MP 1

NTPC Limited
(A GOVERNMENT OF INDIA ENTERPRISE)
Section -VI
TECHNICAL SPECIFICATIONS
FOR
DEVELOPMENT OF 50 MW SOLAR PHOTO
VOLTAIC PLANT AT GANESHPURA
DISTT. RAJGARH (M.P.)
Bid Document No: CS-5707-004-9

TABLE OF CONTENTS
Description
Part-A SCOPE OF SUPPLY AND WORK
1.0 Introduction
2.0 Inputs provided by NTPC
3.0 Scope of Work
4.0 SPV and its Auxiliaries
5.0 Electrical Works
6.0 Civil Works
7.0 General Requirements
8.0 Specifications for Operation & Maintenance
Contract
9.0 Performance Guarantee (PG) Test
10.0 Quality Assurance chapters
Part-B LIST OF EXHIBITS
1.0 Topographical Survey of the proposed area
2.0 Geotechnical Report of Solar Energy Park
3.0 Single Line Diagram of Electrical System
Part-C GENERAL TECHNICAL REQUIREMENTS
Part-D ERECTION CONDITIONS OF CONTRACT
Development of Solar Photo Bid Doc. No. Technical Specifications Page

Voltaic Plant at Rajgarh CS-5707-004-9 Part-A Section-VI 1 of 101
1. INTRODUCTION
NTPC Limited, a public sector company was incorporated in the year 1975 to
accelerate power development in the country as a wholly owned company of the
Government of India. At present, Government of India holds 84.5% of the total equity
shares of the company and the balance 15.5% is held by FIIs, Domestic Banks,
Public and others. Within a span of 36 years, NTPC has emerged as a truly
integrated power company, with power generating facilities in all the major regions of
the country.
NTPC has set a target to have an installed power generating capacity of 1,28,000
MW by the year 2032. The capacity will have a diversified fuel mix comprising 56%
coal, 16% Gas, 11% Nuclear and 17% Renewable Energy Sources(RES) including
hydro. By 2032, non fossil fuel based generation capacity shall make up nearly 28%
of NTPC’s portfolio.
As on date the installed capacity of NTPC is 39,174 MW through its 16 coal based
(30,855 MW), 7 gas based (3,955 MW) and 6 Joint Venture Projects (4,364 MW).
In view of Global Warming and fast depleting fossil fuels, Renewable Energy based
projects are being considered as one of fuel mix portfolio. In this context, NTPC has
formulated its business portfolio including a capacity addition of 1000 MW through
Renewable Energy Sources by 2017. In addition 301 MW is proposed to be added
through Solar Energy by 2014.
PROJECT INFORMATION
The proposed Solar Photo Voltaic plant shall be located at village Ganeshpura of
Distt. Rajagrh in Madhya Pradesh(MP). Rajgarh is located in western part of Madhya
Pradesh. It borders the state of Rajasthan, and the districts of Shajapur, Sehore, and
Bhopal. Rajgarh District extends between the parallels of latitude 23027' 12" North to
24017' 20" North and between the meridians of longitude 76011' 15" East to 77014'
East. The total geographical area of the District is 6,154 sq.km.. The district lies on
the northern edge of the Malwa plateau, and the Parbati River forms the eastern
boundary of the district, while the Kali Sindh River forms the western boundary. The
district has six tehsils, Rajgarh, Khilchipur, Zirapur, Biaora, Narsinghgarh, and
Sarangpur. The district is bounded by Rajasthan state to the north, and by the
districts of Guna to the northeast, Bhopal to the east, Sehore to the southeast, and
Shajapur to the south and west. It is situated on Jabalpur- Jaipur National highway
NH-12 at a distance of 145 km from the state capital Bhopal toward Jabalpur.
LAND
Appx. 250 acres of land shall be made available for the plant and other facilities at
solar park, Rajgarh. Prior to submission of bid, bidder is expected to visit the site for
first hand experiences of the project site. Topographical survey of total area with
boundary details is under progress and shall be provided to successful bidder.

2.0 INPUTS PROVIDED BY NTPC
1. Land details and topographical survey of the solar park.

2. Solar Global radiation on horizontal surface as per MNRE/NREL for each
month (kWhr/m2/day) for 12 months.
3. Monthwise ambient temperature of Rajgarh

3.0 SCOPE OF WORK
Design, engineering, supply, packing and forwarding, transportation, unloading,

storage, installation and commissioning of 50 MW Capacity grid connected (export of
power to grid) Solar PV based power project on turnkey basis at Ganeshpura Village
of Rajgarh.
Bidder shall provide comprehensive operation & maintenance of the plant for a
period of one year from the date of successful completion of trial run.
3.1 PLANT EQUIPMENT AND ASSOCIATED WORKS
3.1.1 Civil Works
1. Site grading, ground preparation of the identified area including soil testing and
cutting and clearing of vegetation including trees.
2. Requisite foundation and structures wherever required
3. Requisite cable routings through cable trenches and/or cable tray wherever
required.
4. Main and service roads, with suitable drainage arrangements wherever
necessary.
5. Construction of Control room and other facilities as per clause 6.2.
6. Fencing of complete plant including module yard, control room and switchgear
room.
3.1.2 Solar PV Plant
The system shall consist of (but not limited to) following equipment:
(a) Suitable Nos. of SPV Module ≥ 150 Wp

(b) Power conditioning unit
(c) SCADA
(d) Control equipments
(e) Mounting structures
(f) Cables and hardware
(g) Junction boxes and distribution boxes
(h) Earthing kit
(i) Lightning arrestors
(j) Tool Kits for maintenance
(k) Pyranometer
(l) Mandatory spares
3.1.3 Grid interfacing, including all equipments required for the same such as
transformers, breakers, isolators, lightning arrestors, panels, protection

equipments, cables, conductors, earthing of transformer and SPV Panel yard
etc. as per statutory requirements.
3.1.4 Evacuation of Power through 11 kV underground cable to 11/132 kV

Switchyard Control Room.
3.1.5 Design & construction of Centralized Monitoring & Control System (CMCS) to
house control panels, protection panels, inverters, SCADA system for remote
monitoring & control of the plant etc.
3.1.6 Fire protection and fire fighting equipments.
3.1.7 Arrangement of supply of water and power including construction and O&M
period shall be done by the contractor. Bidder shall also lay suitable pipe lines
etc along with isolating vales to make permanent arrangement for module
washing and their drainage arrangement.
3.1.8 Supply & providing suitable illumination for the proposed SPV plant,
evacuation system including control room and other facilities.
3.1.9 Providing drainage system for the plant and connection to discharge system
as per applicable pollution norms
3.2 ENGINEERING DATA & DRAWINGS
3.2.1 Engineering drawings, data etc including calculations shall be prepared by

the bidder and got approved from the owner before commencement of the
project.
3.2.2 Successful bidder shall furnish operation and maintenance manual in six (06)
sets prior to commencement of warranty period in hard as well as soft form.
3.3 TRAINING OF EMPLOYERS PERSONNEL
The bidder shall provide training free of cost to at least four personnel of NTPC for a
minimum period of 10 days at his works and at site for erection, testing,
commissioning and O&M. Expenses towards travel, stay, lodging, and boarding and
other expenses for the personnel shall be borne by NTPC.
3.4 TERMINAL POINTS & EXCLUSIONS
The terminal point under the scope of this assignment shall be cable termination of
all the outgoing cables at 11 kV switchgear at 11/132 kV Switchyard of NTPC.
The scope of the contractor shall be deemed to include all such items which
although are not specifically mentioned in the bid documents and/or in contractor’s
proposal but are needed to make the system complete in all respects for its safe,
reliable, efficient and trouble free operation and the same shall be furnished and
erected unless otherwise specifically excluded in the bid document.

4.0 SPV and Its Accessories
4.1 SPV Module & Guaranteed Generation
Only Silicon Crystalline SPV cells shall be used in the Solar Photovoltaic module.
Peak power rating of the individual module shall not be less than 150 Wp. The
module efficiency shall be more than 13.5 % at standard test condition and the cell
should have minimum fill factor of 0.7. It shall be made of high transitivity glass &
front surface shall give high encapsulation gain. Bidder shall guarantee minimum
78.661 Million Unit (annually) at 11 kV bus of 11/132 kV substation taking
consideration of all 11 kV feeders from solar plant.
Bidder shall also furnish the month wise generation in the datasheet
corresponding to the radiation data provided by NTPC and the system has to be
designed for the generation quoted by the bidder.
The monthwise Solar Global radiation on horizontal surface and ambient temperature of
Rajgarh which shall be used for arriving guaranteed annual generation are as follow.
Month Ambient temperature Solar Global radiation on horizontal

(deg C) surface( kWhr/(m2x day))
January 21.3 4.709
February 26.1 5.693
March 31.3 6.578
April 36.6 7.324
May 40.1 7.669
June 39.1 6.533
July 32.7 4.9651
August 30.6 4.258
September 31.1 5.6716
October 32.1 5.8211
November 27.7 4.987
December 22.5 4.4589
All materials used shall have a proven history of reliability and stable operation in
external applications. It shall perform satisfactorily with temperatures between -10° C
and +50° C and shall withstand gust up to 150 km/h on the surface of the panel.
Each and every SPV module shall be checked for conformity with relevant standard
and no negative tolerance shall be accepted.
4.1.1 General requirements for PV module:
a. Modules shall be manufactured in India. Modules shall be made up of mono or

poly crystalline silicon cells.
b. The interconnected cells shall be laminated in vacuum to withstand adverse

environmental conditions
c. The module frame is made of corrosion resistant materials, preferably having

aluminium anodized finish

d. The minimum clearance between the lower edge of the modules and the
developed ground level shall be minimum 500 mm. All the panels shall have
provision to tilt at three angular positions at an approximate interval of 15 deg
angular difference. Bidder to bring out the season wise angles in the datasheet.
e. Surge protection devices to be provided at junction boxes and modules shall be

provided with bypass diodes.
f. Combiner box shall also house string monitors which shall give operational status
of each sub array/string by current and/or power and shares the information with
SCADA
g. The bidder shall carefully design & accommodate requisite numbers of the
modules in the available area (refer topographical survey) to achieve the rated
power in his bid. NTPC shall allow only minor changes, only during erection of
modules.
h. The bidder shall provide protection against atmospheric lightning discharge to the
PV arrays as per industry standards.
i. Each Solar PV module used in solar power plants/ systems must be warranted
for their output peak watt capacity, which should not be less than 90% at the end
of 10 years and 80% at the end of 25 years from the completion of the trial run.
j. The SPV modules must be IEC 61215 and IEC 61730 Part I and Part II certified
from any of the accredited certifying agencies.
k. The bidder shall provide the sample solar PV module electrical characteristics
including current-voltage (I-V) performance curves and temperature coefficients
of power, voltage and current.
l. Each PV module deployed must use a clearly visible RF identification tag. The
following information must be mentioned in the RFID used on each module (This
can be inside or outside the laminate, but must be able to withstand harsh
environmental conditions).
i. Name of the manufacturer of the PV module
ii. Name of the manufacturer of Solar Cells
iii. Month & year of the manufacture(separate for solar cells and modules)
iv. Country of origin(separately for solar cells and module)
v. I-V curve for the module
vi. Wattage, Im, Vm and FF for the module
vii. Unique Serial No and Model No of the module
viii. Date and year of obtaining IEC PV module qualification certificate

ix. Name of the test lab issuing IEC certificate
x. Other relevant information on traceability of solar cells and module as per

ISO 9001.
4.1.2 MODULE MOUNTING STRUCTURE
1. Modules shall be mounted on a non-corrosive support structures
2. All the Panels shall have provision to adjust it at three angular positions
as per Clause No 4.1.1(d). The locking arrangement for adjusting the
angle of module shall be accessible from the ground.
3. The base columns shall be made with reinforced cement concrete.

Bidder may propose other type of foundation depending on soil
conditions, geographical condition, regional wind speed, bearing
capacity, slope stability etc. In such case, the detailed foundation design
should be proof checked by IIT/NIT and have to be got approved from
NTPC before actual start of work.
4. In case offered support structure is of MS type then, the frames and leg
assemblies of the array structures shall be made of MS hot dip
galvanized. Galvanisation coating shall as per IS 4759 or equivalent
standards.
5. All fasteners shall be of Stainless steel - SS 304. Nut & bolts, supporting
structures including module Mounting Structures shall have to be
adequately protected against all climatic conditions.
4.2 INSTRUMENTS FOR METEOROLOGICAL MEASUREMENTS.
Bidder shall provide following measuring instruments with all necessary

software & hardware required to make it compatible with SCADA.
4.2.1 Pyranometer:
Bidder shall provide at least two (02) pyranometer for measuring incident
global solar radiation. The specification is as follow:
1. Spectral Response- 0.31 to 2.8 micron.

2. Sensitivity-9 micro-volt/w/m2
3. Time response(95%): Max 15 s
4. Non linearity: ±0.5%
5. Temperature Response: ±2%
6. Tilt error: ±0.5%.
7. Zero offset thermal radiation: ±7 w/m2
8. Zero offset temperature change ±2 w/m2
9. Operating temperature range: - 40 deg to +80 deg.
10. Uncertainty(95% confidence Level): Hourly- Max-3%
Daily- Max-2%
11. Resolution: Min + / - 1 W/m2
12. Input Power for Instrument & Peripherals: 230 VAC (If required)
13. Output Signal: Analogue form which is compatible with the data
Each instrument shall be supplied with necessary cables. Calibration

certificate with calibration traceability to World Radiation Reference (WRR) or
World Radiation Centre (WRC) shall be furnished along with the equipment.
The signal cable length shall not exceed 20m. Bidder shall provide Instrument
manual in hard and soft form.
4.2.2 Thermometer:
Bidder shall also provide at least one RTD type / semiconductor type ambient
temperature measuring instrument at suitable place in PV arrays. Instrument
shall have a range of 0o C to 80oC.
4.2.3 Anemometer:
Bidder shall provide anemometer on tubular type made up of hot dipped

Galvanized iron. Velocity range- Upto 25 m/s, accuracy limit of 0.2 m/s upto
10 m/sec.
The anemometer shall have valid calibration certificates which should be
produced within one month after the installation.
4.3 POWER CONDITIONING UNIT
Power Conditioning Unit (PCU) consisting of an electronic Inverter alongwith

associated control, protection and data logging devices. The system shall
incorporate a uni-directional inverter designed to supply the AC power to the
grid at load end conforming to IEC 61727 or equivalent standard. The power
conditioning unit shall adjust the voltage & frequency levels to suit the Grid.
Rating of each PCU shall not be less than 500 kVA and the combined kVA
rating of all PCUs shall not be less than 50 MVA at standard temperature. All
three phases shall be supervised with respect to rise/fall in programmable
threshold values of frequency. PCU must have provision to be isolated from
grid through Air Circuit Breaker.
4.3.1 General Requirements
a. The efficiency of the PCU shall be equal to or more than 97 % at 75% load as
per IEC 61683.
b. The PCU shall have internal protection arrangement against any sustained
fault in the feeder line and against lightning in the feeder line
c. The PCU shall have the required protection arrangements against earth
leakage faults.
d. Specifically, the PCU should be three phase power conditioning unit using
static solid state components. DC lines shall have suitably rated isolators to

allow safe start up and shut down of the system. DC lines side of PCU should
have isolator of suitable rating.
e. Each Sub-Array Junction Box (if any) will have Suitable Reverse Blocking
Diodes or fuse with suitable rating.
f. Electrical surge protection shall be provided with surge protection device

(SPD). SPD shall consist of three Metal Oxide Varistor (MOV) type arrestors
connected from positive and negative to earth with inbuilt fuse or thermal
disconnector. During earth fault condition SPD shall safely disconnect the
healthy system.
g. The PCU should be suitably designed for parallel operation. Each solid state
electronic device shall have to be protected to ensure long life of the inverter
as well as smooth functioning of the inverter.
h. The PCU shall have anti islanding protection.
i. The PCU must have the feature to work in tandem with other similar PCU’s
and be able to be successively switched “ON” and “OFF” automatically based
on solar radiation variations during the day.
j. The system shall tend to balance unequal phase voltage (with 3-phase
systems) with reference to the red phase (line-1).
k. The PCU front panel shall be provided with a display (LCD or equivalent) of all
important parameter such as DC input voltage, DC input current, AC input
voltage, AC input current, AC output power, frequency etc.
l. Nuts & bolts and the PCU enclosure shall have to be adequately protected
taking into consideration the atmosphere and weather prevailing in the area.
m. The PCU shall include appropriate self protective and self diagnostic feature
to protect itself and the PV array from damage in the event of PCU component
failure or from parameters beyond the PCU’s safe operating range due to
internal or external causes. The self-protective features shall not allow signals
from the PCU front panel to cause the PCU to be operated in a manner which
may be unsafe or damaging. Faults due to malfunctioning within the PCU,
including commutation failure, shall be cleared by the PCU protective devices.
PCU shall have provision to record event logs, data logs and changing set
points. Control and read-out should be provided on an indicating panel
integral to the Inverter. Display should be simple and self explanatory display
to show all the relevant parameter relating to PCU operational data and fault
condition in form of front Panel meters / LED’s or two line LCD Display.
MODES OF PCU
• STANDBY MODE:

The control system shall continuously monitor the output of the solar power
plant until pre-set value is exceeded & that value to be indicated in the data
sheet.
• BASIC SYSTEM OPERATION (FULL AUTO MODE):
The system shall automatically ‘wake up’ in the morning and begin to export
power provided there is sufficient solar energy and the grid voltage and
frequency is in range. The threshold dc voltage for ‘wake up’ should be
mentioned in the datasheet.
• MAXIMUM POWER POINT TRACKER (MPPT):
MPPT control algorithm shall adjust the voltage of the SPV array to optimise
solar energy fed into the grid.
• SLEEP MODE
Automatic ‘sleep’ mode shall be provided so that unnecessary losses are

minimized at night. Bidder to provide threshold dc voltage of the inverter to
enter in sleep mode and back to standby mode in the technical datasheet.
The power conditioner must also automatically re-enter standby mode when
threshold of standby mode reached.
4.3.2 Maximum Power Tracking
Maximum power point tracker shall be integrated in the power conditioner unit to
maximize energy drawn from the Solar PV array. The MPPT should be
microprocessor based to minimize power losses. The details of working mechanism
of MPPT shall be mentioned by the bidder in his offer. The MPPT must have
provision for constant voltage operation.
4.3.3 Inverter
The inverter shall indoor type and its output shall always follow the grid in terms of
voltage and frequency. This shall be achieved by sensing the grid voltage and
phase and feeding this information to the feedback loop of the inverter. The inverter
shall use self-commutating devices.
Output frequency 50 Hz +/- 0.5% Hz ( Inverter to follow

grid frequency upto +/- 3 Hz of the
nominal output frequency during normal
operation)
Power Factor Control >0.95 lead or lag
Range
Maximum Input 1000 V DC
voltage
THD Less than 4 %
Ambient temperature 0 to 50 deg C
Humidity 95 % non- condensing
Enclosure IP 20
The Inverter shall have following features:
a. No load loss<1% of rated power and maximum loss in sleep mode shall
be less than 0.05%
b. Sinusoidal current modulation with excellent dynamic response.
c. Unit wise & integrated Data logging.
d. Dedicated Prefabs / Ethernet for networking
e. Protection against
• Over current
• Sync loss
• Over temp.
• DC bus over voltage
• Cooling Fan failure(If provided)
f. Power regulation in the event of thermal overloading
g. Set point pre-selection for VAR control
h. Inverter should communicate SCADA via open protocol
i. Remote monitoring via telephone modem or mini web server
j. Integrated protection in the DC and three phase system
k. Insulation monitoring of the PV array with sequential fault location
l. Ground fault detector – which is essential for large PV generators in view

of appreciable discharge current with respect to ground.
m. Over voltage protection against atmospheric lightning discharge to the

PV array is required.
The power conditioner must be equipped with self diagnostic system check which
should occur on start up. Functions should include a test of key parameters on start
up.
4.4 SOIL TEST
Soil Bearing Characteristics of the Solar Park has been attached with the document
and to be used for reference. Bidder after award shall ascertain soil parameters of
the proposed site as per the location of control room & array yard by carrying out
Sub Soil investigation through certified soil consultant

The scope of sub soil investigation covers: execution of complete soil exploration
including boring, drilling, collection of undisturbed soil sample wherever possible,
otherwise disturbed soil samples, conducting laboratory test of samples to find out
the various parameters mainly related to load bearing capacity, ground water level,
settlement and sub soil condition and submission of detail reports with
recommendation regarding suitable type of foundation for each bore hole along with
recommendation for soil improvement wherever necessary.
The soil test also includes analysis of water sample.
4.5 EARTHING
Each array structure of the PV yard shall be grounded properly as per IS 3043 -
1987. All metal casing / shielding of the plant shall be thoroughly grounded in
accordance with Indian electricity act / IE Rules.
4.6 CONTROL, AUTOMATION AND DATA ACQUISITION SYSTEM
The complete Solar PV plant shall be integrated with SCADA which should
communicate with all the inverters and combiner box and displaying parameters as
mentioned below. SCADA shall also have provision to control turning ON and OFF of
any inverter of the grid connected Solar PV plant.
SCADA shall provide instantaneous trend of following parameters
1. Power at all 11 kV feeders

2. Ambient temperature
3. Wind Speed
4. AC and DC side Power of each inverter
5. Solar irradiation/isolation
6. Voltage of the HT Side
7. Current and/or power of each sub-array/string.
8. Any other parameter considered necessary by supplier based on current
prudent practice
In addition to instantaneous trend, bidder shall also have provision for offline viewing
of daily, monthly and yearly averaged value of all above parameters.
SCADA shall provide 15 minute interval daily, monthly and annual average of
following parameters:
1. Exported Energy
2. Energy of each inverter
The SCADA shall have the feature to be integrated with the network system as well
as remotely via the web using either a standard modem or a GSM/WIFI modem. The
bidder shall provide compatible software and hardware so that data can be
transmitted via standard modem.
'The SCADA shall be OPC version 2.0a compliant and implement a OPC-DA 2.0a
server as per the specification of OPC Foundation. All data should be accessible
through this OPC server.'
SCADA shall be provided with a reliable power supply along with a backup supply for
at least one hour to cater to outage of grid.

5.0 ELECTRICAL WORK
The power evacuation system shall comprise of transformers with all associated
switchgear equipment and cable termination to 11 kV bus of indoor switchgear
situated at 11/132 kV switchyard as shown in single line diagram. The nos. of 11
kV outgoing feeder from Solar plant to switchyard should be restricted to eight (08).
Bidder to submit their single line diagram and layout diagram at the time detail
engineering to NTPC for approval.
5.1 AC SWITCH BOARD
If PCU is technically suitable for parallel operation, the same shall be done through
AC Distribution Boards (ACDBs) which shall lie electrically between PCU and 33 kV
transformers. It shall have Air Circuit breaker of Suitable rating for connection and
disconnection of PCU from Grid. The connection between ACDB and Transformer
shall be either Busbar or Cable. It shall have provision to measure bus voltage,
current and power feeding the transformer.
CONSTRUCTIONAL DETAILS OF SWITCHBOARDS
5.1.1 All Switchboards i.e., 415 V Switchgears, Motor Control Centres (MCCs),
ACDBs, DC Distribution Boards (DCDBs) and Solenoid Valve Distribution
Boards, shall be of metal enclosed, indoor, floor-mounted, free-standing type.
5.1.2 All switchboard frames and load bearing members shall be fabricated using
suitable mild steel structural sections or pressed and shaped cold-rolled sheet
steel of thickness 2.0 mm(nom). Frames shall be enclosed in cold-rolled sheet
steel of thickness 1.6 mm(nom). Doors and covers shall also be of cold rolled
sheet steel of thickness 1.6 mm (nom). Stiffeners shall be provided wherever
necessary. The gland plate thickness shall be 3.0 mm (nom) for hot / cold-
rolled sheet steel and 4.0 mm (nom) for non-magnetic material.
5.1.3 All panel edges and cover / door edges shall be reinforced against distortion
by rolling, bending or by the addition of welded reinforcement members. The
top covers of the panels should be designed such that they do not
permanently bulge/ bend by the weight of maintenance personnel working on
it.
5.1.4 The complete structures shall be rigid, self-supporting, and free from flaws,
twists and bends. All cutouts shall be true in shape and devoid of sharp
edges.
5.1.5 All switchboards shall be of dust-proof and vermin-proof construction and shall
be provided with a degree of protection of IP: 5X as per IS: 13947. However,
the busbar chambers having a degree of protection of IP: 4X are also
acceptable where continuous busbar rating is 1600A and above. Provision
shall be made in all compartments for providing IP: 5X degree of protection,
when circuit - breaker or module trolley has been removed. All cutouts shall
be provided with synthetic rubber gaskets.

5.1.6 Provision of louvers on switchboards would not be preferred. However,
louvers backed with metal screen are acceptable on the busbar chambers
where continuous busbar rating is 1600 A and above.
5.1.7 All switchboards shall be of uniform height not exceeding 2450 mm.
5.1.8 Switchboards shall be easily extendable on both sides by the addition of

vertical sections after removing the end covers.
5.1.9 Switchboards shall be supplied with base frames made of structural steel
sections, alongwith all necessary mounting hardware required for welding
down the base frame to the foundation / steel insert plates. The base frame
height shall be such that floor finishing (50 mm thick) to be done by Owner
after erection of the switchboards does not obstruct the movement of doors,
covers, withdrawable modules etc.
5.1.10 All switchboards shall be divided into distinct vertical sections (panels), each
comprising of the following compartments:
5.1.11 Bus Bar Compartment
A completely enclosed bus bar compartment shall be provided for the

horizontal and vertical busbars. Bolted covers shall be provided for access to
horizontal and vertical busbars and all joints for repair and maintenance,
which shall be feasible without disturbing any feeder compartment. Auxiliary
and power busbars shall be in separate compartments.
5.1.12 Switchgear/Feeder Compartment
All equipment associated with an incomer or outgoing feeder shall be housed

in a separate compartment of the vertical section. The compartment shall be
sheet steel enclosed on all sides with the withdrawable units in position or
removed. Insulating sheet at rear of the compartment is also acceptable. The
front of the compartment shall be provided with the hinged single leaf door
with captive screws for positive closure.
5.1.13 Cable Compartment or Cable Alley
A full-height vertical cable alley of minimum 250mm width shall be provided

for power and control cables. Cable alley shall have no exposed live parts and
shall have no communication with busbar compartment. Cable terminations
located in cable alley shall be designed to meet the Form IVb Type 7 (as per
IEC 61439 part 2 Annex AA) for safety purpose. The termination for each
module shall have its own integral glanding facility. Wherever cable alleys are
not provided for distribution boards, segregated cable boxes for individual
feeders shall be provided at the rear for direct termination of cables. For circuit
breaker external cable connections, a separately enclosed cable compartment
shall also be acceptable. The contractor shall furnish suitable plugs to cover

the cable openings in the partition between feeder compartment and cable
alley. Cable alley door shall be hinged.
5.1.14 Control Compartment
A separate compartment shall be provided for relays and other control devices
associated with a circuit breaker.
5.1.15 Sheet steel barriers shall be provided between two adjacent vertical panels
running to the full height of the switchboard, except for the horizontal busbar
compartment. Synthetic rubber gasket shall be provided between the panel
sections to avoid ingress of dust into panels. Each shipping section shall have
full metal sheets at both ends for transport and storage.
5.1.16 After isolation of power and control circuit connections it shall be possible to
safety carryout maintenance in a compartment with the busbar and adjacent
circuit live. Necessary shrouding arrangement shall be provided for this
purpose. Wherever two breaker compartments are provided in the same
vertical section insulating barriers and shrouds shall be provided in the rear
cable compartment to avoid accidental touch with the live parts of one circuit
when working on the other circuit.
5.1.17 All 415V switchgear (circuit-breaker) panels shall be of single-front type.

MCCs and DBs shall be of single-front / double-front construction. All single-
front switch boards shall be provided with single-leaf, hinged or bolted covers
at the rear. The bolts shall be of captive type. The covers shall be provided
with "DANGER" labels. All panel doors shall open by 90 deg or more. In case
of double-front MCCs, if this cannot be achieved for panels adjacent to a
breaker panel, suitable dummy panel shall be provided by the Bidder
wherever necessary.
5.1.18 All ACDBs, DCDBs and Solenoid Valve DBs shall be of fixed module type.
All 415V circuit-breaker modules and MCC modules shall be of fully drawout
type having distinct 'Service' and 'Test' positions. The equipment pertaining to
a drawout type incomer or feeder module shall be mounted on a fully
withdrawable chassis which can be drawn out without having to unscrew any
wire or cable connection. Suitable arrangement with cradle/ rollers and guides
shall be provided for smooth movement of the chassis. For modules of size
more than half the panel height, double guides shall be provided for smooth
removal or insertion of module. All identical module chasis of same size shall
be fully interchangeable without having to carryout any modifications.
5.1.19 All disconnecting contacts for power and control circuits of drawout modules
shall be of robust and proven design, fully self aligning and spring-loaded.
Both fixed and moving contacts shall be silver-plated and replaceable. The
spring-loaded power and control drawout contacts shall be on withdrawable
chassis and the same on fixed portion shall not be accepted. Detachable
plug and socket type control terminals shall also be acceptable.

5.1.20 Individual opening in the vertical bus enclosure shall permit the entry of
moving contacts from the drawout modules into vertical droppers.
5.1.21 Contractor shall supply & mount two (2) coupling relays in the DDC / PLC
controlled modules and breakers.
5.1.22 All equipment and components shall be neatly arranged and shall be easily
accessible for operation and maintenance. The internal layout of all modules
shall be subject to owner's approval. The Contractor shall submit dimensional
drawings showing complete internal details of busbars and module
components, for each type and rating for approval of Owner.
5.1.23 The tentative power and control cable entries (top / bottom) required.
However, the Owner reserves the right to alter the cable entries, if required
during detailed engineering, without any additional commercial implication.
5.1.24 Each switchboard shall be provided with undrilled, removable type gland
plate, which shall cover the entire cable alley. Bidder shall ensure that
sufficient cable glanding space is available for all the cables coming in a
particular section through gland plate. For all single core cables, gland plate
shall be of non-magnetic material. The gland plate shall preferably be
provided in two distinct parts for the easy of terminating addition cables in
future. The gland plate shall be provided with gasket to ensure enclosure
protection. Recommended drilling chart of gland plates for all power and
control cables in the vertical panels shall be indicated by the Contractor in
the respective G.A. drawings of the boards.
5.1.25 The Bidder shall consider layout of panels in a switchboard consisting of

various feeder modules. The actual composition and disposition of various
modules in a switchboard shall be finalised during detailed engineering. The
Bidder shall include in his quoted price the cost of any adopter panel / dummy
panel required to meet various configuration / arrangement of busbars
adopted by the Bidder. The Switchboards fed from indoor transformer will be
flange connected to the same and the same shall be located as close as
desirable to the transformer. The details of transformer flanges shall be given
to the successful Bidder for matching the connections. The switchboards fed
from outdoor transformers shall be connected through cables / busducts.
Busduct connections wherever applicable shall be preferably in a straight line
alignment. The centre line of the busduct will be finalized during detailed
engineering. Adopter panels and dummy panels shall be included in the
quoted price. Unit rates quoted for adopter / dummy panels shall be used for
any addition or deletion during detailed engineering.
5.1.26 CLEARANCES
The minimum clearance in air between phases and between phases and
earth for the entire run of horizontal and vertical busbars and bus-link
connections at circuit-breaker shall be 25 mm. For all other components, the
clearance between "two live parts", "a live part and an earthed part", shall be

atleast ten (10) mm throughout. Wherever it is not possible to maintain these
clearances, insulation shall be provided by sleeving or barriers. However, for
horizontal and vertical busbars the clearances specified above should be
maintained even when the busbars are sleeved or insulated. All connections
from the busbars upto switch / fuses shall be fully shrouded / insulated and
securely bolted to minimise the risk of phase to phase and phase to earth
short circuits.
5.2 Cables
All standards, specifications and codes of practice referred to herein shall be the
latest editions including all applicable official amendments and revisions as on date
of opening of bid. In case of conflict between this specification and those (IS : codes,
standards, etc.) referred to herein, the former shall prevail. All the cables shall
conform to the requirements of the following standards and codes:
TUV DC cable for photovoltaic system

specification 2
Pfg
1169/08.2007
IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto and
including 1100V.
IS : 3961 Recommended current ratings for cables
IS : 3975 Low carbon galvanised steel wires, formed wires and tapes for armouring
of cables.
IS : 5831 PVC insulation and sheath of electrical cables.
IS:7098 (Part - Cross linked polyethylene insulated PVC sheathed cables for working
I) voltages upto and including 1100V.
IS : 8130 Conductors for insulated electrical cables and flexible cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D -2843 Standard test method for density of smoke from the burning or
decomposition of plastics.
IEC-754 (Part- Tests on gases evolved during combustion of electric cables.
I)
IEC-332 Tests on electric cables under fire conditions. Part-3: Tests on bunched
wires or cables (Category-B).
TECHNICAL REQUIREMENTS
The cables shall be suitable for laying on racks, in ducts, trenches, conduits and
under ground buried installation with chances of flooding by water.
All cables including EPR cables shall be flame retardant, low smoke (FRLS) type
designed to withstand all mechanical, electrical and thermal stresses developed
under steady state and transient operating conditions as specified elsewhere in this
specification.
All cables of module area if laid on cable trays should be covered. If cables are to be
laid underground, laying shall be as per latest relevant IS code.

Copper/aluminium conductor used in power cables shall have tensile as per relevant
standards. Conductors shall be stranded.
Conductor of control cables shall be made of stranded, plain annealed copper.
XLPO insulation shall be suitable for a continuous conductor temperature of 120

deg. C and short circuit conductor temperature of 200 deg C for 5 secs.
XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg.

C and short circuit conductor temperature of 250 deg C. PVC insulation shall be
suitable for continuous conductor temperature of 70 deg C and short circuit
conductor temperature of 160 deg. C.
For single core armoured cables, armouring shall be of copper/aluminium wires/

formed wires.
The aluminium used for armouring shall be of H4 grade as per IS: 8130 with
maximum resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of
aluminium armouring shall be same as indicated above for galvanized steel.
The gap between armour wires / formed wires shall not exceed one armour wire /
formed wire space and there shall be no cross over / over-riding of armour wire /
formed wire. The minimum area of coverage of armouring shall be 90%. The
breaking load of armour joint shall not be less than 95% of that of armour wire /
formed wire. Zinc rich paint shall be applied on armour joint surface of G.S.wire/
formed wire.
Outer sheath of DC cable as per TUV specification 2 Pfg 1169/08.2007.
Outer sheath shall be of PVC as per IS: 5831 & black in colour. In addition to
meeting all the requirements of Indian standards referred to, outer sheath of all the
cables shall have the following FRLS properties.
(a.) Oxygen index of min. 29 (as per IS 10810 Part-58).
(b.) Acid gas emission of max. 20% (as per IEC-754-I).
(c.) Smoke density rating shall not be more than 60 % (as per ASTMD-2843).
(d) Cable drum no/ Batch no - To be embossed/printed at every one meter.
Cores of the cables shall be identified by colouring of insulation. Following colour
scheme shall be adopted:
1 core - Red, Black, Yellow or Blue
2 core - Red & Black
3 core - Red, Yellow & Blue
4 core - Red, Yellow, Blue and Black
For control cables having more than 5 cores, core identification shall be done by
numbering the insulation of cores sequentially, starting by number 1 in the inner
layer (e.g. say for 10 core cable, core numbering shall be from 1 to 10). The number
shall be printed in Hindu-Arabic numerals on the outer surfaces of the cores. All the

numbers shall be of the same colour, which shall contrast with the colour of
insulation. The colour of insulation for all the cores shall be grey only. The numerals
shall be legible and indelible. The numbers shall be repeated at regular intervals
along the core, consecutive numbers being inverted in relation to each other. When
the number is a single numeral, a dash shall be placed underneath it. If the number
consists of two numerals, these shall be disposed one below the other and a dash
placed below the lower numeral. The spacing between consecutive numbers shall
not exceed 50 mm.
For reduced neutral conductors (in case of power cable), the core shall be black.
In addition to manufacturer's identification on cables as per IS, following marking
shall also be provided over outer sheath.
(a.) Cable size and voltage grade - To be embossed
(b.) Word 'FRLS' at every 5 metre - To be embossed
(c.) Sequential marking of length of the cable in metres at every one
metre -To be embossed / printed
The embossing shall be progressive, automatic, in line and marking shall be legible
and indelible. For EPR cables identification shall be printed on outer sheath.
All cables except DC cable shall meet the fire resistance requirement as per
Category-B of IEC 332 Part-3.
Dc cable shall meet the fire resistance requirement as per TUV specification 2 Pfg
1169/08.2007.
Allowable tolerances on the overall diameter of the cables shall be +\-2 mm

maximum, over the declared value in the technical data sheets.
Repaired cables shall not be accepted. Pimples, fish eye, blow holes etc. are not
acceptable.
Cable selection & sizing

Cables shall be sized based on the following considerations:
(a) Rated current of the equipment
(b) The voltage drop in the cable, during motor starting condition, shall be
limited to 10% and during full load running condition, shall be limited to
3% of the rated voltage
(c) Short circuit withstand capability

This will depend on the feeder type. For a fuse protected circuit, cable
should be sized to withstand the letout energy of the fuse. For breaker
controlled feeder, cable shall be capable of withstanding the system fault
current level for total breaker tripping time inclusive of relay pickup time.
Control cables shall be sized based on the following considerations:

(a) The minimum conductor cross-section shall be 1.5 sq.mm.
(b) The minimum number of spare cores in control cables shall be as

follows:
No. of cores in cable Min. No. of spare cores
2C, 3C NIL
5C 1
7C-12C 2
14C & above 3
Derating Factors
Derating factors for various conditions of installations including the following shall be
considered while selecting the cable sizes:
a) Variation in ambient temperature for cables laid in air
b) Grouping of cables
c) Variation in ground temperature and soil resistivity for buried cables.
Cable lengths shall be considered in such a way that straight through cable joints
are avoided.
Cables shall be armoured type if laid in switchyard area or directly buried.
All LT power cables of sizes more than 120 sq.mm. shall be XLPE insulated and
preferable sizes are 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm.
TESTS
1.0 All equipments to be supplied shall be of type tested design. During

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

approval.
3.0 All acceptance and routine tests as per the specification and relevant
standards shall be carried out. Charges for these shall be deemed to be
included in the equipment price.
4.0 The type test reports once approved for any projects shall be treated as
reference . For subsequent projects of NTPC, an endorsement sheet will
be furnished by the manufacturer confirming similarity and “No design
Change”. Minor changes if any shall be highlighted on the endorsement
sheet.
Type Tests
The reports for the following type tests shall be submitted for one size each of
LT XLPE, LT PVC Power cables and control cables. Size shall be decided by the
employer during detailed engineering:
S.No. Type test Remarks
For Conductor
1. Resistance test
2. Tensile test* For circular non-compacted
conductors only
3. Wrapping test* For circular non-compacted only
For Armour Wires/ Formed Wires
4. Measurement of Dimensions
5. Tensile Test
6. Elongation test
7. Torsion test For round wires only
8. Wrapping test For aluminium wires / formed wires

only.
9. Resistance test
10(a) Mass of zinc coating test For GS Formed wires/wires only
10(b) Uniformity of zinc coating For GS Formed wires /wires only
11. Adhesion test For GS Formed wires/wires only
For PVC/XLPE insulation & PVC Sheath

12. Test for thickness
13. Tensile strength & elongation tests before ageing and after ageing
14. Ageing in air oven

15. Loss of mass test For PVC insulation and sheath only
16. Hot deformation test For PVC insulation and sheath only
17. Heat shock test For PVC insulation and sheath only
18. Shrinkage test

19. Thermal stability test For PVC insulation and sheath only
20. Hot set test* For XLPE insulation only
21. Water absorption test* For XLPE insulation only

22. Oxygen index test For outer sheath only
23. Smoke density test For outer sheath only
24. Acid gas generation test For outer sheath only
For completed cables
25. Insulation resistance test
(Volume resistivity method)
26. High voltage test
27. Flammability test as per IEC-332 Part-3 (Category-B)
* Not applicable for Control Cable

Indicative list of tests/checks, Routine and Acceptance tests shall be as per Quality
Assurance & Inspection table of LT power and control cables enclosed at relevant
section.
Type test, routine, acceptance tests requirements for DC cable shall be as per TUV
specification 2 Pfg 1169/08.2007.
5.3 PROTECTION CLASS OF CABINET / PANELS, ENCLOSURES etc.
All switch board shall be provided with adequately rated busbar, incoming control,
outgoing control etc. as a separate compartment inside the panel to meet the
requirements of the Chief Electrical Inspector. All live terminals and busbars shall be
shrouded. The out going terminals shall be suitable to receive suitable runs and size
of cables required for the Inverter/Transformer rating.
The degree of protection for following equipment shall be
1. Indoor Junction box : IP 20
2. Outdoor Junction Box : IP 65
Unless specified the degree of protection shall be

1. In door air-conditioned areas :IP 20

2. In-door Non A.C. areas
a. Ventilated enclosure :IP 42
b. Non-Ventilated :IP 54
3. Out-door :IP 55
The Switchboard shall be designed and manufactured in accordance with the

relevant International and Indian standards suitable for the site conditions, and the
specific code number and validity should be mentioned. Separate control and power
panels shall be provided with separate power circuit for isolated operation of control
circuit.
The design of panels, cabinet enclosures and packaging density of components

mounted therein shall be such that the temperature rise does not exceed 10 deg C
above the ambient under the worst conditions.
5.4 TRANSFORMERS
Each step up transformer shall be 3 phase, 50 Hz outdoor type. The combined kVA
rating of all the transformers connected at 11 kV bus shall not be less than 50 MVA.
The noise level shall be in accordance to NEMA TR-1. Transformer shall have Off
Circuit Tap Changer with tapings of at least +/- 5% with individual steps of 2.5%. The
vector group, impedance, bushing rating, HV/LV termination & neutral earthing shall
also meet the system requirement & shall also be inline with standards as mentioned
in this specification. Air clearance shall be inline with Central Board of Irrigation and
Power (CBIP) norms. Suitable Bushing CTs shall be provided to meet the system
protection requirement. Transformer shall be in accordance to IS:2026 or equivalent
to any other international standard.
System voltage 11 kV
(a.)
Cooling ONAN
(b.)
Type Two winding
(c.)
Service Outdoor
(d.)
Duty Continuous
(e.)
Overload capacity As per IS: 6600 and specified
(f.)
elsewhere in the specification.
Permissible Temperature rise over
(g.)
an ambient temp. of 50 deg. C
Winding (by resistance 55 deg. C
(i)
method)
Top oil (by thermometer) 50 deg. C
(ii)
Impedance at 75 deg.C As per IS 2026
(h.)
Noise Level As per NEMA TR- 1
(i.)

System fault level for 6.9 kV or 40 kA
(j.)
Trans. fed from 6.6 KV side
Winding
HV
Sr. No.
Highest System Voltage(kV) 12
Lightning impulse withstand voltage, kVp 75

(ii.)
One min power frequency withstand voltage, 28
(iii.)
kVrms
Insulation Uniform
(iv.)
Bushing Parameters
11 KV
Parameters
11 KV
(i) Rated Voltage(kV)
75
(ii) Lightning impulse withstand voltage, kVp
28
(iii) One min power frequency withstand
voltage , kV (rms)
(iv) Minimum total creepage distances (mm) 25mm/kV x Rated
Voltage of Bushing.
(v) Mounting Tank / Transformer
body
5.4.1 Construction
The features & construction details of each transformer shall be in accordance with
the requirement stated hereunder.
5.4.1.1 Tank and Tank Accessories

Tank shall be of welded construction & fabricated from tested quality low carbon
steel of adequate thickness. The welding procedure specification (WPS), procedure
qualification record (PQR), shop welding schedule, welder’s qualification shall be
subject to Employer’s approval. After completion of welding, all joints shall be
subjected to visual examination. In case of doubt particular weld shall be checked by
D.P.Test. However weld joints of load bearing member shall be left unpainted till
carrying out of jacking test followed by DP Test during final inspection of transformer.
Details of acceptance norms of welding shall be submitted for Employer’s approval
which shall include permissible undercut, overlap, surface crack, porosity, out of
alignment of plate surface in butt joints, maximum gap due to incorrect fit up of fillet
joint etc.
Each tank shall be provided with :
(i.) Lifting lug suitable for lifting the equipment complete with oil.

(ii.) A minimum of four jacking pads in accessible position to enable the
transformer complete with oil to be raised or lowered using hydraulic or
mechanical screw jacks.
(iii.) Suitable haulage holes shall be provided for transformer wheeling in all four
directions.
For all transformers, suitable bi-directional skids with pre-drilled holes shall be
provided integral with the tank body for fixing the transformer tank on foundation.
These skids shall be such that the bottom of the tank body is at a sufficient height
above foundation for cleaning purposes.
The transformers (except transformers upto and including 2 MVA) are to be provided
with four no. of bi - directional flat rollers of detachable type & shall be mounted on
wheels on foundation. Suitable locking arrangement shall be provided for the wheels
to prevent accidental movement of transformer.
At least two adequately sized inspection openings one at each end of the tank shall
be provided for easy access to bushing & earth connections. The inspection covers
shall not weight more than 25 Kg. Handles shall be provided on the inspection cover
to facilitate lifting.
All bolted connections shall be fitted with weather proof, hot oil resistant, rubberized
cork gasket in between for complete oil tightness. If gasket is compressible, metallic
stops shall be provided to prevent over compression.
The tank shall be designed in such a way that it can be mounted on the plinth
directly.
Wherever possible the transformer tank & its accessories shall be designed without
pockets wherein gas may collect. Where pockets can not be avoided, pipes shall be
provided to vent the gas into the main expansion pipe.
The main tank body shall be capable of withstanding full vacuum.
5.4.1.2 Core
The core shall be constructed from cold rolled, super grain oriented (CRGO), silicon
steel laminations.
The core isolation level shall be 2 kV (rms.) for 1 minute in air.
Adequate lifting lugs will be provided to enable the core & windings to be lifted.
5.4.1.3 Windings
The contractor shall ensure that windings of all transformers are made in dust proof
& conditioned atmosphere. The bidder shall furnish details of the facilities available
at his works along with the bid.
The conductors shall be of electrolytic grade copper free from scales & burrs.
All windings of the transformers having voltage less than 66 kV shall be fully
insulated.

Tapping shall be so arranged as to preserve the magnetic balance of the transformer
at all voltage ratio.
5.4.1.4 Insulating Oil

No inhibitors shall be used in the transformer oil. The oil supplied with transformers
shall be new and previously unused and conform to IS: 355.
5.4.1.5 Transformer Foundation

Power Transformer shall be placed on gravel filled foundation if placed on ground/
raised foundation. In this case gravel filled chamber shall be connected through RCC
pipe to an oil chamber
5.4.2 Terminal Arrangements

5.4.2.1 Bushings
a. The electrical & mechanical characteristics of bushings shall be in accordance
with IS: 2099, IS: 3347 & IS: 12676.
b. Bushings for 52 kV & above shall be of the oil filled condenser type & shall be of
draw lead/ rod type to facilitate removal. Bushings of rating below 52 kV shall be
solid porcelain or oil communicating type.
c. Condenser type bushings shall be provided with :
1. Oil level gauge,
2. Oil filling plug & drain valve ( if not hermetically sealed)
3. Tap for capacitance & tan delta test.
d. Clamps & fittings shall be of hot dip galvanized steel.
e. Bushing & fittings shall be provided with vent pipes that shall be connected to
route any gas collection through the Buchholz relay.
f. No arcing horns shall be provided on the bushings.
g. Wherever cable termination is specified, bushing terminals shall be provided with
suitable terminal connectors of approved type and size for cable termination.
h. Where current transformers are specified, the bushings shall be removable
without disturbing the current transformer.
5.4.2.2 Cable boxes & disconnecting chamber
a. Cable boxes shall be of phase segregated air insulated type & shall be of
sufficient size to accommodate Employer’s cable & termination. Phase
segregation shall be achieved by insulating barriers.
b. Cable boxes shall have bus bars / terminal connectors of adequate size & bolt
holes to receive cable lugs.
c. A suitable removable gland plate of non-magnetic material drilled as per the
Employer’s instruction shall also be provided in the cable box.
d. The support from base for the cable box shall be of galvanized iron.
e. The contractor shall provide earthing terminals on the cable box, to suit
Employer’s GI flat.
f. Cable boxes shall be designed such that it shall be possible to move away the
transformer without disturbing the cable terminations, leaving the cable box on
external supports.

g. Cable boxes shall have removable top cover & ample clearance shall be
provided to enable either transformer or each cable to be subjected separately to
high voltage test.
5.4.2.3 Bushing Current Transformer
a. Current transformer shall comply with IS: 2705.
b. It shall be possible to remove turret mounted current transformers from the
transformer tank without removing the tank cover. Necessary precautions shall
be taken to minimize eddy currents & local heat generated in the turret.
c. All secondary leads shall be brought to a weatherproof terminal box near each
bushing. These terminals shall be wired out to transformer marshalling box using
separate cables for each core.
5.4.2.4 Terminal Marking
The terminal marking & their physical position shall be as per IS: 2026 unless
specified otherwise.
5.4.2.5 Marshalling Box(M. BOX) Unit

(a.) Each transformer shall be provided with one Marshalling Box housing all the
cooler control, OTI & WTI etc.
(b.) The sheet steel used for all the cabinet boxes shall be at least 2.5 mm thick. The
gasket used shall be of neoprene rubber. A space heater & cubicle lighting with
on–off switch shall be provided in each cabinet. A circuit breaker/contactor with
thermal overload device for controlling the AC auxiliary supply shall be provided.
(c.) Terminal Blocks
(1.) The terminal blocks to be provided shall be fully enclosed with removable
covers & made of molded, non-inflammable plastic material with blocks &
barriers molded integrally. The terminal blocks shall be of 650V grade &
have 10 A continuous rating. Terminal blocks for current transformer
secondary leads shall be provided with test links & isolating facilities. Also
current transformer secondary leads shall be provided with short circuiting
& earthing facilities. At least 20% spare terminals shall be provided on
each panel & these spare terminals shall be uniformly distributed on all
terminal blocks.
(2.) Terminal blocks shall be suitable for connecting the following conductors
on each side :
(i.) Current transformer circuits – minimum of two No. of 2.5 sq. mm copper
wires each side
(ii.) Other circuits— minimum of one No. of 2.5 sq. mm copper wire each side
(d.) The temperature indicators shall be so mounted that the dials are not more than
1500 mm from ground level. Glazed door of suitable size shall be provided for
convenience of reading.
(e.) All incoming cables shall enter the marshalling box from the bottom. A removable
undrilled gland plate shall be provided at the bottom of the box for
accommodating glands for Employer’s incoming and outgoing cables, which
shall not be less than 450 mm from finished floor level.
(f.) All devices and terminal blocks inside the marshalling box shall be clearly
identified by symbols corresponding to those used on applicable schematic or
wiring diagram.
(g.) It shall be located in such a way that, the same shall not face towards the
transformer.

(h.) The gland plate shall be made into two detachable halves, for facilitating the
termination of Employer’s cable and Contractor’s cables separately. The gland
plate and the associated compartment shall be sealed in a suitable manner to
prevent the ingress to moisture, rodents, insects etc.
(i.) One dummy terminal block in between each trip wire terminal shall be provided.
(j.) Wiring Scheme shall be engraved in a plate and the same shall be fixed inside
the Marshalling Box door.
5.4.2.6 Control Wiring & Cabling

Supply, laying & termination of all cables & accessories required of proper
termination from the M. Box to make equipment complete & functional shall be in
scope of supplier. The cable between the M. Box & transformer shall be laid by the
supplier through GI conduits/ pipes. Cable box / sealing end shall be suitable for
following types of cables:
1) LV Voltage 1100 V grade PVC insulated aluminum conductor cable with

armour.
2) Control 1100 V grade PVC insulated 2.5 sq. mm stranded copper
conductor with armour.
All the control cables for Employer’s unit control panel shall be wired by the
contractor up to M. Box.
5.4.2.7 Cooling Equipment

The radiators shall be detachable type, mounted on the tank. Each radiator shall be
provided with the following:
(a.) A drain plug at the bottom.
(b.) An air release plug at the top.
(c.) Shut off valve at each point of connection to the tank. The location and
configuration of radiators shall be subject to Employer’s approval.
5.4.2.8 TAP CHANGER DEVICE
Off Circuit Tap change Switch
a. The tap change switch shall be three phase, hand operated for simultaneous
switching of similar taps on the three phases by operating on external hand wheel.
b. The tap changing shall be possible without disturbing the transformer in any way
except de-energising.
c. Arrangement shall be made for securing and pad-locking the tap changer in any of
the working positions, and it shall not be possible for setting or padlocking it in any
intermediate position. An indicating device shall be provided to show the tap in use.
d. The Cranking device for manual operation of the off circuit tap changing gear shall be
removable and suitable for operation by a man standing on ground level. The
mechanism shall be complete with the following:-
1. Mechanical tap position indicator which shall be clearly visible from near the
transformer.

2. Mechanical stops to prevent over cranking of the mechanism beyond the extreme
tap positions.
3. The manual operating mechanism shall be labeled to show direction of operation
for raising the secondary voltage and vice versa.
4. A warning plate indicating “The switch shall be operated only when the
transformer has been de-energised” shall be fitted.
5.4.2.9 Valves
a. All valves upto and including 50 mm shall be of gun metal or of cast steel. Larger
valves may be of gun metal or may have cast iron bodies with gun metal fittings.
They shall be of full way type with internal screw and shall open when turned counter
clockwise when facing the hand wheel.
b. Suitable means shall be provided for locking the valves in the open and close
positions. Provision is not required for locking individual radiator valves.
c. Each valve shall be provided with the indicator to show clearly the position of the
valve.
d. Gland packing/gasket material shall be of teflon rope/nitrile rubber. In case of
gate/globe valves, gland packing preferably of teflon rope shall be used to prevent oil
seepage through the gland.
e. After testing, inside surface of all cast iron valves coming in contact with oil shall be
applied with one coat of oil resisting paint/varnish with two coats of red oxide zinc
chromate primer followed by two coats of fully glossy finishing paint conforming to
IS:2932 and of a shade (Preferably red or yellow) distinct and different from that of
main tank surface. Outside surface except gasket setting surface of butterfly valves
shall be painted with two coats of red oxide zinc chromate conforming to IS:2074
followed by two coats of fully glossy finishing paint.
f. All hardware used shall be cadmium plated/electro galvanised.
g. Sampling & drain valves should have zero leakage rate.
5.4.2.10 Bolts & Nuts

All bolts & nuts exposed to weather shall be hot dip galvanised steel
/cadmium plated steel
5.4.2.11 Gasket
The gaskets shall not deteriorate during the life of transformer if not opened
for maintenance at site. Supplier shall also recommend quality & make of
gaskets to be used for replacement during maintenance if required. All joints
flanged or welded associated with oil shall be such that no oil leakage or
sweating occurs during the life of transformer. The quality of these joints is
considered established, only if the joints do not exhibit any oil leakage or
sweating for a continuous period of at least 3 months during the guarantee
period. In case any sweating / leakage is observed, contractor shall rectify
the same & establish for a further period of 3 months of the same. If it is not
established during the guaranteed period, the guaranteed period shall be
extended until the performance is established.
5.4.2.12 Fittings

The following fittings shall be provided with each transformer covered in this
specification:
a. Conservator for main tank with oil filling hole and cap, isolating valves,
drain valve, magnetic oil level gauge with low level alarm contacts and
dehydrating silicagel breather. Breather for conservators shall be mounted
not more than 1400 mm above rail top.
b. Oil preservation system: - as specified elsewhere.
c. Minimum two Nos. of spring operated pressure relief devices with alarm/trip
contacts for transformer of 2 MVA & above rating. Discharge of PRD shall
be properly taken through pipes & directed away from the transformer
/other equipment.
d. Buchholz relay double float type with isolating valves on both sides,
bleeding pipe with Gas collecting device at the end to collect gases and
alarm and trip contacts. Control cable termination at Buchhloz relay shall
be properly sealed to prevent water entry.
e. Air release plug.
f. Inspection openings and covers.
g. Bushing with metal parts and gaskets to suit the termination arrangement.
h. Cover lifting eyes, transformer lifting lugs, jacking pads, towing holes and
core and winding lifting lugs.
i. Protected type Mercury or alcohol in glass thermometer.
j. Bottom and top filter valves with threaded male adapters, bottom Sampling
valve & drain valve.
k. Rating and diagram plates on transformers (English & Hindi) and auxiliary
apparatus.
l. Radiator as specified.
m. Prismatic/toughened glass oil gauge for transformers.
n. 150 mm dial type oil temp indicator with alarm and trip contacts, maximum
reading pointer & resetting device. Accuracy class shall be ± 1.5 % or
better.
o. 150-mm dial type Winding temp indicator with alarm and trip contacts,
maximum reading pointer & resetting device. Accuracy class shall be ± 1.5
% or better.
p. Flanged bi-directional wheels.
q. Marshalling Box.
r. Off load tap changing gear
s. Cooling equipment.
t. Bushing current transformers.
u. Insulating oil.
v. Drain valves/plugs shall be provided in order that each section of pipe work
can be drained independently. Sludge valve at bottom most point of tank to
be provided for easy flush out/removal of sludge during maintenance.
w. Terminal marking plates.

x. Valves schedule plates.
y. Two (2) earthing terminals on all the equipment mounted separately
suitable for connection to suitable GI flat along with 2 Nos. tapped holes.
M10 bolts etc.

z. Rain hoods to be provided on Buchholz, MOG & PRD. Entry points of wires
shall be suitably sealed.
The fittings listed above are only indicative and other fittings, which generally
are required for satisfactory operation of the transformer, are deemed to be
included
5.4.3 Performance
a) The maximum flux density in any part of the core & yoke at the rated MVA,
voltage & frequency shall be such that under 110% continuous voltage
condition it does not exceed 1.9 Tesla.
b) The transformer & all its accessories including CT’s etc, shall be designed
to withstand without injury the thermal & mechanical effects of any external
short circuit to earth & of short circuits at the terminal of any winding for a
period of 2 sec. Bidder shall submit the short circuit withstand calculations.
c) Transformers shall withstand, without injurious heating, combined voltage
& frequency fluctuations, which produce the following over fluxing
condition
1) 110 %- continuous
125%- for one minute
140%- for five seconds
2) Bidder shall indicate 150% & 170% over voltage withstand time.
3) Over fluxing characteristics up to 170 % shall be submitted.
d) The transformers shall be capable of being operated continuously without

danger on any tapping at the rated MVA with voltage variation of ±10%
corresponding to the voltage of tapping.
e) The transformers shall be capable of being loaded in accordance with IS:
6600 / IEC: 60076-7 up to load of 150 %. There shall be no limitation
imposed by bushings, tap changers etc. or any other associated
equipment.
5.4.4 Tests and Inspection
All type tests as per IS 2026 shall be/shall have been conducted on one transformer
of each rating. In addition to this tank Vacuum test and tank pressure test shall also
be carried out as a type test in line with CBIP norms. Oil leakage test shall also be
performed as routine test as per the clause no. c below.
Following Special test as per IS 2026 shall be/shall have been conducted on one
transformer of each rating
1. Short Circuit Test
2. Measurement of Acoustic Noise level
3. Measurement of Zero Sequence Impedance
In case the bidder has conducted such specified type test(s) within last ten years as
on the date of bid opening, he may submit the type test reports to the owner for
waiver of conductance of such type test(s). These reports should be for the tests

conducted on the equipment similar to those proposed to be supplied under this
contract and test(s) should have been either conducted at an independent laboratory
or should have been witnessed by a client.
In case the Bidder is not able to submit report of the type test(s) conducted within
last ten years from the date of bid opening, or in case the type test report(s) are not
found to be meeting the specification requirements, the Bidder shall conduct all such
tests under this contract free of cost to the Employer and submit the reports for
approval.
In addition to above tests, all routine tests as per IS: 2026 shall be conducted on
each of the transformer.
a. Vacuum Test
Each type of transformer tank shall be subjected to the specified vacuum. The tank
designed for full vacuum shall be tested at an internal pressure of 3.33 KN/sq. m
absolute (25 torr) for one hour. The permanent deflection of the plate after the
vacuum has been released shall not exceed the values specified below:
Horizontal length of flat plate (mm) Permanent deflection (mm)

Up to and including 5
750
751 to 1250 6.5
1251 to 1750 8
1751 to 2000 9.5
2001 to 2250 11
2251 to 2500 12.5
2501 to 3000 16
Above 3000 19
b. Tank pressure Test

Transformer tank of each type shall be subjected to a pressure corresponding to
twice the normal head of oil or to the normal pressure plus 35 KN / sq. m whichever
is lower, measured at the base of the tank & maintained for one hour. The
permanent deflection of the plates after the excess pressure has been released shall
not exceed the figure specified above for vacuum test.
c. Oil leakage test on assembled transformer

All tank & oil filled compartment shall be tested for oil tightness by being completely
filled with oil of viscosity not greater than that of specified oil at the ambient
temperature & applying pressure equal to the normal pressure plus 35 KN/sq. m
measured at the base of the tank. The pressure shall be maintained for a period of
not less than 24 hours during which time no sweating shall occur.
5.5 Switchgear Equipments:

5.5.1 Codes and Standards:

All standards, specification and codes of practices referred to herein shall be the
latest editions including all applicable official amendments and revisions as on date
of opening of bid. In case of conflict between this specification and those (IS Codes,
Standards etc.) referred to herein, the former shall prevail. All work shall be carried
out as per the following standards and codes
a) IS: 996 Single phase small AC and universal electrical motors.

b) IS: 1248 Direct Acting indicating analogue electrical measuring
instruments and Accessories.
c) IS: 13947 Degree of protection provided by enclosures for low voltage
switchgear and control gear.
d) IS: 2544 Porcelain post insulators for systems with nominal voltages
greater than 1000 Volts.
e) IS: 2705 Current transformers.
f) IS: 3156 Voltage Transformers

g) IS: 6005 Code of practice for phosphating of iron and steel.
h) IS: 5082 Specification for wrought aluminium and aluminium alloy
bars, rods, tubes and selections for electrical purposes.
j) IEC: 61850 Communication Standard for Numerical relays
k) IEC: 61131-3 Automation Standard for Numerical relays
l) IS: 9046 AC contactors for voltages above 1000 volts and upto and
including 11000 Volts.
m) IS: 13703 Low voltage fuses
n) IS: 9385 HV fuses

o) IS: 9431 Specification for indoor post insulators of organic material
for system with nominal voltages greater than 1000 volts
upto and including 300 kV
p) IS: 9921 A.C. disconnectors (isolators) and Earthing switches for
voltages above 1000 V
q) IS: 11353 Guide for uniform system of marking and identification of

conductors and apparatus terminals.
r) IS: 13118 Specification for high voltage AC circuit breakers.
s) IEC: 60099-4 Metal oxide surge arrestor without gap for AC system
t) IS/IEC: 62271- High voltage alternating current circuit breakers.
100
u) IS/IEC: 62271- High voltage metal enclosed switchgear and control gear.
200
v) IEC: 60947-7-1 Terminal blocks for copper conductors
:
w) IS :513 (2008) Cold Rolled Low Carbon Steel Sheets and Strips
a) SYSTEM PARAMETERS

1 Nominal System voltage 11 kV
2 Highest System voltage 12 kV
3 Rated Frequency 50 Hz
4 Number of phases/ poles Three
5 System neutral earthing Earthed through Resistance to limit fault

current to 300A
6 One minute power frequency withstand voltage
- for Type tests 28
- for Routine tests 28
7 1.2/50 microsecond Impulse 75 kV (peak)

withstand voltage
8 Maximum system fault level 40 kA (rms)

including initial motor
contribution
9 Short time rating for bus bars, 40 kA (rms)

ckt. breakers, current for one (1) sec.
transformers and swgr.
Assembly.
10 Dynamic withstand rating 100 kA (peak)

11 IAS Rating 40 KA 0.2 sec
12 Control supply voltage
- Trip and closing coils 240V DC/120V DC
- Spring charging motor 240V DC/120V DC
- Space heaters 240 V AC single phase with neutral solidly
earthed
13 Maximum ambient air 50 deg. C
temperature
b) SWGR. CUBICLE CONSTRUCTIONAL REQUIREMENTS
1 Color finish
.
Exterior RAL9002 (Main body)
RAL 5012 (Extreme end covers)
2 Cable entry
.
a) Power Cables
b) Control Cables
3 Bus duct entry Top
.
4 Employer's Earthing Galvanized steel strip

. conductor

5.5.2 11 KV CIRCUIT BREAKER:
Circuit breakers shall be Circuit Breaker SF6 or Vacuum, Free standing, Floor
mounted, metal clad, fully compartmentalized, restrike free, trip free, stored energy
operated and with electrical anti-pumping features. They shall comprise of three
separate, identical single pole interrupting units, operated through a common shaft by
a sturdy operating mechanism. DC battery bank required for the breaker shall be in
the scope of bidder. VRLA battery shall not be accepted.
All circuit breaker modules shall have the following accessories :

• Current / Voltage transformers as per requirement
• Relays as per relevant clauses / single line diagrams
• Spring charging motor, with its protection and control
• Auxiliary contacts.
• Terminal blocks
CONSTRUCTIONAL REQUIREMENT
a) During closing, main poles shall not rebound objectionably and

mechanism shall not require adjustments. Necessary dampers shall be
provided to withstand the impact at the end of opening stroke. Slow
closing facility shall preferably be provided for checking and adjustment
of arc chutes and poles when the breaker is completely withdrawn and
isolated.
b) Plug and socket isolating Contacts for main power circuit shall be silver
plated, of self aligning type, of robust design and capable of withstanding
the specified short circuit currents. They shall preferably be shrouded
with an insulating material. Plug and socket contacts for auxiliary circuits
shall also be silver plated, sturdy and of self aligning type having a high
degree of reliability. Thickness of silver plating shall not be less than 10
microns.
c) All working part of the mechanism shall be of corrosion resisting material.
Bearings which require greasing shall be equipped with pressure type
grease fittings. Bearing pins, bolts, nuts and other parts shall be
adequately secured and locked to prevent loosening or change in
adjustment due to repeated operation of the breaker and the mechanism.
d) The operating mechanism shall be such that failure of any auxiliary
spring shall not prevent tripping and shall not lead to closing or tripping of
circuit breaker. Failure of any auxiliary spring shall also not cause
damage to the circuit breaker or endanger the operator.
e) Mechanical indicators shall be provided on the breaker trucks to indicate
OPEN / CLOSED conditions of the circuit breaker, and CHARGED /
DISCHARGED conditions of the closing spring. An operation counter
shall also be provided. These shall be visible without opening the breaker
compartment door.
f) The closing coil and spring charging motor shall operate satisfactorily at
all values of control supply voltage between 187V-242V DC / 93.5V-121V
DC. The shunt trip coil shall operate satisfactorily under all operating
conditions of the circuit breaker upto its rated short circuit breaking
current at all values of control supply voltage between 154V-242V DC /
77V-121V DC. The trip coil shall be so designed that it does not get
energised when its healthiness is monitored by two indicating lamps
(Red) and one trip coil supervision relay.

g) The time taken for charging of closing spring shall not exceed 30
seconds. The spring charging shall take place automatically preferably
after a closing operation. Breaker operation shall be independent of the
spring charging motor which shall only charge the closing spring.
Opening spring shall get charged automatically during closing operation.
As long as power supply is available to the charging motor a continuous
sequence of closing and opening operations shall be possible. One open-
close- open operation of the circuit breaker shall be possible after failure
of power supply to the motor. Spring charging motors shall be capable of
starting and charging the closing spring twice in quick succession without
exceeding acceptable winding temperature when the control supply
voltage is any where between 187V-242V DC / 93.5V-121V DC. The
initial temperature shall be as prevalent in the switchgear panel during full
load operation with 50 deg. C ambient air temperature. The motor shall
be provided with short circuit protection.
h) Motor windings shall be provided with class E insulation or better. The
insulation shall be given tropical and fungicidal treatment for successful
operation of the motor in a hot, humid and tropical climate.
i) Circuit breaker shall be provided with inter pole barriers of insulating
materials. The use of inflammable materials like Hylam shall not be
acceptable.
OPERATIONAL REQUIREMENT:
a) Spring return to neutral type control switch (with NAC/NAT position)
b) Stay - put type selector switches.
c) Thermostatically controlled space heater with switch, illumination and
power plug point.
d) All meters/instruments shall be flush mounted on front panel, at least 96
sq.mm size with 90 deg. scales and accuracy class of 2.0 or better. All
feeders shall have an ammeter and ammeter selector switch
The circuit breaker shall meet the following requirements
a) The breaker shall be controlled locally and/ or remotely as required.

Facilities shall be provided for mechanical tripping of breaker and manual
charging of closing spring to cater to emergency condition
b) Switching over voltage (unipolar) shall not exceed 2.5 PU of nominal
line to neutral voltage, evaluated as per IEEE envelope.
c) Supervision relays provided for trip coil monitoring.
d) Suitable mechanical inter lock shall be provided to prevent inadvertent

earthing of any live part.
e) Castle key interlocks shall be provided to prevent opening of cable

compartment door when breaker is closed and bus bar compartment
when any of the incomers to bus are closed.
f) Testing of circuit breaker shall be possible in isolated position by keeping

the control plug connected
g) Only motor wound closing spring charging arrangement is acceptable.

h) Each breaker truck shall have Service - Isolated - Withdrawn Position.

i) Service & test position indication shall be provided on all panels through
additional lamps.
Salient Feature of Circuit Breaker

1. The circuit breakers current rating shall be selected from the load
current given in SLD which is at an ambient of 50 deg. C.
2. Short circuit breaker 11 kV
Current
a) A.C. component 40 kA
b) D.C. component As per IS: 13118 or IEC-62271
3. Short Circuit making 100 kA
current (peak)
4. Operating Duty B-3 Min-MB-3 Min-MB
5. Total break time Not more than 4 cycles
6. Total make time Not more than 5 cycles
7. Operating Motor wound spring charged stored energy

Mechanism type as per IEC-62271
5.5.3 Instrument Transformer

(a.) All current and voltage transformers shall be completely encapsulated cast resin
insulated type, suitable for continuous operation at the ambient temperature prevailing
inside the switchgear enclosure, when the switchboard is operating at its rated load
and the outside ambient temperature is 50 deg. C. The class of insulation shall be E or
better.
(b.) All instrument transformers shall withstand the power frequency and impulse test
voltage specified for the switchgear assembly. The current transformer shall further
have the dynamic and short time ratings at least equal to those specified for the
associated switchgear and shall safely withstand the thermal and mechanical stress
produced by maximum fault currents specified when mounted inside the switchgear for
circuit breaker modules. However, current transformer mounted in fuse backed
contactor module shall have the dynamic and short time rating compatible with the let
through current of the fuses.
(c.) The parameters of instrument transformers specified in this specification are tentative
and shall be finalised by the Employer in due course duly considering the actual
burden of various relays and other devices finally selected. In case the Bidder finds
that the specified ratings are not adequate for the relays and other devices offered by
him, he shall offer instrument transformer of adequate ratings and shall bring out this
fact clearly in his bid.
(d.) All instrument transformers shall have clear indelible polarity markings. All secondary
terminals shall be wired to separate terminals on an accessible terminal block.
(e.) Current transformers may be multi or single core and shall be located in the cable
termination compartment. All voltage transformers shall be single phase type. The bus
VTs shall be housed in a separate panel on a truck so as to be fully withdrawable.

(f.) Core balance CTs (CBCT) shall be provided on outgoing motor and transformer
feeders having CT ratio more than 50/1A. These CBCTs shall be mounted inside the
switchgear panel. The window size of CBCT's shall be based on the overall diameter
of the cables, to be finalised during detailed engineering. The CBCT shall be of
circular window type.
(g.) All voltage transformers shall have suitable HRC current limiting fuses on both primary
and secondary sides. Primary fuses shall be mounted on the withdrawable portion.
Replacement of the primary fuses shall be possible with VT truck in ISOLATED
position. The secondary fuses shall be mounted on the fixed portion and the fuse
replacement shall be possible without drawing out the VT truck from Service position.
a) CURRENT TRANSFORMER
1. Class of Insulation Class E or better
2. Rated output of each Adequate for the relays and devices connected,
but not less than five (5) VA.
3. Accuracy class
Protection & Measurement Class PS for differential & REF and core balance
CTs; 5P20 for other protection CTs. Required
Accuracy for metering is 0.2s .
4. Minimum primary earth fault
current to be detected by core 3 Amperes
balance current Transformer
Voltage Transformer
1. Rated 1.2 continuous for all VTs, and 1.9 for 30 seconds
Voltage Factor for star connected VTs.
2. Class of insulation Class E or better
3. Other parameters BUS PT-0.5 Class,VA req. adequate for
application. Line PT-0.5 Class for sync./3P for
door interlocks, VA req. adequate for application.
4 Per phase VT ratio 11/ 3 KV / 110/ 3 V
5.5.4 Surge Arrestor
The surge arrestors shall be mounted within the switchgear cubicle between line and earth,
preferably in the cable compartment. Surge arrestor selected shall be suitable for non-
effectively earthed system and rating shall be in such a way that the value of steep fronted
switching over voltage generated at the switchgear terminals shall be limited to the
requirements of switchgear.
5.5.5 Type Tests
The contractor shall carry out the following type tests on the equipment to be supplied
under this contract. The bidder shall indicate the charges for each of these type tests
separately in the relevant schedule of Section - VII- (Forms & Procedures) and the same

shall be considered for the evaluation of the bids. The type tests charges shall be paid only
for the test(s) actually conducted successfully under this contract and upon certification by
the employer’s engineer
The following type tests shall be carried out on circuit breaker / circuit breaker panels, of
each voltage class and current rating.
1) Short circuit duty test on circuit breaker, mounted inside the panel
offered along with CTs, bushing and separators.
2) Short time withstand test on circuit breaker, mounted inside panel
offered together with CTs, bushings and separators.
3) Power frequency withstand test on breaker mounted in side panel.
4) Lightning impulse withstand test on breaker mounted in side panel
5) Temperature rise test on breaker and panel together. For this test, the test set
up shall include three panels with breakers, the test breaker and panel being
placed in the centre.
The adjacent panels shall also be loaded to their rated current capacity.
Alternatively the test panel may be suitably insulated at the sides, which will be
adjoining to other panels in actual site configuration
6) Internal Arc Test as per IEC 62271-200
7) Measurement of resistance of main circuit.
8) Mechanical operation test.
9) Short Circuit withstand test of earthing device(Truck/switch).
The type tests shall be carried out in presence of the employer’s representative, for
which minimum 15 days notice shall be given by the contractor. The contractor shall
obtain the employer’s approval for the type test procedure before conducting the type
test. The type test procedure shall clearly specify the test set–up, instruments to be
used, procedure, acceptance norms, recording of different parameters, interval of
recording, precautions to be taken etc. for the type test(s) to be carried out.
In case the contractor has conducted such specified type test(s) within last ten
years as on the date of bid opening, he may submit during detailed engineering the type
test reports to the owner for waival of conductance of such type test(s). These reports
should be for the tests conducted on the equipment similar to those proposed to be
supplied under this contract and test(s) should have been either conducted at an
independent laboratory or should have been witnessed by a client. The owner reserves
the right to waive conducting of any or all the specified type test(s) under this contract.
In case type tests are waived, the type test charges shall not be payable to the
contractor
The type test reports once approved for any projects shall be treated as reference.
For subsequent projects of NTPC, an endorsement sheet will be furnished by the
manufacturer confirming similarity and “No design Change”. Minor changes if any shall
be highlighted on the endorsement sheet.
Two (2) protected soft copies on CD-ROM of the approved test results shall be
furnished with the equipment . These shall include complete reports and results of the
routine tests and type tests (if the latter is carried out) on equipment. If the type tests are
not conducted, the CDs shall contain copies of the results of type tests carried out on
identical equipment earlier.

Testing to observe compliance to degree of protection, shall be checked for each
switch board enclosure and busbar chambers during routine inspection shall be as
under.
(a.) IP -4X It shall not be possible to insert a one (1) mm. dia steel wire into the
enclosure from any direction, without using force.
(b.) IP-5X It shall not be possible to insert a thin sheet of paper under gaskets
and through enclosure joints.
5.5.6 Routine Tests

All acceptance and routine tests as per the specification and relevant standards IEC 62271-
200 & IEC 62271-100 shall be carried out. Charges for these shall be deemed to be included
in the equipment price
An indicative lists of tests / checks is mentioned as QA chapter on HT switchgear. However,

the manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure
along with relevant supporting documents.
Commissioning Checks / Tests

After installation of panels, power and Control wiring and connections, Contractor shall perform
commissioning checks as listed below to verify proper operation of switchgear / panels and
correctness of all equipment in all respects.
In addition the Contractor shall carry out all other checks and tests recommended by the
manufacturers.
General
a. Check name plate details according to specification.
b. Check for physical damage
c. Check tightness of all bolts, clamps and connecting terminals
a. Check earth connections.
b. Check cleanliness of insulators and bushings
c. Check heaters are provided
d. H.V. test on complete switchboard with CT & breaker / contactor in

position.
e. Check all moving parts are properly lubricated.
f. Check for alignment of busbars with the insulators to ensure alignment

and fitness of insulators.
g. Check for interchange ability of breakers / contactors.

h. Check continuity and IR value of space heater.
i. Check earth continuity for the complete switchgear board.
Circuit Breaker / Contactors

(a) Check alignment of trucks for free movement.
(b) Check correct operation of shutters.
(c) Check slow closing operation (if provided)
(d) Check control wiring for correctness of connections, continuity and IR
values.
(e) Manual operation of breakers completely assembled.
(f) Power closing / opening operation, manually and electrically at
extreme condition of control supply voltage.
(g) Closing and tripping time.
(h) Trip free and anti-pumping operation.
(i) IR values, resistance and minimum pick up voltage of coils.
(j) Simultaneous closing of all the three phases.
(k) Check electrical and mechanical interlocks provided.
(l) Checks on spring charging motor, correct operation of limit switches
and time of charging
(m) All functional checks.
Current Transformers
(a) Megger between windings and winding terminals to body.

(b) Polarity tests.
(c) Ratio identification checking of all ratios on all cores by primary
injection of current.
(d) Magnetisation characteristics & secondary winding resistance.
(e) Spare CT cores, if any to be shorted and earthed.
Voltage Transformers
(a) Insulation resistance test.

(b) Ratio test on all cores.
(c) Polarity test.
(d) Line connections as per connection diagram.
Cubicle Wiring

(a) Check all switch developments.
(b) It should be made sure that the wiring is as per relevant drawings. All
interconnections between panels shall similarly be checked.
(c) All the wires shall be meggered to earth.
(d) Functional checking of all control circuit e.g. closing, tripping interlock,
supervision and alarm circuit including proper functioning of
component / equipment.
(e) Check terminations and connections.
(f) Wire ducting.
(g) Gap sealing and cable bunching.
5.6 HT Cable
CODES AND STANDARDS
All standards, specifications and codes of practice referred to herein shall be

the latest editions including all applicable official amendments and revisions
as on date of opening of bid. In case of conflict between this specification and
those (IS : codes, standards, etc.) referred to herein, the former shall prevail.
All the cables shall conform to the requirements of the following standards
and codes :
IS:7098 (Part -II) Specification for Cross linked polyethylene insulated PVC
sheathed cables. Part-II: For working voltages from 3.3
KV upto and including 33 KV.
IS : 3975 Low Carbon Galvanized steel wires, formed wires and
tapes for armouring of cables.
IS : 4905 Methods for random sampling.
IS : 5831 PVC insulation and sheath of electrical cables.
IS : 8130 Conductors for insulated electrical cables and flexible
cords.
IS : 10418 Specification for drums for electric cables.
IS : 10810 Methods of tests for cables.
ASTM-D -2843 Standard test method for density of smoke from the
burning or decomposition of plastics.
IEC-754 (Part-I) Tests on gases evolved during combustion of electric
cables.
IEC-332 Tests on electric cables under fire conditions. Part-3:
Tests on bunched wires or cables (Category-B).
TECHNICAL REQUIREMENTS
The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under
ground (buried) installation with chances of flooding by water
All cables including EPR cables shall be flame retardant, low smoke (FRLS) type
designed to withstand all mechanical, electrical and thermal stresses developed under
steady state and transient operating conditions as specified elsewhere in this
specification.
Aluminium conductor used in power cables shall have tensile strength of more than 100
N/ sq.mm. Conductors shall be multi stranded.

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

armour
i) Upto 13 mm 1.4mm dia GS wire

ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm
dia GS wire
iii) Above 25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia
GS wire
iv) Above 40 & upto 55mm 1.4 mm thick GS formed wire/2.5mm dia
GS wire
v) Above 55 & upto 70mm 1.4 mm thick GS formed wire/3.15mm dia
GS wire
vi) Above 70mm 1.4 mm thick GS formed wire / 4.0 mm
dia GS wire
The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum
resistivity of 0.028264 ohm-sq.mm/mtr at 20 deg.C. The types and sizes of aluminium
armouring shall be same as mentioned for galvanised steel at 2.06.00 above.
The gap between armour wires / formed wires shall not exceed one armour wire /
formed wire space and there shall be no cross over / over-riding of armour wires /
formed wires. The minimum area of coverage of armouring shall be 90%. The breaking
load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc
rich paint shall be applied on armour joint surface of GS wires/formed wires.
Distinct extruded PVC inner sheath of black colour as per IS:5831 shall be provided for
the cables as follows:
a). For all multicore cables.
b). For single core armoured cables, where armouring is not being used as
metallic screen.
Outer sheath shall be of PVC black in colour. In addition to meeting all the requirements
of Indian standards referred to, outer sheath of all the cables shall have the following
FRLS properties.
(a.) Oxygen index of min. 29 (Test method as per IS 10810 Part-58)

(b.) Acid gas emission of max. 20% as per IEC-754 (Part-I)
(c.) Smoke density rating shall not be more than 60% during Smoke Density
Test as per ASTMD-2843.

Cores of three core cables shall be identified by colouring of insulation or by providing
coloured tapes helically over the cores, with Red, Yellow & Blue colours.
In addition to manufacturer's identification on cables as per IS, following

marking shall also be provided over outer sheath :
(a.) Cable size and voltage grade - To be embossed
(b.) Word 'FRLS' at every 5 metre - To be embossed
(c.) Screen Fault current _ _ _KA for _ _ _ Sec. ( Value of current & time shall
be indicated)
(d.) Sequential marking of length of the cable in metres at every one metre -
To be embossed / printed
The embossing / printing shall be progressive, automatic, in line and marking

shall be legible and indelible. For EPR cables identification shall be printed on
outer sheath
All cables shall meet the fire resistance requirement as per Category-B of
IEC-332 Part-3.
Allowable tolerances on the overall diameter of the cables shall be +\-2 mm
maximum over the declared value in the technical data sheets.
In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc.
are not acceptable.
The cross-sectional area of the metallic screen strip/tape/wires shall be considered in
sizing calculations.
The eccentricity shall be calculated as
tmax -tmin
------------ x 100
tmax
and the ovality shall be calculated as
dmax -dmin
------------ x 100
dmax
Where tmax/tmin is the maximum/minimum thickness of insulation and dmax/dmin

is the maximum / minimum diameter of the core.
The eccentricity of the core shall not exceed 10% and ovality not to exceed
2% .
Cable selection & sizing
HT cables shall be sized based on the following considerations:

a) Rated current of the equipment
b) The voltage drop in the cable, during motor starting condition, shall be
limited to 10% and during full load running condition, shall be limited to
3% of the rated voltage
c) Short circuit withstand capability
Derating Factors
Derating factors for various conditions of installations including the following
shall be considered while selecting the cable sizes:
a) Variation in ambient temperature for cables laid in air
b) Grouping of cables
c) Variation in ground temperature and soil resistivity for buried cables.
Cable lengths shall be considered in such a way that straight through cable
joints is avoided.
Cables shall be armoured type if laid in switchyard area, CHP area or directly
buried.
CONSTRUCTIONAL FEATURES
Cables shall conform to IS-7098 Part-II. These cables shall be multi-stranded,

compacted circular aluminium conductor, XLPE-insulated, metallic screened,
PVC outer sheathed. The conductor screen and insulation screen shall both
be of extruded semiconducting compound and shall be applied along with the
XLPE insulation in a single operation of triple extrusion process so as to
obtain continuously smooth interfaces. Method of curing shall be “dry curing /
gas curing / steam curing “ . The metallic screen for each core shall be
capable of carrying the system earth fault current and shall consist of copper
wires or tape with minimum overlap of 20%. However, for single core
armoured cables, the armouring shall constitute the metallic part of the
screening .
Trailing cables shall have tinned copper (class 5) conductor, insulated with
heat resistant elastomeric compound based on Ethylene Propyline Rubber
(EPR) suitable for withstanding 90 deg.C continuous conductor temperature
and 250deg C during short circuit, inner-sheathed with heat resistant
elastomeric compound, nylon cord reinforced, outer-sheathed with heat
resistant, oil resistant and flame retardant heavy duty elastomeric compound
conforming to IS 9968.
TYPE, ROUTINE AND ACCEPTANCE TESTS
a) The contractor shall carry out the type tests as listed in this specification on the
equipment to be supplied under this contract. The bidder shall indicate the
charges for each of these type tests separately in the relevant schedule of

Section - VII- (Forms & Procedures) and the same shall be considered for the
evaluation of the bids.
b) The type tests shall be carried out in presence of the employer’s

representative, for which minimum 15 days notice shall be given by the
contractor. The contractor shall obtain the employer’s approval for the type test
procedure before conducting the type test. The type test procedure shall clearly
specify the test set–up, instruments to be used, procedure, acceptance norms,
recording of different parameters, interval of recording, precautions to be taken
etc. for the type test(s) to be carried out.
c) In case the contractor has conducted such specified type test(s) within last ten
years as on the date of bid opening, he may submit during detailed engineering
the type test reports to the owner for waival of conductance of such type test(s).
These reports should be for the tests conducted on the equipment similar to
those proposed to be supplied under this contract and test(s) should have been
either conducted at an independent laboratory or should have been witnessed
by a client. The owner reserves the right to waive conducting of any or all the
specified type test(s) under this contract. In case type tests are waived, the
type test charges shall not be payable to the contractor.
d) All acceptance and routine tests as per the specification and relevant standards
shall be carried out. Charges for these shall be deemed to be included in the
equipment price
e) The type test reports once approved for any projects shall be treated as
reference. For subsequent projects of NTPC, an endorsement sheet will be
furnished by the manufacturer confirming similarity and “No design Change”.
Minor changes if any shall be highlighted on the endorsement sheet.
All types and sizes of cables being supplied shall be subjected to type tests, routine
tests and acceptance tests as specified below and according to relevant standards
The following type tests shall be carried out on one size each of 11/11KV cables.
Size shall be decided by the employer during detailed engineering
S. No Type Test Remarks
Conductor
1. Resistance test
For Armour Wires / Formed Wires
2. Measurement of Dimensions
3. Tensile Test
4. Elongation test
5. Torsion test For round wires only
6. Wrapping test
7. Resistance test

S. No Type Test Remarks
8(a) Mass & uniformity of Zinc Coating For GS wires/formed wires only.
tests
8(b) Adhesion test For GS wires/formed wires only
For XLPE insulation & PVC Sheath
9. Test for thickness
10. Tensile strength and elongation

test before ageing and after ageing
11. Ageing in air oven
12. Loss of mass test For PVC outer sheath only.
13. Hot deformation test For PVC outer sheath only.
14. Heat shock test For PVC outer sheath only
15. Shrinkage test
16. Thermal stability test For PVC outer sheath only
17. Hot set test For XLPE insulation only
18. Water absorption test For XLPE insulation only
19. Oxygen index test For PVC outer sheath only
20. Smoke density test For PVC outer sheath only
21. Acid gas generation test For PVC outer sheath only
22 Flammability test as per IEC-332 For completed cable only

Part-3 (Category -B)
The following type tests shall be carried out on each type(voltage grade) &
size of the cable:
S. No. Type Test For all cables
1. Insulation resistance test (Volume Resistivity method)
2. High voltage test
For cables of 11/11KV Grade only.
3. Partial discharge test
4. Bending test
5. Dielectric power factor test

a) As a function of voltage
b) As a function of temperature
6. Heating cycle test
7. Impulse withstand test
Indicative list of tests/ checks, Routine and Acceptance tests shall be as per
Quality Assurance & Inspection table of H.T. Cables enclosed.
5.7 Protections, Control and Metering

5.7.1 General System Description
It is intended to automate the Switchgears specified in the scope of supply and use
Communicable Numerical relays for Protection, Control, Metering and Status
monitoring. This specification is based on the understanding that an integrated
Automation System along with protections shall be provided and same shall have
provisions for Integration with DDCMIS system of the employer for diagnostics and
status monitoring. All the feeders shall be remote controlled from employer’s
DDCMIS and from the Data Concentrator/local console of the numerical relays(for
commissioning purpose) . Provision shall be made for monitoring, metering and
diagnostics from HMI station for all switchgears.
5.7.2 System Architecture and Requirements

The Bidder’s scope of work shall include the supply, delivery, installation, testing and
commissioning of the following:
a) Communicable Numerical Relays
b) Data Concentrators
c) LAN Network along with Ethernet Switches
d) HMI station (with Engineering work stations and printers)
e) Any other equipment required to the intended specification
The integration of the complete automation system (including all status, analogue
indications, alarms and controls) to enable the operator to monitor the complete
auxiliary power supply from the HMI station.
The point-to-point testing of all signals for the Switchgear network at the plant and
protection equipment end and the terminal end (data concentrators/Controller and
HMI Workstations) shall be the responsibility of the bidder. The Bidder shall provide
full details of the offered system Architecture with the Bid.
The system shall be a computer-based system that shall integrate independently
operating subsystems, such as Data Concentrators, Protection Units, Metering, and
Alarm annunciation, into a unified data acquisition, monitoring, protection. During
Bidding, the bidder shall provide details of any similar systems (previous generation
also acceptable) supplied by the contractor that are in successful operation.
The System architecture shall be flexible to allow future extensions.
Each component / module of the system including all the communication links, shall
be provided with built-in supervision and self-diagnostic features and any failures
shall be alarmed to the operator.

The offered equipment shall be of state of art technology and hardware shall be of
proven field track record. Vendor shall submit all type test reports for the offered
model along with the offer.
Vendor shall ensure availability of spare parts and maintenance support services for
the offered equipment for at least 15 years from the date of supply. Vendor shall give
a notice for at least one year to the user of equipment before phasing out the product
/ spares to enable user for the placement of order for spares and services.
Any foreign relay manufacturer through his Indian partner or subsidiary company in
India shall provide application, testing, commissioning and other necessary support
for minimum 15 years. They shall also maintain adequate inventory of each type of
relay or spares to meet the requirement arising during project execution and plant
operation.
5.7.3 Numerical relays
General requirements
b) All numerical relays, auxiliary relays and devices shall be of types, proven for the
application; satisfying requirements specified elsewhere and shall be subject to
Employer's approval. Numerical Relays shall have appropriate setting ranges,
accuracy, resetting ratio, transient overreach and other characteristics to provide
required sensitivity to the satisfaction of the Employer.
c) All relays and timers shall be rated for control supply voltage as mentioned
elsewhere under parameters and shall be capable of satisfactory continuous
operation between 80-120% of the rated voltage. Making, carrying and breaking
current ratings of their contacts shall be adequate for the circuits in which they are
used. Interrogation voltage for the binary inputs shall be suitably selected to ensure
avoidance of mal operation due to stray voltages.
d) The protective relays shall have at least 10 Nos potential free contacts
(Programmable). Auxiliary relays shall have contacts as required. Relay output
contacts shall be suitable for directly wiring in the breaker closing and trip circuit
operating from 240 V DC/120V DC control voltage.
e) Failure of a control or auxiliary supply and deenergisation of a relay shall not initiate
any circuit breaker /contactor operation. All relays shall withstand a minimum test
voltage of 2 kV AC rms for one minute.
f) All the numerical relays shall have communications on two ports, local front port
communication to laptop and a second port on IEC 61850 to communicate with the
data concentrator through LAN.
g) All Numerical relays shall have features for electrical measurement including
voltage, current, power (active/reactive) and energy parameters.
h) Mapping details of all the details shall be submitted in IEC format.
i) Relays shall have separate output for individual functionality and the master trip
shall be software configurable in case of multi output relays. Relays shall have
event recording feature, recording of abnormalities and operating parameters with
time stamping.
j) Preferably comprehensive single numerical relay shall have provision of both
current and voltage inputs. The current operated relay shall have provision for 4
sets of CT inputs, 3 nos. for phase fault & 1 CT input for earth fault. Relay shall be
suitable for both residually connected CT input as well as CBCT input. The voltage-
operated relay shall have provision for 3 PT inputs. Relays shall be suitable for CT

secondary current of 1A / 5A selectable at site. Relays used in incomers, tie and
bus couplers shall have provision of two sets of voltage signal inputs for the
purpose of synchronization.
k) All CT & PT terminals shall be provided as fixed type terminals on the relay to avoid
any hazard due to loose connection leading to CT opening or any other loose
connection. In no circumstances Plug In type connectors shall be used for CT / PT
connections. Vendor to ensure the same for all protective relay models offered.
l) All numerical relay shall have key pad / keys to allow relay setting from relay front.
All hand reset relays shall have reset button on the relay front. Relay to be self or
hand reset shall be software selectable. Manual resetting shall be possible from
remote.
m) Relays shall have suitable output contact for breaker failure protection.
n) Relays shall have self diagnostic feature with self check for power failure,
programmable routines, memory and main CPU failures.
o) Relays shall have at least two sets or groups of two different sets of adaptable
settings. Relays shall have multiple IEC/ ANSI programmable characteristics.
p) Design of the relay must be immune to any kind of electromagnetic interference.
Vendor to submit all related type test reports for the offered model along with the
offer.
5.7.4 Transformer Feeder Protections

The Transformer protection relay shall be suitable for providing the following protections
a. Three Phase Over current and Earth Fault protection (50 & 50 N1/50 N2)
The relay shall have over current and earth fault protection. The over current element
should have the minimum setting adjustable between 250-2000% of CT secondary
rated current. The instantaneous stage also should have cold load pick up (doubling)
feature to allow the lesser short circuit setting for better insulation life of transformer
while ensuring that relay does not mal operate during energizing of transformer. For
definite time delayed over current characteristic the pick up setting should have range of
minimum 150 % to 600 % with time delay of 0.3 sec to 3.0 sec. The second stage of
protection shall be with instantaneous operation.
The earth fault element should be suitable for both residually connected CT input as
well as CBCT input. With CBCT the relay shall be suitable for detection of earth fault
currents in the range of 10 mA secondary.
b. Restricted Earth Fault protection (64 R)
Restricted earth fault protection ( 64R ) connected between CT’s of LT incomer and
neutral of transformer. The protection should be provided with high stability circulating
current relays having pick up setting range of 10 to 40 % of CT secondary. Necessary
stabilizing resistors if required shall be provided.
c. Stand by earth fault protection (51 N)
The stand by earth fault protection should be of Definite time delay type provided having
a pick up setting range of 10% to 40% with a timer delay of 0.3 sec to 3 sec.
Transformer buchholz and WTI / OTI High trips shall be provided.
5.7.4.1 Protections for Incomers, Bus couplers and Tie feeders.

The Incomer, Bus Coupler & Tie feeder protection relay shall be suitable for providing
the following protections
1. The relay shall have over current and earth fault protection. The over current element
should have the minimum setting adjustable between 250-2000% of CT secondary
rated current. The earth fault element should be suitable for residually connected CT
input. The relay shall be suitable for detection of earth fault currents in the range of
5% to 10%. The relay should have built in Lockout feature.
2. Synchronizing check feature as a part of manual live change over and dead bus
closing feature for dead bus closing shall be provided.
3. Bus no volt signal shall be configured in the relay for employer’s use.
5.8 EARTHING
Earthing system shall be in strict accordance with IS:3043 and Indian

Electricity Rules/Acts.
Earthing system network/earthmat shall be interconnected mesh of mild steel
rods buried in ground in the plant. All off-site areas shall be interconnected
together by minimum two parallel conductors. The Contractor shall furnish the
detailed design and calculations for Employer's approval. Contractor shall
obtain all necessary statutory approvals for the system.
The earth conductors shall be free from pitting, laminations, rust, scale and
other electrical, mechanical defects
The material of the earthing conductors shall be as follows
1 Conductors above ground level and in built Galvanized steel
up trenches.
2 Conductors buried in earth Mild steel
3 Earth electrodes Mild steel rod
The sizes of earthing conductors for various electrical equipments shall be as below:
Equipment Earthing Conductor Earthing Conductor above
Buried in Earth ground level & in built-up
trenche
1 Main earth grid 40 mm dia. MS rod 65 x 8mm GS flat
2 11kV switchgear 65 x 8mm GS flat
equipment and --------
415V switchgear
3 415 V MCC/ 50 x 6mm GS flat
Distribution --------
boards /
Transformers
4 Fractional House -------- 8 SWG GS wire
power motor
5 1KW to 25 KW -------- 25 x 3mm GS flat
6 Columns, 50 x 6mm GS flat
structures, cable --------
trays and bus
ducts enclosures
Metallic frame of all electrical equipment shall be earthed by two separate and
distinct connections to earthing system, each of 100% capacity, Crane rails,
tracks, metal pipes and conduits shall also be effectively earthed at two

points. Steel RCC columns, metallic stairs, and rails etc. of the building
housing electrical equipment shall be connected to the nearby earthing grid
conductor by one earthing ensured by bonding the different sections of hand
rails and metallic stairs. Metallic sheaths/screens, and armour of multi-core
cables shall be earthed at both ends. Metallic Sheaths and armour of single
core cables shall be earthed at switchgear end only unless otherwise
approved. Every alternate post of the switchyard fence shall be connected to
earthing grid by one GS flat and gates by flexible lead to the earthed post.
Railway tracks within the plant area shall be bonded across fish plates and
connected to earthing grid at several locations. Portable tools, appliances and
welding equipment shall be earthed by flexible insulated cable
Each continuous laid lengths of cable tray shall be earthed at minimum two
places by G.S. flats to earthing system, the distance between earthing points
shall not exceed 30 meter. Wherever earth mat is not available , necessary
connections shall be done by driving an earth electrode in the ground
Neutral connections and metallic conduits/pipes shall not be used for the
equipment earthing. Lightning protection system down conductors shall not be
connected to other earthing conductors above the ground level.
Connections between earth leads and equipment shall normally be of bolted

type. Contact surfaces shall be thoroughly cleaned before connections.
Equipment bolted connections after being tested and checked shall be painted
with anti corrosive paint/compound.
Suitable earth risers as approved shall be provided above finished

floor/ground level, if the equipment is not available at the time of laying of
main earth conductor.
Connections between equipment earthing leads and between main earthing

conductors shall be of welded type. For rust protection the welds should be
treated with red lead compound and afterwards thickly coated with bitumen
compound. All welded connections shall be made by electric arc welding.
Resistance of the joint shall not be more than the resistance of the equivalent
length of conductors.
Earthing conductors buried in ground shall be laid minimum 600 mm below

grade level unless otherwise indicated in the drawing. Back filling material to
be placed over buried conductors shall be free from stones and harmful
mixtures. Back filling shall be placed in layers of 150 mm.
Earthing conductors embedded in the concrete floor of the building shall have
approximately 50 mm concrete cover.
A minimum earth coverage of 300 mm shall be provided between earth

conductor and the bottom of trench/foundation/underground pipes at
crossings. Earthing conductors crossings the road can be installed in pipes.

Wherever earthing conductor crosses or runs at less than 300 mm distance
along metallic structures such as gas, water, steam pipe lines, steel
reinforcement in concrete, it shall be bonded to the same.
Earthing conductors along their run on columns, walls, etc. shall be supported
by suitable welding / cleating at interval of 1000mm and 750mm respectively.
Earth pit shall be constructed as per IS:3043. Electrodes shall be embedded

below permanent moisture level. Minimum spacing between electrodes shall
be 600mm. Earth pits shall be treated with salt and charcoal if average
resistance of soil is more than 20 ohm meter.
On completion of installation continuity of earth conductors and efficiency of

all bonds and joints shall be checked. Earth resistance at earth terminations
shall be measured and recorded. All equipment required for testing shall be
furnished by contractor.
Earthing conductor shall be buried at least 2000mm outside the fence of

electrical installations. Every alternate post of the fences and all gates shall be
connected to earthing grid by one lead.
Other Requirements of Earthing System:
Standard/Code IEEE 80, IS 3043
Life expectancy 40 Years

System Fault Level As per system requirement
Soil resistivity Actual as per site conditions
Min. Steel corrosion 0.12mm/year
Depth of burial of main 600mm below grade level; where it crosses
earth conductor trenches, pipes, ducts, tunnels, rail tracks,
etc., it shall be at least 300mm below them.
Conductor joints By electric arc welding, with resistance of
joint not more than that of the conductor.
Welds to be treated with red lead for rust protection and then coated with
bitumen compound for corrosion protection.
Surface resistivity - Gravel 3000 ohm-meter
- Concrete 500 ohm-meter
5.9 Miscellaneous Electrical Works and Equipments

5.9.1 Cable Gland
The cable ends shall be terminated with adequate size metallic double compression
cable glands. Cable glands shall be of robust construction capable of clamping cable
and cable armour (for armoured cables) firmly without injury to insulation. The glands
shall be earthed at two locations. Suitable lock type crimping lugs shall be used for

cable end terminations. Where cables are raising from ground, suitable PVC pipe
guarding shall be provided for cable raising with sealing of the guarding PVC pipe
including a suitable clamp.
5.9.2 Cable lugs/ferrules

Cable lugs/ferrules for power cables shall be tinned copper solderless crimping type
suitable for aluminium compacted conductor cables. Cable lugs and ferrules for
control cables shall be tinned copper type. The cable lugs for control cables shall be
provided with insulating sleeve and shall suit the type of terminals provided on the
equipments. Cable lugs and ferrule shall conform to relevant standard
5.9.3 Cable Drums

a) Cables shall be supplied in non returnable wooden or steel drums of heavy
construction. The surface of the drum and the outer most cable layer shall be
covered with water proof cover. Both the ends of the cables shall be properly
sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to
eliminate ingress of water during transportation, storage and erection. Wood
preservative anti-termite treatment shall be applied to the entire drum. Wooden
drums shall comply with IS: 10418.
b) Each drum shall carry manufacturer's name, purchaser’s name, address and
contract number, item number and type, size and length of cable and net gross
weight stenciled on both sides of the drum. A tag containing same information
shall be attached to the leading end of the cable. An arrow and suitable
accompanying wording shall be marked on one end of the reel indicating the
direction in which it should be rolled.
c) The standard drum length for power cables shall not be less than 500 meters.
The length per drum shall be subjected to a maximum tolerance of +/- 5% of the
standard drum length. The Employer shall have the option of rejecting cable
drum with shorter lengths. For each size, the variance of total quantity, adding all
the supplied drum lengths, from the ordered quantity, shall not exceed +/-2%.
5.9.4 Trefoil clamps

Trefoil clamps for single core cables shall be pressure die cast aluminum or fibre
glass or nylon and shall include necessary fixing accessories like G.I. nuts, bolts,
washers, etc. Trefoil clamps shall have adequate mechanical strength to withstand
the forces generated by the peak value of maximum system short circuit current.
5.9.5 Cable Clamps & Straps

The cable clamps required to clamp multicore cables on vertical run shall be made
up of Aluminium strip of 25x3 mm size. For clamping the multicore cables, self-
locking, de-interlocking type nylon clamps/straps shall be used. The clamps/straps
shall have sufficient strength and shall not get affected by direct exposure to sun
rays and outdoor environment
5.9.6 Receptacles
Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot
dipped gavanised or of die-cast aluminium alloy of thickness not less than 2.5 mm.

The boxes shall be provided with two nos. earthing terminals, gasket to achieve IP55
degree of protection, terminal blocks for loop-in loop-out for cable of specified sizes,
mounting brackets suitable for surface mounting on wall/column/structure, gland
plate etc. The ON-OFF switch shall be rotary type heavy duty, double break,AC23
category, suitable for AC supply. Plug and Socket shall be shrouded Die-cast
aluminium. Socket shall be provided with lid safety cover. Robust mechanical
interlock shall be provided such that the switch can be put ON only when the plug is
fully engaged and plug can be withdrawn only when the switch is in OFF position.
Also cover can be opened only when the switch is in OFF position. Wiring shall be
carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of
adequate size. The Terminal blocks shall be of 1100 V grade. The Terminal blocks
shall be of 1100 V grade made up of unbreakable polymide 6.6 grade with adequate
current rating and size. The welding receptacles shall be provided with inbuilt ELCB
rated for suitable mA sensitivity.
5.9.7 Trenches
PCC flooring of built up trenches shall be sloped for effective drainage with sump pits
and sump pumps.
No sub zero level cable vault/trenches shall be provided below control

building/switchgear rooms in plant.
General
The cable slits to be used for motor/equipment power/control supply shall be sand
filled & covered with PCC after cabling.
Sizing criteria, derating factors for the cables shall be met as per respective
chapters. However for the power cables, the minimum conductor size shall be 6
sq.mm. for aluminium conductor and 2.5 sq.mm. for copper conductor cable.
Conscious exceptions to the above guidelines may be accepted under special

conditions but suitable measures should be taken at such location to:
• Meet all safety requirements

• Safeguard against fire hazards, mechanical damage, flooding of water, oil
accumulation, electrical faults/interferences, etc
5.9.8 Cable trays, Fittings & Accessories

Cable trays shall be ladder/perforated type as specified complete with matching
fittings (like brackets, elbows, bends, reducers, tees, crosses, etc.) accessories (like
side coupler plates, etc. and hardware (like bolts, nuts, washers, G.I. strap, hook
etc.) as required. Cable tray shall be ladder type for power & control cables and
perforated for instrumentation cables.
Cable trays, fittings and accessories shall be fabricated out of rolled mild steel
sheets free from flaws such as laminations, rolling marks, pitting etc. These
(including hardware) shall be hot dip galvanized as per relevant IS.

Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard
lengths of 2.5 metre. Thickness of mild steel sheets used for fabrication of cable
trays and fittings shall be 2 mm. The thickness of side coupler plates shall be 3 mm.
Cable troughs shall be required for branching out few cables from main cable route.
These shall be U-shaped, fabricated of mild steel sheets of thickness 2 mm and shall
be hot dip galvanised as per relevant IS. Troughs shall be standard width of 50 mm
& 75 mm with depth of 25 mm
Support System for Cable Trays
Cable tray support system shall be pre-fabricated similar or equivalent to "Unistrut

make".
Support system for cable trays shall essentially comprise of the two components i.e.
main support channel and cantilever arms. The main support channel shall be of two
types : (i) C1:- having provision of supporting cable trays on one side and (ii) C2:-
having provision of supporting cable trays on both sides. The support system shall
be the type described hereunder
a. Cable supporting steel work for cable racks/cables shall comprise of various
channel sections, cantilever arms, various brackets, clamps, floor plates, all
hardwares such as lock washers, hexagon nuts, hexagon head bolt, support
hooks, stud nuts, hexagon head screw, channel nut, channel nut with springs,
fixing studs, etc.
b. The system shall be designed such that it allows easy assembly at site by
using bolting. All cable supporting steel work, hardwares fitings and
accessories shall be prefabricated factory galvanised.
c. The main support and cantilever arms shall be fixed at site using necessary
brackets, clamps, fittings, bolts, nuts and other hardware etc. to form various
arrangements required to support the cable trays. Welding of the components
shall not be allowed. However, welding of the bracket (to which the main
support channel is bolted) to the overhead beams, structural steel, insert
plates or reinforcement bars will be permitted. Any cutting or welding of the
galvansied surface shall be brushed and red lead primer, oil primer &
aluminium paint shall be applied
d. All steel components, accessories,fittings and hardware shall be hot dip

galvanised after completing welding, cutting, drill ing and other machining
operation.
e. The main support channel and cantilever arms shall be fabricated out of 2.5
thick rolled steel sheet conforming to IS.
f. Cantilever arms of 320 mm, 620mm and 750 mm in length are required, and
shall be suitable for assembling the complete arm assembly on to component

constructed of standard channel section. The back plate shall allow sufficient
clearance for fixing bolt to be tightened with tray in position.
g. Support system shall be able to withstand
• weight of the cable trays

• weight of the cables (75 Kg/Metre run of each cable tray)
• Concentrated load of 75 Kg between every support span.
• Factor of safety of minimum 1.5 shall be considered.
Nevertheless, the support system shall be designed by the bidder to fully meet the
requirements of type tests as specified. In case the system fails in the tests, the
components design modification shall be done by the Bidder without any additional
cost to the Employer. The bidder shall submit the detailed drawings of the system
offered by him alongwith the bid.
5.9.9 Pipes, Fittings & Accessories
Pipes offered shall be complete with fittings and accessories (like tees, elbows,
bends, check nuts, bushings, reducers, enlargers, coupling caps, nipples etc.) The
size of the pipe shall be selected on the basis of maximum 40% fill criteria
GI Pipes shall be of medium duty as per IS:1239
Duct banks shall be High Density PE pipes encased in PCC (10% spare of each
size, subject to minimum one) with suitable water-proof manholes.
Hume pipes shall be NP3 type as per IS 458.

6.0 CIVIL WORK
6.1 FENCING
The SPV Plant along with security cabin shall be fenced with combination of
metallic chain link and barbed wire. The height of fencing shall be atleast 2 m above
the ground.
Metallic chain link fencing shall be provided upto 1.6 m above ground with pole
spacing of 2.50 m between adjacent posts. The mesh size of chain link fencing shall
be 50X50 mm of 8 gauge GI wire. The balance 0.4 m shall comprise of fencing of
barbed wire on half Y steel post. The barb wire shall confirm to conforming to IS:
278. The spacing shall of barbed wires shall be maximum 12.5cm center to center.
Pathways between solar panels shall leveled for easy movement of O&M personal
Pathway shall be PCC type with brick soling whenever there is change in elevation.
PCC shall be 1:3:6 & at least 100 mm thickness. Brick should be class II or better
class. The width of the pathways shall be designed so as to carry panel & daily
maintenance. Approach road to control rooms/HT Switchgear room/inverter room
shall be flexible type bituminous of width at least 3.75 m with one meter shoulder
each side as per IRC.
6.2 Control Monitoring and Control Stations(CMCS)
For the operation & maintenance of SPV Plant the central CMCS shall be built at an
area of minimum 200 sq.m which shall have
1. Air conditioned SCADA room
2. Store Room
3. Pantry
4. Toilet and Urinal
In addition to CMCS, inverter room shall be located near to its corresponding solar
arrays. The cumulative total area of Inverter room shall not be less than 1200 sq. m
and total nos. shall not be less than ten (10). The specification of inverter room shall
be as per Cl. 6.5
The bidder to submit the proposed drawing of CMCS along with the bid to the owner
for approval.
The building shall be designed to meet national building code requirement.
i) RCC Works
All RCC works shall be of design mix as per IS 456-2000 and the materials
used viz. Cement reinforcement, steel etc. shall be as per relevant IS
standards. In addition IS: 2502 Code of Practice for Bending and Fixing of
Bars for concrete Reinforcement must be complied. Reinforcement shall be
high strength TMT Fe 415 or Fe 500 conforming to “IS: 1786-1985”
ii) Masonry work

All brick works shall be using at least II class bricks of approved quality as per
IS 2212 and IS: 3495. The cement mortar for brick masonry shall be in the
ratio 1 cement and 5 sand by weight. The cement mortar shall be machine
mixed. Bricks required for masonry work shall be thoroughly soaked in clean
water tank for approximately two hours. Brick shall be laid in English bond
style. Green masonry work shall be protected from rain. Masonry work shall
be kept moist on all the faces for a period of seven days.
iii) Doors & Windows :
Doors, windows and ventilators of air-conditioned areas, entrance lobby of all

buildings (where ever provided), and all windows and ventilators of main plant
and service building shall have, electro colour dyed (anodised with 15 micron
coating thickness) aluminium framework with glazing. Each window of
Control room should have venetian blinds
All doors of toilet areas shall be of steel framed solid core flush shutter. All
other buildings doors windows ventilators (unless otherwise specified) shall be
of steel.
The doors frames shall be fabricated from 1.6 mm thick MS sheets and shall
meet the general requirements of IS: 4351. Steel windows and ventilators
shall be as per IS:1361 and IS:1038.All windows and ventilators on ground
floor of all buildings shall be provided with suitable grill.
Minimum size of door provided shall be 2.1 m high and 1.2 m wide. However
for toilets minimum width shall be 0.75 m and office areas minimum width
shall be 1.20m.
The main entrance shall include Mild Steel single leaf door. The structural
steel shall conform to IS: 7452 and IS: 2062. The holdfasts shall be made
from steel flats (50 mm and 5 mm thick). The fixtures, fastenings and door
latch are to be made with same materials.
All Windows shall be metal steel framed and manufactured from low carbon,
hot-rolled Z-bar steel sections, and 25 mm wide and of minimum thickness 3
mm, drilled and tapped for hardware. The top of frames shall be provided
with rain lip.
Each window unit shall have a solid bronze polished, cam locking handle and
strike. All steel windows shall be suitably painted after fabrication in
accordance with the relevant Indian Standard(s).
Fixing of metalled doors and windows shall be done in accordance to IS: 1081
and IS 7452.
Doors and windows on external walls of the buildings (other than areas
provided, with insulated metal claddings) shall be provided with RCC
sunshade over the openings with 300 mm projection on either side of the
openings. Projection of sunshade from the wall shall be minimum 450 mm

over window openings and 750 mm over door openings except for main
entrance door to the control room where the projection shall be 1500mm.
iv) Glazing
All accessible ventilators and windows of all buildings shall be provided with
min. 4mm thick float glass, plain or tinted for preventing solar radiations,
unless otherwise specified.
For single glazed aluminium partitions and doors, float glass of 8mm or 10
mm thickness shall be used. All glazing work shall conform to IS:1083 and
IS:3548.
6 mm reflective toughened glass, with following minimum technical

characteristics: Solar factor 45% or less, U-value less than 5.7 W/
SQMK,VLT min 35%: The glass to be used should be from the
manufacturers of glass like Glavebel (Belgium), Saint Gobain (France) or Fort
(USA) Or equivalent. The glass should be free from distortion and thermal
stress
v) Plastering:
All external surfaces shall have 18 mm cement plaster in two coats, under
layer 12 mm thick cement plaster 1:5 and finished with a top layer 6 mm thick
cement plaster 1:6 (DSR 13.19) with water proofing compound. White cement
primer shall be used as per manufacturer’s recommendation.
At least one coat of plaster shall be applied to interior walls by hand or

mechanically, to a total thickness of 12 mm using 1:6, 1 cement and 6 sand.
Plastering shall comply to IS: 1542, IS:1661, IS:1630. Oil bound washable
distemper on smooth surface applied with 2 mm thick Plaster of Paris putty for
control room.
Plaster of Paris (Gypsum Anhydrous) conforming to IS:2547 shall be used for

plaster of Paris punning.
vi) Flooring:
The Cement shall be ordinary Portland cement as per IS:269.

Flooring for all air conditioned areas and offices area shall be provided with
vitrified ceramic tiles of size 600X 600 mm of min 9 mm thickness, laid with 3
mm ground joints as per approved pattern, painted neatly with 3X4 mm
stainless epoxy grout or equivalent
Flooring for stores, security cabin shall be of cement concrete flooring as per
IS 2571-1970.
Heavy duty (Grade V) dust pressed ceramic tiles (300X 300 mm) as per IS
13755, shall be provided for flooring of toilets and pantries.

For pantry slab floor mirror polished (6 layers of polish) Granite stone (slab) of
minimum thickness of 18 mm shall be used.
vii) Roofing.
Roof of the C.R. Building shall consist of Cast-in-situ RCC slab treated with a
water proofing system which shall be an integral cement based treatment
conforming to CPWD specification (item no. 25.8 of DSR 1997). The roof of
the building shall be water proof with tarfelt 5 layer over screeding. The roof
shall be designed for minimum superimposed load to 150 kg/m2.
For efficient disposal of rainwater, the run off gradient for the roof shall not be
less than 1:100 and the roof shall be provided with RCC water gutter,
wherever required. Gutter shall be made water tight using suitable watertight
treatment. This gradient can be provided either in structure or subsequently
by screed concrete 1:2:4 (using 12.5 mm coarse aggregate) and/or cement
mortar (1:4). However, minimum 25 mm thick cement mortar (1:4) shall be
provided on top to achieve smooth surface.
viii) Painting of Walls & Ceilings
The paint shall be anti-fungal quality of reputed brand suitable for masonry
surfaces for high rainfall zone. All painting on masonry or concrete surface
shall preferably be applied by roller. If applied by brush then same shall be
finished off with roller. For painting on concrete, masonry and plastered
surface IS:2395 shall be followed. All paints shall be of approved make
including chemical resistant paint. Minimum 2 finishing coats of paint shall be
applied over a coat of primer.
For painting on steel work and ferrous metals, BS: 5493 and IS:1477 shall be
followed. The type of surface preparation, thickness and type of primer,
intermediate and finishing paint shall be according to the painting system
adopted.
The cement paint as per as per IS : 5410 shall be of approved brand and
manufacturer. Ceiling of all rooms except Battery room shall be white
washed. The ceiling of Battery room (if provided) shall be acid resistant paint.
ix) Plinth Protection
Plinth protection shall be provided around all the buildings with Brickbats and
PCC 1:2:4 & smoothly finish of top surface.
x) Water supply
GI pipes of Medium quality conforming to IS 1239 (Part I-1990) and IS 1795-

1982 (reaffirmed 1990) for Mild Steel pipes shall be used for all water supply
and plumbing works.
The Syntax or equivalent make PVC storage water storage tank conforming to

IS:12701 shall be provided over the roof of the control room with adequate
capacity for 10 No person and 24 hr requirement, complete with all fitting
including float valve, stop cock etc. The capacity of the tank shall be minimum
500 litres.
xi) Plumbing and Sanitary
Each toilet shall have the following minimum fittings.

(a) WC (Western type) 390 mm high with toilet paper roll holder and all fittings
and WC (Indian Type) with all fittings (both types of WCs shall be provided
at alternate locations).
(b) Urinal (430 x 260 x 350 mm size) with all fittings.
(c) Wash basin (550 x 400 mm) with all fittings.
(d) Bathroom mirror (600 x 450 x 6 mm thick) hard board backing
(e) CP brass towel rail (600 x 20 mm) with C.P. brass brackets
(f) Soap holder and liquid soap dispenser
All fittings, fastener, grating shall be chromium plated. Necessary plumbing

lines shall be provided for office cum control room building and Security cabin.
The floor finish for washroom, pantry and toilet shall be vitrified ceramic anti-
slip tiles and Dado glaze ceramic tiles upto 2.1m shall be used. The normal
size of Ceramic tiles shall be 300 mm X 300 mm X 9 mm and shall comply IS:
15622.
The bidder shall design & provide below ground one septic tank and two soak
pits and assuming that a total of 10 No. person shall be working for O&M in
combined three shift.
The pantry shall consist of one number stainless steel pantry sink, as per IS :
13983, of size 610 x 510 mm, bowl depth 200 mm with drain board of at least
450 mm length with trap, with inlet and outlet connections and GI concealed
water supply pipe of minimum 12 mm dia of medium class, sanitary pipe of
minimum 75 mm diameter, floor trap with Stainless Steel grating, inlet and
outlet connections for supply and drainage, with all bends, tees, junctions,
sockets, etc., as are necessary for the commissioning and efficient functioning
of the pantry (all sanitary fittings shall be heavy duty chrome plated brass,
unless noted otherwise)
xii) Electrification of Building
Electrification of building shall be carried out as per IS 732-1989, IS 4648-

1968 and other relevant standards.
xiii) Stairs:
Bidder to provide service ladder made up of aluminium with load bearing

capacity of atleast 150 kg to access the roof for maintenance of
communication equipment and water tank.

xiv) False Ceiling:
The control room shall be provided with false ceiling of 15 mm thick mineral
fibre board, in tile form of size 600mm x 600mm, along with galvanised light
gauge rolled form supporting system in double web construction pre painted
with steel capping, of approved shade and colour, to give grid of
maximum size of 1200x600 mm as per manufacturers details including
supporting grid system, expansion fasteners for suspension arrangement
from RCC, providing openings for AC ducts(if required), return air grills(if
required), light fixtures, etc., all complete.
xv) Lighting
The lighting design of the buildings shall be carried out as per IS 3646-1992.
The average illumination level of control room shall be 300 Lux with Mirror
optics with anti-glare type or Decorative Mirror optics type of fixture. The
building shall be provided with adequate light fittings, 5A/ 15A 1 phase
sockets, fans etc. controlled by required ratings of MCBs and MCB DBs. All
MCBs / Isolators shall be mounted inside the panel and a bakelite/fibre glass
sheet shall be provided inside such that operating knobs project out of it for
safe operation against accidental contact. Operating handle of incoming
MCCB/isolator shall project out of door. Wiring inside the panel shall be
carried out with 1100V grade PVC insulated stranded copper conductors of
adequate size.
6.3 WATER WASHING ARRANGEMENT FOR MODULE

Bidder shall provide permanent arrangement for module washing by installing
minimum five (05) nos. of tube wells with pump and motor
The scope of work shall also include laying of GI pipes for each row of PV
panels with sufficient nos. of manual isolating valves. Bidder shall also
provide manual interconnecting valve to connect between the water supply
of one network to other to meet water requirement in case of outage of one
pump
Bidder shall provide the single line diagram of water washing arrangement
with location of pump to NTPC for approval.
6.4 Drainage System

Suitable water drainage system for rainy & storm water.
6.5 SPECIFICATION OF INVERTER ROOM

Cladding system should be a weather tight building envelope, suitable for
complete life of solar plant. The layout of Inverter room shall be designed so
as to divert the heat generated from each inverter outside the room. The
inverter room shall be designed for a life of 25 years. The successful bidder
shall have to get the structural design done as per the prevailing IS codes.
The structural design of inverter room of each identical type shall have to be

proof checked by any IIT / NIT. The structure design shall have to be got
approved from NTPC, before actual start of the work.
i. Structure:
The steel structure of the Shelter shall be designed for loads and load
combination as per Indian Standards (latest revisions) such as IS: 875,
IS:1893, IS:800, IS:456 etc
The steel shall be hot-dipped galvanized with a minimum Z180 coating for
load bearing applications and Z120 for non-load bearing applications.
Alternately, the steel hot-dipped in Alum/Zinc (with 55% Aluminium and 45%
Zinc) can be also used. The applicable codes are ASTM A653 for galvanized
and ASTM A792 for Galvalume/Zincalume.
ii. Fasteners:
Steel bolts, nuts and washers complying with AS 1112:2000. Self-drilling
screws complying with AS 3566.1 and AS 3566.2 shall be used.
iii. Roof:
The roofing shall be double skin trapezoidal profile sheet of pre-painted 0.45
mm BMT (Base Metal Thickness) Hi Tensile Zincalume/Galvalume 0.5 TCT,
confirming to IS:513 and ASTM A792M/AS1397.
Stiffening ribs / subtle fluting for effective water shedding and special male /
female ends with full return legs on side laps for purlin support and anti-
capillary flute in side lap
Both upper and lower sheets shall be separated through spacers and
fastened through zinc /zinc-tin coated self drilling screws. The fastener size
shall be calculated as per the design or manufacturers recommendations.
Both sheets shall be sandwiched with an under insulation of 50mm thick

glass wool of density 50 kg/m3 with aluminum foil backing and complete with
gutters and down take pipes. Along with Flashing & Top cap of required size
and color complete with all necessary hardware complete. Roof shall be
projected atleast 600 mm from the wall.
iv. Doors Frames

Door frames shall be of T-iron frame of mild steel Tee-sections as per DSR-
2007 item no 10.13. All doors shall be provided necessary fittings like hinges,
handles, mortice locks, tower bolts, stopper, hydraulic door closer, magic eye
(for main doors) etc of CP brass complete as detailed in tender drawing or
submitted by bidder in shop drawing and approved by NTPC.
Black powder coated aluminium doors shall be with extruded built up standard
tubular sections, appropriate Z sections and other sections of approved make
conforming to IS:733 and IS:1285, fixed to Pre-engineered structure including
necessary filling up of gaps at junctions with required PVC/neoprene felt etc
including hinges / pivots and double action hydraulic floor spring of approved
brand and manufacture IS:6315 marked, lock, handle and all necessary
fittings

The door entrance shall include Mild Steel single leaf door. The structural
steel shall conform to IS: 7452 and IS: 2062. The holdfasts shall be made
from steel flats (50 mm and 5 mm thick). The fixtures, fastenings and door
latch are to be made with same materials.
v. Windows Frame:
Aluminium black powder coated section, frame shall be of 92x31 mm,
minimum 16G thick as per approved design
vi. Ventilators
Aluminum black powder coated frame of minimum size 62x25 mm and 16G
thick as per approved design. Suitable sunshades made out of approved
colour sheet reinforced with Aluminium angle frame of minimum 35x35x4 mm
size with soffit of same material will be provided to all external windows and
door. The minimum projection for the sunshades will be 450 mm and 300mm
wider than the width of the opening
vii. Plinth Protection:

750 wide plinth protection 50 mm thick of cement concrete 1:3:6 (1cement : 3
coarse sand : 6 graded stone aggregate 20 mm nominal size) over 75 mm
bed of dry brick ballast 40 mm nominal size well rammed and consolidated
and grouted with fine sand including finishing the top smooth, shall be
provided around the Pre-Engineered Structure.
viii. Floor Finish

Flooring, including preparation of surface, cleaning etc shall be of cement
concrete flooring as per IS 2571-1970 with ironite hardener. The inverter
room floor shall be atleast 30 cm above the ground level.
IX. Wall Cladding:

The walls shall be of double skinned trapezoidal profile sheet of pre-painted
0.45 mm BMT (Base Metal Thickness) Hi Tensile Zincalume/Galvalume 0.5
TCT, confirming to IS:513 and ASTM A792M/AS1397. The profile shall be
trapezoidal.
Both the walls should be separated by spacers system made up of cold

formed steel bars and fastened through zinc /zinc-tin coated self drilling
screws.
X. Wall Insulation:
All voids of external and internal metalled walls shall be filled with 50 mm thick
Mineral glass Wool/rockwool insulation of density 50 kg/m3 covered with high
strength meshless Aluminium foil with proper supports etc as approved.
XI. Painting
The exterior sheet(roof as well as wall) shall have total paint thickness of 25
micrometre comprising of 20 micrometre exterior coat of Super Durable
Polyester (XRW) and 5 micrometer primers coats.

Other faces of sheets shall be painted with 10 micron polyester over 5
micrometre primer coats. The colour shade shall be subject to NTPC approval
XII. Lighting:
The inverter room shall be provided with electric light to achieve average
illumination level of 75 Lux. However room should be designed to utilised
maximum natural light during the day.

7.0 GENERAL REQUIREMENTS
7.1 SUBMISSION OF ENGINEERING DATA & DRAWINGS
The bidder shall submit the following Engineering drawings, data, design and
engineering information in both soft copy (CD) and hard copy to owner along with a
“Master Drawing List”:
1. SPV array and cable layout.
2. Module foundation
3. Main & service road with general drainage
4. ACDB Layout
5. Earthing
Any other Engineering drawings, data, design and engineering information (whether
specifically mentioned in the document or not) require to fulfil the stated scope of
work shall be deemed to be included.
7.2 Auxiliary Power Requirement
Arrangement of auxiliary power supply during construction and O&M period shall be
in the scope of the bidders. Bidder shall install transformer(s) of suitable rating for
auxiliary power requirements of lighting, water pumps, Electronics equipments,
switchgear panels etc.
7.3 MANDATORY SPARES & CONSUMABLES
Mandatory spares are listed at relevant schedule of Bid Proposal sheet are those
which are considered essential by the Owner. The Owner reserves the right to buy
any or all of these spares. The Bidder shall furnish the itemized and total prices.
In compliance with the requirements of tender documents, the prices for mandatory
spares must be given separately, and shall be used for bid evaluation purposes. All
mandatory spares shall be delivered at site.
Bidder shall maintain the mandatory spares, consumables & various components of
SPV plant for smooth running during O&M period. Bidder shall also replenish the
consumed mandatory spares during the O&M period to maintain the stock as
mentioned in Bid Proposal Sheet. The bidder shall also mention the source of
supply.
7.4 Fire protection & Fire fighting system
The SPV plant shall be equipped with suitable fire protection & fire fighting systems
for protection of entire equipment switchyard & control room as per CEIG
requirements. Bidder shall comply with recommendation of Tariff Advisory
Committee to incurring minimal premium for insurance. The installation shall meet all
applicable statutory requirements, safety regulations in terms of fire protection.
Bidder to provide following number of portable fire extinguisher

CO2 Foam Type Hand Portable
DCP Type (ABC
Type Hand 9 kg pressurized
type) (10 Kg. Hand 9 Water C02
Cap) kg 9 Litre
Control Room 1 1 1
Inverter room 1 1 1 1
Bidder to provide intelligent microprocessor based main fire alarm panel of modular
construction complete with central processing unit, input and output modules, power
supply module, supervision control and isolator modules with 10% spare provisions.
Fire detection alarm system shall include alarm initiating devices e.g. multisensor
type smoke detectors and alarm notification Appliances (Audio device).
Multisensor type smoke detectors shall be provided for below false ceiling areas of
control room and ACDB and/or inverter room. One (01) sensor shall be provided for
each 25 sqm of area.
Fire Alarm Control Panel Indication

(a) Alarm conditions shall be immediately displayed on the control panel. Alarm
LED shall flash on the control panel until the alarm has been acknowledged.
Once acknowledged the LED shall remain lit. A subsequent alarm received
from another zone after acknowledgement shall illuminate the alarm LED and
the panel display shall show the new alarm information.
(ii) During an alarm condition, an alarm tone shall sound within the control panel
until the alarm is acknowledged.
(iii) If the audible alarm signals are silenced for any reason, they shall
automatically resound if another zone is activated.
(iv) All alarm signals shall be automatically “locked in” at the control panel until the
operated device is returned to its normal condition and the control panel is
manually reset
7.5 TRIAL RUN
SPV Plant site shall be deemed to be successfully erected & commissioned after
submission of relevant commissioning certificate from concerned Authorities.
During the trial operation, SPV plant shall perform trouble-free operation for
cumulative 72 hours during which functionality of all plant components shall be
demonstrated and the system shall be in Generating mode.
7.6 WARRANTY
The successful bidder shall provide a warranty covering mechanical structure,

electrical works including PCU/inverters/maximum power point tracker
unit/distribution boards/digital meters/switchgear and overall workmanship of the

solar power plants/system against any manufacturing/design/installation defects for a
period of five (5) years.
The warranty period shall commence from the date of successful completion of trial
run as per clause No 7.5
7.7 INSURANCE
The bidder’s insurance liabilities pertaining to the scope of works are detailed out in
Clauses titled Insurance in General Conditions of Contract.
7.8 TAKING OVER
Upon successful completion of all the facilities pertaining to the scope of work
contractor shall approach the owner in writing for “final take over” of the plant. On
receipt of such request, owner shall issue to the contractor a taking over certificate
as a proof of the final acceptance of the system. Such certificate shall not relieve the
Contractor of any of his obligations which otherwise survive, by the terms and
conditions of the Contract after issuance of such certificate.

8.0 SPECIFICATION FOR OPERATION AND MAINTENANCE CONTRACT
The successful bidder shall provide Operation and maintenance of SPV Plant for a
period of one year from date of completion of trial run. During O&M period, NTPC
personnel shall have unrestricted entry to the Solar plant and Control Room any
time. NTPC may depute its personals to associate with O&M activities. Contractor
shall assist them in developing expertise through their day to day O&M activities. All
records of maintenance must be maintained by the contractor which can be
accessed by NTPC on demand. These recordings are to be handed over to NTPC
after the O&M period of contract.
After O&M period, NTPC may at its discretion decide to extend the existing O&M
contract on mutually acceptable terms & conditions or undertake the O&M of the
SPV Plant on its own.
The bidder shall be responsible for supply of all spare parts, repairs / replacement of
any defective equipment(s) including civil works at his own cost as required from
time to time during the O&M period.
The contractor shall be responsible for all the required activities for the successful
running, optimum energy generation etc.
(a) Deputation of O&M, engineering and supporting personal.

(b) Ensure, successful running of SPV Plant for optimum energy generation.
(c) Safety and protection of the plant by deputing sufficient security personals
(d) Monitoring, controlling, troubleshooting, maintaining of records, registers.
(e) Supply of all spares, consumables and fixing / application of the same.
(f) Cleaning of the plant including array yard on regular basis and as and when
required.
(g) Normal and preventive maintenance of the plant such as cleaning of module
surface, tightening of all electrical connections, line accessories, transformers
and associated switchgear on the HT side.
(h) Conducting periodical checking, testing, over hauling and preventive action.
(i) Submission of periodical reports to the owner on the energy generation &
operating conditions of the SPV plant.
(j) NTPC shall take only Fire & Allied Peril insurance during O&M period. All
other type of insurance during O&M period shall be taken by the bidder.
(k) Daily work of the operators involves logging the voltage, current, power factor,
power and energy output of the SPV plant, temperature, logging down
individual array output data once a day
(l) The operator shall record monthly energy output of each array and
transformer and reports shall be prepared on performance of SPV plant.
(g) The contractor shall at his own expense provide all amenities to his
workmen as per applicable laws and rules.
(m) The Contractor shall ensure that all safety measures are taken at the site to
avoid accidents to his employees or his Co-contractor’s employees
(n) The Contractor shall immediately report the accidents, if any, to the Engineer
In charge & to all the concerned authorities as per prevailing laws of the state.

(o) The Contractor shall comply with the provision of all relevant Acts of Central
or State Governments including payment of Wages Act 1936, Minimum
Wages Act 1948, Employer's Liability Act 1938, Workmen's Compensation
Act 1923, Industrial Dispute Act 1947, Maturity Benefit Act 1961, Employees
State Insurance Act 1948, Contract Labor (Regulations & Abolishment) Act
1970 or any modification thereof or any other law relating whereto and rules
made there under from time to time.
(p) In order to ensure longevity, safety of the core equipment and optimum
performance of the system the contractor should use only genuine spares of
high quality standards.

9.0 PERFORMANCE GUARANTEE (PG) TEST
The final acceptance test as to prove the Performance Guarantee shall be

conducted at Site by the Contractor in presence of the Employer. The PG test
procedure shall be submitted by successful vendor after the award of contract for
review and finalization of Corporate Operation Services. This test shall be binding on
both the parties of the Contract to determine compliance of the equipment with the
functional guarantee. Any special equipment, instrumentation tools and tackles
required for the successful completion of the Performance Guarantee Test shall be
provided by the Contractor free of cost. The accuracy class of the instrumentation
shall be as per the relevant clause of documents.
The procedure for PG demonstration test shall be as follow:
1. A calibrated pyranometer shall be installed by the Contractor at the location

mutually agreed by Contractor and NTPC. The test report for the calibration
shall be submitted by the Contractor for approval by NTPC. The output of this
pyranometer for three months of the PG test shall be made available at
SCADA.
2. Actual energy exported from the plant supplied by the Contractor shall be
recorded for three consecutive months. Actual energy exported shall be
measured by energy meter installed in 11 kV incomer breaker at 11 kV bus of
11/132 kV substation.
3. This measured value of energy at step-2 shall be compared with “Base

Generation” for the PG test.
4. “Base Generation” for a month is the quoted generation by the bidder in the
Technical Datasheet with a correction factor to take into account the actual
average global solar radiation measured by the calibrated pyranometer for
three months at step-1.
Following factors shall be considered for computing the “Base Generation”
a) Effect due to variation of meteorological parameters e.g. ambient temperature,

wind speed, humidity etc shall not be considered.
b) Generation loss due to grid outage (or power evacuation system which is not in
the scope of the Bidder): The measured global solar radiation of the period of the
outage of the power evacuation system shall be excluded to calculate average
global solar radiation for the period of PG test.
If bidder is not able to demonstrate PG test during these three (03) months he will be
given one more chance to demonstrate the PG test. In that case the steps for PG
test shall be repeated again as above.

Further, if the plant is not able to achieve the calculated “Base Generation” during
the PG test period and there is a shortfall in energy generation, then the contractor
shall compensate NTPC with an amount equivalent to the loss of revenue based on:
Shortfall LD will be levied @ ` 120.71 per kWhr shortfall.
A sample calculation for arriving at the “Base generation” for the month of May to
July and total short fall in energy at Rajgarh site has been done as given in next
page. However NTPC at its discretion may choose any three month for the purpose
of performance guarantee test.

A sample calculation for Total Short fall in Energy for Design life for 50 MW allotted Capacity
Month Global Solar Quoted Measured Exported Energy in The calculated Shortfall in energy
Radiation Generation average Global MWhr measured at “Base Generation” for PG test
(kwh/m2/day) (MWhr) by the Solar Radiation 11 kV incomer in MWhr (e-d)
(Data provided bidder (kwh/m2/day) of breaker at 11/132 kV (b x c)/a
by NTPC) (b) the month of June Substation. (e)
(a) by pyranometer (d)
(c)
May 7.324 8740.597 6.732 7887.208 8034.093 146.885
June 7.669 7235.010 7.223 7015.023 6814.249 -200.774
July 6.533 5829.372 6.873 5912.747 6132.752 220.005
Total Short fall in Energy for the May to July : 146.885-200.774+220.005= 166.116
Quoted Yearly Generation by the bidder : 78.661 MU or MWhr
Quoted Generation of the Quarter by the bidder : 8740.597+7235.010+5829.372= 21804.978
Total Short fall in Energy for one year : 78,661 x 166.116/21804.978= 599.2608 MWhr
Yearly loss of Revenue : 15.39 x 599.2608 x 1000 = ` 92.22624
Lakhs
Present Worth Factor taking discount factor
of 12% for 25 Years : 7.84313
Applicable LD for not achieving PG Test : 7.84313 x 92.22624 Lakhs = ` 723.3424

Lakhs
LD for Per Unit shortfall of Generation : 7.84313 x 15.39 = ` 120.71
Note:
a- Based on Solar Radiation Data of MNRE/NREL
b- Assumed Generation for Sample calculation by REDG
c- Global Solar Radiation measured during test period
d- Actual measured Generation
` 15.39 is the CERC notified tariff which shall be applicable for the project and it has been taken for the financial appraisal of the project

10.0 QUALITY ASSURANCE CHAPTERS
Following QA chapters are attached

a. 11 KV Switchyard equipments
b. Cabling & earthing, Lightning Protection
c. Control cable
d. Pyannometer, anemometer, thermometers
e. LT Switchgear
f. LT Bus Duct
g. Power Conditioning Unit
h. SCADA
i. SPV Module
j. Power Transformers
k. LT power cable
l. HT Cables
m. Civil Work

a. 11 KV Switchyard Equipments
Attributes / Make, model, Routine & Functional
Characteristics Type & Rating, Acceptance Test as requirement
Test Certificate per IS / IEC s as per
NTPC
Items/Components Specificatio
Sub Systems n
Circuit Breaker (IEC:62271-100) Y Y Y

Interruptor & hollow insulator
Y Y Y
(IEC:233/ IS:5284)
Isolator (IEC:62271-102) Y Y Y
Current Transformer (IEC:60044) Y Y Y
Voltage Tramsformer
Y Y Y
(IEC:)
Bus Post Insualtor
Y Y Y
(IEC:168 / 273 / IS:2544)
Disc,Pin & String Insualtor
Y Y Y
(IEC:383 / IS:731)
Surge Arrestor (IEC:99-4) Y Y Y
Hardware fittings for Insulator
Y Y Y
(IS:2486 / BS:3288)
Spacer Clamps & Connector
Y Y Y
(IS:10162 / 5561)
Aluminium Tube
Y Y Y
(IS:5082 / 2673 / 2678)
Conductor (IS:398) Y Y Y
Galvanised Steel Structures
Y Y Y
(IS:2062/2629/4759/6745)
Vibration Damper (IS:9708) Y Y Y
Sag Compensating Spring
Y Y Y
DIN:2089/2096 IS:3195 / 7906
Control & Relay Panel Y Y Y
Leakage Current Analyser Y Y Y
Protection Relays Y Y Y
Tariff Metering System as per IEC 62052- Y
11 & 62053-22 & IS 14697) Y Y
Synchronising Trolley Y Y Y
Relay Test Kit Y Y Y
Surge Monitor Y Y Y
Notes : 1) This is an indicative list of test/checks. The manufacture is to furnish a detailed

Quality Plan indicating the practice and procedure along with relevant supporting
documents during QP finalisation for all items.
2) All major Bought Out Items will be subject to NTPC approval.

b. CABLING, EARTHING, LIGHTNING PROTECTION
ATTRIBUTES /
CHARACTERISTICS
Constructional feature as per NTPC Specification

Acceptance tests as per relevant standard &
Routine tests as per relevant standard &
Paint shade, paint thickness, adhesion
Bought out items/Bill of material

Galvanise Test (If Applicable)
Pre-treatment of sheet
Deflection test*
Surface finish
IP protection
specification
specification
Proof load*
Dimension
Functional
HV & IR
ITEMS/COMPONENTS /
SUB SYSTEMS
Wall Mounted-Lighting Panel Y Y Y Y Y Y Y Y Y Y Y Y

(IS-513, IS:5, IS:2629, 2633,
6745)
Switch box/junction box/ Y Y Y Y Y Y Y Y Y Y Y Y
Receptacles Panel (IS-513,
IS:5, IS:2629, 2633, 6745)
Cable glands(BS-6121) Y Y
Cable lug(IS-8309) Y Y
Lighting wire(IS-694) Y Y
Flexible conduits Y Y Y
Conduits(Galvanise & Epoxy) Y Y Y Y Y
IS-9537 & IS-2629,2633 ,6745
RCC Hume Pipe (IS-458) Y
Cable termination & straight Y Y Y
through joint (VDE-0278)
Cable Trays, Flexible supports Y Y Y Y Y Y Y Y Y Y Y
system & accessories IS-513,
2629,2633,6745
Trefoil clamp Y Y
GI flats for earthing & lighting Y Y Y Y Y
protection (IS 2062, 2629,
6745,2633)
GI wire (IS-280) Y Y
Fire Sealing System ( BS – Y Y Y
476)
.Note:1.This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality Plan
indicating the practice and procedure along with relevant supporting documents.
2.* Deflection Test on cable trays and Proof Load test on cable trays support system will be as per details
given in the NTPC technical specification & approved MQP. The above acceptance tests shall be done
only on one sample from each size of offered lot.
3. Make of all items will be subject to NTPC approval.

c.LT Control Cable
(1.1 KV PVC Cables)
Attributes /
Armour coverage, cross over, looseness,
Thermal stability of insulation and outer

after ageing of insulation &outer sheath
Sequential marking/surface finish/cable
relevant standard & page 2 & 3 of this

Tensile strength, elongation before &
Characteristics
Constructional feature as per NTPC

Routine & Acceptance test as per
Anti termite treatment on wooden drums
gap between two armour wire
Dimension/surface finish
Make, Type, Rating, T.C
Chemical Composition
Mechanical Properties
Lay length/Sequence
Electrical Properties
FRLS Test
Spark Test
Item / Components /
Sub System Assembly
sheath
length
Copper Conductor (IS-8130) Y Y Y Y Y
PVC Compound (IS-5831) Y Y Y Y
FRLS PVC Compound IS- Y Y Y Y
5831
ASTM-D-2843/ IS 10810
(Part-58 )
IEC 60754 Part-1
Armour wire/strip (IS-3975) Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554- 1 ) Y Y Y Y Y Y Y Y Y
ASTM-D-2843/ IS 10810
(Part-58 )
IEC-60754 Part-1
Swedish Chimney: SEN SS
424-1475( F3 category)
Flammability test IEC-60332
Part-3 Cat-B
Wooden drum( IS : 10418) / Y Y
Steel drum
• 1.Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed
quality plan indicating the Practice and procedure along with relevant supporting documents.
(1) Drum number (2) IS 1554 (3)Cable size, Voltage grade , Words “ FRLS” & Screen Fault Current & duration at every 5 meter is to
be embossed. Embossing shall be automatic, in line & marking shall be legible & indelible. (3) Sequential marking of length of cable in
meter at every one meter is to be embossed / printed. Embossing / printing shall be progressive, automatic, in line & marking shall be
legible & indelible

CONTROL CABLE
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all types &
sizes.
Following shall constitute routine tests:
1) Conductor Resistance test
2) High voltage test at room temperature
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size of the cables
on the cable drums selected at random as per sampling plan mentioned in IS: 1554
Part 1
A) For Conductor
1) Annealing test For copper conductor only
2) Resistance test
B) For Armour Wires / Formed Wires ( If applicable )

1) Measurement of Dimensions
2) Tensile Tests
3) Elongation Test
4) Torsion Test For Round wires only
5) Wrapping Test
6) Resistance Test
7) Mass of Zinc coating test For G S wires / Formed wires
only
8) Uniformity of Zinc coating For G S wires / Formed wires
only
9) Adhesion test For G S wires / Formed wires
only
10) Freedom from defects
C) For PVC insulation & PVC Sheath

1) Test for thickness
2) Tensile strength & Elongation before ageing
D) For completed cables

1) Insulation resistance test ( Volume resistivity method )
E) Following tests shall be carried out and only one sample shall be taken from each
offered lot of all sizes for these tests:-
1) Thermal stability test on PVC insulation and outer sheath
2) Oxygen index test on outer sheath

3) Smoke density rating test on outer sheath as per ASTM –D 2843
4) Acid gas generation test on outer sheath as per IEC –60 754 (Part 1)
F) Ageing test on PVC insulation and PVC outer sheath as per following:
In case of regular manufacturers:-

Samples as per relevant IS from every size per type of cable in the offered lot shall be
tested for tensile strength & elongation (before ageing). The values will be compared
with corresponding values mentioned in the type test report accepted by NTPC. In case
values of tensile strength & elongation (before ageing) are within + /- 15% of the type
test reports then 1 sample per type of cable of offered lot will be put on accelerated
ageing test. The accelerated ageing test procedure: sample to be put in air oven at
temperature of 130^c +/- 2^c for 5 hours, tensile strength & elongation acceptance
norms as per relevant IS. However in case the tensile strength and elongation values are
not within +/- 15% of type test values then ageing test will be carried out on that
particular size of cable of offered lot as per relevant IS.
In case of new manufacturers / suppliers (supplying first time to NTPC through

corporate contract):-
with corresponding values mentioned in the type test report accepted by NTPC. In case
values of tensile strength & elongation (before ageing) are not within + /- 15% of the
type test reports then sample from that particular cable size will be put on ageing test as
per relevant IS. However not withstanding above condition, 1 sample per cable type of
offered lot will be put on ageing test as per relevant IS.
G) Flammability test as per IEC 60332 - Part- 3 (Category- B) on completed cable as

per following sampling plan.
The test shall be carried out on every size & type of control cable offered for inspection
as an acceptance test. This test will be carried out using composite sampling i.e.
irrespective of sizes of cables of a particular type, may be tested together as per
calculations in line with the IEC ( all sizes will be covered)
H) Following tests shall be carried on one length of each size of offered lot:
Surface finish, length measurement, sequence of cores, armour coverage, Gap between
two consecutive armour wires / formed wires

d. Pyaronometer, anemometer, thermometers:
Routine test reports as per relevant standard
Calibration tests reports as per standard
Test report (TR): Should be supplied with the unit after all tests. The TR shall include
detailed description of all parameters tested qualified and warranted.

e. LT SWITCHGEAR
( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL MOTOR
STARTERS)
ATTRIBUTES /
All Routine tests as per NTPC spec. & relevant

Degree of Protection Routine test as per NTPC
CHARACTERIS-
Paint Shade, Adhesion, Thickness & Finish

TICS
Functional & Operational Features as per
Item to conform to relevant Standards

Make, Model, Type, Rating & TC
Pretreatment as per IS 6005

Dimensions & Finish
Chemical properties
Electrical properties
Milli-volt drop Test

Functional Checks
IR – HV – IR Test
NTPC Spec.
ITEMS/
COMPONENTS/
spec
SUB SYSTEM
std.
ASSEMBLIY
Sheet Steel (IS : Y Y Y Y Y
513)
Aluminum Bus bar Y Y Y Y Y Y
Material
(IS : 5082)
Copper Bus bar Y Y Y Y Y Y
Material
(IS : 613)
Support Insulator Y Y Y Y Y
Air Circuit Breaker Y Y Y Y Y Y Y
( IEC: 60947)
Energy Meters ( IS Y Y Y Y Y Y
: 13010, 13779 )
Power & Aux. Y Y Y Y Y
Contactors
(IEC : 60947 )
Protection & Aux. Y Y Y Y Y Y
Relays
Control & Selector Y Y Y Y Y
Switches
(IEC : 60947 )
CT’s & PT’s ( IS Y Y Y Y
2705 / 3156)
MCCB (IEC : Y Y Y Y
60947 )
Indicating Meters ( Y Y Y Y Y Y
IS : 1248 )
Indicating Lamps ( Y Y Y Y Y
IS : 13947 )
Air Break Switches Y Y Y Y Y
(IEC : 60947 )
Control Terminal Y Y Y Y
Blocks

LT SWITCHGEAR
( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL
MOTOR STARTERS)
ATTRIBUTES /
CHARACTERIS-
Functional & Operational Features as per
Degree of Protection Routine test as per

TICS
All Routine tests as per NTPC spec. &

Item to conform to relevant Standards
Paint Shade, Adhesion, Thickness &

Make, Model, Type, Rating & TC
Pretreatment as per IS 6005

Dimensions & Finish
Chemical properties
Milli-volt drop Test

Functional Checks
ITEMS/
NTPC Spec.
relevant std.
NTPC spec
COMPONENT
S/ SUB
SYSTEM
ASSEMBLIY
Fuse ( IS 13703) Y Y Y Y
Control Y Y Y Y Y Y
Transformer
( IS : 12021)
Push Buttons ( IS Y Y Y Y Y
: 4794 )
Transducer ( IEC Y Y Y Y Y Y
: 60688)
MCB ( IS : Y Y Y Y Y
8828)
Breaker Y Y Y Y Y Y
Handling Trolley
Synthetic Rubber Y Y Y Y Y
Gasket
LT Y Y Y Y Y Y Y Y Y Y Y
SWITCHGEAR
( IS : 8623 )
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan
2. Makes of all major Bought Out Items will be subject to NTPC approval.

f. LT BUSDUCT
ATTRIBUTES ,
Degree of Protection routine test as per NTPC spec.

CHARACTERIST
ICS
Weld Quality Check ( DP test & x-ray Test)
Galvanizing Test as per IS 2629/ 2633/ 4759

Paint Shade, Thickness, Adhesion & Finish
WPS Approval, Welder Qualification
Tightness by Torque measurement

Item to conform to relevant IS
Dimension & Surface Finish
Make, Type, Rating & TC
Phase Sequence Check

Electrical Clearances
Chemical Properties
ITEM,
COMPONENTS,
SUB SYSTEM
ASSEMBLY
Aluminum Sheets / Y Y Y Y Y Y Y
Plates / Strips /
Flexibles / tubes
( IS : 5082 / 737 )
CRCA Flats / Y Y Y Y Y
ISMC ( IS 2062 )
Neoprene / Y Y Y Y
Synthetic Rubber
Gaskets
Rubber Bellows Y Y Y Y
(IS : 3400)
Support Insulator Y Y Y Y
Galvanized Y Y Y Y
Structure & GI
Earthing Flat
(IS : 2629 / 2633 /
4749 )
Space Heater & Y Y Y
Thermostat
LT Busduct (IS : Y Y Y Y Y Y Y Y Y Y Y
8623 PART 2)
Notes:
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed
Quality Plan indicating the practice and
procedure along with relevant supporting documents.
2. Makes of all major Bought Out Items will be subject to NTPC approval.

g. PCU quality plan:
A) Bought out components & raw material checks, as per internal standards of the manufacturer
B) in-process checks, as per internal standards of the manufacturer
C) Routine tests as per following on the assembled PCU:

1) Function Test to demonstrate operation of its control system and the ability to be
automatically synchronized and connected in parallel with a utility service, prior to its
shipment.
2) Operation of all controls, protective and instrumentation (metering) circuits
demonstrated by direct test if feasible or by simulation
3) Functional check on protection circuits for faults and isolation protection for utility service
interface including calibration
4) Function testing of operation of start up , disconnect and shutdown controls including,

stable operation of the PCU and response to control signals
5) Test to measure maximum power point tracking (MPPT) performance under varying
outdoor conditions using a PV array / PV array simulator.
D) Following sample tests will be carried out on PCU:
Sample testing to include measurement of phase currents, efficiencies, harmonic content

and power factor at 25, 50, 75 and 100% of the rated nominal power.
Test report (TR): Should be supplied with the unit after all tests as per approved quality plan. The
TR shall include detailed description of all parameters tested qualified and warranted.

h. SCADA System
Functional Check for Control Element , Annunciation ®

TESTS
Review of TC for instruments/ Devices/ Recorders,

Indicators/ Mosaic Items/ Transducers ®
GA, BOM ,Lay Out of components ®
Component Rating/ Make / Type ®
Accessibility of TBS/ Devices ®
Test as per Std ® & ( A)

Thickness/Adhesion ®
Dimensions ®
Illumination ®
Paint Shade/
IR & HV ®
Wiring ®
Visual ®
Mimic ®
ITEMS
1. SCADA Panel Y Y Y Y Y Y Y Y Y Y Y Y Y
Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality
Assurance Programme in General Technical Conditions
2) This is an indicative list of test/ checks. The manufacturer is to furnish a detailed quality
plan indicating the Practice and Procedure alongwith relevant supporting documents.
Y - Test Applicable , ® - Routine Test (A) - Acceptance Test

i. SPV module:
SPV modules quality plan should include the following:
A) raw material checks, as per internal standards of the manufacturer
B) in-process checks, as per internal standards of the manufacturer
C) routine tests as per relevant standard on the assembled module.
D) sample tests as per following:

1) SPV modules to be checked visually for following defects:
a) Scratches on the frame and/or glass
b) Excessive or uneven glue marks on glass or frame
c) Gap between frame and glass due to poor sealing
d) Always lower output than stated in data sheet
e) Always lower fill factor than indirectly stated in data sheet
f) Inconsistant cell colors
g) Undurable panel label printing
h) completeness of module in all respects
i) sealing arrangement of module in compliance with relevant type test reports
2) Performance of SPV module at STC
3) Insulation test
4) Robustness of terminations
5) Mechanical load test
Factory test report (FTR): Should be supplied with the unit after all tests as per approved quality
plan. The FTR shall include detailed description of all parameters tested qualified and warranted.

j. Power Transformer
Voltage Ratio, Vector Group
Routine Test as per relevant

Attributes /
Characteristics
NDT / DPT / MPI / UT

Test / Rating /
Visual & Dimensional
Mechanical properties
Compatibility with oil
Model / TC / General
& Polarity, Magnetic
Physical Inspection.
Thermal properties
Electrical strength
WPS & PQR

Ageing Test.
Routine Test
Make / Type
Balance
Items/Components Checks
Sub Systems
test
Tank, H.V. & L.V. Cable
Y Y Y
Box / Flange throat
Conservator / Radiator /
Y Y Y
Cooler / Pipes
Copper Conductor (IS:191) Y Y Y Y
Insulating Material Y Y Y Y Y Y
CRGO Lamination & Built Y Y Y Y Y
Core
Bushing / Insulator
Y Y Y Y
( IS:2544 / 5621)
Gasket Y Y Y Y Y
Transformer Oil Y
OLTC / Off-Circuit Tap
Y Y Y
Changer
Core Coil Assembly & Pre- Y Y
tanking
Marshalling Box Y Y Y Y
WTI, OTI, MOG, PRD,
Breather, Terminal
Y Y
Connector, Bucholz Relay,
Globe & Gate Valve,
Welding (ASME Sect-IX) Y Y
Complete Transformer
Y Y
(IS:2026/ IEC-60076)
Note: 1) This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality
Plan indicating the practice and procedure along with relevant supporting documents.
2) All major Bought out Items will be subject to NTPC approval.

k. LT Power Cables
(1.1 KV & XLPE Cables )
Attributes /
Tensile strength, elongation before & after ageing of

Characteristics
Thermal Stability of insulation and outer sheath *
Constructional / requirement as per NTPC Spec.

Sequential marking/surface finish /cable length
Armour coverage, Cross over, looseness, Gap
Relevant Standard and NTPC specification

Anti ternite treatment on wooden drums
Routine and acceptance test as per

between two armour wire/strip
Make, Rating, Type & TC
insulation & outer sheath

Lay length / Sequence

Hot set test (XLPE)

Item / Components /
FRLS Test
Spark Test
Sub System Assembly
Aluminum (IS-8130) Y Y Y Y Y
PVC Compound (IS-5831) Y Y Y Y
XLPE Compound(IS-7098 Part-I) Y Y Y Y Y
FRLS PVC Compound(IS-5831 ) Y Y Y
ASTM-D-2843/ IS 10810 (Part-58)
IEC-60754 Part-I
Armour wire/strip (IS-3975) Y Y Y
Insulated Core Y Y Y Y
Laid up core Y Y
PVC Inner sheath Y
Armouring Y Y
Outer sheath Y Y Y Y Y
Finish cable (IS-1554 & 7098 – Part-1) Y Y Y Y Y Y Y Y Y
ASTM-D-2843/ IS 10810 ( Part- - 58 )
IEC-60754 Part-I
Swedish Chimney SS 4241475 for (F3
category)
Flammability test IEC-60332 Part –3
Cat-B
Wooden drum (IS-10418) / Steel drum Y Y
Note: This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the practice and procedure
along with relevant supporting documents.
∗ 2. Not applicable for XLPE insulation
(1) Drum number (2) IS 1554 / 7098-Part I (3)Cable size, Voltage grade , Words “ FRLS” & Screen Fault Current & duration at
every 5 meter is to be embossed. Embossing shall be automatic, in line & marking shall be legible & indelible. (3) Sequential
marking of length of cable in meter at every one meter is to be embossed / printed. Embossing / printing shall be
progressive, automatic, in line & marking shall be legible & indelible

ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all types & sizes.

ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size of the
cables on the cable drums selected at random as per sampling plan mentioned in
IS: 1554 Part 1 & IS 7098 Part-I
A) For Conductor
3) Annealing test For copper conductor only
4) Tensile test For aluminium conductor only
5) Wrapping test For aluminium conductor only
6) Resistance test
12) Tensile Tests
13) Elongation Test
15) Wrapping Test
16) Resistance Test
only
only
only
C) For PVC / XLPE insulation & PVC Sheath
4) Hot set test For XLPE insulation only

F) Ageing test on PVC / XLPE insulation and PVC outer sheath as per following:

with corresponding values mentioned in the type test report accepted by NTPC. In
case values of tensile strength & elongation (before ageing) are within + /- 15% of the
type test reports then 1 sample per type of cable of offered lot will be put on
accelerated ageing test. The accelerated ageing test procedure: sample to be put in air
oven at temperature of 130^c +/- 2^c for 5 hours, tensile strength & elongation
acceptance norms as per relevant IS. However in case the tensile strength and
elongation values are not within +/- 15% of type test values then ageing test will be
carried out on that particular size of cable of offered lot as per relevant IS.

with corresponding values mentioned in the type test report accepted by NTPC. In
case values of tensile strength & elongation (before ageing) are not within + /- 15% of
the type test reports then sample from that particular cable size will be put on ageing
test as per relevant IS. However not withstanding above condition, 1 sample per cable
type of offered lot will be put on ageing test as per relevant IS.

The test shall be carried out on every size & type of control cable offered for
inspection as an acceptance test. This test will be carried out using composite sampling
i.e. irrespective of sizes of cables of a particular type, may be tested together as per
calculations in line with the IEC ( all sizes will be covered)
H) Following tests shall be carried on one length of each size of offered lot:
Surface finish, length measurement, sequence of cores, armour coverage, Gap between

l. H.T CABLES
Armour coverage, cross over, looseness, gap

Attributes /
Constructional requirements feature as per
Routine & Acceptance Test as per relevant

T.S & elongation before & after ageing on
Metallic ( Cu ) Screening ( If applicable)

Characteristics
Sequential marking/surface finish/ cable
Anti termite coating on wooden drums

Hot Set Test/ Eccentricity & Ovality
Thermal seability on outer sheath
standard & NTPC specification

Make, Type, Rating & T.C
Spark Test(as applicable)
outer sheath & insulation

Lay length & Sequence

Mechanial properties
NTPC specification
between two wire
Item / Curing Properties
Components /
FRLS Test
Sub System
Assembly
length
Aluminium (IS-8130) Y Y Y Y Y
Semiconducting Y Y Y Y
Compound
XLPE Compound Y Y Y Y Y
(IS-7098 Part-II)
FRLS PVC Compound Y Y Y Y Y
(IS-5831, ASTM-
D2843, IS10810( Part
58)
,IEC-60754 Part-1)
Triple Extrusion & Y Y Y Y
curing /Manufacturing
of Core
Copper Tape Y Y Y Y
Polyster tape Y Y
Armour wire/strip Y Y Y
Copper tapping Y Y Y
Inner sheath Y Y
Armouring Y Y
Outer Sheathing Y Y Y Y Y Y
Power Cable (Finished) Y Y Y Y Y Y Y Y Y
(IS : 7098 Part II,
IEC : 60332 (Part 3
Cat. B), IS-5831,
ASTM-D2843,
IS10810(Part 58) ,
IEC-60754 Part-1)

Wooden drum(IS- Y Y
10418) /Steel Drum
Notes:
3. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan
4. Make of all major Bought Out Items will be subject to NTPC approval.
5. (1) Drum number (2) IS 7098-Part II (3)Cable size, Voltage grade , Words “ FRLS” & Screen Fault Current & duration at every 5 meter
is to be embossed. Embossing shall be automatic, in line & marking shall be legible & indelible. (3) Sequential marking of length of cable in
meter at every one meter is to be embossed / printed. Embossing / printing shall be progressive, automatic, in line & marking shall be
legible & indelible
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all types &
sizes.

6) High voltage test
7) Partial discharge test ( for Screened cables only )
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size of the cables
on the cable drums selected at random as per sampling plan mentioned in IS: 7098
Part 1I
A) For Conductor
7) Tensile Test
8) Wrapping Test
9) Resistance test

22) Tensile Tests
23) Elongation Test
25) Wrapping Test
26) Resistance Test
only
only
only
C) For XLPE insulation & PVC Sheath

3) Hot set test (For XLPE insulation)

6) High voltage test
3 Partial discharge test ( for Screened cables only )
F) Ageing test on XLPE insulation and PVC outer sheath as per following:

tested for tensile strength & elongation (before ageing). The values will be compared with
corresponding values mentioned in the type test report accepted by NTPC. In case values
of tensile strength & elongation (before ageing) are within + /- 15% of the type test
reports then 1 sample per type of cable of offered lot will be put on accelerated ageing
test. The accelerated ageing test procedure: sample to be put in air oven at temperature of
130^c +/- 2^c for 5 hours, tensile strength & elongation acceptance norms as per relevant
IS. However in case the tensile strength and elongation values are not within +/- 15% of
type test values then ageing test will be carried out on that particular size of cable of
offered lot as per relevant IS.

tested for tensile strength & elongation (before ageing). The values will be compared with
corresponding values mentioned in the type test report accepted by NTPC. In case values
of tensile strength & elongation (before ageing) are not within + /- 15% of the type test
reports then sample from that particular cable size will be put on ageing test as per
relevant IS. However not withstanding above condition, 1 sample per cable type of
offered lot will be put on ageing test as per relevant IS.

The test shall be carried out on 1 sample per type of cable offered irrespective of sizes
offered as an acceptance test.
F) Following tests shall be carried on one length of each size of offered lot:

1) Surface finish, length measurement, sequence of cores, armour coverage, Gap between
2) Measurement of Eccentricity & Ovality

m. Civil Works
QUALITY ASSURANCE AND INSPECTION FOR CIVIL WORKS
INTRODUCTION
This part of the specification covers the sampling, testing and quality assurance requirement
(including construction tolerances and acceptance criteria) for all civil and structural works covered
in this specification.
This part of the technical specification shall be read in conjunction with other parts of the technical
specifications, general technical requirements & erection conditions of the contract which covers
common QA requirements. Wherever IS code or standards have been referred they shall be the latest
revisions.
The rate for respective items of work or price shall include the cost for all works, activities,
equipment, instrument, personnel, material etc. whatsoever associated to comply with sampling,
testing and quality assurance requirement including construction tolerances and acceptance criteria
and as specified in subsequent clauses of this part of the technical specifications. The QA and QC
activities in all respects as specified in the technical specifications/ drawings / data sheets / quality
plans / contract documents shall be carried out at no extra cost to the owner.
The contractor shall prepare detailed construction and erection methodology scheme which shall be
compatible to the requirements of the desired progress of work execution, quality measures, prior
approvals if any and the same shall be got approved by the Engineer. If required, work methodology
may be revised/ reviewed at every stage of execution of work at site, to suit the site conditions by
the contractor at no extra cost to the owner.
QA AND QC MANPOWER
The contractor shall nominate one overall QA coordinator for the contract detailing the name,
designation, contact details and address at the time of post bid discussions. All correspondence
related to Quality Assurance shall be addressed by the contractor’s QA coordinator to NTPC. NTPC
shall address all correspondence related to Quality issues to the contractor’s QA coordinator. The
contractor’s QA coordinator shall be responsible for co‐ordination of Quality activities between
various divisions of the contractor and their sub‐vendors on one hand & with NTPC on the other
hand.
The contractor shall appoint a dedicated, experienced and competent QA&QC in‐charge at site,
preferably directly reporting to the Project Manager, supported as necessary by experienced
personnel, to ensure the effective implementation of the approved QAP. The contractor shall finalize
and submit a deployment schedule of QA&QC personnel along with their details to NTPC for
approval/ acceptance and further shall ensure their availability well before the start of the concern
activity.
SAMPLING AND TESTING OF CONSTRUCTION MATERIALS
The method of sampling for testing of construction materials and work / job samples shall be as per
the relevant IS / standards / codes and in line with the requirements of the technical specifications /
quality plans. All samples shall be jointly drawn, signed and sealed wherever required, by the
contractor and the engineer or his authorized representative.
The contractor shall carry out testing in accordance with the relevant IS / standards / codes and in
line with the requirements of the technical specifications / quality plans. Where no specific testing

procedure is mentioned, the tests shall be carried out as per the best prevalent engineering practices
and to the directions of the Engineer. All testing shall be done in the presence of the engineer or his
authorized representative in a NABL accredited / Govt. Laboratory acceptable to NTPC. This includes
all IITs, NCB, CSMRS, reputed government / autonomous laboratories / organizations, NITs and
other reputed testing laboratories. The test samples for such test shall be jointly selected and sealed
by the engineer and thereafter these shall be sent to the concerned laboratory through the covering
letter signed by NTPC engineer. The test report along with the recommendations shall be obtained
from the laboratories without delay and submitted to NTPC.
PURCHASE AND SERVICE
Structural steel supply if in the scope of the contractor shall be procured from main steel producers
like SAIL, TISCO, IISCO, RINL, Essar Steel, Ispat Industries, JSW Steel, Lloyds Steel, Jindal Steel &
Power. In case of non‐availability of some of the sections with main steel producers the contractor
may propose to procure the sections from the re‐rollers of the main steel producers, the name of
such re‐rollers will have to be cleared by corporate quality assurance of NTPC for which details such
as BIS approval, main steel producer’s approval, past experience for production of sections of
specified material, details of machines plants testing facilities etc., Confirmation that the process
control and manufacturing of steel sections by re‐rollers shall be same as that of main steel
producers, that billets for re‐rolling will be sourced from main steel producers only shall be
furnished with regards to re‐roller.
Even after clearance of re‐rollers, induction of billets with identified and correlated Mill test
certificates (TC’s) in the process of re‐rolling, sampling of steel, quality checks thereof and stamping
of final product for further identification and correlation with TC’s prior to dispatch shall be the
responsibility of the contractor and these shall be performed in presence of the authorized
representative of the main Contractor.
Reinforcement steel supply if in the scope of the contractor shall be procured from main steel
producers like SAIL, TISCO, IISCO, RINL, Essar Steel, Ispat Industries, JSW Steel, Lloyds Steel, Jindal
Steel & Power, Jai Balaji Industries Ltd, Durgapur (for 8‐40mm reinforcement steel) and mill test
certificates (TC) is to be obtained and submitted to NTPC for co‐relation. In case any size /diameter
specified is not available with main steel producers and are proposed to be supplied from the
conversion agent of the main steel producer the name of such conversion agent / re‐roller shall have
to be approved by NTPC for which details such as BIS approval, Main steel producer’s approval, Past
experience for production of sections of specified material, details of machines, plants testing
facilities etc., and confirmation that the process control and manufacturing of steel sections by re‐
rollers is the same as that of main steel producers, that billets for re‐rolling are sourced from main
steel producers only shall be furnished with regards to re‐roller.
The other conditions are covered in the chapter ‘GTR’.
FIELD QUALITY PLAN
Well before the start of the work, the contractor shall prepare and submit the Field Quality Plans
(FQP) on the format No. QS‐01‐QAI‐P‐09/F2‐R1, and obtain approval of NTPC, which shall detail out
for all the works, equipments, services, quality practices and procedures etc in line with the
requirement of the technical specifications to be followed by the contractor at site. This FQP shall
cover for all the items / activities covered in the contract / schedule of items required, right from
material procurement to completion of the work at site. An Indicative Field Quality Plan for civil
works is enclosed at Annexure – I (Indicative FQP for civil works) & Annexure – II (Indicative FQP for
structural steel works).

GENERAL QA REQUIREMENTS
The contractor shall ensure that the works, BOIs and services under the scope of contract whether
manufactured or performed within contractor’s works or at his sub‐contractor’s premises or at the
NTPC’s site or at any other place of work are in accordance with the NTPC technical specification,
applicable standards / codes, approved drawings / data sheets / quality plans and BOQ. All the
works, BOIs and services shall be carried out as per the best prevalent engineering practices and to
the directions of the Engineer.

Part-B
LIST OF EXHIBITS

Exhibit-1
Exhibit-2
A
TEST REPORT
OF
SUB-SOIL INVESTIGATION
FOR
Rajgarh Solar Energy Park

DISCUSSIONS AND INTERPRETATION OF TEST RESULTS
1. GENERAL NATURE OF SOIL STRATA
The result of lab test and bore hole log charts indicate that the general nature of soil
strata from ground level to 5.00 meter depth explored, comprises of red yellow silty
sands red murrum mix kopara with hard rock of Low’ to ‘Medium’ plasticity and
compressibility belonging to ‘ SM ‘ group of I.S. classification. The result of
classification tests indicates that the strata at the site comprise of red yellow silty
sands red murrum mix kopara with hard rock.
2. S.P.T. VALUES
SPT value more than 100 indicating a ‘Stiff Consistency’.

The result of SPT values indicate that the strata at the site is ‘Well’ compacted.
3. WATER TABLE
Water table at the Site was not met with up to 1.5 meter depth below existing
ground level on the day of soil investigation in the 1st week of July. A water table
beyond effective zone has been adopted for calculation purposes.
4. BEARING CAPACITY CALCULATIONS
The safe bearing capacity of the foundation of a building without any distress or
failure can be determined from the consideration of the following criteria.
(a) Shear failure criteria
The soil beneath the foundation shall be safe from risk of shear failure
The bearing capacity calculations for a foundation on shallow footing shall be

governed by I.S. 1904-1986, I.S. 6403-1981 and I.S. 8009-1981 on the basis of
available information regarding the proposed design and have been done in the
following paragraphs.
5. BEARING CAPACITY ON SHEAR CONSIDERATIONS
As per I.S. 6403-1981, the Ultimate Net bearing capacity ’qd’ on shear
considerations for a structure is given by the formula-
In case of general shear
qd = c. Nc. sc. dc. ic. + q (Nq-1). Sq. dq. iq. +1/2 B.r. Nr. Sr. dr. ir. W
1
In case of local shear
q’d = 2/3c. N’c. sc. dc.ic + q (N’q-1).sq.dq.iq + ½ Br. N’r. Sr. dr. ir.W’
6. UNCONFINED COMPRESSIVE STRENGTH
Unconfined Compressive Strength of rock is determined in the laboratory as per IS:

9143 and the value is given the Table No.1
TABLE NO.1
Laboratory Test Results on Rock Sample
Depth (m) Weathering Unconfined Water Specific

Condition/Rock Compressive Absorption Gravity
Type Strength
1.50 m Moderately 15.56 kg/cm2 1.67% 2.58
Weathered/
Basalt
7. ESTIMATE OF SAFE BEARING PRESSURE FROM THE CORE

STRENGTH
Qs = Qc Nj
Qs = Safe bearing pressure
Qc = Average uniaxial compressive strength of rock core
Nj = Empirical coefficient depending on the spacing of
Discontinuities
NET SAFE BEARING CAPACITY
Ultimate net bearing capacity = 15.56 kg/sqcm.

Factor of safety = 3.5
Net safe bearing capacity = 15.56 x 1/3.5 kg/sqcm.
= 4.445 kg/sqcm.
8. HARMFUL SALTS
Soil samples obtained from the site were analyzed for the presence of harmful salts like
Carbonates, Bi-Carbonates, Chlorides and Sulphate. The results given in table no. 2
indicate that the harmful salts are within safe permissible limits.
2
TABLE NO. 2
Depth in Carbonates % Bi Carbonates % Chlorides % Sulphates %

meters
0.50 ND 0.0589 0.0042 ND
1.00 ND 0.0545 0.0012 ND
7. RECOMMENDATIONS
1. The strata in the effective zone of influence comprises of, red yellow silty sands
red murrum mix kopara with hard rock soil. The design load has therefore to
ensure safety against due to shear.
2. Filled up soil has not been found to exist up to 1.50 meter depth below ground
level as revealed at the site.
3. (A) A safe allowable bearing capacity of 4.445 kg/sqcm i.e. 44.45 ton/sqmeter is
recommended to be adopted at 2.0 meter depth of foundation below ground
level for Isolated or raft footing of size 2.0 meter x 2.0 meter.
3. (B) Analysis of soil samples obtained at the site indicates that harmful salts are
well within permissible limits.
Summary of soil report Bore Hole No.:
Existing Plot Level Level of Road*/ Proposed Remark on Top Remarks

1 Ground / High Finished Grade soil and raising
flood level Level plot level to FGL
( FGL)
100m 100m/100m/100 100.30 m Top soil is red
m yellow silty sands
red murrum mix
kopara with hard
rock plot level is
equal to road level.
Therefore plot level
should be required
to raising to FGL.
2 Conclusion and The safe bearing capacity 4.445 kg/cm2 i.e. Remarks
Recommendation 44.45ton/sqmeter at the depths of 2.0m. It should be
used both isolated or RCC raft foundation.
3
Summary of Laboratory Test Results
BORE HOLE NO. 1
DEPTH OF BORE HOLE (1.5 Mts)
PERCENT PASSING ON I.S. ATTERBERG’S PARTICLES SIZE SHEAR
SPECIFIC GRAVITY
SIEVES LIMIT ANALYSIS STRENGTH
CLASSIFICATION
BULK DENSITY
DRY DENSITY
SPT VALUE
I. S. GROUP
(T/CUM)
(T/CUM)
Sand % (.75-0.075)
(0.075-0.002) mm
Angle of internal
Clay % (< 0.002
Type of Sample
Cohesion (C )
0.075 mm
friction φ
4.75 mm
4.25 mm
2.00 mm
Silt %
Depth
PL %
(mts)
LL%
PI %
mm)
mm
DS-1 0.50 90.56 83.23 75.15 23.47 38 20 18 SM
UD-1 1.00 87.36 82.48 71.63 21.56 37 20 17 50 38 12 SM 1.92 1.60 2.71 0.8 21
2
SPT-1 1.50 Hard rock at 1.5m >100
Notes : UD- Undisturbed sample DS- Disturbed Sample SPT – Standard Penetration test sampl
4
RECORD OF BORING
, Water Table Depth: Not met
Depth of Bore:1.5 Mtr
Bore Hole No. 1
Filled up: Mtr.

Type of Depth (Mtr.) Description S.P.T. Blows Count Remarks
Sample From To of Strata N1 N2 N3 N=N2+N3
15 15 15
Cm Cm Cm
DS GL 0.50 Red
murrum
UD-1 1.00 1.50 Kopara
SPT-1 1.50 2.0 Hard rock More than
at 1.5m 100
5
Exhibit-3
NTPC LIMITED
SECTION-VI
PART-C
TECHNICAL SPECIFICATIONS
(GENERAL TECHNICAL REQUIREMENTS)
CLAUSE NO. GENERAL TECHNICAL REQUIREMENTS
1.00.00 INTRODUCTION
This part covers technical requirements which will form an integral part of
the Contract. The following provisions shall supplement all the detailed
technical requirements brought out in the Technical Specifications and
the Technical Data Sheets.
2.00.00 BRAND NAME
Whenever a material or article is specified or described by the name of a

particular brand, manufacturer or vendor, the specific item mentioned
shall be understood to be indicative of the function and quality desired,
and not restrictive; other manufacturer's products may be considered
provided sufficient information is furnished to enable the Employer to
determine that the products proposed are equivalent to those named.
3.00.00 BASE OFFER & ALTERNATE PROPOSALS
The Bidder's proposal shall be based upon the use of equipment and
material complying fully with the requirements specified herein. It is
recognized that the Contractor may have standardized on the use of
certain components, materials, processes or procedures different than
those specified herein. Alternate proposals offering similar equipment
based on the manufacturer's standard practice may also be considered,
provided the base offer is in line with technical specifications and such
proposals meet the specified design standards and performance
requirement and are acceptable to the Employer. Sufficient amount of
information for justifying such proposals shall be furnished to Employer
alongwith the bid to enable the Employer to determine the acceptability of
these proposals.
4.00.00 COMPLETENESS OF FACILITIES
4.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant shall be engineered and
designed in accordance with the specification requirement. All engineering
and associated services are required to ensure that a completely
engineered plant is provided.
4.02.00 All equipment furnished by the Contractor shall be complete in every

respect, with all mountings, fittings, fixtures and standard accessories
normally provided with such equipment and/or those needed for erection,
completion and safe operation & maintenance of the equipment and for the
safety of the operating personnel, as required by applicable codes, though
they may not have been specifically detailed in the respective specifications,
unless included in the list of exclusions.
Development of Bid Doc. No. Technical Page 2
50 MW Solar Photo Voltaic Plant CS-5707-004-9 Specifications of 28
at Rajgarh(M.P.) Part-C Section-VI
All similar standard components/ parts of similar standard equipment

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

of India
(i.) Pollution Control Regulations of Department of Environment, Government

of India
(j.) State Pollution Control Board.
(k.) Rules for Electrical installation by Tariff Advisory Committee (TAC).
(l.) Any other statutory codes / standards / regulations, as may be applicable.
5.02.00 Unless covered otherwise by Indian codes & standards and in case nothing to
the contrary is specifically mentioned elsewhere in the specifications, the latest
editions (as applicable as on date of bid opening), of the codes and standards
given below shall also apply:
(a.) Japanese Industrial Standards (JIS)
(b.) American National Standards Institute (ANSI)
(c.) American Society of Testing and Materials (ASTM)

(d.) American Society of Mechanical Engineers (ASME)
(e.) American Petroleum Institute (API)
(f.) Standards of the Hydraulic Institute, U.S.A.
(g.) International Organisation for Standardization (ISO)
(h.) Tubular Exchanger Manufacturer's Association (TEMA)
(i.) American Welding Society (AWS)
(j.) National Electrical Manufacturers Association (NEMA)
(k.) National Fire Protection Association (NFPA)
(l.) International Electro-Technical Commission (IEC)
(m.) Expansion Joint Manufacturers Association (EJMA)
(n.) Heat Exchange Institute (HEI)
5.03.00 Other International/ National standards such as DIN, VDI, BS, GOST etc.
shall also be accepted for only material codes and manufacturing standards,
subject to the Employer's approval, for which the Bidder shall furnish,
alongwith the offer, adequate information to justify that these standards are
equivalent or superior to the standards mentioned above. In all such cases
the Bidder shall furnish specifically the variations and deviations from the
standards mentioned else where in the specification together with the
complete word to word translation of the standard that is normally not
published in English.
5.04.00 As regards highly standardized equipment such as Steam Turbine and

Generator, National /International standards such as JIS, DIN, VDI, ISO,
SEL, SEW, VDE, IEC & VGB shall also be considered as far as applicable
for Design, Manufacturing and Testing of the respective equipment. In
addition, these standards shall be referred for the design of machine
foundations, wherever specifically mentioned in the specifications. However,
for those of the above equipment not covered by these National /
International standards, established and proven standards of manufacturers
shall also be considered.
5.05.00 In the event of any conflict between the codes and standards referred to in
the above clauses and the requirement of this specification, the requirement
of Technical Specification shall govern.
5.06.00 Two (2) English language copies of all-national and international codes
and/or standards which are not available with NTPC and same is used in
the design of the plant, equipment, civil and structural works shall be
provided by the Contractor to the Employer within two calendar months from
the date of the Notification of Award.
5.07.00 In case of any change in codes, standards & regulations between the date
of bid opening and the date when vendors proceed with fabrication, the
Employer shall have the option to incorporate the changed requirements or
to retain the original standard. It shall be the responsibility of the Contractor
to bring to the notice of the Employer such changes and advise Employer of
the resulting effect.
6.00.00 EQUIPMENT FUNCTIONAL GUARANTEE
6.01.00 The functional guarantees of the equipment under the scope of the Contract
is given elsewhere in the technical specification. These guarantees shall
supplement the general functional guarantee provisions covered under
General Conditions of Contract.
6.02.00 Liquidated damages for shortfall in meeting functional guarantee(s) during
the performance guarantee tests shall be assessed and recovered from the
Contractor as specified elsewhere in this specification.
7.00.00 DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY

CONSIDERATIONS
7.01.00 Design of Facilities
All the design procedures, systems and components proposed shall have
already been adequately developed and shall have demonstrated good
reliability under similar conditions elsewhere.
The Contractor shall be responsible for the selection and design of

appropriate equipment to provide the best co-ordinated performance of
the entire system. The basic requirements are detailed out in various
clauses of the Technical Specifications. The design of various
components, assemblies and subassemblies shall be done so that it
facilitates easy field assembly and dismantling. All the rotating
components shall be so selected that the natural frequency of the
complete unit is not critical or close to the operating range of the unit.
7.02.00 Maintenance and Availability Considerations
Equipment/facilities offered shall be designed for high availability, low

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

the hoist / crane shall be provided by the contractor for lifting the
equipment and accessories covered under the specification.
8.00.00 DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY

CONTRACTOR
8.01.00 Bidders may note that this is a contract inclusive of the scope as indicated
elsewhere in the specification. Each of the plant and equipment shall be fully
integrated, engineered and designed to perform in accordance with the
technical specification. All engineering and technical services required
ensuring a completely engineered plant shall be provided in respect of
mechanical, electrical, control & instrumentation, civil & structural works as
per the scope.
8.02.00 The Contractor shall furnish engineering data/drgs. for entire equipment
covered under this specification in accordance with the schedule of
information as specified in Technical Specification and Data sheets.. This
documentation shall include but not be limited to the following :
8.02.01 INSTRUCTION MANUALS
The Contractor shall submit to the Employer, draft Instruction Manuals for
all the equipment covered under the Contract by the end of one year from
the date of his acceptance of the Letter of Award. The Instruction
manuals shall contain full details required for erection, commissioning,
operation and maintenance of each equipment. The manual shall be
specifically compiled for this project. After finalization and approval of the
Employer the Instruction Manuals shall be submitted. The Contract shall
not be considered to be completed for purposes of taking over until the
final Instructions manuals have been supplied to the Employer. The
Instruction Manuals shall comprise of the following.
(a.) Erection & Commissioning Manuals/Checklists
The erection & Commissioning Manuals/Checklists shall be submitted

atleast three (3) months prior to the commencement of erection activities
of particular equipment/system. The erection manual should contain the
following as a minimum.
a) Erection strategy.
b) Sequence of erection.
c) Erection instructions.
d) Critical checks and permissible deviation/tolerances.
e) List of tool, tackles, heavy equipment like cranes, dozers, etc.
f) Bill of Materials
g) Procedure for erection.
h) General safety procedures to followed during erection/installation.
i) Procedure for initial checking after erection.
j) Procedure for testing and acceptance norms.
k) Procedure / Check list for pre-commissioning activities.
l) Procedure / Check list for commissioning of the system.
m) Safety precautions to be followed in electrical supply distribution
during erection
(b.) Operation & Maintenance Manuals
i) The operating and maintenance instructions together with

drawings (other than shop drawings) of the equipment, as
completed, shall be in sufficient detail to enable the Employer to
operate, maintain, dismantle, reassemble and adjust all parts of
the equipment. They shall give a step by step procedure for all
operations likely to be carried out during the life of the plant /
equipment including, operation, maintenance, dismantling and
repair including periodical activities such as chemical cleaning of
the generator. Each manual shall also include a complete set of
drawings together with performance/rating curves of the
equipment and test certificates wherever applicable. The contract
shall not be considered to be completed for purposes for taking
over until these manuals have been supplied to the Employer.
ii) If after the commissioning and initial operation of the plant, the
manuals require any modification / additions / changes, the same
shall be incorporated and the updated final instruction manuals
shall be submitted to the Employer for records.
iii) A separate section of the manual shall be for each size/ type of
equipment and shall contain a detailed description of
construction and operation, together with all relevant pamphlets
and drawings.
iv) The manuals shall include the following :

a) List of spare parts along with their drawing and

catalogues and procedure for ordering spares.
b) Lubrication Schedule including charts showing

lubrication checking, testing and replacement
procedure to be carried daily, weekly, monthly & at
longer intervals to ensure trouble free operation.
c) Where applicable, fault location charts shall be

included to facilitate finding the cause of mal-
operation or break down.
v) Detailed specifications for all the consumables including lubricant

oils, greases, chemicals etc. system/equipment/assembly/sub-
assembly - wise required for the complete plant.
vi) On completion of erection, a complete list of bearings /

equipment giving their location, and identification marks etc. shall
also be furnished to the Employer indicating lubrication method
for each type/category of bearing.
8.02.02 Project Completion Report
The Contractor shall submit a Project Completion Report at the time of

handing over the plant. After final acceptance of individual equipment
/system by the Employer, the Contractor will update all original drawings
and documents for the equipment/ system to "as built" conditions and
submit.
8.03.00 ENGINEERING INFORMATION SUBMISSION SCHEDULE
Prior to the award of Contract, a Detailed Engineering Information

Submission Schedule shall be tied up with the Employer. For this, the
bidder shall furnish a detailed list of engineering information alongwith the
proposed submission schedule. This list would be a comprehensive one
including all engineering data / drawings / information for all bought out
items and manufactured items. The information shall be categorised into
the following parts.
(a.) Information that shall be submitted for the approval of the Employer
before proceeding further, and
(b.) Information that would be submitted for Employer’s information only.
The Engineering Information Schedule shall be updated month-wise.
The schedule should allow adequate time for proper review and
incorporation of changes/ modifications, if any, to meet the contract
without affecting the equipment delivery schedule and overall project

schedule. The early submission of drawings and data is as important as
the manufacture and delivery of equipment and hardware and this shall
be duly considered while determining the overall performance and
progress.
8.04.00 ENGINEERING PROGRESS AND EXCEPTION REPORT
8.04.01 Report giving the status of each engineering information including
(a.) A list of drawings/engineering information which remains

unapproved for more than four (4) weeks after the date of first
submission
(b.) Drawings which were not submitted as per agreed schedule.

8.04.02 The draft format for this report shall be furnished to the Employer
within four (4) weeks of the award of the contract, which shall then
be discussed and finalised with the Employer.
8.05.00 TECHNICAL CO-ORDINATION MEETING
• The Contractor shall organize and attend at least one monthly progress
Meetings with the Employer/Employer's representatives during the period
of Contract at mutually agreed venues for review of progress & resolving
technical clarifications, if any. The Contractor shall attend such meetings
at his own cost and fully co-operate with such persons and agencies
involved during the discussions.
• The Contractor shall ensure availability of the concerned experts /

consultants/ personnel who are empowered to take necessary decisions
during these meetings. The Contractor shall be equipped with necessary
tools and facilities so that, if required, the drawings/documents can be
resubmitted after incorporating necessary changes and approved during
the meeting itself.
• The Contractor shall furnish monthly progress report to the Employer

detailing out the progress achieved on all erection activities as compared
to the schedules. This shall be supplemented by printed colour
photographs and video in VCD/DVD indicating various stages of erection
and the progress of the work done at Site. The report shall also indicate
the reasons for the variance between the scheduled and actual progress
and the action proposed for corrective measures, wherever necessary.
8.06.00 DESIGN IMPROVEMENTS
The Employer or the Contractor may propose changes in the specification

of the equipment or quality thereof and if the parties agree upon any such
changes the specification shall be modified accordingly.

If any such agreed upon change is such that it affects the price and
schedule of completion, the parties shall agree in writing as to the extent
of any changing the price and/or schedule of completion before the
Contractor proceeds with the change. Following such agreement, the
provision thereof, shall be deemed to have been amended accordingly.
8.07.00 EQUIPMENT BASES
A cast iron or welded steel base plate shall be provided for all rotating
equipment which is to be installed on a concrete base, unless otherwise
specifically agreed to by the Employer. Each base plate which support
the unit and its drive assembly, shall be of a neat design with pads for
anchoring the units, shall have a raised lip all around, and shall have
threaded drain connections.
8.08.00 PROTECTIVE GUARDS
Suitable guards shall be provided for protection of personnel on all

exposed rotating and/or moving machine parts. All such guards shall be
designed for easy installation and removal for maintenance purpose.
8.09.00 LUBRICANTS, SERVO FLUIDS AND CHEMICALS
The Bidder’s scope includes all the first fill and one year’s topping,
requirements of consumables such as oils, lubricants including grease,
servo fluids, gases and essential chemicals etc. Consumption of all these
consumables during the initial operation and final filling after the initial
operation shall also be included in the scope of the Bidder.
8.09.01 As far as possible lubricants marketed by reputed companies shall be
used. The variety of lubricants shall be kept to a minimum possible.
Detailed specifications for the lubricating oil, grease, gases, servo fluids,
control fluids, chemicals etc. required for the complete plant covered
herein shall be furnished. On completion of erection, a complete list of
bearings/ equipment giving their location and identification marks shall be
furnished to the Employer alongwith lubrication requirements.
8.09.02 Lubrication
Equipment shall be lubricated by systems designed for continuous
operation. Lubricant level indicators shall be furnished and marked to
indicate proper levels under both standstill and operating conditions.
8.10.00 Material of Construction
All materials used for the construction of the equipment shall be new and
shall be in accordance with the requirements of this specification.
Development of Bid Doc. No. Technical Page

50 MW Solar Photo Voltaic Plant CS-5707-004-9 Specifications 10 of
at Rajgarh(M.P.) Part-C Section-VI 28
Materials utilised for various components shall be those which have

established themselves for use in such applications.
8.11.00 RATING PLATES, NAME PLATES & LABELS
8.11.01 Each main and auxiliary item of plant including instruments shall have
permanently attached to it in a conspicuous position, a rating plate of non-
corrosive material upon which shall be engraved manufacturer’s name,
equipment, type or serial number together with details of the ratings,
service conditions under which the item of plant in question has been
designed to operate, and such diagram plates as may be required by the
Employer.
8.11.02 Such nameplates or labels shall be of white non-hygroscopic material

with engraved black lettering or alternately, in the case of indoor circuit
breakers, starters, etc. of transparent plastic material with suitably
coloured lettering engraved on the back. The name plates shall be
suitably fixed on both front and rear sides.
8.11.03 Hanger/ support numbers shall be marked on all pipe supports, anchors,
hangers, snubbers and restraint assemblies. Each constant and variable
spring support shall also have stamped upon it the designed hot and cold
load which it is intended to support. Suitable scale shall also be provided
to indicate load on support/hanger.
8.11.04 Nameplates shall be as per best practices of the industry
8.11.05 All such plates, instruction plates, etc. shall be bilingual with Hindi
inscription first, followed by English. Alternatively, two separate plates one
with Hindi and the other with English inscriptions may be provided.
8.11.06 All segregated phases of conductors or bus ducts, indoor or outdoor, shall
be provided with coloured phase plates to clearly identify the phase of
the system
8.12.00 TOOLS AND TACKLES
The Contractor shall supply with the equipment one complete set of all
special tools and tackles and other instruments required for the erection,
assembly, disassembly and proper maintenance of the plant and
equipment and systems (including software). These special tools will also
include special material handling equipment, jigs and fixtures for
maintenance and calibration / readjustment, checking and measurement
aids etc. A list of such tools and tackles shall be submitted by the Bidder
alongwith the offer.
The price of each tool / tackle shall be deemed to have been included in
the total bid price. These tools and tackles shall be separately packed
and sent to site. The Contractor shall also ensure that these tools and
tackles are not used by him during erection, commissioning and initial
operation. For this period the Contractor should bring his own tools and
tackles. All the tools and tackles shall be of reputed make acceptable to
the Employer.
8.13.00 Welding
If the manufacturer has special requirements relating to the welding

procedures for welds at the terminals of the equipment to be per formed
by others the requirements shall be submitted to the Employer in advance
of commencement of erection work.
8.14.00 COLOUR CODE FOR ALL EQUIPMENTS/ PIPINGS/ PIPE SERVICES
All equipment/ piping/ pipe services are to be painted by the Contractor in

accordance with Employer’s standard colour coding scheme, which will
be furnished to the Contractor during detailed engineering stage.
8.15.00 PROTECTION AND PRESERVATIVE SHOP COATING
8.16.00 PROTECTION
All coated surfaces shall be protected against abrasion, impact,

discoloration and any other damages. All exposed threaded portions
shall be suitably protected with either metallic or a nonmetallic protection
device. All ends of all valves and pipings and conduit equipment
connections shall be properly sealed with suitable devices to protect them
from damage. The parts which are likely to get rusted, due to exposure to
weather, should also be properly treated and protected in a suitable
manner. All primers/paints/coatings shall take into account the hot humid,
corrosive & alkaline, subsoil or overground environment as the case may
be.
8.17.00 Preservative Shop Coating
All exposed metallic surfaces subject to corrosion shall be protected by

shop application of suitable coatings. All surfaces which will not be easily
accessible after the shop assembly, shall be treated beforehand and
protected for the life of the equipment. All surfaces shall be thoroughly
cleaned of all mill scales, oxides and other coatings and prepared in the
shop. The surfaces that are to be finish-painted after installation or
require corrosion protection until installation, shall be shop painted with at
least two coats of primer.
Transformers and other electrical equipment if included shall be shop

finished with one or more coats of primer and two coats of high grade
resistance enamel. The finished colors shall be as per manufacturer’s
standards, to be selected and specified by the Employer at a later date.

Shop primer for all steel surfaces which will be exposed to operating
temperature below 95 degrees Celsius shall be selected by the
Contractor after obtaining specific approval of the Employer regarding the
quality of primer proposed to be applied. Special high temperature primer
shall be used on surfaces exposed to temperature higher than 95
degrees Celsius and such primer shall also be subject to the approval of
the Employer.
All other steel surfaces which are not to be painted shall be coated with
suitable rust preventive compound subject to the approval of the
Employer.
All piping shall be cleaned after shop assembly by shot blasting or other
means approved by the Employer. Lube oil piping or carbon steel shall
be pickled.
Painting for Civil structures shall be done as per relevant part of technical
specification
9.00.00 QUALITY ASSURANCE PROGRAMME
9.01.00 The Contractor shall adopt suitable quality assurance programme to

ensure that the equipment and services under the scope of contract
whether manufactured or performed within the Contractor’s works or at
his sub-contractor’s premises or at the Employer’s site or at any other
place of work are in accordance with the specifications. Such
programmes shall be outlined by the Contractor and shall be finally
accepted by the Employer/authorised representative after discussions
before the award of the contract. The QA programme shall be generally
in line with IS/ISO-9001.A quality assurance programme of the contractor
shall generally cover the following:
9.02.00
(a.) His organisation structure for the management and implementation
of the proposed quality assurance programme
(b.) Quality System Manual
(c.) Design Control System
(d.) Documentation and Data Control System
(e.) Qualification data for bidder’s key personnel.
(f.) The procedure for purchase of materials, parts, components and
selection of sub-contractor’s services including vendor analysis,
source inspection, incoming raw-material inspection, verification of
materials purchased etc.
(g.) System for shop manufacturing and site erection controls including
process, fabrication and assembly.

(h.) Control of non-conforming items and system for corrective actions

and resolution of deviations.
(i.) Inspection and test procedure both for manufacture and field
activities.
(j.) Control of calibration and testing of measuring testing equipment.
(k.) System for Quality Audits.
(l.) System for identification and appraisal of inspection status.
(m.) System for authorising release of manufactured product to the
Employer.
(n.) System for handling, storage and delivery.
(o.) System for maintenance of records, and
(p.) 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.
9.03.00 GENERAL REQUIREMENTS - QUALITY ASSURANCE
9.03.01 All materials, components and equipment covered under this specification
shall be procured, manufactured, erected, commissioned and tested at all
the stages, as per a comprehensive Quality Assurance Programme. An
indicative programme of inspection/tests to be carried out by the
contractor for some of the major items is given in the respective technical
specification. This is, however, not intended to form a comprehensive
programme as it is the contractor’s responsibility to draw up and
implement such programme duly approved by the Employer. The
detailed Quality Plans for manufacturing and field activities shall be drawn
up by the Bidder and will be submitted to Employer for approval.
Schedule of finalisation of such quality plans will be finalised before
award on enclosed format No. QS-01-QAI-P-01/F3. Monthly progress
reports on MQP/FQP submission/approval shall be furnished on enclosed
format No. QS-01-QAI-P-02/F1
9.03.02 Manufacturing Quality Plan will detail out for all the components and
equipment, various tests/inspection, to be carried out as per the
requirements of this specification and standards mentioned therein and
quality practices and procedures followed by Contractor’s/ Sub-
contractor’s/ sub-supplier's Quality Control Organisation, the relevant
reference documents and standards, acceptance norms, inspection
documents raised etc., during all stages of materials procurement,
manufacture, assembly and final testing/performance testing. The Quality
Plan shall be submitted on electronic media e.g. floppy or E-mail in
addition to hard copy, for review and approval. After approval the same
shall be submitted in compiled form on CD-ROM.

9.03.03 Field Quality Plans will detail out for all the equipment, the quality
practices and procedures etc. to be followed by the Contractor’s "Site
Quality Control Organisation", during various stages of site activities
starting from receipt of materials/equipment at site.
9.03.04 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 Employer’s
approval without which manufacturer shall not proceed. These approved
documents shall form a part of the contract. In these approved Quality
Plans, Employer shall identify customer hold points (CHP), i.e.
test/checks which shall be carried out in presence of the Employer’s
Project Manager or his authorised representative and beyond which the
work will not proceed without consent of Employer in writing. All
deviations to this specification, approved quality plans and applicable
standards must be documented and referred to Employer along with
technical justification for approval and dispositioning.
9.03.05 No material shall be dispatched from the manufacturer’s works before the
same is accepted, subsequent to predispatch final inspection including
verification of records of all previous tests/inspections by Employer’s
Project Manager/Authorised representative and duly authorised for
dispatch by issuance of Material Despatch Clearance Certificate (MDCC).
9.03.06 All material used for equipment manufacture including casting and forging
etc. shall be of tested quality as per relevant codes/standards. Details of
results of the tests conducted to determine the mechanical properties;
chemical analysis and details of heat treatment procedure recommended
and actually followed shall be recorded on certificates and time
temperature chart. Tests shall be carried out as per applicable material
standards and/or agreed details.
9.03.07 The contractor shall submit to the Employer Field Welding Schedule for
field welding activities in the enclosed format No.: QS-01-CQA-W-11/F1.
The field welding schedule shall be submitted to the Employer along with
all supporting documents, like welding procedures, heat treatment
procedures, NDT procedures etc. at least ninety days before schedule
start of erection work at site.
9.03.08 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 Employer.
All welding/brazing procedures shall be submitted to the Employer or its

authorised representative for approval prior to carrying out the
welding/brazing.

9.03.09 All brazers, welders and welding operators employed on any part of the
contract either in Contractor’s/sub-contractor’s works or at site or
elsewhere shall be qualified as per ASME Section-IX or BS-4871 or other
equivalent International Standards acceptable to the Employer.
9.03.10 Welding procedure qualification & Welder qualification test results shall
be furnished to the Employer for approval. However, where required by
the Employer, tests shall be conducted in presence of
Employer/authorised representative.
9.03.11 For all pressure parts and high pressure piping welding, the latest
applicable requirements of the IBR (Indian Boiler Regulations) shall also
be essentially complied with. Similarly, any other statutory requirements
for the equipment/systems shall also be complied with. On all back-
gauged welds MPI/LPI shall be carried before seal welding.
9.03.12 Unless otherwise proven and specifically agreed with the Employer,
welding of dissimilar materials and high alloy materials shall be carried
out at shop only.
9.03.13 No welding shall be carried out on cast iron components for repair.
9.03.14 All the heat treatment results shall be recorded on time temperature
charts and verified with recommended regimes.
9.03.15 All non-destructive examination shall be performed in accordance with

written procedures as per International Standards, The NDT operator
shall be qualified as per SNT-TC-IA (of the American Society of non-
destructive examination). NDT shall be recorded in a report, which
includes details of methods and equipment used, result/evaluation, job
data and identification of personnel employed and details of co-relation of
the test report with the job.
All plates of thickness above 40mm & all bar stock/Forging above 40mm
dia shall be ultrasonically tested. For pressure parts, plate of thickness
equal to or above 25mm shall be ultrasonically tested.
9.03.16 The Contractor shall list out all major items/ equipment/ components to be
manufactured in house as well as procured from sub-contractors (BOI).
All the sub-contractor proposed by the Contractor for procurement of
major bought out items including castings, forging, semi-finished and
finished components/equipment etc., list of which shall be drawn up by
the Contractor and finalised with the Employer, shall be subject to
Employer's approval on enclosed format No. QS-01-QAI-P-01/F3. The
contractor’s proposal shall include vendor’s facilities established at the
respective works, the process capability, process stabilization, QC
systems followed, experience list, etc. along with his own technical
evaluation for identified sub-contractors enclosed and shall be submitted
to the Employer for approval within the period agreed at the time of pre-
awards discussion and identified in "DR" category prior to any

procurement. Monthly progress reports on sub-contractor detail
submission / approval shall be furnished on enclosed on format no. QS-
01-QAI-P-02/F2. Such vendor approval shall not relieve the contractor
from any obligation, duty or responsibility under the contract.
9.03.17 For components/equipment procured by the contractors for the purpose

of the contract, after obtaining the written approval of the Employer, the
contractor’s purchase specifications and inquiries shall call for quality
plans to be submitted by the suppliers. The quality plans called for from
the sub-contractor shall set out, during the various stages of manufacture
and installation, the quality practices and procedures followed by the
vendor’s quality control organisation, the relevant reference
documents/standards used, acceptance level, inspection of
documentation raised, etc. Such quality plans of the successful vendors
shall be finalised with the Employer and such approved Quality Plans
shall form a part of the purchase order/contract between the Contractor
and sub-contractor. With in three weeks of the release of the purchase
orders /contracts for such bought out items /components, a copy of the
same without price details but together with the detailed purchase
specifications, quality plans and delivery conditions shall be furnished to
the Employer on the monthly basis by the Contractor along with a report
of the Purchase Order placed so far for the contract. **
9.03.18 Employer reserves the right to carry out quality audit and quality
surveillance of the systems and procedures of the Contractor’s or their
sub-contractor’s quality management and control activities. The
contractor shall provide all necessary assistance to enable the Employer
carry out such audit and surveillance.
9.03.19 The contractor shall carry out an inspection and testing programme
during manufacture in his work and that of his sub-contractor’s and at site
to ensure the mechanical accuracy of components, compliance with
drawings, conformance to functional and performance requirements,
identity and acceptability of all materials parts and equipment. Contractor
shall carry out all tests/inspection required to establish that the
items/equipment conform to requirements of the specification and the
relevant codes/standards specified in the specification, in addition to
carrying out tests as per the approved quality plan.
9.03.20 Quality audit/surveillance/approval of the results of the tests and

inspection will not, however, prejudice the right of the Employer to reject
the equipment if it does not comply with the specification when erected or
does not give complete satisfaction in service and the above shall in no
way limit the liabilities and responsibilities of the Contractor in ensuring
complete conformance of the materials/equipment supplied to relevant
specification, standard, data sheets, drawings, etc.

9.03.21 For all spares and replacement items, the quality requirements as agreed
for the main equipment supply shall be applicable.
9.03.22 Repair/rectification procedures to be adopted to make the job acceptable

shall be subject to the approval of the Employer/ authorised
representative.
9.03.23 Burn in and Elevated Temperature Test Requirement for Electronics Solid
State Equipment
(a.) All solid state electronic systems/equipment shall be tested as a

complete system/equipment with all devices connected for a
minimum of 168 hours (7 Days) continuously under energized
conditions prior to shipment from manufacturing works, as per the
following cycle.
(1.) Elevated Temperature Test Cycle
During the elevated temperature test which shall be for 48 hours of the
total 168 hours of testing, the ambient temperature shall be maintained at
50 deg. C. The equipment shall be interconnected with devices which will
cause it to repeatedly perform all operations it is expected to perform in
actual service with load on various components being equal to those
which will be experienced in actual service.
During the elevated temperature test the cubicle doors shall be closed (or
shall be in the position same as they are supposed to be in the field) and
inside temperature in the zone of highest heat dissipating
components/modules shall be monitored. The temperature rise inside the
cubicle should not exceed 10 deg. C above the ambient temp. at 50 deg.
C.
(b.) Burn in Test Cycle
The 48 hours elevated temperature test shall be followed by 120 hours of

burn in test as above except that the temperature shall be reduced to the
ambient temperature prevalent at that time.
During the above tests, the process I/O and other load on the system
shall be simulated by simulated inputs and in the case of control systems,
the process which is to be controlled shall also be simulated. Testing of
individual components or modules shall not be acceptable.
In case the Contractor/ sub-contractor is having any alternate established

procedure of eliminating infant mortile components, the detail procedures
followed by the Contractor/ sub- contractor along with the statistical
figures to validate the alternate procedure to be forwarded.

The Contractor/Sub-contractor shall carry out routine test on 100% item

at contractor/sub-contractor’s works. The quantum of check/test for
routine & acceptance test by employer shall be generally as per
criteria/sampling plan defined in referred standards. Wherever standards
have not been mentioned quantum of check/test for routine / acceptance
test shall be as agreed uring detailed engineering stage.
9.03.24 QUALITY ASSURANCE AND INSPECTION FOR CIVIL WORKS
INTRODUCTION
This part of the specification covers the sampling, testing and quality
assurance requirement (including construction tolerances and acceptance
criteria) for all civil and structural works covered in this specification.
This part of the technical specification shall be read in conjunction with

other parts of the technical specifications, general technical requirements
& erection conditions of the contract which covers common QA
requirements. Wherever IS code or standards have been referred they
shall be the latest revisions.
The rate for respective items of work or price shall include the cost for all
works, activities, equipment, instrument, personnel, material etc.
whatsoever associated to comply with sampling, testing and quality
assurance requirement including construction tolerances and acceptance
criteria and as specified in subsequent clauses of this part of the technical
specifications. The QA and QC activities in all respects as specified in the
technical specifications/ drawings / data sheets / quality plans / contract
documents shall be carried out at no extra cost to the owner.
The contractor shall prepare detailed construction and erection

methodology scheme which shall be compatible to the requirements of
the desired progress of work execution, quality measures, prior approvals
if any and the same shall be got approved by the Engineer. If required,
work methodology may be revised/ reviewed at every stage of execution
of work at site, to suit the site conditions by the contractor at no extra cost
to the owner.
QA AND QC MANPOWER
The contractor shall nominate one overall QA coordinator for the contract
detailing the name, designation, contact details and address at the time of
post bid discussions. All correspondence related to Quality Assurance
shall be addressed by the contractor’s QA coordinator to NTPC. NTPC
shall address all correspondence related to Quality issues to the
contractor’s QA coordinator. The contractor’s QA coordinator shall be
responsible for co-ordination of Quality activities between various

divisions of the contractor and their sub-vendors on one hand & with
NTPC on the other hand.
The contractor shall appoint a dedicated, experienced and competent

QA&QC in-charge at site, preferably directly reporting to the Project
Manager, supported as necessary by experienced personnel, to ensure
the effective implementation of the approved QAP. The contractor shall
finalize and submit a deployment schedule of QA&QC personnel along
with their details to NTPC for approval/ acceptance and further shall
ensure their availability well before the start of the concern activity.
SAMPLING AND TESTING OF CONSTRUCTION MATERIALS
The method of sampling for testing of construction materials and work /

job samples shall be as per the relevant IS / standards / codes and in line
with the requirements of the technical specifications / quality plans. All
samples shall be jointly drawn, signed and sealed wherever required, by
the contractor and the engineer or his authorized representative.
The contractor shall carry out testing in accordance with the relevant IS /
standards / codes and in line with the requirements of the technical
specifications / quality plans. Where no specific testing procedure is
mentioned, the tests shall be carried out as per the best prevalent
engineering practices and to the directions of the Engineer. All testing
shall be done in the presence of the engineer or his authorized
representative in a NABL accredited / Govt. Laboratory acceptable to
NTPC. This includes all IITs, NCB, CSMRS, reputed government /
autonomous laboratories / organizations, NITs and other reputed testing
laboratories. The test samples for such test shall be jointly selected and
sealed by the engineer and thereafter these shall be sent to the
concerned laboratory through the covering letter signed by NTPC
engineer. The test report along with the recommendations shall be
obtained from the laboratories without delay and submitted to NTPC.
PURCHASE AND SERVICE
Structural steel supply if in the scope of the contractor shall be procured

from main steel producers like SAIL, TISCO, IISCO, RINL, Essar Steel,
Ispat Industries, JSW Steel, Lloyds Steel, Jindal Steel & Power. In case
of non-availability of some of the sections with main steel producers the
contractor may propose to procure the sections from the re-rollers of the
main steel producers, the name of such re-rollers will have to be cleared
by corporate quality assurance of NTPC for which details such as BIS
approval, main steel producer’s approval, past experience for production
of sections of specified material, details of machines plants testing
facilities etc., Confirmation that the process control and manufacturing of
steel sections by re-rollers shall be same as that of main steel producers,
that billets for re-rolling will be sourced from main steel producers only
shall be furnished with regards to re-roller.

Even after clearance of re-rollers, induction of billets with identified and

correlated Mill test certificates (TC’s) in the process of re-rolling, sampling
of steel, quality checks thereof and stamping of final product for further
identification and correlation with TC’s prior to dispatch shall be the
responsibility of the contractor and these shall be performed in presence
of the authorized representative of the main Contractor.
Reinforcement steel supply if in the scope of the contractor shall be

procured from main steel producers like SAIL, TISCO, IISCO, RINL,
Essar Steel, Ispat Industries, JSW Steel, Lloyds Steel, Jindal Steel &
Power, Jai Balaji Industries Ltd, Durgapur (for 8-40mm reinforcement
steel) and mill test certificates (TC) is to be obtained and submitted to
NTPC for co-relation. In case any size /diameter specified is not available
with main steel producers and are proposed to be supplied from the
conversion agent of the main steel producer the name of such conversion
agent / re-roller shall have to be approved by NTPC for which details such
as BIS approval, Main steel producer’s approval, Past experience for
production of sections of specified material, details of machines, plants
testing facilities etc., and confirmation that the process control and
manufacturing of steel sections by re-rollers is the same as that of main
steel producers, that billets for re-rolling are sourced from main steel
producers only shall be furnished with regards to re-roller.
9.04.00 QA DOCUMENTATION PACKAGE
The Contractor shall be required to submit the QA Documentation in two

hard copies and two CD ROMs, as identified in respective quality plan
with tick mark.
9.04.01 Each QA Documentation shall have a project specific Cover Sheet

bearing name & identification number of equipment and including an
index of its contents with page control on each document.
The QA Documentation file shall be progressively completed by the

Supplier’s sub- supplier to allow regular reviews by all parties during the
manufacturing.
The final quality document will be compiled and issued at the final
assembly place of equipment before dispatch. However CD-Rom may be
issued not later than three weeks.
9.04.02 Typical contents of QA Documentation is as below:-
(a.) Quality Plan
(b.) Material mill test reports on components as specified by the

specification and approved Quality Plans.

(c.) Manufacturer / works test reports/results for testing required as per

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

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

deviation, including complete technical details / repair procedure).
(g.) CHP / Inspection reports duly signed by the Inspector of the

Employer and Contractor for the agreed Customer Hold Points.
(h.) Certificate of Conformance (COC) wherever applicable.
(i.) MDCC
9.04.03 Similarly, the contractor shall be required to submit two sets (two hard
copies and two CD ROMs), containing QA Documentation pertaining to
field activities as per Approved Field Quality Plans and other agreed
manuals/ procedures, prior to commissioning of individual system.
9.04.04 Before dispatch / commissioning of any equipment, the Supplier shall

make sure that the corresponding quality document or in the case of
protracted phased deliveries, the applicable section of the quality
document file is completed. The supplier will then notify the Inspector
regarding the readiness of the quality document (or applicable section) for
review.
(a.) If the result of the review carried out by the Inspector is satisfactory,
the Inspector shall stamp the quality document (or applicable
section) for release.
(b.) If the quality document is unsatisfactory, the Supplier shall endeavor

to correct the incompleteness, thus allowing to finalize the quality
document (or applicable section) by time compatible with the
requirements as per contract documents. When it is done, the
quality document (or applicable section) is stamped by the
Inspector.
(c.) If a decision is made dispatch, whereas all outstanding actions

cannot be readily cleared for the release of the quality document by
that time. The supplier shall immediately, upon shipment of the
equipment, send a copy of the quality document Review Status
signed by the Supplier Representative to the Inspector and notify of
the committed date for the completion of all outstanding actions &
submission. The Inspector shall stamp the quality document for
applicable section when it is effectively completed. The submission
of QA documentation package shall not be later than 3 weeks after
the dispatch of equipment.
9.04.05 TRANSMISSION OF QA DOCUMENTATION
On release of QA Documentation by Inspector, one set of quality

document shall be forwarded to Corporate Quality Assurance Department
and other set to respective Project Site of Employer.
For the particular case of phased deliveries, the complete quality

document to the Employer shall be issued not later than 3 weeks after the
date of the last delivery of equipment.
9.05.00 Project Manager’s Supervision
9.05.01 To eliminate delays and avoid disputes and litigation, it is agreed between
the parties to the Contract that all matters and questions shall be referred
to the Project Manager and without prejudice to the provisions of
‘Arbitration’ clause in Section GCC of Vol.I, the Contractor shall proceed
to comply with the Project Manager's decision.
9.05.02 The work shall be performed under the supervision of the Project
Manager. The scope of the duties of the Project Manager pursuant to the
Contract, will include but not be limited to the following:
(a.) Interpretation of all the terms and conditions of these documents

and specifications:
(b.) Review and interpretation of all the Contractor’s drawing,

engineering data, etc:
(c.) Witness or his authorised representative to witness tests and trials

either at the manufacturer’s works or at site, or at any place where
work is performed under the contract :
(d.) Inspect, accept or reject any equipment, material and work under
the contract :
(e.) Issue certificate of acceptance and/or progressive payment and final

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

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

stages of the works.
9.06.00 INSPECTION, TESTING AND INSPECTION CERTIFICATES
9.06.01 The word ‘Inspector’ shall mean the Project Manager and/or his
authorised representative and/or an outside inspection agency acting on
behalf of the Employer to inspect and examine the materials and
workmanship of the works during its manufacture or erection.
9.06.02 The Project Manager or his duly authorised representative and/or an

outside inspection agency acting on behalf of the Employer shall have
access at all reasonable times to inspect and examine the materials and
workmanship of the works during its manufacture or erection and if part of
the works is being manufactured or assembled on other premises or
works, the Contractor shall obtain for the Project Manager and for his duly
authorised representative permission to inspect as if the works were
manufactured or assembled on the Contractor’s own premises or works.
9.06.03 The Contractor shall give the Project Manager/Inspector fifteen (15) days
written notice of any material being ready for testing. Such tests shall be
to the Contractor’s account except for the expenses of the Inspector’s.
The Project Manager/Inspector, unless the witnessing of the tests is
virtually waived and confirmed in writing, will attend such tests within
fifteen (15) days of the date on which the equipment is noticed as being
ready for test/inspection failing which the contractor may proceed with
test which shall be deemed to have been made in the inspector’s
presence and he shall forthwith forward to the inspector duly certified
copies of test reports in two (2) copies.
9.06.04 The Project Manager or Inspector shall within fifteen (15) days from the
date of inspection as defined herein give notice in writing to the
Contractor, or any objection to any drawings and all or any equipment
and workmanship which is in his opinion not in accordance with the
contract. The Contractor shall give due consideration to such objections
and shall either make modifications that may be necessary to meet the
said objections or shall inform in writing to the Project Manager/Inspector
giving reasons therein, that no modifications are necessary to comply with
the contract.
9.06.05 When the factory tests have been completed at the Contractor’s or sub-
contractor’s works, the Project Manager /Inspector shall issue a certificate
to this effect fifteen (15) days after completion of tests but if the tests are
not witnessed by the Project Manager /Inspectors, the certificate shall be
issued within fifteen (15) days of the receipt of the Contractor’s test
certificate by the Project Manager /Inspector. Project Manager /Inspector
to issue such a certificate shall not prevent the Contractor from
proceeding with the works. The completion of these tests or the issue of
the certificates shall not bind the Employer to accept the equipment
should it, on further tests after erection be found not to comply with the
contract.
9.06.06 In all cases where the contract provides for tests whether at the premises
or works of the Contractor or any sub-contractor, the Contractor, except
where otherwise specified shall provide free of charge such items as
labour, material, electricity, fuel, water, stores, apparatus and instruments
as may be reasonably demanded by the Project Manager /Inspector or
his authorised representatives to carry out effectively such tests on the
equipment in accordance with the Contractor and shall give facilities to
the Project Manager/Inspector or to his authorised representative to
accomplish testing.
9.06.07 The inspection by Project Manager / Inspector and issue of Inspection
Certificate thereon shall in no way limit the liabilities and responsibilities of
the Contractor in respect of the agreed Quality Assurance Programme
forming a part of the contract.
9.06.08 To facilitate advance planning of inspection in addition to giving

inspection notice as specified at clause no 9.05.03- of this chapter, the
Contractor shall furnish quarterly inspection programme indicating
schedule dates of inspection at Customer Hold Point and final inspection
stages. Updated quarterly inspection plans will be made for each three
consecutive months and shall be furnished before beginning of each
calendar month.
9.06.09 All inspection, measuring and test equipment used by contractor shall be
calibrated periodically depending on its use and criticality of the
test/measurement to be done. The Contractor shall maintain all the
relevant records of periodic calibration and instrument identification, and
shall produce the same for inspection by NTPC. Wherever asked
specifically, the contractor shall re-calibrate the measuring/test equipment
in the presence of Project Manager / Inspector.
9.07.00 ASSOCIATED DOCUMENT FOR QUALITY ASSURANCE

PROGRAMME:
9.07.01 List of items requiring quality plan and sub supplier approval. Format
No.:QS-01-QAI-P-01/F3-R0 (Annexure-III).
9.07.02 Status of items requiring Quality Plan and sub supplier approval. Format
No.: QS-01-QAI-P-02/F1-R0 (Annexure-IV).
9.07.03 Field Welding Schedule Format No.: QS-01-CQA-W-11/F1-R0

(Annexure-V).
9.07.04 Manufacturing Quality Plan Format No.: QS-01-QAI-P-09/F1-R0

(Annexure-VI).
9.07.05 Field Quality Plan Format No.: QS-01-QAI-P-09/F2-R0 (Annexure-VII).
10.00.00 PRE-COMMISSIONING AND COMMISSIONING FACILITIES

The Contractor upon completion of installation of equipments and

systems, shall conduct pre-commissioning and commissioning activities,
to make the equipment/systems ready for safe, reliable and efficient
operation on sustained basis. During commissioning the Contractor shall
carry out system checking and reliability trials on various parts of the
facilities. All pre-commissioning/commissioning activities considered
essential for such readiness of the equipment/systems including those
mutually agreed and included in the Contractor’s quality assurance
programme as well as those indicated in clauses elsewhere in the
technical specifications shall be performed by the contractor.
The pre-commissioning and commissioning activities of the

equipment/systems furnished and installed by the contractor shall be the
responsibility of the Contractor. The Contractor shall provide, in addition,
temporary instrumentation and other measuring devices, test
instruments, calibrating devices etc. and labour required for successful
performance of these operations. If it is anticipated that the above test
may prolong for a long time, the Contractor’s workmen required for the
above test shall always be present at site during such operations.
10.01.00 All erection & commissioning checks shall be as per manufacturer’s

manual on mutually agreed terms.
(a) As soon as the facilities or part thereof has been completed operationally
and structurally and before start-up, each item of the equipment and
systems forming part of facilities shall be thoroughly cleaned and then
inspected jointly by the Employer and the Contractor for correctness of
and completeness of facility or part thereof and acceptability for initial pre-
commissioning tests, commissioning and start-up at Site. The list of pre-
commissioning tests to be performed shall be as mutually agreed and
included in the Contractor's quality assurance programme as well as
those included elsewhere in the Technical Specifications.
(b) The Contractor's pre-commissioning/ commissioning/start-up engineers,

specially identified as far as possible, shall be responsible for carrying out
all the pre-commissioning tests at Site. On completion of inspection,
checking and after the pre-commissioning tests are satisfactorily over, the
commissioning of the complete facilities shall be commenced during
which period the complete facilities, equipments shall be operated integral
with sub-systems and supporting equipment as a complete plant.
(c) The time consumed in the inspection and checking of the units shall be
considered as a part of the erection and installation period.
(d) The check outs during the pre - commissioning period should be
programmed to follow the construction completion schedule. Each
equipment/system, as it is completed in construction and turned over for
commissioning (start-up), should be checked out and cleaned. The
checking and inspection of individual systems should then follow a

prescribed commissioning documentation [SCL (Standard Check List) /
TS (Testing Schedule) / CS (Commissioning Schedule)] to be furnished
by the manufacturer/supplier.
(e) The Contractor shall conduct vibration testing to determine the 'base line'
of performance of all plant rotating equipment. These tests shall be
conducted when the equipment is running at the base load, peak load as
well as lowest sustained operating condition as far as practicable.
11.00.00 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION
In addition to the requirements given in Erection Conditions of Contract

(ECC) the following shall also cover:
(a.) Working platforms should be fenced and shall have means of

access.
(b.) Ladders in accordance with Employer’s safety rules for construction

and erection shall be used. Rungs shall not be welded on columns.
All the stairs shall be provided with handrails immediately after its
erection.
12.00.00 PACKAGING AND TRANSPORTATION
All the equipment shall be suitably protected, coated, covered or boxed

and crated to prevent damage or deterioration during transit, handling and
storage at Site till the time of erection. While packing all the materials, the
limitation from the point of view of the sizes of railway wagons available in
India should be taken account of. The Contractor shall be responsible for
any loss or damage during transportation, handling and storage due to
improper packing. The Employer's Inspector shall have right to insist for
completion of works in shops before dispatch of materials for
transportation.
13.00.00 ELECTRICAL ENCLOSURE
All electrical equipment and devices, including insulation, heating and

ventilation devices shall be designed for ambient temperature and a
maximum relative humidity as specified elsewhere in the specification/
14.00.00 INSTRUMENTATION AND CONTROL
All instrumentation and control systems/ equipment/ devices/

components, furnished under this contract shall be in accordance with the

requirements stated herein, unless otherwise specified in the detailed

specifications.
14.01.00 All instrument scales and charts shall be calibrated and printed in metric
units and shall have linear graduation. The ranges shall be selected to
have the normal reading at 75% of full scale.
All scales and charts shall be calibrated and printed in Metric Units
14.02.00 All instruments and control devices provided on panels shall be of

miniaturized design, suitable for modular flush mounting on panels with
front draw out facility and flexible plug-in connection at rear.
14.03.00 All electronic modules shall have gold plated connector fingers and
further all input and output modules shall be short circuit proof. These
shall also be tropicalised & components shall be of industrial grade or
better.
15.00.00 ELECTRICAL NOISE CONTROL
The equipment furnished by the Contractor shall incorporate necessary

techniques to eliminate measurement and control problems caused by
electrical noise. Areas in Contractor’s equipment which are vulnerable to
electrical noise shall be hardened to eliminate possible problems. Any
additional equipment, services required for effectively eliminating the
noise problems shall be included in the proposal. The equipment shall be
protected against ESD as per IEC-801- 2. Radio Frequency interference
(RFI) and Electro Magnetic Interference (EMI) protection against
hardware damage and control system mal-operations/errors shall be
provided for all systems.
16.00.00 ELECTRONIC MODULE/COMPONENT DETAILS
The Bidder shall have to furnish all technical details including circuit
diagrams, specifications of components, etc., in respect of each and
every electronic card/module as employed on the various solid state as
well as microprocessor based systems and equipment including
conventional instruments, peripherals etc.
It is mandatory for the Bidder to identify clearly the custom built ICs used
in the package. The Bidder shall also furnish the details of any
equivalents of the same.

NTPC LIMITED
SECTION-VI
PART-D
ERECTION CONDITIONS OF
CONTRACTS
CLAUSE NO. ERECTION CONDITIONS OF CONTRACTS
ERECTION CONDITIONS OF CONTRACT

1.00.00 GENERAL
1.01.00 The following provisions shall supplement the conditions already

contained in the other parts of these specifications and documents and
shall govern that portion of the work of this contract which is to be
performed at site. The erection requirements and procedures not specified
in these documents shall be in accordance with the recommendations of
the equipment manufacturer, or as mutually agreed to between the
Employer and the Contractor prior to commencement of erection work.
1.02.00 The Contractor upon signing of the Contract shall, in addition to a Project
Co-ordinator, nominate another responsible officer as his representative at
Site suitably designated for the purpose of overall responsibility and co-
ordination of the Works to be performed at Site. Such a person shall
function from the Site office of the Contractor during the pendency of Con-
tract.
2.00.00 CODE REQUIREMENTS
The erection requirements and procedures to be followed during the

installation of the equipment shall be in accordance with the relevant
Government of India Rules & Codes, accepted good practices in the
industry and shall fulfill all statutory requirements.
3.00.00 ELECTRICAL SAFETY REGULATIONS
The contractor shall ensure that entire electrical installation work is

executed by adopting applicable statutory safety regulations and best
practices in the industry. The Contractor shall employ the necessary
number of qualified, full time electricians to maintain his temporary
electrical installation.
4.00.00 INSPECTION AND TESTING INSPECTION CERTIFICATES
The provisions of the clause entitled Inspection and Testing in the

Technical Specification, shall also be applicable to the erection portion of
the Works. The Employer shall have the right to re-inspect any equipment
though previously inspected and approved by him at the Contractor’s
works, before and after the same are erected at Site. If by the above
inspection, the Employer rejects any equipment, the Contractor shall make
good for such rejections either by replacement or modification/ repairs as
at Rajgarh(M.P.) Part-D Section-VI
may be necessary to the satisfaction of the Employer. Such replacements

will also include the replacements or re-execution of such of those works
of other Contractors and/or agencies, which might have got damaged or
affected by the replacements or re-work done to the Contractor’s work.
5.00.00 CONTRACTOR’S SITE OFFICE ESTABLISHMENT
The Contractor shall establish an Office at the Site and keep posted an
authorised representative for the purpose of the Contract. Any written
order or instruction of the Employer or his duly authorised representative
shall be communicated to the said authorised resident representative of
the Contractor and the same shall be deemed to have been
communicated to the Contractor at his legal address
6.00.00 CONTRACTOR’S FIELD OPERATION
The Contractor shall keep the Employer informed in advance regarding his
field activity plans and schedules for carrying out each part of the works.
Any review of such plan or schedule or method of work by the Employer
shall not relieve the Contractor of any of his responsibilities towards the
field activities. Such reviews shall also not be considered as an
assumption of any risk or liability by the Employer or any of his
representatives and no claim of the Contractor will be entertained because
of the failure or inefficiency of any such plan or schedule or method of
work reviewed. The Contractor shall be solely responsible for the safety,
adequacy and efficiency of plant and equipment and his erection methods.
The Contractor shall have the complete responsibility for the conditions of
the Work-Site including the safety of all persons employed by him or his
Sub-Contractor and all the properties under his custody during the
performance of the work. This requirement shall apply continuously till the
completion of the Contract and shall not be limited to normal working
hours. The construction review by the Employer is not intended to include
review of Contractor’s safety measures in, on or near the Work-Site, and
their adequacy or otherwise.
7.00.00 PROTECTION OF WORK
The Contractor shall have total responsibility for protecting his works till it
is finally taken over by the Employer. No claim will be entertained by the
Employer or the representative of the Employer for any damage or loss to
the Contractor’s works and the Contractor shall be responsible for
complete restoration of the damaged works to original conditions to
comply with the specification and drawings. Should any such damage to
the Contractor’s Works occur because of any other agency/individual not
being under his supervision or control, the Contractor shall make his claim
directly with the party concerned. The Contractor shall not cause any
delay in the repair of such damaged Works because of any delay in the
resolution of such disputes. The Contractor shall proceed to repair the
Work immediately and no cause thereof will be assigned pending
resolution of such disputes.
8.00.00 FACILITIES TO BE PROVIDED BY THE CONTRACTOR
Contractor's site office Establishment
The Contractor shall establish a site office at the site and keep posted an
authorized representative for the purpose of the contract, pursuant to
GCC.
Tools, tackles and scaffoldings
The Contractor shall provide all the construction equipments, tools, tackles
and scaffoldings required for pre-assembly, installation, testing,
commissioning and conducting Guarantee tests of the equipments
covered under the Contract. The Contractor shall arrange machinery &
equipment such as Dozer, Hydra, Cranes, Trailer, etc. wherever required
for the purpose of fabrication, erection and commissioning.
Testing Equipment and Facilities:
The contractor shall provide the necessary testing, equipment and

facilities.
Testing of construction material at the site:
Contractor shall make arrangements for the testing of construction

material at the site wherever required, under the scope of services of the
contract.
First-aid
The Contractor shall provide necessary first-aid facilities for all his
employees, representatives and workmen working at the Site. Enough
number of Contractor’s personnel shall be trained in administering first-
aid.
Water

Contractor shall make all arrangements himself for the supply of

construction water as well as potable water for labour and other personnel
at the worksite/colony.
9.00.00 FIRE PROTECTION
The work procedures that are to be used during the erection shall be
those which minimise fire hazards to the extent practicable. Combustible
materials, combustible waste and rubbish shall be collected and removed
from the Site regularly. Fuels, oils and volatile or flammable materials shall
be stored away from the construction and equipment and materials
storage areas in safe containers. Untreated canvas, paper, plastic or other
flammable flexible materials shall not at all be used at Site for any other
purpose unless otherwise specified. If any such materials are received
with the equipment at the Site, the same shall be removed and replaced
with acceptable material before moving into the construction or storage
area.
All materials used for storage or for handling of materials shall be of water
proof and flame resistant type. All the other materials such as working
drawings, plans etc. which are combustible but are essential for the works
to be executed shall be protected against combustion resulting from
welding sparks, cutting flames and other similar fire sources.
All the Contractor’s supervisory personnel and sufficient number of

workers shall be trained for fire-fighting and shall be assigned specific fire
protection duties. Enough of such trained personnel must be available at
the Site during the entire period of the Contract.
The Contractor shall provide suitable quantity & type fire protection
equipment for the warehouses, office, temporary structures etc.
10.00.00 SECURITY
The Contractor shall have total responsibility for all equipment and
materials in his custody stores, loose, semi-assembled and/or erected by
him at Site. The Contractor shall make suitable security arrangements
including employment of security personnel to ensure the protection of all
materials, equipment and works from theft, fire, pilferage and any other
damages and loss.
11.00.00 PACKAGING AND TRANSPORTATION
All the equipments shall be suitably protected, coated, covered or boxed

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

and boxed or crated for moist humid tropical shipment and to prevent
damage or deterioration during handling and storage at the site.
Equipment shall be packed with suitable desiccants, sealed in water proof

vapour-proof wrapping and packed in lumber of plywood enclosures,
suitably braced, tied and skidded. Lumber enclosures shall be solid, not
slatted.
Desiccants shall be either silica gel or calcium sulphate, sufficiently

ground to provide the required surface area and activated prior to placing
in the packaging. Calcium sulphate desiccants shall be of a chemical
nature to absorb moisture. In any case, the desiccant shall not be of a
type that will absorb enough moisture to go into solution. Desiccants shall
be packed in porous containers, strong enough to withstand handling
encountered during normal shipment. Enough desiccant shall be used for
the volumes enclosed in wrapping.
Packaging or shipping units shall be designed within the limitations of

unloading facilities and the equipment which will be used for transport.
Complications involved with ocean shipment and the limitations of ports,
railways and roads shall be considered. It shall be the Contractor's
responsibility to investigate these limitations and to provide suitable
packaging to permit safe handling during transit and at the job site.
Electrical equipment, control and instrumentation shall be protected

against moisture and water damage. All external gasket surfaces and
flange faces, couplings, motor pump shafts, bearing and like items shall
be thoroughly cleaned and coated with rust preventive compound as
specified above and protected with suitable wood, metal or other

substantial type covering to ensure their full protection.
Equipment having antifriction or sleeve bearings shall be protected by

weather tight enclosures.
Coated surfaces shall be protected against impact, abrasion,

discolouration and other damage. Surfaces which are damaged shall be
repaired.
All exposed threaded parts shall be greased and protected with metallic or
other substantial type protectors. All female threaded openings shall be
closed with forged steel plugs. All pipings, tubing, and conduit equipment
and other equipment openings shall be sealed with metallic or other rough
usage covers and tapped to seal the interior of the equipment piping,
tubing, or conduit.
Provisions shall be made to ensure that water does not enter any
equipment during shipment or in storage at the plant site.
Returnable containers and special shipping devices shall be returned by

the manufacturer's field representative at the Contractor's expense.
While packaging the material, care shall be taken for the limitation from
the point of view of availability of railway wagon sizes in India.
13.00.00 MATERIALS HANDLING AND STORAGE
All the equipments furnished under the Contract and arriving at Site shall
be promptly received, unloaded and transported and stored in the storage
spaces by the Contractor.
Contractor shall be solely responsible for any shortages or damage in

transit, handling and / or in storage and erection of the equipment at Site.
Any demurrage, wharfage and other such charges claimed by the trans-
porters, railways etc. shall be to the account of the Contractor.
The equipment stored shall be properly protected to prevent damage

either to the equipment or to the floor where they are stored. The
equipment from the store shall be moved to the actual location at the
appropriate time so as to avoid damage of such equipment at Site.
All electrical panels, controls gear, motors and such other devices shall be
properly dried by heating before they are installed and energised. Motor
bearings, slip rings, commutators and other exposed parts shall be
protected against moisture ingress and corrosion during storage and

periodically inspected. Heavy rotating parts in assembled conditions shall
be periodically rotated to prevent corrosion due to prolonged storage.
All the electrical equipment such as motors, etc. shall be periodically

tested for insulation resistance from the date of receipt till the date of
commissioning and a record of such measured insulation values
maintained by the Contractor. Such records shall be open for inspection
by the Employer.
The Contractor shall ensure that all the packing materials and protection
devices used for the various equipments during transit and storage are
removed before the equipment are installed.
The consumables and other supplies likely to deteriorate due to storage

must be thoroughly protected and stored in a suitable manner to prevent
damage or deterioration in quality by storage.
All the materials stored in the open or dusty location must be covered with
suitable weatherproof and flameproof covering material wherever
applicable.
14.00.00 CONSTRUCTION MANAGEMENT
Contractor shall be responsible for performance of his works in

accordance with the specified construction schedule. If at any time, the
Contractor is falling behind the schedule, he shall take necessary action to
make good for such delays by increasing his work force or by working
overtime or otherwise accelerate the progress of the work to comply with
the schedule and shall communicate such actions in writing to the
Employer, satisfying that his action will compensate for the delay. The
Contractor shall not be allowed any extra compensation for such action.
The Employer shall however not be responsible for provision of additional

labour and/or materials or supply or any other services to the Contractor.
15.00.00 FIELD OFFICE RECORDS
The Contractor shall maintain at his Site Office up-to- date copies of all
drawings, specifications and other Contract Documents and any other
supplementary data complete with all the latest revisions thereto. The
Contractor shall also maintain in addition the continuous record of all
changes to the above Contract Documents, drawings, specifications,
supplementary data, etc. effected at the field and on completion of his total
assignment under the Contract shall incorporate all such changes on the
drawings and other Engineering data to indicate as installed conditions of
the equipment furnished and erected under the Contract. Such drawings
and Engineering data shall be available for inspection & review to the
Employer.
16.00.00 PROTECTION OF PROPERTY AND CONTRACTOR’S LIABILITY
The Contractor shall be responsible for any damage resulting from his
operations. He shall also be responsible for protection of all persons
including members of public and employees of the Employer and his own
employees and all public and private property including structures,
building, other plants and equipments and utilities either above or below
the ground.
The Contractor will ensure provision of necessary safety equipment such

as barriers, sign - boards, warning lights and alarms, etc. to provide
adequate protection to persons and property.
17.00.00 PAINTING
All exposed metal parts of the equipment including pipings, structure

railings, etc. wherever applicable, after installation unless otherwise
surface protected, shall be first painted in accordance with relevant codes
& standards, after throughly cleaning all such parts of all dirt, rust, scales,
greases, oils and other foreign materials by wire brushing, scraping or
sand blasting.
18.00.00 UNFAVOURABLE WORKING CONDITIONS
The Contractor shall confine all his field operations to those works which
can be performed without subjecting the equipment and materials to
adverse effects during inclement weather conditions, like monsoon,
storms, etc. and during other unfavourable construction conditions. No
field activities shall be performed by the Contractor under conditions which
might adversely affect the quality and efficiency thereof, unless special
precautions or measures are taken by the Contractor in a proper and
satisfactory manner in the performance of such Works and with the
concurrence of the Employer. Such unfavourable construction conditions
will in no way relieve the Contractor of his responsibility to perform the
Works as per the schedule.
19.00.00 PROTECTION OF MONUMENTS AND REFERENCE POINTS
The Contractor shall ensure that any finds such as relic, antiquity, coins,
fossils, etc. which he may come across during the course of performance

of his Works either during excavation or elsewhere, are properly protected

and handed over to the Employer.
20.00.00 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/

EQUIPMENT BASES
The surfaces of foundations shall be dressed to bring the top surface of

the foundations to the required level, prior to placement of
equipment/equipment bases on the foundations.
All the equipment/ equipment bases shall be grouted and finished as per
these specifications unless otherwise recommended by the equipment
manufacturer.
The concrete foundation surfaces shall be properly prepared by chipping,

grinding as required to bring the top of such foundation to the required
level, to provide the necessary roughness for bondage and to assure
enough bearing strength.
20.01.00 GROUT
The grout shall be high strength grout having a minimum characteristic

compressive strength of 60 N/mm2 at 28 days. The grout shall be chloride
- free, cement based, free flowing, non-metallic grout.
The Grout shall have good flowability even at very low water/ grout
powder ratio.
The Grout shall have characteristics of controlled expansion to be able to

occupy its original volume to fill the voids and to compensate for
shrinkage. Grout shall be of pre-mix variety so that only water needs to be
added before use.
The mixing of the Grout shall conform to the recommendations of the

manufacturer of the Grout.
20.02.00 PLACING OF GROUT
After the base has been prepared, its alignment and level has been
checked and approved and before actually placing the grout, a low dam
shall be set around the base at a distance that will permit pouring and
manipulation of the grout. The height of such dam shall be at least 25mm
above the bottom of the base. Suitable size and number of chains shall
be introduced under the base before placing the grout, so that such chains
can be moved back & forth to push the grout into every part of the space
under the base.
The grout shall be poured either through grout holes if provided or shall be
poured at one side or at two adjacent sides to make the grout move in a
solid mass under the base and out in the opposite side. Pouring shall be
continued until the entire space below the base is thoroughly filled and the
grout stands at least 25 mm higher all around than the bottom of the base.
Enough care should be taken to avoid any air or water pockets beneath
the bases.
In addition to the above, recommendations of Grout manufacturer shall

also be followed.
20.03.00 FINISHING OF THE EDGES OF THE GROUT
The poured grout should be allowed to stand undisturbed until it is well

set. Immediately thereafter, the dam shall be removed and grout which
extends beyond the edges of the structural or equipment base plates shall
be cut off, flushed and removed. The edges of the grout shall then be
pointed and finished with 1:2 cement mortar pressed firmly to bond with
the body of the grout and smoothened with a tool to present a smooth
vertical surface. The work shall be done in a clean and scientific manner
and the adjacent floor spaces, exposed edges of the foundations, and
structural steel and equipment base plates shall be thoroughly cleaned of
any spillage of the grout.
21.00.00 SHAFT ALIGNMENTS
All the shafts of rotating equipment shall be properly aligned to those of

the matching equipments to as perfect accuracy as practicable. The
equipment shall be free from excessive vibration so as to avoid
overheating of bearings or other conditions which may tend to shorten the
life of the equipment. The vibration level of rotating equipments measured
at bearing housing shall conform to VDI 2056. All bearings, shafts and
other rotating parts shall be thoroughly cleaned and suitably lubricated
before starting.
22.00.00 DOWELLING
All the motors and other equipment shall be suitably doweled after
alignment of shafts with tapered machined dowels as per the direction of
the Employer.
23.00.00 CABLING

at Rajgarh(M.P.) Part-D Section-VI 18
All cables shall be supported by conduits or cable tray run in air or in cable
channels. These shall be installed in exposed runs parallel or
perpendicular to dominant surfaces with right angle turn made of
symmetrical bends or fittings. When cables are run on cable trays, they
shall be clamped at a minimum intervals of 2000mm.
Each cable, whether power or control, shall be provided with a metallic or

plastic tag of an approved type, bearing a cable reference number
indicated in the cable and conduit list (prepared by the Contractor), at
every 5 meter run or part thereof and at both ends of the cable adjacent to
the terminations. Cable routing is to be done in such a way that cables
are accessible for any maintenance and for easy identification.
Sharp bending and kinking of cables shall be avoided. Installation of

other cables like high voltage, coaxial, screened, compensating, mineral
insulated shall be in accordance with the cable manufacturer’s
recommendations. Wherever cables cross roads and water, oil, sewage
or gaslines, special care should be taken for the protection of the cables in
designing the cable channels.
In each cable run some extra length shall be kept at a suitable point to
enable one or two straight through joints to be made, should the cable
develop fault at a later date.
Control cable terminations shall be made in accordance with wiring

diagrams, using identifying codes subject to the Employer’s approval.
Multicore control cable jackets shall be removed as required to train and
terminate the conductors. The cable jacket shall be left on the cable, as
far as possible, to the point of the first conductor branch. The insulated
conductors from which the jacket is removed shall be neatly twined in
bundles and terminated. The bundles shall be firmly but not tightly tied
utilising plastic or nylon ties or specifically treated fungus protected cord
made for this purpose. Control cable conductor insulation shall be
securely and evenly cut.
The connectors for control cables shall be covered with a transparent

insulating sleeve so as to prevent accidental contact with ground or
adjacent terminals and shall preferably terminate in Elmex terminals and
washers. The insulating sleeve shall be fire resistant and shall be long
enough to over pass the conductor insulation. All control cables shall be
fanned out and connection made to terminal blocks and test equipment for
proper operation before cables are corded together.
24.00.00 EQUIPMENT INSTALLATION

24.01.00 General Requirements
The Contractor shall furnish all construction materials, tools and

equipment and shall perform all work required for complete installation of
all control and instrument equipment furnished under this specification.
Contractor shall prepare detailed installation drawings for each equipment

furnished under this specification. Installation of all equipment/systems
furnished by this specification shall be as per installation drawings.
Erection procedures not specified herein shall be in accordance with the

recommendations of the equipment manufacturers. The procedures shall
be acceptable to the Employer.
The Contractor shall coordinate his work with other suppliers where their
instruments and devices are to be installed under specifications.
24.02.00 Installation Materials
All materials required for installation, testing and commissioning of the

equipment shall be furnished by the Contractor.
24.03.00 Regulatory Requirements
All installation procedures shall confirm with the accepted good

engineering practice and with all applicable governmental laws,
regulations and codes.
24.04.00 Cleaning
All equipment shall be cleaned of all sand, dirt and other foreign materials
immediately after removal from storage and before the equipment is
installed.
24.05.00 Installation of Field Mounted Instruments/Devices and Non-free

Standing Equipment
The installation drawings for all field mounted

equipment/instrument/devices furnished under this specification shall meet
the requirements of this specification, applicable codes and standards and
recommendations of manufacturers of instruments/devices. In addition to
above relevant Portion as specified elsewhere in technical specification
may be referred.

Field mounted instruments and accessories shall be bracket or sub panel

mounted on the nearest suitable firm steel work or masonry. The
brackets, stands, supports and other miscellaneous hardware required for
mounting instruments and accessories such as receiver gauge, air set,
valve manifold, purge-meter etc. shall be furnished and installed. No field
mounted instruments shall be installed such that it depends for support or
rigidity on the impulse piping or on electrical connection to it.
All free standing instrumentation cabinets and panels shall be located

within the construction tolerances of +/- 3 mm of the location dimensions
indicated on the plant arrangement drawings.
Non-free standing local enclosures and cabinets shall be mounted in

accessible locations on columns, walls, or stands. Bracket and stands
shall be fabricated as required to install the local enclosures and cabinets
in a workman like manner. Rough edges and welds on all fabricated
supports shall be ground smooth. The supports shall be finished with two
coats of primer and two coats of paint as specified in this part.
24.06.00 Defects
All defects in erection shall be corrected to the satisfaction of the

Employer and the Project Manager. The dismantling and reassembly of
Contractor furnished equipment to remove defective parts, replace parts,
or make adjustments shall be included as a part of the work under these
specifications.
The removal of control and instrument equipment in order to allow bench

calibration, if required, and the re-installation of the said equipment after
calibration shall also be included as a part of the work under these
specifications.
24.07.00 Equipment Protection
All equipment to be erected under these specifications shall be protected

from damage of any kind from the time of contract award until
commissioning of each unit.
The equipment shall be protected during storage as described herein.
Equipment shall be protected from weld spatter during construction.
Suitable guards shall be provided for protection of personnel on all

exposed rotating or moving machine parts. All such guards with

necessary spares and accessories shall be designed for easy removal

and maintenance.
Equipment having glass components such as gauges, or equipment

having other easily breakable components, shall be protected during the
construction period with plywood enclosures or other suitable means.
Broken, stolen, or lost components shall be replaced by the Contractor.
Machine finished surfaces, polished surfaces, or other bare metal surfaces

which are not to be painted, such as machinery shafts and couplings shall
be provided temporary protection during storage and constructional
periods by a coating of a suitable non- drying, oily type, rust preventive
compound.
25.00.00 DEVIATIONS DISPOSITIONING:
Any deviation to the contract and employer approved documents shall be

properly recorded in the format prescribed by NTPC. All the deviations
shall be bought to the knowledge of employer’s representative for suitable
dispositioning.
26.00.00 STATUTORY REQUIREMENTS
In addition to the local laws and regulations, the Contractor shall also
comply with the Minimum Wages Act and the Payment of Wages Act (both
of the Government of India) and the rules made there under in respect of
its labour and the labour of its sub-contractors currently employed on or
connected with the contract.
All registration and statutory inspection fees, if any, in respect of his work
pursuant to this Contract shall be to the account of the Contractor.
However, any registration, statutory inspection fees lawfully payable under
the provisions of any statutory laws and its amendments from time to time
during erection in respect of the plant equipment ultimately to be owned by
the Employer, shall be to the account of the Employer. Should any such
inspection or registration need to be re-arranged due to the fault of the
Contractor or his Sub-Contractor, the additional fees for such inspection
and/or registration shall be borne by the Contractor.
27.00.00 EMPLOYMENT OF LABOUR
In addition to all local laws and regulations pertaining to the employment

of labour to be complied with by the Contractor pursuant to GCC, the
Contractor will be expected to employ on the work only his regular skilled
employees with experience of the particular work. No female labour shall
be employed after darkness. No person below the age of eighteen years

shall be employed.
All travelling expenses including provisions of all necessary transport to

and from Site, lodging allowances and other payments to the Contractor’s
employees shall be the sole responsibility of the Contractor.
In case the Employer becomes liable to pay any wages or dues to the
labour or any Government agency under any of the provisions of the
Minimum Wages Act, Workmen Compensation Act, Contact Labour
Regulation Abolition Act or any other law due to act of omission of the
Contractor, the Employer may make such payments and shall recover the
same from the Contractor’s Bills.
28.00.00 WORK & SAFETY REGULATIONS
The Contractor shall ensure proper safety of all the workmen, materials,
plant and equipments belonging to him or to Employer or to others,
working at the Site. The Contractor shall also be responsible for provision
of all safety notices and safety equipment required both by the relevant
legislation and the Employer as he may deem necessary.
28.01.00 Where it is necessary to provide and/or store petroleum products or

petroleum mixtures and explosives, the contractor shall be responsible for
carrying-out such provision and/or storage in accordance with the rules
and regulations laid down in petroleum act 1934, explosives act, 1948,
and petroleum and carbide of calcium manual published by the chief
inspector of explosives of india. All such storage shall have prior approval
of the employer. In case, any approvals are necessary from the chief
inspector (explosives) or any statutory authorities, the contractor shall be
responsible for obtaining the same.
Where explosives are to be used, the same shall be used under the direct
control and supervision of an expert, experienced, qualified and
competent person strictly in accordance with the Code of Practices/Rules
framed under Indian Explosives Act pertaining to handling, storage and
use of explosives.
28.02.00 All equipment used in construction and erection by Contractor shall meet
Indian/International Standards and where such standards do not exist, the
Contractor shall ensure these to be absolutely safe. All construction and
erection equipments shall be strictly operated and maintained by the
Contractor in accordance with statutory safety regulations. Periodical
Examinations and all tests for all lifting/ hoisting equipment & tackles shall
be carried-out in accordance with the relevant provisions of Factories Act
1948, Indian Electricity Act 1910 and associated Laws/Rules in force from
time to time.
28.03.00 The Contractor shall provide suitable safety equipment of prescribed

standard to all employees and workmen according to the need, as may be
directed by Employer who will also have right to examine these safety
equipments to determine their suitability, reliability, acceptability and
adaptability.
(a) Working platforms should be fenced and shall have means of access.
(b) Ladders in accordance with stautory safety rules for construction and
erection shall be used. Rungs shall not be welded on columns. All the
stairs shall be provided with handrails immediately after its erection.
The Contractor shall provide safe working conditions to all workmen and
employees at the Site including safe means of access, railings, stairs,
ladders, scaffoldings etc. The scaffoldings shall be erected under the
control and supervision of an experienced and competent person. For
erection, good and standard quality of material only shall be used by the
Contractor.
28.04.00 The Contractor employing more than 250 workmen whether temporary,
casual, probationer, regular or permanent or on contract, shall employ
atleast one full time officer exclusively as Safety Officer to supervise
safety aspects of the equipments and workmen, who will coordinate with
the Employer Safety Officer. In case of work being carried out through
sub-Contractors, the Sub-Contractor’s workmen/employees will also be
considered as the Contractor’s employees/workmen for the above
purpose.
In case any accident occurs during the construction/ erection or other

associated activities undertaken by the Contractor thereby causing any
minor or major or fatal injury to his employees due to any reason, what-
soever, it shall be the responsibility of the Contractor to promptly inform
the same to the Employer and also to all the authorities envisaged under
the applicable laws.
The Contractor shall follow and comply with relevant provisions of

applicable laws pertaining to the safety of workmen, employees plant and
equipment as may be prescribed from time to time without any demur,
protest or contest or reservation.
If the Contractor does not take all safety precautions and/or fails to
comply with the Safety Rules as prescribed by the Employer or under the
applicable law for the safety of the equipment and plant and for the safety
of personnel and the Contractor does not prevent hazardous conditions
which cause injury to his own employees or employees of other
Contractors, or the Employer's employees or any other person who are at
Site or adjacent thereto, the Contractor shall be responsible for payment
of compensation to Employer as per the following schedule:-
1 Fatal injury or accident. These Rs. 1,00,000/- per person

are causing death applicable
2 Major injuries or accident Rs. 20,000/- per personfor death/
causing 25% or more injury to any
permanent disablement to person
workmen or employees whosoever
Permanent disablement shall have same meaning as indicated in

Workmen’s Compensation Act. The compensation mentioned above shall
be in addition to the compensation payable to the workmen/employees
under the relevant provisions of the Workmen’s Compensation Act and
rules framed thereunder or any other applicable laws as applicable from
time to time. In case the Employer is made to pay such Compensation
then the Contractor is liable to reimburse the Employer such amount in
addition to the compensation indicated above.
If the Contractor observes all the Safety Rules and Codes, Statutory Laws
and Rules during the currency of Contract awarded by the Employer and
no accident occurs then the Employer may consider the performance of
the Contractor and award suitable “ACCIDENT FREE SAFETY
MERITORIOUS AWARD” as per scheme as may be announced
separately from time to time.
29.00.00 INSURANCE
In addition to the conditions covered under the Clause entitled “Insurance”

in Section General Conditions of Contract (GCC), the following provisions
will also apply to the portion of works to be done beyond the Contractor’s
own or his Sub-Contractor’s manufacturing Works and all statutory
obligations shall be fulfilled.
29.01.00 WORKMEN’S COMPENSATION INSURANCE
This insurance shall protect the Contractor against all claims applicable under the
Workmen’s Compensation Act, 1948 (Government of India). This policy shall also
cover the Contractor against claims for injury, disability disease or death of his or
his Sub-Contractor’s employees, which for any reason are not covered under the
Workmen’s Compensation Act, 1948. The liabilities shall not be less than the
following:
Workmen's Compensation - As per Statutory Provisions

Employee's Liability - As per Statutory Provisions
29.02.00 COMPREHENSIVE AUTOMOBILE INSURANCE
This insurance shall be in such a form to protect the Contractor against all claims
for injuries, disability, disease and death to members of public including the
Employer’s men and damage to the property of other arising from the use of
motor vehicles during on or off the Site operations, irrespective of the Ownership
of such vehicles. The liability covered shall be as herein indicated:
Fatal Injury : Rs.100,000 each person

: Rs.200,000 each occurrence
Property Damage : Rs.100,000 each occurrence
29.03.00 COMPREHENSIVE GENERAL LIABILITY INSURANCE
The insurance shall protect the Contractor against all claims arising from
injuries, disabilities, disease or death of members of public or damage to
property of others, due to any act or omission on the part of the Contractor,
his agents, his employees, his representatives and Sub-Contractors or
from riots, strikes and civil commotion. This insurance shall also cover all
the liabilities of the Contractor arising out of the Clause entitled “Defence
of Suits” in Section General Conditions of Contract (GCC).
The hazards to be covered will pertain to all the Works and areas where
the Contractor, his Sub-Contractors, his agents and his employees have
to perform work pursuant to the Contract.
The above are only illustrative list of insurance covers normally required
and it will be the responsibility of the Contractor to maintain all necessary
insurance coverage to the extent both in time and amount to take care of
all his liabilities either direct or indirect, in pursuance of the Contract.


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NTPC Limited

(A GOVERNMENT OF INDIA ENTERPRISE)

Bid Document No: CS-5707-004-9

Development of Solar Photo Bid Doc. No. Technical Specifications Page

Development of Solar Photo Bid Doc. No. Technical Specifications Page

1. Land details and topographical survey of the solar park.

Development of Solar Photo Bid Doc. No. Technical Specifications Page

Design, engineering, supply, packing and forwarding, transportation, unloading,

3.1 PLANT EQUIPMENT AND ASSOCIATED WORKS

3.1.1 Civil Works

3.1.2 Solar PV Plant

(a) Suitable Nos. of SPV Module ≥ 150 Wp

Development of Solar Photo Bid Doc. No. Technical Specifications Page

3.1.4 Evacuation of Power through 11 kV underground cable to 11/132 kV

3.1.6 Fire protection and fire fighting equipments.

3.2 ENGINEERING DATA & DRAWINGS

3.2.1 Engineering drawings, data etc including calculations shall be prepared by

3.3 TRAINING OF EMPLOYERS PERSONNEL

3.4 TERMINAL POINTS & EXCLUSIONS

Development of Solar Photo Bid Doc. No. Technical Specifications Page

4.1 SPV Module & Guaranteed Generation

Month Ambient temperature Solar Global radiation on horizontal

4.1.1 General requirements for PV module:

a. Modules shall be manufactured in India. Modules shall be made up of mono or

b. The interconnected cells shall be laminated in vacuum to withstand adverse

c. The module frame is made of corrosion resistant materials, preferably having

Development of Solar Photo Bid Doc. No. Technical Specifications Page

e. Surge protection devices to be provided at junction boxes and modules shall be

i. Name of the manufacturer of the PV module

ii. Name of the manufacturer of Solar Cells

iv. Country of origin(separately for solar cells and module)

v. I-V curve for the module

vi. Wattage, Im, Vm and FF for the module

vii. Unique Serial No and Model No of the module

viii. Date and year of obtaining IEC PV module qualification certificate

Development of Solar Photo Bid Doc. No. Technical Specifications Page

x. Other relevant information on traceability of solar cells and module as per

4.1.2 MODULE MOUNTING STRUCTURE

1. Modules shall be mounted on a non-corrosive support structures

3. The base columns shall be made with reinforced cement concrete.

4.2 INSTRUMENTS FOR METEOROLOGICAL MEASUREMENTS.

Bidder shall provide following measuring instruments with all necessary

1. Spectral Response- 0.31 to 2.8 micron.

Each instrument shall be supplied with necessary cables. Calibration

Bidder shall provide anemometer on tubular type made up of hot dipped

4.3 POWER CONDITIONING UNIT

Power Conditioning Unit (PCU) consisting of an electronic Inverter alongwith

4.3.1 General Requirements

Development of Solar Photo Bid Doc. No. Technical Specifications Page

f. Electrical surge protection shall be provided with surge protection device

h. The PCU shall have anti islanding protection.

Development of Solar Photo Bid Doc. No. Technical Specifications Page

• BASIC SYSTEM OPERATION (FULL AUTO MODE):

• MAXIMUM POWER POINT TRACKER (MPPT):

Automatic ‘sleep’ mode shall be provided so that unnecessary losses are

4.3.2 Maximum Power Tracking

Output frequency 50 Hz +/- 0.5% Hz ( Inverter to follow

b. Sinusoidal current modulation with excellent dynamic response.

c. Unit wise & integrated Data logging.