall
schedule prescribed by Owner.
The master network should be submitted along with the bid, which
would be mutually discussed and finalised before the Award of
Contract. This master network would clearly indicate the responsibility
of the Bidder and project management team. This master network
would form a part of the contract. The master network shall also identify
a complete list of inputs to be furnished by the Owner which may be
required for proper interfacing and tie-up. Scheduled dates for providing
such inputs shall also be indicated, which will be mutually discussed
and finalised.
b) Monitoring & Progress Reporting
The progress reports would be emanated every month, one from the
head office of the Contractor and another from the site office. The
progress report emanating from the head office should necessarily
include the following sections:
i) Report on key milestones.
ii) Management summary indicating critical areas with details of

actions initiated and effect of any on the project.
iii) Action needing attention of the Owner/Consultant.
iv) Detailed package wise status of Owner’s Engineering

submissions, quality plan submissions and approval,
procurement manufacture and despatch.
The monthly report generated from the site office should necessarily
include:
i) Report on key milestones.
ii) Management summary indicating critical areas with details of

actions initiated and effect if any on the project.
iii) Action needing attention of the Owner/Consultant.
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iv) This report would also cover the areas pertaining to the receipt
of the equipment at the port, port clearance, transport, receipt at
site, erection and commissioning.
In addition to the above, as the project execution progresses, the

Contractor shall also be responsible for generating more frequent
reports in the form of fax/e-mail information on progress in critical areas
so that actions can be expedited. The exact format of the progress
report shall be finalised after award of Contract.
1.04.02 Owner’s Engineering Management
Based on the master network for the project (L-1) the Contractor will prepare an
exhaustive list of Owner’s Engineering activities for the equipment/systems
covered in his scope and a detailed programme of accomplishing the same
within the time frame specified in the master network. This schedule will form
the Level-2 (L-2) network for Owner’s Engineering activities.
Based on (L-2) network, the Bidder shall further develop the Level-3 (L-3)
network for Owner’s Engineering activities which will indicate schedule for data
availability, drawing release date and document submission dates.
Detailed (L-2) and (L-3) networks would be submitted sequentially by the

Contractor within two months from the date of issue of Letter of Award and
finalised within one (1) month thereafter.
All such networks shall be provided in MS PROJECT software.
The Owner’s Engineering management team should also co-ordinate all

interface Owner’s Engineering activity between the Contractor and the
equipment sub-vendors so as to ensure the correctness and completeness of
related Owner’s Engineering documentation before the same is submitted to
the Owner.
1.04.03 Contracts Management
Based on the master network, the Contractor shall submit L-2 programmes of
manufacture and despatch. In addition, the master network shall also include
periods considered for site activities viz. erection, commissioning etc. These
L-2 programmes would be submitted in 2 months time from the date of award
of contract and finalised within one (1) month thereafter. The Contractor will
also submit site mobilisation plan. This programme would be submitted at the
time of finalisation of award of contract and agreed immediately thereafter so
that immediate development of the various activities at site could take place.
The Contractor should also submit L-3 programmes for the manufacturing,
despatch of the various items. These networks shall also show the customer
hold points (CHP) which have to be cleared by Owner or their authorised
representative(s) before further manufacturing can take place. These L-3
programmes for the manufacture and despatch would clearly identify
responsibilities of the Contractor, sub-Contractor and Owner. These networks
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shall be submitted within one (1) month of the date of finalisation of the various
sub-contracts by the Contractor.
In case all the manufacture is being done by the Contractor then the L-2
programmes would be themselves amplified to cover details of the
manufacture, inspection, clearance by Owner and despatch.
The Contractor shall also submit the programme for procurement of bought out
items, detailed shipping schedule and cash flow statement for Owner's
approval.
1.04.04 Quality Assurance, Inspection and Expediting
The Contractor shall submit the list of manufacturers/sub-vendors from whom

the equipment are expected to be procured and the quality assurance plans
thereof for the manufacture shall be approved by the QA group of Owner
before the manufacturing is commenced. The list of major suppliers would be
submitted along with the bid and this shall be mutually discussed and approval
will be given by the Owner during contract negotiation meeting prior to
placement of Letter of Award. This approved list will be binding to the bidder. In
the said list, Owner reserves the right to include reputed/reliable vendors of his
own choice. Regarding the various other sub-vendors, the list would be
submitted within six (6) months of the award of the contract that shall be
scrutinized by the Owner to accord approval. In such list Owner reserves the
right to include vendors of his own choice. No further vendor approval will be
given after six (6) months. On the quality plans, the customer hold points will
also be identified based on which Owner would give clearance for the
manufacture to proceed further.
Quality assurance/Inspection group of Owner or its representative would issue

a material despatch clearance certificate (MDCC) after the inspection clearance
which will enable the Contractor to despatch the equipment and claim the
payment. In the despatch programme, the Contractor shall indicate a schedule
of estimated programme, tonnages specifically identifying various oversize
dimensioned consignments (ODC). Further the Contractor will also be required
to ensure at all stages of shipment that packing of all shipments despatched
are suitable for ocean freight to India, handling at the port of entry, inland
transportation and preservation at site up to erection. All despatch details &
item lists shall be made available to both Owner & site immediately after
shipping.
The Contractor shall also expedite all despatches from their own works/works
of their sub-vendors, so as to match with the various activities mentioned at
1.04.03 above.
1.04.05 Construction Management
Based on the L-1 Master Network Programme, within two (2) months of the
issue of Letter of Award, the Contractor shall submit a programme of
construction/erection/commissioning, either in continuation with the
manufacture and despatch or separately for the implementation. These
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programmes would be amplified showing when the civil drawings shall be

released by him and construction of civil works shall be completed by him to
facilitate start of erection and subsequent activities and shall form the basis for
site execution and detailed monitoring. The three monthly rolling programme
with the first month's programme being tentative based on the site conditions
would be prepared based on these L-3 programmes. The Contractor shall also
be involved along with the Owner to tie up detailed resource mobilisation plan
over the period of time of the contract matching with the performance targets.
The L-3 programme would be jointly finalised by the site in-charge of the
Contractor with the Owner's project coordinator as well as the site planning
representative. The erection programme will also identify the sequential
erectable tonnages that are required for various equipment which should be
taken care of in the despatch programmes.
Erection and commissioning of the equipment shall also be done under the
supervision of experts from the respective equipment/ system supplier.
1.04.06 Spares Management
Along with the proposal for the plant and equipment, the Contractor shall also
submit proposals/schedule for the following:
a) Mandatory spares
b) Recommended spares
While the award for mandatory spares will be finalised at the time of the award
of contract, recommended spares will be finalised within twelve (12) months
thereafter.
1.05.00 Project Progress Review Meetings
Keeping in mind the overall responsibility of the Contractor it is intended that

periodic progress reviews on the entire activities of execution in respect of
Sagardighi Thermal Power Plant unit #5 will be held initially at least once in two
(2) months at Kolkata/site. During peak period it may be held once in a month.
These meetings will be attended by reasonably higher officials of the
Contractor and their leading subcontractors and will be used as a forum for
discussing all areas where progress needs to be speeded up. Actions will be
placed on the concerned agencies and decisions will be taken to
expedite/speed up the progress. Minutes of such meetings will be issued
reflecting the major discussions and decisions taken and circulated to all
concerned for reference and action. The Contractor shall be further responsible
for ensuring that suitable steps are taken to meet various targets decided upon
such meetings.
In addition to the above, and to streamline the construction and erection at site,
a suitable frequency and forum of periodic meetings between the Contractor
and the Owner will be decided upon as part of erection coordination procedure.
Site co-ordination meeting may be held on weekly basis.
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1.06.00 Owner's Consultant
The Owner would appoint a consultant to assist him in some of the areas
mentioned at 1.01.00 above. The details of interaction and procedures for
coordination between Owner/Owner's Consultant and Contractor/Contractor's
project management team shall be finalised during contract negotiations.
1.07.00 Commissioning Management
1.07.01 For commissioning of the various equipment/system covered under the scope
of contract, Owner will form an organisation structure which may consist of the
following committees. The Contractor shall nominate his representative on one
or more of the committee as decided by the Owner:
a) Commissioning Teams.
b) Testing Teams.
1.07.02 Commissioning documents shall be prepared by the Contractor in the following

manner and submitted for Owner's approval :
a) Paper of Principle
This document shall be prepared for the various equipment/ systems

under commissioning and shall have the following objectives to fulfill
and shall be submitted for Owner's approval at least six (6) months
before their actual commissioning :
i) Establish design data against which Plant Performance will be

compared.
ii) Set-out the testing objectives and proposals.
iii) Define the documentation required.
b) Testing/Commissioning Schedule
These shall be prepared for the various equipment/systems under

consideration and shall contain sections like detailed testing method,
programme, safety, individual responsibility and results.
c) Standard Check Lists
Standard checklists are intended for use at the completion of erection to

ensure correct erection, testing and to a limited extent operation for
repetitive items.
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1.07.03 Test Reports
After the completion of commissioning activity of equipment/ systems, the

Contractor shall prepare the test reports which shall include all the relevant
information related to various commissioning checks, tests carried out, any
deviations/commissions noticed with respect to the intended design
requirements, sequence of various commissioning activities as actually
adopted vis-à-vis as recommended in the procedures, programme schedules
achieved and any other such information as required. These test reports shall
be submitted in requisite number of copies to the Owner and this should be
duly signed jointly by the Owner/Consultant and the Contractor/Equipment
supplier, who are involved during the commissioning activities.
2.00.00 SITE SERVICES
These services shall be rendered by the Bidder as part of the overall project
management service. The services shall broadly include but not be limited to
the following :
2.01.00 Arranging material despatch from the shop by rail/road and/or sea as
applicable.
2.02.00 Monitoring movement of materials & follow-up as necessary with Railways,

road transport, port clearance etc. from the time of despatch F.O.R.
works/F.O.B. port of shipment by Contractor till receipt of the same at site.
2.03.00 Unloading of materials at Railway Station/Railway Siding inside project area,

transportation to site store, assessment of lost/damaged items in transit and
arranging insurance claims and replacement of lost/damaged items. The
Contractor shall submit to the Owner’s Engineer a report detailing all the
receipts during the week.
2.04.00 Issuing materials from site store/open yard from time to time for erection as per
the construction programme. The Contractor shall be the custodian of all the
materials issued till the plant is officially taken over by the Owner after complete
erection and successful trial run & commissioning.
2.05.00 Transportation of materials to their respective places of erection and erection of

the complete plant & equipment as supplied under this specification.
2.06.00 Trial run and commissioning of individual equipment/sub-systems and the plant
as a whole to the satisfaction of the Owner, including supply of temporary
equipment & services for chemical cleaning, steam blowing as well as
performance guarantee tests.
For Coal Handling Plant, satisfactory operation of the system, amongst

others, shall consist of operation without spillage or choking anywhere even
during monsoon.
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Provision for preservation of individual equipment after trial run and

commissioning e.g. Nitrogen blanketing etc. as necessary shall also be in the
scope of the Bidder.
2.07.00 Supply and application of the final paints lubricating oils and all consumable till
completion of facilities and hand over..
2.08.00 For the purpose of erection and commissioning the Contractor's scope of work
shall include but not be limited to the following :
2.08.01 Deployment of all skilled and unskilled manpower required for erection,
supervision of erection, watch & ward, commissioning and other services to be
rendered under this specification.
2.08.02 Deployment of all erection tools & tackle, construction machinery,

transportation vehicles and all other implements in adequate number and size,
appropriate for the erection work to be handled under the scope of this
specification.
Supply of commissioning spares.
2.08.03 Supply of all chemicals and consumables, e.g. Regeneration chemicals, alum,
lime, polyelectrolyte, resin, welding electrodes, cleaning agents, diesel oil,
grease, lubricant etc. as well as materials required for temporary supports,
scaffolding etc. as necessary for such erection commissioning work till
completion of facilities and hand over, except those listed under exclusion
elsewhere in this specification.
2.08.04 Construction of all civil/structural/architectural works, including construction of

foundation for all equipment supplied as required, grouting of equipment on
foundation after alignment, and all other incidental civil activities as detailed
elsewhere.
2.08.05 All structural steel fabrication and erection work as detailed elsewhere in the
specification.
2.08.06 Providing support services for the Contractor's erection staff e.g. construction of
site offices, temporary stores, residential accommodation and transport to work
site for erection personnel, insurance cover, watch & ward for security and
safety of the materials under the Contractor's custody etc. as required.
2.08.07 Maintaining proper documentation of all the site activities undertaken by the
Contractor as per the proforma mutually agreed with the Owner; submitting
monthly progress reports as also any such document as and when desired by
the Owner; taking approval of all statutory authorities e.g. Boiler Inspector,
Factory Inspector, Inspector of Explosives etc. for respective portions of work
under the jurisdiction of such statutes or laws.
2.08.08 The Contractor shall provide Ìndustrial Relations' unit and `Medical' unit to take
care of his erection staff and the Owner shall have no obligation in this regard.
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2.09.00 Site Organisation
The Contractor shall maintain a site organisation of adequate strength in

respect of manpower, construction machinery and other implements at all times
for smooth execution of the contract. This organisation shall be reinforced from
time to time, as required, to make up for slippages from the schedule without
any commercial implication to the Owner. The site organisation shall be headed
by a competent construction manager having sufficient authority to take
decisions at site.
On award of contract, the Contractor shall submit to the Owner a site

organisation chart indicating the various levels of experts to be deployed on the
job. The Owner reserves the right to reject or approve the list of personnel
proposed by the Contractor. The persons, whose bio-data have been approved
by the Owner, will have to be posted at site and deviations in this regard will not
generally be permitted.
The Contractor shall also submit to the Owner for approval a list of construction
equipment, erection tools, tackle etc. prior to commencement of site activities.
These tools & tackle shall not be removed from site without written permission
of the Owner.
2.10.00 General Guidelines for Field Activities
2.10.01 The Contractor shall execute the works in a professional manner so as to

achieve the target schedule without any sacrifice on quality and maintaining
highest standards of safety and cleanliness.
2.10.02 The Contractor shall co-operate with the Owner and other Contractors working
in site and arrange to perform his work in a manner so as to minimise
interference with other Contractors' works. The Owner's Owner’s Engineer shall
be notified promptly of any defect in other Contractor's works that could affect
the Contractor's work. If rescheduling of Contractor's work is requested by the
Owner's Owner’s Engineer in the interest of overall site activities, the same
shall be complied with by the Contractor. In all cases of controversy, the
decision of the Owner shall be final and binding on the Contractor without any
commercial implication to owner.
2.10.03 The Owner’s Engineer shall hold weekly meetings of all the Contractors
working at Site at a time and a place to be designated by the Owner’s
Engineer. The Contractor shall attend such meetings and take notes of
discussions during the meeting and the decisions of the Owner’s Engineer and
shall strictly adhere to those decisions in performing his Work. In addition to the
above weekly meeting, Owner’s Engineer may call for other meetings either
with individual contractors or with selected number of contractors and in such a
case the Contractor, if called will also attend such meetings.
2.10.04 Time is the essence of the Contract and the Contractor shall be responsible for
performance of his Work in accordance with the specified construction
schedule. If at any time the Contractor is falling behind the schedule, he shall
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take necessary action to make good of 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 action in writing to the
Owner’s Engineer, satisfying that his action will compensate for the delay. The
Contractor shall not be allowed any extra compensation for such action.
2.10.05 The Owner’s Engineer 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 co-ordination work between various Contractors as
set out earlier.
2.10.06 The works under execution shall be open to inspection & supervision by the
Owner's Owner’s Engineer at all times. The Contractor shall give reasonable
notice to the Owner before covering up or otherwise placing beyond the reach
of inspection any work in order that same may be verified, if so desired by the
Owner.
2.10.07 Every effort shall be made to maintain the highest quality of workmanship by
stringent supervision and inspection at every stage of execution.
Manufacturer's instruction manual and guidelines on sequence of erection and
precautions shall be strictly followed. Should any error or ambiguity be
discovered in such documents, the same shall be brought to the notice of the
Owner's Owner’s Engineer. Manufacturer's interpretation in such cases shall be
binding on the Contractor.
2.10.08 The Contractor shall comply with all the rules and regulations of the local
authorities, all statutory laws including Minimum Wages, Workmen
Compensation etc. The contractor shall engage maximum number of local
unskilled and semi skilled labours for construction works. All registration and
statutory inspection fees, if any, in respect of the work executed by the
Contractor shall be to his account.
2.10.09 All the works such as cleaning, checking, leveling, blue matching, aligning,
assembling, temporary erection for alignment, opening, dismantling of certain
equipments for checking and cleaning, surface preparation, edge preparation,
fabrication of tubes and pipes as per general Owner’s Engineering practice at
site, cutting grinding, straightening, chamfering, filling, chipping, drilling,
reaming, scrapping, shaping, fitting-up bolting/welding, etc., as may be
applicable in such erection and are necessary to complete the work
satisfactorily, are to be treated as incidental and the same shall be carried out
by the Contractor as part of the work.
2.10.10 In case of any class of work for which there is no such specification as laid
down in the contract such as, blue matching, welding of stainless steel parts,
etc., the work shall be carried out in accordance with the instructions and
requirements of the Owner’s Engineer.
2.10.11 It may sometimes be necessary to remove some of the erected structural

members to facilitate erection of bigger/pre-assembled equipment. In such
cases, the removal and re-erection of such members, which are essential, and
if so agreed by the Owner’s Engineer, will have to be done by the Contractor.
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2.10.12 Attachment welding of necessary instrumentation tapping points, thermocouple

pads, root valves, condensing vessels, flow nozzles and control valves etc.,
both for regular measurement and performance testing to be provided on
equipment, its auxiliaries or pipelines covered within the scope of this tender,
will also be the responsibility of the Contractor and the same will be done as
per the instructions of Owner’s Engineer. The erection and welding of all above
items will be the Contractor's responsibility, even if :
a) Product groups under which these items are re-leased are not covered
in the scope of this tender.
b) Items are supplied by an agency other than the Contractor.
2.10.13 Preservation of all materials/equipment under custody of the Contractor during

storage, pre-assembly & erection, commissioning etc., shall be the
responsibility of the Contractor. All necessary preservatives and consumables
like paints, etc., shall be arranged by the Contractor. Necessary touch up
painting, periodic application of preservatives/paints on pressure parts/other
equipment even after erection until completion of work shall be carried out by
the Contractor. The Contractor shall fabricate piping, install lub oil systems and
carry out the acid cleaning of fabricated piping. The Contractor shall also
service the lub oil system, carryout the hydraulic test of oil coolers, etc.
2.10.14 It is responsibility of the Contractor to do the alignment etc. if necessary,

repeatedly to satisfy Owner’s Engineer, with all the necessary tools & tackles,
manpower, etc. The alignment will be complete only when jointly certified so, by
the Contractor's Owner’s Engineer & Owner. Also the Contractor should ensure
that the alignment is not disturbed afterwards.
2.10.15 Additional platforms for approaching different equipment as per site

requirement, which may not be indicated in drawings, shall be fabricated and
erected by the Contractor. The materials required for these works shall be
supplied by the Contractor and he will have to fabricate them to suit the
requirement.
2.10.16 Equipment and material, which are wrongly installed, shall be removed and
reinstalled to comply with the design requirement at the Contractor's expense,
to the satisfaction of the Owner/ Consultant.
2.10.17 Before erection of any equipment on a foundation, the Contractor shall check
and undertake if necessary rectification of foundation bolts, reaming of holes,
drilling of dowels, matching of bolts and nuts, making new dowel pin, etc.
2.10.18 Assistance for calibrating/testing the power cylinders, valves, gauges,
instruments, etc., and setting of actuators coming under various groups shall be
provided by Contractor.
2.10.19 It shall be the responsibility of the Contractor to provide ladders on columns for
initial works till such time stairways are completed. For this, the ladder should
not be welded on the column and should be prefabricated clamping type. No
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temporary welding on any structural member is permitted except under special

circumstances with the approval of Owner.
2.10.20 Structural materials required for the supporting/operating platforms required for
the valves at various levels for the safe operation of valves will be arranged by
the Contractor.
2.10.21 For civil, structural and architectural works, volume IIG/1 & IIG/2 may be
referred. For Instrumentation and Electrical works Vol. IIE and Vol. IIF1 & F2
may be referred.
2.11.00 Safety
2.11.01 Safety and overall cleanliness of work site shall be given top priority. The
Contractor shall ensure the safety of all workmen, materials and equipment
either belonging to him or to others working at site. He shall observe safety
rules & codes applied by the Owner at site without exception.
2.11.02 The Contractor shall notify the Owner of his intention to bring to site any
equipment or material which may create hazard. The Owner shall have the
right to prescribe the conditions under which such equipment or material may
be handled and the Contractor shall adhere to such instructions. The Owner
may prohibit the use of any construction machinery, which according to him is
unsafe. No claim for compensation due to such prohibition will be entertained
by the Owner.
2.11.03 Storage of petroleum products & explosives for construction work shall be as
per rules and regulation laid down in Petroleum Act, Explosive Act and
Petroleum and Carbide of Calcium Manual. Approvals as necessary from Chief
Inspector of Explosives or other statutory authorities shall be the responsibility
of the Contractor.
2.11.04 The Contractor shall be responsible for safe storage of his and his
sub-contractor's radioactive sources.
2.11.05 All requisite tests & inspection of handling equipment, lifting tools & tackle shall
be periodically done by the Contractor. Defective equipment shall be removed
from service. Any equipment shall not be loaded in excess of its recommended
safe working load.
2.11.06 All combustible waste and rubbish shall be collected and removed from the
worksite at least once each day. Use of undercoated canvas paper, corrugated
paper, fabricated carton, plastic or other flammable materials shall be restricted
to the minimum and promptly removed.
2.11.07 The Contractor shall provide adequate number of fire protection equipment of
the required types for his stores, office, temporary structures, labour colony etc.
Personnel trained for fire-fighting shall be made available by the Contractor at
site during the entire period of the Contract.
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2.11.08 All electrical appliances used in the work shall be in good working condition and
shall be properly earthed. No maintenance work shall be carried out on live
equipment. The Contractor shall maintain adequate number of qualified
electricians to maintain his temporary electrical installation.
2.11.09 All workmen of the Contractor working in construction site shall wear safety
helmets, safety boots and safety belts. The Contractor shall take appropriate
insurance cover against accidents for his workmen as well as third party.
2.11.10 All the worksites shall be provided with adequate lighting facilities e.g. flood
lighting, hand lamps, area lighting etc. by the Contractor for proper working
environment during night times.
2.11.11 Adequate number of temporary toilets/urinals (men & women separate) shall be
provided at work places with soak pits. Adequate drinking water facilities and
rest rooms shall be provided for workers to take food and rest.
2.11.12 All safety precautions shall be taken for welding and cutting operations as per
IS-818.
2.11.13 All safety precautions shall be taken for foundation and other excavation marks
as per IS-3764.
2.12.00 Taking Delivery & Storage
2.12.01 The Contractor shall arrange issue of all equipment and materials to be erected
under the contract from the stores/open yard at site by signing on standard
indent forms. After completion of work, detailed auditing of the materials so
issued shall be submitted to the Owner.
2.12.02 The Contractor shall arrange for proper and safe storage of materials till the
same are taken over by the Owner as per terms of the contract. Manufacturer's
instructions for preservation shall be strictly followed.
2.12.03 All empty containers, packing materials, gunny bags, transport frames and also
surplus and unused materials reconciliation prior to completion of contract shall
be the property of the Owner and returned to the Owner by the Contractor.
2.13.00 Site Welding & Heat Treatment
2.13.01 Welding shall be done in accordance with IS-813, IS-816, IS-9595 & other
relevant IS/International standards and as per instructions of Contractor. Only
those welders, who are qualified as per IS-817 for ordinary welds and as per
IBR/ASME Section-IX for high pressure welds, shall be employed in the job.
2.13.02 All welders shall be tested and approved by Owner’s Engineer before they are
actually engaged on the work even though they may possess the requisite
certificates. The Owner reserves the right to reject any welder without assigning
any reason. The welder identification code as approved by the Owner’s
Engineer shall be stamped by the welder on each joint done by them. The
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Contractor will be responsible for the periodic renewal, re-testing of the welders
as demanded by Owner.
2.13.03 The Owner’s Engineer is entitled to stop Contractor's any welder from his work
if his work is unsatisfactory for any technical reason or there is a high
percentage of the rejection of joints welded by him, which in the opinion of
Owner’s Engineer will adversely affect the quality of welding even though the
welder has earlier passed the tests. The welders having passed the tests do
not relieve the Contractor from his contractual obligations, to check the
performance of the welders.
2.13.04 All charges for testing of welders including destructive and non- destructive
tests if conducted by Owner or by the inspection authority at site shall have to
be borne by the Contractor. The necessary test materials and consumables will
have to be arranged by the Contractor and all testing facility made available, as
required.
2.13.05 All welded joints shall be subject to acceptance by Owner’s Engineer.

Inspection of welds shall be in accordance with IS-822 or equivalent code.
2.13.06 Preheating/post-heating and stress relieving after welding are part of fabrication
and erection work and shall be performed by the Contractor in accordance with
the instruction of Owner’s Engineer. Contractor shall arrange to supply
heating equipment with automatic recording devices. Also the Contractor shall
have to arrange for the labour, heating elements, thermocouples,
compensating cables, insulation materials like mineral wools, asbestos cloth,
ceramic beads, asbestos rope, etc. required for the heat-treatment and stress
relieving works. During pre- heat/stress relieving operations, the temperature
shall be measured at one or more points as required by attaching
thermocouples and recorded on a continuous printing type recorder. All the
record graphs for the heat treatment works carried out shall be got signed by
the Owner’s Engineer prior to the commencement of each cycle and handed
over to Owner’s Engineer on completion. The graphs will be the property of
Owner. The Contractor has to provide thermo-chalks temperature recorders,
thermocouple attachments, units, graph sheets, etc. required for the job and
maintain them in good condition.
2.13.07 All electrodes shall be baked and dried in the electric/electrode drying oven to
the required temperature and for the period specified by the Owner’s Engineer
before they are used in erection work. The electrodes used shall be as per
IS-814, IS-815, IS-1442, IS-7280 and other codes as applicable, and shall be of
approved reputed manufacture. The electrodes shall meet the requirement of
the pipe material. No electrode manufactured more than 12 months ago and
the type covered under certificate issued after conducting tests more than 6
months ago shall be used. All electrodes shall be preserved at works and at
site as per manufacturer's recommendations.
2.13.08 Oxy-acetylene flame or Exothermic chemical heating for stress relieving is not
permitted. Heating shall be by means, of electric induction coil or electric
resistance coil.
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2.13.09 It may become necessary to adopt inter layer radiography/MPT/UT depending

upon the site/technical requirement necessitating interruptions in continuation
of the work and making necessary arrangement for carrying out the above
work.
2.13.10 Gas tungsten arc welding process (TIG) shall be adopted for all root pass
welds except for structural works until 4.75 mm thickness is deposited.
Subsequent welding after root pass can be carried out by manual metal arc
welding with coated electrodes. For pipes of thickness less than 6 mm the
entire welding has to be carried out by TIG welding.
Fillet weld shall be made by shielded metal arc process as per applicable
codes.
However, the Owner’s Engineer will have the option of changing the method of
welding as per site requirement. The method adopted for manual arc welding
shall be weaving technique and the width of weaving shall not exceed 1.5 times
of the dia. of the electrode.
In case of deviation from welding process and electrodes, the Contractor shall
take approval of the Owner prior to adoption of same.
2.13.11 The root pass for butt joints shall be such as to achieve full penetration with
complete fusion of root edges.
2.13.12 Each pass shall be cleared and freed of slag before the next pass is deposited.
2.13.13 On completion of each run, craters, weld irregularities, slag etc. shall be
removed by grinding or chipping.
2.13.14 Each layer of welding shall have an even and smooth appearance.
2.13.15 Welding sequence shall be adjusted in such a way that distortion due to
welding shrinkage is minimised. Further any movement, shock or vibration
during welding shall be avoided to prevent weld cracks.
2.13.16 Proper protection of welders and the work shall be taken during periods of rain.
No welding shall be carried out when surfaced to be welded are wet from any
cause.
2.13.17 Following will be stages of inspection during welding:
a) Two pieces to be joined shall be individually checked for the weld edge
preparation and profile dimensionally and to the template. Dye
penetrant check shall be carried out on edge prepared surfaces at
random. The percentage will depend upon on criticality as specified by
Owner’s Engineer.
b) Joint fit up will be a stage of inspection. Misalignment after fit up may
vary from 0.3 mm to 1.6 mm depending on outside diameter and
thickness.
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c) All joints shall be offered for visual inspection after root run. Subsequent
welding should be made only after the approval of root run.
2.13.18 All welded joints shall be painted with anti-corrosive paint immediately on
completion of radiography and stress-relieving.
2.14.00 For further details on procedures of work at site on civil, architectural, electrical
and instrumentation & control services, refer Volume: II-E, II-F1 & F2 and
II-G/1 G/2 & G/3 of this specification.
3.00.00 PROTECTION AND CARE
3.01.00 All construction and erection activities for this project are to be carried out in the
plant premises.
3.02.00 Generator Stator Lifting may be considered by either of the two options as
mentioned below:
a) With the help of two (2) nos. turbine room cranes.
b) With the help of separate lifting arrangement to be provided by the
Bidder from outside the TG building A-row column before the
construction of A-row building wall.
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SECTION-VII
ENGINEERING SERVICES
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CONTENTS
1.00.00 GENERAL 1
2.00.00 DESIGN COORDINATION MEETING 1
3.00.00 CO-OPERATION WITH OTHER 1

SUCCESSFUL BIDDERS AND CONSULTANTS
4.00.00 GUIDELINES FOR OWNER’S ENGINEERING 2

SERVICES
5.00.00 INSTRUCTION MANUALS 3
6.00.00 PLANT HANDBOOK 5
7.00.00 TENDER STAGE DOCUMENT SUBMISSION 5
8.00.00 CONTRACT STAGE DOCUMENT 6

SUBMISSION AND APPROVAL PROCEDURE
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SECTION-VII
OWNER’S ENGINEERING SERVICES
1.00.00 GENERAL
1.01.00 As part of the overall project management activity, the Successful Bidder shall
be responsible for proper Owner’s Engineering and co-ordination of activities
during various phases of execution of the contract. The Successful Bidder shall
identify a person, designated as Project Manager, with whom the Owner, the
Consulting Owner’s Engineer or the Review Consultant shall interact on
matters related to Owner’s Engineering as well as execution of the contract.
The Project Manager shall be the single-point contact person on behalf of the
Successful Bidder and shall be responsible for all Owner’s Engineering
co-ordination. The Owner /Consultant /Review Consultant shall interact with the
Project Manager only on all matters of co-ordination between the Owner and
the Successful Bidder or on matters involving the Successful Bidder, his
manufacturing units and sub-vendors. For the purpose of expediting the Owner
or his representative may sometimes interact with the manufacturing units or
sub-vendors of the Successful Bidders. However such interaction will not,
under any circumstance, dilute the responsibility of the Successful Bidder to
provide a fully Owner’s Engineered and coordinated package under this
contract.
1.02.00 On finalization of the contract, a procedure for exchange of Owner’s

Engineering information will be mutually agreed and finalized between the
Owner and the Successful Bidder.
2.00.00 DESIGN COORDINATION MEETING
The Successful Bidder and his sub-vendors will be called upon to attend design
co-ordination meetings with the Owner’s Engineer, other Successful Bidders
and the Consultants of the Owner during the period of execution of contract.
The Successful Bidder including his sub-vendors shall attend such meetings at
their own cost at Owner's or Consultant’s office in Kolkata/ or at mutually
agreed venue as and when required and fully cooperate with such persons and
agencies involved during those discussions.
3.00.00 CO-OPERATION WITH OTHER CONTRACTORS AND CONSULTING

OWNER’S ENGINEERS
The Successful Bidder shall agree to cooperate with the Owner's other
Contractors and Consulting Owner’s Engineers and freely exchange with them
such technical information as is necessary to obtain the most efficient and
economical design and to avoid unnecessary duplication of efforts. The
Owner’s Engineer shall be provided with copies of all correspondences
addressed by the Successful Bidder to other Sub- Vendors and Consulting
Owner’s Engineers in respect of such exchange of technical information.
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4.00.00 GUIDELINES FOR OWNER’S ENGINEERING SERVICES
4.01.00 Prior to commencement of the Owner’s Engineering work as part of design

submissions, all aspects of design viz., criteria for selection and sizing of all
equipment and systems, design margins etc. including that for structural steel
and civil work shall be outlined and these shall form the basis for the detailed
Owner’s Engineering work.
4.02.00 Owner’s Engineering work shall be performed on modern and proven concepts
and internationally accepted good Owner’s Engineering practices but fully
compatible with the Indian environments. Owner shall have the right to review
and approve the Owner’s Engineering work by themselves and/or through
consultant and ask for any clarifications and changes/modifications to the work
performed by Successful Bidder.
4.03.00 At any stage during the performance of assignment, the Successful Bidder may
be required to make certain changes/modification/improvements in design/
drawing/other documents, which in the opinion of the Owner could result in
better improved design, layout, operability, plant availability, maintainability,
reliability or economy of the plant and its systems/sub-systems in view of
revised and more accurate information/data available at a later date(s) or
feedback(s) received during execution/operation of similar units. Such changes/
modifications/improvements required could be identified by Owner and/or
consultant and mutually discussed. Owner requires the Bidder to incorporate
such action in the subject assignment appropriately without any additional cost
liability and time implication to the Owner and same shall be within the
responsibilities and Scope of the Successful Bidder.
4.04.00 During the course of review of detailed Owner’s Engineering stages, it may be
essential in the opinion of Owner to obtain certain classified data for review
purposes only. In case Owner so desires, the Bidder shall submit such data to
Owner.
4.05.00 During the course of review of detailed Owner’s Engineering, it may be

essential in Owner's opinion to obtain data and information on similar
equipment and plants Owner’s Engineered by the Bidder. In case Owner so
desires the Bidder shall submit such data and information to the Owner.
4.06.00 It is not the intent to give details of every single task covered in the total
Owner’s Engineering work to be carried out by Successful Bidder, however, all
Owner’s Engineering work required for the satisfactory completion of the
plant/systems as specified shall be carried out by the Successful Bidder.
Broadly, the following are the minimum requirements in respect of scope of
major items of work:
4.06.01 Preparation, updating and finalisation of scheme drawings, control and interlock
diagrams, detailed and fully dimensioned layout drawings (plant layout and
equipment layout detailed plan, elevation and cross-sectional drawings at
different elevations/ floor levels) covering all mechanical, electrical, C&I, civil
and structural items, equipment, systems and facilities. Drawings and
Schedules prepared by the Successful Bidder from time to time, as detailed
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designs are developed, shall be submitted for Owner's/ Consultant's approval

before the work is taken up. Revisions, corrections, additions to drawings and
schedules shall not be considered to change the scope of work.
4.06.02 Preparation of detailed technical specifications including data sheets, tender

drawings and bill of material for all bought out items, as also finalisation of
corresponding sub-Vendors.
4.06.03 Review of sub-Vendor's data, drawings, design calculations, schedules, bill of

materials, instruction manuals etc. for all equipment, before forwarding them to
Owner/Consultant for approval.
4.06.04 Preparation of civil construction drawings for all equipment showing foundation
details and full details regarding equipment loads, floor openings, details of
embedments, etc. required for preparation of civil construction drawings and
also as referred at relevant sections of Scope & Exclusions. These documents
shall be preceded by appropriate design calculations, static and dynamic
analysis as necessary.
4.06.05 Preparation and finalisation of process piping and instrumentation diagrams

and schematics, complete in all respects for all systems/packages of the power
plant.
4.06.06 Preparation of consolidated schedules and bills of materials, including line

numbers, tag numbers, source of supply, service conditions, specifications,
materials, types and connections details, quantities for items of the plant
including dampers, steam traps, strainers, instrumentations, ducting.
4.06.07 Sizing of all piping and equipment as per the stipulated design criteria; carrying
out of flexibility analysis/dynamic analysis as necessary; hangers & support
Owner’s Engineering.
4.06.08 Final revision of all documents including preparation and compilation of

Instruction Manuals for installation, commissioning, operation and maintenance
for all equipment and systems. Refer clause 5.00.00 for the specific
requirement in this regard.
4.06.09 Certification and submission of final as-built drawings for all areas.
4.06.10 Preparation and compilation of all drawings, schedules and instructions which
may be required at site, whether separately mentioned or not.
4.06.11 All erection and assembly drawings which may be required at site.
5.00.00 INSTRUCTION MANUALS
5.01.00 The Bidder shall provide all necessary instruction manuals for the Owner’s
review, comment, and final acceptance as required in the contract. The
instruction manual shall contain full details required for erection,
commissioning, operation and maintenance of each equipment. The instruction
manual shall be submitted in the form of one (1) soft copy in CD and 15 hard
copies.
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5.02.00 Erection Manuals
5.05.01 The erection manuals shall be submitted at least three (3) months prior to
commencement of erection activities of particular equipment/system. The
manuals shall contain the following as a minimum:
a) Erection strategy.
b) Sequence of erection.
c) List of tools, tackles, heavy equipments like cranes, dozers etc required
for erection.
d) Bill of Materials.
e) Safety precautions to be followed during erection.
f) Erection instructions.
g) Critical checks and permissible deviation/tolerances.
h) Check-list for pre-commissioning activities
i) Check-list for commissioning of the system.
j) Procedure for initial checking, testing and acceptance norms.
5.03.00 Operation & Maintenance Manuals
5.03.01 The operating and maintenance instructions together with drawings of the
equipment, as completed, shall be in sufficient detail to enable the Owner to
operate, maintain, dismantle, reassemble, and adjust all parts of the
equipment. They shall outline a step-by-step procedure for all operations likely
to be carries out during the life of the plant/ equipment. Each manual shall
include a complete set of drawings together with performance/ rating curves of
the equipment and test certificates wherever applicable.
5.03.02 If after commissioning and initial operation of the plant, the manuals require any
modification/ additions in the view of the Owner or Bidder, the same shall be
incorporated and the updated final manuals shall be submitted to the Owner.
5.03.03 The manuals shall include the following:
a) List of spare parts along with their drawing and catalogue and Pro-
forma for ordering spares.
b) Location and identification guide for bearings of various equipments and

lubrication schedule including charts showing lubrication checking,
testing and replacement procedure.
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c) Wherever applicable, fault location charts shall be included to facilitate

fault detection.
d) Detailed specification for all consumables (including lubricating oils,

greases, chemicals etc.) required for each equipment.
6.00.00 PLANT HANDBOOK
The Bidder shall provide the plant handbook to the Owner as per provision of
the contract.
The Plant Handbook shall contain the following as a minimum:
a) Design and performance data
b) Process & instrumentation diagrams
c) Single line diagrams
d) Sequence & Protection interlock schemes
e) Alarm and trip values
f) Performance curves
g) General layout plan and layout of Balance of Plant building and auxiliary
buildings
h) Important Do’s and Don’ts.
7.00.00 TENDER STAGE DOCUMENT SUBMISSION
7.01.00 The Bidder shall submit along with his bid all documents/drawings as specified
in RFP and respective sections of the Technical Specifications in Vol-II and
Vol-III. The documents shall include but not be limited to the following:
a) All Bid proposal sheets duly filled up.
b) Detailed experience list and financial resources of the Prime Bidder his
collaborators/associates in this bid as well as the sub-vendors
proposed.
c) Scheme drawings indicating scope of supply and service as offered by

the Bidder indicating clearly exclusions, if any.
d) List of terminal points of the package offered together with quality and
quantity of various input (i.e. water, air, electricity etc.) as required from
the Owner at such interfaces.
e) Equipment GA, Layout, Design Calculations, interlock and other

write-up, catalogues/literature etc. as required for clear understanding
of the bid submitted.
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f) High level project schedule network indicating target dates for

intermediate milestones and final commissioning of plant systems; This
network shall be supplemented by a detailed write-up on proposed
sequence and method of execution for project implementation,
deployment schedule for Key personnel with their bio-data, schedule of
construction machinery etc.
8.00.00 CONTRACT STAGE DOCUMENT SUBMISSION AND APPROVAL

PROCEDURE
8.01.00 Owner’s Engineering schedule shall be submitted by the Bidder as indicated in

the RFP. Owner’s Engineering schedule shall be developed in format as
desired by the Owner/consultant.
The documents shall be divided into two categories: a) for approval and b) for
information/further Owner’s Engineering and co-ordination by the Consultant.
In preparing this schedule, the Bidder shall allow one (1) week from date of
receipt for review and comments by the Consultant for each submission of a
document.
This document submission schedule shall require acceptance by the

Owner/Consultant.
Bidder shall also develop and submit a Master drawing list to the
Owner/consultant.
8.02.00 All contract documents shall be marked with the name of the Owner, the
Project, the specification title and number and the unit designation.
All dimensions shall be in metric units.
All notes, markings etc. shall be in English.
8.03.00 Documents/Drawings, submitted during tender stage, shall be revalidated or

revised as required and submitted as certified contract document for
approval/information of the Owner/Consultant.
8.04.00 Unless specified otherwise, the following categories of documents/drawings

would require approval of the Owner/Consultant:
a) System scheme and Process & instrumentation Diagrams (P & IDs).
b) Design basis documents / memoranda / calculations justifying sizing

and selection of equipment, vessels, tanks, piping, valves & specialities
as well as the process parameters.
c) Equipment data sheets and general arrangement drawings.
d) Materials of construction.
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e) General Arrangement and Layout drawings.
f) Typical control schemes, circuit diagrams, drive/ feeder-wise control

scheme showing all external interfaces.
g) Control System Configuration
g) Shop Inspection and Testing Procedures, Test Set-up &

Instrumentation, Acceptance Criteria and Codes / Standards followed,
correction curves / charts, etc.
h) Performance Test Procedures, Instrumentation, Acceptance Criteria

and Codes / Standards followed, correction curves / charts, etc.
i) Schedules covering equipment delivery schedules, erection, testing and

commissioning schedules at L1 and L2 levels.
8.05.00 Unless specified otherwise, the following categories of documents / drawings

would be treated for information/further Owner’s Engineering by the
Owner/Consultant. The Bidder shall, however, incorporate all additional
information and clarifications in these documents/ drawings as and when
desired by the Owner/ Consultant.
a) Equipment foundation drawings.
b) Equipment cross-section drawings, product literature etc. which are of

proprietary nature.
c) Predicted performance curves of equipment.
d) Various bills of quantity, schedules etc.
e) Piping fabrication drawings, isometrics etc.
f) Panel wiring diagrams.
g) Instruction/Operation manuals.
h) Service manuals and trouble shooting guide for C & I system including
field instruments.
i) Operation logic diagrams.
j) Cable schedule and interconnection chart.
In essence, the Bidder is solely responsible for corrections and adequacy of

design & Owner’s Engineering for documents under this category.
8.06.00 Upon review, the Consultant shall put his remarks and one of the following
action stamps on the drawing / document:
a) Approved.
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b) Approved except as noted, forward final drawing
c) Approved except as noted, resubmission required.
d) Disapproved.
e) For information/reference only.
For action stamps in category (c) & (d), documents must be resubmitted for
review by the Owner/Consultant. For action stamp in category (b), further
review by Owner/Consultant would not be necessary provided the Bidder
agrees & incorporates the minor comments made on the document.
Except for action stamp under category (c) & (d), the Bidder can proceed with
manufacturing and other sequential activities for those areas of a
drawing/document which do not have any review comment by the Owner/
Consultant.
The Consultant may accord approval in category (c) or (d) in more than one
submission of a document till he is satisfied that the intent of the specification
has been fully complied with. The Bidder shall be responsible for delay in such
cases and no extension of time shall ordinarily be allowed on such grounds.
The Bidder's work shall be in strict accordance with the finally approved
drawings and no deviation shall be permitted without written approval of the
Consultant.
8.07.00 Except key plan/general yard plan, any layout drawing requiring scrutiny shall
not be drawn to a scale less than 1:50.
8.08.00 For review by the Consultant, the Bidder shall furnish three (3) prints of each
drawing (only for first submission). There upon all transaction of drawings
including reviewed comments and stamping shall be done in soft. All
transaction of drawings shall be accompanied by a reference letter mentioning
the date, revision no. and document status. Only on receiving the Approval
Stamping, bidder shall distribute 6 sets of drawings (2 at WBPDCL corporate
office and 4 sets at WBPDCL site office).. The Bidder shall furnish three (3)
CDs of all as built/final drawings for Owner/Consultant site.
8.09.00 In case of contradiction between the stipulations above and those stated
elsewhere in the specification, the stipulations herein shall prevail.
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SECTION-VIII
QUALITY ASSURANCE REQUIREMENTS
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CONTENT
1.00.00 QUALITY ASSURANCE PROGRAMME 1
2.00.00 GENERAL REQUIREMENTS QUALITY ASSURANCE 2
3.00.00 QUALITY ASSURANCE DOCUMENTS 4
4.00.00 INSPECTION, TESTING & INSPECTION 5

CERTIFICATES
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1x660 MW Unit No. 5, Phase – III
WBPDCL
SECTION-VIII
QUALITY ASSURANCE REQUIREMENTS
1.00.00 QUALITY ASSURANCE PROGRAMME
1.01.00 To ensure that the equipment and services under the scope of Contract
whether manufactured or performed within the Successful Bidder's works or at
his Sub-Vendor's premises or at the Owner's site or at any other place or work
are in accordance with the specifications, the Successful Bidder shall adopt
suitable quality assurance programme to control such activities at all points, as
necessary. Such programmes shall be outlined by the Successful Bidder and
shall be finally accepted by the Owner/Authorised representative after
discussions before the award of contract. A quality assurance programme of
the Successful Bidder shall generally cover the following :
a) His organisation structure for the management and implementation of

the proposed quality assurance programme.
b) Documentation control system.
c) Qualification data for Bidder's key personnel.
d) The procedure for purchase of materials, parts, components and

selection of Sub-Vendor's services including vendor analysis, source
inspection, incoming raw-material inspection, verification of materials
purchased etc.
e) System for shop manufacturing and site erection control including

process controls and fabrication and assembly controls.
f) Control of non-conforming items and system for corrective actions.
g) Inspection and test procedure both for manufacture and all site related
works.
h) Control of calibration and testing of measuring and testing equipments.
i) System for quality audit.
j) System for indication and appraisal of inspection status.
k) System for authorising release of manufactured product to the Owner.
l) System for handling storage and delivery.
m) System for maintenance of records.
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n) 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 format enclosed at Annexure-A to this section.
2.00.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE
2.01.00 All materials, components and equipment covered under this specification shall
be procured, manufactured and tested at all the stages, as well as Services
provided for erection, commissioning and testing shall be as per a
comprehensive Quality Assurance Programme. An indicative programme of
inspection/tests to be carried out by the Bidder 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 Bidder's responsibility to draw up
and implement such programme and reviewed by by the Owner/Consultant.
The detailed Quality Plans for manufacturing and field activities should be
drawn up by the Bidder, separately in the format attached at Annexure-I and
will be submitted to Owner/Owner’s representative for review. Schedule of
finalisation of such quality plans will be finalised before award.
2.02.00 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 Bidder'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.
2.03.00 Field Quality Plans will detail out for all the equipment, the quality practices and
procedures etc. to be followed by the Bidder's site Quality Control organisation,
during various stages of site activities from receipt of materials/equipment at
site.
2.04.00 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 Consultant's approval without which
manufacture shall not proceed. In these approved quality plans,
Owner/Authorised representative/Consultant shall identify Customer Hold
Points (CHP), test/checks which shall be carried out in presence of the
Owner/Consultant/Owners Owner’s Engineer or his Authorised Representative
and beyond which the work will not proceed without consent of
Owner/Authorised representative/Consultant in writing. All deviations to this
specification, approved quality plans and applicable standards must be
documented and referred to Owner/Authorised Representative/Consultant for
acceptance and dispositioning.
2.05.00 The Bidder shall provide adequate notice to the Owner for inspection before the
material is dispatched as per the provisions of the Contract. No material shall
be despatched from the manufacturer's works before the same is accepted
subsequent to pre-despatch final inspection including verification of records of
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WBPDCL
all previous tests/inspections by Owner's Owner’s Engineer/Authorised

representative, and duly authorised for despatch issuance of Material Despatch
Clearance Certificate (MDCC).
2.06.00 All materials used or supplied shall be accompanied by valid and approved
materials certificates and tests and inspection report. These certificates and
reports shall indicate the sheet numbers or other such acceptable identification
numbers of the material. The material certified shall also have the identification
details stamped on it.
2.07.00 All the individual and assembled rotating parts shall be statically and
dynamically balanced in the works.
Where accurate alignment is necessary for component parts of machinery

normally assembled on site, the Bidder shall allow for trial assembly prior to
despatch from place of manufacture.
2.08.00 Castings and forgings used for construction shall be of tested quality. Details of
results of chemical analysis, heat treatment record, mechanical property test
results shall be furnished.
2.09.00 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 Owner.
All brazers, welders etc. employed on any part of the contract at

Bidder's/Sub-Vendor's works or at site shall be qualified as per ASME
Section-IX or BS-4871 or equivalent international standard approved by the
Owner. Such qualification tests shall be conducted in presence of Owner/his
authorised representative.
For welding of pressure parts and high pressure piping the requirements of IBR
shall also be complied with.
Under no circumstances any repair or welding of castings be carried out

without the consent of the Owner. Proof of the effectiveness of each repair by
radiographic and/or other non-destructive testing technique, shall be provided
to the Owner.
All pressure parts shall be subjected to hydraulic testing as per the

requirements of IBR. Other parts shall be tested for one and half times the
maximum operating pressure, for a period not less than thirty (30) minutes.
2.10.00 All non-destructive examination (NDT) shall be carried out in accordance with
approved international standard. The NDT operator shall be qualified as per
SNT-TC-IA (of American Society of non- destructive examination). Results of
NDT shall be properly recorded and submitted for acceptance.
All welding procedures adopted for performing welding work shall be qualified
in accordance with the requirements of Section-IX of ASME code or IBR as
applicable. All welded joints for pressure parts shall be tested by liquid
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EPC Bid Document
WBPDCL
penetrant examination according to the method outlined in ASME Boiler and

Pressure Vessel code. Radiography, magnetic particle examination and
ultrasonic testing shall be employed wherever necessary/ recommended by the
applicable code. At least 10% of all major butt welding joints shall be
radiographed. Statutory payments in respect of IBR approvals including
inspection shall be made by Bidder. Bidder’s scope and responsibility shall also
include preparation and submission of all necessary documents in the specific
formats and manner stipulated by the statutory bodies, coordination and follow up
for above approvals.
2.11.00 All the Sub-Vendors proposed by the Bidder for procurement of major bought
out items including castings, forgings, semi-finished and finished
components/equipment list of which shall be drawn up by the Bidder and
finalised with the Owner shall be subject to Owner's review. Quality Plans of the
successful Sub-Vendors shall be discussed, finalised and accepted by the
Owner/Authorised representative and form part of the Purchase Order between
the Bidder and the Sub-Vendor.
2.12.00 All the purchase specifications for the major bought-out items, list of which shall
be drawn up by the Bidder and finalised with the Owner shall be furnished to
the Owner for comments and subsequent acceptance before orders are
placed.
Owner reserves the right to carry out quality audit and quality surveillance of
the systems and procedures of the Bidder's or their Sub-Vendor’s quality
management and control activities. The Bidder shall provide all necessary
assistance to enable the Owner carry out such audit and surveillance.
Quality audit/acceptance of the results of tests and inspection will not prejudice
the right of the Owner to reject equipment not giving the desired performance
after erection and shall not in no way limit the liabilities and responsibilities of
the Bidder in earning satisfactory performance of equipment as per
specification.
2.13.00 Quality requirements for main equipment shall equally apply for spares and
replacement items.
2.14.00 Repair/rectification procedures to be adopted to make any job acceptable shall

be subject to the acceptance of the Owner.
2.15.00 For quality assurance of all civil works refer to the specifications for civil works.
3.00.00 QUALITY ASSURANCE DOCUMENTS
3.01.00 The Bidder shall be required to submit two (2) copies and two (2) sets of
microfilms of the following Quality Assurance documents within three (3) weeks
after despatch of the equipment:
a) Material mill test reports on components as specified by the

specification.
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WBPDCL
b) The inspection plan with verification, inspection plan check points,

verification sketches, if used and methods used to verify that the
inspection and testing points in the inspection plan were performed
satisfactorily.
c) Non-destructive examination results /reports including radiography

interpretation reports.
d) Factory tests results for testing required as per applicable codes and
standards referred in the specification.
e) Welder identification list listing welder's and welding operator's

qualification procedure and welding identification symbols.
f) Sketches and drawings used for indicating the method of traceability of

the radiographs to the location on the equipment.
g) Stress relief time temperature charts.
h) Inspection reports duly signed by QA personnel of the Owner and

Bidder for the agreed inspection hold points. During the course of
inspection, the following will also be recorded :
i) When some important repair work is involved to make the job

acceptable.
ii) The repair work remains part of the accepted product quality.
i) Letter of conformity certifying that the requirement is in compliance with

finalised specification requirements.
4.00.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES
4.01.00 The Successful Bidder shall give the Owner’s Engineer/Inspector fifteen (15)
days written notice of any material being ready for testing. Such tests shall be
to the Successful Bidder's account except for the expenses of the Inspector.
The Owner’s Engineer/Inspector, unless the witnessing of the tests is virtually
waived, will attend such tests within fifteen (15) days of the date on which the
equipment is notified as being ready for test/inspection failing which the
Successful Bidder 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 six (6) copies.
4.02.00 The Owner’s Engineer or Inspector shall within fifteen (15) days from the date
of Inspection as defined herein give notice in writing to the Successful Bidder,
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 Successful
Bidder shall give due consideration to such objections and shall either make
modifications that may be necessary to meet the said objections or shall
confirm in writing to the Owner’s Engineer/Inspector giving reasons therein, that
no modifications are necessary to comply with the contract.
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EPC Bid Document
WBPDCL
4.03.00 When the factory tests have been completed at the Bidder's or sub-Vendor's
works, the Owner/Inspector shall issue a certificate to this effect fifteen (15)
days after completion of tests but if the tests are not witnessed by the Owner/
Inspectors, the certificate shall be issued within fifteen (15) days of the receipt
of the Bidder's test certificate by the Owner/Inspector. Failure of the
Owner/Inspector to issue such a certificate shall not prevent the Bidder from
proceeding with the works. The completion of these tests, or the issue of the
certificates shall not bind the Owner to accept the equipment should it, on
further tests after erection be found not to comply with the contract.
4.04.00 The Bidder 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.
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WBPDCL
FORMAT OF QUALITY ASSURANCE PROGRAMME
Name of NAME OF CONTRACT QUALITY PLAN FOR

Company PACKAGE
/
Successf
ul Bidder
Package No. : QP No. : _____________ Date _____________
___________________
Rev.No.: _____________ Date _____________
Contractorr :
___________________
Sl. No. Component & Characte Class Type of Quantum Reference Acceptance Format Agency Remarks
Operation ristics Check of Check Document Norm of
Record
Volume : II-A
Page 159 of 348

REV. 00
AGITATORS
Date: FEB. 2022
SECTION-I,
Sub Section-C2 – C
PAINTING SPECIFICATION
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EPC Bid Document
SECTION-XI
PROTECTIVE COATING AND PAINTING
1.00.00 INTENT OF SPECIFICATION
1.01.00 This specification addresses the requirements of all labour, material,

and appliances necessary with reference to preparations for lining /
painting, application as well as finishing of all lining / painting for all
mechanical and electrical equipment, piping and valves, structures etc.
included under the scope of this Package.
1.02.00 The Bidder shall furnish and apply all lining, primers including wash primers
if required, under-coats, finish coats and colour bands as described
hereinafter or necessary to complete the work in all respects.
2.00.00 CODES & STANDARDS
2.01.00 The Bidder shall follow relevant Indian and International Standards
wherever applicable in cleaning of surface, selection of lining material /
paints and their application. The entire work shall conform to the following
standards / specifications (latest revision or as specified).
a) SSPC SP 10 / NACE 2 / : Near White Blast Cleaning

Sa2½
b) SSPC PA 2 : Measurement of dry film coating
thickness with magnetic gauges.
c) ASTM D 45 : Method for pull off strength using
portable Adhesion Tester.
d) NACE RP 0274 – 2004 : High-Voltage Electrical Inspection of
Pipeline Coatings.
e) NACE SP 0188 – 2006 : Discontinuity (Holiday) Testing of

New Protective Coatings on
Conductive Substrates.
f) NACE RP 0169 – 2002 : Control of External Corrosion of

Underground or Submerged Metallic
Piping Systems.
g) AWWA C 210 – 2007 : Liquid-Epoxy Coating Systems for

the Interior and Exterior of Steel
Water Pipelines.
h) IS 3589:2001 Annexure-B : Steel Pipes for Water and Sewage

Specification.
i) AWWA C222-2000 : Polyurethane Coating for the Interior

and Exterior of Steel Water Pipe and
Fittings.
Volume : II-A
Development Consultants Pvt. Ltd. Page 1 of 10 Section : XI
Protective Coating and Painting
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EPC Bid Document
j) IS 13213 : 2000 : Polyurethane Full Gloss Enamel

(Two pack)
k) ISC HD 20 (11902) : Polyurethane coating for Interior and

Exterior of steel pipe and fittings.
l) ISC HD 20 (11055) : Solvent less Liquid epoxy system by

application of Interior and Exterior
surface of steel pipeline.
3.00.00 GENERAL REQUIREMENTS
3.01.00 The steel surface preparation prior to actual commencement of coating

shall conform to SSPC SP 10 / NACE 2 / Sa2½ (near white metal) with
sand blasting.
3.02.00 The contractor shall submit a detailed written description in the form of
a manual covering coating equipment, procedures, materials inspection
test, and repair etc. to Owner/Consultant for approval.
3.03.00 The contractor shall also provide copies of test reports from NABL
approved laboratory (like National Test House, Kolkata) in support of the
paint/primer materials to be used shall conform to the specification
requirement.
3.04.00 The contractor shall also provide certificates from paint/primer

manufacturer mentioning the batch numbers, date of manufacture and shelf
life etc. of the materials to be used. In addition to that Manufacturing
Quality Plan (MQP) and Field Quality Plan (FQP) shall also be submitted
prior to commencement of supply of material and field application.
3.05.00 Paint/coating application work at site shall be done either by

paint manufacturer or by their authorized applicator. The authorized
applicator shall have proper training & certification from manufacturer.
Applicator s h a l l possess all the necessary specialized equipment and
manpower experienced in similar job.
3.06.00 Applied coating shall be tested for dry film thickness, holiday
(electrical inspection for continuity) and adhesion as per relevant
standard such as SSPC PA 2, NACE RP 0274 and ASTM D 4541.
3.07.00 If necessary, the material may be heated and applied by airless spray /
plural component spray system.
3.08.00 Manufacturer's specific recommendation, if any, shall be followed during

application of lining / paints.
3.09.00 In areas where there is danger of spotting automobiles or other finally

finished equipment or building by wind borne particles from paint
spraying, a Purchaser approved method shall be adopted.
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EPC Bid Document
3.10.00 The colour scheme of the entire Plant, covered under this specification
shall be approved by the Purchaser in advance before application.
3.11.00 All indoor and outdoor piping, insulated as well as uninsulated will
have approved colour bands painted on the pipes at conspicuous
places throughout the system, as approved by Purchaser.
3.12.00 Inside surfaces of vessels / tanks shall be protected by anticorrosive paints

or rubber lining as required / specified elsewhere in the specification.
External surfaces of all vessels / tanks shall be protected by anti-corrosive
painting.
3.13.00 For vessels / tanks requiring lining and epoxy painting all inside surface
shall be blast cleaned using non-siliceous abrasive after usual wire brushing.
3.14.00 Natural rubber lining shall be provided on the inside of vessels / tanks
as required / specified elsewhere in the specification, in three layers
resulting in a total thickness not less than 4.5 mm.
3.15.00 Surface hardness of rubber lining shall be 65 +/- 5 deg. A (shore).
3.16.00 After the lining is completed, the vessels / tanks shall not be subjected to
any prolonged exposure to direct sunlight in course of its transportation,
erection etc. They shall not be stored in direct sunlight. No further lining
or burning shall be carried out on the vessel, after application of the lining.
3.17.00 All lining projecting outside of the vessel shall be protected adequately
from mechanical damages during shipment, handling storage etc.
3.18.00 Suitable warnings, indicating the special care that must be taken with
respect to these lined vessels shall be stenciled on their outside surface
with the letters at least 12 mm high.
3.19.00 All insulated piping shall have aluminium sheet jacketing.
4.00.00 EQUIPMENT, MATERIAL AND SERVICES TO BE FURNISHED BY

THE BIDDER
4.01.00 After erection at site, the outside surfaces of all equipment having a shop
coat shall be given further priming coat and finished coats of paint as
detailed in following clauses. However, if the painting system is such that
the shop coat and primer coat to be applied at site are not compatible,
then shop coat has to be removed from the surface of equipment before
application of primer coat with prior blasting.
All factory finished paints shall be touched up at site as required.
All uninsulated piping shall be finished with final paintings after use of
proper wash primer and primer. Aluminium sheet jacketed piping need not
be painted. Colour bands of Purchaser's approved shade shall however be
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EPC Bid Document
applied on jacketed piping near walls or partitions, at all junctions,

near valves and all other places as instructed by the Purchaser. All
structures shall be painted with approved paint.
4.02.01 Unless mentioned otherwise, all rust and mill scale shall be removed
by blasting up to SSPC SP10/NACE2/Sa2½ level to get “near white metal”
surface before applying the primer.
4.02.02 Special care shall be taken to remove grease and oil by means of
suitable solvents like Trichloroethylene or Carbon Tetrachloride.
4.03.00 Painting
4.03.01 Specification for application of paints for external surfaces protection

of vessels / tanks / equipment / piping / fittings / valves shall be as
follows :
a) Surface preparation shall be done by means of sand blasting,

which shall conform to SSPC SP10/NACE 2/Sa2½ Standard.
b) Primer Coat shall consist of one coat (minimum DFT of 100

microns) of epoxy resin based zinc phosphate primer.
c) Intermediate Coat (or Under Coat) shall consist of one coat

(minimum DFT of 100 microns) epoxy resin based paint pigmented
with Titanium Dioxide.
d) Top Coat shall consist of one coat (minimum DFT of 75 microns)

of epoxy paint of approved shade and colour with glossy finish.
Additional one coat (minimum DFT of 25 microns) of Finish Coat
of polyurethane shall be provided.
e) Total DFT of paint system shall not be less than 300 microns.
4.03.02 Specification for application of paints for external surfaces protection of

steel pipes and fittings which are buried underground / laid inside a Hume
Pipe & or submerged Under Water and laid under Pipe Trenches (in
road/rail/pipe or trench crossings) shall be as follows :
a) Surface preparation by means of sand blasting and shall conforms

to SSPC SP10/NACE2/ Sa2½.
b) External surface of the pipe, fittings, specialties etc. handling raw

water/ clarified water/filter water shall be painted with one coat of two
part chemically cured polyurethane primer of min 50 micron dry film
thickness followed by three or maximum four coats of two part
solvent less polyurethane to build up coating of dry film thickness of
1500 micron including primer coat.
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EPC Bid Document
4.03.03 Specification for application of paints for internal surface protection of

large diameter pipes, if any, shall be as follows :
a) Surface preparation by means of sand blasting which shall

conforms to SSPC SP10/NACE2/Sa2½ standard.
b) All Internal surfaces of steel pipes, fittings, specialties etc.

buried underground or located within pipe trenches shall be given
epoxy coating to protect them from (except for drinking water
service, where the compatible painting shall be so selected to meet
relevant quality standards) corrosion.
c) Internal surface of the pipe should be coated with one coat of two
part epoxy primer with not less than 50 micron DFT (dry film
thickness) followed by two part polyamide cured solvent less epoxy.
d) The minimum dry film thickness (DFT) of internal lining shall be

5 00 micron.
4.03.04 Specification for application of paints for protection of internal surfaces of

DM Water Storage Tank(s) shall be as follows :
a) Primer - One coat of epoxy primer containing high level of

Zinc Phosphate anticorrosive pigment. Total Dry Film Thickness
(DFT) of primer shall not be less than 125 microns.
b) Finish Paint - Three (3) coats Polyamine HB Epoxy Paint. Total

Dry Film Thickness (DFT) of finish paint shall not be less than 125
microns per coat.
c) Total thickness of primer and paint should not be less than

500 microns.
4.03.05 All motors, local push button stations, cable racks, structures used
for supports etc. are to be painted with acid proof paint.
4.03.06 The following surfaces shall not be painted - stainless steel, galvanized
steel, aluminum, copper, brass, bronze and other nonferrous materials.
4.03.07 No painting or filler shall be applied until all repairs, hydrostatic tests and
final shop inspection are completed.
4.03.08 All machined surfaces shall have two (2) coats of water repellant grease
after thorough cleaning.
5.00.00 COATING PROCEDURE AND APPLICATION
5.01.00 Surface preparation :
Pipe shall be blast cleaned by sand. The cleanliness achieved prior to

application shall be in accordance with the requirement of SSPC SP 10 /
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EPC Bid Document
NACE 2 / Sa2½ of ISO 8501 (near white metal)
a) The blast pattern or profile depth shall be 40 to 100 micron and

shall be measured by dial micrometer.
b) Before sand blasting is started or during blasting or

coating, temperature of the pipe surface should be more than 3°C
above dew point temperature. Blast cleaned surface should be
primed within 4 hours and shall be protected from rainfall or
surface moisture and shall not be allowed to flash rust. If the rust
occurs, the surface again to be prepared by sand blasting or wire
brushing.
5.02.00 Application of Epoxy Coating
a) Coating shall be applied when
i) When the pipe surface temperature shall be at least 3°C

above dew point temperature.
ii) The temperature of mixed coating material and the pipe at

the time of application shall not be lower than 10°C or
greater that
50°C.
b) Material p r e p a r a t i o n s h a l l b e in accordance with

m a n u f a c t u r e r ’ s recommendations.
c) Application of epoxy coating system :
The epoxy coating system shall be applied as per recommendation

of the manufacturer and shall be applied by airless spray / plural
component spray machine. For more than one coat, the second
shall be applied with the time limits as recommended by the
manufacturer.
5.03.00 Application of PU Coating
a) PU coating shall be applied when the pipe surface temperature

at least 3°C above dew point temperature (when R.H is more than
85%).
b) Material preparation and application shall be done as

per manufacturer recommendation.
6.00.00 TEST REQUIREMENTS
6.01.00 Measurement of dry film thickness
Measurement of dry film thickness of coating: Coating thickness shall be

in the range of ±20% and as per SSPC PA 2.
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EPC Bid Document
6.01.01 Apparatus / Instrument
The instrument used for dry film thickness may be Type 1 pull of gauges
or Type 2 electronic gauges.
6.01.02 Procedures
a) Number of measurements
For 100 square feet (9.29 square meters), five (5) spots per test
area (each spot is 3.8 cm) in diameter. Three gauge readings per
spot (average becomes the spot measurement).
b) If the structure is less than 300 square feet, each 100 square
feet should be measured.
c) If the structure is between 300 and 1000 sq ft, select 3 random

100 square feet test areas and measure.
d) For structure exceeding 1000 square feet, select 3 random

100 square feet testing areas for the first 1000 sq ft and select 1
random 100 square feet testing area for each additional 1000 square
feet
e) Coating thickness Tolerance: Individual reading taken to get

a representative measurement for the spot are unrestricted (usually
low or high readings are discarded). Spot measurements (the
average of 3 gauge readings) must be within 80% of the minimum
thickness and 120% of the maximum thickness.
Area measurement must be within specified range.
6.02.00 Electrical Inspection (Holiday) Test
6.02.01 All the coated / lined pipes shall be tested with an approved high
voltage holiday detector preferably equipped with an audio visual signaling
device to indicate any faults, holes, breaks or conductive particles in the
protective coating.
6.02.02 The applied output voltage of holiday detector shall have a spark discharge
of thickness equal to at least twice the thickness of the coating to assure
adequate inspection voltage and compensate for any variation in coating
thickness. The electrode shall be passed over the coated surface at
approximately half the spark discharge distance from the coated surface
only one time at the rate of approximately 10 to 20m/min. The edge effect
shall be ignored. Excessive voltage shall be avoided as it tends to induce
holiday in the coated surface thereby giving erroneous readings.
6.02.03 While selecting test voltages, consideration should be given to the

tolerance on coating thickness and voltage should be selected on the
basis of maximum coating thickness likely to be encountered during testing
of a particular pipe.
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EPC Bid Document
The testing voltage shall be calculated by using following formula. (as

per NACE 0274 : 2004)
Testing Voltage V = 7900 √T ± 10 percent where T is the average

coating thickness in mm.
6.02.04 Any audio visual sound or spark leads to indicate pinhole, break or
conductive particle.
6.03.00 Adhesion Pull off Test
After holiday the coated surface is subjected to adhesion pull off test as
per ASTMD 4541.
6.03.01 Apparatus / Instrument: Adhesion tester consists of three basic components:
A hand wheel, a black column containing a dragging indicator pin and scale
in the middle and a base containing three legs and a pulling “Jaw” at the
bottom and also dollies.
6.03.02 Prepare the test surface
Once test area is selected, test area shall be free of grease, oil, dirt, water.
The area should be flat surfaces and large enough to accommodate the
specified number of replicate test.
6.03.03 Prepare Dolly (Test Pull Stub)
The dolly is a round, two sided aluminium fixture. Both sides of the dolly
looks same, however, one side sloped on top surface while flat on bottom
surface. As the surface of the dolly is polished aluminium, roughen the
same using a coarse sand paper.
6.03.04 Select an adhesive
Use araldite, a 100% solid epoxy adhesive. This adhesive requires at least
24 hours at room temperature to cure.
6.03.05 Attach the dolly to the surface
a) Using a wooden stick, apply an even layer of adhesive to the

entire contact surface area of the dolly.
b) Carefully remove the excessive adhesive by using a cotton

swab. Allow the adhesive to fully cure before performing the adhesion
test.
c) Attach the dolly to the coated surface and gently push downward
to displace any excessive adhesive.
d) Push the dolly inward against the surface, then apply tape across
the head of the dolly.
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EPC Bid Document
6.03.06 Adhesion Test Procedure
a) Attach the adhesion tester to the dolly by rotating the hand

wheel counter clockwise to lower the jaw of the device.
b) Slide the jaw completely under the head of the dolly. Position the
three legs of the instruments so that they are sitting flat on the
coated surface.
c) Slide the dragging indicator pin on the black column to zero

by pushing it downward.
d) Firmly hold the base of the instrument in one hand and rotate
the hand wheel clockwise to raise the jaw of the device that is
attached to the head of the dolly. The dragging indicator pin will
move upward on the black column as the force is increased and will
hold the reading. Apply the tension using a moderate speed.
Continue to increase the tension on the head of the dolly until (a) the
minimum PSI/MPa/Kg/cm² required by project specification is
exceeded and the test is discontinued, (b) the maximum
PSI/MPa/Kg/cm² of adhesion tester has been achieved and dolly is
still attached, (c) The force applied by the adhesion tester causes the
dolly to dislodge.
e) Read the scale and record the adhesion value.
6.04.00 Coating Repair
Defective Coating shall be repaired in accordance with the

following subsections.
Accessible areas of pipe requiring coating repairs shall be cleaned to

remove debris and damaged coating using surface grinders or other means.
The adjacent coating shall be feathered by sanding, grinding or other
method. Accumulated debris shall be removed by blowing with contaminant
free air or wiping with clean rags.
6.04.02 Areas not accessible for coating repair such as interior surfaces of
small diameter pipe shall be reprocessed and recoated.
6.04.03 Coating Application
The coating system shall be applied to the prepared areas in accordance

with procedure.
6.04.04 Repair Inspection:
Repaired portion shall be electrically inspected using a holiday detector.
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EPC Bid Document
6.05.00 Welded Field Joints
6.05.01 Preparation
The weld joints shall be cleaned so as to be free from mud, oil, grease,
welding flux, weld spatter and other foreign contaminants. The cleaned
metal surfaces of the weld joint shall then be blasted or abraded using
rotary abrading pads. The adjacent liquid Epoxy / PU coating shall be
feathered by abrading the coating surface for a distance of 25 mm.
6.05.02 Electrical Inspection
After curing the coating system applied to the welding joints shall be holiday
tested. Any holidays indicated by the detector shall be marked with chalk to
identify the area of repair.
7.00.00 INFORMATION/DATA REQUIRED
The Bidder shall submit complete list of paints and primers proposed, giving
detail information, such as, chemical composition, drying time etc. and also
unit rates for application of each type of paint along with supply shall be
furnished.
Volume : II-A
Page 170 of 348

1X660MW SAGARDIGHI STPP SPECIFICATION No: PE‐TS‐445‐167‐A002
MISC. TANKS ‐ SITE FABRICATED SECTION‐I, SUB‐SECTION‐ D
JULY 2021
SHEET : 4 OF 1
PAINTING SPECIFICATION
PAINTING SPECIFICATION FOR MISCELLANEOUS TANKS,

Condensate storage Tank NaOH BREATHER AND SEAL POT
Coat Tank Internal Tank External, Structural Tank Underneath

Description steel works, piping,
stairways & other
accessories
Surface SA 2.5 SA 2.5 Wire Brushing/ hand
Preparation (As tool cleaning to ST‐2.
per SSPC, Vis 1
or DIN 55928,
Section‐4 or SIS
055900)
Primer One (1) coat of epoxy primer One (1) coat (minimum DFT One (1) coat of high
containing high level of Zinc of 100 microns) of Epoxy build coal tar epoxy
Phosphate resin based zinc phosphate suitably pigmented
Anticorrosive pigment. Total primer. (2 pack), DFT: 80 –
Dry Film Thickness (DFT) of 100 microns each
primer shall not be less than coat.
125 microns.
Intermediate N. A. One (1) coat (minimum DFT N. A.
coat of 100 microns) epoxy resin
based paint pigmented with
Titanium Dioxide.
Finish Three (3) coats Polyamine One (1) coat (minimum DFT N. A.
HB Epoxy Paint. Total Dry of 75 microns) of epoxy paint
Film of approved shade and color
Thickness (DFT) of finish with glossy finish. Additional
paint shall not be less than one coat (minimum DFT of
125 microns per coat. 25 microns) of Finish Coat of
polyurethane shall be
provided.
Total DFT 500 microns 300 microns 80‐100 microns
Note:
Final colour of paint shall be “Sea Green”, Shade no. 217.
Page 171 of 348

REV. 00
AGITATORS
Date: FEB. 2022
SECTION-I,
Sub Section-C2 – D
HARDCOPY DISTRIBUTION SCHEDULE
Page 172 of 348

Vendor
Vendor
Vendor
Vendor
Page 173 of 348

REV. 00
AGITATORS
Date: MARCH 2022
SECTION-I,
Sub Section-C3
ELECTRICAL SPECIFICATION
Page 174 of 348

AGITATOR
PACKAGE

!"

Page 175 of 348

TITLE: SPECIFICATION NO.
TECHNICAL SPECIFICATION VOLUME NO. : II-B
FOR
AGITATOR
LUBE MOTOR
OIL TRANSFER PUMPS SECTION: I
REV NO.: 00 DATE: 11.11.21
SAGARDIGHI THERMAL POWER PROJECT SHEET: 1 OF 1
1 x 660 MW UNIT NO. 5, PHASE – III
CONTENTS
SECTION TITLE NO OF SHEETS
I SPECIFIC TECHNICAL REQUIREMENTS 1
I ELECTRICAL SCOPE BETWEEN BHEL & VENDOR (ANNEXURE-I) 2
I ELECTRICAL LOAD DATA FORMAT (ANNEXURE-II) 1
I CABLE SCHEDULE FORMAT (ANNEXURE-III) 1
I EXPLANATORY NOTES FOR CABLE ROUTING 2
I TECHNICAL SPECIFICATION FOR MOTORS 10
I MOTOR DATASHEET-A 1
I TECHNICAL SPECIFICATION FOR CABLES 12
I SUB-VENDOR LIST 1
II MOTOR DATASHEET-C 2
II GENERAL TECHNICAL REQUIREMENT FOR LV MOTORS 4
II SQP_LV MOTORS UPTO 55KW 2
II SQP_LV MOTORS 55KW & ABOVE 9
The requirements mentioned in Section-I shall prevail and govern in case of conflict between the
same and the corresponding requirements mentioned in the descriptive portion in Section-II.
Page 176 of 348

TITLE: SPECIFICATION NO.
FOR
AGITATOR
LUBE MOTORPUMPS
OIL TRANSFER VOLUME NO. : II-B
SAGARDIGHI THERMAL POWER PROJECT SECTION: I
1 X 660 MW UNIT NO. 5, PHASE-III REV NO.: 00 DATE: 11.11.2021
SHEET: 1 OF 1
SPECIFIC TECHNICAL REQUIREMENT: ELECTRICAL
1.0 EQUIPMENT & SERVICES TO BE PROVIDED BY BIDDER:

The equipment and services to be provided by bidder under this specification shall be as
detailed here below but shall not be limited to the following:
a) Services and Equipment as per “Electrical Scope between BHEL and Vendor”.
b) Any item/work either supply of equipment or erection material which have not been
specifically mentioned but are necessary to complete the work for trouble free and efficient
operation of the plant shall be deemed to be included within the scope of this specification.
The bidder without any extra charge shall provide the same.
c) Supply of mandatory spares as specified in the specifications of mechanical equipment’s.
d) Electrical load requirement for AGITATOR.
LUBE OIL TRANSFER PUMPS.
e) All equipment shall be suitable for the power supply fault levels and other climatic conditions
mentioned in the enclosed project information.
f) Bidder to furnish list of makes for each equipment at contract stage, which shall be subject
to customer / BHEL approval without any commercial and delivery implications to BHEL.
g) Various drawings including GA drg, data sheet as per required format, quality plans,
calculations, test reports, test certificates, operation and maintenance manuals,
characteristic curves, wiring diagrams/schemes etc. shall be furnished as specified at
contract stage. All documents shall be subject to customer / BHEL approval without any
commercial implications to BHEL.
h) The sub-vendor list for various electrical items is subject to BHEL/Customer approval without
any commercial implications.
i) Motors shall meet minimum requirement of Electric motor specification.
j) All routine tests and type tests reports as per applicable standards shall be furnished at
contract stage.
k) Vendor to clearly indicate equipment locations and local routing lengths in their cable listing
furnished to BHEL.
l) Cable BOQ worked out based on routing of cable listing provided by the vendor for “both
end equipment in vendor’s scope” shall be binding to the vendor with +10 % margin to take
care of slight variation in routing length & wastages.
2.0 EQUIPMENT & SERVICES TO BE PROVIDED BY PURCHASER FOR ELECTRICAL &

TERMINAL POINTS:
Refer “Electrical Scope between BHEL and Vendor”.
3.0 DOCUMENTS TO BE SUBMITTED ALONG WITH BID
3.1 Bidder shall confirm total compliance to the electrical specification without any deviation
from the technical / quality assurance requirements stipulated in the form of compliance
certificate/ NO deviation certificate.
3.2 No technical submittal such as copies of data sheets, drawings, write-up, quality plans, type
test certificates, technical literature, etc, is required during tender stage. Any such
submission even if made, shall not be considered as part of offer.
4.0 LIST OF ENCLOSURES
4.1 Electrical scope between BHEL & vendor

4.2 Load Data Format. (Annexure –II)
4.3 BHEL Cable listing format (Annexure–III) & Explanatory notes for filling up cable list
4.4 Technical specification – Specification for Electric Motors/Actuators & Cables.
4.5 Datasheets & quality plan for motors & General technical requirements for LV
Motors
Page 177 of 348

REV: 0 DATE: 11.3.2020
11/11/2021
STANDARD ELECTRICAL SCOPE BETWEEN BHEL AND VENDOR (FOR EPC PROJECTS)
PACKAGE: AGITATOR
PROJECT: 14X250
X 660
3X800 MW
MWMW SAGARDIGHI
BRBCL
PATRATU STPP
NABINAGAR
TPS FGD
S.NO DETAILS SCOPE SUPPLY SCOPE E&C REMARKS
1 415 V MCC BHEL BHEL 415 V AC (3 PHASE 4 WIRE) supply shall be provided by BHEL based on
load data provided by vendor at contract stage for all equipment supplied by
vendor as part of contract. Any other voltage level (AC/DC) required will be
derived by the vendor.
2 Local Push Button Station ( for motors) BHEL BHEL Located near the motors.
3 Power cables, control cables and screened control cables Incoming cable from BHEL supplied MCC will be informed by BHEL. Vendor
shall provide lugs & glands accordingly.
BHEL BHEL
4 Cable trays, accessories & cable trays supporting system BHEL BHEL
Page 159 of 266
5 Cable glands and lugs for equipments supplied by Vendor Vendor BHEL 1. Double compression Ni-Cr plated brass cable glands
2. Solder less crimping type heavy duty tinned copper lugs for power and
control cables.
6 Conduit and conduit accessories for cabling between BHEL BHEL
equipments supplied by vendor
7 Equipment grounding & lightning protection BHEL BHEL
8 Below grade grounding BHEL BHEL

9 LT Motors with base plate and foundation hardware Vendor BHEL Makes shall be subject to BHEL approval at contract stage.
10 Mandatory spares Vendor - Vendor to quote as per specification.
11 Recommended O & M spares Vendor - As per specification
12 Any other equipment/material/service required for Vendor BHEL
completeness of system but not specified above (to ensure
trouble free and efficient operation of the system).
13 Electrical equipment GA drawing Vendor - For necessary interface review.
NOTES:
03/02/2021
1. Make of all electrical equipments/items supplied shall be reputed make & shall be subject to approval of BHEL after award of contract.
2. All QPs shall be subject to approval of BHEL after award of contract without any commercial implication.
Page 178 of 348

Section-I

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Page 179 of 348

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Page 180 of 348

Section-I
Explanatory notes for filling up cable list for routing through WinPath, the cable routing program
(developed by Corporate R&D) being used in PEM.
1. For the purpose of clarity, it may please be noted that the information given in regard to the cables to
be routed through WinPath as per the system elaborated below is called “Cable List”, while the term
“Cable Schedule” applies to the cable list with routing information added after routing has been
carried out.
2. The cable list shall be entered as an MS Excel file in the format as per enclosed template
EXT_CAB_SCH_FORMAT.XLS. No blank lines, special characters, header, footer, lines, etc. shall be
introduced in the file. No changes shall be made in the title line (first line) of the template.
3. The field properties shall be as under:
a. UNITCABLENO: A/N, up to sixteen (16) characters; each cable shall have its own unique,
unduplicated cable number. In case this rule is violated, the cable cannot be taken up for
routing.
b. FROM: A/N, up to sixty (60) characters; the “From” end equipment/ device description and
location to be specified here. Information in excess of 60 characters will be truncated after 60
characters.
c. TO: A/N, up to sixty (60) characters; the “To” end equipment/ device description and location
to be specified here. Information in excess of 60 characters will be truncated after 60
characters.
d. PURPOSE: A/N, up to sixty (60) characters; the purpose (i.e. power cable/ indication/
measurement, etc.) to be specified here. Information in excess of 60 characters will be
truncated after 60 characters.
e. REMARKS: A/N, up to forty (40) characters; Any information pertinent to routing to be
specified here (e.g., cable number of the cable redundant to the cable number being entered).
Information in excess of 40 characters will be truncated after 40 characters.
f. CABLESIZE: A/N, 7 characters exactly as per the codes indicated below shall be specified
here. The program cannot route cables described in any other way/ format.
g. PATHCABLENO: Field reserved for utilization by the program. User shall not enter any
information here.
4. One list shall be prepared for each system/ equipment (i.e., separate and unique cable lists shall be
prepared for each system).
5. The cables shall be described as per the scheme listed below:
A NN A NNN
| | | |
Cable No. of cores Cable code Cable size
Voltage (e.g. 01,03,3H, 07) (See C below) (e.g. 035,185,2.5, 0.5)
Code (see B
below)
(A) SYSTEM VOLTAGE CODES:

(ac) A = 11KV, B = 6.6KV, C = 3.3KV, D = 415V, E = 240V, F = 110V
(dc) G = 220V, H = 110V, J = 48V, K = +24V, L = -24V
(B) CABLE VOLTAGE CODES:

A = 11KV (Power cables)
Rev 0 27 October 2016 Page 1 of 2
Page 181 of 348

Section-I
Explanatory notes for filling up cable list for routing through WinPath, the cable routing program
(developed by Corporate R&D) being used in PEM.
B = 6.6KV (Power cables)
C = 3.3KV (Power cables)
D = 1.1KV (LV & DC system power & control cables)
E = 0.6KV (0.5 sq. mm. Control cables)
(C) CABLE CODES
PVC Copper
A = Armoured FRLS B = Armoured Non-FRLS
C = unarmoured FRLS D = Unarmoured Non-FRLS
PVC Aluminium
E = Armoured FRLS F = Armoured Non-FRLS
G = unarmoured FRLS H = Unarmoured Non-FRLS
XLPE Copper
J = Armoured FRLS K = Armoured Non-FRLS
L = unarmoured FRLS M = Unarmoured Non-FRLS
XLPE Aluminium
N = Armoured FRLS P = Armoured Non-FRLS
Q = unarmoured FRLS R = Unarmoured Non-FRLS
S = FIRE SURVIVAL CABLES

T = TOUGH RUBBER SHEATH
U = OVERALL SCREENED
V = PAIRED OVERALL SCREENED
W = PAIRED INDIVIDUAL SCREENED
Y = COMPENSATING CABLES
I = PRE-FABRICATED CABLES
Z = JELLY FILLED CABLES
Rev 0 27 October 2016 Page 2 of 2
Page 182 of 348

Section-I
EPC Bid Document
SECTION - II
A.C. & D.C. MOTORS
1.00.00 SCOPE
1.01.00 This specification covers the general requirements of the electric motors for
plant auxiliary equipment except for special application like crane, lift,
submersible pump etc., motors for which are covered in individual equipment
specifications.
1.02.00 Motors shall be furnished in accordance with both this general specification
and the accompanying driven equipment specification.
1.03.00 In case of any discrepancy, the driven equipment specification shall govern.
2.00.00 STANDARDS
2.01.00 All motors shall conform to the latest applicable IS, IEC and CBIP
Standards/Publications except when otherwise stated herein or in the driven
equipment specification.
2.02.00 Equipment and materials conforming to any other standard, which ensures
equal or better quality may be accepted. In such case, copies of the English
version of the standard adopted shall be submitted along with the bid.
3.00.00 SERVICE CONDITIONS
3.01.00 The motors will be installed in hot, humid and tropical atmosphere, highly
polluted area.
3.02.00 Unless otherwise noted, electrical equipment/system design shall be based

on the service conditions and auxiliary power supply given in the annexure of
this specification.
3.03.00 For motor installed outdoor and exposed to direct sun rays, the effect of solar
heat shall be considered in the determination of the design ambient
temperature.
4.00.00 TYPE AND RATING
4.01.00 A.C. Motors
4.01.01 Motors shall be general purpose, constant speed, squirrel cage, three/single
phase, induction type.
4.01.02 All motors shall be either totallyy enclosed fan cooled (TEFC)
( ) or totallyy enclosed
(
tube ventilated (TETV) ) or closed air circuit air cooled (CACA)
( ) or closed air
water cooled ((CACW) type. Temperature rise shall be limited to 70 deg C by
resistance method.
4.01.03 All motors shall be rated for continuous duty. They shall also be suitable for
long period of inactivity.
Development Consultants Pvt. Ltd. Page 1 of 10 Volume : II-F/1

Section : II
A.C. & D.C. Motors
Page 183 of 348
Section-I
EPC Bid Document
IE3
4.01.04 All LT motor shall conform to minimum efficiency performance standards
(MEPS) of IE2 mentioned in IS: 12615. All HT motors shall have efficiency and
power factor higher than 90% and 0.83 respectively.
4.01.05 The motor name-plate rating at 50qC shall have at least 15% margin for LT
system and 10% margin for HT system, over the input power requirement of the
driven equipment at rated duty point and also covering the maximum load
demand of the driven equipment under entire operating range, including voltage
and frequency variations, unless stated otherwise in driven equipment
specification or in general electrical specification.
4.01.06 The motor characteristics shall match the requirements of the driven
equipment so that adequate starting, accelerating, pull up, break down and
full load torques are available for the intended service. The direction of
rotation of motor and its cooling fan should be properly matched with the
driven equipment.
4.02.00 AC motor for VFD application (If applicable)
4.02.01 Inverter duty motors are designed according to the requirements of IEC/TS-
60034 part17 & part 25 or NEMA MG-1, Part-30, Part 31 and have
performance characteristics match with the driven equipment and variable
speed requirement.
4.02.02 Induction motors to be operated in adjustable-speed drive applications should

be de-rated as per NEMA/IEC standard due to the reduction in cooling
resulting from any reduction in operating speed and the effect of additional
losses introduced by harmonics generated by the control.
4.02.03 Inverter duty motors shall have VPI/improved insulation systems that do not
degrade readily due to transient voltage spikes and have an adequate
thermal margin.
4.02.04 Inverter duty motors shall be self ventilated without any auxiliary blower.
Force ventilation shall be subject to purchaser approval.
4.02.05 Inverter motor shall be suitable for scalar (open loop) control, without any
speed feedback signal, where fast response is not required. Vector (closed
loop) control will be used with encoder if specified.
4.02.06 The breakdown torque at any frequency within the defined frequency range
shall be not less than 150% of the rated torque at that frequency when rated
voltage for that frequency is applied.
4.02.07 The motor should be capable of producing a breakaway torque of at least

140% of rated torque requiring not more than 150% rated current when the
voltage boost is adjusted to develop rated flux in the motor and when the
inverter is able to produce the required minimum fundamental frequencies
4.02.08 The motor shall be provided with insulated bearing on one side.
4.02.09 Normally the maximum safe speed shall be as per IEC/NEMA, however it
should be coordinated with VSD requirement.

Section : II
A.C. & D.C. Motors
Page 184 of 348
Section-I
EPC Bid Document
4.02.10 In case of a conflict, the requirement mentioned under clause no. 4.02.00 for
motors for VFD application shall supersede the corresponding requirement for
standard motors.
4.03.00 D. C. Motors
4.03.01 D.C. motor provided for emergency service shall be shunt wound type. It can
also be of compound-wound type with the series field shorted.
4.03.02 Motor shall be sized for operation with fixed resistance starter for maximum
reliability. Starter panel complete with all accessories shall be included in the
scope of supply.
5.00.00 PERFORMANCE
5.01.00 Running Requirements
5.01.01 Motor shall run continuously at rated output over the entire range of voltage
and frequency variations as given in the annexure.
5.01.02 The motor shall be capable of operating satisfactorily at full load for 5 minutes
without injurious heating with 75% rated voltage at motor terminals.
5.02.00 Starting Requirements
5.02.01 Motor shall be designed

g for direct on line starting
g at full voltage.
g Starting g
current at rated voltage for LT motors shall be 6 times of full load current plus
IS tolerance. For 3.3KV and 11KV motor except BFP, starting current shall be
maximum 6 times of full load current inclusive IS tolerance. For Boiler feed
pump motor, starting current shall be limited to 4.5times of full load current
plus IS tolerance.
For D.C. Motors the starting current shall be limited to 2 times full load current.
5.02.02 The motor shall be capable of withstanding the stresses imposed if started at
110% rated voltage.
5.02.03 Motor shall start with rated load and accelerate to full speed with 80% rated
voltage at motor terminals without exceeding acceptable winding
temperature.
5.02.04 Motor shall be capable of three equally spread starts per hour, two starts in
quick succession from cold condition and one restart from hot condition.
5.02.05 Pump motor subject to reverse rotation shall be designed to withstand the
stresses encountered when starting with non-energized shaft rotating at
125% rated speed in reverse direction.
5.03.00 Stress During Bus Transfer
5.03.01 The motor may be subjected to sudden application of 150% rated voltage
during bus transfer, due to the phase difference between the incoming
voltage and motor residual voltage.
5.03.02 The motor shall be designed to withstand any torsional and/or high current
stresses, which may result, without experiencing any deterioration in the
normal life and performance characteristics.

Section : II
A.C. & D.C. Motors
Page 185 of 348
Section-I
EPC Bid Document
5.04.00 Locked Rotor Withstand Time
5.04.01 For motors with starting time upto 20 secs, starting time at minimum
permissible voltage should be less than the locked rotor withstand time under
hot condition at highest voltage limit by at least 2.5 secs.
For motors with starting time more than 20 secs. and upto 45 secs, starting
time at minimum permissible voltage should be less than the locked rotor
withstand time under hot condition at highest voltage limit by at least 5 secs.
For motors with starting time more than 45 secs, starting time at minimum
permissible voltage should be less than the locked rotor withstand time under
hot condition at highest voltage limit by at least 10% of the starting time
5.04.02 To prevent unwanted tripping of a high inertia load at start-up, there may be
need to shunt out the motor’s overload trip device. Speed switches mounted
on the motor shaft may be provided in such case. Heating experienced during
start-up must still be considered when sizing the motor.
5.04.03 Hot thermal withstand curve shall have a margin of at least 10% over the full
load current of the motor to permit relay setting utilising motor rated capacity.
5.05.00 Torque Requirements
5.05.01 Accelerating torque at any speed with the lowest permissible starting voltage
shall be at least 10% motor full load torque.
5.05.02 Pull out torque at rated voltage shall not be less than 205% of full load torque.
6.00.00 SPECIFIC REQUIREMENTS
6.01.00 Enclosure
6.01.01 Enclosures for the motor and the cable box shall conform to the degree of
protection IP-55 unless otherwise specified.
6.01.02 Motors like circulating water pumps of large output ratings, located inside a
building and not directly exposed to coal dust or fly ash, could have screen
protected drip proof enclosure conforming to IP-23.
6.01.03 Motor located in hazardous area shall have flameproof enclosure conforming
to IS: 2148 /Equiv. as detailed below:
a) Fuel Oil area : Group IIB

b) Hydrogen generation
plant area : Group IIC (or Group-I, Div-II as per NEC or
Class-1, Gr-B, Div-II as per
NEMA/IEC60034)
Separate Canopy shall be provided for LT motors located in outdoor or semi-

outdoor area.

Section : II
A.C. & D.C. Motors
Page 186 of 348
Section-I
EPC Bid Document
6.02.00 Cooling
6.02.01 The motor shall be self ventilated type, either totally enclosed fan cooled
(TEFC) or closed air circuit air cooled (CACA).
6.02.02 For large capacity motors, totally enclosed tube ventilated (TETV) may be
considered for acceptance. In case of motors rated 3000kW and above,
closed air circuit water cooled (CACW) motors may be offered for
consideration before proceeding with design and manufacturing.
6.03.00 Winding and Insulation
6.03.01 All insulated winding shall be of copper.
6.03.02 HT motors shall have Class F insulation with winding temperature limited to
120ºC. Windings shall be impregnated to make them non-hygroscopic and oil
resistant. The lightning impulse and coil inter-turn insulation surge withstand
level shall be as per IEC-60034 – Part 15.
6.03.03 LT motors shall have Class F or higher insulation with temperature limited to
120ºC.
6.04.00 Tropical Protection
6.04.01 All motors shall have fungus protection involving special treatment of
insulation and metal against fungus, insects and corrosion.
6.04.02 All fittings and hardware shall be corrosion resistant.
6.05.00 Bearings
6.05.01 Motor rated above 1000kW shall have insulated bearings to prevent flow of
shaft currents.
6.05.02 Vertical shaft motors shall be provided with thrust and guide bearings.
6.06.00 Noise & Vibration
6.06.01 Noise level shall not exceed 85 db (A) except for BFP motor for which the
maximum limit shall be 90 db (A).
6.06.02 Peak amplitude of vibration shall be limited within the values prescribed in
IS:12075 / IEC 60034-14.
6.07.00 Motor Terminal Box
6.07.01 Motor terminal box shall be detachable type, made of cast iron or pressed
steel and located in accordance with Indian Standards clearing the motor
base- plate/ foundation.
6.07.02 Terminal box shall be capable of being turned 360o in steps of 90o, unless
otherwise approved.
6.07.03 Terminal box for all LT motors shall be diagonally split type and shall have the
same degree of protection as motor.

Section : II
A.C. & D.C. Motors
Page 187 of 348
Section-I
EPC Bid Document
6.07.04 The terminal box shall have sufficient space inside for termination /connection
of suitable sized HT cables. Where the specified main cable size demands,
adopter/extension box of suitable size shall be provided as a part integral to
the motor, for easy termination of the cable.
6.07.05 Terminals shall be stud or lead wire type, substantially constructed and
thoroughly insulated from the frame.
6.07.06 The terminals shall be clearly identified by phase markings, with

corresponding direction of rotation marked on the non-driving end of the
motor.
6.07.07 The terminal box shall be capable of withstanding maximum system fault
current for a duration of 0.25 sec.
6.07.08 For HT motor, the terminal box shall be phase segregated type. The neutral
leads shall be brought out in a separate terminal box (not necessarily phase
segregated type) with shorting links for star connection.
6.07.09 Motor terminal box shall be furnished with suitable cable lugs and double
compression brass glands to match Owner's cable. All threads shall be ISO
metric thread only.
6.07.10 The gland plate for single core cable shall be non-magnetic type.
6.08.00 Grounding
6.08.01 The frame of each motor shall be provided

p with two separate
p and distinct
grounding pads complete with tapped hole, GI bolts and washer.
6.08.02 The grounding connection shall be suitable for accommodation of ground

conductors as follows:
Motor above 90 kW 50 x 6 mm GI Flat

Motor above 30 kW upto 90 kW 35 x 6 mm GI Flat
Motor above 5 kW upto 30 kW 25 x 3 mm GI Flat
Motor upto 5 kW 8 SWG GI Wire
The above sizes shall be superseded by different sizes if so indicated in the

relevant clause of the General Electrical Specification.
6.08.03 The cable terminal box shall have a separate grounding pad.
6.09.00 Rating Plate
In addition to the minimum information required by IS, the following

information shall be shown on motor rating plate :
a. Temperature rise in oC under rated condition and method of

measurement.
b. Degree of protection.
c. Bearing identification no. and recommended lubricant.
d. Location of insulated bearings.

Section : II
A.C. & D.C. Motors
Page 188 of 348
Section-I
EPC Bid Document
7.00.00 ACCESSORIES
7.01.00 General
Accessories shall be furnished, as listed below, or if otherwise required by

driven equipment specification or application.
7.02.00 Space Heater
7.02.01 Motor of rating 30 kW and above shall be provided with space heaters,
suitably located for easy removal or replacement.
7.02.02 The space heater shall be rated 240 V, 1 phase 50 Hz and sized to maintain
the motor internal temperature above dew point when the motor is idle.
7.03.00 Temperature Detectors
7.03.01 All HT motors shall be provided with minimum four (4) numbers simplex or
two (2) numbers duplex platinum resistance type winding temperature
detectors per phase.
7.03.02 Each bearing of HT shall be provided with minimum one (1) duplex or two (2)
simplex type temperature detectors.
7.03.03 The temperature detector mentioned above shall be resistance type, 3 wire,
platinum wound, 100 Ohms at 0oC.
7.04.00 Indicator/Switch
7.04.01 Dial type local indicator with alarm contacts shall be provided for the
following: -
a) HT motor bearing temperature.
b) Hot and cold air temperature of the closed air circuit for CACA and
CACW motor.
7.04.02 Flow switches shall be provided for monitoring cooling water flow of CACW
motor and oil flow of forced lubrication bearing, if used.
7.04.03 Alarm switch contact rating shall be minimum 0.5 A at 220V D.C. and 5A at
240V A.C.
7.05.00 Current Transformer for Differential Protection
7.05.01 Motor above 1000 kW shall be provided with three differential current
transformers (PS class) mounted over the neutral leads within the enclosure.
Matching three (3) numbers PS class CTs shall be mounted on the
switchgear end.
7.05.02 The arrangement shall be such as to permit easy access for C.T. testing and
replacement. Current transformer characteristics shall match Owner's
requirements to be intimated later.

Section : II
A.C. & D.C. Motors
Page 189 of 348
Section-I
EPC Bid Document
7.06.00 Accessory Terminal Box
7.06.01 All accessory equipment such as space heater, temperature detector, current
transformers etc., shall be wired to and terminated in terminal boxes,
separate from motor (power) terminal box.
7.06.02 Accessory terminal box shall be complete with double compression brass
glands and pressure type terminals to suit owner's cable connections.
7.07.00 Drain Plug
Motor shall have drain plugs so located that they will drain the water, resulting
from the condensation or other causes from all pockets of the motor casing.
7.08.00 Lifting Provisions
Motor weighing 25 kg. or more shall be provided with eye bolt or other
adequate provision of lifting.
7.09.00 Dowel Pins
The motor shall be designed to permit easy access for drilling holes through
motor feet or mounting flange for installation of dowel pins after assembling
the motor and driven equipment.
7.10.00 Painting
Motor including fan shall be painted with corrosion proof paints. The paint
shade shall be as specified in the Annexure.
8.00.00 TESTS
8.01.00 Upon completion, each HT & LT motor shall be subject to routine tests as
per Schedule-C of Section -I. In addition, any special test called for in the
driven equipment specification shall be performed.
8.02.00 Unless and otherwise stated, Six (6) copies of routine test certificates shall be
submitted for approval prior to the despatch of the motors from works.
8.03.00 The following type test reports shall be submitted for each type and rating of
HT motor:
a) Degree of protection test for the enclosure followed by IR, HV and no

load run test.
b) Fault level withstand test for each type of terminal box.
c) Lightning impulse withstand test on the sample coil as per IEC 60034,
part-15.
d) Surge withstand test on inter-turn insulation as per clause no. 5.1.2 of

IEC 60034, part-15.
8.03.04 The following type tests shall be performed on a representative sample of

11000V and 3300V motor of each type & rating, even if type test certificates
of these tests are submitted by the Bidder for Purchaser's approval:

Section : II
A.C. & D.C. Motors
Page 190 of 348
Section-I
EPC Bid Document
a. Measurement of stator resistance (and rotor resistance on slip ring

motors).
b. No load test at rated voltage to determine voltage, current, power

input and speeds.
c. Locked rotor reading of voltage, current, power input and values of

torque of motor.
d. Full load test to determine efficiency, power factor and slip.
e. Temperature rise test. During heat run test, bearing temperature,

Winding temperature, core temperature, coolant flow and its
temperature shall be recorded. In case temperature rise test is carried
at any load other than rated load, specific approval for test procedure
and method has to be obtained.
f. Momentary overload test.
g. Test for noise level of motor.
9.00.00 SPARE
Recommended spares p for three (3)

( ) years
y operation
p shall be quoted
q along
g
with the bid clearly identifying the part numbers with recommended quantities.
10.00.00 DRAWINGS, DATA & MANUALS
Drawings, data & manuals for the motors shall be submitted as indicated
below :
10.01.00 Along with the bid
a) List of the motors

b) Individual motor data sheet as per Annexures
c) Scheme & write up on forced lubrication system, if any.
d) Type test report
10.02.00 After Award of Contract for Information (I)/ Approval (A)
a) Dimensional General Arrangement drawing (I)

b) Foundation Plan & Loading (I)
c) Cable end box details.(I)
d) Space requirement for rotor removal (I)
e) Thermal withstands curves hot & cold (I)
f) Starting and speed torque characteristics at 80%, 100% & 110%
voltage (A)
g) Complete motor data sheet (A)
h) Erection & Maintenance Manual (I)

Section : II
A.C. & D.C. Motors
Page 191 of 348
Section-I
EPC Bid Document
ANNEXURE-A
DESIGN DATA
1.0 AUXILIARY POWER SUPPLY
Supply Description Consumer
H.T. Supply 11 kV, 3 0//, 3W, 50 Hz Motors above 1500 kW

Non-effectively earthed
Fault level 40 KA symm.

for 3 second.
H.T. Supply 3.3 kV, 3 0//, 3W, 50 Hz Motors above 160kW

Non-effectively earthed upto 1500 kW.

for 3 second.
L.T. Supply 415V, 3 0//, 3W, 50 Hz Motors above 200W

Effectively earthed upto 160 kW

for 1 seconds.
240V, 1 0//, 2W, 50 Hz Motors below 200W

Effectively earthed Lighting, space heating,
A.C. control protective devices
D.C. Supply 220V, 2W, unearthed D.C. alarm, control protective

devices
Fault level 25* KA

for 1 second (Min.)
* However actual value shall be substantiated by the bidder through

calculation.
2.0 RANGE OF VARIATION
A.C. Supply
Voltage : ±10%
Frequency : ±5%
Combined Volt & frequency : 10% (absolute sum)
D.C. Supply
Voltage : 190 to 240 Volt
3.0 Paint Shade : RAL 7032

Section : II
A.C. & D.C. Motors
Page 192 of 348
TITLE SPECIFICATION NO.
LV MOTORS VOLUME II B
DATA SHEET-A SECTION I
REV NO. 00 DATE 11.11.2021

SAGARDIGHI THERMAL POWER PROJECT
1 x 660 MW UNIT NO. 5, PHASE – III SHEET 1 OF 1
1.0 Design ambient temperature : 50 oC
2.0 Maximum acceptable kW rating of LV motor : Up to & Including 160KW
3.0 Installation (Indoors/ Outdoors) : As required
4.0 Details of supply system
a) Rated voltage (with variation) : 415V  10%

b) Rated frequency (with variation) : 50 Hz (Variation: +5% TO –5%)
c) Combined voltage & freq. variation : 10% (sum of absolute values)
d) System fault level at rated voltage : 50 kA for 1 sec
e) Short time rating for terminal boxes
*Above 90 kW up to & including 160kW (Breaker Controlled): 50 KA for 0.25 sec.
* Rated up to & including 90 kW (Contactor Controlled): 50 KA protected by MCCB
f) LV System grounding : Solidly
5.0 Class of insulation : Class ‘F’, with temp rise limited to class B.
6.0 Minimum voltage for starting : 80% of rated voltage
7.0 Power cables data : Shall be given during Detailed engineering.
8.0 Earth Conductor Size & Material : Shall be given during Detailed engineering.
9.0 Space heater supply (30KW & ABOVE) : 240 V, 1Φ , 50 Hz
10.0 Rating up to which Single phase motor : Acceptable below 0.20 Kw
11.0 Locked rotor current

a) Limit as percentage of FLC : As per IS 12615
12.0 Makes : BHEL/ Customer approval (Package

owner to take care)
13.0 Paint shade : RAL 7032
15.0 Additional tests : As per QP

14.0 Degree of protection for motor/ terminal box: IP 55
* LT motors of continuous duty shall be energy efficient IE3 class conforming to IS-12615
15.0 TESTING REQUIREMENTS: IN LINE WITH SPECIFICATION
 Also detailed Customer spec. for Motors is to be referred as enclosed with technical spec.
Page 193 of 348

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EPC Bid Document

WBPDCL 1x660 MW Unit No. 5, Phase - III
SECTION - IV
CABLES
1.00.00 SCOPE OF SUPPLY
1.01.00 Cables shall be furnished in accordance with this specification and the
following annexures :-
a. HV. Power Cables : Annexure A
b. LV. Power Cables : Annexure B
c. Control Cables : Annexure C
1.02.00 Other cables including special cables, fire survival cables if any, which are
necessary as per proven engineering practice for satisfactory & trouble free
operation of the entire cable system of the main plant shall also be within the
scope of supply. These shall include all such cables for electrical integral with
mechanical equipment systems and sub-systems.
1.03.00 Special tools and tackle.
1.04.00 All relevant drawings, data and instruction manuals.
2.00.00 CODES AND STANDARDS
2.01.00 All cable and materials shall be designed, manufactured and tested in
accordance with the latest applicable Indian Standards (IS) and IEC except
where modified and/or supplemented by this specification.
2.01.01 Cable and material conforming to any other standard which ensures equal or
better quality, may be accepted. In such case, copies of the English version of
the standard adopted shall be submitted along with the bid.
2.01.02 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended upto date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
3.00.00 DESIGN CRITERIA
3.01.00 The Cables will be used for connection of power and control circuits of the
auxiliary electrical systems.
3.02.00 Cables will be generally laid on ladder type trays or drawn through rigid
PVC/GI /HDPE pipe/conduits or directly buried in ground depending on layout
requirement.
Volume : II-F/2
Development Consultants Pvt. Ltd. Page 1 of 14 Section : IV
Cables
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3.03.00 For continuous operation at specified rating, maximum conductor temperature

shall be limited to the permissible value as per relevant standard or this
specification which one is more stringent.
3.04.00 The insulation and sheath materials shall be resistant to oil, acid and alkali
and shall be tough enough to withstand mechanical stresses during handling.
3.05.00 The outer sheath of power and control cables shall have rodent and termite
repulsion treatment.
3.06.00 Core identification for multicore cable shall be provided by colour coding.
3.07.00 For 3.3KV and above rating cables shall be dry cured in pressurized nitrogen
atmosphere.
3.08.00 The allowable voltage drop at terminal of the connected equipment shall be
maximum 2.5% at full load while choosing the conductor size and calculations
shall be submitted for purchaser's approval. In case of squirrel cage induction
motors, the cable size shall be so chosen that the motor terminal voltage
does not fall below 80% of the rated voltage, at the time of starting.
3.09.00 Cable selection criteria
1> In cable sizing the following are to be taken into consideration.
a. Short circuit current and duration

b. Continuous current.
c. Installation conditions.
d. Voltage drop under normal running and starting condition.
e. Fault contribution of motor and expected time up to which motor
contribution persists
2> Apart from above, consideration shall also be given to limit the cable
to some standard sizes instead of using too many types.
3> The standard cable sizes, capacities, derating factors, etc. as given in
IS will be generally followed.
a) For breaker protected circuits minimum size will be determined by

short circuit rating.
b) For motor circuits the selection of size will be made ensuring that the
cable shall withstand a short circuit fault directly following a second.
For fuse protected circuit, the conductor size will depend on full load
current subject to voltage drop not exceeding 2.5%.
4> For practical purposes, the minimum size chosen is as below:

a) Aluminium : 16 Sq. mm.
b) Copper : 2.5 Sq. mm.
All drives of small rating where terminations with 16 Sq. mm. cables
are not feasible, shall have copper cable.
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5> All control cables shall be 2.5 Sq. mm. copper cable.
4.00.00 SPECIFIC REQUIREMENTS
4.01.00 H.V. Power Cables
The type and quantity shall be furnished as indicated in Annexure -A
4.02.00 L.V. Power Cables
The type and quantity shall be furnished as indicated in Annexure -B
4.03.00 Control Cables
The type and quantity shall be furnished as indicated in Annexure -C
4.04.00 Separate cables for each type of following services / functions as applicable
shall be used for each feeder. Same multicore cable using different services
and different voltage class/grade shall not be acceptable:
a) Power.
b) Control, interlock and indication.
c) Metering and measuring.
d) Alarm and annunciation.
e) C.T. Cables.
f) V.T. Cables.
4.05.00 Double/ multi run cable termination at motor end shall be avoided.
4.06.00 Drum Length & Tolerance
The cables shall be supplied in non-returnable packing steel drum for HV

power cables, wooden drums for LV power and control cables, each
containing minimum 500 meters length of larger sizes of cable unless
specifically asked for. For smaller sizes of cables, each drum shall contain
1000 meters length of cable. Allowable tolerance on individual drum length is
±5%.
4.07.00 Total Quantity Variation
Total supplied quantity shall not vary by more than r 2-1/2% of total quantity
for ordered length for all types of cables.
4.08.00 Non-Standard Length
Owner shall not accept any non-standard lengths of the total ordered quantity.
Cable lengths shall not be less than 500 meters in any case.
4.09.00 Cable identification
Cable identification shall be provided by embossing on every meter on the

outer sheath the following:
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a) Manufacturer’s name or trade mark
b) Voltage grade
c) Year of manufacture
d) Type of insulation, e.g. XLPE/PVC etc.
e) No. of core and size of cables.
f) Type of improved fire performance, e.g. FR/FR-LSH
g) IS number
4.10.00 Packing
4.10.01 Cables shall be supplied in non-returnable drums. The drums shall be of

heavy construction. All wooden parts shall be manufactured from seasoned
wood. All ferrous parts used shall be treated with suitable rust preventive
finish or coating to avoid rusting during transit or storage.
4.10.02 Cable shall be wound and packed on drums in such a manner that it will be
properly sealed and firmly secured to the drum. The ends of each length
shall be sealed before shipment.
4.10.03 The cable drums should carry the following details in printed form:
a) Manufacturer’s name or trade make
b) Type of cable & voltage grade
c) Year of manufacture
d) Type of insulation e.g. XLPE
e) No. of core and size of cables
f) Cable code
g) Length of cable on drum
h) No. of length on drum, if more than one
i) Direction of rotation, by arrow
j) Approx. gross mass.
k) IS number and ISI mark
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4.11.00 Joints and Terminations
Materials of construction for a joint/termination shall perfectly match with the

dielectric chemical and physical characteristics of the associated cables. The
material and design concepts shall incorporate a high degree of operating
compatibility between the cable and joints. The protective outer covering
(jacket) used on the joints/terminations shall have the same qualities as that
of the cable outer sheath in terms of ambient/operating temperature withstand
capability and resistance to hazardous environments and corrosive elements.
5.00.00 TESTS
5.01.00 Shop Tests
The Cables shall be subject to shop tests in accordance relevant IS/IEC

standards to prove the design and general qualities of the Cables as below: -
5.01.01 Routine tests on each drum of cables.
5.01.02 Acceptance tests on drums chosen at random on each type, size and batch
for acceptance of the lot.
5.01.03 Type tests on each type of cable, size and batch inclusive of measurement of
armour D.C. resistance of power cables.
5.02.00 Additional Tests
Following additional acceptance tests shall also be performed on each type of

cables having outer sheath with improved fire performance (category C1,
Type FR/ Category C2, Type FRLSH):
5.02.01 Oxygen index test (for both C1 & C2)
The Oxygen index shall not be less than 29
5.02.02 Temperature Index Test (for both C1 & C2)
The measured value of temperature index shall be 21 at a temperature of

250°C
5.02.03 Flame Retardance test on single cable and on bunched cables (for both C1 &
C2)
After the test, there should be no visible damages on the test specimen within
300mm from its upper end.
After burning has ceased, the cables should be wiped clean and the charred
or affected portion should not have reached a height exceeding 2.5 meter
above the bottom edge of the burner, measured at the front and rear of the
cable assembly.
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EPC Bid Document

5.02.04 Halogen acid gas evolution test (for category C2).
The level of HCL evolved shall not exceed 20 per cent by weight
5.02.05 Smoke density test (for category C2)
The cables shall meet the requirements of light transmission of minimum 40%
after the test.
5.02.06 test for specific optical density of smoke (for category C2)
(to be considered later)
5.02.07 Test for rodent & termite repulsion property
The test shall be carried out to note the presence of rodent and termite
repelling chemical in PVC compound. Normal procedure is that a few
chippings of the PVC compound are slowly ignited in a porcelain dish or
crucible in a muffle furnace at about 600°C. The resulting ignited ash is boiled
with a little ammonium acetate solution (10%). A drop of aqueous sodium
sulphide solution is placed on a thick filter paper and it is allowed to soak.
The spot is touched with a drop of above extract. A black spot indicates the
presence of anti-termite & rodent compound.
5.03.00 Test Witness
Tests shall be performed in presence of Owner's representative if so desired

by the Owner. The Contractor shall give at least thirty (30) days' advance
notice of the date when the tests are to be carried out.
5.04.00 Test Certificates
5.04.01 Certified reports of all the tests carried out at the works shall be furnished in
six (6) copies for approval of the Owner.
5.04.02 Test reports shall be completed with all details and shall also contain IS
specified limit values, wherever applicable, to facilitate review
5.04.03 The cables shall be dispatched from works only after receipt of Owner’s
written approval of the test reports.
6.00.00 SPECIAL TOOLS & TACKLE
6.01.00 A set of special tools & tackle which are necessary or convenient for erection,
commissioning, maintenance and overhauling of the equipment shall be
supplied. These special tools and tackles shall include but not limited to:
a. Splice-cum-insulation remover for control cable : 10 Nos

b. Hand operated compression tools with a set of : 4 Nos. + 4 Sets of dies
dies for different cable sizes for each size of cables
c. Hydraulically operated Compression tools with a : 4 Nos. + 4 Sets of dies
set of dies for different cable sizes for each size of cables
d. Wire-wrap gun with accessories for 0.5 Sq. mm. : 10 Nos
instrumentation cables
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Section-I
EPC Bid Document

e. Maxi-terminal connection gun with accessories : 10 Nos

for 0.5 Sq. mm. instrumentation cables
6.02.00 The tools shall be shipped in separate containers, clearly marked with the
name of the equipment for which they are intended.
7.00.00 DRAWINGS, DATA & MANUALS
7.01.00 Drawings, Data & Manuals shall be submitted with the bid and in quantities
and procedures as specified in General Conditions of Contract and/or
elsewhere in this specification for approval & subsequent distribution after the
issue of Letter of Intent.
7.02.00 To be submitted with the Bid :
a. Manufacturer's catalogues giving cable construction details and

characteristics.
b. Cable current ratings for different types of installation, inclusive of

derating factors for ambient temperature, grouping etc.
c. Write-up on Manufacturer's recommended method of splicing, jointing,

termination etc. of the cables.
d. Type test reports on H.V. power cable.
7.03.00 To be submitted for Information (I) / Approval (A)
7.03.01 Guaranteed Technical Particulars(A)
7.03.02 Quality assurance plan.(A)
7.03.03 Shop Test reports(A)
7.03.04 Instruction manuals(I)
The manual shall clearly indicate method of laying, termination, check-ups

and tests to be carried out before commissioning.
7.03.05 Any other relevant drawing or data necessary for satisfactory installation
operation and maintenance (I) or as required by purchaser.
7.04.00 The Owner may review the documents marked (I) if thought necessary. The
contractor shall note that the approval of drawings & documents by the Owner
does not relieve him of his contractual obligation.
7.05.00 The bidder may note that the drawings, data and manuals listed herein are
minimum requirement only. The bidder shall ensure that all other necessary
write-up, information, etc required to fully describe the cable are to be
submitted with the bid.
7.06.00 All drawings shall be prepared by using AutoCAD and documents shall be
generated using Electronic version. The paper copy of the drawings &
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Section-I
EPC Bid Document

document shall be submitted for approval & reference. All final drawings and
documents shall be submitted in CD in AutoCAD 2000 and MS office format
as applicable for Owner’s future reference.
Volume : II-F/2
Cables
Page 201 of 348

Section-I
EPC Bid Document

Annexure-B
LV POWER CABLE
1.0 1100 V grade, 90º C continuous rating under normal condition and 250°C
under short circuit condition rating, XLPE heavy duty, power cable conforming
to following requirement and in line with IS 7098. IS 8130 & IS 5831 and IS
3975.
1.1 Conductor : Stranded and compacted plain aluminium of

grade H2 for cable sizes above 2.5 mm2and
class 2 stranded high conductivity annealed
plain copper for cable sizes upto 2.5 mm2
conforming to IS:8130.
1.2 Insulation : Extruded cross-linked polyethylene (XLPE)

conforming to IS:7098(Part-3)
1.3 Core Identification : By color coding
1.4 Inner Sheath : Extruded PVC compound conforming to type

ST2 of IS:5831 for multicore cable. Single core
cables shall have no inner sheath.
1.5 Armour : Galvanised single round steel wire armour for

twin and multicore cables.
Non-magnetic hard drawn aluminium single

round wire conforming to H4 grade for single
core cables.
1.6 Overall Sheath : Extruded FRLS PVC compound conforming to

type ST2 of IS:5831. having improved fire
performance category and type as stated below.
Category Type
C2 FRLSH (Fire Retardant Low

smoke and halogen evolution)
1.7 Drum Conforming to IS-10418(Wooden Drum)
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Section-I
EPC Bid Document

Annexure-C
CONTROL CABLES
1.0 1100 V grade 70ºC continuous rating under normal condition and 160°C
under short circuit condition rating PVC Control cable (YWY) conforming to
following requirement and in line with IS:1554, IS:8130, IS:5831 and IS:3975.
1.1 Conductor : Stranded non-compacted and circular, high

conductivity annealed plain copper, generally
conforming to IS:8130.
1.2 Insulation : Extruded PVC compound conforming to type A of

IS : 5831.
1.3 Core Identification : By color coding and numbering at interval of

100mm or less
1.4 Inner Sheath : Extruded PVC compound conforming to type

ST1 of IS:5831 for multi-core cables. Filler shall
be of same material as of inner sheath i.e. ST1.
Single core cables shall have no inner sheath.
1.5 Armour : : Galvanised single round steel wire for twin and
Multi-core cables.
1.6 Overall Sheath : Extruded PVC compound conforming to type

ST1 of IS 5831 having improved fire performance
category and type as stated below.
Category Type
C2 FRLSH (Fire Retardant Low

smoke and halogen evolution)
1.7 Drum : Conforming to IS-10418 (Wooden Drum)
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Section-I
EPC Bid Document

Annexure-D
STANDARD CABLE SIZES
Sl. No. Cable Size Conductor Insulation
1.0 H. T. CABLES
1.1 1 core 630 Sq. mm. (3.3/3.3 KV & 11/11KV AL XLPE (FRLSH)
(UE)
(UE)
(UE)
(UE)

(UE)
2.0 L. T. POWER CABLES
2.1 3 core 2.5 Sq. mm. Cu XLPE (FRLSH)
2.2 3 core 6 Sq. mm. Cu XLPE (FRLSH)
2.3 2 core 16 Sq. mm. Cu XLPE (FRLSH)
2.4 2 core 16 Sq. mm. AL XLPE (FRLSH)
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Section-I
EPC Bid Document

Sl. No. Cable Size Conductor Insulation

2.14 31/2 core 95 Sq. mm. AL XLPE (FRLSH)
3.0 CONTROL CABLE
3.1 2 core 2.5 Sq. mm. Cu. PVC (FRLSH)
3.5 9 core 2.5 Sq. mm PVC (FRLSH)
4.0 CABLES FOR ELECTRONIC EQUIPMENT GROUNDING
4.1 1 core 35 Sq. mm. Cu. XLPE (FRLSH)
4.2 1 core 150 Sq. mm. Cu. XLPE (FRLSH)
Volume : II-F/2
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Section-I
ANNEXURE-I
SUB-VENDOR LIST
The list of approved make of the LT Motors are as mentioned below:
S.No. LIST OF LT MOTORS

1. BHARAT BIJLEE LTD.
2. CROMPTON GREAVES
3. ASEA BROWN BOVERI
4. KIRLOSKAR ELECTRIC CO LTD.
5. NGEF
6. SIEMENS
7. MARATHON
8. GE-POWER
9. RAJINDRA ELECT INDUSTRIES
10. LAXMI HYDRAULICS PVT. LTD
However, the final list of makes for the LT Motors is subjected to BHEL/Customer
approval, during contract stage, without any commercial implications.
Page 206 of 348

LV MOTOR VOLUME II B
SECTION DII
DATA SHEET - C REV NO. 00 DATE
SHEET 1 OF 2
S. Description Data to be filled by successful

No. bidder
A. General
1 Manufacturer & country of origin
2 Motor type
3 Type of starting
4 Name of the equipment driven by motor & Quantity
5 Maximum Power requirement of driven equipment
6 Rated speed of Driven Equipment
7 Design ambient temperature
B. Design and Performance Data
1 Frame size & type designation
2 Type of duty
3 Rated Voltage
4 Permissible variation for
5 a Voltage
6 b Frequency
7 c) Combined voltage & frequency
8 Rated output at design ambient temp (by resistance method)
9 Synchronous speed & Rated slip
10 Minimum permissible starting voltage
11 Starting time in sec with mechanism coupled
12 a) At rated voltage
13 b) At min starting voltage
14 Locked rotor current as percentage of FLC (including IS tolerance)
15 Torque
a) Starting
b) Maximum
16 Permissible temp rise at rated output over ambient temp & method
17 Noise level at 1.0 m (dB
18 Amplitude of vibration
19 Efficiency & P.F. at rated voltage & frequency
a) At 100% load
c) At 75% load
NAME OF VENDOR
REV.
NAME SIGNATURE DATE SEAL
Page 207 of 348

LV MOTOR VOLUME II B
SECTION II
D
DATA SHEET - C REV NO. 00 DATE
SHEET 2 OF 2
S. Description Data to be filled by successful

No. bidder
c) At starting
C. Constructional Features
1 Method of connection of motor driven equipment
2 Applicable Standard
3 DOP of Enclosure
4 Method of cooling
5 Class of insulation
6 Main terminal box
a) Type
b) Power Cable details (Conductor, size, armour/unarmour)
c) Cable Gland & lugs details (Size, type & material)
d) Permissible Fault level ( kArms & duration in sec)
7 Space heater details (Voltage & watts)
8 Flame proof motor details (if applicable)
a) Enclosure
b) suitability for hazardous area
i Zone O / I / II
ii Group IIA / IIB / IIC
9 No. of Stator winding
10 Winding connection
11 Kind of rotor winding
12 Kind of bearings
13 Direction of rotation when viewed from NDE
14 Paint Shade & type
15 Net weight of motor
16 Outline mounting drawing No (To be enclosed as annexure)
D. Characteristic curves/ drawings
(To be enclosed for motors of rating t 55KW)
a) Torque speed characteristic
b) Thermal withstand characteristic
c) Current vs time
d) Speed vs time
NAME OF VENDOR
REV.
NAME SIGNATURE DATE SEAL
Page 208 of 348

TITLE : SPECIFICATION NO.
GENERAL TECHNICAL REQUIREMENTs PE-SS-999-506-E101
VOLUME NO. : II-B
FOR SECTION : DII
REV NO. : 00 DATE : 29/08/2005
LV MOTORS
SHEET : 1 OF 1
FOR
LV MOTORS
SPECIFICATION NO.: PE-SS-999-506-E101 Rev 00
Page 209 of 348

VOLUME NO. : II-B
FOR SECTION : IID
REV NO. : 00 DATE : 29/08/2005
LV MOTORS
SHEET : 1 OF 4
1.0 INTENT OF SPECIFIATION
The specification covers the design, materials, constructional features, manufacture, inspection and
testing at manufacturer’s work, and packing of Low voltage (LV) squirrel cage induction motors
along with all accessories for driving auxiliaries in thermal power station.
Motors having a voltage rating of below 1000V are referred to as low voltage (LV) motors.
2.0 CODES AND STANDARDS
Motors shall fully comply with latest edition, including all amendments and revision, of following
codes and standards:
IS:325 Three phase Induction motors

IS : 900 Code of practice for installation and maintenance of induction motors
IS: 996 Single phase small AC and universal motors
IS: 4722 Rotating Electrical machines
IS: 4691 Degree of Protection provided by enclosures for rotating electrical machines
IS: 4728 Terminal marking and direction of rotation rotating electrical machines
IS: 1231 Dimensions of three phase foot mounted induction motors
IS: 8789 Values of performance characteristics for three phase induction motors
IS: 13555 Guide for selection and application of 3-phase A.C. induction motors for
different types of driven equipment
IS: 2148 Flame proof enclosures for electrical appliance
IS: 5571 Guide for selection of electrical equipment for hazardous areas
IS: 12824 Type of duty and classes of rating assigned
IS: 12802 Temperature rise measurement for rotating electrical machnines
IS: 12065 Permissible limits of noise level for rotating electrical machines
IS: 12075 Mechanical vibration of rotating electrical machines
In case of imported motors, motors as per IEC-34 shall also be acceptable.
3.0 DESIGN REQUIREMENTS
3.1 Motors and accessories shall be designed to operate satisfactorily under conditions specified in data
sheet-A and Project Information, including voltage & frequency variation of supply system as defined
in Data sheet-A
3.2 Motors shall be continuously rated at the design ambient temperature specified in Data Sheet-A and
other site conditions specified under Project Information
Motor ratings shall have at least a 15% margin over the continuous maximum demand of the driven
equipment, under entire operating range including voltage & frequency variation specified above.
3.3 Starting Requirements
3.3.1 Motor characteristics such as speed, starting torque, break away torque and starting time shall be
properly co-ordinated with the requirements of driven equipment. The accelerating torque at any
speed with the minimum starting voltage shall be at least 10% higher than that of the driven
equipment.
3.3.2 Motors shall be capable of starting and accelerating the load with direct on line starting without
exceeding acceptable winding temperature.
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VOLUME NO. : II-B
FOR SECTION : IID
REV NO. : 00 DATE : 29/08/2005
LV MOTORS
SHEET : 2 OF 4
The limiting value of voltage at rated frequency under which a motor will successfully start and
accelerate to rated speed with load shall be taken to be a constant value as per Data Sheet - A during
the starting period of motors.
3.3.3 The following frequency of starts shall apply
i) Two starts in succession with the motor being initially at a temperature not exceeding the
rated load temperature.
ii) Three equally spread starts in an hour the motor being initially at a temperature not exceeding
the rated load operating temperature. (not to be repeated in the second successive hour)
iii) Motors for coal conveyor and coal crusher application shall be suitable for three consecutive
hot starts followed by one hour interval with maximum twenty starts per day and shall be
suitable for mimimum 20,000 starts during the life time of the motor
3.4 Running Requirements
3.4.1 Motors shall run satisfactorily at a supply voltage of 75% of rated voltage for 5 minutes with full load
without injurious heating to the motor.
3.4.2 Motor shall not stall due to voltage dip in the system causing momentary drop in voltage upto 70% of
the rated voltage for duration of 2 secs.
3.5 Stress During bus Transfer
3.5.1 Motors shall withstand the voltage, heavy inrush transient current, mechanical and torque stress
developed due to the application of 150% of the rated voltage for at least 1 sec. caused due to vector
difference between the motor residual voltage and the incoming supply voltage during occasional auto
bus transfer.
3.5.2 Motor and driven equipment shafts shall be adequately sized to satisfactorily withstand transient
torque under above condition.
3.6 Maximum noise level measured at distance of 1.0 metres from the outline of motor shall not exceed
the values specified in IS 12065.
3.7 The max. vibration velocity or double amplitude of motors vibration as measured at motor bearings
shall be within the limits specified in IS: 12075.
4.0 CONSTRUCTIONAL FEATURES
4.1 Indoor motors shall conform to degree of protection IP: 54 as per IS: 4691. Outdoor or semi-indoor
motors shall conform to degree of protection IP: 55 as per IS: 4691and shall be of weather-proof
construction. Outdoor motors shall be installed under a suitable canopy
4.2 Motors upto 160KW shall have Totally Enclosed Fan Cooled (TEFC) enclosures, the method of
cooling conforming to IC-0141 or IC-0151 of IS: 6362.
Motors rated above 160 KW shall be Closed Air Circuit Air (CACA) cooled
4.3 Motors shall be designed with cooling fans suitable for both directions of rotation.
Page 211 of 348

VOLUME NO. : II-B
FOR SECTION : IID
REV NO. : 00 DATE : 29/08/2005
LV MOTORS
SHEET : 3 OF 4
4.4. Motors shall not be provided with any electric or pneumatic operated external fan for cooling the
motors.
4.5 Frames shall be designed to avoid collection of moisture and all enclosures shall be provided with
facility for drainage at the lowest point.
4.6 In case Class ‘F’ insulation is provided for LV motors, temperature rise shall be limited to the limits
applicable to Class ‘B’ insulation.
In case of continuous operation at extreme voltage limits the temperature limits specified in table-1 of
IS:325 shall not exceed by more than 10qC.
4.7 Terminals and Terminal Boxes
4.7.1 Terminals, terminal leads, terminal boxes, windings tails and associated equipment shall be suitable
for connection to a supply system having a short circuit level, specified in the Data Sheet-A.
Unless otherwise stated in Data Sheet-A, motors of rating 110 kW and above will be controlled by
circuit breaker and below 110 kW by switch fuse-contactor. The terminal box of motors shall be
designed for the fault current mentioned in data sheet “A”.
4.7.2 unless otherwise specified or approved, phase terminal boxes of horizontal motors shall be positioned
on the left hand side of the motor when viewed from the non-driving end.
4.7.3 Connections shall be such that when the supply leads R, Y & B are connected to motor terminals A B
& C or U, V & W respectively, motor shall rotate in an anticlockwise direction when viewed from the
non-driving end. Where such motors require clockwise rotation, the supply leads R, Y, B will be
connected to motor terminals A, C, B or U W & V respectively.
4.7.4 Permanently attached diagram and instruction plate made preferably of stainless steel shall be
mounted inside terminal box cover giving the connection diagram for the desired direction of rotation
and reverse rotation.
4.7.5 Motor terminals and terminal leads shall be fully insulated with no bar live parts. Adequate space
shall be available inside the terminal box so that no difficulty is encountered for terminating the cable
specified in Data Sheet-A.
4.7.6 Degree of protection for terminal boxes shall be IP 55 as per IS 4691.
4.7.7 Separate terminal boxes shall be provided for space heaters.. If this is not possible in case of LV
motors, the space heater terminals shall be adequately segregated from the main terminals in the main
terminal box. Detachable gland plates with double compression brass glands shall be provided in
terminal boxes.
4.7.8. Phase terminal boxes shall be suitable for 360 degree of rotation in steps of 90 degree for LV motors.
4.7.9 Cable glands and cable lugs as per cable sizes specified in Data Sheet-A shall be included. Cable lugs
shall be of tinned Copper, crimping type.
4.8 Two separate earthing terminals suitable for connecting G.I. or MS strip grounding conductor of size
given in Data Sheet-A shall be provided on opposite sides of motor frame. Each terminal box shall
have a grounding terminal.
4.9 General
Page 212 of 348
VOLUME NO. : II-B
FOR SECTION : IID
REV NO. : 00 DATE : 29/08/2005
LV MOTORS
SHEET : 4 OF 4
4.9.1 Motors provided for similar drives shall be interchangeable.
4.9.2 Suitable foundation bolts are to be supplied alongwith the motors.
4.9.3 Motors shall be provided with eye bolts, or other means to facilitate safe lifting if the weight is 20Kgs.
and above.
4.9.4 Necessary fitments and accessories shall be provided on motors in accordance with the latest Indian
Electricity rules 1956.
4.9.5 All motors rated above 30 kW shall be provided with space heaters to maintain the motor internal air
temperature above the dew point. Unless otherwise specified, space heaters shall be suitable for a
supply of 240V AC, single phase, 50 Hz.
4.9.6 Name plate with all particulars as per IS: 325 shall be provided
4.9.7 Unless otherwise specified, the colour of finish shall be grey to Shade No. 631 and 632 as per IS:5 for
motors installed indoor and outdoor respectively. The paint shall be epoxy based and shall be suitable
for withstanding specified site conditions.
5.0 INSPECTION AND TESTING
5.1 All materials, components and equipments covered under this specification shall be procured,
manufactured, as per the BHEL standard quality plan No. PED-506-00-Q-006/0 and PED-506-00-Q-
007/2 enclosed with this specification and which shall be complied.
5.2 LV motors of type-tested design shall be provided. Valid type test reports not more than 5 year shall
be furnished. In the absence of these, type tests shall have to be conducted by manufacturer without
any commercial implication to purchaser.
5.3 All motors shall be subjected to routine tests as per IS: 325 and as per BHEL standard quality plan.
5.4 Motors shall also be subjected to additional tests, if any, as mentioned in Data Sheet A.
6.0 DRAWINGS TO BE SUBMITTED AFTER AWARD OF CONTRACT
a) OGA drawing showing the position of terminal boxes, earthing connections etc.
b) Arrangement drawing of terminal boxes.
c) Characteristic curves:
(To be given for motor above 55 kW unless otherwise specified in Data Sheet).
i) Current vs. time at rated voltage and minimum starting voltage.

ii) Speed vs. time at rated voltage and minimum starting voltage.
iii) Torque vs. speed at rated voltage and minimum voltage.
For the motors with solid coupling the above curves i), ii), iii) to be furnished for the
motors coupled with driven equipment. In case motor is coupled with mechanical
equipment by fluid coupling, the above curves shall be furnished with and without
coupling.
iv) Thermal withstand curve under hot and cold conditions at rated
voltage and max. permissible voltage.
Page 213 of 348

Section-II
MANUFACTURER/ BIDDER/
SUPPLIER NAME & ADDRESS STANDARD QUALITY PLAN SPEC. NO : DATE:
CUSTOMER : QP NO.: PE-QP-999-Q-006, REV-02 DATE: 17.04.2020
PROJECT: PO NO.: DATE:

ITEM: AC ELECT. MOTORS
SYSTEM: SECTION: II SHEET 1 of 2
UPTO 55KW (LV (415V))
COMPONENT CHARACTERISTI CLA REFERENCE FORMAT

S. TYPE OF QUANTUM ACCEPTANCE AGENC REMARKS
& CS SS DOCUMENT OF
NO. CHECK OF CHECK NORMS Y
OPERATIONS RECORD
6 * **
1 2 3 4 5 7 8 9
M C/ N D M C N
1.WORKMANSHI LOG
MA VISUAL 100% - MFG. SPEC. MFG. SPEC. P - -
P BOOK
MFG. DRG./ MFG. DRG./ MFG. LOG
2.DIMENSIONS MA VISUAL 100% - P - -
MFG. SPEC. SPEC. BOOK
3.CORRECTNESS
1.0 ASSEMBLY
COMPLETENESS
TERMINATIONS/ LOG
MA VISUAL 100% - MFG.SPEC./ MFG.SPEC. P - -
MARKING/ BOOK
COLOUR CODE
MFG. SPEC/ MFG. SPEC/

SAM LOG
2.0 PAINTING 1.SHADE MA VISUAL
PLE
- APPROVED APPROVED
BOOK ✔ P V -
DATASHEET DATASHEET
IS-325 / IS-
1.ROUTINE TEST IS-325 / IS-12615/ TEST/
12615/ V
INCLUDING MA VISUAL 100% - APPROVED INSPN. ✔ P - * NOTE -1
APPROVED *
SPECIAL TEST DATA SHEET REPORT
3.0 TESTS DATA SHEET
2.OVERALL APPROVED TEST/ * NOTE -1
MEASUREME APPROVED DRG/ V
DIMENSIONS & MA 100% - DRG/ DATA INSPN. ✔ P - &
NT & VISUAL DATA SHEET *
ORIENTATION SHEET REPORT NOTE-2
BHEL BIDDER/ SUPPLIER FOR CUSTOMER REVIEW & APPROVAL
ENGINEERING QUALITY Sign & Date Doc No:

Sign & Date Name Sign & Date Name Seal Sign & Date Name Seal
Digitally signed by Kunal
Prepared HEMA Digitally signed by HEMA KUSHWAHA

DN: cn=HEMA KUSHWAHA, o=BHEL,
ou=PEM-ELECT,
HEMA Checked Gandhi
DN: cn=Kunal Gandhi,
o=BHEL, ou=PEM,
KUNAL GANDHI Reviewed
by: KUSHWAHA email=hemakushwaha@bhel.in, c=IN
Date: 2020.10.08 12:07:07 +05'30'
KUSHWAHA
KHUSHWAHA by:
email=kunalgandhi@bhel.in
, c=IN
Date: 2020.10.09 10:20:18 by:
+05'30'
Reviewed PRAVEEN Digitally signed by PRAVEEN DUTTA

DN: c=IN, o=BHARAT HEAVY ELECTRICALS
LIMITED, ou=PS PEM, postalCode=201301,
st=UTTAR PRADESH,
2.5.4.20=da8948aa0c3e2703a98a0aacaa2aedd6
PRAVEEN Reviewed RITESH Digitally signed by RITESH KUMAR JAISWAL
DN: c=IN, o=Bharat Heavy Electricals Ltd, ou=BHEL /
PS-PEM, postalCode=201301, st=Uttar Pradesh,
RITESH KUMAR Approved
DUTTA 1dd68dbef4c976429c5c374e3b47b930,
DUTTA KUMAR 2.5.4.20=16692a281523bf78b46a8e18c5cd0bb1897
JAISWAL
by: by: by:
77532609b5349ae8d7191a9e51174,
cn=PRAVEEN DUTTA serialNumber=8cfaddf001b4875a8b03a31b000e93f
Date: 2020.10.08 18:43:51 +05'30' f205304f62c650e6d5f9d9980e09bc448, cn=RITESH
KUMAR JAISWAL
JAISWAL
Date: 2020.10.09 10:25:03 +05'30'
Page 214 of 348

Section-II
MANUFACTURER/ BIDDER/
SUPPLIER NAME & ADDRESS STANDARD QUALITY PLAN SPEC. NO : DATE:
CUSTOMER : QP NO.: PE-QP-999-Q-006, REV-02 DATE: 17.04.2020
PROJECT: PO NO.: DATE:

ITEM: AC ELECT. MOTORS
SYSTEM: SECTION: II SHEET 2 of 2
UPTO 55KW (LV (415V))
IS-325 / IS-12615 TEST/

3.NAMEPLATE
MA VISUAL 100% - / APPROVED SAME AS COL. 7 INSPN. ✔ P V -
DETAILS
DATA SHEET REPORT
SURFACE FINISH
AS PER MFG. AS PER MFG. INSPC.
4.0 PACKING & MA VISUAL 100% 100% ✔ P W - (#) REFER NOTE-8
STANDARD / (#) STANDARD / (#). REPORT
COMPLETENESS
NOTES:
1. Routine tests on 100% motors shall be done by the vendor. However, BHEL/ Customer shall witness routine tests on random samples. The sampling plan shall be mutually agreed upon.
2. For exhaust/ventilation fan motors of rating up to 1.5 KW, only routine test certificates shall be furnished for scrutiny.
3. In case test certificates for these tests on similar type, size and design of motor from independent laboratory are available, the same is valid for 5 years.
4. BHEL reserves the right to perform repeat test, if required.
5. After packing and prior to issue MDCC, photographs of items to be despatched shall be sent to BHEL for review.
6. In case of any changes in QP commented by customer at contract stage, same shall be carried out by bidder without any implication to BHEL/ Customer.
7. Project specific QP to be developed based on customer requirement.
8. For export job, BHEL technical specification for seaworthy packing to be followed.
9. Packing shall be suitable for storage at site in tropical climate conditions.
10. Latest revision/ year of issue of all the standards (IS/ ASME/ IEC etc.) indicated in QP shall be referred.
LEGENDS:
*RECORDS, INDENTIFIED WITH "TICK"(√) SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION,
** M: SUPPLIER/ MANUFACTURER/ SUB-SUPPLIER, B: MAIN SUPPLIER/ BHEL/ THIRD PARTY INSPECTION AGENCY, C: CUSTOMER,
P: PERFORM, W: WITNESS, V: VERIFICATION, AS APPROPRIATE
MA: MAJOR, MI: MINOR, CR: CRITICAL
D: DOCUMENTATION

Sign & Date Name Sign & Date Name Seal Sign & Date Name Seal
Digitally signed by Kunal
Prepared HEMA Digitally signed by HEMA

KUSHWAHA
DN: cn=HEMA KUSHWAHA,
o=BHEL, ou=PEM-ELECT,
HEMA Checked Gandhi
DN: cn=Kunal Gandhi,
o=BHEL, ou=PEM,
KUNAL GANDHI Reviewed
by: KUSHWAHA
email=hemakushwaha@bhel.in,
c=IN
Date: 2020.10.08 12:07:43 +05'30' KHUSHWAHA
KUSHWAHA by:
email=kunalgandhi@bhel.in,
c=IN
Date: 2020.10.09 10:20:31
+05'30'
by:
Reviewed PRAVEE
Digitally signed by PRAVEEN DUTTA
st=UTTAR PRADESH,
PRAVEEN Reviewed RITESH Digitally signed by RITESH KUMAR JAISWAL
DN: c=IN, o=Bharat Heavy Electricals Ltd,
RITESH KUMAR
ou=BHEL / PS-PEM, postalCode=201301, st=Uttar
Approved
2.5.4.20=da8948aa0c3e2703a98a0aacaa2a
KUMAR
Pradesh,
by: N DUTTA edd61dd68dbef4c976429c5c374e3b47b93

0, cn=PRAVEEN DUTTA
Date: 2020.10.08 18:44:21 +05'30'
DUTTA by:
2.5.4.20=16692a281523bf78b46a8e18c5cd0bb189
777532609b5349ae8d7191a9e51174,
serialNumber=8cfaddf001b4875a8b03a31b000e93
ff205304f62c650e6d5f9d9980e09bc448,
cn=RITESH KUMAR JAISWAL
JAISWAL by:
JAISWAL Date: 2020.10.09 10:25:30 +05'30'
Page 215 of 348

Section-II
STANDARD QUALITY PLAN SPEC. NO :
CUSTOMER : QP NO.: PE-QP-999-Q-007, REV-04

DATE:17.04.2020
MANUFACTURER/ BIDDER/ SUPPLIER NAME & ADDRESS

PROJECT: PO NO.:
ITEM: AC ELECT. MOTORS 55 KW & ABOVE (LV (415V)) SYSTEM: SECTION: II SHEET 1 OF 9
Sl No. Component & Operations Characteristics Class Type of Check Quantum Of check Reference Document Acceptance NORMS FORMAT OF RECORD AGENCY
9
6 * **
1 2 3 4 5 7 8
M C/N D M C N
RAW MATERIAL & BOUGHT
1.0
OUT
CONTROL
1.1 SHEET STEEL, PLATES, 1.SURFACE MA VISUAL 100% - - FREE FROM LOG BOOK P - -
SECTION, EYEBOLTS CONDITION BLINKS,
CRACKS,
WAVINESS
ETC
2.DIMENSIONS MA MEASUREMENT SAMPLE - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -

DRG./SPEC DRG./SPEC
3.PROOF LOAD MA MECH. TEST SAMPLE - MANUFACTURER'S MANUFACTURER'S TEST P/V -

TEST (EYE DRG./SPEC DRG./SPEC REPORT
BOLT)
1.2 HARDWARES 1.SURFACE MA VISUAL 100% - FREE FROM TEST P - -

CONDITION CRACKS, UN- REPORT
EVENNESS
ETC.
2.PROPERTY MA VISUAL SAMPLES - MANUFACTURER'S MANUFACTURER'S TC P/V - - PROPERTY CLASS

CLASS DRG./SPEC DRG./SPEC MARKING SHALL BE
CHECKED BY THE
VENDOR
1.3 CASTING 1.SURFACE MA VISUAL 100% - MANUFACTURER'S FREE FROM LOG BOOK P/V -
CONDITION DRG./SPEC CRACKS,
BLOW HOLES
ETC.
2.CHEM. & MA CHEM & MECH 1/HEAT NO. - MANUFACTURER'S MANUFACTURER'S TC P/V - HEAT NO. SHALL BE
PHY. PROP. TEST DRG./SPEC DRG./SPEC VERIFIED
3.DIMENSIONS MA MEASUREMENT 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P/V -

DRG. DRG.
1.4 PAINT & VARNISH 1.MAKE, SHADE, MA VISUAL 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P/V -
SHELF LIFE & CONTINUOUS DRG./SPEC DRG./SPEC
TYPE

Sign &
Sign & Date Name Sign & Date Name Name Seal
Date
Digitally signed by HEMA
HEMA KUSHWAHA
DN: cn=HEMA KUSHWAHA, Digitally signed by Kunal Gandhi
Seal
Prepared by: KUSHWAHA
o=BHEL, ou=PEM-ELECT,
email=hemakushwaha@bhel.in,
c=IN
HEMA KHUSHWAHA Checked by: DN: cn=Kunal Gandhi, o=BHEL, ou=PEM,
email=kunalgandhi@bhel.in, c=IN
Date: 2020.10.09 10:13:39 +05'30'
KUNAL GANDHI Reviewed by:
Date: 2020.10.08 12:02:30 +05'30'
Reviewed by: PRAVEEN Digitally signed by PRAVEEN DUTTA

PRAVEEN DUTTA Reviewed by: RITESH Digitally signed by RITESH KUMAR JAISWAL
Pradesh,
R K JAISWAL Approved by:
st=UTTAR PRADESH,
2.5.4.20=da8948aa0c3e2703a98a0aacaa2aedd61
KUMAR 2.5.4.20=16692a281523bf78b46a8e18c5cd0bb1
89777532609b5349ae8d7191a9e51174,
serialNumber=8cfaddf001b4875a8b03a31b000e
DUTTA dd68dbef4c976429c5c374e3b47b930, 93ff205304f62c650e6d5f9d9980e09bc448,

cn=PRAVEEN DUTTA
Date: 2020.10.08 19:00:37 +05'30'
JAISWAL cn=RITESH KUMAR JAISWAL
Date: 2020.10.09 10:27:57 +05'30'
Page 216 of 348

Section-II

DATE:17.04.2020

PROJECT: PO NO.:
9
6 * **
1 2 3 4 5 7 8
M C/N D M C N
1.5 SHAFT 1. SURFACE MA VISUAL 100% - - FREE FROM LOG BOOK P - - VENDOR'S APPROVAL
(FORGED OR ROLLED) COND. VISUAL IDENTIFICATION SHALL BE
DEFECTS MAINTAINED
2. CHEM. & MA CHEM. & 1/HEAT NO. - MANUFACTURER'S DRG./ MANUFACTURER'S DRG./ TC P/V -
PHYSICAL PHYSICAL OR HEAT SPEC. STD.
PROPERTIES TESTS TREATMENT
BATCH NO
3. DIMENSIONS MA MEASUREMENT 100% - MANUFACTURER'S DRG./ MANUFACTURER'S LOG BOOK P/V -

SPEC. DRG.
4.INTERNAL CR ULTRASONIC TEST 100% - ASTM-A388 MANUFACTURER'S INSPECTION ✔ P/W V - FOR DIA OF 55 MM &
FLAWS STD. REPORT ABOVE
1.6 SPACE HEATERS, CONNEC- 1. MAKE & MA VISUAL 100% - MANUFACTURER'S MANUFACTURER'S INSPECTION P/V - -
TORS, TERMINAL BLOCKS, RATING DRG./STD. DRG./STD. REPORT
CABLES, CABLE LUGS,
CARBON BRUSH TEMP.
DETECTORS, RTD, BTD'S
2. PHYSICAL MA VISUAL 100% - MANUFACTURER'S NO PHYS. DAMAGE, INSPECTION P/V - -

COND. DRG./STD. NO ELECTRICAL REPORT
DISCONTINUITY
3.DIMENSIONS MA MEASUREMENT SAMPLE - MANUFACTURER'S MANUFACTURER'S INSPECTION P/V - -

(WHEREVER DRG./ STD DRG. / STD. REPORT
APPLICABLE)
4.PERFORMANCE/ MA TEST 100% - MANUFACTURER'S MANUFACTURER'S TEST P/V - -

CALIBRATION DRG./ STD DRG. / STD. REPORT

Sign &
Date
HEMA Digitally signed by HEMA KUSHWAHA
ou=PEM-ELECT,
Digitally signed by Kunal Gandhi
DN: cn=Kunal Gandhi, o=BHEL,
Seal
Prepared by: KUSHWAHA email=hemakushwaha@bhel.in, c=IN
Date: 2020.10.08 12:03:19 +05'30' HEMA KHUSHWAHA Checked by: ou=PEM,
Date: 2020.10.09 10:14:22 +05'30'
Reviewed by: PRAVEEN DN: c=IN, o=BHARAT HEAVY
ELECTRICALS LIMITED, ou=PS PEM,
PS-PEM, postalCode=201301, st=Uttar Pradesh,
KUMAR
2.5.4.20=16692a281523bf78b46a8e18c5cd0bb1897
postalCode=201301, st=UTTAR PRADESH, 77532609b5349ae8d7191a9e51174,
serialNumber=8cfaddf001b4875a8b03a31b000e93ff
2.5.4.20=da8948aa0c3e2703a98a0aacaa2 205304f62c650e6d5f9d9980e09bc448, cn=RITESH
DUTTA aedd61dd68dbef4c976429c5c374e3b47b
930, cn=PRAVEEN DUTTA
Date: 2020.10.08 19:01:01 +05'30'
JAISWAL
KUMAR JAISWAL
Date: 2020.10.09 10:28:25 +05'30'
Page 217 of 348

Section-II

DATE:17.04.2020

PROJECT: PO NO.:
9
6 * **
1 2 3 4 5 7 8
M C/N D M C N
1.7 OTHER INSULATING 1. SURFACE MA VISUAL 100% - - NO VISUAL TEST P/V - -

MATERIALS LIKE SLEEVES, COND. ETC. DEFECTS REPORT
BINDINGS CORDS, PAPERS,
PRESS BOARDS ETC.
2.DIMENSION(BORE DIA, WALL
THICKNESS, MA TEST SAMPLE - MANUFACTURER'S MANUFACTURER'S LOG BOOK P/V - -
BDV AS RECEIVED, STD. STD. AND OR
BDV AFTER FOLDING AT 180º SUPPLIER'S
TC
1.8 SHEET STAMPING 1. SURFACE MA VISUAL 100% - - NO VISUAL LOG BOOK P - -

(PUNCHED) COND. DEFECTS
(FREE FROM
BURS)
2.DIMENSIONS MA MEASUREMENT SAMPLE - MANUFACTURER'S MANUFACTURER'S LOG BOOK P/V - -

INCLUDING BURS DRG. . DRG.
HEIGHT
3. ACCEPTANCE MA ELECT. & MECH SAMPLE - MANUFACTURER'S DRG./ MANUFACTURER'S DRG./ TC P/V - -
TESTS TESTS STD. STD.
1.9 CONDUCTORS 1. SURFACE MA VISUAL 100% - - FREE FROM LOG BOOK *P/V - - * MOTOR MANUFACTURER TO
FINISH VISUAL CONDUCT VISUAL CHECK FOR
DEFECTS SURFACE FINISH ON RANDOM
BASIS (10% SAMPLE) AT HIS
WORKS AND MAINTAIN RECORD
FOR VERIFICATION BY
2.ELECT. PROP, & MA ELECT. & SAMPLES - MANUFACTURER'S DRG./ MANUFACTURER'S / TC & P/V - -
MECH. PROP MECH.TEST SPEC. SPEC. VENDOR'S
TEST
REPORTS

Sign &
Date
ou=PEM,
Seal
ou=PEM-ELECT,
email=hemakushwaha@bhel.in, c=IN
Date: 2020.10.08 12:03:48 +05'30'
HEMA KHUSHWAHA Checked by: email=kunalgandhi@bhel.in,
c=IN
Date: 2020.10.09 10:14:42
+05'30'

RITESH
Reviewed by: PRAVEEN PRAVEEN DUTTA Reviewed by: R K JAISWAL Approved by:
Digitally signed by RITESH KUMAR JAISWAL
DN: c=IN, o=BHARAT HEAVY DN: c=IN, o=Bharat Heavy Electricals Ltd,
ELECTRICALS LIMITED, ou=PS PEM, Pradesh,
postalCode=201301, st=UTTAR PRADESH,
2.5.4.20=da8948aa0c3e2703a98a0aacaa2
KUMAR 2.5.4.20=16692a281523bf78b46a8e18c5cd0bb189
777532609b5349ae8d7191a9e51174,
serialNumber=8cfaddf001b4875a8b03a31b000e93
DUTTA
ff205304f62c650e6d5f9d9980e09bc448,
aedd61dd68dbef4c976429c5c374e3b47b
Date: 2020.10.08 19:01:33 +05'30'
JAISWAL cn=RITESH KUMAR JAISWAL
Date: 2020.10.09 10:28:47 +05'30'
Page 218 of 348

Section-II

DATE:17.04.2020

PROJECT: PO NO.:
9
6 * **
1 2 3 4 5 7 8
M C/N D M C N
3.DIMENSIONS MA MEASUREMENT SAMPLES - MANUFACTURER'S DRG./ MANUFACTURER'S / LOG BOOK P/V - -

SPEC. SPEC.
LOG BOOK
MANUFACTURER'S DRG./ MANUFACTURER'S DRG./

1.10 BEARINGS 1.MAKE & TYPE MA VISUAL 100% - P/V - -
APPROVED DATASHEET APPROVED DATASHEET
2.DIMENSIONS MA MEASUREMENT SAMPLE - APPROVED DATASHEET APPROVED DATASHEET/ LOG BOOK P/V - -
BEARING
MANUF'S
CATALOGUES
3.SURFACE MA VISUAL 100% - - FREE FROM LOG BOOK P/V - -

FINISH VISUAL
DEFECTS
1.11 SLIP RING 1.SURFACE MA VISUAL 100% - - FREE FROM LOG BOOK P - -
(WHEREVER APPLICABLE) COND. VISUAL
DEFECTS
DRG DRG
3.TEMP.WITH- MA ELECT.TEST SAMPLE - MANUFACTURER'S MANUFACTURER'S LOG BOOK P/V - -

STAND CAPACITY STD./ APPROVED DATASHEET STD./ APPROVED DATASHEET
4.HV/IR MA -DO- 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P/V - -

STD./ APPROVED DATASHEET STD./ APPROVED DATASHEET
1.12 OIL SEALS & GASKETS 1.MATERIAL OF MA VISUAL 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -
GASKET DRG/SPECS DRG./ SPECS.
2.SURFACE MA VISUAL 100% - - FREE FROM LOG BOOK P - -

COND. VISUAL
DEFECTS

DRG DRG

Sign &
Date
DN: cn=Kunal Gandhi, o=BHEL, Seal
ou=PEM-ELECT,
Date: 2020.10.08 12:04:13 +05'30'
HEMA KHUSHWAHA Checked by: ou=PEM,
Date: 2020.10.09 10:15:21 +05'30'
Reviewed by: PRAVEEN DN: c=IN, o=BHARAT HEAVY ELECTRICALS

LIMITED, ou=PS PEM, postalCode=201301, PRAVEEN DUTTA Reviewed by: RITESH Digitally signed by RITESH KUMAR JAISWAL
ou=BHEL / PS-PEM, postalCode=201301, R K JAISWAL Approved by:
st=Uttar Pradesh,
st=UTTAR PRADESH,
2.5.4.20=da8948aa0c3e2703a98a0aacaa2ae KUMAR 2.5.4.20=16692a281523bf78b46a8e18c5cd0b
b189777532609b5349ae8d7191a9e51174,
DUTTA
serialNumber=8cfaddf001b4875a8b03a31b00
dd61dd68dbef4c976429c5c374e3b47b930, 0e93ff205304f62c650e6d5f9d9980e09bc448,
cn=PRAVEEN DUTTA
Date: 2020.10.08 19:02:03 +05'30' JAISWAL cn=RITESH KUMAR JAISWAL
Date: 2020.10.09 10:29:53 +05'30'
Page 219 of 348

Section-II

DATE:17.04.2020

PROJECT: PO NO.:
9
6 * **
1 2 3 4 5 7 8
M C/N D M C N
2.0 IN PROCESS
2.1 STATOR FRAME WELDING 1.WORKMANSHIP MA VISUAL 100% - MANUFACTURER'S GOOD FINISH LOG BOOK P/W - -
(IN CASE OF FABRICATED & CLEANNESS DRG
STATOR )
2.DIMENSIONS MA MEASUREMENT 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -

DRG DRG
2.2 MACHINING 1.FINISH MA VISUAL 100% - -DO- GOOD FINISH LOG BOOK P - -
2.DIMENSIONS MA MEASUREMENT 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -

DRG DRG
3.SHAFT SURFACE MA PT 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK ✔ P V -

FLOWS STD./ STD./
ASTM-E165 APPROVED DATASHEET.
2.3 PAINTING 1.SURFACE MA VISUAL 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -

PREPARATION STD./APPROVED DATASHEET STD./APPROVED DATASHEET
2.PAINT THICKNESS MA MEASUREMENT SAMPLE - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -

(BOTH PRIMER & BY ELCOMETER STD./APPROVED DATASHEET STD./APPROVED DATASHEET
FINISH COAT)
3.SHADE MA VISUAL SAMPLE - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -

STD./APPROVED DATASHEET STD./APPROVED DATASHEET
4.ADHESION MA CROSS SAMPLE - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -
CUTTING & STD./APPROVED DATASHEET STD./APPROVED DATASHEET
TAPE TEST

Sign &
Date
Seal
ou=PEM-ELECT,
Date: 2020.10.08 12:04:39 +05'30'
HEMA KHUSHWAHA Checked by: ou=PEM, email=kunalgandhi@bhel.in,
c=IN
Date: 2020.10.09 10:17:42 +05'30'
Reviewed by: PRAVEEN PRAVEEN DUTTA Reviewed by: RITESH R K JAISWAL Approved by:
Digitally signed by PRAVEEN DUTTA Digitally signed by RITESH KUMAR JAISWAL
DN: c=IN, o=BHARAT HEAVY ELECTRICALS ou=BHEL / PS-PEM, postalCode=201301,
LIMITED, ou=PS PEM, postalCode=201301, st=Uttar Pradesh,
KUMAR
st=UTTAR PRADESH, 2.5.4.20=16692a281523bf78b46a8e18c5cd
0bb189777532609b5349ae8d7191a9e5117
2.5.4.20=da8948aa0c3e2703a98a0aacaa2aed 4,
DUTTA d61dd68dbef4c976429c5c374e3b47b930,
cn=PRAVEEN DUTTA
Date: 2020.10.08 19:02:42 +05'30' JAISWAL
serialNumber=8cfaddf001b4875a8b03a31b
000e93ff205304f62c650e6d5f9d9980e09bc
448, cn=RITESH KUMAR JAISWAL
Date: 2020.10.09 10:30:21 +05'30'
Page 220 of 348

Section-II

DATE:17.04.2020

PROJECT: PO NO.:
9
6 * **
1 2 3 4 5 7 8
M C/N D M C N
2.4 SHEET STACKING 1.COMPLETENESS MA MEASUREMENT SAMPLE - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -
STD. STD.
2.COMPRESSION MA MEASUREMENT 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -

& TIGHTENING STD. STD.
2.5 WINDING 1.COMPLETENESS CR VISUAL 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -

2.CLEANLINESS CR VISUAL 100% - MANUFACTURER'S MANUFACTURER'S LOG BOOK P - -

3.IR-HV-IR CR ELECT. TEST 100% - IS-325//IS-12615/IEC-60034 PART-1 IS-325//IS-12615/IEC-60034 PART-1 TEST/INSPC. ✔ P V -
REPORT
4.RESISTANCE CR ELECT. TEST 100% - IS-325//IS-12615/IEC-60034 PART-1 IS-325//IS-12615/IEC-60034 PART-1 TEST/INSPC. ✔ P V -
REPORT
5.INTERTURN CR ELECT. TEST 100% - IS-325//IS-12615/IEC-60034 PART-1 IS-325//IS-12615/IEC-60034 PART-1 TEST/INSPC. P - -
INSULATION REPORT
LOG BOOK
2.6 IMPREGNATION 1.VISCOSCITY MA PHY. TEST AT STARTING - MANUFACTURER'S STANDARD MANUFACTURER'S STANDARD P - -
2.TEMP. MA PROCESS CONTINUOUS - MANUFACTURER'S STANDARD MANUFACTURER'S STANDARD LOG BOOK P - -

PRESSURE CHECK
VACCUM
3.NO. OF DIPS MA PROCESS CONTINUOUS - MANUFACTURER'S STANDARD MANUFACTURER'S STANDARD LOG BOOK ✔ P V - THREE DIPS TO BE
CHECK
GIVEN

Sign &
Date
HEMA Digitally signed by HEMA KUSHWAHA Digitally signed by Kunal Gandhi

Seal
Prepared by: DN: cn=HEMA KUSHWAHA, o=BHEL,
ou=PEM-ELECT,
email=kunalgandhi@bhel.in, c=IN KUNAL GANDHI Reviewed by:
KUSHWAHA email=hemakushwaha@bhel.in, c=IN
Date: 2020.10.08 12:05:02 +05'30' Date: 2020.10.09 10:17:59 +05'30'

ou=BHEL / PS-PEM, postalCode=201301,
st=Uttar Pradesh,
st=UTTAR PRADESH,
2.5.4.20=da8948aa0c3e2703a98a0aacaa2aed KUMAR 2.5.4.20=16692a281523bf78b46a8e18c5cd0
bb189777532609b5349ae8d7191a9e51174,
DUTTA d61dd68dbef4c976429c5c374e3b47b930,
cn=PRAVEEN DUTTA
Date: 2020.10.08 19:03:18 +05'30' JAISWAL
000e93ff205304f62c650e6d5f9d9980e09bc
448, cn=RITESH KUMAR JAISWAL
Date: 2020.10.09 10:31:31 +05'30'
Page 221 of 348

Section-II

DATE:17.04.2020

PROJECT: PO NO.:
9
6 * **
1 2 3 4 5 7 8
M C/N D M C N
4.DURATION MA PROCESS CONTINUOUS - MANUFACTURER'S STANDARD MANUFACTURER'S STANDARD LOG BOOK ✔ P V -

CHECK
2.7 COMPLETE STATOR 1.COMPACTNESS MA VISUAL 100% - MANUFACTURER'S STANDARD MANUFACTURER'S STANDARD LOG BOOK P - -
ASSEMBLY & CLEANLINESS
2.8 BRAZING/COMPRESSION 1.COMPLETENESS CR VISUAL 100% - MANUFACTURER'S STANDARD MANUFACTURER'S STANDARD LOG BOOK P - -
JOINT
2.SOUNDNESS CR MALLET TEST 100% - MANUFACTURER'S STANDARD MANUFACTURER'S STANDARD TEST/INSPC. ✔ P V -
& UT REPORT
3.HV MA ELECT. TEST 100% - MANUFACTURER'S STANDARD MANUFACTURER'S STANDARD TEST/INSPC. ✔ P V -

REPORT
2.9 COMPLETE ROTOR 1.RESIDUAL CR DYN. BALANCE 100% - MANUFACTURER'S SPEC./ MANUFACTURER'S DWG. LOG BOOK P - -
ASSEMBLY UNBALANCE ISO 1940
2.SOUNDNESS CR ELECT. 100% - MANUFACTURER'S SPEC. MANUFACTURER'S SPEC. TEST/INSPC. ✔ P V -

OF DIE (GROWLER REPORT
CASTING TEST)
2.10 ASSEMBLY 1.ALIGNMENT MA MEAS. 100% - MANUFACTURER'S SPEC. MANUFACTURER'S SPEC. LOG BOOK P - -
2.WORKMANSHIP MA VISUAL 100% - MANUFACTURER'S SPEC. MANUFACTURER'S SPEC. LOG BOOK P - -
3.AXIAL PLAY MA MEAS. 100% - MANUFACTURER'S SPEC. MANUFACTURER'S SPEC. LOG BOOK ✔ P V -
4.DIMENSIONS MA MEAS. 100% - MANUFACTURER'S DRG./ MANUFACTURER'S DRG./ LOG BOOK P - -

MANUFACTURER'S SPEC. MANUFACTURER'S SPEC.
5.CORRECTNESS, MA VISUAL 100% - MANUFACTURER'S SPEC. MANUFACTURER'S SPEC. LOG BOOK P - -

COMPLETENESS
TERMINATIONS/
MARKING/
COLOUR CODE
6. RTD, BTD & SPACE MA VISUAL 100% - MANUFACTURER'S SPEC. MANUFACTURER'S SPEC. LOG BOOK ✔ P V -
HEATER MOUNTING.

Sign &
Date
ou=PEM-ELECT,
Seal
Prepared by: KUSHWAHA email=hemakushwaha@bhel.in, c=IN
Date: 2020.10.08 12:05:25 +05'30' HEMA KHUSHWAHA Checked by: ou=PEM,
Date: 2020.10.09 10:18:20 +05'30'

st=UTTAR PRADESH,
2.5.4.20=da8948aa0c3e2703a98a0aacaa2aedd
PRAVEEN DUTTA Reviewed by: RITESH
KUMAR
ou=BHEL / PS-PEM, postalCode=201301,
st=Uttar Pradesh,
2.5.4.20=16692a281523bf78b46a8e18c5cd0
bb189777532609b5349ae8d7191a9e51174,
DUTTA JAISWAL 000e93ff205304f62c650e6d5f9d9980e09bc
61dd68dbef4c976429c5c374e3b47b930, 448, cn=RITESH KUMAR JAISWAL
cn=PRAVEEN DUTTA Date: 2020.10.09 10:32:25 +05'30'
Date: 2020.10.08 19:03:54 +05'30'
Page 222 of 348

Section-II

DATE:17.04.2020

PROJECT: PO NO.:
9
6 * **
1 2 3 4 5 7 8
M C/N D M C N
3.0 TESTS 1.TYPE TESTS MA ELECT.TEST 1/TYPE/SIZE 1/TYPE/SIZE IS-325//IS-12615/APPROVED IS-325/IS-12615/APPROVED TEST ✔ P W* - * NOTE - 1
INCLUDING DATASHEET DATASHEET REPORT
SPECIAL
TESTS
-
2.ROUTINE MA ELECT.TEST 100% - IS-325//IS-12615/APPROVED IS-325/IS-12615/APPROVED TEST ✔ P V$ $
NOTE - 2
TESTS INCLUDING DATASHEET DATASHEET REPORT -
SPECIAL TEST
3.VIBRATION & MA ELECT.TEST 100% - IS: 12075 / IEC 60034-14 & IS-12065 IS: 12075 / IEC 60034-14 & IS-12065 TEST ✔ P V$ - $
NOTE - 2
NOISE LEVEL REPORT
4.OVERALL MA MEASUREMENT 100% 100% APPROVED APPROVED TEST/INSPC. ✔ P W -

DIMENSIONS & VISUAL DRG/DATA DRG/DATA REPORT
AND ORIENTATION SHEET SHEET &
-
5.DEGREE OF MA ELECT. & 1/TYPE/ - IEC 60034-5/IS-12615 APPROVED DATASHEET TC ✔ P V TC FROM AN INDEPENDENT
PROTECTION MECH. TEST SIZE - LABORATORY, REFER NOTE-3
6. MEASUREMENT OF MA ELECT. & 100% - IS-325//IS-12615/IEC-60034 PART- IS-325/IS-12615/IEC-60034 PART-1/IS: TC ✔ P V $ - $

NOTE - 2
RESISTANCE OF RTD MECH. TEST 1/IS: 12802 12802
& BTD
7. MEASUREMENT OF MA ELECT. & 100% - IS-325//IS-12615/IEC-60034 PART-1 IS-325/IS-12615/IEC-60034 PART-1 TC ✔ P V$ - $

NOTE - 2
RESISTANCE, IR OF MECH. TEST
SPACE HEATER
8. NAME PLATE MA VISUAL 100% - IS-325//IS-12615& IS-325//IS-12615 & TEST/INSPC. ✔ P V$ - $

NOTE - 2
DETAILS DATA SHEET DATA SHEET REPORT
9.EXPLOSION MA EXPLOSION 1/TYPE - IS 2148 / IEC 60079-1 IS 2148 / IEC 60079-1 TC ✔ P V - TC FROM AN INDEPENDENT
FLAME PROOF FLAME PROOF LABORATORY, REFER NOTE-3
NESS (IF TEST
SPECIFIED)
10. PAINT SHADE, MA VISUAL & SAMPLE SAMPLE APPROVED DATASHEET APPROVED DATASHEET TC ✔ P W$ - SAMPLING PLAN TO BE
THICKNESS MEASUREMENT DECIDED BY INSPECTION
& FINISH BY ELKOMETER AGENCY
$
NOTE - 2

Sign &
Date
Seal
ou=PEM-ELECT,
Date: 2020.10.08 12:05:48 +05'30'
Date: 2020.10.09 10:18:39 +05'30'

st=UTTAR PRADESH,
DN: c=IN, o=Bharat Heavy Electricals Ltd, ou=BHEL / PS-
PEM, postalCode=201301, st=Uttar Pradesh,
2.5.4.20=da8948aa0c3e2703a98a0aacaa2aed KUMAR 2.5.4.20=16692a281523bf78b46a8e18c5cd0bb1897775
32609b5349ae8d7191a9e51174,
serialNumber=8cfaddf001b4875a8b03a31b000e93ff20
DUTTA d61dd68dbef4c976429c5c374e3b47b930, 5304f62c650e6d5f9d9980e09bc448, cn=RITESH KUMAR

JAISWAL
cn=PRAVEEN DUTTA
JAISWAL
Date: 2020.10.09 10:32:50 +05'30'
Date: 2020.10.08 19:04:18 +05'30'
Page 223 of 348

Section-II

DATE:17.04.2020

PROJECT: PO NO.:
9
6 * **
1 2 3 4 5 7 8
M C/N D M C N
AS PER MANUFACT. STANDARD / (#) AS PER MANUFACT. STANDARD / INSPC. REPORT ✔ P W -
SURFACE FINISH & (#)
4.0 PACKING MA VISUAL 100% 100% (#): REFER NOTE-8
COMPLETENESS
NOTES:
1 DEPENDING UPON THE SIZE AND CRITICALLY, WITNESSING BY BHEL SHALL BE DECIDED.
2 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL/CUSTOMER SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES.
THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON.
3 IN CASE TEST CERTIFICATES FOR THESE TESTS ON SIMILAR TYPE, SIZE AND DESIGN OF MOTOR FROM INDEPENDENT LABORATORY ARE AVAILABLE,
THE SAME IS VALID FOR 5 YEARS.
4 BHEL RESERVES THE RIGHT TO PERFORM REPEAT TEST, IF REQUIRED.
5 AFTER PACKING AND PRIOR TO ISSUE MDCC, PHOTOGRAPHS OF ITEMS TO BE DESPATCHED SHALL BE SENT TO BHEL PURCHASE GROUP FOR REVIEW.
6 IN CASE , ANY CHANGES IN QP COMMENTED BY CUSTOMER AT CONTRACT STAGE SHALL BE CARRIED OUT BY BIDDER WITHOUT ANY IMPLICATION TO BHEL/ CUSTOMER.
7 PROJECT SPECIFIC QP TO BE DEVELOPED BASED ON CUSTOMER REQUIREMENT.
8 FOR EXPORT JOB, BHEL TECHNICAL SPECIFICATION FOR SEAWORTHY PACKING TO BE FOLLOWED.
9 PACKING SHALL BE SUITABLE FOR STORAGE AT SITE IN TROPICAL CLIMATE CONDITIONS.
10 LATEST REVISION/ YEAR OF ISSUE OF ALL THE STANDARDS (IS/ ASME/ IEC ETC.) INDICATED IN QP SHALL BE REFERRED.
LEGENDS:
*RECORDS, INDENTIFIED WITH "TICK"(√) SHALL BE ESSENTIALLY INCLUDED BY SUPPLIER IN QA DOCUMENTATION,
** M: SUPPLIER/ MANUFACTURER/ SUB-SUPPLIER, B: MAIN SUPPLIER/ BHEL/ THIRD PARTY INSPECTION AGENCY, C: CUSTOMER,
P: PERFORM, W: WITNESS, V: VERIFICATION, AS APPROPRIATE
MA: MAJOR, MI: MINOR, CR: CRITICAL
D: DOCUMENT

Sign &
Date
Digitally signed by HEMA KUSHWAHA
DN: cn=Kunal Gandhi, o=BHEL, Seal
Prepared by: HEMA KHUSHWAHA Checked by: KUNAL GANDHI Reviewed by:
ou=PEM,
HEMA KUSHWAHA DN: cn=HEMA KUSHWAHA, o=BHEL, ou=PEM-
ELECT, email=hemakushwaha@bhel.in, c=IN
Date: 2020.10.08 12:06:08 +05'30'
Date: 2020.10.09 10:19:41 +05'30'

RITESH
Reviewed by: PRAVEEN PRAVEEN DUTTA Reviewed by: R K JAISWAL Approved by:
DN: c=IN, o=BHARAT HEAVY PS-PEM, postalCode=201301, st=Uttar Pradesh,
ELECTRICALS LIMITED, ou=PS PEM,
KUMAR
2.5.4.20=16692a281523bf78b46a8e18c5cd0bb1897
77532609b5349ae8d7191a9e51174,
postalCode=201301, st=UTTAR PRADESH, serialNumber=8cfaddf001b4875a8b03a31b000e93f
f205304f62c650e6d5f9d9980e09bc448, cn=RITESH
2.5.4.20=da8948aa0c3e2703a98a0aacaa2
JAISWAL
KUMAR JAISWAL
DUTTA aedd61dd68dbef4c976429c5c374e3b47b
Date: 2020.10.08 19:05:11 +05'30'
Date: 2020.10.09 10:33:43 +05'30'
Page 224 of 348

TECHNICAL SPECIFICATIONS FOR SECTION-I, SUB-SECTION-D
AGITATORS
Date: MARCH 2022
SECTION-I, SUB-SECTION-D
ANNEXURE-I
LIST OF MAKES
Page 225 of 348

MISC. TANKS ‐ SITE FABRICATED SECTION –I, SUB SECTION – D
TECHNICAL SPECIFICATION REVISION 00 DATE: JULY 2021
PAGE 1 of 5
ANNEXURE‐I
LIST OF MAKES OF SUB‐VENDOR ITEMS
MISCELLANEOUS TANKS
Page 226 of 348

PAGE 2 of 5
SUB‐VENDORS ‐ MISCELLANEOUS TANKS

S.NO ITEM SUB‐VENDORS PLACE TECHNICAL LIMIT
TISCO JAMSHEDPUR UP TO 350 NB
SAIL ROURKELA
SURYA ROSHNI BAHADURGARH UP TO 400 NB
1 CS PIPES ERW JINDAL GHAZIABAD UP TO 350 NB
RATNAMANI KUTCH UP TO 400 NB
MAHARASHTRA SEAMLESS RAIGARH UP TO 500 NB
WELSPUN ANJAR UP TO 400 NB (IS 3589)
MAHARASHTRA SEAMLESS RAIGARH UP TO 350 NB
ISMT AHMEDNAGAR UP TO 150 NB
CS PIPES JINDAL SAW NASHIK
2
SEAMLESS UP TO 150 NB HOT FINISH & UPTO 100NB
REMI METAL GUJRAT LTD
BHARUCH COLD FINISH
ISMT BARAMATI UP TO 200 NB
REMI TARAPUR
RATNAMANI KUTCH
3 SS PIPES APEX TUBES BEHROR (ALWAR)
PRAKASH STEELAGE LTD MUMBAI SS SEAMLESS PIPE UPTO 50MM
SUMITAMO JAPAN
SAIL
ESSAR STEEL
TISCO
RINL
STRUCTURAL
JINDAL
4 STEEL / MS‐
M/S UTTAM VALUE STEEL
PLATE
(LLOYDS)
ISPAT
JSW
INDIAN IRON & STEEL CO. LTD
A.V. VALVES LTD AGRA
GATE VALVES:
Up to 50NB – Class-800 with MOC as
FCS. Class 150 with MOC as CSS.
Size 65 NB to 600 NB- Class up to 600
with MOC as CCS/CSS.
NR VALVES:
GATE, GLOBE MICON VALVES(INDIA) PVT FCS. Class 150 with MOC as CSS.
MUMBAI Size 65 NB to 700 NB- Class up to 600
AND CHECK LTD
5 with MOC as CCS/CSS.
(STAINLESS STEEL
VALVES)
GLOBE VALVES:
Size 65 NB to 80 NB- Class 150 with
MOC as CCS.
FLUIDLINE VALVES COMPANY

GHAZIABAD
PVT.LTD.
M/S GM ENGINEERING RAJKOT
Page 227 of 348

PAGE 3 of 5
A) STEEL GATE VALVES: UPTO 50NB, #800

AND 65NB TO 150NB, #150 B) STEEL
INTERVALVE (INDIA) LTD. PUNE GLOBE VALVES: UPTO 50NB, #800 AND
65NB TO 100NB, #150 C)SUPPLIER NOT
REGISTERED FOR NR VALVES
LEADER VALVES LTD. JALANDHAR
NITON VALVE INDUSTRIES
MUMBAI
PVT LTD
NSSL LIMITED. NAGPUR
STEEL STRONG VALVES (I) LIMIT AS PER VD FILE AS ATTACHED IN
MUMBAI
PVT.LTD., SHEET 2
CAST CARBON & ALLOY STEEL ‐
VALVE/RATING/SIZE‐
GV/150/900,GV/300/400, GV/600/300 ,
VALTECH INDUSTRIES MUMBAI GV/GLV/NRV/900/250 ,
GLV/300/300,GLV/150/350/ ,
SCNRV/150/700, SCNRV/300/350,
SCNRV/600/250.
V.K. VALVES PVT. LTD., JALANDHAR
WEIR BDK VALVES NEW DELHI
AUDCO
OSWAL INDUSTRIES
A.V. VALVES LTD AGRA
GATE VALVES:
Size 65 NB to 600 NB- Class up to 600
NR VALVES:
MICON VALVES(INDIA) PVT FCS. Class 150 with MOC as CSS.
MUMBAI Size 65 NB to 700 NB- Class up to 600
LTD
GLOBE VALVES:
Size 65 NB to 80 NB- Class 150 with
GATE, GLOBE
MOC as CCS.
6 AND CHECK (CS
STEEL VALVES)
ATAM VALVES PVT. LTD. JALANDHAR
FLUIDLINE VALVES COMPANY
GHAZIABAD
PVT.LTD.
M/S GM ENGINEERING RAJKOT
A) STEEL GATE VALVES: UPTO 50NB, #800
AND 65NB TO 150NB, #150 B) STEEL
INTERVALVE (INDIA) LTD. PUNE GLOBE VALVES: UPTO 50NB, #800 AND
65NB TO 100NB, #150 C)SUPPLIER NOT
REGISTERED FOR NR VALVES
LEADER VALVES LTD. JALANDHAR
NITON VALVE INDUSTRIES
MUMBAI
PVT LTD
NSSL LIMITED. NAGPUR
STEEL STRONG VALVES (I) LIMIT AS PER VD FILE AS ATTACHED IN
MUMBAI
PVT.LTD., SHEET 2
Page 228 of 348

PAGE 4 of 5
CC/CSS‐GATE‐BBT‐UPTO600NB CL
UPTO300,GATE‐PSBT UPTO250NB CL
VENUS PUMPS AND ENGG. 1500,GLV‐BBT‐UPTO300NB CL
KOLKATA
WORKS UPTO600,SCNRV‐BBT‐UPTO600NB CL
UPTO150,SCNRV‐BBT‐UPTO300NB CL
300,SCNRV‐PSBT‐UPTO150NB CL UPTO900
CAST CARBON & ALLOY STEEL ‐
VALVE/RATING/SIZE‐
GV/150/900,GV/300/400, GV/600/300 ,
VALTECH INDUSTRIES MUMBAI GV/GLV/NRV/900/250 ,
GLV/300/300,GLV/150/350/ ,
SCNRV/150/700, SCNRV/300/350,
SCNRV/600/250.
V.K. VALVES PVT. LTD., JALANDHAR
WEIR BDK VALVES NEW DELHI
CHENNAI /
AUDCO ‐L&T
COIMBATORE
OSWAL INDUSTRIES
HITECH AHMEDABAD
KSB WATER PUMPS / VALVES COIMBATORE
KBL KONDHAPURI
HAWA ENGINEERS AHMEDABAD
BHEL GOINDWAL
FOURESS ENGG MUMBAI UPTO 600 NB, CL‐300 & 300NB CL‐600
FOURESS ENGG AURANGABAD
SBEM PUNE
LEVEL INDIATOR LEVCON KOLKATA

7 FLOAT AND SIGMA MUMBAI
BOARD TYPE CHEMTROL
DK INSTRUMENT KOLKATA
V AUTOMAT DELHI
ASIAN PAINT
BERGER
KANSAI NEROLAC
JOTUN
SHALIMAR
JENSON & NICHOLSON (I) LTD
8 PAINT
CDC CARBOLINE (I) LTD.
ADDISON PAINTS LTD
GRAND POLYCOAT
BOMBAY PAINTS
HEMPLE PAINTS (SINGAPORE)
AKZONOBEL COATINGS
PIPE FIT ENGINEERS VADODARA
GUJRAT INFRA PIPES VADODARA
MS FITTINGS KOLKATA
TUBE PRODUCT VADODARA
FITTINGS
9 SIDDARTH & GAUTAM FARIDABAD
(MS/SS)
EBY MUMBAI
NL HAZRA KOLKATA
EXCEL METAL
INTERTECH
Page 229 of 348

PAGE 5 of 5
FITTECH
METAL LLOYDS MUMBAI
TRUE FORGE FARIDABAD
SEAL POT /
10 SELF MANUFACTURED ITEM
NAOH BREATHER
INSPECTION CATEGORIZATION
1 Cat‐I: WBPDCL/ DCPL will directly participate in inspection and MDCC shall be issued to BHEL.
Cat‐II: Inspection will be carried out by BHEL third party inspection agency / BHEL and BHEL MDCC shall be
2
issued to the vendor for physical dispatch.
Cat‐III: For COC items, BHEL will be fully responsible for meeting the contractual requirements including
3 drawings / Documents. BHEL shall duly certify and approve the COC and BHEL MDCC shall be issued to the
vendor for physical dispatch.
The make of Sub‐vendor items shall be generally as indicated above which is subject to customer / BHEL
approval during detail engineering.
Make of any unlisted items shall be subject to customer / BHEL approval during detail engineering. For such
items, bidder to furnish list of sub‐vendors during detail engineering stage for Customer / BHEL’s review and
approval. Bidder shall furnish following supporting documentation within 1 month of placement of LOI.
Thereafter no request for additional sub‐vendor shall be entertained.
a) Documentation to show that the equipment /system has been supplied for a plant of similar or higher
capacity.
b) Documentation in the form of certificate that the equipment/system has been operating satisfactorily
for two years as on the scheduled date of bid opening.
The successful bidder will get the makes of all items approved from Customer/ Consultant during detail
engineering within two months of placement of LOI. The complete list will be necessarily being submitted
within one month of placement of LOI to ensure timely placement of order for BOIs
Bidder to assess the capability of their proposed sub‐vendors in terms of preparation of drawings, calculations,
documents, quality assurance, supply of material etc. as per project schedule before placing the order on
them.
Dealers are not acceptable for any item of the package. Bidder shall procure all items including plates,
structural, flanges; counter flanges etc. from approved sub vendor only.
Page 230 of 348

Agitator
Makes
approved by
WBPDCL
Page 231 of 348

Agitator
Makes
approved by
WBPDCL
Page 232 of 348

Page 233 of 348
MISC. TANKS - SITE FABRICATED SECTION –I, SUB SECTION – D
DECLARATION BY BIDDER FOR AGITATOR MAKE
For Agitator, bidder to note that the makes approved by WBPDCL (as above) for the supply of
Agitators, need not submit credentials as specified below. However, in case bidder proposes
any additional sub-vendor for the Agitators during detail engineering, the sub-vendor shall
meet the following technical requirement. Acceptance of the make is is subject to End
customer approval during detail engineering.
The sub-vendor or his technology partner/colloborator should have designed, engineered, supplied,
erected/ supervised erection and commissioned/supervised commissioning of the Horizontal & vertical
agitators in at least one (1) wet limestone based Flue Gas Desulphurization System in Thermal Power Plant
of capacity 500 MW or more which is in successful operation as on 01.07.2020.
In case the FGD plant as mentioned above is not operational but the execution of work is in advanced stage
at any State/Central PSU in India, sub-vendor/design of Plant shall also be eligible provided the Work Order
for the plant has not been issued prior to 01.07.2016.
The Acceptance of the proposed make is subjected to End customer approval during detail
engineering. No deviations/Price implication on account of the above shall be entertained at
any stage during the contract execution.
Name : __________________
Designation: __________________
Signature : __________________
Page 234 of 348

TECHNICAL SPECIFICATIONS FOR SECTION-I, SUB-SECTION- D
REV. 00
AGITATORS
Date: MARCH 2022
SECTION-I, SUB-SECTION- D
ANNEXURE-II
QUALITY PLANS
Page 235 of 348

Page 236 of 348
Page 237 of 348
**
**
Page 238 of 348

MANUFACTURERIBIDDERNENDOR
NAM E & ADDRESS QUALITY PLAN SPEC. NO: PE-TS-435-100-MOOI DATE: 17.01.2020
In!
SLNO. COMPONENT & CHARACTERIST
CUSTOMER: Mis T ANGEDCO
PROJECT: 2X660 UDANGUDI STPP.
ITEM: CAST SS GATEI GLOBE VALVE (ABOVE 50NB
SIZE),CLASS 150, MANUAL
CLASS TYPE OF QUANTUM
I SYSTEM: LP PIPING
(WATER SYSTEM)
REFERENCE ACCEPTANCE
QP NO.: PE-QP-435-1 00-M004(C)
PO NO.: LATER
SECTION:
FORMAT OF AGENCY
DATE: 17.01.2020
DATE: XXX
SHEET 1 OF 4
REMARKS
OPERATIONS ICS CHECK OF CHECK DOCUMENT NORMS RECORD
I~
1 2 3 4 5 6 7 8 9 ** 10
M I C/N Mlcl N
1.0 MATERIAL:
1.1 BODY, BONNET,
YOKE,WEDGEI
I. PHYSICAL &
CHEMICAL
MA PHYS, CHEM .
TESTS
ONEI
HEAT
- APPD. DRo. APPO. DRG. MTC PI
W
V V CORRELATION
OF BODY&
~
DISC, SEAT, PROPERTIES BONNET REQD.
SPINDLE BODY WITH MTC
SEAT, BACK SEAT, HEAT NO.
THRUST PLATE 2. HEAT MA REVIEW OF 100% - -DO -00 H.T. ~ PI V V SOLUTION
TREATMENT H.T. RECORDS INTERNAL W ANNEALING
INSPN FOR SS VALVES
RECORDS
3. SURFACE MA VISUAL 100% - MSS-SP-55 MSS-SP-55 fNSPN . ~ PI V V
DEFECTS REPORT W
1.2 BODY, BONNET & a) CASTINGS CR PT 100% - ASME 816.34 ASME B16.34 fNSPN ~ PI V V
DISCI WEDGE I. SURFACE REPORT W RT ON CHANGE OF
DEFECTS SECTION FOR
I.ALL VALVES.
(RT FILM
2. SUB-SURFACE CR RT/uT 100% ASME B16.34 ASMEBI6.34
INSPN REVIEW BY
DEFECTS
REPORT BHEL)
b) FORGINGS
I. SURFACE
CR PT 100% - ASME 816.34 ASME B16.34 INSPN
REPORT
~ P V V
DEFECTS
2. SUB-SURFACE CR UT 100% -DO -00 -DO

DEFECTS
2.0 SSI STELLITE
DEPOSIT ON DISC
I. SURFACE
DEFECTS
CR PT 100% - ASTM EI65 & APP.DRG. ASME B16.34 fNSPN
REPORT
~ PI
W
V V
& BODY SEAT,

BACK SEAT 2. HARDNESS MA TESTING 100% APP.DRG. APP.DRG.lASME MTC. PI V V
B16.34 ~ W
BHEL BIDDER! SUPPLIER FOR CUSTOMER REVIEW & APPROVAL

Name Seal Sign & Date Name Seal
Prepared by: ~ ~ . GK Morye Reviewed
by:
Reviewed by: I :!!_~ Sanj ay Kumar Jaiswal Approved
by:
Page 239 of 348

MANUFACTURERlBIDDERlVENDOR
NAME & ADDRESS QUALITY PLAN SPEC. NO: PE-TS-435-100-MOOI DATE: 17.01:2020
CUSTOMER:MUsTANGEDCO QP NO.: PE-QP-435-100-M004(C) DATE: 17.01.2020
mP"
SLNO. COMPONENT & CHARACTERIST
PROJECT: 2X660 UDANGUDI STPP.
ITEM: CAST SS GATE/ GLOBE VALVE (ABOVE 50NB
SIZE),CLASS 150, MANUAL
CLASS TYPE OF QUANTUM REFERENCE
I
SYSTEM: LP PIPING
(WATER SYSTEM)
ACCEPTANCE
PO NO.: LATER
SECTION:
FORMAT OF AGENCY
DATE: XXX
SHEET20F4
REMARKS
1 2
3.0 GEAR BOX (AS APPLICABLE)

3 4 5
M
6
I C/N
7 8 9
I: Mlcl
**
N
10
3.1 GEAR, WORM I. PHYSICAL, MA PHYSICAL, IIBATCH REL. STD.I DATA SHEETI REL. STD.I DATA MTC V PI V V
GEAR & SHAFT CHEMICAL CHEM. - MFG. DRG . SHEETI MFG . W
PROPS. TESTING DRG.
2. HARDNESS MA MEASUREME 100% REL. STD.I DATA SHEETI REL. STD.I DATA MTC V PI V V
NT MFG . DRG. SHEETI MFG . W
DRG.
3.2 GEAR BOX I. APPEARANCE MA MEASUREME 100% APPD . DRGI IS 8935 APPD.DRG.I ACTUATO V PI V V
ASSEMBLY NT DATA SHEETI IS R W
8935 CERT.
2. PERFORMANCE MA ELECTRICAL SAMPLE MFG. STD. MFG . STD. TEST V PI V V
REPORT W
3. DIMENSIONS MA PHYSICAL 100% APPD . DRGI IS 8935 APPD . DRGI IS -DO V PI V V
• 8935 W
4. DESIGN
VERIFICATION
a) TORQUE MA TESTING ONEI

- APPROVED PROCEDURE APPROVED MTC V PI V V REFER NOTE-3
CAPABILITY (TORQUE AT TYPE/SI PROCEDURE W
TWICE OF ZE/RATE
RATED D
TORQUE OF TORQUE
GEAR BOX)
b) GEAR BOX MA CYCLE ONEI APPROVED PROCEDURE APPROVED MTC V PI V V REFER NOTE-3
P.O.D. TESTING TYPE/SI PROCEDURE W
(LIFE CYCLE TEST) ZE/RATE
D
TORQUE
4.0 IN-PROCESS INSPECTION
4.1 MACHINING OF
ALL COMPONENTS
I. DIMENSIONS,
WORKMANSHIP
MA I ~EAS,VISUA 100% - MFG.DRG . MFG .DRG.
I LOG
BOOK I- IP IV IV I
INCLUDING BW AND FINISH I I I I I

Prepared by: ~~ .. I GK Morye Reviewed
by:
Reviewed by: Sanjay Kumar Approved
by:
Page 240 of 348

MANUFACTURERlBIDDERIVENDOR
NAME & ADDRESS QUALITY PLAN SPEC. NO: PE-TS-435-100-MOOI DATE: 17.01.2020
CUSTOMER: Mis TANGEDCO QP NO.: PE-QP-435-100-M004(C) DATE: 17.01.2020
CVDfj PROJECT: 2X660 UDANGUDI STPP.

ITEM : CA ST SS GATEI GL OBE VALVE (ABOVE 50NB I SYSTEM: LP PIPING
PO NO.: LATER
SECTION:
DATE: XXX
SHEET 3 OF4
SIZE),CLA SS 150, MANUA L (WATER S YSTEM)
SLNO. COMPONENT & CHARACTERIST CLASS TYPE OF QUANTUM REFERENCE ACCEPTANCE FORMAT OF AGENCY REMARKS
I~
1 2 3 4 5 6 7 8 9 ** 10
M I C/N M Ic I N
ENDS 2.SURFACE & SUB CR 1. PT 100% - ASME B16.34 ASME BI6.34. LOG - PI V V
SURFACE DEFECTS 2. MPI BOOK W
(ACCESSIBLE
AREA OF BODY &
BONNET)
~.
3.SUB SURFACE CR UT 100% - ASME B16.34 ASME B16.34 LOG - PI V V IF DlA/THK IS
EQUAL OR GREATER
DEFECTS BOOK W THAN 40mm.
(SPINDLE, BODY / IF BODYI DISC SEATS
DISCS SEAT RING) THICKNESS EQUAL
OR GREATER THAN
25MM
4.2 WEDGE/DISC & 1. LAPPING CR BLUE 100% - UNIFORM METAL TO UNIFORM INSPN. ~ P V V
SEAT RING, MATCHING METAL CONTACT METAL TO REPORT
SPINDLE AND METAL
BACK SEAT CONTACT
5.0 ASSEMBLY 1. DIMENSIONS MA MEAS. 100% - APPD.DRG. APPD.DRG. -DO ~ P V V
2. WEAR TRAVEL MA MEAS. 100% - BSEN ISO 10434 -00 -DO ~ P V V FOR GATE
VALVE ONLY
3. VALVE LIFT MA MEAS . 100% - APPD.DRG. -DO -DO ~ P V V
6.0 TESTING
6.1 BODY, SEAT, BACK I. LEAK TIGHTNESS CR HYDRAULIC 100% REFER APPD. DRG. IASME NO LEAKAGE INSPN . ~ P W V
SEAT OF BODY TEST NOTE-2 B16.34 REPORT
2. LEAK TIGHTNESS CR HYDRAULIC 100% -DO LEAKAGE -DO ~ P W V
OF BACK TEST PERMISSIBLE AS
SEA T AND SEAT PER API 598
3. LEAK TIGHTNESS CR PNEUMATIC 100% -DO -00 -DO ~ P W V
OF SEAT TEST
6.2 OPERATIONAL SMOOTH & FULL CR MANUAL 100% REFER -DO SMOOTH INSPN. ~ P W V
TESTING FOR OPENING AND NOTE-2 OPERA TION OF REPORT
MANUALLY CLOSING VALVES &
OPERATED CLEAR BORE
VALVES -

Prepared by: GK Morye Reviewed
by:
Reviewed by: Sanjay Kumar Jaiswal Approved
by:
Page 241 of 348
crt NAME & ADDRESS QUALITY PLAN SPEC. NO: PE-TS-435-100-MOOI DATE: 17.01 .2020
CUSTOMER: M/s T ANGEDCO QP NO.: PE-QP-435-1 00-M004(C) DATE: 17.01.2020
PROJECT: 2X660 UDANGUDI STPP. PO NO.: LATER DATE: XXX

ITEM: CAST SS GATE/ GLOBE VALVE (ABOVE 50NB I SYSTEM: LP PIPfNG SECTION: SHEET 4 OF4
SIZE),CLASS 150, MANUAL (WATER SYSTEM)
I~
1 2 3 4 5 6 7 8 9 ** 10
M I C/N M I C I N
7.0 COMPLETE OVERALL MA MEASUREME SAMPLE - APPD.DRG APP.DRG. INSPN . ~ P V V
VALVES DIMENSION NT REPORT
8.0 END CONNECTION DIMENSIONS MA MEASUREME 100% REFER APPD. DRG . APPD. DRG. -DO ~ P W V
DETAILS NT NOTE-2
9.0 FINAL INSPECTION CLEANLINESS & MA VISUAL 100% - APPD. DRG .. APPD. DRG. INSPN . ~ P V V
COMPLETENESS, REPORT
NAME WITH VALVE
TAG NOS.
10.0 PACKING APPD. DRG. MA VISUAL 100% - APPD. DRG . APPD. DRG. SOFT
COpy OF
- P V V REFER NOTE-4
PHOTO
- - - -
GRAPH
NOTES:
I. In case of foreign supplier, all test certificates shall be furnished by the supplier, duly witnessed/verified by supplier's TPI.
2. 10% or min. 2 nos. at random by BHEL/Customer & 100% by supplier for each type, size & rating.
3. Review/ Verification of Test Report/Certificate, in case these tests have been carried out earlier (Within the last 5 years from placement of PO) on the identical Model/Type/Rating of tested
Gear Box at an independent laboratory or witnessed by reputed customer like NTPC etc. or third party inspection agency like Lloyds, TUV, DNV etc. if the above Test Reports/Certificates are
not available or not found satisfactory by BHEL/Customer, then the required TYPE TEST to be carried out by the Vendor on Gear Box without any commercial implications at his own cost &
witnessed by BHEL/Customer.
4. Supplier to provide the followings:
a. Photographs of valves duly placed inside the wooden box just before the final packing.
b. Photographs of the wooden box in which valves have been finally packed just before dispatch.
c. Clearance for dispatch of valves will be given only after receipt of the photos of valves in satisfactory condition as mentioned above.
LEGENDS:
*D: Records, identified with "Tick"(--J) shall be essentially included by supplier in QA Documentation.
** M: Sl!Pplier/ Manufacturer/ Sub-Supplier C: Main SupplierlBHEL/ Third Party Inspection agency N: Customer
P: Perform W: Witness V: Verification
MA: Major Characteristic MI: Minor Characteristic CR: Critical Characteristic
MTC: Mill Test Certificate PT: Penetrant Test UT: Ultrasonic Testing
RT= Radiographic Test MPI=Magnetic Particle Inspection
BHEL , , BIDDER! SUPPLIER FOR CUSTOMER REVIEW & APPROVAL
ENGINEERING ~S_ig_n_&
__D_a_te-++________________~ Doc No:
~::---+--+-~-+-_ _N....;;a,;.;;.m;;.;;.e~ N::tme Seal Sign & Date Name Seal
GK Morye Reviewed
by:
Reviewed by: I ~ I Sanjay Kumar IReviewed I, ~\ ' __ ~K Jaiswal Approved
by:
Page 242 of 348

MANUF ACTURERlBIDDERlVENDOR
NAME & ADDRESS QUALITY PLAN SPEC. NO: PE-TS-435-100-MOOI DATE: 17.01.2020
CUSTOMER :TANGEDCO QP NO.: PE-QP-435-100-M004(A) DATE: 17 .01.2020
PROJECT: 2X660MW UDANGUDI STPP. PO NO.: LATER DATE: XXX
mz'"
SLNO. COMPONENT & CHARACTERIST -
ITEM: FORGED SS GATE,GLOBE VALVEI HOSE VALVE(FCS),
SIZE 25 TO 50NB,CLASS 800,MANUAL OPERATION
CLASS TYPE OF QUANTUM
SYSTEM:
REFERENCE
I
ACCEPTANCE
SECTION:
FORMAT OF AGENCY
SHEET 1 OF3
REMARKS
I 2 3 4 5
M
6
l C/N
7 8 9
/: MlclN
** 10
1.0 MATERIAL:
1.1 BODY, BONNET,
DISC, SPINDLE,
I. PHYS. & CHEM .
PROPERTIES
MA PHYSICAL & ONEI - APPROVED DRAWING APPROVED MTC PI
W
V V CORRELA TION
OF BODY&
CHEMICAL HEAT DRAWING
~ BONNET REQD.
TEST
WITH MTC
HEAT NO.
2. HEAT
TREATMENT
MA REVIEW OF
H.T.
100% - -DO- -DO- HT(MTC) V PI
W
V V SOLUTION
ANNEALING
FOR STAINLESS
STEEL
1.2 BODY, BONNET SURFACE & SUB
SURFACE DEFECTS
CR PT 100% - ASME B16.34 AND TECH .
SPEC.
ASME B16 .34 MTC V PI
W
V V PT FOR SS
VALVES
2 .0 SSI STELLITE SURFACE DEFECTS CR PT 100% - ASME B16.34 & APPD ASME B16.34 & MTC V PI V V
DEPOSIT ON DISC DRG . APPD DRG. W
& BODY SEAT
3.0 IN-PROCESS INSPECTION:

3.1 MACHINING OF
ALL COMPONENTS
I . DIMENSIONS,
WORKMANSHIP
MA MEAS.,VISUA 100% - MFG.DRG . MFGDRG . LOG
BOOK
- P V V
L
AND FINISH
2.SURFACE & SUB CR PT 100% - ASME B16.34 ASME B16 .34 -DO- - P V V
SURFACE DEFECTS (machined
hard
surfaces)
3.2 DISC & SEAT RING LAPPING CR BLUE 100% - UNIFORM METAL TO METAL CONTACT INSPN . V P V V
MATCHING REPORT
4.0 TESTING:
4.1 BODY, SEAT, BACK I. LEAK TIGHTNESS CR HYDRAULIC 100% APPD. DRG./ BSEN ISO NO LEAKAGE INSPN ~ P W V
SEAT OF BODY TEST REFER 15761 REPORT
2. LEAK TIGHTNESS CR HYDRAULIC 100% NOTE-2 -DO- LEAKAGE -DO-- V P W V
OF BACK SEAT AND TEST PERMISSIBLE AS
- SEAT PER API 598 - - - - - -'---
ENGINEERING Sign & Date Doc No:

Name Name Seal S!gn & Date Name Seal
Prepared by: GK Morye "~ • ...JU1 .... ....... yadav Reviewed
L-2 by:
Reviewed by: Sanjay Kumar Approved
by: - -
Page 243 of 348

NAME & ADDRESS
QUALITY PLAN SPEC. NO: PE-TS-435-100-MOOI DATE: 17.01.2020
CUSTOMER :TANGEDCO QP NO.: PE-QP-435-1 00-M004(A) DATE: 17.01.2020
!'lVj PROJECT: 2X660MW UDANGUDI STPP.

ITEM : FORGED SS GATE,GLOBE VALVE/ HOSE VALVE(FCS),
SYSTEM: I
PO NO.: LATER
SECTION:
DATE: XXX
SHEET2 OF 3
SIZE 25 TO 50NB,CLASS 800,MANUAL OPERATION
t 2 3 4 5
M
6
I C/N
7 8 9
I: MICI
**
N
10
3. LEAK TIGHTNESS CR PNEUMATIC 100% REFER APPD . DRG./ BSEN ISO LEAKAGE INSPN ~ P W V
OF SEAT TEST NOTE-2 15761 PERMISSIBLE AS REPORT
PER API 598
4 .2 OPERATIONAL SMOOTH & FULL CR MANUAL 100% SMOOTH OPERATION OF VALVES & CLEAR INSPN . ...j P W V
TESTING FOR OPENING ANO REFER BORE REPORT
MANUALLY CLOSING NOTE-2
OPERATED
VALVES
5.0 COMPLETE OVERALL MA MEAS SAMP - APPD.DRG APP.ORG . -00 ...j P V V
VALVES DIMENSION LE
6 .0 END CONNECTION DIMENSIONS MA MEAS. 100% REFER APPD . DRG. APPO . DRG. -00 ...j P W V
DETAILS NOTE-2
7.0 FfNAL INSPECTION CLEANLINESS &

COMPLETENESS,
MA VISUAL 100% - APPD. DRG. APPO. DRG. INSPN.
REPORT
...j P V V
NAME WITH VALVE

TAG NOS.
8 .0 PAINTING I. SURFACE MI VISUAL 100% APPD. DRG. APPO. DRG. -00 ...j P V V APPLICABLE
PREPARATION FOR FCS HOSE
2 .UNIFORMITY & MI MEASUREME 100% -DO -00 -00 VALVE
THICKNESS NT
9 .0 PACKING APPD. DRG . MA VISUAL 100% - APPD. DRG . APPD. DRG. SOFT
COpy OF
...j P V V REFER NOTE '3'
PHOTOGR
'--
APH
ENGINEERING Sign & Date Ooc No:

Prepared by: GK Morye Reviewed
by:
Reviewed by: laiswal Approved
by:
Page 244 of 348

MANUFACTlJRERIBIDDERIVENDOR
NAME & ADDRESS QUALITY PLAN SPEC. NO : PE-TS-435-1 OO-MOO I DATE: 17.01 .2020
IIfj
CUSTOMER :TANGEDCO QP NO.: PE-QP-435-1 00-M004(A) DATE: 17.01 .2020
PROJECT: 2X660MW UDANGUDI STPP. PO NO.: LATER DATE: XXX

ITEM: FORGED SS GATE,GLOBE VALVE/ HOSE VALVE(FCS),
SIZE 25 TO 50NB,CLASS 800,MANUAL OPERATION I SYSTEM: SECTION: SHEET30F3
1 2 3 4 5
M
6
I C/N
7
-
8 9
I: MICI N
** 10
NOTES:
1. In case of foreign supplier, all test certificates shall be furnished by the supplier, duly wirnessed/verified by supplier's TPI.
2. 10% or min. 2 nos. at random by BHEL/Customer & 100% by supplier for each type, size & rating.
3. Supplier to provide the followings:

a. Photographs of valves duly placed inside the wooden boxjust before the final packing.
b. Photographs of the wooden box in which valves have been finally packed just before dispatch.
c. Clearance for dispatch of valves will be given only after receipt of the photos of valves in satisfactory condition as mentioned above.
LEGENDS:
*D: Records, identified with "Tick"(-V) shall be essentially included by supplier in QA Documentation.
** M: Supplier/ Manufacturer/ Sub-Supplier C: Main SupplierlBHEL/ Third Party Inspection agency N: Customer
P: Perfonn W: Witness V: Verification
MA: Major Characteristic MI: Minor Characteristic CR: Critical Characteristic
MTC: Mill Test Certificate
ENGINEERING Sign & Date Doc No :

Prepared by: ~,~ KKyadav Reviewed
' JA) by:
Reviewed by: \ U '" ~,~ IRK Jaiswal
_ \,'~ -
Approved
by:
Page 245 of 348
Tech Spec.
Page 246 of 348

-Above quality plan is tentative. Final QAP shall be decided during detailed engineering.
Page 247 of 348

Annexure-8
SYSTEMEQUIPMENT ST Anurmr,o ALITY PLAN qP NO.:0000€99QOM - t 401
To cbDE:ls:803-1976
cofrFoEMtNG
Misc. STOR.{GE TA}[K
Tanks
DM WA"ER
SUB-SYSTEM
DMPLANT
CHARACTERISTICS/
ACTIVITYAND INSTRUMENTS ^d4 EtiB::7;r-r-Fc
OPERATION
i-ot'ngtn" joo, tnen te{ualification is not necessary'
' i eV Suppfr-bRIN qA DuL UivtEiiTA;iiii\.
il'l#';''d;""î;^";mnr"."""'
li.?#.Y,'"1"+i'îd:J;&îilffi 1+J;iiilriib"riiirNesseoevNrP
:'dl[{i'F;:'+iTflyT}"J?T;l'#ffi
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fuhTAr Noi Q$-ol o/F4-Rl
Page
Page 386248
b ofof386
348
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Page 249 of 348

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-Z[``ÿjÿ^l)hÿcY\aÿ]Zÿ3hc^Yÿ[;\ÿa]ÿ`<3ÿh=gÿ]ÿÿ[aa`^ÿe]' Uÿml
ÿ[bcÿhjÿabÿ[Yÿnÿ#oÿl`hgÿ]`fÿ%hg]ÿbc\hÿ^_ÿh%gc̀Uÿÿa[ÿ`h%jÿ%cY\]&Zhc^ÿYÿ[d)]Y#ÿZc]\ÿT[\ÿ
%[)aab4cÿZ>[pb]Vÿ\gÿ[bbÿpÿ]ÿa7`êcU]ÿU*ÿ+, pj-ÿqÿrs tÿÿUl%`cYdÿU]ÿh[cb%ÿ]YdcYÿ]]`ÿcYdnu]ÿYU^`ÿ g[\ÿh^ÿ_l8`Yc\gÿqÿrs ÿt%ÿhgÿ]ÿ%cY%\a]&Zhc^ÿYÿ
`]a^)`h#\ÿ%[)YUÿ^hg)]#ÿ`ÿU"^Zlv]
ÿ#Yÿh\ÿ̀ÿ]1wl%c̀]Uÿ[\ÿa3]"`ÿ[aa#ÿ`^7e]Uÿÿml[bÿc'
hjÿab[YÿU7lbjÿ*ÿ\+, cdY-]?Uÿÿp&jÿhg'ÿ
]ÿXY\aÿ]Zhc^%Yÿxd]Y4ÿZjÿ[_h]`ÿ
ÿhg]c̀ÿkchY]\\ÿ_^`ÿqrsty\ÿ̀]ec]kÿ[YUÿ[ZZ]ah[YZ]n
KLMÿOPÿQRS @ABCÿEFGÿHIÿJJE
Page 251 of 348
REV. 00
AGITATORS
Date: MARCH 2022
ANNEXURE-III-A
DATASHEET AND SKETCH OF CONDENSATE STORAGE

TANKS
Page 252 of 348

DATA SHEET‐A FOR CONDENSATE STORAGE
TANK DOC NO: PE‐DC‐445‐167‐A001
BHEL PEM
PROJECT TITLE: 1X660MW SAGARDIGHI
STPP
Sl.No.
1 SERVICE IDENTIFICATION CONDENSATE STORAGE TANK
2 SYSTEM DM SYSTEM
APPLICABLE CODES/ STATUTORY

3 REGULATIONS IS‐803/API650
4 EFFECTIVE CAPACITY (m3 ) 750
5 NUMBER REQUIRED ONE (01) NO.
6 STORAGE MEDIUM DM WATER

6A OPERATING PRESSURE ATMOSPHERIC PRESSURE
6B DESIGN PRESSURE FILLED WATER HEAD + ATMOSPHERIC
6C HYDROTEST PRESSURE FILLED WATER HEAD
6D DESIGN TEMPERATURE 60 DEG.C
7 TYPE VERTICAL, CYLINDRICAL
8 SIZE 3
10.8 M DIA x 9.8 M HEIGHT (REFER NOTE‐1)
9 CORROSION ALLOWANCE 2 MM
10 PRESSURE CLASS DESIGN FOR FILLED WATER HEAD / ATOMSPHERIC
MINIMUM PLATE THICKNESS INCLUDING

Bottom – 8 MM, Shell ‐ 8 MM , Roof‐ 8 MM
11 CORROSION ALLOWANCE
12 JOINT EFFICIENCY 0.85
13 MATERIAL OF CONSTRUCTION MILD STEEL TO IS:2062 Gr. B
14 COURSE WIDTH OF PLATES 1.5M/1.8M/2.0M AS PER IS:803.
15 LOCATION OF INSTALLATION OUTDOOR
16 DRAIN VALVE FOR TANK 100 NB
17 DRAIN VALVE FOR NaOH/CO2 BREATHER 25 NB
18 DRAIN VALVE FOR SEAL POT 50 NB
i)Size of pipe: 32 NB
19 HAND RAILING ii)Material: ERW pipe as per IS:1239 (Medium Gr.),Part‐I, Galvanized
20 NOZZLE CONNECTIONS REQD / AS PER ENCLOSED SKETCH / SOCKET WELDED FOR

END CONNECTION SIZE <= NB50 & BUTT WELDED FOR SIZE > NB50
STAINLESS STEEL TO SA312 TP 304, SCH 10S FOR > NB50 & 40S FOR <=
21 PIPING/NOZZLE MATERIAL
NB50
22 VALVES MATERIAL STAINLESS STEEL (refer datasheet)
Page 253 of 348

DATA SHEET‐A FOR CONDENSATE STORAGE
TANK DOC NO: PE‐DC‐445‐167‐A001
BHEL PEM
PROJECT TITLE: 1X660MW SAGARDIGHI
STPP
Sl.No.
23 VALVES END CONNECTION SOCKET WELDED FOR SIZE <= NB50

FLANGED FOR SIZE > NB50
(a) CONSERVATION VENT VALVE /NAOH BREATHER(TO BE PLACED ON

GROUND).
(b) OVERFLOW OF 200 NB & DRAIN PIPING OF 100 NB WITH DRAIN
VALVE.
(c) SEAL POT WITH DRAIN VALVE ETC FOR OVERFLOW.
(d) LEVEL GAUGE FLOAT & BOARD TYPE (REFER ANNEXURE‐V) TO COVER
ENTIRE RANG.
(e) 2 NOS INSTRUMENT CONNECTIONS ON TANK ROOF FOR LEVEL
TRANSMITTERS (RADAR TYPE).
(f) SAMPLING CONNECTION WITH 25 NB VALVE ON TANK.
24 INSTRUMENTS / ACCESSORIES PROVIDED (g) 3 NOS. INSTRUMENT CONNECTIONS ON TANK ROOF FOR FLOAT AND
BOARD TYPE LEVEL GUAGE.
(h) STEEL STAIRS AND PLATFORMS FOR EXTERNAL APPROACH &
INTERNAL VERTICAL LADDER.
(i) FOLLOWING SPARE CONNECTION SHALL BE PROVIDED WITH SPARE
VALVE:
1)SPARE VALVE SIZE 200 NB, QUANTITY : 4 NOS.
2)SPARE VALVE SIZE 150 NB, QUANTITY : 2 NOS.
(j)DIP HATCH
(k) Spiral staircase along the shell of tanks and internal rung ladder to
access through roof manhole.
25 REFER ANNEXURE‐VI REGARDING PAINTING

INSIDE PROTECTION & EXTERNAL PAINTING
TWO(2) NOS. ONE ON SHELL (SIZE 600 MM) & OTHER ON ROOF.
26
MANHOLE & TYPE MANHOLE.
FOR FUNCTION DEMONSTRATION OF CS TANKS THE FOLLOWING SHALL

BE DONE:
1) SPOT RADIOGRAPHY
27 FUNCTIONAL DEMONSTRATION
2) BOTTOM PLATE TESTING BY AIR OR VACUUM BOX.
3) SHELL TESTING BY FILLING WITH WATER (HYDROTEST).
4) FIXED ROOF TESTING BY AIR
SKETCH FOR CONDENSATE WATER STORAGE TANK: PE‐DC‐445‐167‐S001

28 LIST OF DRAWINGS ATTACHED
NOTE
1)ALL OTHER STANDARD TECHNICAL REQUIREMENTS / ACCESSORIES & SPARES AS APPLICABLE SHALL BE CONSIDERED
2)ALL THE REQUIREMENTS SHOWN UNDER DATASHEET AND SKETCH OF CONDENSATE STORAGE TANKS ARE BARE MINIMUM ,
ANY OTHER ITEM FOUND APPLICABLE DURING DETAILED ENGINEERING AS PER TECHNICAL SPECIFICATION/ FUNCTIONAL
REQUIREMENT SHALL BE SUPPLIED BY BIDDER WITHOUT ANY COMMERCIAL IMPLICATION TO BHEL
3)ADDITIONAL HEIGHT REQUIRED TO MEET THE EFFECTIVE CAPACITY TO BE PROVIDED BY THE BIDDER WITHOUT ANY
COMMERCIAL IMPLICATION.
Page 254 of 348

Page 255 of 348
REV. 00
AGITATORS
Date: MARCH 2022
ANNEXURE-III-B
GA DRAWING FOR AUX. ABSORBENT TANK WITH

AGITATOR AND PROCESS WATER TANK
Page 256 of 348

Page 257 of 348
1) ABSORBER TANK AGITATOR
Tank Shell
MOTOR
FLEXIBLE
COUPLING
(APPROX)
RPM
3 BLADED PROPELLER
GEAR BOX
LANTERN SUPPORT
SPACER COUPING
TANK BOTTOM
SINGLE MECH. SEAL
MOUNTING FLANGE
BRG.HSG.
AGITATOR SHAFT NOT IN REMI'S

SCOPE OF SUPPLY
OR
GITAT
C OF A
C OF TANK
NOTES:
1) All supporting arrangement along with the mounting flange shall be in bidders scope.
2) The erection of the agitator shall be in bidder's scope. The agitators shall be provided as free
issue item by BHEL. Further the supervision of the erection shall be arranged by BHEL.
3)Commissioning of agitator is excluded from the scope of bidder.
4) There shall be minimum 3nos. of agitator for the absorber tank.
INDICATIVE SKETCH
FOR REFERENCE ONLY
TYPICAL MOUNTING ARRANGEMENT OF SIDE MOUNTEDREV.

A/C DRN. VISHAL 16/06/18
P.O.No. CHD.
AGITATOR-SKETCH-002 DATE - APPD.

W.O.No. QTY.- DRG.No.
0
TITLE - GENERAL ARRAGEMENT OF TOP ENTRY AGT. AMS:-28286
Page 258 of 348
Page 259 of 348
REV. 00
AGITATORS
Date: MARCH 2022
ANNEXURE-III-C
TYPICAL DETAILS OF DRAIN SUMPS
Page 260 of 348

s
oo
oia
g
J
)i
u!
o
iTti
Height (H)
For dimension,pl easereferclause Table No: 4of technical specificaion

DRAWING NO.: SKETCH-02
261 of 386
Page 267 348
REV. 00
AGITATORS
Date: MARCH 2022
ANNEXURE-III-D
TANK SCHEDULE AND AGITATOR SCHEDULE
Page 262 of 348

WBPDCL Sagardighi (1X660MW) FGD system
TECHNICAL INFORMATION FOR SIZING OF TANKS & AGITATORS
SLNO Description AUXILIARY ABSORBENT TANK PROCESS WATER TANK
1 Tank Details
1.1 Tank shape Circular Circular

1.2 Dimension of tank (m) 12.5 Dia X 13.1 H 6.0 Dia X 6.3 H
3 3
1.3 Capacity of tank (in m3) 1510 m 164 m
1.4 No. of tanks 1 no. 1 no.
1.6 MOC of tanks CS+3mm thick Glass Flake Lining CS+Epoxy Painted
2 Agitator selection data
2.1 Type Side entry
2.2 Medium to be handled Gypsum slurry

2.3 Seal Type Mechanical seal (Flushless type)
2.4 Agitator location Outdoor
NOT APPLICABLE
2.5 Operation Intermittent -Whenever FGD is under maintenance
Shaft - Stainless steel or Nickel alloy

2.6 MOC of Agitator Blade- Stainless steel or Nickel alloy or CS + rubber lining
with minimum life of 2 years.
2.7 Type of Agitation Required Off Bottom Suspension

2.8 Minimum liquid level in the tank 1.0 1.0
2.9 Normal liquid level in the tank 12.1 5.6
2.10 Maximum liquid level in the tank 12.3 5.8
2.11 Agitator Blade Level As per vendor design
2.12 Quantity of Agitators per Tank 2 Working+1 Standby NOT APPLICABLE
3 Slurry Analysis
3.1 Maximum solid particle size 200 mesh (74 µ)
3.2 Normal solid particle size, d50 325 mesh (44 µ)
3.3 Solid to be handled gypsum along with Limestone & other impurities
3.4 Chloride concentration max 25000 ppm
3.5 Hardness of particle 5-7 mohs scale
3.6 Slurry concentration, wt% 30%
3.7 Sp. Gravity of slurry 1.206
NOT APPLICABLE
3.8 Sp. Gravity of Lime Stone & Gypsum 2.32(avg)
3.9 Viscosity of Slurry 10 cP
3.10 pH 4 to 8
3.11 SiO2 Content 4 to 6 g/l
Normal -65.2 deg C;
3.12 Temperature
Design-75 deg C.
4 Mandatory spares refer tender spec
Project:WBPDCL Sagardighi (1X660MW) FGD system

Cont No: R4W1
Engineer KMK
Reviewer MKT
Approver PNR
Page 263 of 348

REV. 00
AGITATORS
Date: MARCH 2022
ANNEXURE-III-E
DETAILS OF 500 MM NOZZLE FOR BOTTOM DRAIN
Page 264 of 348

56
056 ** 1. 939
056
285=79 @
x6 285=79 @
x6
005
009
t t
056
285 =79 @
x6
005
005
57
13 ) P YT(
058 05
1. 939 1. 678
Page 265 of 348

8
1. 939
REV. 00
AGITATORS
Date: MARCH 2022
ANNEXURE-IV
MASTER DRAWING LIST WITH SCHEDULE OF

SUBMISSION
Page 266 of 348

1X660MW SAGARDIGHI STPP SPEC. NO.: PE-TS-445-167-A002
TECHNICAL SPECIFICATIONS FOR SECTION-I, SUB-SECTION- D,
MISC. TANKS (SITE FABRICATED) AND AGITATORS ANNEXURE-IV
REV. NO.: 00
DATE: MARCH 2022
DRAWINGS/ DOCUMENTS REQUIRED DURING DETAIL ENGINEERING
The successful bidder shall submit the following drawings / documents during detail engineering for approval / information / reference
(as the case may be): -
Schedule
Sl. BHEL Drawing / Drawing
Title Submission
No. Document No. Classification
Date from LOI
FABRICATION DRAWING OF MISC. TANK Primary
1 PE-V0-485-167-A001 5 weeks
DESIGN CALCULATION OF MISC. TANKS INCLUDING ROOF STRUCTURE Primary
2 PE-V0-485-167-A002 4 weeks
WITH STAAD CALCULATION
Primary
3 PE-V0-485-167-A003 GA DRAWING OF MISC. TANKS 4 weeks
DATASHEET & GA DRAWING OF VINYL ESTER GLASS FLAKE FOR MISC. FGD Primary
4 PE-V0-485-167-A004 6 weeks
TANKS
5 PE-V0-485-167-A005 DATASHEET & GA DRAWING OF COMPONENTS FOR MISC. TANKS 6 weeks Primary
6 PE-V0-485-167-A006 QAP OF VINYL ESTER GLASS FLAKE FOR MISC. FGD TANKS 6 weeks Primary
7 PE-V0-485-167-A007 QAP OF COMPONENTS FOR MISC. TANKS 6 weeks Primary
8 PE-V0-485-167-A008 SUB VENDOR LIST WITH INSPECTION CATEGORY FOR MISC. FGD TANKS 3 weeks Primary
9 PE-V0-485-167-A009 SURFACE PREPARATION AND LINING PROCEDURES FOR MISC. FGD TANKS 7 weeks Secondary
10 PE-V0-485-167-A010 O&M MANUAL FOR VINYL ESTER GLASS FLAKE 8 weeks Secondary
11 PE-V0-485-167-A011 O&M MANUAL FOR MISC. TANKS 8 weeks Secondary
Page 267 of 348

REV. NO.: 00
DATE: MARCH 2022
Datasheet & GA drawing, Exploded view, sectional view with Material of 3 weeks from
12 PE-V0-457-571-A001 Primary
construction, mechanical seal , gearbox for Agitator LOI
3 weeks from Secondary
13 PE-V0-457-571-A003 Agitator Performance curve of all Agitators
LOI
Electrical motor GA drawing & Data sheet and performance curves of all 4 weeks from Primary
14 PE-V0-457-571-A004
motors LOI
6 weeks from Primary
15 PE-V0-457-571-A005 Quality plan & Inspection and Test Procedure
LOI
17 PE-V0-457-571-A007 O&M Manual for Agitator
LOI
18 PE-V0-457-571-A010 Lubricating oil list
LOI
19 PE-V0-457-571-A011 Special tools list, Start-up & Commissioning Spares
LOI
20 PE-V0-457-571-A012 Installation and assembly procedure including Pre Commissioning Check List
LOI
NOTE: Drwg/ Document shall be uploaded by the successful bidder on WRENCH /DMS.Procedure for the same will be informed after award of contract.
Commented document shall be submitted within one week of comments furnished by BHEL.
1. The above drawing list is tentative and shall be finalized with the successful bidder after placement of order. While some of the drawings indicated
above may not be applicable, some additional drawings may also be required based on scope of work.
2. Drawings shall be prepared in Auto-Cad latest edition. Required no. of hard and soft copies (editable) of the drawings shall be furnished as per
requirement specified elsewhere in the specification.
3. Only manual calculation with authentic supporting literature (e.g. extracts of hand Book/ standard/codes) shall be acceptable. All design
calculations and drawings shall be in SI system only.
4. All the drawings and documents including general arrangement drawing, data sheet, calculation etc. to be furnished to the customer during
detailed engineering stage shall include / indicate the following details for clarity w.r.t. Inspection, construction, erection and maintenance etc.:
Page 268 of 348
REV. NO.: 00
DATE: MARCH 2022
a) All drawings and documents shall indicate the list of all reference drawings including General Arrangement.
b) All drawings shall include / show plan, elevation, side view, cross-section, skin section, blow-up view; all major self-manufactured and bought
out items shall be labelled and included in BOQ / BOM in tabular form.
c) Painting schedule shall also be made as a part of general arrangement drawing of each equipment / items indicating at least 3 trade names.
d) All the drawings required to be furnished to customer during detailed engineering stage shall include technical parameters, details of paints
and lubrication, hardness and BOQ / BOM in tabular form indicating all major components including bought out items and their quantity, material
of construction indicating its applicable code / standard, weight, make etc.
e) Void.
f) Drawings and documents not covered above but required to check safety of machines/ system, shall be submitted during detailed engineering
stage without any commercial implication.
g) All drawings shall include "B.O.M" and indicate quantity, material of construction, make along with IS/BS No., Technical parameters,
dimensions, hardness, machining symbol and tolerance, requirement of radiography and hydraulic tests, painting details, elevation, side view,
plan, skin section and blow-up view for clarity.
h) All drawings shall be prepared as per BHEL's title block and shall bear BHEL's drawing No. Documents marked for submission to BHEL’s
Customer shall also bear BHEL's Customer’s drawing No.
i) Schedule of drawings submissions, comment incorporations & approval shall be as stipulated in the specifications. The successful bidder shall
depute his design personnel to BHEL’s/ Customer’s/ Consultant’s office for across the table resolution of issues and to get documents approved in
the stipulated time.
j) Bidder to follow the following the drawing submission schedule:
k) 1st submission of drawings from date of LOI as per the submission schedule.
l) Every revised submission incorporating comments – within 7 days.
m) Bidder to submit revised drawings complete in all respects incorporating all comments.
Page 269 of 348

REV. NO.: 00
DATE: MARCH 2022
o) The primary drawings are to be considered as the basic engineering drawings.
Any incomplete drawing submitted shall be treated as non-submission with delays attributable to bidder’s account. For any clarification/ discussion
required to complete the drawings, the bidder shall depute his personal to BHEL for across the table discussions/ finalizations/ submissions of drawings.
SIGNATURE : ___________________
COMPANY SEAL
NAME : ___________________
DESIGNATION : ___________________
COMPANY : ___________________
DATE : ___________________
Page 270 of 348

REV. 00 ANNEXURE - V
AGITATORS
Date: MARCH 2022
ANNEXURE - V
PACKING PROCEDURE
Page 271 of 348

AA0490010
CORPORATE STANDARD Rev. No. 02
PAGE 1 of 24
DOMESTIC PACKING
COMMON GUIDELINES
1 GENERAL:
This standard lays down packing instructions for domestic packing of Components/ Assemblies/
Equipment to be despatched against Customer's contracts, for which there are no special instructions
issued by the Engineering Departments. For Seaworthy Packing refer standard AA0490004 wherever
applicable.
The Components/Assemblies need to be packed suitably to a void physical damage & corrosion during
The Information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED.
It must not be used directly or indirectly in any way detrimental to the Interest of the company.
transit & storage. For specific applications the concerned engineering department shall issue a product
standard. Reference of this product standard, must appear in the Shipping list/Packing List.
2 SCOPE:
This procedure gives minimum guidelines to be complied with for domestic packing of Components
/Assemblies/ Equipment. This domestic packing shall be suitable for different handling operations and
for the adverse conditions during transportation and during indoor / ou tdoor storage of materials.
3 WOOD SPECIFICATION
COPYRIGHT AND CONFIDENTIAL
Based on availability, the wood shall conform to specification AA51401 or AA51402.
4 TYPES OF PACKING:
The following 5 types of packing have been standardized for packing of General Components/
Assemblies.
1) 'OP' - Open Type.

2) 'PP' - Partially Packed.
3) 'CP' – Crate/Box Packing - Components/Equipment requiring physical protection.
4) ‘CQ' - Case Packing – Machined components-Small & Medium Components/ Assemblies/ Equipment
which require corrosion & physical protection.
5) ‘CR’ - Case Packing – Electrical/Electronic Components/ Assemblies, which require special packing
viz. Water Proof, Shock Proof etc…
5 DESCRIPTION OF TYPES OF PACKING:

The various types of packing, as standardized above, are described below.
5.1 'OP’ - Open Type

In case, of components which are not affected by water & dust and do not require special protection, are
generally not machined, shall be sent as open packages. However, these components may be sent in
crates, wherever necessary.
5.2 'PP’ - Partially Packed

Components which need special protection at selected portions only shall be despatched partially
packed. Machined surfaces should not be allowed to come directly in contact with the wood. Such
surfaces should be protected with 100GSM(Colourless) Multi Layered Cross Laminated Polyethylene
Revisions: APPROVED:
PROCEDURAL GUIDELINES COMMITTEE –
PGC (Packing)
DRC-5197
Rev. No. 02 Amd. No. Reaffirmed Prepared Issued Dt. of 1 st Issue

Dt: 28-08-2018 Dt: Year: HPBP, Trichy Corp. R&D 31-05-2018
Page 272 of 348

AA0490010
Rev. No. 02 CORPORATE STANDARD
PAGE 2 of 24
Film to Specification No. AA51420. All sharp corners and edges shall be protected by rubber mats to
prevent damage to the polyethylene film
5.3 'CP’ - Crate Packing

Assemblies/Components which need only physical protection from the point of view of handling shall be
despatched duly packed in crates.
5.4 ‘CQ’ - Case Packing - Machined Components/Assemblies/Equipment

Small and medium sized components/assemblies/equipment due to size/weight and to avoid handling
and pilferage problems shall be packed in Case/Containers. Wherever required adequate quantity of
silica gel to AA55619 or VCI Powder/Tablets, packed in thin muslin cloth cotton bags shall be suitably
placed. Small machines/components of less weight shall be provided with suitable cushioning by
Rubberised coir. The components inside the case shall be entirely covered with 100GSM(Colourless)
Multi Layered Cross Laminated Polyethylene Film Specification No . AA51420, wherever required. This
may be prescribed for electronic parts/critical machined components/surfaces.
For mechanical product like valves where motors are separately securely wrapped in polyethylene, the
requirement of individual component wrapping shall be exempted.
5.5 'CR’ - Case Packing - Electrical & Electronic Components/Assemblies

Delicate components likely to be damaged e.g. Gauges, Instruments etc. are to be wrapped in waxed
paper or polyethylene air bubble film and packed in cartons. Adequate quantity of Silica gel to AA55619
packed in cotton bags of 100grams each are to be suitably placed in the cartons. The cartons shall be
entirely covered with 100GSM(Colourless) Multi Layered Cross Laminated Polyethylene Film
Specification No. AA51420 before being packed in the cases. VCI Powder/Tablets can be used as an
alternative to Silica Gel to AA55619.
Empty space in the cartons shall be filled with rubberized coir to get proper cushioning effect. The
cartons shall be manufactured from corrugated Fiber Board, meeting requirements of AA51414 .
6 PREPARATION OF PACKING CASES

6.1 DIMENSIONS:
a) Thickness of planks for Front, rear, top and bottom sides and binding, jointing battens shall be
25/20mm +2/-3 mm as per applicable drawings of the respective units.
b) Width of all planks including the tongue shall be more than 125mm and after pla ining it shall be
minimum 100mm.
c) Minimum number of planks shall be used for a shook.
d) Horizontal, vertical, diagonal planks shall be given for binding (number of such planks depend on
the dimension of panel.
e) Width of binding planks shall be minimum 100mm.
f) Distance between any 2 binding planks shall be less than 750mm.
g) diagonal planks shall be used in between vertical binding pla nks when distance between inner to
inner of vertical planks is more than 750mm
h) Distance of the outer edges of these planks from the edge of case shall be less than 250mm.
i) Diagonal planks are not required for top planks and width side, if the width of pallet is less than
750mm.
6.2 JOINTING OF PLANKS
Single length planks shall be used for cubicles whose overall length is less than 2400mm. For cubicles
of length more than 2400mm, jointing is permitted. The jointing shall be done with one single or
maximum of 2 planks of wood same as other planks of width 250 mm (minimum) with two rows of nails
on either side of the joint in zigzag manner. From the joint along height side, it shall be of lap joint with
overlap of at least the width of plank.
Page 273 of 348

AA0490010

PAGE 3 of 24
6.3 TONGUE AND GROOVE JOINTS

Two consecutive planks shall be joined by tongue and groove joint. Depth of tongue shall be 12+1 mm,
thickness of tongue shall be 8 +1 mm. The groove dimensions shall be such that the tongue fits tightly
into the groove to make a good joint. This type of joint can be done based on the product requirement
wherever required.
6.4 PERMISSIBLE DEFECTS

Wood shall be free from knots, bows, visible sign of infection and any kind of decay caused by insects,
fungus, etc.
End splits: Longest end splits at each end shall be measured and lengths added together. The added
length shall not exceed 60mm per meter run of shook’s. Wood pins shall be used to prevent further
development of split.
Surface cracks: Surface cracks with a maximum depth of 3mm are permissible. A continuous crack of
any depth all along the length is not allowed.
6.5 OTHER MATERIALS

6.5.1 NAILS
The dia. of the nails shall be 3.15mm. The length of the nails shall be 65mm wherever two planks of
25mm thickness are joined and 75mm wherever a 25mm planks is joined to a 50mm plank.
6.5.2 BLUE NAILS

These are used for nailing bituminized Kraft paper/he ssian cloth to the planks. The length of the nails
shall be 16mm.
6.5.3 HOOP IRON STRIPS

These are used for strapping the boxes. The width of the strips shall be 19+1mm and thickness
0.6+0.01mm. The material shall be free from rust. If sufficient nailing is done for bigger boxes, strapping
need not be done.
6.5.4 CLIPS
These shall be used for strapping the hoop iron strips on the boxes.
6.5.5 BRACKETS
These brackets are used for nailing to the corners of cubicle boxes. The brackets shall be of mild steel of
thickness min 2mm and width 25+1mm. The brackets shall be of “L" shape, the length of each side being
100+2mm. Two holes shall be provided towards the end of each side for screwing /nailing.
6.5.6 FASTENERS
Bolts, double nuts, spring washers will have to be used for packing of so me special items like
transformers, reactors, breakers, etc., to hold the job to the bottom plank of the box. The bolts, nuts,
washers will be provided by the vendor. Drilling of holes will have to be done using contractor's tools.
6.5.7 MULTI LAYERED CROSS LAMINATED POLYTHELENE FILM

100GSM (Colourless) Multi Layered Cross Laminated Polythelene Film Specification No: AA51420 are
used to make covers to the jobs individually. The cross lamination gives qualities of extra toughness,
together with flexibility and lightness coupled with good weather resistance to ultra violet rays.
6.5.8 RUBBERISED COIR:

The rubberized coir is used as cushioning material. For the packing of loose items, items are to be
arrested by using rubberized coir. For the packing of cubicles rubberized coir of thickness 25mm and
width 75mm shall be used.
6.5.9 FOAM RUBBER / 'U' FOAM:

This is used for covering the delicate items. This material is provided by the vendor.
Page 274 of 348

AA0490010
PAGE 4 of 24
6.5.10 MARKING PLATE:

This shall be of anodized aluminium sheet. Size of the marking plate shall be maintained minimum of
size as per the details specified in the Figure 4.
6.5.11 PACKING SLIP HOLDER:

This shall be of galvanized iron tinned sheet /Aluminium sheet
6.5.12 SILICA GEL:

This shall be of indicating type to conform to IS: 3401/AA55619.Silical gel shall be used for such
products only where moisture needs to be avoided.
6.5.13 COTTON BAGS:

These are used for holding silica gel. The bags shall have the following matter indicated on them :
------------------------------------------------------------------------------------------------------------------------------
BHEL-UNIT NAME PLACE-PINCODE
SILICA GEL INDICATING TYPE
BLUE : ACTIVE
ROSE : REDUCED ACTIVITY
WHITE : NO ACTIVITY. TO BE REPLACED WITH FRESH SILICA GEL
--------------------------------------------------------------------------------------------------------------------------------
6.5.14 COTTON/ PLASTIC TAPE:

This is used for tying small items. And also to prevent vibrations of moving parts within the cubicles.
6.5.15 MARKING INK:

The ink used normally is black in color. In some special cases other color also will have to be used. The
ink shall be non-fading/indelible and non-washable by water.
6.5.16 POLYETHYLENE BAGS:

These are to be used for keeping the Packing slips. The bag shall be of size 70mm X 100mm (minimum).
6.5.17 Hessian cloth, twine thread, paint will have to be used in packing certain items.
6.5.18 Mechanical Latching clamps:
For CLW Railway panels and similar Panels self -locking clamps can also be used on need basis in
conjunction with or apart from regular bolt and nut fixin g arrangement. For reusable boxes, these clamps
provide easy locking and unlocking arrangement. These clamps will be made available from BHEL in
some cases.
6.5.19 STICKERS
The following stickers to be put by the vendor on cubicles/Boxes after packing.
1) Case No sticker: 2 nos. Size 25.Cm x 0.45Cm

2) BHEL Monogram sticker: 1 no. Size 1.75Cm x 2.3Cm
3) Address sticker: 2 nos. Size 3.8Cm x 3.0Cm
4) Direction sticker “Front” & “Back” - 4 nos. Size 2.0Cm x 0.75Cm
5) Chain Mark Sticker: 4 Nos. Size – 3.0Cm x 0.75Cm
6) "Fragile” sticker: 2 Nos. Size. 2.1Cm x 1.5Cm
7) "DO NOT STACK” sticker - 2 Nos. Size 3.0Cm x 2.2Cm
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In place of stickers, writing all the details legibly with paint shall be allowed & respective units may
take decision accordingly.
7 PACKING OF CUBICLES:
7.1 The packing is to be done as per clause 5 in all respects.
7.2 The cubicles are already fixed on wooden pallets. Hence the contractor need not arrange the
bottom pallets normally.
7.3 The cubicles will be of different sizes both width wise and lengthwise. The cubicles may be made
up of single suite, 2 Suite, 3 Suite, 4 Suite, etc., The width of the cubicles generally varies from
400 mm to 1650mm.The length of the cubicle, generally varies from 1500 mm to 4800 mm. The
height is normally 2430 mm. In some cases, the height may be less/more .
7.4 MULTI LAYER CROSS LAMINATED POLY FILM
The inner surface of 4 sides of shook's shall be nailed with Multi-layer cross laminated poly film (as per
6.5.7) using blue nails (as per 6.5.2) wherever 2 pieces of Cross laminated poly film are used, the joint
shall have an overlap of minimum 20mm.
The inner surface of top cover shall be nailed with Multi -layer cross laminated poly film (as per 6.5.7).
This sheet shall project outside on 4 sides by at least 100mm and shall be nailed properly on sides.
Joining of sheets should have overlap of minimum 20mm.
The cubicles shall be covered with Multi-layer cross laminated poly film (as per 6.5.7).
7.5 SILICA GEL:

Silica gel (as per 6.5.12) packed in cotton bags shall be kept at different places inside the cubicle as per
BHEL-Unit directions. Each suit of cubicle shall be provided with 1 kg of Silica gel (for a 4 suit cubicle 4
kgs of Silica Gel to be used. The bag containing silica gel to be as per 6.5.13).
7.6 LOOSE PARTS:

Any loose parts in the cubicles shall be tied using cotton/ plastic tape. Wooden battens shall be provided
wherever necessary.
7.7 WOODEN BATTENS:

In case of cubicle which are not rectangular in shape like control desks, sufficient number of wooden
rafters/battens of proper size shall be provided to give strength to the package.
7.8 RUBBERISED COIR:

Gap between the cubicle and the case shall be filled with rubberized coir (as per 6.5.8) with distance
between consecutive layers less than 500mm.
7.9 CLAMPING:
Packing shall be bound at edges by nailing M.S. Clamps / Brackets (as per 6.5.5). Each vertical edge
shall have minimum 3 clamps. Top horizontal edges will have one clamp for every meter length of
package. However, minimum 4 clamps shall be nailed at the top for any cubicle.
7.10 PACKING SLIP:

Packing slip kept in the polyethylene bag (As per 6.5.16) shall be placed in the box at appropriate place.
In addition, one more packing slip covered in polyethylene cover and packing slip holder (as per 6.5.11)
shall be nailed to front / rear of case.
7.11 MARKING PLATE:

One no. (As per 6.5.10) shall be nailed to the front side of the case.
7.12 CASE MOUNTING:

After complete packing, stencil marking of various details and marking of symbols shall be done as per
BHEL instructions using indelible / non washable marking ink.
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7.13 Different types (Typical) of Cubicles with size s for Packing

1. Single suite cubicle - 900 x 950 x2500
2. Two suite cubicle - 1650 x 950 x 2500
3. Three suite cubicle - 2400 x 950 x2500
4. Four suite cubicle - 3150 x 950 x 2500
5. Regulation cub - 1300 x 1350 x 2500
6. Thy cub - 2870 x 1350 x 2500
7. VFD Cub - 3800 x 1550 x 2500
7.14 PACKING OF CUBICLES FOR EXPORT
Refer Corporate Standard AA0490009.
8 PACKING OF LOOSE ITEMS/SPARES

1) Shape of cases shall be square, rectangular with single gabled roof or with double gabled roof
depending on the nature of the job to be packed. Construction shall be as per drawings enclosed.
Only gable will be additional as required.
2) Wood shall conform to specification AA51401 or AA51402 with Tongue and Groove joint as per
clause 6.3.
3) Width of planks shall be at least 100 mm. Width of binding planks (battens) shall be at least 75mm.
4) External surface of planks on front and rear shall be plane 100% (except bottom plank).
5) Inner surfaces of all 6 sides shall be lined with Multi Layered Cross Laminated Polythelene Film (as
per clause 6.5.7) using blue nails.
6) Rubberized coir of minimum 25mm thickness and 100 mm width shall be nailed to inner surfaces of
bottom and 4 sides of box.
7) Internal packing: Items that go into the box shall be packed using 100GSM, (Colourless) Multi
Layered Cross Laminated Polyethylene Film Specification No: AA51420. Any space left between the
job and the sides and the top of the box shall be filled with rubberized coir to get proper cushioning
effect.
8) Certain items like transformers, reactors, breakers, etc., shall be bolted to the bottom of the box
using bolts, nuts and washers.
9) Silica gel as per clause 6.5.12 held in cotton bags as per clause 6.5.13 shall be kept at proper places
in the box.
10) Packing slip kept in polyethylene bag (clause 6.5.16) shall be placed in the box.
11) Marking plate as per clause 6.5.10 shall be nailed to side of the box.
12) Two numbers of hoop iron strips as per clause 6.5.3 shall be strapped tightly on the case using clips.
13) Stencil marking of various details and marking of various symbols shall be done as per BHEL
instructions using indelible/non-washable marking ink.
14) Loose items to be kept inside the cubicle
- The components which are removed from cubicle for shipping purpose only, such as meters shall be
kept inside the cubicle individually, kept in wooden box and tied firmly in bottom of Cubicle.
- Other items which are given loose in addition to cubicle shall be packe d in separate boxes.
9 BOX SIZES
9.1 BOX SIZES
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Table 1 – SPARES WOODEN BOX DETAILS Table 2 – WOODEN BOX DETAILS
SNO BOX BOX SIZE BOX Wt Carrying BOX BOX SIZE BOX Wt Carrying
TYPE (in mm) (in KG) Capacity TYPE (in MM) (in KG) Capacity
1 A 800 X 200 X 200 15 1 320X250X260 10

2 B 1500 X 200 X 200 22 2 320X250X430 15
3 C 2000 X 200 X 200 27 3 430X370X430 25
4 D 1100 X 200 X 200 15 4 670X670X470 65
5 E 200 X 200 X 200 5 5 720X630X600 75
6 F 320 X 250 X 260 13 6 1000X770X660 100
7 G 320 X 250 X 430 16 7 1100X430X670 80

8 H 430 X 370 X 430 23 8 1200X1200X900 80
9 I 1100 X 400 X 400 45 9 1300X770X1050 155
10 J 1500 X 500 X 400 65 10 2500X850X800 225
11 K 2000 X 500 X 400 93 11 2000X1500X1200 305
12 L 2500 X 500 X 400 88 12 1850X1050X1250 260
13 M 900 X 600 X 600 100 13 2000X800X800 180
14 N 3000 X 400 X 400 60 14 2600X1500X1600 470

15 P 600 X 500 X 400 35 15 250X250X600 20
16 Q 710 X 630 X 600 90 16 250X250X880 30
17 R 850 X 630 X 670 102 17 300X300X700 25
18 S 1000 X 770 X 670 140 18 380X380X880 45
19 T 2500 X 850 X 800 180 19 510X510X1400 60
20 U 1500 X 700 X 700 120 20 570X570X1400 80
21 W 1200X900X600 120 21 575X575X1875 105
22 Y 450 X 200 X 200 10 22 3600X1100X1100 390
23 900X500X800 110
24 2000X950X740 225
25 1600X1120X700 220
26 2500X2000X1200 490
27 2900X1900X1400 525
28 3000X1000X900 370
29 3200X2200X950 450
30 2150X1100X750 325
31 2000X2000X700 130
32 700X1200X1325 130
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Table 3 – STEEL BOXES
SL NO TYPE DIMENSION IN MM WEIGHT CARRYING CAPACITY

LENGTH BREADTH HEIGHT (KGS)
1 I 2480 1680 1500 339 4500

2 II 1200 900 600 061 2000
3 IIB 1800 850 950 115 2500
4 III 900 600 600 029 1000
5 IV 600 450 500 019 750
6 V 400 350 300 011 500
TYPICAL PATTERN OF WOODEN BOX
Figure 1
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Figure 2
9.2 STEEL CONTAINERS:

Steel containers for packing can be used in case of repeated supplies of the same equipment. Empty
steel containers are to be returned back from customer's end and to be reused for the next supplies. The
containers are to be made of structural steel as per AA10108 with proper reinforcement with I, C and T
Sections. Depends on the availability of resources & requirements units may be allowed to use standard
cargo containers also instead of fabricated steel boxes.
a) Following precautions are to be taken during packing: -

b) Put the machine in the steel container properly,
c) Cover the machine with polythene.
d) To arrest the movement in the steel container necessary wooden Blocks/Battons may be put.
e) Put cover on steel, container and Bolt Properly
9.3 SEALED PACKING:

Components sub-assemblies and assemblies sensitive to climatic conditions shall be packed seal tight.
All the openings of the sensitive components, sub-assemblies and assemblies shall be blanketed to
prevent the ingress of dust and moisture. The components sub -assemblies and assemblies are
completely covered with 2 layers of polyethylene sheet. All sharp corners and edges are to be protected
by rubber mats to prevent the polyethylene sheet from damage. Top surface of the case shall be free
from dents to prevent rain water pockets.
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10 MARKINGS/STENCILINGS
Center of Gravity
Figure 3
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DESIGN- DIMENSION IN MM
ATION
a1 a2 a3 a4 b1 b2 b3 b4 b5 b l h1 h2 h3 h4 h5 k1 k2 k3 l1 l2 l3 R
A 1 12 5 5 4 52 25 19 8 21 2 84 23
2 17 7 7 6 75 36 29 11 30 3 119 33
3 24 10 10 8 104 50 38 16 42 4 168 46
4 34 14 14 11 147 71 59 23 60 5 239 65
B 1 5 5 50 33 2 84 25
2 7 7 71 47 3 119 36
3 10 10 100 66 4 168 50
4 14 14 142 94 5 239 71
C 1 4 3 66 2 80 39 19 5 11 6
2 6 4 85 3 114 55 27 7 16 9
3 8 6 120 4 160 78 38 10 22 12
4 11 9 170 5 227 110 54 14 31 17
D 1 6 30 4 148 30 30 10
2 9 42 5 209 42 42 14
E 1 3 69 47 10 16 2 91 26 17 8 11
2 4 98 67 15 23 3 128 33 24 11 16
3 6 138 94 20 32 4 182 62 34 16 22
Table 4
Black and Red Marking Ink to IS:1234 "Ink, Stencil, Oil Base, For Marking Porous Surfaces" or
duplicating ink stencilling, oil base for marking porous surfaces.
All cases containing fragile items are to be stencilled with red marking and stencilling paint/ink
"HANDLE WITH CARE", "FRAGILE DO NOT TURN OVER".
Besides the caution signs the product information’s shall be stencilled of letters with 13mm to 50mm
height.
In case of consignment consists of more than one package, each package shall carry its package no as
given in shipping list. All caution signs shall be stencilled in high quality full glossy out door finishing
paint red in colour (AA56126). All other markings shall be carried out in black enamel(AA56126).
Caution signs & other markings shall be stencilled on both the end shooks & the side shooks.
Caution sign (for slinging) shall be stencilled only on side shooks at the appropriate place.
Note: Incase the size of package is small for using the stencils, then hand written letters/figures shall be allowed.
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BHEL – <unit> - <location> - <pin>
CONSIGNEE
MATERIAL
CUSTOMER REF. MO. NO.

DESPATCH
CASE NO
ADVICE NOTE NO
DIMENSIONS(MM) NET GROSS
LxBxH WT –KGS WT –KGS
HANDLE WITH CARE - KEEP DRY

SPECIAL
INSTRUCTIONS
DO NOT DROP - DO NOT TILT
Figure 4 – TYPICAL MARKING PLATE (225 X 170)
Figure 5
Easy spares [Initial and O&M] Traceability and Identification at units and as well as at sites:
11 RECYCLING OF INCOMING WOODEN PACKING CASES

OBJECTIVES
– To utilize useable wood of incoming packing cases, for manufacturing of new packing boxes.
– To recycle incoming wooden packing cases, as such, wherever possible.
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1) All incoming wooden packing cases received from suppliers /customers will be opened carefully, with
the intention of reusing them, by Shop.
2) After carefully taking out the contents, the empty wooden packing cases will be shifted by Shop to
the specified locations i.e. bin / nearly spaces, already earmarked in stores.
3) Material shifting contractor engaged by store, will collect all such wooden packing cases and scrap
wood from specified points, on a regular basis.
4) After collecting / loading the empty packing cases/ scrap wood, contractor will take the carrier first to
Weighment Bridge for weighment, thereafter; he will go to Carpentry, where Carpentry representative
will identify the packing cases which can be used by Carpentry for m anufacturing of New Packing
Boxes. All such identified packing boxes will be unloaded and handed over to Carpentry by
contractor.
5) These packing boxes will be made re-useable after necessary rectification and additional work.
6) Contractor will again take the carrier for weighment and this second reading will also be recorded on
the same “Weighment Slip”.
7) Weight of empty packing cases / scrap wood taken will be calculated on the basis of 1st and 2nd
weighment readings recorded on the “Weighment Slip”. A copy of “Weighment Slip” (where both the
weighment readings are recorded) will be given by the contractor to the carpentry representative.
Based on this “Weighment Slip”, carpentry will maintain a register in which details of quantity
received will be recorded.
8) All “Weighment Slips” will invariably be signed by carpentry representative (even when no boxes
have been unloaded by carpentry). Store will accept the scrap wood only if “Weighment Slips” are
signed by carpentry representative.
9) Balance empty packing cases / scrap wood will be handed over by contractor to Store, for storing in
scrap yard.
10) A separate area in Scrap yard will be provided, for executing the work of de nailing of wooden
packing cases, under supervision of carpentry.
11) Carpentry contractor will identify packing cases / scrap wood for denailing, which will behanded over
to him by Store, at Scrap yard, for denailing and further operation.
12) Quality and Carpentry will jointly inspect the wood generated by de -nailing process and will prepare
“INSPECTION CUM RECEIPT REPORT OF USEABLE WOOD RECEIVED FROM TPS – STORE BY
CARPENTRY”.
13) After acceptance of the wood by Quality and Carpentry, the same will be shifted to carpentry for
receipt and its record will be maintained by carpentry.
14) This will be a Permanent Productivity Project executed by carpentry. “Productivity Savings “duly
verified at the current Purchase Order rate of wood, will be sent every month to Resource
Management Department, for highlighting it in their monthly progress report.
12 STANDARD METHOD OF PACKING

Table 5 - Standard Method of Packing
DESCRIPTION CASE CRATE SKID BUNDLE BARE DRUM METAL DRUM FIBRE DRUM
PRESSUE VESSELS
TOWERS O
TANKS O
VESSELS O
GASKETS O
FASTENERS O
COVERS O
EXCHANGERS
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HEAT EXCHANGERS O
TUBE BUNDLE O
SHELL O
AIR FIN COOLERS O
COLOUMNS, MOTOR O
SUSPENSIONS, PLENUM
CHAMBERS, SCREEN GUARDS,
ETC
BEARING BLOCKS O
FANS O O
MOTORS O
GASKETS O
FASTENERS O
TEST FLANGES O
TEST RINGS O
COVERS O
CRYOGENIC VESSELS
COLD CONVERTERS O
HORIZONTAL STORAGE TANKS O
TRANSPORTATION TANK O
COLD BOX O
DRYING UNIT O
DRYING BOTTLES O
MOISTURE SEPARATORS O
SILENCERS O
ONGC SKIDS O
VAPORISER O
SPECIAL PRODUCTS
SI/VI PIPING O
CRO BIO CONTAINERS O
AIR BOTTLES O
TITANIUM BOTTLE O
WAR HEAD CONTAINER O
MISSILE CONTAINER O
FUEL CONTAINER O
AIR LOCK ASSEMBLY O
BOILER DRUMS O
BOILER ITEMS
COILS O
PANELS O
HEADERS O O
FEEDERS
MACHINED ITEMS
SHELL SEGMENTS O
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SHELL SEGMENTS IN STACKS O
SPHERE PETALS
COLOUMNS, BASE PLATES, O
TIERCOS, PIPES, NOZZLE E1, F1,
INTERNAL PIPES, PADS ETC.
ROLLERS O
VALVE TRAYS
VALVE TRAY COMPONENTS O
LATTICE GIRDERS O
FASTENERS O
GASKETS O
SUB CONTRACTS
FAB STRUCTURALS O
SUPPORTING STRUCTURALS O
STRUCTURE SUB ASSEMBLY O
FAB PIPES O
GRATINGS O
STAIR CASES O
HANDRAILS/ PLATFORMS O
BOUGHT OUT COMPONENTS
IRON & STEEL (LIKE PLATES, O
BEAMS, ANGLES, CHANNELS
ETC.)
PIPE FITTINGS
CS PIPES, TUBES O
SS PIPES, TUBES O
FIN TUBES O
ELBOWS O O
FLANGES O O
VALVES O
GAUGES O
DEMISTERS O
ABSCRBANTS (LIKE MOLECULAR O
SIEVES, ACTIVATED ALUMINA,
MOBILE SORBID)
PAINT TINS O
PAINT DRUMS O
IGNITORS O
SPRAY NOZZLES O
ELECTRICAL INSTRUMENTATION
MOTORS, PUMPS, O
COMPRESSORS, TURBINES
SWITCH BOARDS, DISTRIBUTION O

BOARDS, STARTERS, JUNCTION
BOXES
INDICATORS, VIBRATOR O
SWITCHES
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CABLE BUNDLES, CABLE DRUMS O
CABLE TRAYS, CABLE RACKS, O
EARTHING MATERIAL
OPERATIONAL SPARES O
13 PROCEDURE FOR HANDLING OF COMPONENTS

The purpose of this procedure is to protect the quality of the components/e quipment while handling in
various stages of manufacturing packing & despatching.
13.1 Adequate care shall be taken in handling the material, and com ponents to avoid damage during
receipts, storage issue manufacture & despatch operations.
13.2 Appropriate material handling equipment like fork lifters, cranes etc. shall be used where needed.
13.3 Lifting by crane and transportation by trolley of critical items and large components like rotors
castings etc. shall be done carefully.
13.4 For critical items, where specified, special handling fixtures shall be used for lifting.
13.5 Slings and shackles used for lifting the components/equipment shall be checked for fitness and
suitability before use.
13.6 Slings used on machined surfaces shall be suitably padded. No slings shall be used on journal
surfaces.
13.7 Precision machined components like blades, catches, rollers et c. shall be lifted using suitable
wooden pallets.
13.8 HANDLING OF COMPONENTS ON RECEIPT/DESPATCH
Before loading/unloading a packing case from the carrier look for the following shipping instructions
painted on the packing case.
a) The markings showing the upright position.

b) The markings showing the sling position
c) Markings showing the fragile contents.
d) Other required markings as per clause no.10
13.8.1 Appropriate cranes and slings should be used for different components/ cases. Slings should
normally make an angle as minimum as possible (width wise) but in no case more than 15º.
13.8.2 Handling and lifting should be done without jerks or impacts.
13.8.3 Immediately after receipt of the goods, the packing should be examined all -round for any sign of
damage. If necessary, lift the cover or a number of boards of the case so as to make the
contents visible. In the event of sealed packing being used the plastic sheeting sh ould not be
damaged. It is imperative that the packing material is restored in original condition after the
inspection.
13.8.4 On receipt of the equipment it should be checked with the shipping list and missing or damage if
any should be reported immediately. It is important to arrange for immediate examination to
determine the extent of the damage, the cause of the damage and where applicable the person
or persons responsible for the damage. According to general practice when transporting by
railway or by road vehicle the carrier concerned should be immediately called upon (within
specified periods) for jointly establishing a statement of the damage. This is essential as a basis
for a subsequent claim and possible damage report to the insurance company.
13.8.5 Protective coating applied on machined surfaces should not be disturbed. The plastic covering
should be put back carefully so that it prevents ingress of dust and moisture. Some packing may
have vapour phase inhibitor (VPI) paper enclosed inside the packing cases. T his should be
restored to its original place as far as possible.
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13.8.6 Silica gel and such other chemicals kept in the box as desiccants and indicators should also be
left in the box itself.
14 GENERAL GUIDELINES FOR ODC TRANSPORTATION/DESPATCH

Based on the Dimensions/Weight indicated in the Transportation Sketch, the type of Trailer is decided
and indicated in the Tender Enquiry.
14.1 TRANSPORTATION:
1. LOW BED TRAILERS (LB 8):
Well Bed Length : 10000mm
Over Gooseneck : 13000mm
Width : 3000mm
Carrying Capacity : 40MT
2. LOW BED TRAILERS (LB 16):

Well Bed Length : 12000mm
Over Gooseneck : 16000mm
Width : 3000mm
Carrying Capacity : 75MT
3. TOW TYPE TRAILERS (WITH FRONT DOLLEY 16 TYRES): 12000MM length

(for Exceptional equipment length: 30000mm and above)
Bigger Dia equipment are loaded in the Well with overhanging.
Smaller Dia equipment with excess length are loaded over Gooseneck with rear hanging.
The Vehicle Dimensions are defined above are only guidelines for selection based on actual
Dimensions/ Weight of the Consignment
14.2 PACKING:
For all ODCs, Wooden Saddles are cut to the diameter of equipment as per the Transportation Sketch .
Wooden Saddles For Diameter up to 4000mm For Diameter above 4000mm

Length: 1836/2743mm (6’0”/9’0”) 3353mm (11’0”)
Width: 300mm (1’0”) 300mm (1’0”)
Height: Saddle + one/two wedges a top Saddle + three/four wedges a top
Number of Saddles:
Minimum 3 in case of Loading inside Well

+1 when loaded on Gooseneck
Maximum: 4 in case of Loading inside Well
+2 when loaded on Gooseneck
For Securing the equipment firmly on the Trailer, 19mm (3/4”), wire rope with 25mm (1”) Heavy Duty
Turn Buckles / BD Clamps are used as Lashing for the e quipment.
14.3 NUMBER OF LASHINGS:
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CONSIGNMENT LOADED INSIDE CONSIGNMENT LOADED OVER

WELL BED GOOSENECK
4 (2 Single Line lashing 2 Double 5 (3 Single Line Lashing 2 Double

a) up to 40MT
Line Lashing) Line Lashing)
5 (3 Single Line Lashing 2 Double 5 (Single Line Lashing 3Double Line

b) 40MT to 60MT
Line Lashing) Lashing)
5 (2 Single Line Lashing 3 Double 6 (3 Single Line Lashing 3 Double

c) 60MT and above
Line Lashing) Line Lashing)
15 GUIDELINES FOR HANDLING/LOADING/LASHING

15.1 HANDLING
Figure 6
Before unloading the jobs Completely painted and neatly stencilled will be checked.
Pipes with split type end cover will be checked
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Figure 7
All Coil Tubes to be provided with End Caps.
Figure 8
Neatly stacked Coil Assemblies.
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Figure 9
Columns to be lifted with Nylon belts. This protect painting, edges and attachments.
Figure 10
15.2 LOADING
All the components to be transported by putting inside the properly fabricated Crating
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Figure 11
Small components may fall down while transporting without closed crating and there are chances of
missing of small parts. Hence, it is always better to transport small components in closed
containers/crating. Loose to be being shipped in a closed crating.
Figure 12
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No component loaded over the crating.
Figure 13
Headers supported with wooden V blocks at 3 meters interval.
Figure 14
Spacers in between each coil assembly.
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Figure 15
Goose pipe to be provided with rubber pad protects removal of painting and damage to the job.
Figure 16
15.3 LASHING
Use Nylon belts only for lashing of all components. It prevents removal off painting and cut in the
materials.
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PAGE 24 of 24
Figure 17
Nylon Belts used for lashing the beams.
Figure 18
16 PRODUCT WISE SPECIAL INSTRUCTION

Additional instructions of packing not included in this standard shall be covered by individual product
standard.
17 REFERRED STANDARDS (Latest publications including amendments):

1) AA51420 2) AA55619 3) AA51414 4) IS:3401 5) AA10108
6) AA56126 7) AA51402 8) AA51401 9) IS:1234
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AA0490006
PAGE 1 of 3
VACUUM PACKING FOR ELECTRONIC COMPONENTS

1 GENERAL
This standard l ays do wn the pac king i nstructions for p acking of components / E lectronic module /
Assemblies to be dispatched against Customer contracts.
2 SCOPE
This pr ocedure covers m ethod of packing electronic components us ing vacuum packing i n a w ooden
packing boxes.
3 OBJECTIVE
To establish a rust proof safe packing procedure and w here t he components required t o protect against
temperature a nd hum idity. I n g eneral m inimum t emperature + 5 d eg C an d m aximum t emperature
45 deg C, and relative humidity between 10% to 40%.
4 PACKING BOX
Wooden Box shall be made as per BHEL Standard AA0490010 for Domestic/ AA0490009 for Export/
AA0490004 for Seaworthy packing. S ize of the box as per the contract requirement which has to be
checked by QC.
5 PACKING PROCEDURE
a) Cleaning parts shall be thoroughly cleaned just before VCI (Volatile Corrosion Inhibitor) Vacuum
packing. Finger prints on cleaned items are to be avoided as the same are very corrosive.
b) VCI R ust pr eventive oi l (Ferrous grade oil b ase) s hall b e applied t o all the components t o w ithstand
any corrosion.
6 VCI VACUUM PACKING

a) Bubble wrapping the items VCI vacuum packing.
b) Appropriate v apour c orrosive packets one p ouch ( 1 gm . / pouch) of V CI A nticorrosive P owder a nd
one pouch ( 10gm./ p ouch) of V CI D esiccant per 1 000 c ub. m eter p acking s pace s hall be placed
inside the VCI vacuum packing.
c) All t he c omponents s hall be s eparately packed u sing VCI l aminated A luminium f oils f rom w hich
air/moisture are r emoved b y t he a ir vacuum de vice a nd s ealed t horoughly using heat s ealing
machine. At the time of the evacuation the vacuum inside the pack should be less than 0.5 ata.
d) One i dentification s lip c ontaining c omponent information s uch as d escription of i tem, M aterial No.
Customer PO, Item No. Quantity etc. shall be put inside the VCI vacuum packing.
e) Top c over of t he wooden box s hall be s ealed only after f inal c learance f rom Q C f or c onfirmation of
above.
f) All boxes should be covered by water proof tarpaulin over top and on all sides.
g) The pac king b oxes s hall be c overed with G I s heets (0.25 -0.4mm t hick) on a ll t he s ides f or E xport /
Seaworthy packing.
h) Vacuum packing room temperature an d R elative H umidity should b e m aintained as m entioned
below:
Min. +5 deg. C and Max. 45 deg. C, Relative humidity between 10% to 40%.
PGC (Packing)
DRC-5190

Dt: 12-06-2018 Dt: Year: EDN, Bangalore Corp. R&D 31-05-2018
Page 296 of 348

AA0490006
PAGE 2 of 3
7 COMPONENTS REQUIRED
7.1 VCI laminated Aluminium foil
Volatile C orrosion I nhibitor ( VCI) s afe f oil s hall b e with a luminium bar rier l aminated which is f lexible,
heat sealable, water vapour and anticorrosion resistant barrier laminate of polyester, Aluminium foil and
VCI P olyethylene. I t i s u sed as a pr imary p ackaging material for packing m etal components and sealed
with the help of a heat sealer after vacuuming with vacuum machine maintaining the humidity level below
40 RH inside the package.
7.2 Composition construction of VCI laminated Aluminium foil

a) PET Film : 12 Microns
b) Bonding layer : 2 Microns
c) Aluminium Foil : 9 Microns
d) Bonding layer : 2 Microns
e) VCI Poly film : 100 Microns
f) Total thickness : 125 Microns + or – 5%
7.3 Properties of VC Laminated Aluminium foil
a) Basic Weight : 138 gsm +/- 8%
b) Sealing condition : 180 C/ 2 sec
c) Tensile strength
MD: 20 kgf
CD: 18 kgf
d) Tear Strength
MD 4.8 kg
CD:3.4 kg
e) Heat Seal Strength : 30.380 N/cm
f) WVTR Value : 0.05gms/m /24 hrs.
g) OTR Value : 0.1 cc/m/24 hrs
8 MARKING OF PACKING BOX

Mark the following information on the two adjacent sides of the each package
a) Material No.
b) Customer PO
c) Item No.
d) Quantity
e) Storage Requirement : Indoor
f) Content Description : Electronic Module
g) Net weight (in kg)
h) Dimension (L x W x H in centimetres)
i) Project Name
j) Consignee
k) Water proofing (Umbrella Stencilling)
l) Upside direction
Page 297 of 348

AA0490006

PAGE 3 of 3
Figure 1
Page 298 of 348

AA0490008
PAGE 1 of 4
VACUUM PACKING FOR ELECTRICAL COMPONENT

1 GENERAL
This s tandard l ays down t he p acking i nstructions f or packing of c omponents / Electrical c omponents
Stator/ Rim punching, Wound Pole/ Field Coils and Stator coils / bars to be dispatched against Customer
contracts.
2 SCOPE
This procedure covers method of packing component in a wooden packing boxes.
3 OBJECTIVE
To establish a rust proof safe packing procedure and w here t he components required to protect against
temperature a nd hum idity. I n g eneral m inimum t emperature + 5 d eg C an d m aximum t emperature
45 deg C, and relative humidity between 10% to 40%.
4 PACKING BOX
Wooden Box shall be made as per BHEL Standard AA0490010 for Domestic/AA0490009 for Export/
AA0490004 for Seaworthy packing. Size of the box as per the contract requirement, which has to be
checked by QC.
5 PACKING PROCEDURE
a) All i tems packed ar e to be marked b y QC w ith “OK” stickers. V arnished s tator punchings are t o be
brought dow n t o room t emperature b efore labelling them “ OK” f or packing. Do n ot p ack h ot/warm
stator punchings that have is just received from the varnishing.
b) Packing of stator punchings, w ound p ole/ field coils a nd stator coils / b ars should b e do ne in a
covered shed.
c) Packed materials are to be stacked in proper alignment and to be kept in wooden packing.
6 Additional Packing Methodology for Stator / Rim Punchings (Double stacking) only
In or der t o e liminate t he us e of s tuds a void double s tack pac kaging per box. Where do uble stacked
packing boxes are unavoidable, the stator /rim punchings are to be securely tightened using GI studs,
nuts and s oft m aterial washers ( rubber/plastic). GI s tuds, nut s and s oft material only to be used i n
case of do uble s tacking of r im / s tator punchings ( with h oles). U se s oft r ubber washers t o s eal t he
punctured op ening at t he bo ttom from where the studs p ass i n e ach l ayer of V CI (Volatile C orrosion
Inhibitor) paper, polythene and tarpaulin sheet in case of rim /stator punchings (with holes).
a) GI studs with rubber washer to be placed initially inside the wooden packing box.
b) Over the wooden base, place water proof tarpaulin sheet.
c) Rubber washer shall be placed after the layer of tarpaulin sheet.
d) Then p lace a layer of porous p lastic s heet with total t hickness of at l east 5m m ( for c ushioning a nd
reduces the chances of damage to punchings).
e) Place the Aluminium Barrier laminated Bags over this porous sheet, place the rubber washer over it.
f) Place VCI papers on the Aluminium barrier bag and fix with rubber washer.
PGC (Packing)
DRC-5192

Dt: 12-06-2018 Dt: Year: EDN, Bangalore Corp. R&D 31-05-2018
Page 299 of 348

AA0490008
PAGE 2 of 4
g) PVC P ipes shall be i nserted o ver the GI studs. T hese p ipes ar e to b e used t o cover e ach stud, t o
protect its direct contact and hence rubbing with punchings.
h) Now place the stack of punchings over the VCI paper and securely tighten the punchings using nuts
and soft material, washers.
i) Each l ayer should be secured i n pos ition. Wrap the p unchings w ith V CI p aper a nd pr operly sealed
separately using an adhesive tape.
j) Silica Gel packets are to be placed over the VCI pa per and uniformly distributed inside the boxes o n
the VCI paper to remove/prevent moisture.
k) Aluminium barrier laminated bag has secured in position and properly sealed by using heat sealing
machine and a ir t o b e dr ained out b y using vacuum pum p. At t he t ime of t he e vacuation t he
vacuum inside the pack should be less than 0.5ata.
Use two s eparate VCI papers f or doubled s tacked boxes i ndependently covering e ach s tack. S imilarly
two Aluminium barrier laminated bag are to be used to wrap the two stacks independently, as explained
above.
7 Additional Packing Methodology for Wound Pole/ Field Coils and Stator Coils/Bars
only
a) Over the wooden base, place the waterproof tarpaulin sheet.
b) Then place a layer of p orous plastic s heet with t otal t hickness of a t least 5m m ( for c ushioning a nd
reduces the chances of damage to Wound pole/field coils and stator coils/ bars.
c) Place the Aluminium barrier laminated bag over this porous sheet.
d) Place t he V CI p aper ( Volatile C orrosion I nhibitor as per BHEL S tandard AA51406) on t he
Aluminium barrier laminated bag along with rubber washer.
e) Bare copper portion of field coils and stator coils / bars to be covered by VCI paper pouch and fasten
with VCI tape.
f) Now place the wound pole, stack of field coil and stator coil / bars over the VCI paper.
g) Each layer s hould be s ecured in position. Wrap w ound pole / f ield c oils and s tator c oils / bars with
VCI paper and properly sealed separately using an adhesive tape.
h) Silica G el p ackets ar e t o be placed and uniformly distributed inside t he boxes on t he V CI paper t o
remove/prevent moisture.
i) Then A luminium bar rier laminated b ag has s ecured i n position and pr operly s ealed by us ing heat
sealing machine and ai r t o b e drained ou t by us ing v acuum pump. At t he t ime of evacuation the
vacuum inside the pack should be less than 0.5ata.
j) The VCI paper must contact the stator / rim punchings, wound pole / field coils and stator coils/bars.
It h as to e nsure that the VCI p aper, Aluminium ba rrier bag s hould n ot get dam age / puncture during
the packing process.
k) Top c over of t he wooden box s hall be s ealed only after f inal c learance f rom Q C f or c onfirmation of
above.
l) All boxes should be covered by water proof tarpaulin over top and on all sides.
m) The pac king b oxes s hall be c overed with G I sheets ( 0.25 -0.4mm t hick) on a ll t he s ides f or E xport /
Seaworthy packing.
n) Vacuum packing room temperature an d R elative H umidity should b e m aintained as mentioned
below:
Min. +5 deg. C and Max. 45 deg. C, Relative humidity between 10% to 40%.
Page 300 of 348

AA0490008

PAGE 3 of 4
8 COMPONENT REQUIRED
8.1 VCI laminated Aluminium foil
Volatile C orrosion I nhibitor ( VCI) s afe f oil s hall b e with a luminium bar rier l aminated which is f lexible,
heat s ealable, water v apour and anticorrosion r esistant b arrier l aminate of po lyester, Aluminium f oil &
VCI P olyethylene. I t i s u sed as a pr imary p ackaging material for packing m etal components and sealed
with the help of a heat sealer after vacuuming with vacuum machine maintaining the humidity level below
40 RH inside the package.
8.2 Composition construction of VCI laminated Aluminium foil

a) PET Film : 12 Microns
b) Bonding layer : 2 Microns
c) Aluminium Foil : 9 Microns
d) Bonding layer : 2 Microns
e) VCI Poly film : 100 Microns
f) Total thickness : 125 Microns + or – 5%
8.3 Properties of Aluminium Barrier laminated Bag
a) Basic Weight : Unit: g/sq. m 150 +/- 5
b) Tensile strength : Unit: N/sq. mm MD: 40 (min.)
Unit: N/sq. mm TD: 41 (min.)
c) Water Vapour Transmission : Unit: g/m 2 0.01 in 24 hrs. at 38 deg C & 90% RH(max)
d) Oxygen Transmission : Unit: cm 3 /m 2 0.02 in 24 hrs. at 38 deg C & 90% RH (max)
e) Sealing Temp. : Unit : Degree C 180-220 deg C
9 MARKING ON PACKING BOX

Mark the following information on the two adjacent sides of the each package.
a) Box No.
b) Customer PO
c) Product Name.
d) Project Name
e) Quantity
f) Storage Requirement : Indoor
g) Net weight (in kg)
h) Dimension (L x W x H in centimetres)
i) Consignee
j) Water proofing (Umbrella Stencilling)
k) Upside direction
l) Sling position indicator
Page 301 of 348

AA0490008
PAGE 4 of 4
Figure 1
Figure 2 Figure 3
Figure 4 Figure 5
Page 302 of 348

REV. 00 DATE: March2022
JULY 2021
SHEET : 1 OF 1
VI
ANNEXURE‐V
DATASHEETS FOR BOUGHT OUT ITEMS

FOR CONDENSATE STORAGE TANK
Page 303 of 348

REV. 00 DATE:March2022
JULY 2021
SHEET : 1 OF 1
DATASHEET OF LEVEL INDICATOR
S.NO. COMPONENT DESCRIPTION

1 Type Float and Board
2 Float Material & Tape MOC SS 316
3 Pulley and Pulley housing material SS‐304
4 Guide wire SS‐316
5 Accuracy ± 10 mm /Manufacturer std.
6 Spring tension Assembly SS‐304
7 Anchor plate SS‐304
9 Calibrated scale board Aluminum with black graduation
10 Quantity One (1) No. per tank
DATASHEET OF PIPES, FITTINGS, FLANGES & ACCESSORIES
S.No. Description Material Standard Dimensional Standard

1.0 SS Pipes
Stainless steel pipe as per ASTM As per ANSI B‐36.19,
1.1 50 NB and below A‐312, TP 304, Seamless, Sch. socket welded
40S
Stainless steel pipe as per ASTM As per ANSI B‐36.19, BW
1.2 65 NB and above
A‐312, TP 304, ERW, Sch.10S ends
SS Fittings(Elbow, Tees
2.0
& Reducers)
Forged Stainless steel as per
50 NB and below ANSI B 16.11, S/W ends
2.1 ASTM A‐182, F‐304
Stainless Steel as per ASTM A‐
2.2 65 NB and above 351‐ CF8 or ASTM A 403 WP304, ANSI B 16.9, B/W ends
ERW
3.0 SS Flanges
For SS Pipes up to 50 NB ASTM A182 F304 ANSI B16.5, RF

3.1
For SS Pipes above 50
ASTM A403 Gr. 304 ANSI B16.5, FF
3.2 NB
4.0 Gaskets
Neoprene to suit ANSI B16.5 RF ANSI B16.21
4.1 All Gaskets
flange 3 mm Thk
5.0 Bolts & Nuts
Wherever applicable in ASTM A‐193, Gr. B7 for Bolts ANSI B 18.2.1 & ANSI
5.1
all the tanks. ASTM A‐194, Gr. 2H for Nuts 18.2.2
Page 304 of 348

REV. 00 DATE: March2022
JULY 2021
SHEET : 2 OF 1
DATASHEET OF VALVES:
S.NO. COMPONENT DESCRIPTION

ASTM A182 Gr.F304 ( 50NB &
1. Body & Bonnet below)
ASTM A351 Gr.CF8M ( 50NB above)
ASTM A182 Gr.F304 ( 50NB &
2. Wedge & Seat ring below)
ASTM A351 Gr.CF8M ( 50NB above)
3. Trim ASTM A182 Gr F304
Class 800 ( 50NB & below)
4. Rating
Class 150 ( 50NB above)
SW to B16.11 (50NB &below)
5. Ends
Flanged to B16.5 ( 50NB above)
B16.34 / API600 for Gate valve
6. Design Standards
B16.34 / BS1873 for Globe valve
7. Testing standards API 598 for all valve ( All sizes)
8. Bolts & Nuts A193 Grb7 & A194 Gr.2H
Page 305 of 348

TECHNICAL SPECIFICATIONS FOR SECTION-I, SUB-SECTION-D
AGITATORS
Date: MARCH 2022
SECTION-I, SUB-SECTION-D
ANNEXURE-VII
MANDATORY SPARES
Page 306 of 348

1x660 MW Sagardighi TPP Extn unit-5 of WBPDCL , List of Mandatory
Spares For Miscellaneous Tank and Agitator Package
MANDATORY SPARES
Sl. No. Description Qty.
(1) (2) (3)

A For Auxiliary Absorbent Agitator
(i) Impeller Assembly 1 no. of each type
(ii) Bearing Assembly 1 no. of each type
(iii) Motor 1 no. of each type
B For Absorber Drain Pit Agitator
(i) Impeller Assembly 1 no. of each type
(ii) Bearing Assembly 1 no. of each type
(iii) Motor 1 no. of each type
C For Condensate Storage Tank
Level gauges (Float & Board type) for
(i) 1 no.
Condensate Water Storage tank
Page 307 of 348

TECHNICAL SPECIFICATIONS FOR SECTION-II
AGITATORS
DATE: MARCH 2022
SECTION-II
Page 308 of 348

TECHNICAL SPECIFICATIONS FOR SECTION-II
AGITATORS
DATE: MARCH 2022
SUB-SECTION-A
STANDARD TECHNICAL SPECIFICATIONS- MECHANICAL
Page 309 of 348

PEM-6666-0

TECHNICAL SPECIFICATIONS FOR SECTION II SUB-SECTION A
MISC. TANKS (SITE FABRICATED) AND AGITATORS REVISION 00 DATE: MARCH 2022
PAGE 1 of 9
1.0 SCOPE
This specification covers design, engineering, supply of material, fabrication, assembly, inspection
and testing at shop as well as at site, erection and commissioning, painting and functional
demonstration testing at site.
2.0 CODES & STANDARDS
The design, fabrication & assembly, erection & performance of steel tanks shall comply with all latest
statutory regulations and safety codes applicable in the locality where the tanks are to be installed.
Tanks shall conform to the latest applicable Indian / British / USA standards. The vendor shall not be
construed to be relieved of his responsibility by virtue of this specification. The tank in general shall
conform to the latest editions, as applicable, out of the following standards.
I. IS-800: Code of practice for use of steel in general building construction
II. IS-803: Code of practice for design, fabrication and erection of vertical mild steel cylindrical welded
oil storage tank.
III. IS-804: Specification for rectangular pressed steel tanks
IV. IS-805: Code of practice for use of steel in gravity water tank.
V. IS-816: Code of practice for metal arc welding for general construction in MS.
VI. IS-817: Code of practice for training and testing for metal arc welder
VII. IS-2825: Code of practice for unfired pressure vessel
VIII. BS-2594: Specification for carbon steel welded horizontal cylindrical storage tank
IX. BS-2654: Specification for vertical steel welded storage tanks with butt welded shells for the
petroleum industry
X. Indian Factories Act
XI. American code for oil tanks API 650
XII. Material Specification as per relevant IS / or approved equal
XIII. American water works association standards (AWWA D100)
3.0 DESIGN REQUIREMENT
3.1 General Requirement
3.1.1 All tanks will be mild steel tanks. The tanks will be of welded construction and will be designed to
withstand satisfactorily the internal forces due to the liquid which these tanks have to hold as
specified and external forces due to wind and seismic forces without deformation or undue strain.
Page 310 of 348

PEM-6666-0

PAGE 2 of 9
The plates will be cold rolled through plate bending machines by several no. of passes to the
curvature.
3.1.2 Tank thickness shall be calculated as per IS803 latest edition. Intermediary wind girder design, Wind
Design, Seismic design, anchor bolt design / selection etc. shall be done as per API 650 latest edition,
latest addendum available at the time of detail engineering.
3.1.3 All tanks will be designed for the capacities, dimensions and working conditions as specified in this
specification. The tanks will be provided with all necessary connections as specified. The design of
tanks will be such as to allow easy inspection, cleaning and repair. Due consideration will be given to
wind loading and adequate stiffening will be provided to prevent failure of tank due to buckling
when it is empty. Corrosion allowance (as specified in section - C) for shells, bottom and roofs above
and beyond the required thickness / calculated thickness / nominal thickness as specified in the
design code shall be provided.
3.1.4 Vessel seams shall be so positioned that they do not pass through nozzle connections on vessel. For
vessels consisting of more than two sections, longitudinal seams shall be offset.
3.1.5 The inside seam should be ground smooth, suitable for application of corrosion resistant primer. If
the stiffening of shell, bottom and / or roof is necessary, tanks will be stiffened from outside.
3.1.6 Flange faces of all nozzles shall be machined and squared with the vessel center line.
3.1.7 All roofs and supporting structures shall be designed to support dead load plus a uniform live load of
not less than 150 kg/m2 of projected area.
3.1.8 The tanks shall be designed to have all courses truly vertical. Adequate distance between vertical
joints in adjacent courses shall be taken so that the distortion is reduced to minimum.
3.1.9 When removing temporary attachments from shell plates, care should be taken that parent plate is
not damaged. Holes in plate work to assist in fabrication / erection should be avoided as far as
possible. The location of holes and method of filling shall be indicated in the fabrication drawing.
Any projection of metal shall be chipped and ground flush with the plate surface. The plate shall not
be gouged or torn in process of removing lugs.
3.1.10 In the construction of shell, very care shall be taken to minimize distortion or lack of circularity due
to welding or for any other reason.
3.1.11 Material of construction (MOC) of all tanks shall be MS conforms to IS:2062 Gr. B unless otherwise
specified in the specification. MOC for structure (angles, channels etc.) shall be IS: 2062 Gr. A.
3.2 Alignment
3.2.1 Plates to be joined by butt-welding shall be matched accurately. Misalignment in completed vertical
joints shall not exceed 10% of the plate thickness or 1.5 mm for plates of 20 mm thick and under,
whichever is larger.
3.2.2 In completed horizontal butt joints, the upper plate shall not project beyond the face of the lower
plate at any point by more than 20% of the upper plate thickness with a maximum of 3 mm for plate
Page 311 of 348

PEM-6666-0

PAGE 3 of 9
thickness exceeding 8 mm except that for plate thickness 8 mm and under, the maximum shall be
1.5 mm.
3.2.3 Each tank shall be properly constructed ensuring perfect vertical alignment with 5 mm or as
specified in the relevant code / standard and tank circularity within 5 mm on diameter or as
specified in the relevant code / standard. Local bulging and / or depressions at any location of tank
particularly shell shall not be permitted.
3.3 WELDING
3.3.1 Tanks and other attachments shall be welded as per IS-816.
3.3.2 Welding sequence shall be so adopted that distortion due to welding shrinkage shall be minimum.
Welding procedure specification shall be submitted for approval of BHEL giving details of material,
welding position, sequence, type of electrode used, pre-heat & post weld requirement etc as per the
code of construction. Brand name of electrodes to be used with proper classification (e.g. E 6013)
shall be as per BHEL’s approval.
3.3.3 Welding shall not be carried out when the surface is wet and during periods of rain and high winds
unless the welder and the work are properly shielded which should meet the approval of the
purchaser.
3.3.4 Inspection of all welds shall be carried out in accordance with the governing code of construction. All
material used by the purchaser such as electrodes, gaskets, bolts, nuts etc. shall be
conforming to relevant standards of repute and approved by the purchaser prior to use.
3.3.5 Each tank shall be complete with access staircase, ladder and safety cage and fittings like drain
connection, overflow connection(pipe) till bottom of tank, tank inlet and outlet covers, level gauge
glass, fittings with isolation cocks and protection covers, tank vent connection etc. all complete with
needed accessories for the completeness of the tanks.
3.3.6 All openings in tank plate shall be well reinforced in approved manner by adding pad plates of
adequate size and / or structural sections.
3.4 STAIRCASE / ACCESS LADDER AND HAND RAILING
3.4.1 All cylindrical vertical tanks shall be provided with spiral staircase and shall conform to the
requirements specified in design codes / standards unless specified otherwise. All stair treads shall
be 32 mm steel fabricated gratings. Each tread, if needed, shall be housed in individual steel
fabricated frame which shall be adequately supported from the tank outer periphery. The staircase
shall have minimum 1200 mm clear width.
3.4.2 Access ladder, one (1) for each horizontal cylindrical / rectangular tank shall be provided for access
to the tank roof. It shall be steel fabricated having minimum 450 mm width. Ladder stringers shall be
heavy steel flats or angle section. All rungs shall be minimum 20 mm diameter rods spaced at not
more than 30 mm center to center. All ladders shall have steel fabricated safety cage to the
approved construction. Safety cage shall be provided about 2.5 m clear height of the ladder. Access
ladder’s stringers shall be widely spaced at top for free access to the tank roof.
3.4.3 All staircase and roofs of vertical cylindrical tanks shall be provided with pipe hand railings of
effective height as indicated in the relevant code / standard throughout. Handrails shall be
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PEM-6666-0

PAGE 4 of 9
constructed out of 32 mm medium class galvanized steel pipe conforming to IS- 1239: 1968. Handrail
posts shall be arranged at spacing not greater than 1850 mm. Two (2) sets of pipes horizontal
runners all along the length shall be provided. All welds joints in the handrails shall be ground flush
to protect any person getting injured. Steel toe plates of 100 mm flats shall be used. Hand railing
shall be fabricated and installed in an approved manner as directed by purchaser in accordance with
approved drawings.
3.4.4 Unless otherwise specified, for all flanged connections, vendor shall furnish suitable counter flanges
and necessary nuts, bolts and gaskets materials.
3.4.5 Unless otherwise specified, bolts and nuts shall be hexagonal head conforming to bolts and nuts
shall be SA 193 & 194 respectively.
3.4.6 Gaskets shall be 3 mm thick full-face rubber. On completion of hydraulic test / water fill test,
contractor shall replace the gaskets used during testing at his own cost.
3.4.7 During erection of tank, shell plates shall be suitably supported both for outside and inside to avoid
buckling / collapsing of tank due to high-speed wind, gust or severe storm, if any, occurring during
erection.
3.5 VERTICAL CYLINDRICAL STORAGE TANKS
3.5.1 The vertical cylindrical storage (non- pressure) tanks shall be of mild steel welded construction and
shall be designed in accordance with codes and standards as specified. The vertical cylindrical
storage tanks shall have slightly sloping bottom towards an adequately sized sump inside the tank to
enable complete draining of the tank. The tank shall be designed for a wind pressure and seismic
coefficient as specified.
3.5.2 Conical roof shall be either self-supported or supporting. The roof shall have a slope as specified in
the relevant design code to ensure drainage of rainwater. Needed roof rafters and purlins
adequately designed shall be provided.
3.5.3 All plates to be used for fabrication of tank shall be checked and all sides trimmed to make them
square.
3.5.4 All bottom plates shall have butt weld joints to adequately support lining.
3.5.5 All shell course plates shall be taken during bending to prevent plate skewing. For butt weld joints,
edges shall be prepared which shall be uniform and smooth throughout. To maintain needed root
penetration gap at any butt weld joint, sufficient numbers of erection cleats shall be provided on all
sides of outer periphery of each shell plate. Plates for tanks shall be straightened by pressing or by
other non-injurious methods.
3.5.6 Each shell course shall be of uniform width throughout longitudinal weld in plates. Make up for the
course width shall not be permitted. Shell plates in each course width shall be so arranged that all
vertical joints be staggered having a minimum of 600 mm stagger. Shell thickness could be reduced
in upper courses depending on design requirements but in no case the plate thickness shall be less
than 6 mm.
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PEM-6666-0

PAGE 5 of 9
3.5.7 The tank height shall be completed by the provision of top curb/ angle which shall be butt-welded to
the adjacent tank plate courses. The outstanding leg of the curb angle shall be kept outside the tank
periphery. All butt weld joints shall be full strength welds but for design of shell plate thickness
adequate weld efficiency as recommended by applicable code(s) shall be used.
3.5.8 Tank roof shall be either self-supported or supported from rafters / steel fabricated central
column(s). Adequately sized and spaced rafters and purlins shall be provided. All rafters shall have
sliding bolted connections at one end and preferably on the tank periphery side. The roof-supporting
frame shall have needed tie rods or bracing sets.
3.5.9 Roof plates shall have butt-joints to adequately support lining. No joint of roof plate over the
supporting frame shall be made.
3.5.10 Openings needed for mounting various specified accessories shall be well reinforced in accordance
with application codes and as approved. Manhole shall the bolted and hinged covers unless
otherwise specified.
3.5.11 All inlet pipe nozzles located at the top of tanks shall be provided with internal piping up to 500 mm
high above the tank’s bottom inside with suitable weir plate at bottom. The inside piping shall be
adequately supported and shall be provided with adequately sized vent connection at pipe top.
3.6 RECTANGULAR TANKS
3.6.1 Rectangular tanks shall be fabricated in steel material and shall be designed to withstand internal
hydrostatic pressure. In addition, these shall be checked for a wind pressure and seismic coefficient
as specified wherever applicable. While worst of these two shall be considered, the permissible
stress shall be increased as per good engineering practice when their effect considered with tank
load.
3.6.2 Tank bottom and / or side plates shall be of minimum 8 mm thick plate. Corrosion margin of at least
2 mm shall be provided over the design thickness of bottom and / or side plates.
3.6.3 To support tank plates and to maintain required unsupported plate length, adequately sized and
spaced steel structural closed frame shall be provided inside the tank. Longitudinal and / or vertical
structural members to connect and adequately support these frames shall be provided at corners.
Horizontal diagonal members / sway bracings at corner shall also be provided.
3.6.4 Tank plates cut to size shall be welded on these frames. Plate butt weld joints at other locations shall
be eliminated to avoid warping of the plates at free joints. Adequate openings in the structural
frames, particularly at the bottom shall be provided to ensure complete unrestricted drainage of
tank at one point. Suitable sized drain valve of size minimum 25 NB unless otherwise specified, shall
be provided below the tank bottom for proper draining of the tank.
3.6.5 Complete assembled tank shall have at its bottom longitudinal steel fabricated bearer beams welded
to it. The tank with bearer will rest over number of concrete blocks to be provided by purchaser. The
tank shall be adequately bolted / welded to the concrete blocks. Needed inserts / anchor bolts shall
be furnished by the bidders. Grouting of tank over concrete blocks in approved manner shall be
included in bidder’s scope of work, if erection is also awarded to the bidder.
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PAGE 6 of 9
3.6.6 Where rectangular tanks are flushed in dual compartments the inside partition plate shall be well
reinforced to withstand hydrostatic test pressure completely on one side throughout the full height.
3.6.7 The rectangular tank shall be designed as per good engineering practice and reference shall be taken
from the book named “Theory of plates and shells” by Timoshenko. Design calculation shall be done
in accordance with the above mentioned book.
3.6.8 Suitable steel structural e.g. channels shall be provided below the bottom plate so that tank can rest
on the foundation / slabs through the structural supports.
3.9 HORIZONTAL CYLINDRICAL TANK
3.9.1 The horizontal cylindrical tank with dished ends shall be of mild steel welded construction and shall
be designed in accordance with BS – 2594 / IS – 2825 / ASME as specified. The tank shall be designed
for a wind pressure and seismic coefficient as specified. While worst of these two shall be
considered, the permissible stress shall be increased as per relevant code / standard.
3.9.2 The shell and dished end plate thickness shall be chosen as per design requirement but in no case
the dished end and shell plate thickness shall be less than 8 mm.
3.9.3 All seams, longitudinal as well as circumferential, shall be butt-welded. Longitudinal seams should
not be situated in the lower one-third of a tank or on the top center line.
3.9.4 All tank shall be supplied with integral saddle support and shall be designed in accordance with BS-
2594 / IS – 2825 / ASME as specified.
4.0 TESTING AND INSPECTION AT MANUFACTURERER’S WORKS
4.1 General
4.1.1 The supplier shall provide inspection to establish and maintain quality of workmanship in his works
and that of his subcontractors to ensure the mechanical accuracy of components, compliance with
drawings identity and acceptability of all materials, parts and equipment. He shall conduct all tests
required to ensure that the equipment and material furnished shall conform to requirements of the
acceptable codes. All tests and test procedure proposed by manufacturer shall be submitted to the
purchaser for their prior approval.
4.1.2 All materials used for manufacture of the equipment under this specification shall be of tested
quality. Relevant test certificates shall be made available to the purchaser before the final shop
inspection. In case the relevant correlating test certificates are not available, the supplier shall
arrange to carry out the necessary tests required by codes at his own cost.
4.1.3 Alloy cast iron and cast steel components shall be tested for both physical and chemical properties in
absence of purchaser’s representatives. Test bears shall be either integral or taken from the same
ladle of material as the casting they represent.
4.1.4 All materials including valves, instruments, pipings, flanges, counter flanges etc. shall be procured
from BHEL approved manufacturer’s only. Dealers are not acceptable.
4.2 TESTING AND INSPECTION FOR TANKS
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PAGE 7 of 9
4.2.1 The scope of testing and inspection for pressure vessel covered in this specification shall generally
comprise of the following:
I. Examination and approval of fabrication drawings to ensure that design, materials and fabrication
details meet requirement of code and specifications. Purchaser will review these drawings for
interface problems and conformity with the general arrangement drawings and accord their
approval.
II. Examination of materials of construction and identification with material test certificates.
III. All the plates of thickness 50 mm or more shall be ultrasonically tested to ensure freedom from
laminations.
IV. Ensuring the relevant weld procedure and welder qualification tests are in accordance with
stipulated code requirements.
V. Inspection of dished end flanges and alloy steel bolting where required.
VI. Inspection during fabrication at appropriate stages including fit ups.
VII. For all butt welds, the root run and final run shall be subjected to dye-penetrate or magnetic particle
inspection. For all fillet welds the final run shall be subjected to dye-penetrate / magnetic particle
examination.
VIII. Examination of radiographs including radiographic techniques, supervision of other non - destructive
tests and heat treatment procedure as required by codes and specifications.
IX. Examination of internal cleanliness before final closure.
X. Dimensional examination of completed vessel including axis marking, proof marking, match marking
etc.
XI. Witnessing of hydrostatic, pneumatic or vacuum tests or special tests as required by the code and
specification. In case of hydrostatic tests, the test pressure must be kept for a minimum of two
hours.
XII. Witnessing cleanliness, preservation, packing and marking.
XIII. Stamping of vessel and issue of certificates.
XIV. All tanks under this specification shall be tested as per the relevant design and testing code /
standard. Supplier shall submit the detailed testing procedure for the tanks during detail engineering
stage for BHEL / customer / consultant’s approval and approved document shall be adhered by them
and testing shall be done accordingly without any commercial implication.
4.2.2 NON - PRESSURE TANKS
The scope of testing and inspection for non-pressure tanks covered in this specification will comprise
of the following:
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PAGE 8 of 9
i. Identification of materials to manufacturer’s test certificates.
ii. Inspection of plate edges after edge preparation and checking curvature against templates if shell
plates sent after rolling.
iii. Checking of dimension and match marking.
iv. Bottom testing
a. After the bottom and bottom course of shell plates have been welded, the bottom shall be tested by
pumping air beneath the bottom plates to a pressure just sufficient to lift them off the foundation
and in any case not less than 100 mm water gauge. The pressure shall be held by construction of a
temporary dam of clay or other suitable material around the tank periphery. Soap suds or other
suitable material shall be applied to all joints for detection of leaks.
b. Fuel oil may be used instead of air and soap suds to test for leaks, subject to prior agreement and
approval of purchaser.
c. Alternatively, the bottom seams may be tested by vacuum box method subject to prior agreement
and approval of the purchaser. The vacuum box used shall comply with IS- 803, 1976 (figure-24)
v. Shell testing
The shell of fixed roof non - pressure tanks shall be tested after completion of roof. Testing shall be
done by filling the tank with water to the level of the top leg of the top curb angle and noting any
leaks.
vi. Roof testing
The roof of the tank shall be tested by pumping air under the roof plates while the tank is still full of
water. In the non - pressure tank, the roof shall be tested to a pressure of 75 mm of water gauge and
in case of pressure roof tanks, to a pressure of one and a quarter times the pressure at which the
pressure sides of the pressure / vacuum relief valve is designed to open. Soap suds or other suitable
material shall be applied to all joints for detection of leaks.
vii. All field-testing shall be performed prior to any painting or coating application.
4.3 REPAIR OF LEAKS
4.3.1 All leaks detected during testing shall be repaired to the satisfaction of the purchaser and on
completion retested for leakage as per approved procedure.
4.3.2 In the joints between roof plates only, pin hole leaks may be repaired by mechanical caulking.
However, where there is any indication of considerable porosity, the leaks shall be sealed by laying
down an additional layer of weld over the porous sections.
4.3.3 In all other joints, whether between shell plates or bottom plates or both, leak shall be repaired only
by welding and if necessary, after first cutting out the defective part.
4.3.4 When the tank is filled with water for testing, defects in the shell joints shall be repaired with the
water level at least 300 mm below the joint being repaired.
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PAGE 9 of 9
4.3.5 No welding shall be done on any tank unless all lines connecting thereto have been completely
blanked off. No repairs shall be attempted on tanks while filled with oil, nor any tanks which have
contained oil until the tanks have been emptied, cleaned and freed from gas in a safe manner. No
repair shall be attempted on a tank which has contained oil except in a manner approved in writing
by the purchaser, and in absence of the purchaser’s inspector.
Page 318 of 348

TECHNICAL SPECIFICATIONS FOR REV. 00
Date: MARCH 2022
AGITATORS
SECTION-II, SUB-SECTION- B
(FORMAT FOR O& M MANUAL)
Page 319 of 348

Check List for Operation & Maintenance Manual
Project name:
Project number:
Package Name:
Sl.no. & Description Yes No Not Remarks
Sections Applicable
1. Cover page
1.1 Project Name
1.2 Customer Name
1.3 Name of Package
1.4 Supplier details with phone, FAX email address
1.5 Name and sign of prepared by , checked by &
approved by
2.0 Index
2.1 showing the sections & related page nos

All the pages should be numbered section wise
3.0 Description of Plant
3.1 Description /write up of operating principle of
system equipment/ associated sub‐systems &
accessories/controls system , operating
conditions, performance parameters under
normal , start up and special cases
3.2 Equipment list and basic parameter with Tag
numbers
3.3 Data sheets approved by Customer/for
information and catalogues provided by original
manufacturer
3.4 Associated other packages and Interface
/terminal points
3.5 P&ID & Process Diagrams
3.6 GA Layout drawings, As‐built drawings
3.7 Single line/wiring diagrams
3.8 Control philosophy /control write‐ups
4.0 Commissioning Activities (if not covered
in separate document i.e. erection
manual, commissioning manual)
4.1 Pre‐Commissioning Checks
4.2 Transportation and handling at site
4.3 Storage at site
4.4 Unpacking & Installation procedure
5.0 Operation Guidelines for plant
personal/user/operator
5. 1 Interlock & Protection logic along with the
limiting values of protection settings for the
Page 320 of 348

equipment along with brief philosophy behind
the logic, drawings etc. to be provided.
5. 2 Start up and shut down procedure for

equipments along with the associated systems
in step by step mode. Valve sequence chart,
step list, interlocks etc with Equipment isolating
procedures to be mentioned.
5. 3 Do’s & Don’t of the equipments.
5. 4 Safety precautions to be taken during normal
operation. Safety symbols, Emergency
instructions on total power failure
condition/lubrication failure/any other
condition
5. 5 Parameters to be monitored with normal values
and limiting values
5. 6 Trouble shooting with causes and remedial
measures
5. 7 Routine operational checks, recommended logs
& records
5. 8 Changeover schedule if more than one auxiliary
for the same purpose is given
5. 9 Painting requirement and schedule
5. 10 Inspection, repair , Testing and calibration
procedures
6.0 Maintenance guidelines for plant
personal
6.1 List of Special Tools and Tackles required for
Overhaul/Trouble shooting including special
testing equipment required for calibration etc.
6.2 Stepwise dismantling and re‐assembly
procedure clearly specifying the tools to be
used, checks to be made, records to be
maintained, clearances etc. to be mentioned.
Tolerances for fitment of various components
to be given.
6.3 Preventive Maintenance & Overhauling
schedules linked with running hours/calendar
period along with checks to be given
6.4 Long term maintenance schedules especially for
structural, foundations etc.
6.5 Consumable list along with the estimated
quantity required during commissioning, normal
running and during maintenance like Preventive
Maintenances and Overhaul.
6.6 List of lubricants with their Indian equivalent,

Lubrication Schedule, Quantity required for each
equipment for complete replacement is to be
given
Page 321 of 348

6.7 List of vendors & Sub‐vendors with their latest
addresses, service centres ,Telephone Nos., Fax
Nos., Mobile Nos., e‐mail IDs etc.
6.8 List of mandatory and recommended spare parts
list
6.9 Tentative Lead time required for ordering of
spares from the equipment supplier
6.10 Guarantee and warranty clauses
7.0 Statutory and other specific requirements
considerations.
Page 322 of 348

SECTION-II, SUB-SECTION- C
AGITATORS Date: MARCH 2022
SECTION-II, SUB-SECTION- C
SITE STORAGE AND PRESERVATION MANUAL
Page 323 of 348

PROJECT ENGINEERING MANAGEMENT, POWER SECTOR
BHARAT HEAVY ELECTRICALS LIMITED-NOIDA
Page 324 of 348

CONTENT
1 SCOPE OF THE DOCUMENT
2 PURPOSE OF STORAGE & PRESERVATION
3 MEASURES TO BE TAKEN FOR STORAGE AND PRESERVATION
a) GENERAL STORAGE REQUIREMENTS
b) GENERAL PRESERVATION REQUIREMENTS
c) GENERAL INSPECTION REQUIREMENTS
4 TYPE OF STORAGE FOR VARIOUS EQUIPMENT
5. CONCLUSION
6. STACKING ARRANGEMENT FOR PLATES AND STRUCTURAL STEEL
Page 325 of 348

1. SCOPE OF THE DOCUMENT
This guideline is prepared in intent to provide proper site storage and preservation of the
Mechanical, Electrical and C & I items / equipment supplied under various bought out
packages/items. This storage procedure shall be followed at different power plant sites by
concerned agency for storage and preservation from the date of equipment received at
site until the same are erected and handed over to the customer.
2. PURPOSE OF STORAGE & PRESERVATION
Many of the items may be required to be kept in stores for long period. It shall therefore
be essential that proper methods of storage and preservation be applied so that items do
not deteriorate, loose some of their properties and become unusable due to atmospheric
conditions and biological elements.
3. MEASURES TO BE TAKEN FOR STORAGE, HANDLING & PRESERVATION
a) GENERAL STORAGE REQUIREMENTS
1. To the extent feasible, materials should be stored near the point of erection. The
storage areas should have adequate unloading and handling facilities with adequate
passage space for movement of material handling equipment such as cranes, fork lift
trucks, etc. The storage of materials shall be properly planned to minimise time loss
during retrieval of items required for erection.
2. The outdoor storage areas as well as semi-closed stores shall be provided with
adequate drainage facilities to prevent water logging. Adequacy of these facilities shall
be checked prior to monsoon.
3. The storage sheds shall be built in conformity with fire safety requirements. The stores
shall be provided with adequate lights and fire extinguishers. ‘No smoking’ signs shall
be placed at strategic locations. Safety precautions shall be strictly enforced.
4. Adequate lighting facility shall be provided in storage areas and storage sheds and
security personnel positioned to ensure enforcement of security measures to prevent
theft and loss of materials.
5. Adequate number of competent stores personnel and security staff shall be deployed
to efficiently store and maintain the equipment / material.
7. The equipment shall be stored in an orderly manner, preserving their identification

slips, tags and instruction booklets, etc., required during erection. The storage of
materials shall be equipment-wise. Loose parts shall be stored in sheds on racks,
Page 1 of 13
Page 326 of 348
preserving the identification marks and tags in good condition. The group codes shall
be displayed on the racks
6. At no time shall any materials be stored directly on ground. All materials shall be
stored minimum 200 mm above the ground preferably on wooden sleepers
b) GENERAL PRESERVATION REQUIREMENTS
1. All special measures to prevent corrosion shall be taken like keeping material in dry
condition, avoiding the equipment coming in contact with corrosive fluid like water,
acid etc.
2. Materials which carry protective coating shall not be wrapped in paper, cloth, etc., as
these are liable to absorb and retain moisture. The material shall be inspected and in
case of signs of wear or damages to protective coating, that portion shall be cleaned
with approved solution and coated with an approved protective paint. Complete record
of all such observations and protective measures taken shall be maintained.
3. Generally equipment supplied at site are properly greased or rust protective oil is
applied on machined/ fabricated components. However periodic inspection shall be
carried out to ensure that protection offered is intact.
4. While handling the equipment, no dragging on the ground is permitted. Avoid using
wire rope for lifting coated components. Use polyester slings (if possible) otherwise
protective material (e.g. clothes, wood block etc.) should be used while handling the
components with rope / slings
5. For Equipment supplied with finished paint, touch paint shall be done in case any
surface paint gets peeled off during handling. Otherwise such surfaces shall
necessarily be wrapped with polythene to avoid any corrosion. Further for equipment
wherein finish coat is to be applied at site, site to ensure that equipment is received
with primer coat applied.
6. It shall be ensured by periodic inspection that plastic inserts are intact in tapped holes,
wherever applicable.
7. Pipes shall be blown with air periodically and it shall be ensured that there is no
obstruction.
8. Silica gel or approved equivalent moisture absorbing material in small cotton bags
shall be placed and tied at various points on the equipment, wherever necessary.
9. Heavy rotating parts in assembled conditions shall be periodically rotated to prevent

corrosion/jamming due to prolonged storage.
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Page 327 of 348
10. All the electrical equipment such as motors, generators, etc. shall be tested for
insulation resistance at least once in three months and a record of such measured
insulation values shall be maintained.
11. Following preservatives/preservation methods can be used depending upon type of

equipment
a. Rust preventive fluid (RPF)
b. Rust protective paints
c. Tarpaulin covers, in case of outdoor storage
d. De-oxy aluminate for weld-ments
c) GENERAL INSPECTION REQUIREMENTS
1. Period inspection of materials with specific reference to –
 Ingress of moisture and corrosion damages.
 Damage to protective coating.
 Open ends in pipes, vessels and equipment -
- In case any open ends are noticed, same shall be capped.
2. Any damages to equipment / materials.
- In case of any damages, these shall be promptly notified and in all cases, the
repairs / rectification shall be carried out.
- Any items found damaged or not suitable as per project requirements shall be
removed from site. If required to store temporarily, they shall be clearly
marked and stored separately to prevent any inadvertent use.
Page 3 of 13
Page 328 of 348
4. TYPE OF STORAGE FOR VARIOUS EQUIPMENT
The types of storage are broadly classified under the following heads:
i Closed storage with dry and dust free atmosphere. (C )
The closed shed can be constructed by using cold-rolled / tubular components for
structure and corrugated asbestos sheets / galvanised iron sheets for roofing. Brick
walls / asbestos sheets can be used to cover all the sides. The floor of the shed can
be finished with plain cement concrete suitably glazed. The shed shall be provided
with proper ventilation and illumination.
ii Semi-closed storage. (S)

The semi closed shed can be constructed by using cold-rolled / tubular components
for structure and corrugated / asbestos sheets for roofing. The floor shall be brick
paved. If required a small portion of sides can be covered to protect components from
rainwater splashing onto the components.
Page 4 of 13
Page 329 of 348
iii Open storage (O )
The open yard shall be levelled, well consolidated to achieve raised ground with the
provision of feeder roads for crane approach along with access roads running all
sides. One part of the open yard shall be stone pitched, levelled and consolidated with
raised ground suitable for storing / stacking heavier and critical components with due
space to handle them by cranes etc . Adequate number of sleepers, concrete block
etc. to be provided to make raised platforms to stack critical materials.
A separate yard to be identified as “scrap yard” slightly away from main open yard to
store wooden/steel scraps, which are to be disposed off. This is required to avoid mix
up with regular components as well as to avoid fire hazard.
Some of the components, which are having both machined & un-machined surfaces
and are bulky, shall be stored in open storage area on a raised ground and suitably
covered with water proof / fire retardant tarpaulin.
Page 5 of 13
Page 330 of 348
The equipment listed below shall be stored and inspected as per requirement mentioned in the
table below.
Type of
Sl. No. Description of the equipment Check for Remarks
Storage
Raw material /mechanical items like pipes, plates, structure sections etc.)
Damage , paint,
Provide end
1. Steel pipes ( lined/unlined) S corrosion, rubber
cap
lining peeling
Damage, paint,
2. MS Plates S
corrosion
3. SS Plates S Damage
Provide end
4. Non-metallic pipes S Damage, cracks
cap
Provide end
5. Stainless steel pipes S Damage ,
cap
Damage, paint,
6. MS sections, beams S
corrosion
Damage, condition of
7. Cable trays S
preservations
8. Insulation sheets S Damage
9. Insulation C Damage, packing
Damage, paint,
10. Hangers Rods S
packing
Damage, paint , Provide end

11. Tubes S
packing cap
12. Hume pipes O Damage
Damage, paint,
13. Castings O
corrosion
Fabricated mechanical items (pressure vessels, tanks etc.)
Damage, paint, Covered

14. Pressure vessels (unlined) O
corrosion, nozzles
Covered
Atmospheric storage tanks Damage, paint, nozzles
15. O
(unlined) corrosion
Page 6 of 13
Page 331 of 348
Type of
Storage
Damage, paint,
16. Pressure vessels (lined) S corrosion, rubber
lining
Damage, paint,
17. Atmospheric storage tanks(lined) S corrosion, rubber
lining
Damage , paint,
18. Support structures O
corrosion
Damage , paint,
19. Flanges C
corrosion
Damage , paint, Provide end

20. Fabricated pipes S
corrosion cap
Damage , paint,
21. Vessels internals C
corrosion ,packing
Damage , paint,
22. Grills S
corrosion
Damage , paint,
23. Angles S
corrosion
Bridge mechanism/clarifier Damage , paint,

24. O
mechanism corrosion
Damage , paint,
25. Cranes, rails S
corrosion
Damage , paint,
26. Stair cases O
corrosion
Damage , paint,
27. Ladders/handrails O
corrosion
Damage , paint,
28. Fabricated ducts S
corrosion
Damage , paint,
29. Isolation Gates O
corrosion
Damage , paint,
30. Fabricated boxes/panels S
corrosion
Mechanical components like valves, fittings, cables glands, spares etc.)
31. Valves S Damage , packing
Page 7 of 13
Page 332 of 348
Type of
Storage
Provide end
32. Fittings S Damage , packing
cap
33. Cable glands C Damage , packing
34. Tools & tackles C Damage , packing
35. Nut , bolts, washers, C Damage , packing
36. Gasket & Packings C Damage , packing
Damage , packing, Provide end

37. Copper tubes C
corrosion cap
Provide end
38. SS tubing C Damage , packing
cap
Rotating assemblies (pumps, blowers, stirrers, fans, compressors etc.)
Damage , packing, Shaft

39. Pumps S
corrosion rotation

40. Blowers/Compressors S
corrosion rotation

41. Agitators/stirrers/radial launders C
corrosion rotation
Rollers for chlorine tonner Damage , packing,

42. C
mounting corrosion
43. Centrifuge S Damage , packing,
Damage , packing,
44. Gear box C
corrosion
Damage , packing,
45. Bearings C
corrosion
Damage , packing,
46. Fans S
corrosion
Damage , packing,
47. Dosing skids S
corrosion
Damage , packing,
48. Pump assemblies S
corrosion
49. Air washers( INTERNALS) S Damage , packing
50. Air conditioners ( split) C Damage , packing
Page 8 of 13
Page 333 of 348
Type of
Storage
Damage , packing,
51. Elevators( CONTAINERIZED) O
corrosion
52. Chillers/VA machines S Damage , packing
53. Air handling Unit/Package unit S Damage , packing
54. Chlorinators & Evaporators C Damage , packing
55. Ejectors C Damage , packing
56. Electrolyser C Damage , packing
Miscellaneous items like chain pulley blocks, hoists etc.
57. Chain pulley blocks S Damage, Packing
58. Electric hoists S Damage, Packing
59. Fire extinguishers C Damage, expiry date
60. Fork Lift Truck S Damage, Packing
61. Hydraulic Mobile Crane O Damage, Packing
62. Mobile Pick Up & Carry Crane O Damage, Packing
63. Motor boats O Damage, Packing
64. Safety showers S Damage, Packing
65. Diffusers/dampers S Damage, Packing
Chemicals and consumables ( acid, alkali, paints, oils, reagents and special chemicals)
Store in
canes/
storage
tank in Date of production/ hazardous
66. Hydro Chloric Acid (HCl)
dyke leakage/fumes chemical
area
Store in
canes/
storage
tank in Date of production/ hazardous
67. Sulphuric acid (H2SO4 )
dyke leakage/fumes chemical
area
Page 9 of 13
Page 334 of 348
Description of the Type of
Sl. No. Check for Remarks
equipment Storage
Store in canes/ hazardous

storage tank in Date of production/ chemical
68. Sodium hydroxide (NaOH) dyke area leakage/ fumes/ ,breather to be
breather checked for air
ingress
hazardous
chemical ,self-life
To be stored Date of production/ normally 15-30
69. Sodium hypo chlorite
under shed leakage/ fumes days after which
strength of
chemical decays
Store in closed
Date of production/ storage tanks,
70. Ammonia S
leakage/ fumes hazardous
chemical
Date of production , Store in closed

71. CW treatment chemicals S
Self-life canes
Date of production , Store in closed

72. RO/UF cleaning chemicals S
Self-life canes
Damage to packing , Prevent moisture,

73. Lime C
seepage rain
Prevent moisture,
74. Alum bricks C Damage to packing
rain
Store in closed
75. Poly electrolyte S
storage tanks
Laboratory chemicals( Damage, Packing self-

76. C
powder) life
Laboratory chemicals( Damage, Packing self-

77. C
liquid) life
78. Lubrication oils C Leakage
79. Paints S Leakage ,air tightness
80. Sand O Damage of packing No hooks
Damage of packing, Prevent moisture,

81. Salt (NaCl) C
water ingress rain
82. Anthracite S Damage of packing
83. Activated carbon S Damage of packing
Page 10 of 13
Page 335 of 348
Description of the Type of
Sl. No. Check for Remarks
equipment Storage
84. Thermal insulation S Damage of packing
Prevent moisture,
85. Cement C Damage of packing
rain
86. Gravels O Damage of packing
Refer
87. ION exchange resins C Damage , packing manufacturer
guidelines
Refer
88. RO membranes C Damage , packing manufacturer
guidelines
Refer
89. UF membranes C Damage , packing manufacturer
guidelines
Refer
90. Cleaning chemicals C Damage , packing manufacturer
guidelines
Refer
Chemicals for
91. C Damage , packing manufacturer
analysers/calibration
guidelines
Electrical and C & I items (motors, cables etc.)
92. Motors C Damage , packing
93. Cable drums O Damage
Control Panel /control desk, UPS

94. S Damage, Packing
,JB
95. Instruments( gauges/analysers) C Damage
As per Manufacturer’s item, like Hydrogen cylinders,

Special items
Ozonator, Analyser, Chlorine dioxide generators etc.
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Page 336 of 348
5. CONCLUSION
Concerned storage agency at site should make sure that loss in equipment performance
and wear & tear are minimised through proper storage and preservation. The above are
broad guidelines and cover major equipment / materials. However specific storage
practices shall be followed as per manufacturer recommendation. All the necessary
measures even in addition to the ones mentioned above, if found necessary, should be
taken to achieve the objective.
Page 12 of 13
Page 337 of 348
Figure – 1 – PLATE STACKING ARRANGEMENT
Figure – 2 – STRUCTURAL STEEL STACKING ARRANGEMENT
Page 13 of 13
Page 338 of 348
SECTION-III
Date: MARCH 2022
AGITATORS
SECTION-III
Page 339 of 348

M
P
E
6
6
6
6
0
-
-
SECTION : III, ANNEXURE-1
TECHNICAL SPECIFICATIONS FOR REV: 00
1.1
BIDDER SHOULD SUBMIT THE SIGNED AND STAMPED COPY OF THE

FOLLOWING DOCUMENTS:
1. Compliance cum confirmation certificate (refer annexure-2 of section-III)

2. Pre-bid clarification schedule as per format given under Section‐III (Annexure-3), in case
of any clarifications.
3. Amendment to specification, if any, issued by BHEL dully signed and stamped.
4. Deviation schedule as per format given under Section‐III (Annexure-4), in case of any
deviations by bidder.
5. Un priced format for main package (mentioning quoted against each item)
6. Un priced format for Tools and Tackles (mentioning quoted against each item)
7. Un priced format for Commissioning spare (mentioning quoted against each item)
8. Declaration by Bidder for Agitator Make (refer Annexure-I of Sub Section-D, Section-I).
9. FGD Tanks Schedule & GA Drawing (refer annexure-III of Sub Section-D, Section-I)
Document for Reference:
1. Electrical Load data filled up by the bidder (Refer Annexure-8 of section-II).
Details mentioned under reference documents are subject finalization during detail engineering
meeting requirements mentioned in various parts of the specification.
Page 340 of 348

TECHNICAL SPECIFICATIONS FOR REV. NO. 00
Date: MARCH 2022
COMPLIANCE CUM CONFIRMATION CERTIFICATE
The bidder shall confirm compliance with following by signing / stamping this compliance
certificate (every sheet) and furnish same with the offer.
a) The scope of supply, technical details, construction features, design parameters etc. shall
be as per technical specification & there are no exclusions, other than those mentioned
under “exclusion and those resolved as per ‘Schedule of Deviations’, with regard to same.
b) There are no other deviations w.r.t. specifications other than those furnished in the
‘Schedule of Deviations’. Any other deviation, stated or implied, taken elsewhere in the
offer stands withdrawn unless specifically brought out in the ‘Schedule of Deviations’
c) Bidder shall submit QP in the event of order based on the guidelines given in the
specification & QP enclosed therein. QP will be subject to BHEL / CUSTOMER approval &
customer hold points for inspection / testing shall be marked in the QP at the contract
stage. Inspection / testing shall be witnessed as per same apart from review of various
test certificates/ Inspection records etc. This is within the contracted price without any
extra implications to BHEL after award of the contract.
d) All drawings/ data-sheets / calculations etc. submitted along with the offer shall not be
taken cognizance off.
e) The offered materials shall be either equivalent or superior to those specified in the
specification & shall meet the specified / intended duty requirements. In case the material
specified in the specifications is not compatible for intended duty requirements then same
shall be resolved by the bidder with BHEL during the pre-bid discussions, otherwise BHEL /
Customer’s decision shall be binding on the bidder whenever the deficiency is pointed out.
For components where materials are not specified, same shall be suitable for intended
duty, all materials shall be subject to approval in the event of order.
f) The commissioning spares shall be supplied on ‘As Required Basis’ & prices for same
included in the base price itself.
g) All sub vendors shall be subject to BHEL / CUSTOMER approval in the event of order.
h) Guarantee for plant/equipment shall be as per relevant clause of GCC / SCC / Other
Commercial Terms & Conditions
i) In the event of order, all the material required for completing the job at site shall be
supplied by the bidder within the ordered price even if the same are additional to
approved billing break up, approved drawing or approved Bill of quantities within the
scope of work as tender specification. This clause will apply in case during site
commissioning, additional requirements emerges due to customer and / or consultant’s
comments. No extra claims shall be put on this account
Page 341 of 348

Date: MARCH 2022
j) Schedule of drawings submissions, comment incorporations & approval shall be as

stipulated in the specifications. The successful bidder shall depute his design personnel to
BHEL’s / Customer’s / Consultant’s office for across the table resolution of issues and to
get documents approved in the stipulated time.
k) As built drawings shall be submitted as and when required during the project execution.
l) The bidder has not tempered with this compliance cum confirmation certificate and if at
any stage any tempering in the signed copy of this document is noticed then same shall be
treated as breach of contract and suitable actions shall be taken against the bidder.
m) Successful bidder shall furnish detailed erection manual for each of the equipment
supplied under this contract at least 3 months before the scheduled erection of the
concerned equipment / component or along with supply of concerned equipment /
component whichever is earlier.
n) Document approval by customer under Approval category or information category shall

not absolve the vendor of their contractual obligations of completing the work as per
specification requirement. Any deviation from specified requirement shall be reported by
the vendor in writing and require written approval. Unless any change in specified
requirement has been brought out by the vendor during detail engineering in writing
while submitting the document to customer for approval, approved document (with
implicit deviation) will not be cited as a reason for not following the specification
requirement.
o) In case vendor submits revised drawing after approval of the corresponding drawing, any
delay in approval of revised drawing shall be to vendor’s account and shall not be used as
a reason for extension in contract completion.
Page 342 of 348

Date: MARCH 2022
PRE-BID CLARIFICATION SCHEDULE
Section/Clause/ Statement of the referred

S.No. Clarification required
Page No. clause
The bidder hereby certifies that above mentioned are the only clarifications required on the
technical specification for the subject package.
SIGNATURE: ___________________
NAME : ___________________
DESIGNATION: __________________
COMPANY: _____________________
DATE: __________________________
COMPANY SEAL
Page 343 of 348

ANNEXURE - 4 : DEVIATION SHEET (COST OF WITHDRAWL)
PROJECT:-1X660MW SAGARDIGHI STPP

TENDER ENQUIRY REFERENCE:-
NAME OF VENDOR:-
REFERENCE OF NATURE OF
PRICE SCHEDULE COST OF
TECHNICAL COST OF
SL VOULME/ PAGE COMPLETE DESCRIPTION OF ON WHICH COST WITHDRAWL OF REASON FOR QUOTING
CLAUSE NO. SPECIFICATION/ WITHDRAWL
NO SECTION NO. DEVIATION OF WITHDRAWL OF DEVIATION DEVIATION
TENDER DOCUMENT OF DEVIATION
DEVIATION IS (POSITIVE/
APPLICABLE NEGATIVE)
TECHNICAL DEVIATIONS
COMMERCIAL DEVIATIONS
PARTICULARS OF BIDDERS/ AUTHORISED REPRESENTATIVE
NAME DESIGNATIONS SIGN & DATE
NOTES:
1. For self manufactured items of bidder, cost of withdrawl of deviation will be applicable on the basic price (i.e. excluding taxes, duties & freight) only.
2. For directly dispatchable items, cost of withdrawl of deviation will be applicable on the basic price including taxes, duties & freight.
3. All the bidders have to list out all their Technical & Commercial Deviations (if any) in detail in the above format.
4. Any deviation not mentioned above and shown separately or found hidden in offer, will not be taken cognizance of.
5. Bidder shall submit duly filled unpriced copy of above format indicating "quoted" in "cost of withdrawl of deviation" column of the schedule above along with their Techno-commercial offer, wherever
applicable.
6. Bidder shall furnish price copy of above format along with price bid.
7. The final decision of acceptance/ rejection of the deviations quoted by the bidder shall be at discretion of the Purchaser.
8. Bidders to note that any deviation (technical/commercial) not listed in above and asked after Part-I opening shall not be considered.
9. For deviations w.r.t. Payment terms, Liquidated damages, Firm prices and submission of E1/ E2 forms before claiming 10% payment, if a bidder chooses not to give any cost of withdrawl of deviation
loading as per Annexure-VIII of GCC will apply. For any other deviation mentioned in un-priced copy of this format submitted with Part-I bid but not mentioned in priced copy of this format submitted with
Priced bid, the cost of withdrawl of deviation shall be taken as NIL.
10. Any deviation mentioned in priced copy of this format, but not mentioned in the un-priced copy, shall not be accepted.
11. All techno-commercial terms and conditions of NIT shall be deemed to have been accepted by the bidder, other than those listed in unpriced copy of this format.
12. Cost of withdrawl is to be given seperately for each deviation. In no event bidder should club cost of withdrawl of more than one deviation else cost of withdrawl of such deviations which have been
clubbed together shall be considered as NIL.
13. In case nature of cost of withdrawl (positive/negative) is not specified it shall be assumed as positive.
14. In case of descrepancy in the nature of impact (positive/ negative), positive will be considered for evaluation and negative for ordering.
Page 1 of 1
Page 344 of 348

1X660MW SAGARDIGHI STPP SPECIFICATION NO. PE-TS-445-167-A002
M
P
E
6
6
6
6
0
-
-
SECTION : III, ANNEXURE :5
TECHNICAL SPECIFICATIONS FOR REV 00
1.1
LIST OF MAKES OF ITEMS
S.NO. ITEM NAME MANUFACTURER LOCATION
VOID
Page 345 of 348

1X660MW SAGARDIGHI STPP SPECIFICATION NO. PE-TS-445-167-A002
M
P
E
6
6
6
6
0
-
-
TECHNICAL SPECIFICATIONS FOR REV 00
1.1
LIST OF SPECIAL TOOLS AND TACKLES
Bidder shall supply a set of special tools and tackles required either for erection or
operation or maintenance of the Tanks and agitator units. A list of such tools and
tackles shall be submitted along with the offer in the format below.
Sl.no. Description of item Quantity
In case bidder indicates that no special tools and tackles are required but the same
is found applicable during detailed engineering the same shall be supplied by the
bidder without any commercial and delivery implications.
SIGNATURE: ___________________
NAME : ___________________
DESIGNATION:__________________
COMPANY: _____________________
DATE:__________________________
COMPANY SEAL
Page 346 of 348

SECTION- III, ANNEXURE-7

LIST OF COMMISSIONING SPARES

Break up price for COMMISSIONING SPARES
Sl.
Description Qty. Unit
no
1 CAF Gasket of each size 2 nos.
Nuts, bolts & washers of each size (nos. of bolts, 1 lot
2 nuts & washers as required for each nozzle) as per
approved Drg.
Any other item required for successful 1 lot
commissioning of the tanks including rubber lining
3
& VE Glass Flake lining (to be specified clearly by
bidder)
Any other item required for successful 1 lot
4 commissioning of the Agitators (to be specified
clearly by bidder)
NOTE -
1. The items indicated in the above list are minimum. Any other spares if required shall be included
by bidder in the above list.
2. Bidder shall furnish unit price of commissioning spares in above format alongwith the Bid. Any
part even though not mentioned in list furnished but required at later date shall be supplied free of
cost.
3.Bidder to note that the items indicated in the above list shall be provided prior to commissioning of
the Misc Tanks & Agitators package. Further, items indicated in the list shall be supplied over and
above the consummables that is supplied along with the Misc. Tanks & Agitators package prior to
start up.
Page 347 of 348

RATING (KW / A) Nos. CABLE
CONT.(C)/ INTT.(I)
VOLTAGE CODE*
FEEDER CODE**
UNIT (U)/STN (S)
EMER. LOAD (Y)
STARTING TIME
BLOCK CABLE
LOAD TITLE
ANNEXURE-8 MAX. BOARD CONTROL
>5 SEC (Y)

LOCATION REMARKS LOAD No.
STANDBY
RUNNING
NAME CONT. SIZE
DRG. No.
NO. NOs CODE
PLATE DEMAND CODE
(MCR)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Auxiliary Absorbent Tank Agitator 2 1 C
NOTES: 1. COLUMN 1 TO 12 & 18 SHALL BE FILLED BY THE REQUISITIONER (ORIGINATING AGENCY); REMAINING COLUMNS ARE TO BE FILLED UP BY PEM (ELECTRICAL)/ CUSTOMER
2. ABBREVIATIONS : * VOLTAGE CODE (7):- (ac) A=11 KV, B=6.6 KV, C=3.3 KV, D=415 V, E=240 V (1 PH), F=110 V (cc): G=220 V, H=110 V, J=48 V, K=+24V, L=-24 V
: ** FEEDER CODE (8):- U=UNIDIRECTIONAL STARTER, B=BI-DIRECTIONAL STARTER, S=SUPPLY FEEDER, D=SUPPLY FEEDER (CONTACTER CONTROLLED)
JOB NO. 485 ORIGINATING AGENCY PEM (ELECTRICAL)
ANNEXURE-8 PROJECT TITLE 1X660MW SAGARDIGHI STPP NAME DATA FILLED UP ON
LOAD DATA SYSTEM
MISCELLANEOUS FGD TANKS SIGN.
DATA ENTERED ON
(ELECTRICAL) AND AGITATORS
DEPTT. / SECTION MAUX SHEET 1 OF 1 REV. 00 DE’S SIGN. & DATE
Page 348 of 348

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WBPDCL

1X660MW SAGARDIGHI THERMAL POWER EXTENSION PROJECT,

SPECIFICATION NO.: PE-TS-445-167-A002

BHARAT HEAVY ELECTRICALS LTD

SUB- SECTIONS TITLE Page No.

Sub-Section-A INTENT OF SPECIFICATION 04

D)TANK SCHEDULE AND AGITATOR SCHEDULE 262

E) DETAILS OF 500 MM NOZZLE FOR BOTTOM DRAIN 264

ANNEXURE-IV MASTER DRAWING LIST WITH SCHEDULE OF 266

ANNEXURE-VI DATASHEET FOR BOUGHT OUT ITEMS 303

ANNEXURE-VII MANDATORY SPARES 306

SUB SECTIONS TITLE Page No.

1.0 INTENT OF SPECIFICATION

PROJECT INFORMATION WITH WIND AND

PROJECT SYNOPSIS AND GENERAL INFORMATION

CLAUSE NO. DESCRIPTION PAGE NO.

2.00.00 APPROACH TO SITE 1

4.00.00 SOURCE OF COAL 2

5.00.00 SOURCE OF WATER 2

6.00.00 ASH DISPOSAL AREA 2

7.00.00 DETAILS OF EXISTING 3

8.00.00 SALIENT DESIGN DATA 16

PROJECT SYNOPSIS AND GENERAL INFORMATION

The West Bengal Power Development Corporation Limited (WBPDCL)

2.00.00 APPROACH TO SITE

Sagardighi Super Thermal Power Station site is located at Manigram village,

Nearest Airport – Kolkata.

Nearest Seaport –Haldia.

All construction material, heavy equipment, over dimensioned consignments

4.00.00 SOURCE OF COAL

5.00.00 SOURCE OF WATER

6.00.00 ASH DISPOSAL AREA

7.00.00 DETAILS OF EXISTING FACILITIES OF PHASE-II

MAIN & AUXILIARY COOLING WATER SYSTEMS & ACCESSORIES

Provision kept of miscellaneous BOP coolers in DMCW (SG) pump capacity of

i) AHP compressor coolers – 2X300 = 600 m3/hr (for 2X500 MW units)

i) AHP compressor coolers 158 m3/hr (for 2X500 MW units)

The following excess capacity of DMCW(SG) system of Phase-II is available,

i) AHP system coolers- 372 m3/hr

Condensate Storage Tanks & Transfer System:

c) Two (2) nos. (1W+1S) CPU Regeneration pumps

a) One (1) no cycle make-up pump

c) Two (2) nos. (1W+1S) CPU Regeneration pumps

WATER & WASTEWATER TREATMENT SYSTEMS

To inhibit incidental growth of organic matters in raw water, pre chlorination of

The sludge generated from Clarifiers as addressed above will be collected in

The Chlorination System will be complete with Electrically Operated Monorail

Ultrafiltered water from UF Permeate Storage Tank shall be pumped to

Required quantity of antiscalant shall be dosed before Cartridge Filters in

The entire RO System shall be designed to achieve minimum 85% recovery.

Degassified RO Permeate, finally be pumped to MB Exchanger for further

A full-fledged chemical cleaning system comprising One (1) no. chemical

The entire UF-RO-MB Exchanger System along with Chemical Dosing /

EFFLUENT TREATMENT SYSTEM

An Effluent Treatment Plant is already under construction for the Treatment of

COAL HANDLING SYSTEM

1. a) Track Hopper : 5100T with paddle feeders to twin

b) Wagon Tippler : One (1) no (Rated capacity 20 Tips/ Hr

c) Side Arm Charger : One (1) no

2. Conveyors : Twin stream conveyor line of 2000 /

3. Crushers : Type: Ring granulator.

6. Stacker-cum-reclaimer : Type: Hydraulic motor-driven rail-

Stacking Capacity: 2000 TPH