Tendernotice 1

TAMIL NADU GENERATION AND DISTRIBUTION
CORPORATION LIMITED (TANGEDCO)
METTUR THERMAL POWER STATION - I

(4X210MW)
TENDER SPECIFICATION
FOR
SEMI DRY FLUE GAS DESULPHURIZATION
(FGD) SYSTEM & ITS AUXILIARIES
VOLUME – II A
GENERAL
TECHNICAL SPECIFICATION
MECON LIMITED
RANCHI – 834 002
DOC. No: MEC/11/S3/10KP/TS/2569/R-0, Rev. 01 November, 2020

© 2020 MECON Limited. All rights reserved.
METTUR THERMAL POWER STATION-I (4X210MW)
TENDER SPECIFICATION FOR

SEMI DRY FLUE GAS DESULPHURIZATION(FGD) SYSTEM
& ITS AUXILIARIES
INDEX TO VOLUMES
Volumes Title
Volume – I Commercial
Volume – II Technical
Volume - IIA General Technical Specification
Section 01.00 Preamble
Section 02.00 Intent of specification
Section 03.00 Project information
Section 04.00 Special Instructions to Bidder
Section 05.00 Scope of Work, Supply & Services
Section 06.00 Quality Assurance System / Requirement
Section 07.00 Painting
Section 08.00 Finalization of Sub-vendors / Sub-contractors
Section 09.00 Performance Guarantees
Section 10.00 Terminal Points & Exclusion
Section 11.00 Layout and Maintenance Requirement
Section 12.00 Drawings / Documents to be submitted along with Bid / Offer
and after award of contract
Volume - IIB Technical Specification
Section 01.00 Flue Gas Desulphurization System (Semi Dry)
Section 02.00 Technical Data Sheets – Mechanical
Volume -IIC Balance of Plant (BOP) Facilities
Section 01.00 Water Supply System
Section 02.00 Air conditioning & Ventilation System
Section 03.00 Elevators, Cranes & Hoists
Section 04.00 Fire Protection System
Section 05.00 Piping, Valves & Fittings
Section 06.00 Thermal Insulation, Lagging, Cladding
Section 07.00 Compressed Air System
Vol. – IIA INDEX TO VOLUME Page 2 of 3


& ITS AUXILIARIES
Volumes Title
Volume - III Instrumentation & Control System
Volume -IV Electrical System
Volume -V Civil, Architectural & Structural Works
Volume -VA Civil Works.
Volume - VB Architectural Works
Volume - VC Structural Works
Volume - VI Mandatory Spares and Tools & Tackles
Volume - VII Tender Drawings

SECTION 01.00
PREAMBLE
© 2020 MECON Limited. All rights reserved..

METTUR THERMAL POWER STATION - I (4X210MW)

& ITS AUXILIARIES
01.00 PREAMBLE
01.01 M/s Tamil Nadu Generation and Distribution Corporation Limited intends
to install suitable Flue Gas Desulphurisation Plant (FGD) in the existing 4
X 210 MW Mettur Thermal Power Station-I at Mettur, in order to adhere
to MoEF&CC latest Notification. This Tender Specification is meant for
inviting bids from prospective FGD plant suppliers for the scope of work
given in the Tender Specification.
01.02 This Tender Specification shall be read in conjunction with general

conditions and other project requirements as described in other parts /
sections / volumes of this Tender document. Tender Document has been
structured as follows:
Volumes Title
Section 02.00 Intent of Specification
Section 03.00 Project Information
Section 12.00 Drawings / Documents to be submitted along with Bid /
Offer and after award of contract
Vol. – IIA, Section 01.00 PREAMBLE Page 1 of 2


& ITS AUXILIARIES
Volumes Title
Section 02.00 Air Conditioning & Ventilation System
01.03 Tender drawings
a. The drawings enclosed with the Tender Document form part of the Tender and
shall supplement the requirements specified herein. These drawings shall be
read in conjunction with the texts of the specifications.
b. The Tender drawings are for “Tender Purpose Only” and indicative for
Purchaser’s basic minimum outline requirements to enable the Bidder to make
a suitable offer.
c. Bidder shall note that only certain terminal point details are depicted in the
tender drawings. For complete details of terminal points and scope of work,
relevant write up of Tender document shall also be referred. The terminal
points and scope details shown in the drawings are complementary and
supplementary to that available in the relevant portion of the write up of
Tender Document.
Vol. – IIA, Section 01.00 PREAMBLE Page 2 of 2

SECTION 02.00
INTENT OF SPECIFICATION


& ITS AUXILIARIES
02.00 INTENT OF SPECIFICATION
02.01 This Specification is for installation of Flue gas desulphurization plant (FGD) at
TANGEDCO Limited’s existing 4X210 MW Mettur Thermal Power Station-I, located
at Mettur.
02.02 This specification is intended to cover design, engineering, manufacture / supply,

inspection and testing at supplier’s works, packing, forwarding to site, transportation,
unloading, storage, preservation, insurance, handling at site, pre-assembly, assembly,
erection / supervision of erection, final painting, start-up, pre-commissioning, testing &
trial run, commissioning, performance guarantee testing and warranty of FGD system
up to completion of warranty period, training of purchaser’s personnel for complete
FGD equipment/ system covering all mechanical, electrical, C&I, associated steel
structure, civil & architectural works as indicated in the relevant portion of the technical
specification of Semi Dry Flue Gas desulphurisation system for all units of 210 MW
Steam Generators with complete associated auxiliaries, accessories and other related
items of respective work for the complete FGD plant and equipment on turnkey
Engineering, Procurement and Construction basis, necessary for putting into operation,
a highly reliable, safe, efficient and environmentally compliant FGD Plant.
02.03 The entire scope shall be on EPC turnkey basis and also on single point responsibility
basis.
The scope shall also cover the following activities and services in respect of all the
equipment and works specified in various sections of this specification:
a) Basic Engineering of all equipments/ systems;
b) Detailed design of all the equipments/ systems including complete civil,

architectural & structural works;
c) Providing engineering drawings, data, instruction manuals, as built drawings and

other information for purchaser’s review, approval and records;
d) Compliance with statutory requirements and obtaining clearances from statutory

authorities (local/state/central), wherever required;
e) Complete manufacturing including shop testing;
f) Packing and transportation from the manufacturer’s works to the site including
customs clearance, port charges, if any;
g) Receipt, movement to proper storage, storage, preservation and conservation of
Vol. – IIA, Section 02.00 INTENT OF SPECIFICATION Page 1 of 3


& ITS AUXILIARIES
equipment at the site, movement from storage area to interim/ final foundation
location / Shop.
h) Fabrication, pre-assembly, erection, testing, pre-commissioning and

commissioning and putting into satisfactory operation of all the equipment
including successful completion of Trial operation;
i) Performance guarantee / acceptance tests after successful completion of Trial

operation & commissioning;
j) Supply of mandatory spares as per specified list
k) Supply of any other equipment including special tools and tackles, commissioning
spares and services required for satisfactory completion of the project and
operation and maintenance of the same;
l) Supply of consumables including chemicals, resins, lubricants, lube oils with

topping up requirements, with 10 % additional quantity upto handing over.
m) Training of purchaser’s personnel nominated by the purchaser during erection,

testing and commissioning, and for operation and maintenance;
n) Reconciliation with customs authorities, in case of imported equipments;
o) Satisfactory conclusion of the contract;
p) All items and equipment though not specifically mentioned in the specification,
but needed to complete the system to meet the intent of the specification shall be
deemed to be included in the scope of the bidder.
It is not the intent to completely specify all details of design and construction, but only
to lay down broad sizing and quality criteria for the major equipment and systems and it
is expected that the equipments shall conform in all respects to high standards of
engineering, design and workmanship and shall be capable of performing in continuous
commercial operation up to the bidder’s guarantee in a specified manner acceptable to
the purchaser.
The bidder is required to carefully examine and understand the specifications and seek
clarifications, if required, to ensure that he has understood the specifications as intended
by the purchaser. In the absence of any specific clarifications made by the Bidder during
bidding stage, the interpretation of Purchaser shall be final. The bidder’s offer should
not carry any sections like clarifications, interpretations and/or assumptions. All such
points are required to be clarified during bidding stage.


& ITS AUXILIARIES
In the event of conflict between the requirements of any two clauses of this
specification/document or requirements of different codes/standards, the more stringent
requirement will govern, unless confirmed otherwise by the Purchaser/Consultant in
writing, in reply to a written request from the bidder for such clarifications.
In case all the above requirements are not complied with, the bid may be considered as
incomplete and liable to be treated as non-responsive. Whenever a material or article is
specified or described by the name of a particular brand, manufacturer or vendor, the
specific items mentioned shall be understood as establishing type, function and quality
desired. Other manufacturers’ products may be considered provided sufficient
information is furnished so as to enable the Purchaser to determine without the need for
any additional clarification/data, that the products proposed are proven and equivalent
or superior to those named.

SECTION 03.00
PROJECT INFORMATION
© 2017 M © 2020 MECON Limited. All rights reserved..


SEMI DRY FLUE GAS DESULPHURIZATION(FGD) SYSTEM &
ITS AUXILIARIES
03.00 PROJECT INFORMATION
03.01 This Tender Specification is for installation of Flue gas desulphurization plant (FGD) in
TANGEDCO Limited’s existing 4X210 MW Mettur Thermal Power Station-I.
03.02 General & Project Information
03.02.01 All the facilities of FGD system as covered under this Tender Specification shall be executed as
a single EPC Turnkey Contract on Single Point Responsibility Basis. The power plant site (i.e.
4X210 MW MTPS-I) is located at Mettur.
03.03 Project & Site Information
i) Owner/Purchaser TANGEDCO Limited, Mettur Thermal

Power Station-I (MTPS-I), Mettur Dam -
636406, Tamil Nadu, India
ii) Consultant MECON LIMITED, Ranchi
iii) Project Title Semi Dry Flue Gas Desulphurization System
in 4 X 210 MW MTPS-I.
iv) Location Around 363 km south-west of Chennai and
in Salem District, Tamil Nadu.
v) Latitude 11° 56’ 10” N
vi) Longitude 77° 49’ 10” E
vii) Elevation above MSL (+) 225m from MSL
viii) Near by Village Chinnakkavoor
ix) Nearest City/ Town 56 kms from Salem town, 60
kms from Erode
x) Nearest Railway Station Mettur Dam Railway Station km from
site
xi) Nearest Sea Port Chennai, at a distance of 340 km
.
xii) Nearest Airport Coimbatore at a distance of 140
kms from site. Salem -42 kms
xiii) Road Access/Approach to State Highway no. SH 158 & SH 20.
Site Mettur Thermal Power Plant Road from
SH 20 (Thoppur- Mettur-Bhavani-Erode) -
1.50 km.
xiv) Ambient Temp. Absolute Max. 40°C
Absolute Min. 22°C
xv) Max. Relative Humidity 97%
xvi) Min. Relative Humidity 65%
xvii) Annual Average Rainfall 1123 mm (Avg.) During 2005
xviii) Wind Speed 4.7 km/hr (Max.)
Vol. – IIA, Section 03.00 PROJECT INFORMATION Page 1 of 5


ITS AUXILIARIES
Calm (Min.)
xix) Seismicity Zone III Moderate damage risk zone- IS:
1893 -2002
xx) Languages spoken in the English, Tamil
region
xxi) Tropicalisation All equipment supplied against this
specification shall be given tropical and
fungicidal treatment in view of climatic
conditions prevailing at site.
The plants and equipments covered under this Tender Specification shall consist of the
following:
Four (4) nos. FGD plant for 4x210 MW Thermal Power Station.
Layout of Plant & Equipment shall be such that it provides a complete integrated system for
smooth, efficient and safe operation. The layout scheme, orientation of various facilities etc. are
shown in the layout drawings enclosed with the Tender Specification.
03.04 FGD Design parameters:
Operating Conditions Design Case

Guarantee
case
S. No. Condition Unit 100% TMCR 100% TMCR
1. Flue Gas flow(wet) Nm3/hr. 10,94,650 10,94,650
2. FGD Inlet Gas Temperature °C 140 140
3. PM level at FGD inlet mg/Nm3 <800
4. SO2 Concentration in mg/Nm3(Wet) 1800 1800
flue gas at FGD inlet
5. PM level at FGD outlet mg/Nm3(Wet) 70
6. SO2 (dry) at 6% O2 at FGD mg/Nm3 500 500
outlet
7. SO2 Removal efficiency % 80% 80%
(minimum)
03.05 Primary Fuel Characteristics
Sl. No. Description Symbol Normal Worst Best

Coal Coal Coal
A. Proximate Analysis(As received basis)
1. Total moisture % 15.00 16.00 14.10
2. Ash % 37.40 45.70 26.40
3. Volatile matter % 19.10 18.80 21.30


ITS AUXILIARIES
Sl. No. Description Symbol Normal Worst Best

Coal Coal Coal
4. Fixed carbon % 28.50 19.50 38.20
B. Ultimate Analysis(As received basis)
1. Carbon C% 36.80 28.67 45.88
2. Hydrogen H2% 3.24 3.05 4.09
3. Nitrogen N2% 0.48 0.45 0.54
4. Oxygen (By difference) O2% 5.85 5.38 8.42
5. Sulphur S% 0.45 0.49 0.4
6. Carbonates CO3% 0.30 0.21 0.10
7. Phosphorous P2% 0.28 0.03 0.09
8. Total Moisture H2O% 15.00 16.00 14.00
9. Ash % 37.40 45.70 26.40
10. Gross Calorific Value kcal/kg 3900 3300 4900
03.06 Lime Chemical and Sieve Analysis
S.No. Name of the Parameter UOM Specifications

1 Available Cao % 90 (MIN)
2 MgO % 2% ( Max)
3 Silica % 1.5%Max
4 R2O3( Al2O3+ Fe2O3) % 0.8%(Max)
5 Sulpher as S % 0.12% Max
6 Moisture % 1% Max
7 Reactivity T60 Seconds 150 ( Max)
8 LOI % 3.5% ( Max)
9 Size 0-10mm/0-80mm
Size Distribution 0-10mm Quick lime

+10mm 5
+8mm 19
+1mm 38
-1mm 38
100
Size Distribution 0-80mm

+80mm 0
+60mm 24
+50mm 26
+40mm 29
+20mm 12
-10mm 9


ITS AUXILIARIES
Size Distribution 0-10mm Quick lime

100
Note:
1. Guaranteed parameters (guarantee on lime consumption, auxiliary power consumption)
shall be based on available (reactive) CaO content of 92.5%. The design of flue Gas
Desulphurization (FGD) system & auxiliaries shall be based on available (reactive) CaO
content of 80%.
2. For the design of various components/ equipment of lime receiving, handling, feeding,
conveying, storage etc. the bulk density of lime shall be considered as 880 kg/m3 for
volumetric computations and 1920 kg/m3 for torque, drive & structural load calculation.
3. For by-product, the bulk density shall be taken as 800 kg/m3 for volumetric
computation and 1600 kg/m3 for torque, drive & structural load requirement
03.07 The flue gas analysis at FGD inlet (ID fan outlet) shall be considered as below:
Sl. Parameter Unit Guarantee Point Design Point

No. 100% TMCR load BMCR
1. CO2 % v/v wet 9.87 9.54
2. O2 % v/v wet 6.26 6.04
3. SO2 % v/v wet 0.063 0.061
4. N2 % v/v wet 70.96 68.56
5. H2O % v/v wet 12.82 15.77
6. Inlet SO2 mg/Nm3-wet 1800 1800
7. SO3 ppm 10.5 10.2
8. HCL ppm-wet 45 45
9. HF ppm-wet 12 12
11 NOx mg/Nm3 750 mg/Nm3 750 mg/Nm3
03.08 Raw water analysis


ITS AUXILIARIES
03.09 Light Diesel Oil (LDO) Characteristics (As per IS 15770 – 2008)
Sl No. Characteristics LDO

1 Pour point (max) 21 deg.C and 12 deg.C in Summer and
Winter respectively
2 Kinematic Viscosity in Centistokes at 2.5 to 15
40 deg. C
3 Sediment percent by mass (max) 0.10
4 Total Sulphur percent by mass (max) 1.5
5 Ash percent by mass (max) 0.02
6 Carbon Residue (Rams bottom) 1.5
percent by mass (max)
7 Acidity (Inorganic) NIL
8 Flash Point (Min.) (Pensky Martens) 66 deg.C
9 Copper strip corrosion for 3 hours at Not worse than No. 2
100 deg.C
10 Water content, % by Volume (max) 0.25
11 GCV, kCal/kg 10,000
12 Density at 15 0C 850 – 870 kg/m3
03.10 Heavy Fuel Oil (HFO) Specification- used for startup/low load only
Sl No. Standard IS -1593/1971 Grade HV/LSHS

1 Flash Point minimum, (Pansky-Martens 66 0C
closed cup)
2 Viscosity maximum 370 CST at 50oC
3 Total sulphur maximum 4.5 % by weight
4 Gross heating value 10,000 kcal/kg.

SECTION 04.00
SPECIAL INSTRUCTION
TO BIDDER


SEMI DRY FLUE GAS DESULPHURIZATION (FGD) SYSTEM &
ITS AUXILIARIES
04.00 SPECIAL INSTRUCTION TO BIDDER
04.01 General
i. Under this Tender Specification, installation of FGD plants has been envisaged at
4X210 MW Mettur Thermal Power Station-I (MTPS-I) of TANGEDCO.
ii. The Bidder shall base the equipment design on the information given in this
specification. The equipment shall be complete in all respects. Any item which is not
specifically mentioned herein but found essential for safe and efficient operation and
maintenance and satisfactory performance of the system shall be deemed to have been
included in the scope of the Bidder. It shall be presumed that the Bidder has studied the
site, all the drawings, tender documents and is fully aware of the scope of work
involved and the site conditions prevailing. Bidders are strongly advised to visit the site
and thoroughly get acquainted with the site features before submitting their offer.
iii. The Bidder shall include Mandatory Spares, Tools and Tackles, and Erection &
Commissioning spares. No erection and commissioning activity shall be stranded
because of non availability of commissioning spares. All these spares shall be new and
unused. The mandatory spares to be included have been listed in Volume -VI of the
specification.
iv. The Bidder shall include one set of new and unused Tools & Tackles as specified in
Volume -VI of the specification.
v. For Initial Fill, oil, Lubricants and consumables (including supply of reagents and other
chemicals if any), Bidder shall refer Vol. IB of the Tender Specification.
vi. A stainless steel name plate with letters engraved in English language shall be provided
for all the equipment. The name plate shall indicate make, identification, number,
capacity, rating and weight of the equipment. The name plate shall be fitted at a
prominent place on the body of each equipment with the help of S.S. screws.
vii. All the instruments shall be calibrated only in metric units. English shall be the
language of all communications.
viii. Any additional work / equipment and materials which may not have been specially
mentioned in this specification but are required to make the plant complete in every
respect in accordance with technical specification and are necessary for safe & efficient
operation & maintenance and guaranteed performance of the plant shall be deemed to
have been included under the scope of this specification and shall be provided by the
successful Bidder within the contract price.
Vol. – IIA, Section 04.00 SPECIAL INST. TO BIDDER Page 1 of 9


ITS AUXILIARIES
ix. Any loss of plant and equipment due to imprudence, negligence and / or inequitable
treatment and handling, shall be replaced by the Bidder at his own cost.
x. The Bidder shall not off load the contract or part thereof to any sub vendor / sub-Bidder
without the written permission of the Purchaser, subject to the “stipulations related to
selection / finalization of sub vendors / sub contractors” stipulated elsewhere in the
Tender Specification. In the event of subletting of any part of the work with due
permission by the Purchaser, such permission shall not absolve the Bidder from any of
his obligations and liabilities under the contract.
xi. It shall be the responsibility of the Bidder to obtain the necessary approval of the
concerned inspecting Authority / Chief Inspector of Boiler and Chief Controller of
Explosives, approval of Electrical inspector and all other statutory inspecting authorities
for the design and design calculations, manufacturing and erection procedure as called
for under the above regulations and any other applicable statutes. Obtaining stability
certificate in case of buildings & structure, from Director of Factories, Govt. of Tamil
Nadu shall also be in the scope of the Bidder. Bidder shall have a certified engineer who
is authorized to authenticate the documents to be submitted to the Director of Factories,
Govt. of Tamil Nadu.
xii. The Bidder shall furnish all the drawings, documents, load data and other information /
data like fault diagnosis, operation, maintenance, erection manuals etc, general details
and layout drawings, design calculations and equipment specification of plant and
equipment, together with “as built drawings” for all civil, structural, mechanical,
electrical and control & instrumentation portion.
xiii. All civil, architectural and structural works shall be carried out by the Bidder and the
related foundation drawings, arrangement drawings with design calculations shall be
submitted to Purchaser/consultant for review/approval.
xiv. It shall be Bidder’s responsibility to provide necessary and adequate arrangements for
safe disposal of effluent generated from the plant and equipment. The method / scheme
of disposal shall meet statutory regulation and shall also be acceptable to the Purchaser.
All facilities required for treatment of such effluents to make them suitable for disposal
shall be provided. Required neutralization / treatment system, pumps with drives, pipes
with valves and accessories, supports etc., as may be required, shall be included under
Bidder’s scope.
xv. Bidder in his offer shall clearly indicate the quantity, quality and frequency of
generation of effluent from the plant and equipment.


ITS AUXILIARIES
04.02 Codes and Standards
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. Indian Electricity Act

b. Indian Electricity Rules
c. Indian Explosives Act
d. Indian Factories Act and State Factories Act
e. Indian Boiler Regulations (IBR)
f. Regulations of the Central Pollution Control Board, India
g. Regulations of the Ministry of Environment, Forest & Climate Change (MoEF
&CC), Government of India
h. Pollution Control Regulations of Department of Environment, Government of
India
i. State Pollution Control Board.
j. Rules for Electrical installation by Tariff Advisory Committee (TAC).
k. Building and other construction workers (Regulation of Employment and
Conditions of services) Act, 1996
l. Building and other construction workers (Regulation of Employment and
Conditions of services) Central Rules, 1998
m. Explosive Rules, 1983
n. Petroleum Act, 1984
o. Petroleum Rules, 1976
All equipments, systems and works covered under this specification shall comply, in all
respect, with requirements of applicable latest statutes and that of latest editions of
codes and standards. Latest regulations and safety & environmental requirements as
applicable in India / state of installation shall also be complied with.
Unless covered otherwise in the specifications, the latest editions (as applicable as on
date of bid opening), of the codes and standards given below shall also apply:
a) Bureau of Indian standards (BIS)

b) Japanese Industrial Standards (JIS)
c) American National Standards Institute (ANSI)
d) American Society of Testing and Materials (ASTM)
e) American Society of Mechanical Engineers (ASME)
f) American Petroleum Institute (API)
g) Standards of the Hydraulic Institute, U.S.A.


ITS AUXILIARIES
h) International Organisation for Standardisation (ISO)

i) Tubular Exchanger Manufacturer's Association (TEMA)
j) American Welding Society (AWS)
k) National Electrical Manufacturers Association (NEMA)
l) National Fire Protection Association (NFPA)
m) International Electro-Technical Commission (IEC)/European Norm (EN)
n) Expansion Joint Manufacturers Association (EJMA)
o) Heat Exchange Institute (HEI)
p) IEEE standard
q) JEC standard
Other International/ National standards such as DIN, JIS, VDI, EN, BS, GOST etc. shall
also be accepted for only material codes and manufacturing standards, subject to the
Employer's approval, for which the Bidder shall furnish, adequate information to justify
that these standards are equivalent or superior to the standards mentioned above. In all
such cases the Bidder shall furnish specifically the variations and deviations from the
standards mentioned elsewhere in the specification together with the complete word to
word translation of the standard that is normally not published in English.
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 Technical
Specification shall govern.
If the equipment supplied does not conform to the above codes and standards, but is
manufactured to the Bidder's own standard, developed as a result of his experience, is
also acceptable provided the same is found to be superior to the above mentioned codes
and standards. The Bidder shall identify such plant and equipment and shall also present
sufficient data to the Purchaser / Consultant to support his design and to establish the
superiority. The design may be accepted by Purchaser / his Consultant only if the
Purchaser / his consultant is satisfied that sufficient experience exists with the design
proposed.
Design not meeting the stipulations of the codes and standards will not be acceptable.
04.03 Deviations & Assumptions
i. Bidder is requested to carefully examine and understand the

specifications and seek clarifications, if required, to ensure that they
have understood the specifications before submission of offer / bid. The Bidder's offer
should not carry any sections like clarifications, interpretations and/or assumptions.
ii. Normally deviations from the specification / assumptions are not acceptable. However,
if it becomes absolutely necessary for the Bidder to take deviation, the Bidder shall


ITS AUXILIARIES
mention clearly in the offer / bid, the deviation taken by him from the specification and
statement of non-conformity in detail with reasons for each such deviation. The
statements shall also show that the quality of the equipment standards shall be entirely
suitable for the purpose intended and substitute for the specified ones. Such deviations
shall be discussed during the techno commercial discussions with the Bidder. Such
points which are discussed and mutually agreed upon during techno commercial
discussions only shall be included in the Contract.
iii. In case the Bidder does not submit any list of deviations / assumptions, all requirement
and provisions of the specification shall be automatically deemed to have been agreed
and complied by the Bidder. To accept or reject, in full or part thereof, any of the
deviations shall be under the privilege of the Purchaser / his Consultant without
assigning any reason thereby. All the technical deviations taken by the Bidder, if any,
shall be indicated at only one place as per the format given in commercial volume of the
Tender Specification. Deviations, indicated at any other place shall not be considered /
entertained.
iv. While in general the design, manufacture and supply of the plant and equipment shall
comply with the requirements and conditions stipulated in this specification, any
assumption made, to arrive at different solution / calculation for working out details as
indicated in the offer, shall be clearly spelt out and brought out in the bid / offer by the
Bidder.
v. Any contradiction between the provisions called for in the technical specification and
other documents enclosed with the tender enquiry shall be a matter of clarification to be
sought for by the Bidder from the Purchaser / his Consultant. However, on any
contradiction / difference of opinion / ambiguity arising during the course of Bid due to
any lack of clarity on such account and not settled during the tender stage, the
interpretation of the Purchaser / his consultant shall be final and binding on the Bidder.
vi. In the event of conflict between requirements of any two clauses of the
specification documents, the more stringent requirements shall apply, unless otherwise
confirmed by the Purchaser in writing before the award of this contract, based on a
written request from the Bidder for such clarification.
04.04 Limit of Contract
Equipment furnished shall be new, unused and complete in every respect with all
mountings, fittings, fixtures and standard accessories normally provided with such
equipments and/ or needed for erection, commissioning and safe operation of the
equipments as required by applicable codes though they may not have been specifically
detailed in the respective specifications, unless included in the list of exclusions. All
similar standard components/ parts of similar standard equipments provided shall be


ITS AUXILIARIES
interchangeable with one another.
During execution of the contract, successful Bidder will furnish the engineering data /
drawings / calculations, etc. in accordance with the schedule of information agreed
between Purchaser and the successful Bidder. Review of these data by the Purchaser’s
Engineer / Consultant shall cover only general conformance of the data to the
specifications and documents interfaces with the equipments provided under
specifications, external connections and of the dimensions which might affect plant
layout.
This review by the Purchaser’s Engineer / Consultant may not indicate a thorough
review of all dimensions, quantities and details of the equipments, materials, any
devices or items indicative of the accuracy of the information submitted. This review
and/ or approval by the Engineer shall not be construed by the Contractor, as limiting
any of his responsibilities and liabilities for mistakes and deviations from the
requirements specified under these specifications and documents.
04.05 Completion Schedule
The Bidder shall submit Time Bar chart indicating completion date of major activities
such as submission of design data / calculations and drawings for approval,
manufacturing of components / units, supply, inspection, erection, testing and
commissioning etc. without which the Tender shall not be considered. Time Bar Chart
furnished shall afterwards form part of the contract and cannot be altered arbitrarily
except Force Majeure conditions as may be agreed with the Purchaser.
The successful Bidder shall submit monthly progress report to the Purchaser right from
the commencement of the work till finishing and handing over of the work. The report
shall cover all the major activities and shall be a subject of discussion with the
Purchaser/ Consultant, for timely completion of the project.
On commencement of site work, the successful Bidder shall submit to the Purchaser, a
weekly site “Progress Report”. This report shall be discussed at the regular site
meetings between Bidder and Purchaser as an agreed accurate record of the weekly
progress.
04.06 Workmanship and Quality Control
The plant and equipment shall be designed to have maximum reliability with ease of
operation and maintenance as primary consideration. The plant offered shall be from a
family having basic design at par with other plants which have already been supplied
and have operated efficiently and reliably elsewhere under similar climatic and
operating conditions.


ITS AUXILIARIES
All moving parts of equipment, which can conceivably cause injury to the operator and
otherwise authorized personnel within the vicinity of working area shall be suitably
guarded and warning displays shall be put at prominent places.
The Bidder shall clearly indicate and identify the plans and procedures, which shall be
followed in the design, manufacture and installation of plant and equipment to control
and assure to the Purchaser of the desired quality.
04.07 Inspection and Testing
The plant and equipment shall be subjected to inspection and witnessing of shop tests
by the Purchaser / Consultant or the agency mutually agreed between Purchaser and the
Bidder. The successful Bidder shall inform the Purchaser/his Consultant sufficiently
well in advance of the date when the plant and equipment shall be made available for
inspection and testing. The Purchaser and / or his Consultant shall be given full access
to the tests and testing premises and can inspect the factories and offices of the Bidder
or sub-vendor, if so required. After inspection and testing, all certificates /documents as
required by the Purchaser / Consultant shall be submitted for approval to the purchaser
before clearance for dispatch of equipment can be given.
For plant and equipment for which tests at works may not have been witnessed by
Purchaser / Consultant, the tests and quality certificates duly signed by appropriate
authority acceptable to Purchaser / Consultant shall be submitted to the Purchaser /
Consultant for approval within 6 weeks in advance of the dispatch.
Inspection by the Purchaser or his representative shall not relieve the Bidder of his
liability for rectifying any defects which may subsequently appear or be detected during
or after erection and during guarantee test. After rectification, the testing of equipment
shall be repeated to the satisfaction of the Purchaser / Consultant.
04.08 Drawings / Data to be submitted with the Tender
In order to enable the Purchaser / Consultant to properly evaluate the tenders, the
drawings / documents / technical particulars as indicated in respective chapters of this
specification shall be submitted by the Bidder along with the bid / offer.
04.09 Approval of Drawings and Documents
The Bidder shall furnish the details of the drawings for Purchaser’s/ his Consultant’s
approval and/or for use, to detail out the other connected systems / facilities not forming
part of this tender, within the period of one month of placement of order or as mutually
agreed between the Purchaser and the Bidder and shall fit in the total implementation


ITS AUXILIARIES
schedule of the project.
04.10 Surface Preparation and Painting
The surface of plant & equipment shall be suitably cleaned and coated with anti-rust
primer to protect against corrosion and damage during transit and transportation to the
site.
Painting shall be done as per details indicated in the relevant Chapter and as per the
approved painting schedule.
04.11 Packing, Dispatch, Handling & Transportation
All equipment, pipes, valves, instruments, etc. shall be suitably packed for protection
against mechanical damages and climatic conditions during transit and storage. Packing
and weather proofing shall be subject to approval of the Purchaser / Consultant. This
approval shall be general and may not be required every time for an article to be
dispatched. However, the Purchaser reserves the right to examine the packing for any
particular consignment at supplier’s/ manufacturer’s works before dispatch.
The Bidder shall be entirely responsible for the insurance, shipment, handling and
transportation of all plant & equipment, construction tools, labourers and materials
including unloading at destination, transportation to site, off-loading, storing and
protection at site till erection.
The equipment shall not be dispatched by the Bidder from the place of manufacture to
the site until the dispatch instructions are issued by the Purchaser.
04.12 Storage, Handling, Supervision of Erection, Testing & Commissioning and

Demonstration of Performance Guarantee tests
The plant and equipment supplied shall be properly stored at site, handled, erected,
tested and commissioned individually as well as for integrated operation by the
successful Bidder.
During site testing and commissioning, Bidder shall follow approved safety clearance
system. The details of these systems are to be approved by the Purchaser / Consultant.
The performance guarantee parameters of the plant shall be demonstrated by the Bidder
within the agreed time frame.


ITS AUXILIARIES
04.13 Performance Guarantee and Penalties
All the plant and equipment supplied shall be guaranteed for quality workmanship and
compliance with the specified requirements for integrated performance to deliver rated
outputs. Non-compliance and non-performance shall be subjected to correction or L.D. /
penalty to be paid by the Bidder to the Purchaser as specified elsewhere in the Tender
Specification.
04.14 Drawings & Documents for Purchaser’s use and Archives
The Bidder shall submit all final drawings, documents, manuals for Purchaser’s use and
for reference / record required during course of operation and maintenance of the plant.
Numbers of copies and their form (hard copy, electronic form, reproducible) to be
submitted is indicated elsewhere in the Tender Specification. The details of the
documents, drawings, manual etc. to be furnished by the Bidder are described elsewhere
in the Tender specification.

SECTION 05.00
SCOPE OF WORK,
SUPPLY & SERVICES


& ITS AUXILIARIES
05.00 SCOPE OF WORK, SUPPLY & SERVICES FOR SEMI DRY BASED FLUE
GAS DESULPHURISATION (FGD) SYSTEM
05.01 General
The scope of work for the equipment and accessories to be furnished in

accordance with this specification defines the scope and minimum requirements
for the design, engineering, supply, erection, fabrication, testing &
commissioning, performance testing, and handing over of semi dry Flue Gas
Desulfurization system & auxiliaries in Mettur Thermal Power Plant-I (MTPS-I
4X210 MW).
Brief summary of the Bidder's Scope of Work are as indicated below. Any item or
works though not specifically mentioned in this specification but needed to
complete the equipment & systems in all respect as per the intent of the
Specification shall also be deemed to be included in the scope unless specifically
mentioned under “Exclusion” and accepted by Purchaser during the bidding stage
and shall be provided by the successful bidder within the quoted price:
• Design, Engineering, Manufacture, Supply, Delivery at site, Unloading

Storage, Handling , testing , erection & commissioning of complete
mechanical, electrical, Controls & Instrumentation and associated civil and
structural works for four (4 numbers) of Semi- Dry type Flue Gas
Desulphurization system and its auxiliaries for four (4) number of Steam
Generators of four units i.e. Unit #1 to Unit #4 of 210MW equivalent capacity
each, as detailed in this specification. The FGD system shall be necessarily
based on CDS technology (or SDA technology, if bidder cannot offer CDS
technology) and is intended to reduce the emissions of Sulphur Dioxide (as per
the latest MoEF & CC norms) in flue gas produced by firing coal (Mix of
indigenous and imported) in the boilers to the limits specified in the technical
specification.
• Complete Civil, Structural, Architectural, Electrical and Control &

Instrumentation system, as required for the FGD system and specified in detail
under separate volumes elsewhere shall be included in the scope of supply.
• Complete Civil, Structural, Architectural works, including supply of

materials, excavation, back filling, compaction, sub structures, super structures
& dismantling works, required for the technological equipment as well as all
ancillary buildings & structures are included in the bidder’s scope of work. The
bidder shall also include all supporting and structural works, like pipe & cable
trestles/raceways/trenches/duct bank, platforms, staircases etc. in their scope of
work / supply.
Vol. – IIB, Section 05.00 SCOPE OF WORK, SUPPLY & SERVICES Page 1 of 12

& ITS AUXILIARIES
• Complete C&I work including field instruments, analysers, PLC based control
system along with it’s RTU’s ( Remote Terminal Unit)( if required), UPS
system, Instrumentation Cable (FRLS type & Armoured) & Fibre Optic
cables( as required ), cabling, branch cable trays up to the plant main cable tray,
hardware required (like networking equipment/ cabinet etc) for
interfacing with local and remote-control systems including plant DCS, and
defined power feed terminal point are included in the scope of work.
The package scope shall also include the following:

• Making connection of supplier scope equipment with already existing /
commissioned equipment, wherever an interface has been envisaged. The
successful bidder has to obtain prior permission from the purchaser for such
connections.
• Study possible interference/hindrance with already erected structures/foundation

etc. and obtain written permission from Owner for modification, if required.
It is suggested that the bidder shall visit the site to get first-hand information
and feel o f the existing layout, free space available for the FGD package,
mechanical/electrical/instrument/ civil scope interfaces.
The scope of supply identified for FGD system here are minimum requirements
and unless specifically excluded from the bidder’s scope (Terminal Points
and Exclusions) and accepted by Purchaser / Consultant, any equipment/system
not included in this specification but integral to the system offered by the bidder
to meet the intent of this specification, shall also be included in the scope of the
bidder.
The scope of the bidder shall be deemed to include all such items which although
not specifically mentioned in the specification but are needed to make the
equipment complete in all respect for safe, reliable, efficient and trouble-free
operation of the FGD system.
FGD system needs an independent, reliable, emergency A.C. source when all other
A.C. power supplies fail (i.e. Plant blackout condition). The bidder shall identify
the emergency load requirement for the FGD plant.
• Training of Owner's personnel.

• Conducting testing, trial runs etc.
• Structures, equipment, and enclosures directly associated with the dry scrubber
bagfilter house & allied auxiliaries.
• Lower enclosure completes with heating, ventilation, structural support,
framing,
and access doors.

& ITS AUXILIARIES
• Upper enclosure completes with ventilation, structural support, framing and

access doors.
• Access to equipment, Valves, instruments etc.
• All specialty tools necessary to construct, test, and maintain the FGD System.
• Start-up spare parts and Project specific priced spare parts list for 3 yrs O&M.
• Prime and finish painting of new buildings, equipment and materials as
detailed in this specification.
• Documentation, including drawings, equipment and other lists, indexes and
data sheets, specifications, quality assurance procedures and manuals, system
description manual, operating procedures, testing procedures, operations and
maintenance training manuals, spare parts lists and information, monthly
reports, schedules, minutes of the meeting and actionable item lists.
05.02 Scope of Work, Supply & Services for Mechanical Systems
Bidder shall offer either Circulating Dry Scrubber (CDS) type semi dry FGD
system or Spray Dryer Absorber (SDA) type semi dry FGD system for each unit
of Mettur Thermal Power Plant-I (MTPS-I 4X210 MW).
Semi Dry FGD shall consist of a main Reactor section, a pulse jet fabric filter
(PJFF) baghouse, by-product recycle system, booster fans and associated ducts,
dampers, lime storage and handling system and by-product storage and handling
system.
Bidder shall only offer proven system in successful operation in previous
installations as defined under qualification criteria.
The FGD system shall be generally in line with the Tender scheme / drawing
enclosed along with this tender document.
05.02.1 Circulating Dry Scrubber (CDS)
The CDS system shall be designed to utilizes a semi-dry reactor to offer the
proper chemistry and in-situ conditions for simultaneous and effective
absorption of sulphur dioxide, acid gases and associated heavy metals. Hydrated
lime powder and water injection system into the reactor vessel shall be designed
to cater maximum contact and reaction with the untreated flue gas. To optimize
reagent utilization, a portion of the dry reaction solid products may be collected
downstream of the system and recycled back to the reactor
Four (04) no. CDS reactor, one for each unit shall be provided for 4x210 MW
Mettur thermal power station (MTPS), Each capable of treating the total flue gas
flow. If modular CDS system is offered, one offline module shall be provided.
The offered CDS reactor(s) shall be capable of meeting simultaneously all
guarantee parameters from minimum to maximum boiler load operation.
The design shall include controlling dust concentration in the influent flue gas as

& ITS AUXILIARIES
co benefit.
Low leak guillotine isolation dampers at inlet and outlet of CDS vessel shall be
provided. Low leak is defined as Maximum 5%.
Also, bidder to provide thermal insulation for all supplied equipment, ductwork,
and piping systems per the design conditions.
05.02.2 Spray Dryer Absorber (SDA)
In case the bidder is offering SDA system then bidder shall provide the
following, as a minimum:
a) Each unit shall have one (01) no of SDA vessel complete with gas distribution
devices; rotary atomizers with drives and self-contained lubrication system;
conical hoppers at the outlets, atomizer monorail and radio-controlled hoist
system, dedicated hoists and rails for SDA vessel and access doors shall be
provided for each unit.
b) Bidder to provide N+1 configuration of rotary atomizers with drives and self-
contained lubrication system, where N stands for no of atomizers in operation to
meet the guaranteed performance.
c) Low leak guillotine isolation dampers at inlet and outlet of SDA vessel shall be
provided. Low leak is defined as Maximum 5%.
d) Thermal insulation for all supplied equipment, ductwork, and piping systems per
the design conditions.
05.02.3 Flue Gas Ducting System

a) New Flue gas duct and modification in existing duct work, isolation
gates/dampers, reinforcing steel, expansion joint, flow straighteners, access
doors, test ports, insulation & cladding (as required), and instrument connection
with internal and external supports starting from common existing ID fan outlet
duct to common inlet duct to booster fan, booster fan inlet & outlet duct, inlet &
outlet duct to reactor, inlet & outlet duct to fabric filter up to common existing
duct inlet to chimney. The interfaces of ductwork shall be as defined under
chapter “Terminal Points”.
b) Bidder to offer 2X50% Booster fans for each unit. The aggregate capacity of
the booster fan(s) shall match with that of the ID Fans at the guarantee and
design points as well as over the entire operating range. Margins as specified
under design criteria shall be adopted. The fans shall have blade pitch type or
inlet guide vane control system to vary the air flow, depending on the type of
fan.

& ITS AUXILIARIES
c) Each fan shall be of Axial or centrifugal type with blade pitch control, with
coupling and drive motor. Each Booster Fan shall be provided with bearing
lubrication and hydraulic blade pitch control unit(s), each system consisting of:
(i) 2x100% oil pumps with motor, coupling and coupling guard.
(ii) 2x100% oil coolers.
(iii) 2x100% filters, differential pressure switches, etc.
(iv) 1x100% oil storage tank.
(v) Instrumentation, vibration monitoring, inter connected piping, valves and
fittings including pressure relief valves and non-return valves.
(vi) Electrical actuator with accessories etc. bearing temperature at motor and
fan end along with motor winding temperature monitoring,
(vii) Alternatively, a forced oil lubrication system (consisting of i to vi
above) common for bearing lubrication and for servo motor operation for
each Booster Fan will also be acceptable.
d) At least two (02) nos. of duplex thermocouples or duplex platinum RTDs (100
ohm at 0oC) and one number of temperature indicators shall be provided for
bearing metal temperature measurement, control and monitoring for each fan.
e) Inlet and outlet dampers at each Booster fan.
f) Inlet flue gas duct damper at common inlet duct to booster fan
g) FGD outlet clean gas duct damper.
h) Bypass damper at existing common duct before FGD outlet duct connection to
common duct at chimney inlet.
i) Seal air fan with heater for each damper.
05.02.4 Lime Storage and Handling System
The system shall be sized to store and transfer the required amount of lime to
the lime preparation system, based on the range of operating conditions. Lime
shall be pneumatically conveyed (system provided by bidder) from trucks to
Lime Storage Silos.
a) Two (02) nos. of Lime storage silo shall be designed for 07 days storage
capacity for maximum lime requirement of the all the five units
b) Lime shall be delivered to site primarily by trucks.
c) Pneumatic conveying system for unloading the lime from truck.
d) Pneumatic conveying system shall be provided for unloading the lime from
storage silo to bins in the lime preparation area. To allow operation flexibility,

& ITS AUXILIARIES
the conveying arrangement shall be such that the Lime conveyed from any one
storage silo can be delivered to either of the bins.
e) Silo vent filters shall be provided to remove collected lime dust
f) Compressed dry air shall be provided to pulse the bags or cartridges.
g) Pressure and vacuum relief devices shall be provided.
h) Complete dust extraction and natural ventilation system shall be provided in
open transfer points or enclosed areas, as required.
i) One (01) no. lime bin shall be provided to aid feeding lime to the hydrator, if
provided shall be for each unit.
j) Access and platforms shall be provided for all instrumentation, valves etc.
05.02.5 By Product Recycle System
By product recycle system for each unit shall include the following equipment,
as a minimum:
a) Fluid troughs for each unit to collect by product from fabric filter bag house.
b) Expansion joints for each unit, as required.
c) Three (3)x 50% (02 Working + 01 stand by) fluidized air blowers for each unit.
d) Rotary Feeder(s) for controlling by-product recirculation for each unit.
Alternatively, if a modular design is provided, a recycle mixer based on Bidder

proven design may be provided for by-product recycle for each module.
05.02.6 By Product Storage and Handling System
The system shall be sized to transfer and store the by-product in the silo.
Suitable arrangement shall be provided at the discharge of silo for unloading in
to truck. The system shall include the following equipments, as a minimum:
a) One (01) no. intermediate byproduct silo to store 1 days generation of by product
for each unit.
b) Pneumatic conveying system to transfer the by-product from bag house hopper
to intermediate silo.
c) Motorised knife gate valve along with telescopic chute (motorized) shall be
provided at each silo discharge.
d) Two (02) no. Main byproduct silo for storing the byproduct of the entire 4 units
and the same shall be placed outside the plant boundary at a specified location
approved by the purchaser.
e) All necessary arrangements shall be made by the contractor for conveying the
byproduct from the main byproduct silo upto the trucks.
05.02.7 Pulse Jet Fabric Filter (PJFF) Bag House

The bidder shall provide the fabric filter bag house, including the following
equipment, as a minimum;

& ITS AUXILIARIES
a) Fabric filter bag house for each reactor/absorber

b) Pulse jet cleaning system for each fabric filter bag house
The fabric filter bag house shall be capable of operating and meeting emission
and performance guarantees with one bag house compartment offline. The
system shall be designed to operate in conjunction with the r eactors, recycle,
and waste handling systems.
05.02.8 Compresserd Air System

Service air and instrument air shall be provided to various location of plant
from the
FGD plant compressor is as follows;
a) For Pneumatic conveying system of lime unloading from truck and transfer
from plant silo to process and recycle.
b) For pneumatic conveying system for by-product recycle to reactor and loading
into silo.
c) For fabric filter pulse jet cleaning in bag house system
d) For reactor /absorber
Any other as per OEM’s technology
05.02.9 Plant Water System

Plant water system shall be designed to supply water as required as per bidder’s
proven practice. Bidder to provide 2x100% pumps at the respective terminal
points to meet the FGD plant requirement. The minimum requirement as
indicated below shall be met by the plant water system;
a) For reactor/absorber
b) For hydrator
c) For service water
d) For potable water
e) Any other as per OEM’s technology.
05.02.10 Off-Load Drainage & Cleaning System

Area sumps each with 2x100% vertical sump pumps shall be provided for
the following areas:
a) Lime storage and handling area

b) Lime preparation / Lime Slurry Preparation Area
Bidder to consider 12 hours storage capacity of each sump.

& ITS AUXILIARIES
05.02.11 General Service System

a) Fire Detection and Protection System (Refer Volume IIC, Section 04.00)
b) Complete HVAC System for buildings and control/electrical rooms (Refer Volume
IIC, Section 02.00)
c) Drainage & Waste water collection system
d) Elevators & Hoists (Refer Volume IIC, Section 03.00)
e) Miscellaneous (Pipe works, valves, pumps, compressor & agitators,
equipment noise & vibration, coatings & painting protection, special tools & spare
parts, lubricants etc.)
f) Detailed information about the above utility consumptions/process
parameters and building facilities shall be included in offer in attached Technical
Data sheet.
05.03 General Technical Requirements

a) The FGD system shall be constructed within the scheduled time without affecting
operation of the existing plant/ units. The plant shutdown will be taken only for
interconnection of the FGD system as per quoted/ mutually agreed period for the
same in the contract. The bidder shall properly plan and ensure that the work of
structural/ mechanical/ electrical/ C&I interconnection with the existing plant
systems is completed within the scheduled shutdown period. In case time taken is
more, liquidated damages shall be applicable for each day of delay as indicated
elsewhere in the specification.
b) The bidder shall submit with the offer, comprehensive information on how the
mass balance, spray nozzle cone angle, spray nozzle arrangement, lime
consumption etc. as applicable for the proposed design have been arrived at. The
bidder shall also submit along with the offer, a detailed write up on the proposed
design features and control philosophy at varying loads to achieve the desired
level/ efficiency of SO2 and PM removal.
c) In general, the material selection is the bidder’s responsibility, but the quality of
material for pressure vessels, piping, etc., however, must meet the requirements of
the relevant IS/ASME standards. The bidder shall specify in his bid the material
quality and the standards applied to each equipment, piping system, etc.
d) Where necessary, an internal anticorrosive protection based on the bidder’s proven

experience shall be applied. Bidder shall include a comprehensive list of
anticorrosion protection including equipment on which respective corrosion
protection has been provided. Reference information on the application, reliability
and suitability of the proposed anticorrosion protection as per the equipment
supplied by the bidder and operating successfully for a long period shall also
be furnished. Life of anti-corrosion protection, necessary repairs required, their
frequency and time demands shall also be indicated.

& ITS AUXILIARIES
e) In order to be compatible for operation in conjunction with existing units, the

design of the plant must guarantee a rapid availability during start-up, a fine and
favourable characteristic during load changes and are reliable and stable mode of
continuous operation at conditions encountered during the power plant operation.
g) The FGD plant shall be able to handle the load imposed on the FGD plant by the
boiler, including rate of load changes, minimum load and the anticipated daily and
annual load schedules. Furthermore, the FGD plant shall be able to be put in
operation, while the boiler is in operation at any load, without any disturbance in
the operation of the Unit.
h) In case of a failure of an item of equipment (e.g. pumps, etc.) the stand-by unit
has to be activated and put into service automatically without delay and without
interruption of the plant operation and audio-visual alarm to such effect shall
be provided in the control room.
i) In case of failure of the boiler and ancillary equipment, the associated FGD plant
shall be brought automatically to the off-load operation without restriction by the
current loading.
j) All items of equipment which are known to be subject to wearing, abrasion or

failure (e.g. nozzles, pumps, pipe work etc.) and thereby affecting availability of
FGD plant shall be designed and installed so as to facilitate easy replacement,
repair and maintenance, even if installed redundantly
k) The dry FGD system offered by the bidder shall be in line with the specified
scheme of FGD process. However, proven variations are permissible for
optimization of the process based on bidder’s design and experience. These
variations shall, however, not change the basic essence or configuration of the
process specified. Specific advantages of such variations shall be indicated by the
bidder in his bid. All modifications/variations proposed from the process specified
shall be subject to approval from the Owner. Description of the process which
has been offered by the Bidder must be submitted in detail indicating clearly the
function of each equipment.
l) The materials of construction for all exposed metal/ concrete surfaces shall be so
chosen as to withstand the prevailing environment at plant site. Also suitable
weather protection shall be provided to all exposed surfaces as required. The
equipment and the auxiliaries shall be designed for maximum reliability and
availability; operability and maintainability. The bidder shall specifically state the
design features incorporated to achieve the high degree of reliability and
availability.
m) Adequate maintenance facilities shall be provided as required, for assembly,

& ITS AUXILIARIES
disassembly, handling during maintenance and alignment work of all- important

equipment and auxiliaries.
n) All stand-by auxiliaries shall be designed for auto start up, on failure of
running auxiliaries with minimum time delay and without runback on unit load.
o) The plant and its units shall be designed to operate with all the specified margins
for continuous operation without any limitations under any of the conditions
indicated in the Technical Specification.
p) All materials used for the construction of the equipment shall be new and shall
be in accordance with the requirements of this specification. Materials utilised for
various components shall be those which have established themselves for use in
such applications. It would be the responsibility of the bidder to furnish the
relevant information in this regard, as required, at the time of detailed
engineering.
q) The process proposed must be free of any danger for personnel handling the
equipment, for related operations and for the surroundings. This requirement
applies for normal operation as well as for starting up & shut down.
r) Equipment/works offered shall be designed for high availability, low

maintenance and ease of maintenance. The Bidder shall specifically state the design
features incorporated to achieve high degree of reliability/availability and ease
of maintenance. The FGD plant shall be designed for minimum need for
inspection. The time between inspection for reactor internals and major equipment
shall correspond to capital overhaul period of units (once in 5 years). The FGD
plant must operate without the replacement of the most important equipment and
devices for 25 years at least. The quality of material, internal anticorrosion
protection and whole performance must correspond to this requirement. The bidder
shall enumerate the special measures incorporated in the designs to meet these
requirements. The following details on maintenance requirements for each major
equipment shall be furnished:
• Maintenance requirements for the equipment given in hours per year.

• Special methods used in maintenance and in performing repairs.
• Recommended maintenance model and proposal of the organization of repairs.
• Special aids and devices necessary for performing repairs and
maintenance including stationary lifting devices or possibly other mechanisms
necessary for vertical as well as horizontal transport of parts to be replaced.
• A brief description of main works, handling, transport, etc. performed
during the plant operation and connected with maintenance performance.
s) Automated protection as well as alarm systems must be installed at the places

where emergency conditions could occur due to a failure. These systems must be

& ITS AUXILIARIES
“fail safe” i.e. they must be triggered in the case of an electric voltage or air
pressure outage.
t) Roller bearings provided on pumps, fans, air compressors, agitators and other
equipment shall have a life of at least 10 years with maximum loading conditions.
Journal bearings provided should have operational life equal to the life of the
equipment.
u) All heavy parts of the plant must be provided with some convenient arrangement
for aligning and for handling during erection and overhaul. Any item of plant
required to be stripped or lifted during period of maintenance and weighing one
tons or more shall be marked with its approximate weight. All equipment shall be
designed to run satisfactorily without any undue noise and vibrations.
Corresponding parts throughout shall be made to gauge and shall be
interchangeable wherever possible. No welding, filling or plugging of defective
parts shall be allowed without the permission in writing of the Owner.
v) The structure of the FGD plant shall be adequately designed taking into
account the local seismic factors and wind conditions prevailing at site. A project
design manual indicating design data and detailed design criteria for civil and
structure steel work shall be submitted for the approval of the consultant/Owner.
In case of coastal climatic conditions, the special measures adopted to protect
reinforced concrete and structural steel shall be included in the design criteria.
05.04 Control & Instrumentation
Refer Vol. III for Control & Instrumentation scope of work
05.05 Electrical
Refer Vol. IV for electrical scope of work
05.06 Tests
The scope of the bidder includes all shop tests, type tests, site tests, routine tests
etc., fulfilment of compete quality assurance and inspection requirements and
related activities for all the equipment and systems covered under the scope of
work of bidder as per the stipulations of technical specifications.
05.07 Tools, Tackles, Mandatory Spares & Commissioning Spares
The bidder shall include a complete new set of all special tools and tackles,
mandatory spares, commissioning spares of reputed make and model which are
required for erection, ease in maintenance to have a minimum down time,

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testing and calibration of all the equipment and systems in his scope of supply
under this specification for the above-mentioned items.
05.08 Paint Shade

The painting of all equipment shall be epoxy based with suitable additives. The
thickness of finish coat shall be minimum of 50 microns (minimum total DFT
shall be 100 microns). However, in case electrostatic process of painting is
offered for any equipment, the Bidder shall furnish the complete painting details
during detailed engineering stage for owner/consultant approval.
05.09 Civil
Refer Vol. V for Civil, Architectural & Structural electrical scope of work.
SECTION 06.00
QUALITY ASSURANCE
SYSTEM


ITS AUXILIARIES
06.00 QUALITY ASSURANCE SYSTEM / REQUIREMENT
06.01 General
Inspection & testing of plant & equipment shall be witnessed by Purchaser / his
representative / Purchaser as per approved QAP at the works of successful bidder
during manufacturing and / or on final product to ensure conformity of the same with
the acceptable criteria of technical specifications, approved drawings, manufacturing
drawings and applicable national / international standards.
06.02 Quality System Requirements
The successful bidder must recognise the importance of quality and follow defined
quality programme in all stages of. manufacturing and quality control activities of the
product. Contractor must define and implement the tasks and controls that will provide
needed assurance, in case manufacturing of product is sub-contracted either partly or
fully and/or for the procured components of the product. All bought-out equipment or
component shall be procured from preferred vendor list of concerned project.
Purchaser / his representative / Purchaser reserve the right to verify the quality
programme of bidder & its vendors/sub- vendors to assure the effectiveness of the
programme to meet the intended and specified quality of the product.
06.03 Quality Assurance Plan (QAP)
06.03.01 The successful bidder shall furnish Quality Assurance Plan (QAP) for all equipment
in respective packages after finalization of billing schedule / equipment
identification number for Purchaser / his representative’s approval at least one
month prior to start of manufacturing in accordance with clause 06.03.02 and
06.03.03 of this chapter.
06.03.02 QAP shall be prepared & furnished separately by Contractor in Form Nos.
11.20(DQM)F-09,10 , 11, Rev 0 (specimen blank enclosed) for structural, mechanical,
electrical, instrumentation and refractory items respectively , including major bought-
out items. QAPs must be submitted in requisite sets as per contract for approval and
shalll be duly stamped and signed by the successful bidder . Also, column no. 4, 5, 6 &
7 of QAP formats are tentative and for reference purpose only. QAP submitted in any
format other than those mentioned above will not be accepted.
06.03.03 The successful bidder shall submit copies of P.O., Sub-P.O., T.S., approved GA
drawings/ data sheets & detailed manufacturing drawings(if asked for) along with
QAP as backup reference materials for scrutiny & final approval of QAP by Purchaser
/ his representative. All billable items as per approved billing schedule of same
category (i.e mechanical, electrical, structural, refractory etc) shall preferably be
submitted in a single lot, serial wise, to avoid unnecessary delay in the process of QAP
Approval.
Vol. – IIA, Section 06.00 QUALITY ASSURANCE SYSTEM Page 1 of 10


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06.03.04 Inspection and test requirements shall be decided with due consideration of factors like
safety, duty cycle, operating conditions, equipment life, environmental conditions,
place of installation and statutory regulations, as applicable, for a particular equipment.
Any, additional type or special tests or routine tests if found necessary to establish the
intended quality after detailed engineering, then same have to be incorporated in the
QAP without any commercial implication.
06.03.05 QAPs shall be prepared by the successful bidder in consultation with their
Sub-contractors / Manufacturers to avoid any complicacy later .
06.03.06 Soft copies may be forwarded in advance for intimation. However, hard copies shall be
submitted in requisite sets to enable Client to forward comments if any.
06.03.07 Approval of QAP does not gives approval of make. Make shall be as per contract.
06.04 Calibration of Measuring Equipment
06.04.01 All the measuring equipment used for inspection & testing shall be of appropriate
accuracy class and shall have valid calibration certificate with traceability to national
standards of NPL / NABL accredited laboratories with unbroken chains of
comparison. Same calibration certificates shall be submitted to Purchaser / his
representative/ Purchaser for review prior to inspection.
06.04.02 Calibration certificate shall also indicate reference no. of calibration standards
calibrated by NPL / NABL accredited laboratories and copies of such calibration
certificates of calibration standards shall be included in the compiled dossiers of
inspection/test results.
06.04.03 In case valid calibration certificates are not available, inspection will not be carried
out using uncalibrated instruments and cost of revisit in that eventuality shall be
borne by the successful bidder.
06.05 Test Certificates and Documents
06.05.01 For each of the items being manufactured as per approved QAP , following test
certificates and documents, as applicable for each of the equipment, in requisite copies
including original, duly endorsed by the Manufacturer and successful bidder with
appropriate linkage to project, purchase order and acceptance criteria etc shall be
submitted to Purchaser / his representative/ Purchaser.
i) Raw materials identification & physical and chemical test certificates for all materials
used in manufacture of the equipment.
ii) WPS, PQR & WPQ documents as per applicable code.


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iii) Details of stage-wise inspection & rectification records for fabricated items, castings,
forgings and machined articles.
iv) Control dimension chart with records of alignment, squareness etc.
v) Manufacturer's material and performance/relevant test certificates for all bought-out

items.
vi) Details of heat-treatment and stress relieving charts as per specification.
vii) Non-Destructive Test reports as per respective code carried out by NABL
accredited laboratory.
viii) Static/dynamic balancing certificate for rotating components/machines.
ix) Hardness test certificate.
x) Pressure / Leakage Test Certificates.
xi) Performance Test Certificates for all characteristics.
xii) Routine / Type / Calibration /Acceptance / Special tests ( Type Tests etc) certificates
for electrical/ power electronics/ automation/ instrumentation items as identified in
QAP. Furnishing valid type test certificate for similar design of above items is
mandatory until unless exemption is granted specifically in technical specification for
any item. In case, type test certificate of similar design is not available, successful
bidder shall organize to carry out such tests at his cost without affecting the project
schedule.
xiii) Surface preparation and painting certificates.
xiv) Certificates from competent authority for the items coming under statutory regulations
(IBR/ FM/ UL/ CMRI/ NEPA/ Weights & Measures etc.)
xv) Environmental test reports for electronics/ automation items
06.05.02 Where physical and chemical test certificates of raw material are not available, the
successful bidder /Sub-contractor shall arrange to have specimens and test samples
of the materials, tested in NABL accredited laboratory at his cost and submit the
copies of test results in requisite numbers to Purchaser / his representative/Purchaser
for review. Number of test samples against each heat/cast/lot or batch of materials, as
applicable shall be as per relevant Indian or International Standards. This is
admissible only if specific makes are not indicated in the contract.


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06.06 Internal Inspection by Successful Bidder/ Manufacturer
06.06.01 Inspection and tests shall be carried out by Contractor and Manufacturer in accordance
with approved drawings/datasheet/material specification/T.S/P.O., relevant standards
(BIS/ASME/IEC/DIN/API etc.) and approved QAP. Records shall be maintained for
each inspection & test carried out and signed documents shall be submitted to
Purchaser/Purchaser / his representative for verification.
06.06.02 The successful bidder shall carry out their internal inspection & obtain clearance from
statutory bodies e.g. IBR, CCE, TAC, Weights & Measures, safety (NEPA/ UL/ FM
etc.), IE rules, CMRI etc. prior to offering any equipment for Purchaser/Purchaser /
his representative's inspection in accordance with approved QAP.
06.06.03 The successful bidder/ Manufacturer shall identify all the inspected
equipment/component/raw materials & shall maintain the record of status of inspection
viz. inspected & found acceptable, require rectification/rework, rejected etc.
06.06.04 The successful bidder shall establish and maintain procedures to ensure that the
product that does not conform to specified requirements, is prevented from inadvertent
use or installation. The description of non-conformity that has been accepted
subsequently by Purchaser / his representative/ Purchaser by concession and/or of
repairs, shall be recorded.
06.06.05 Where facilities for testing does not exist in the successful bidder / Sub-contractor's
laboratories or in case of any dispute, samples and test pieces shall be drawn by the
successful bidder /Sub-contractor in presence of Purchaser / his representative /
Purchaser and sealed sample shall be sent to any NABL accredited laboratory for
necessary tests at former’s own cost.
06.06.06 The Purchaser / his representative / Purchaser shall have the right to be present and
witness all tests being carried out by the successful bidder / Sub- contractor at their
own laboratory or approved laboratories. Also, the Inspection Agency shall reserve the
right to call for confirmatory test on samples, at his discretion.
Repaired and reworked product shall be offered for re- inspection to Purchaser / his
representative/ Purchaser along-with records of corrective action taken.
06.07 Manufacturing and Inspection Schedule
Successful bidder shall submit the schedule for manufacturing and inspection
indicating equipment / components, sub- assembly/ assembly, date of approval of
drawings / data sheets, address of manufacturer with contact person and scheduled date
of inspection. Such reports shall be submitted to respective Purchaser / his
representative Inspecting Offices with a copy to Inspection Co- ordinating Office once
in a month. These monthly reports shall state the planning for next three months.


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Submission of first reports must commence one month prior to commencement of

manufacturing activities of the product.
06.08 Method of Undertaking Inspection & Testing by Purchaser / his

representative/Purchaser
06.08.01 Inspection call shall be given only on readiness of the equipment/ assembly/
sub-assembly & after approval of all relevant drawings and QAP. Client/MECON
shall be given 10 working days notice period to organize inspection for indigenous
items and 30 working days notice period for imported items. In case, equipment/
assembly/ sub-assembly offered for inspection are found not ready, the call shall be
cancelled. All the cost of visit of Client/Purchaser / his representative's engineer shall
have to be borne by the successful bidder . Photographic evidence to support
readiness of material may be required to furnish along with fresh inspection call.
If the equipment/assembly / sub-assembly after inspection found not acceptable,

requiring rework or involve Purchaser / his representative's re- inspection, all the cost
of such re-inspections shall also have to be borne by the successful bidder as per
contract.
06.08.02 Inspection call shall be raised to Purchaser / his representative through IMS (Inspection
Management System). Soft copy of all documents like test Certificates, Internal
Inspection Reports, P.O., Sub-P.O., T.S., Approved QAP, approved GA drawings/ data
sheets/manufacturing drawings and all other relevant certificates as per approved QAP
shall be attached with inspection call in IMS. All TC’s shall be signed and endorsed by
successful bidder . Inspection calls without above documents shall be treated as
invalid and shall be ignored. Also, the hard copy comprising of all documents along
with signed and stamped inspection call shall be submitted to Purchaser / his
representative/ Client for further processing. Scrutinizing of call documents will be
start only after receipt of hard copies of inspection call.
06.08.03 The successful bidder shall offer substantial quantities of items for inspection
considering economical aspect of inspection with respect to size of order.
06.08.04 On receipt of the Inspection call, pertaining to particular package / equipment / item,
QA & Inspection group of Purchaser / his representative, Ranchi ( Overall co-
ordinating office for Inspection activities ) shall organize inspection visit or will issue
Inspection assignment to other Purchaser / his representative’s office ( based on
nearness to the vendor's manufacturing works / relevant job expertise ) as per approved
QAP.
06.08.05 Inspection waiver shall be processed based on document review and scrutiny as per
approved QAP.
06.08.06 After scrutiny of documents, comments forwarded by client/Purchaser / his

representative through IMS / mail shall be complied within 1 month from date of such


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comments. In case the compliance is not submitted within 1 month by successful

bidder , inspection call shall be treated as cancelled. New inspection call shall be raised
as per regular inspection calls in accordance with approved QAP.
06.08.07 In absence of Approved / Approved as Noted QAP and Drg./ datasheet, Inspection call
shall not be raised. New inspection call shall be raised as regular inspection calls in
accordance with approved QAP.
06.09 Obligations of Successful Bidder
06.09.01 The successful bidder shall provide all facilities and ensure full and free access of the
Inspection Engineer of Purchaser/Purchaser / his representative to their own or their
Sub-Contractor's premises at any time, during contract period, to facilitate him to carry
out inspection & testing of the product during or after manufacture of the same.
06.09.02 The successful bidder shall delegate a Representative / Co-ordinator to deal with
Purchaser / his representative/ Purchaser on all inspection matters. Representative of
successful bidder shall be present during all inspection at Sub-Contractor's works.
06.09.03 The successful bidder shall comply with instructions of Purchaser / his representative/
Purchaser fully and with promptitude.
06.09.04 The successful bidder shall provide all instruments, tools, necessary testing & other
inspection facilities to Purchaser / his representative / Purchaser free of cost for
carrying out inspection.
06.09.05 The cost of testing welds by ultrasonic, radiographic and dye penetration tests etc. in
the fabrication workshop shall be borne by the successful bidder .These tests need to
be witnessed & approved by ASNT/ISNT Level-II qualified NDT personals
06.09.06 The successful bidder shall ensure that the equipment / assembly / component of the
plant and equipment required to be inspected, are not dismantled or dispatched before
inspection.
06.09.07 The successful bidder shall not offer equipment for inspection in painted condition
unless otherwise agreed in writing by Purchaser / his representative/ Purchaser.
06.09.08 The successful bidder shall ensure that the equipment and materials once rejected by
the Purchaser / his representative/Purchaser, are not re-used in the manufacture of the
plant and equipment. Where parts rejected during inspection have been rectified as per
agreed procedures laid down in advance, such parts shall be segregated for separate
inspection and approval, before being used in the work.
06.10 Stamping and issue of Inspection Documents


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06.10.01 Inspection Memo:- For rejected items/items, which do not conform to Technical
Specification in one or more quality characteristics requiring rectification / rework,
Inspection Memo [Form No.- 11.20(DQM)F-18] shall be issued indicating therein
the details of observation & remarks. All the non-conformities with respect to
specification of the product shall be indicated in the Inspection Memo for further
quality control by successful bidder .
06.10.02 Inspection Certificate:- On satisfactory completion of final inspection & testing, all
accepted plant & equipment shall be stamped suitably and Inspection Certificate[Form
No.11.20(DQM)F-19] shall be issued by the Purchaser / his representative for the
accepted items.
06.10.03 Inspection Waiver Certificate :- MECON shall release Inspection Waiver Certificate
[Form No. 11.20(DQM)F-20] for the items, which are identified as waiver category in
the approved QAP upon verification of all inspection & test reports as indicated in the
QAP.
06.11 General Clause
06.11.01 Inspection & tests carried out by Purchaser / his representative / Purchaser shall not
absolve the responsibility of the successful bidder / Manufacturer to provide
acceptable product as per the terms of contract nor shall it preclude subsequent
rejection.
06.11.02 Purchaser/ Purchaser / his representative reserve the right to inspect any product at any
stage of manufacturing beyond pre-identified stages & hold points of approved QAP.

SECTION 07.00
PAINTING


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07.00 PAINTING
07.01 General
This specification covers the materials, tools, facilities and quality requirement for
surface preparation and painting of steel structures, mechanical & electrical
equipments, technological structures, piping, ducts, chutes etc. for FGD & Auxiliary
system for 4 X 210 MW Mettur Thermal Power Plant-I as elaborated in the tender
specification.
This specification will be read in conjunction with other sections / volumes of the
Tender specification where other related project requirements have been indicated.
The term “Painting” referred herein covers rust preventive, preventive and decorative
coating along with surface preparation of the following areas.
a) All Mechanical equipment, Technological structures, chutes, piping, ducts

etc. unless otherwise specifically indicated in the relevant section.
b) Various types of static and rotary equipment inclusive of electric motors
etc.
c) Steel tanks and vessels
d) Pipe work including trestles, supports, hangers, etc.
e) Metallic duct work such as ventilation ducts, gas ducts including supports,
hangers, etc.
This is a general guideline to the paining scheme to be followed. However, in case if a

specific painting procedure is stipulated in any Tender specification, then this general
guideline will be superseded. Any special case which may arise from time to time
will be dealt with individually on the merits of each case.
07.02 Surfaces made of aluminium, brass, bronze, stainless steel, and other corrosion
resistant alloys are not required to be painted unless specified except for identification
bands or for aesthetic purposes.
07.03 All machined mating surfaces (e.g. flanges) will be properly cleaned, and will be
provided with protective coating before dispatch.
07.04 The complete painting scheme for any item includes the following basic activities:
i) Proper surface preparation
ii) Application of primer coats
iii) Application of intermediate coats and
iv) Application of finish coats
All the above coats will be of quality paint products and of approved make as
stipulated in this specification. The scope of work will also include supply of all paint
Vol. – IIA, Section 07.00 PAINTING Page 1 of 11


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materials as per specification described herein and of approved quality/ specifications.
07.05 Painting For Mechanical & Electrical And Other Equipment, Mechanical
Structures, Piping, Ducts Etc.
07.05.01 This section covers the painting requirements for the power plant equipment,
structures, piping etc. and any other surface required to be painted
07.05.02 Codes and Standards
Painting of equipment will be carried out as per the specifications indicated below
and will conform to the relevant IS specification for the material and workmanship.
The following Indian Standards may be referred to for carrying out the painting
job:
IS:5 : Colors for ready mixed paints and enamels
IS:1303 : Glossary of terms relating to paints

IS:2379 : Colour code for identification of pipelines
IS:1477 : Code of practice for painting of ferrous metals in buildings
(Parts I & II)
IS:2524 : Code of practice for painting of non-ferrous metals in buildings
(Parts I & II)
IS:2395 : Code of practice for painting of concrete, masonry and plaster
surfaces (Parts I & II)
IS:2338 : Code of practice for finishing of wood and wood based materials
(Parts I & II)
IS:6278 : Code of practice for white washing and colour washing
IS:3140 : Code of practice for painting asbestos cement building products
IS:158 : Ready mixed paint, brushing, bituminous, black, lead free,
acid, alkali, water and heat resisting
IS : 2074 : Ready mixed paint, air drying, red Oxide Zinc Chrome, priming
IS : 104 : Ready mixed paint, brushing, Zinc Chrome, priming
IS: 2932 : Enamel , synthetic, exterior (a) undercoating (b) finishing
specification.
07.06 Preparation of Surfaces
a) Surface preparation being a pre requisite for any paint application, will be such as to
clean the surface thoroughly of any materials which will be conducive to premature
failure of the paint substrates.
b) All surfaces to be painted will be thoroughly cleaned of all grease, oil, loose mill
scale, dust, rust and any other foreign matter. Mechanical cleaning by power tool and


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scrapping with steel wire brushes will be adopted to clear the surfaces. However, in
certain locations where power tool cleaning cannot be carried out, sand scrapping may
be permitted with steel wire brushes and/or abrasive paper. Cleaning with solvents
will be resorted to only in such areas where other methods specified above have not
achieved the desired results. Cleaning with solvents will be adopted only after written
approval of the Purchaser/ consultant.
c) The workmanship will, in general, be in accordance with IS: 1477- 1971. Surface of
all the steel works to be painted will be thoroughly cleaned and degreased in
accordance with IS:1477 (Part-I) by means of mechanical and power tool cleaning or
shot blasting. The cleaning quality will conform to second quality blast cleaning as per
BS-4332 or to SA 2-1/2 of Swedish Standards Institution SIS 055900. Cleaning of
surface will ensure primer coat is rigidly anchored to the virgin metal surface. Primer
paint will be applied not later than 2-3 hours after preparation of surface, unless
otherwise specified.
07.07 The acceptable surface preparation quality/grade are described under each painting
scheme. The procedures covered are solvent cleaning, hand tool cleaning, power tool
cleaning and blast cleaning
a) Solvent cleaning (SP 1) (If applicable)
The surface will be cleaned by wiping, immersion, spraying or vapour contacting of

a suitable solvent or washing with an emulsion or alkaline solution to remove oil,
grease, dirt, old paint, etc. Solvent cleaning will not remove rust, scales, mill scales or
weld flux. Therefore, before application of paint, solvent cleaning will be followed by
other cleaning procedures as stated below.
b) Hand tool cleaning (SP 2)
The surface will be cleaned by vigorous wire brushing done manually to St-2
quality. This method effectively removes loosely adherent materials, but would
not affect residues of rust or mill scales that are intact and firmly adherent.
c) Power tool cleaning (SP 3)
The surface will be cleaned by electric or pneumatic tools to St-3 quality. The tools
will be used carefully to prevent excessive roughing of surface and formation of
ridges and burns. This method will remove loosely adherent materials but would not
affect residues of rust or mill scales that are firmly adherent.
d) Blast cleaning (SP 4)
The surface will be cleaned by impingement of abrasive materials, such as graded

sand at high velocity created by clean and dry compressed air blast. This method will


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remove loosely adherent materials as well as adherent scales and mill scales. Prior
to application of blast, heavy deposit of oil and grease are removed by solvent
cleaning and excessive surface scales are removed by hand tools or power tool
cleaning. The surface will be cleaned to Sa-2 1/2 quality which means that to 95% of
surface area is free from all rust, mill scales and visible residues, foreign materials,
etc. The blast cleaning is not recommended for sheet metal work.
07.08 Primer Paints (P)
After the surface is prepared in a manner acceptable to purchaser/ consultant, two (2)
coats of Primer paints will be applied only on dry and clean surfaces. Second coat of
red oxide primer will be applied only after first coat has dried up completely. Coating of
primer will in general conform to IS:2074-92 and will be applied by brushing to ensure a
continuous film without “holidays”.
a) Primer paint P1: (Epoxy based)

A two pack air drying epoxy polyamide resin based red oxide –zinc phosphate
(primer):
Epoxy content ( % wt) 15 to 18
Air drying time About 30 minutes ( touch dry) Over night
(hard dry)
Dry film thickness ( DFT/coat) 30 microns (min)
Temperature resistance Upto 120 deg.C dry heat
b) Primer paint P2 ( Epoxy based)
A two pack air drying epoxy polyamide with zinc dust of at least 92% zinc dust on the
dry film.
Epoxy content ( % wt) 8 to 10

Air drying time About 10 minutes ( touch dry)
2 hours ( hard dry)
Dry film thickness 40 microns ( min)
( DFT/coat)
c) Primer paint P3 (Ethyl zinc silicate, EZS, based)
A two pack heavy duty zinc dust rich silicate primer:

Total solids (% wt) 84 + 2
Air drying time 16 hours
Density 3.07 + 0.005


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Dry film thickness ( DFT/coat) 60 microns ( min)

07.09 Intermediate paints (N)

These paints will be applied over primer coats as an intermediate layer to provide
weatherproof seal of primer coats.
a) Intermediate paint N1
A two pack air drying high build epoxy resin based paint with MIO.
Air drying time 6 to 8 hours (touch dry) 7 days

(Full Care)
Dry film thickness ( DFT/coat) 80 microns
Compatible with Primer P1
07.10 Finish Paint (F)
Finish paint coats will be applied over primer coats and intermediate coats after
proper cleaning and touch up of primed coats. Synthetic enamel paint comprising of
IS: 2932-95 will be used for finish coats.
a) Finish paint (F1)

A two pack air drying epoxy polyamide enamel suitably pigmented.
Air drying time 2 to 3 hours (touch dry) 7 days (full cure)
Dry film thickness (DFT/coat) 30 microns
Compatible with Primers P1 and P2
Intermediate N1
Colour Generally all shades
b) Finish paint (F2)

A single pack synthetic rubber based enamel paint.
Air drying time 2 hours (touch dry)
24 hours (hand dry)
Dry film thickness ( DFT/coat) 25 microns
Compatible with No primers
Colour Generally all shades


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c) Finish Paint (F3)

A single pack heat resistant silicon Aluminum paint.
Air drying time 3 to 4 hours (touch dry) 24 hours
(hard dry)
Dry film thickness ( DFT/coat) 25 microns (min)
Temperature resistance upto 400 deg.C dry heat
Compatible with Primer paint P3
Colour smooth aluminium
Heat resistant Silicone Aluminium Paint with suitable air drying time as per IS 13183
Gr I , 25 microns per coat.
d) After cleaning the dust on the dried up primer/ intermediate paint, first coat of
synthetic enamel will be applied. After this first coat dries up hard, the surface is wet
scrubbed cutting down to a smooth finish and ensuring that at no place the first coat
is completely removed.
After allowing the water to get evaporated completely, the second finish coat of
synthetic enamel paint will be applied only after gently removing the gloss of first
coat from entire surface and it is dusted off the surface. The requirement of
workmanship will be as per IS:1477-71.
e) Equipment No. and the name of the equipment will be painted on the surface of the
equipment on visible locations in English. Service of the Pipe/Line designation with
arrow identification for the direction of flow will be painted on all pipes at visible
locations at an interval of 20 metres. Wherever pipelines are insulated, the service of
the piping and arrow mark will be painted over the clad surface.
f) For painting of structure, equipment, tanks & vessels etc. suggested colour code is
given in clause 17.2.8. For items not specified, the colour code to be followed for
piping will be in line with IS 9404:2002 (Identification of pipelines used in Thermal
Power Plants – Colour Code).
g) For insulated pipeline the finish paint will be applied at that place where colour
band is to be painted on the aluminium sheeting. The finished paint (colour band) will
be of 1m length at that place.
h) Colour band for piping will be applied at these following locations-

i) At start and end point.
ii) At every 10m intervals.
iii) At every T joints and cross connection of piping.
iv) At every battery limit of pipeline
v) Near valves before connection with the consumer.


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i) Width of band
Size of pipe including insulated Pipe line outside Width of band

diameter
80 mm and below 25 mm
Above 80 mm upto 150 mm 50 mm
Above 200 mm upto 300 mm 75mm
Above 350 mm 100 mm
j) Direction of flow will be indicated by black or white arrow in contrast to the base
colour on the pipeline. Length of the arrow will be minimum 125 mm and width will
be minimum 65 mm. These will be put at an interval of 10 m.
07.11 Suggested Color Codes For Painting of Structures, equipments, tanks & vessels
etc.
S.No Item/service
1. Structures, platforms, galleries, 176 - -
ladders and handrails PHIROZI
2. Pumps, motors, compressors. Light grey 631 - -
3. Outdoor, Stand pipes, vent pipes Aluminium - - -
4. Indoor Tanks Aluminium - - -
5. Vessels & all other proprietary Light grey 631 - -
equipment (without insulation
& cladding)
6. Tanks (without insulation and Aluminium
cladding)
7. Switchgear Light grey 631 - -
8. MCC/ PDB, Control, relay Light grey 631/ - -
panels, Bus 7078 of
duct IS:1650
9. Transformers Dark admiralty 632 - -
grey
10. Machinery guards Signal red 537 - -
11. Piping (without insulation and cladding)
14 D M Water Sea Green 217 Light 557
orange
15 Soft water Sea green 217 French 166
blue
16 Bearing cooling water Sea green 217 French 166
blue
17 Potable & filtered water Sea green 217 French 166
blue
18 Service & clarified water Sea green 217 French 166


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S.No Item/service
blue
19 Service air Sky Blue 101 - -
20 Instrument air blue 101 White -
21 Lubricating oil Light brown 410 Light 631
grey
22 Control oil Light brown 410 Light 557
orange
23 Transformer oil Light brown 410 Light 557
orange
25 Carbon dioxide Canary yellow 309 Light 631
grey
26 Vacuum pipes Sky blue 101 Black -
27 Drainage Black - - -
28 Stand pipes and all Aluminium - - -
Vent pipes
29 Fire Water Lines Fire red - - -
Notes:
Where band colour is specified, same will be provided at 10 meter intervals on long
uninterrupted lines and also adjacent to valves and junctions.
07.12 Paint Application
a) Paint will be applied in accordance with manufacturer’s recommendations.

The work will generally follow IS 1477 (Part II) for jobs carried out in India and SSPC-
PA-I or DIN 55928 or equivalent for jobs carried out outside India. Touch up paint to be
applied to cover scratches after erection and assembly of equipment at site.
b) Paint will not be applied when the ambient temperature is 5 deg. C and below. Also paint
will not be applied in rain, wind, fog or at relative humidity of 80% and above.
c) Each coat of paint will be continuous, free of pores and of even film thickness without thin
spots. The first coat of finish paint at site will be applied preferably within three months of
the shop paint.
d) Each coat of paint will be dry sufficiently before application of next coat.
e) Surface which cannot be painted but require protection will be given a coat of rust
inhibitive grease according to IS:958-75 or solvent deposited compound according to
IS:1153-75 or IS:1674-60.
f) Surface which will be inaccessible after assembly will receive minimum coats of specified


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primer. Surface to be in contact with wood, brick or other masonry will be given one shop
coat of the specified primer.
g) Parts of steel structure to be embedded in concrete will be given a protective coat of

Portland cement slurry immediately after fabrication and thoroughly cleaning the surfaces
from grease, rust, mill scales etc. No paint will be applied on this part.
h) The bidder will furnish paint manufacturer’s test report or technical data sheet pertaining
to the paint selected. The data sheet will indicate among other things the relevant
standards, if any, composition in weight percent of pigments, vehicles, additives, drying
time, viscosity, spreading rate, flash points, methods of application quality of surface
preparation required, corrosion resistance properties and colour.
i) Rust preventive coating will be given to HSFG bolt and nut threads.
j) Machined surfaces / weld edges will be applied with a coating of temporary rust preventive
oil.
k) All threaded and other surfaces of foundation bolts and its materials, insulation pins,
anchor channels, sleeves will be coated with temporary rust preventive fluid and during
execution of civil works; the dried film of coating will be removed using organic solvents.
l) The temporary rust preventive coating that had already been applied on any components,
tubes, pipes etc., will be removed by suitable solvents/ heating to 350-400 Deg.C for an
hour before primer paint application-but it will be ensured that the minimum surface
cleanliness required for primer paint application will be Sp2 (equivalent to hand tool
cleaning).
m) All weld edge preparation for site welding will be applied with one coat of weldable
primer.
n) For internal protection of pipes/tubes, VCI pellets will be used at both ends after sponge
testing and ends capped. VCI pellets will not be used for SS components and composite
assemblies.
o) Wherever inside surfaces of ducts need protection till erection, two coats of red oxide zinc
phosphate primer (P1) paint to IS 12744 to a DFT of 60 microns will be applied after
power tool cleaning.


ITS AUXILIARIES
07.13 Painting scheme
a) For a complete painting scheme of any item being painted, all types of paints are to
be procured from the same manufacturer as approved by the Purchaser.
b) The painting scheme to be followed for various mechanical/ electrical equipment /

structures is briefly given below for guidance to the Bidder.
Legend
SP Surface preparation quality
P Primer Paint
2P1 stands for Two (2) coats of primer paint type P1
N Intermediate paint
1N 1 One (1) coat of intermediate paint type 1
F Final Paint
2F1 stands for Two (2) coats of finish paint type F1
DFT Dry film thickness
CRT Clean and retouch
Sa - 2.5 Quality of surface cleaning (i.e. 95 % of the
surface area is free from all rust, mill scales and
visible residues, foreign materials etc.
c) Painting Scheme
Painting Scheme Total

S. Description Surface DFT in
No Preparation At shop At site micron
1 Steel Structure Sa 2½ 2P1+1N1 2F1 200
2 Mechanical Sa 2½ 2P1+1 N1 2F1 200
equipment
(temp. not over 80
deg. C) Both static
and rotary equipment
Pipe line and Valves
3 Pressure Vessels and Sa 2½ 2P1+1N1 3F1 200
Tanks
4 Non insulated Sa 2½ 2P1+1N1 2F1 200
pipe/ duct
works -
Temperature not over
80 °C
5 Insulated pipe/duct St3 2 coats of Not 60µ
works Alkyd requ
Red Oxide ired
Zinc


ITS AUXILIARIES
Painting Scheme Total

S. Description Surface DFT in
No Preparation
At shop At site micron
Phosphate
primer to
IS 12744 –
DFT
30µ/ coat
6 service water, potable Hand tool/ 2 coats of 2 coats 160µ
water piping and Power tool HB of
minor structures etc. cleaning to Chlorinate Chlorin
SSPC-SP2 d rubber ated
based red rubber
oxide based
zinc finish
phosphate paint
primer each
each 50µ 30µ
PAINTING SCHEME (AIR CYCLE)

PAINTING SCHEME
SURFACES TO BE SURFACE PRIMER INTERM. FINISHING AT
PAINTED PREPARATIO AT AT SHOP SITE
N SHOP
1) PIPE LINE AND
VALVES (SA)
- OUTSIDE SA 2.5 2P1 1N1 2F1
- INSIDE -- -- -- --
2) FILTERS /
STRAINERS
- OUTSIDE SA 2.5 2P1 1N1 2F1
- INSIDE -- -- -- --
07.14 Submission of Painting Schedule
Tender or will submit a comprehensive painting schedule indicating surface

preparation quality, paint applied, total DFT, colour code etc. for Customer/
consultant’s approval before the painting of any equipment/ component/ structure
etc.

SECTION 08.00
FINALISATION OF
SUBVENDOR


ITS AUXILIARIES
08.00 FINALIZATION OF SUB-VENDOR
08.01 General
i) The successful Bidder is responsible for performance / guarantee of the complete

package including bought out items and out sourced processes. The Bidder shall
supply the equipment/component/system from the Purchaser/Consultant approved sub
vendors list only.
ii) The Bidder has to necessarily indicate in their bid, their proposed sub vendors for the
items listed at 08.04 below. Sufficient number of sub vendors may be proposed to
meet their requirement.
iii) The items listed are not exhaustive. Hence If considered necessary the Bidder can
include additional items and indicate their proposed sub vendors for those items also.
iv) The proposed list of sub vendors furnished by the Bidder will be reviewed during
Techno Commercial / Pre-award discussions by Purchaser/Consultant and the sub
vendors will be categorized as below.
(a) Category – I: Sub vendors accepted. The acceptance shall be based on past
experience of Purchaser/Consultant.
(b) Category – II: Sub vendors enlisted for future acceptance. Such acceptance
shall be based on the various details regarding capacity, capability, experience etc of
the sub-vendor proposed by the successful Bidder. It is the responsibility of the
successful Bidder to get the details of the sub vendors under category II,
compiled and submitted to Purchaser / consultant for scrutiny and acceptance. The
acceptance criteria are mentioned below. However, Purchaser reserves the right to
accept or reject any of the proposed vendors based on information available with them.
v) The consolidated list of sub vendors under category I and category II shall be made
available to all the qualified Bidders before price cover opening.
vi) Purchaser may consider the Bidder’s proposal for inclusion of new sub vendors, if
any during post award stage for approval, based on merits, in the overall interest of
the Package, after establishing that the sub vendors proposed meet the acceptance
criteria specified. However, price advantage if any, arising out of inclusion of new sub
vendors shall be passed on to the Purchaser.
vii) For all other components/equipments/systems which are not figuring in the following
list or in the additional list furnished by the Bidder in their bid, Bidder’s standard
practice of selection of vendors may be carried out.
Vol. – IIA, Section 08.00 FINALISATION OF SUB VENDOR Page 1 of 12


ITS AUXILIARIES
08.02 Acceptance Criteria for Sub Vendors:
i) For all Mechanical, Electrical, Control and Instrumentation (Except for items mentioned
under ii and iii below)
For Class I Items:
Bidder to furnish documentary evidence to show that similar or higher capacity

component/equipment / system has been supplied by the vendor or their associate /
collaborator, the same has been operating satisfactorily for two years as on the date of
issue of LOA. The documentary evidence shall be in the form of Performance
certificates furnished by the end user.
For Class II Items:
Bidder to furnish documentary evidence to show that similar or higher capacity

component/equipment / system has been supplied by the vendor or their associate /
collaborator. The documentary evidence shall be in the form of Material Receipt
Certificate or Site Inspection Report, etc from the end user for having received the
material by the end user site/Purchaser premises for having received the material.
The component/equipment / system covered under Class I and Class II are furnished
below for Mechanical, Electrical, Control and Instrumentation.
ii) For Programmable Logic Controller (PLC):
(a) The sub-vendor shall be a manufacturer of PLC and the offered PLC should have
been supplied, erected, tested and commissioned as control system.
(b) Each or higher and running successfully with proven performance for a period of two
(2) years from the date of issue of LOA.
(c) The sub-vendor shall furnish all required information to fully satisfy the Purchaser/
Consultant regarding successful operation and high reliability of products/systems
furnished.
iii) For all civil items
(a) It should conform to relevant Indian/international Standards.
(b) It should be of reputed makes supplied to similar construction / infrastructure

projects.
(c) The Bidder should furnish documentary evidence to prove (a) and (b) above


ITS AUXILIARIES
iv) For Cement:
(a) It should conform to relevant Indian / International Standards.
(b) It should be of reputed makes supplied to similar construction/Infrastructure projects.
(c) For cement, minimum quantity of supply shall be 2500 MT for a single project.
(d) The Bidder should furnish documentary evidence to prove (a), (b) and
(c) above.
(iv) For reinforcement steel:
(a) The quality shall conform to relevant Indian standard/ International Standards.
(b) The firm should have been in the market for a minimum period of 3 years as on the
original date of Tender opening and should have supplied & used the reinforcement
steel in any industrial project.
(c) For reinforcement steel – minimum quantity of supply & used shall be 1000 MT for a
single project.
(d) The Bidder should furnish documentary evidence to prove (a), (b)
and (c) above.
(v) For structural steel (for use in Civil & Structural buildings only):
(a) The quality shall conform to relevant Indian standard / International Standards.
(b) The firm should have been in the market for a minimum period of 3 years as on the
original date of Tender opening and should have supplied & used the structural steel
in any industrial project.
(c) For structural steel – minimum quantity of supply & used shall be 1000 MT for a
single project.
(d) The Bidder should furnish documentary evidence to prove (a), (b) and (c) above.
Design, Supply, Fabrication & Erection of Steel Structures (On turnkey basis).
The Bidder should fulfill the following eligibility criteria: -
Technical Requirements
The bidder shall have experience of design of industrial steel structures of similar


ITS AUXILIARIES
nature, preparation structural design drawings, preparation of fabrication drawings,

supplied fabricated steel structures and erected the fabricated steel structures for a
industrial steel structural building, junction houses & conveyor galleries having roof as
well as side claddings including transportation of fabricated steel structures at the site of
erection.
The bidders should have successfully completed similar works in any consecutive 6
months during last 7(seven) Years ending last day of month previous to the one in
which bids are invited and shall be in compliance of either of the following:-
One similar completed work having quantity not less than the volume of steel structural
work equal 1000 MT.
Documents to be furnished in support of fulfillment of above criteria
The bidder shall submit attested copy of the following documentary evidence issued by
client to the bidder/ultimate purchaser, as proof of meeting the prescribed eligibility
criteria, with specific mention of information required:
Letter of Award of work/Work orders/Contract
Satisfactory completion certificate indicating quantum of work executed, specifying the

date of completion.
The bidder should clearly mention documents/certificates, which he has submitted, as

reference to be considered, for evaluation of technical eligibility.
(vi) For Welding Electrodes

(a) The welding electrodes shall be conforming to AWS and related BIS and as per
the Technical specification.
(b) The Firm should have executed orders for the supply of electrodes for an order
value not less than Rs. 3 lakhs in a calendar year for any or all sizes of the subject
electrode within last three(3) years as on the original scheduled date of tender
opening..
(c) The Bidder should furnish documentary evidence to prove (a)&(b) above
08.03 Acceptance Criteria for Sub Vendors
i) For Mechanical and Electrical works


ITS AUXILIARIES
Bidder to furnish documentary evidence to prove that similar mechanical / electrical

erection and installation work had been carried out by the Sub vendor.
ii) For Control and Instrumentation items
In case the C&I vendor is engaging a sub Bidder for C&I works
Documentation proof shall be furnished in the form of Bid award copy and
performance certificate (End user’s certificate) to show that similar C&I erection &
installation activities were carried out and the job completed satisfactorily by the C&I
sub vendor.
iii) For Civil items
The main Bidder may engage one or more sub vendor for carrying out Civil works.
However, the Civil sub-Bidder shall have the following qualifying requirements.
(a) He shall have experience in carrying out civil engineering works for Industrial
buildings / equipment foundations / high-rise buildings (3 storeys and more) etc.,
(b) He should have executed not less than 5000 Cu.M of R.C.C work in a single
agreement.
(c) Any structural steel works of quantity not less than 1000 metric tones in a single
agreement.
(d) The work in S.Nos i to iii should have been completed within the past 7 years, as
on the original scheduled date of tender opening.
(e) Bidder to furnish necessary documentary evidence to prove the above requirements
and get approval from the Purchaser, prior to engaging them for civil works.
08.04 List of items/ components for which Bidders shall submit the sub vendor list are
indicated below. Purchaser/Consultant shall categories those vendors in Category-I &
II and shall inform to all the bidders before price cover opening.
08.05 List of Sub Vendors – Mechanical
A. Common Equipments
i) Class I items: Items for which Performance Certificates shall be furnished for
approval of Category II sub vendors during detail engineering
Sl. No. Item/System Description Sub Vendors

1. Booster Fan
2. Slurry pumps (if applicable)
3. Air Compressors


ITS AUXILIARIES
Sl. No. Item/System Description Sub Vendors

4. Hydrator
5. Reagent Feeder
6. Air Slide Device
7. Bag Filter
8. Elevators
9. EOT Crane (Single/double girder)
10. Flue gas ducting and Dampers/Gates
Bidder may add any other item as per their own system.
ii) Class II items: The documentary evidence for approval of Category II sub
vendors shall be in the form of Material Receipt Certificate or Site Inspection Report,
etc from the end user for having received the material by the end user.
Sl. No Item/System Description Sub Vendors

1. Thermal insulation
2. Metallic expansion joints
3. Non Metallic expansion joints
4. Butterfly Valve (less tha 500 NB)
5. Knife edge gate valve
6. Gate valve
7. Globe valve
8. Check valve
9. Diaphragm Valve
10. Spray nozzles
11. Electric hoist
Bidder may add any other item as per their own system.
08.06 List of Sub Vendors- Electrical

I) Class I items: Items for which Performance certificates shall be furnished for
approval of Category II sub vendors during detail engineering.
Sl.No Item Description Sub Vendors
1. HT SWITCHBOARD
2. ACB
3. VCB
4. 415 V SWITCHGEAR
(PCC/PMCC/ MCC)
5. LT BUSDUCT (NON-
SEGREGATED PHASE )
6. LT TRANSFORMER (DRY
TYPE)


ITS AUXILIARIES
Sl.No Item Description Sub Vendors

7. LIGHTING
TRANSFORMER
8. H.T. MOTORS
9. L.T. MOTORS (AC & DC)
10. ELECTRICAL
ACTUATORS
11. VARIABLE FREQUENCY
DRIVE (VFD)
12. NUMERICAL
PROTECTION RELAYS
13. ELECTRO MECHANICAL
RELAYS
14. AUXILIARY RELAYS
15. H.T. POWER CABLES
(XLPE)
16. LT POWER CABLES
(XLPE)
17. LT TRAILING CABLES
18. LT CONTROL CABLES
19. PLANTE BATTERY
20. BATTERY CHARGER
(FC/FCBC)
21. MLDB/PDB/ACDB/WDB/E
LDB/DCDB/LCP/LPBS/DC
LDB
22. UPS
II) Class II items: The documentary evidence for approval of Category II sub vendors shall
be in the form of Material Receipt Certificate or Site Inspection Report, etc from the end
user for having received the material by the end user.
Sl.No. Item Description Sub Vendors

1. AC/DC CONTROL
CONTACTORS
2. AC/DC POWER
CONTACTORS
3. CABLE GLANDS
4. CABLE LUGS
5. CABLE TERMINATION &
JOINTING KITS


ITS AUXILIARIES

6. CABLE TRAYS
7. CONTROL
TRANSFORMERS
8. CT / PT
9. ENERGY METERS/MULTI
FUNCTION METERS
10. HIGH MAST
11. LED LIGHTING
12. LIGHTING FIXTURES
(FLAME PROOF)
13. LIGHTING FIXTURES
(GENERAL)
14. MCCB/MPCB/MCB
15. METERS
(ANALOG/DIGITAL)
16. STREET LIGHT POLES
17. TRANSDUCER
08.07 List of Sub Vendors – Control & Instrumentation
Sl. Item Description Sub Vendors

No.
A. Field Instruments:
1. Pressure / Differential Pressure :
gauge (Class II)
switches. (Class II)
Transmitters (Class I)
4. Temperature gauges (Class II) :
5. Thermocouple & RTD / thermowell :
(Class I)
6. Temperature Switch (Class II) :
7. Temperature transmitter (Class I) :
8. Rotameters(Class II) :
9. Orifice Plate & flanges Assembly/ :
Venturi , Flow nozzle (Class I)
10. DP type Flow / Level Transmitters :
(Class I)


ITS AUXILIARIES

No.
11. Flow Switch (Class II) :
12. Electromagnetic flow meter (Class :
II)
13. Vortex Flow meter (Class II) :
14. Mass (coriolis) flow meter (Class I)
15. Level gauge (magnetic & reflex
type) (Class II)
16. Level Switch (Conductivity type) :
(Class II)
17. Level Switch (Capacitance/RF :
type) (Class II)
18. Level Switch (Tuning fork/ Rod :
type) (Class II)
19. Level Switch (Float & Board type) :
(Class II)
20. Level Switch/ Transmitter :
(Displacer type) (Class I)
(Ultrasonic type) (Class I)
22. Level Switch/ Transmitter (Radar :
type) (Class I)
(Nucleonic type) (Class I)
24. Level switch (Electro- mech type) :
(Class II)
25. Control valve (Class I) :
26. Pneumatic Actuator (Class I) :
27. Electro-hydraulic actuator (Class I) :
28. Self- regulating pressure control :
valve (Class I)
29. I/P converter :
(Class II)
30. Fibre Optic Cable (Class I) :
31. Smart positioner (Class I)
32. Solenoid Valve (Class I) :
33. Air filter regulator (Class II)
34. Junction Boxes :
(Class II)
B. Control room Instrumentation
1. Programmable Logic Controllers. :


ITS AUXILIARIES

No.
(Class I)
2. Digital Indicator (Class I) :
3. Bargraph Indicator (Class I) :
4. Recorders (Chart Less) (Class I) :
5. Microprocessor based controller :
(Class I)
6. Digital scanners (Class I) :
7. DC Power Supply Unit (Class I) :
8. IS Interface/Zenner Barrier
9. Signal isolators (Class I) :
10. Annunciation system (Class I) :
11. a. Instrument Panels :
(Class II)
b. Modular Control Desk
(Class II)
c. Computer Furniture
(Class II)
12. Instrumentation Cable (Class I)
13. Thermocouple Compensating Cable :
(Class I)
C. Analytical / Special Instruments
1. Gas analysis Instruments (CEMS) :
(Class I)
2. O2 Analyser
(Class I)
3. Calorific Value (CV) analyzers :
(Class I)
4. Moisture Analyzers (Nucleonic) :
(Class I)
5. ORP/PH/ Conductivity meter / :
Transmitter (Class I)
6. Moisture Sensor & Transmitter :
(Class I)
7. Vibration sensors & monitors :
(Class I)
8. Positive Displacement meter (Class :
I)
9. Annubar / Flow tube :
(Class I)


ITS AUXILIARIES

No.
10. Infrared radiation pyrometer :
(Class I)
11. SPM analyser (Class I)
12. SOx- NOx analyser (Class I)
Network Equipment (Class I)
 Active components (Switches) : CISCO/Siemens
 Passive components : LUCENT/AMP
 Application software including
Process control models : Supplier
For any other equipment/supplies which are not covered above, the
make/manufacturer’s name shall be mutually agreed between Client /Consultant
and the successful Tendere
08.08 List of Sub Vendors - Civil Supply Portion
i). Building Materials

Sl. No Item Description Sub Vendors
1. Flush doors
2. Plywood products, particle boards
3. Steel doors, windows and ventilators
4. Aluminium doors, windows, partitions
5. Water proofing compounds/construction
chemicals
6. Paints and distempers
7. Water proof cement paints and exterior
emulsion paints
8. Metal cladding system
9. Glazing glass
10. Tiles (terrazo mosaic plain)
11. Hardeners
12. Perssed steel door and window frame
13. Door closer
ii) Sanitary and Water Supply Work


ITS AUXILIARIES
1. PVC Pipes & UPVC Pipes and Specials

2. G.I. Pipes & Specials
3. W.C. PanWashBasin, Urinals Sink Low down
flushing Cistern & EWC
4. Colour/White Glazed Tiles, Ceramic tiles and
Vitrified Tiles.
iii) RCC Items

1. Reinforcement Steel- Corrosion Resistant
Steel and properties conforming to IS
1786
2. cement
iv) Structural Steel

1. Structural Steel

SECTION 09.00
PERFORMANCE
GUARANTEES


& ITS AUXILIARIES
09.00.00 PERFORMANCE GUARANTEES, LIQUIDATED DAMAGES FOR

SHORTFALLIN PERFORMANCE AND PERFORMANCE
GUARANTEE TESTS
GENERAL
The term “Performance Guarantees”, wherever appears in the technical

specification shall have the same meaning and shall be synonymous to
“Functional Guarantees”. Similarly the term “Performance Tests” wherever
appears in the Technical Specification shall have the same meaning and
shall be synonymous to “Guarantee Tests”.
09.01.00 PERFORMANCE GUARANTEES / PERFORMANCE TESTS
09.01.01 General Requirements:
09.01.01.01 The contractor shall guarantee that the equipment offered shall meet the
ratings and performance requirements stipulated for various equipment
covered in these specifications.
09.01.01.02 The guaranteed performance parameters furnished by the Bidder in his

offer, shall be without any tolerance values whatsoever. All margins
required for instrument inaccuracies and other uncertainties shall be
deemed to have been included in the guaranteed figures. No tolerance or
allowance on the test result will be permitted for instrument errors or
inaccuracy, the method of testing or any other cause.
09.01.01.03 The Contractor shall conduct performance test and demonstrate all the
guarantees covered herein. The various tests which are to be carried out
during performance guarantee tests are listed in this chapter / section. The
guarantee tests shall be conducted by the Contractor at site in presence of
Purchaser on each unit individually.
09.01.01.04 All costs associated with the tests including cost associated with the supply,
calibration, installation and removal of the test instrumentation shall be
included in the contract price.
09.01.01.05 It shall be responsibility of the Contractor to make the plant ready for the
performance guarantee tests.
09.01.01.06 The performance tests shall be performed using only the normal number of
Purchaser’s supplied operating staff. Contractor, vendor or other
subcontractor personnel shall be used only for instructional purposes or
data collection. At all times during the Performance Tests, the emissions
Vol. – IIA, Section 09.00 PG PARAMETERS Page 1 of 11


& ITS AUXILIARIES
and effluents from the plant shall not exceed the guaranteed emission and
effluent limits.
09.02.00 Test Instrumentation, Flow Measurement and their Calibration:
09.02.01 All instruments required for performance testing shall be of the type and
accuracy required by the code and prior to the test, the Contractor shall get
these instruments calibrated in an independent test Institute approved by the
Purchaser and submit the same to Purchaser prior to commencement of test.
All test instrumentation required for performance tests shall be supplied by
the Contractor and shall be retained by him upon satisfactory completion of
all such tests at site. All calibration procedures and standards shall be
subject to the approval of the Purchaser prior to commencement of test. The
protecting tubes, pressure connections and other test connections required
for conducting guarantee test shall conform to the relevant codes.
Tools & tackles, thermo wells (both screwed and welded) instruments /
devices including flow devices, matching flanges, impulse piping & valves
etc. and any special equipment, required for the successful completion of
the tests, shall be provided by the Contractor free of cost.
The Performance test shall be carried out as per the agreed procedure. The
detailed PG test procedure shall be submitted within 90 days of the
Notification of Award and finalization of PG test procedure shall be done
within 180 days from the date of Notification of Award.
09.02.02 The Performance and Guarantee test procedures shall be submitted for
equipment / system & sub system under Contractor’s scope for all
guarantees as mentioned below, as per latest international codes / standards
including correction curves, meeting the specification requirements along
with sample calculations & detailed activity plan of preparation (including
test instrumentation), conductance and evaluation of Guarantees.
09.02.03 The Contractor shall submit for Purchaser’s approval, the detailed
Performance Test Procedure containing the following:
a) Objective of the test

b) Various guaranteed parameters & tests as per contract
c) Method of conducting the test and test code
d) Duration of test, frequency of readings & number of test runs
e) Method of calculation
f) Correction calculation & curves
g) Instrument list consisting of range, accuracy, least count, and location
of instruments
h) Scheme showing measurement points

& ITS AUXILIARIES
i) Sample calculation
j) Acceptance criteria
k) Any other information required for conducting the test.
09.03.00 Test Reports
After the conductance of Performance test, the Contractor shall submit the
test evaluation report of performance test results to Purchaser promptly but
not later than one month from the date of conductance of Performance Test.
Preliminary test reports shall be submitted to the Purchaser after
completing each test run. Four (4) hard copies and two (2) soft copies of
each test report of final conducted test on each equipment / plant / system
shall be submitted to Purchaser for approval.
09.03.01 Performance Guarantee Tests on the equipments / systems not covered in
this chapter / section shall be carried out as per the procedure / test codes
specified in respective detailed specifications.
09.04.00 Acceptance of Guarantee Test Results:
i) For Category – I Guarantees (which attract Liquidated Damages)
In case during performance Guarantee test(s), it is found that the equipment

/ system has failed to meet guarantees, the Contractor shall carry out all
necessary modifications and / or replacements to make the equipment /
system comply with the guaranteed requirements at no extra cost to the
Purchaser and re-conduct the performance guarantee test(s) with
Purchaser’s consent. In case the specified performance guarantee(s) are still
not met but are achieved within the Acceptable Shortfall Limit as specified
at Clause 09.05.00 of this chapter / section, Purchaser will accept the
equipment / system / plant after levying liquidated damages as per Clause
09.05.00 of this chapter / section. However, if the demonstrated
performance guarantee(s) continue to be beyond the stipulated Acceptable
Shortfall Limit, even after the above modifications / replacements within 90
days or a reasonable period allowed by the Purchaser, after the tests have
been completed, the Purchaser will have the right to either of the following:
Reject the equipment / system / plant and recover from the Contractor the
payments already made
OR
Accept the equipment / system / plant after levying Liquidated Damages.
The liquidated damages for shortfall in performance indicated in Clause
09.05.00 of this chapter / section shall be levied separately for each unit.
The rates indicated in Clause 09.05.00 of this section / chapter are on per
unit basis. The liquidated damages shall be prorated for the fractional parts
of the deficiencies.

& ITS AUXILIARIES
The performance guarantees coming under this category shall be called

‘Category-I Guarantees’.
ii) For Category-II Guarantees
Reject the equipment/ plant/ system and recover from the Contractor the
payments made.
The performance guarantees under this category shall be called ‘Category-

II Guarantees’. Conformance to the performance requirements under
Category-II is mandatory.
iii) For category – III Guarantees:
In case during performance guarantee test(s) it is found that the equipment /

system has failed to meet the guarantees, the Contractor shall carry out all
necessary modifications and / or replacements to make the equipment /
system comply with the guaranteed requirements at no extra cost to the
Purchaser and re-conduct the performance guarantee test(s) with
Purchaser’s consent. In case the specified performance guarantee(s) are still
not met even after the modifications / replacements within 90 (Ninety) days
or a reasonable period allowed by the Purchaser, after the tests have been
completed, the Purchaser will have the right to either of the following:
Reject the equipment / system / plant and recover from the Contractor the
payments already made.
OR
Accept the equipment / system after assessing the deficiency in respect of

the various ratings, performance parameters and capabilities and recover
from the contract price an amount equivalent to the damages as determined
by the Purchaser. Such damages shall, however be limited to the cost of
replacement of the equipment(s) / system(s), replacement of which shall
remove the deficiency so as to achieve the guaranteed performance. These
parameters / capacities shall be termed as “Category – III” Guarantees.
09.04.01 General Requirements
i) The contractor shall guarantee that the equipment offered shall meet the
ratings and performance requirements stipulated for various equipment
covered in these specifications.
ii) The guaranteed performance parameters furnished by the bidder in his
offer, shall be without any tolerance values and all margins required for


& ITS AUXILIARIES
instrument inaccuracies and other uncertainties shall be deemed to have

been included in the guaranteed figures.
iv) The Contractor shall demonstrate all the guarantees covered herein
during functional guarantee/acceptance test. The various tests which are to
be carried out during performance guarantee/acceptance test are listed in
this Sub-section. The guarantee tests shall be conducted by the contractor at
site in presence of purchaser on each unit individually.
v) All costs associated with the tests shall be included in the bid price.
vi) In case during tests it is found that the equipment/system has failed to meet
the guarantees, the contractor shall carry out all necessary
modifications and/or replacements to make the equipment/system
comply with the guaranteed requirements at no extra cost to the
purchaser. However, if the contractor is not able to demonstrate the
guarantees, even after the above modifications/ replacements within
ninety (90) days or a reasonable period allowed by the purchaser, after the
tests have been completed, the purchaser will have the right to either of the
following:
09.05.00 AMOUNT OF LIQUIDATED DAMAGES (LD) APPLICABLE FOR

GUARANTEES
The rate of liquidated damages and acceptable shortfall limits for different
guarantees shall be as under and such liquidated damages shall be deducted
from the Contract Price:
09.05.01 LDs for FGD System

Sl. Guarantee Rate of Liquidated Acceptable
No. Damage (LD) Shortfall Limit
with LD
1. SO2 removal INR 31,54,562 (Rupees (-)0.25%points
efficiency: Thirty One Lakh Fifty From the
For shortfall Four Thousand Five guaranteed SO2
inguaranteed hundred Sixty Two removal efficiency
SO2 removal only) for every0.1%short
efficiency in fall in guaranteed
Percentage. SO2removal efficiency.
2. Lime Consumption INR 9 ,33,385(Rupees (+)10%ofthe
Rate: For increase in N i n e Lakhs thirty guaranteed
lime consumption three Thousand three Lime consumption
under Guarantee hundred and eighty
conditions five
only)forevery1Kg/hr
increase in lime
consumption rate from
the guaranteed value.
3. For increase in INR6,81,211 (Rupees (+)1%of the

& ITS AUXILIARIES
Sl. Guarantee Rate of Liquidated Acceptable

No. Damage (LD) Shortfall Limit
with LD
theTotal Auxiliary Six Lakhs eighty one guaranteed
power consumption thousand two hundred auxiliary power
in KW guaranteed as and eleven only)per consumption
per the requirements 1KW increase in
this specification Auxiliary Power
Consumption
Note:
1. The LD values are applicable on per unit basis.
2. Each of the liquidated damages specified above shall be independent and
these liquidated damages shall be levied concurrently as applicable.
3. If the Contract currency is other that IN (Indian Rupees), then the
liquidated damages shall be in equivalent amount in Indian Rupees
based on bill selling exchange rate of State Bank of India prevailing on
the date of award of contract.
4. All these liquidated damages for shortfall in performance shall be
deducted from the contract price as detailed in accompanying
Commercial Volumes of the Tender Specification.
5. Bids will be rejected for quoting efficiency lower than 81.8 % and no
evaluation benefit given to the bidders quoting removal efficiency higher
than 81.8%.
6. Bids will be rejected in case the calculated SO2 removal efficiency is
found to be lower than 81.8 %.
** For evaluation purpose, the SO2 removal efficiency will be calculated as follows:
SO2 removal efficiency = (Inlet SO2 concentration – Outlet SO2concentration)

Inlet SO2 concentration
Note: For SO2 removal efficiency calculation both the inlet and outlet
SO2concentration shall be at 6% O2 dry basis. Outlet SO2 concentration shall be
considered as the quoted value by the bidder and with necessary corrections as
applicable, for calculation purpose.
Correction from Wet to dry basis (For Inlet SO2 concentration)
Sinlet= Ssp / (1-w)

Where,
Sinlet – Inlet SO2 Concentration corrected to dry basis
Ssp – Specified inlet SO2 Concentration on wet basis
w – Specified Moisture % by volume
Correction from Wet to dry basis (For O2 % by Volume)


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O2(M) = O2(WET) /(1-w)
Where ,
O2(M) – O2(WET) % by volume corrected to dry basis
O2(WET)– Specified O2 % by volume on wet basis
w – Specified Moisture % by volume
Correction for O2 %
SO2 (6% O2 % dry) = SM x(20.9-6)/(20.9-O2M)

Where,
SO2 (6% O2 dry )- Inlet SO2 Concentration corrected to 6% dry basis
LD for Non-fulfilment of Time Schedule
Refer clause no. 21 for “LIQUIDATED DAMAGES FOR DELAY IN

COMPLETION” of VOLUME – I (Commercial Volume).
09.06.00 GUARANTEES PARAMETERS:
09.06.01 Guarantees Under Category – I
The performance guarantees which attract liquidated damages shall be as follows:
a) FGD SO2 Removal Efficiency
The Contractor shall guarantee the SO2 removal efficiency for inlet
SO2concentrationcorresponding to coal analysis and 210 MW unit (100% TMCR)load.
The Guaranteed SO2removal efficiency shall not be less than 80 % at guarantee case.
b) Lime Consumption Rate
The Contractor shall guarantee the lime consumption in kg/h of FGD system under
guarantee case at 210 MW (TMCR) load with required coal firing, meeting anSO2(6%
O2, dry condition) at FGD outlet at 210 MW emission of 500 mg/Nm3unit load.
c) Auxiliary Power Consumption
The Contractor shall guarantee the total auxiliary power consumption for units, FGD plant
in normal operation at guarantee case at 210 MW unit load (100% TMCR). Bidder to refer
cl.no. 09.06.04 of this section.
09.06.02 Guarantees under Category – II
SO2 removal in treated flue gas: Maximum concentration of SO2 in treated flue gas at the
exit of FGD for the unit shall not exceed the guaranteed values.


& ITS AUXILIARIES
Conformance to the performance requirements under Category-II is

mandatory as compliance of limiting the SO2 emission from the plant
is a statutory requirement. If the stipulated guarantee is not met, the
purchaser as his discretion will reject the FGD Plant/ System and
recover from the Contractor the payments made for the entire
contract
09.06.03 Guarantees under Category – III
The parameters / capabilities to be demonstrated for various systems / equipment

shall include but not be limited to the following:
09.06.03.01 Pressure drop across FGD

The bidder shall demonstrate that the total pressure drop in the gas path across the
FGD System shall not exceed the guaranteed values for the range of lime and
loads specified in the Technical Specification.
09.06.03.02 Availability of FGD plant

The Bidder shall guarantee the maximum availability of FGD plant for the range
of coal and lime specified in line with cl. no. 09.10.00 of this section.
09.06.03.03 Particulate Matter(PM) output Level

Bidder’s design shall ensure that the particulate emission at chimney inlet shall not be
more than 70 mg/Nm3 at guarantee case at 210 MW unit load (100% TMCR).
09.06.03.04 Capabilities of all major electric drives

The capabilities of the following drives for one set of each type shall be
demonstrated as per Owners choice.
a) Booster fan
b) Lime slurry pumps
c) Air Compressor
d) Atomiser
09.06.03.05 SO2 Design Emissions

The bidder shall demonstrate the design capability for SO2outlet emission less
than300 mg/Nm3 (6% O2dry basis) at design case at 210 MW unit load(100%
TMCR).
09.06.03.06 Performance characteristics of booster fans (capacity, head developed, etc.)

The bidder shall demonstrate performance characteristics of the booster fans.
09.06.03.07 Pumps, fans, compressors and blowers etc.

Satisfactory operation of booster fans, compressors and blowers without undue
noise and vibration while operating in isolation or in parallel with other fans shall
be demonstrated at site.
09.06.03.08 Pneumatic conveying system

Design capacity of pneumatic conveying system shall be demonstrated at site.

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09.06.03.09 Cranes, monorails etc.

Over load test, Travel and speed checks, functional tests, performance tests, safety
test as per relevant Indian standards and codes shall be demonstrated at site.
09.06.03.10 Operating time of the dampers.

The bidder shall demonstrate the opening and closing time of dampers.
09.06.03.11 Noise
a) All the plant, equipment and systems covered under this specification shall
perform continuously without exceeding the noise level of 85 dBA over the entire
range of output and operating frequency.
b) Noise level measurement shall be carried out using applicable and
internationally acceptable standards. The measurement shall be carried out with a
calibrated integrating sound level meter meeting the requirement of IEC 651 or BS
5969 or IS 9779.
c) Sound pressure shall be measured all around the equipment at 1.0 m
horizontally from the nearest surface of any equipment/ machine and at a height of
1.5 m above the floor level in elevation.
d) A minimum of 6 points around each equipment shall be covered for
measurement. Additional measurement points shall be considered based on the
applicable standards and the size of the equipment. The measurement shall be
done with slow response on the A – weighting scale.
09.06.04 Auxiliary Power Consumption

The unit auxiliary power consumption shall be calculated using the following
relationship.
Pa = Pu + TL
Pa = Guaranteed Auxiliary Power Consumption.
Pu = Power consumed by the auxiliaries of the unit under test.
TL = Losses of the transformers supplied by bidder based on works test
reports.
While guaranteeing the auxiliary power consumption the bidder shall necessarily
include all continuously operating auxiliaries under dry FGD package for each
unit of 210 MW.
All equipments required for continuous operation of the system shall be
considered for calculation of auxiliary power consumption.
The bidder shall furnish an auxiliary power consumption breakup list indicating
the list of equipments (continuously and intermittent operating) with duty factor
to be covered under auxiliary power consumption along with the bid.
Note:
1. Bidder to consider duty factor of 1.0 for booster fan and all other
continuously operating equipments.
2. Bidder to consider duty factor of 1.0 for Air conditioning and ventilation
system.
3. Bidder to consider duty factor of 1.0 for UPS Power Supply system.


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4. Bidder to consider duty factor of 0.5 for all intermittent operating

equipments.
5. Bidder to include the cabling losses in the auxiliary power consumption.
09.09.00 METHOD OF COMPUTING TEST EFFICIENCY OF FGD
The performance tests shall be carried out in accordance with ASME PTC
40 (1991) code. The details of the test shall, however, be mutually agreed
upon between the Purchaser and the contractor.
09.10.00 METHOD OF COMPUTING AVAILABILITY
The contractor shall guarantee minimum 95% availability of FGD plant for
a continuous period of 120 days. An availability guarantee test shall be
conducted to assure this level of availability for a period of 120 days as per
the procedure indicted below.
Availability “A” in %
A = TFGD X 100%
TBoiler
TFGD = recorded time of FGD operation, expressed in hours.

TBoiler = recorded time of boiler operation, expressed in hours,
However, it is required that:
(i) In order to calculate the FGD availability, operation hours will be counted
normal operation of boiler excluding start-ups and shutdown periods.
Operation hours counting of the FGD plant will start on the moment of shut
down of all oil burners.
(ii) If FGD is out of operation during the boiler operation time as a result of the
Purchaser’s decision, this time will not be counted as boiler operation time
for calculating the FGD availability.
(iii) Boiler operation hours will be counted based on the recorded boiler
operation hours and the recorded data will be made available to the
Contractor by the Purchaser.
Mandatory spares have been identified by the Purchaser. Contractor can use
the mandatory spares supplied under the contract during this period in


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agreement with the Purchaser. However, if other additional spares are

required for demonstration of availability demonstration guarantee, Bidder
should clearly indicate the same along with their offer.
If the calculated availability after 120 days availability test is lower than the
guaranteed value, the Contractor will undertake actions as per clause
09.04.00 (ii) of this chapter / section to achieve the guaranteed availability.

SECTION 10.00
TERMINAL POINT


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10.00 TERMINAL POINTS & EXCLUSIONS
Terminal Points
FGD
The terminal points for each stage identified herein below shall be read in conjunction
with the tender drawings, scope of supply and technical specifications of various systems
covered under the package.
10.01 Mechanical
TP. NO. Items Description Remarks
arks
TP-1 Process
ss Water supply From the existing plant Bidder
dder to provide
to FGD plant
p CT blow down water necessary
essary ppumps to fill
storage tank, if required.
TP-2 Fire Waater Nearest tapping
TP-3 Flue gas inlet to ID fans outlet Refer General Layout
FGD plaant common duct drawing
TP-4 Treated Flue gas from Ducting up to inlet of Refer General Layout
FGD plaant common flue gas ducting drawing
to chimney
TP-5 Equipmment Cooling Nearest tapping from the
water (E
ECW) supply ECW supply header
network
TP-6 Equipmment Cooling Nearest tapping to the
water (E
ECW) return ECW return header
network
TP-7 Potable Water Nearest tapping from the Bidder to provide
plant potable water necessaary pumps to fill
distribution storage
ge tank, if required.
TP-8 By-Product
oduct To the outlet of telescopic
Discharge
arge chute of by-product silo
TP-9 Lime Discharge of lime
unloading trucks
TP-10 Maintena
nance Waste Up to existing drainage
water/m
misc. drain water network system
TP-11 Service Water From nearest service Bidder to provide
water header necessaary pumps to fill
storage
ge tank, if required.
TP-12 Process steam for From nearest steam a.) Temperature – 180◦C –
VAM header 200◦C
b. Pressure – 12 KSC/cm
c. Flow – 2.5 T/hr
d. Elevation of the header
– 6 meters
e. Dia of the header – 100
mm
Vol. – IIB, Section 10.00 Terminal Point Page 1 of 2


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10.02 Electrical
1250A VCB feeders, two each from station bus C1 & C2 in the existing 6.6KV station
switch gears shall be used as two incomers to each of new FGD HT switch board to be
located in the proposed FGD electrical cum control room building. Replacement of 1250A
VCB breaker by 2000A VCB breaker with necessary modification/
modification/ changes in power,
control, protection, metering & associated components like new VCB’s (2000A,40KA,
7.2KV, floor mounted), bushing CT’s core balance CT’s, relay, meters etc including
retrofitting of the new 2000A VCB in the existing 6.6KV station
station bus C1 & C2 shall be
under bidder scope.
Required HT cables from these modified 2000A VCB panel up to FGD 6.6KV new HT
SWGR board shall also be covered under the scope of FGD package(approx. distance
500mtr. Each) including laying of cable & termination
termination at both ends and allied works.
Regarding Power Requirement:

a).Maximum load (in MVA) Electrical operation of proposed FGD system shall be
indicated in the offer by the bidder. In this context, bidder shall note that maximum power
that can be made available
available from the existing station transformer viz. ST
ST-1 & ST-2 ( rating
31.5MVA each) is limited upto 10MVA each (i.e. total 20MVA for proposed FGDs for all
four units of power plant) inclusive of all standard design and operational margins.
b). In case if the connected load designed by the bidder exceeds 10MVA for FGD for each
of 2*210MW Units, the existing station transformer (viz) ST1 & ST2 ( rating 31.5 MVA
each) and allied HT bus C1 & C2 including bus duct, incoming breaker and bus to be
enhanced at the scope
ope of the bidder.
10.05 Exclusions
a) Reagent suppply at plant boundary

c) By-product disposal outside plant boundary
d) Process, serv
vice, cooing water supply
e) Green Belt.
f) Main Statioon Switchgear
g) Control wiri
ring external to the bidder’s terminal point
h) Laboratory Equipment
Equ
Vol. – IIB, Section 10.00 Terminal Point Page 2 of 2

SECTION 11.00
LAYOUT AND
MAINTENANCE
REQUIREMENT


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11.00 LAYOUT AND MAINTENANCE REQUIREMENT
11.01 General layout plan indicating the available spaces for proposed FGD is as shown in the
tender drawing. It shall form the basis for further elaboration by the Bidder for the plant
facilities, which are in his scope.
11.02 While preparing the detailed layout, planning the facilities in the Bidder’s scope and
deciding upon the transportation and construction / erection strategy and functional
requirements, the Bidder shall ensure the following aspects:
i) Face of the buildings and facilities shall be located in such a way so as to have an
offset of minimum 20 m with respect to center line of double lane road and 15
meter with respect to center line of single lane road. The spacing between various
buildings and facilities shall be suitably decided so as to avoid interference
between the foundations.
ii) The entire construction activity shall take into account the commissioning of the
units.
ii) The area for construction/erection facilities like lay-down, pre-assembly, offices
and stores is to be managed by the Bidder within the areas available in General
Layout Plan.
iv) Chemical storage shall be designed in accordance with statutory agencies

guideline.
v) All the buildings and facilities shall be approachable by the fire tenders.
vi) All statutory requirements including safe distances between various facilities as
per applicable rules/acts/laws including local bye-laws are met.
Vol. – IIA, Section 11.00 LAYOUT & MAINTENANCE REQ. Page 1 of 1

SECTION 12.00
DRAWING /
DOCUMENT TO BE
SUBMITTED ALONG
WITH THE BID / OFFER
AND AFTER AWARD OF
CONTRACT
REQUIREMENT


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12.00 DRAWING / DOCUMENT TO BE SUBMITTED ALONG WITH THE

BID / OFFER AND AFTER AWARD OF CONTRACT
12.01 General
12.01.01 As part of the Bidder’s activity, the Bidder shall be responsible for proper
engineering and co-ordination of activities during various phases of execution of the
contract. The Bidder shall identify a person, designated as Project Manager, with whom
the Purchaser/Consultant shall interact on matters related to engineering as well as
execution of the project. The Project Manager shall be the single-point contact person
on behalf of the Bidder and shall be responsible for all engineering co-ordination. The
Purchaser/Consultant shall interact with the Project Manager only on all matters of
co-ordination between the Purchaser/Consultant and the Bidder or on matters involving
the Bidder, his manufacturing units and sub-vendors. For the purpose of expediting, the
Purchaser/Consultant may sometimes interact with the manufacturing units or sub-
vendors of the Bidders. However such interaction shall not, under any circumstance,
dilute the responsibility of the Bidder to provide a fully engineered and co-ordinated
package under this contract.
12.01.02 On finalization of the contract, a procedure for exchange of engineering

information shall be mutually agreed and finalized between the
Purchaser/Consultant and the Successful Bidder.
12.02 Engineering Coordination Meeting
The Bidder and his sub-vendors shall be called upon to attend engineering co-
ordination meetings with the other Bidders and the Purchaser/Consultant during the
period of execution of contract. The Bidder including his sub- vendors shall attend
such meetings at their own cost. Normally coordination meeting with respect to any
specific design problem shall be held at the Purchaser/Consultant’s office.
12.03 Co-Operation with Other Bidders of purchaser
The Bidder shall agree to cooperate with the Purchaser’s other Bidders and freely
exchange with them such technical information as is necessary to obtain the most
efficient and economical design and to avoid unnecessary duplication of efforts. The
Consultant shall be provided with copies of all correspondences addressed by the
Bidder to other Sub- contractors in respect of such exchange of technical information.
12.04 Guidelines for Engineering Services
12.04.01 Prior to commencement of the engineering work as part of design submissions,

all aspects of design viz., criteria for selection and sizing of all equipment and systems,
Vol. – IIA, Section 12.00 DWGS DOC TO BE SUBMITTED BY BIDD. Page 1 of 15


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

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


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by the Bidder from time to time, as detailed designs are developed, shall
be submitted for Purchaser/Consultant's approval before the work is taken up.
Revisions, corrections, additions to drawings and schedules shall not be considered to
change the scope of work.
12.04.08 Preparation of detailed technical specifications including data sheets, tender drawings
and bill of material for all bought out items and also finalization of corresponding Sub-
vendors.
12.04.09 Review of sub-contractor's/Sub vendor’s data, drawings, design calculations, schedules,

bill of materials, instruction manuals etc. for all equipment, before forwarding them to
Purchaser/Consultant for approval.
12.04.10 Preparation of civil assignment drawings (furnishing 100% input information) for all
equipment showing foundation details and full details regarding equipment loads, floor
openings, details of embedment etc. required for preparation of civil design
construction drawings by the bidder for his scope of work. These documents shall be
preceded by appropriate design calculations, static and dynamic analysis as necessary.
12.04.11 Preparation and finalization of process piping and instrumentation diagrams and
schematics, complete in all respects for all the sub-packages of the FGD package.
12.04.12 Preparation of consolidated schedules and bills of materials, including line numbers, tag
numbers, source of supply, service conditions, specifications, materials, types and
connections details, quantities for items of the plant including dampers, steam traps,
strainers, instrumentations, ducting.
12.04.13 Sizing of all piping and equipment as per the stipulated design criteria; carrying
out of flexibility analysis/dynamic analysis as necessary; hangers & support
engineering.
12.04.14 Final revision of all documents.
12.04.15 Preparation and compilation of Instruction Manuals for installation, Commissioning,

operation and maintenance for all equipment and systems of all the sub-packages.
12.04.16 Certification and submission of final as-built drawings for all sub-packages.
12.04.17 Preparation and compilation of all drawings, schedules and instructions, which may be
required at site, whether separately, mentioned or not.
12.04.18 All erection and assembly drawings, which may be required at site.
12.04.19 For all bought out items, the Bidder shall provide complete material/ component


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list along with detail specification, drawings component part no. etc. during detail
engineering stage prior to final approval. Such approved drawing/document shall be
made available at site in adequate number prior to commencement of work. Moreover,
such document/drawing shall be provided in soft form (CD) also.
12.04.20 Preparation of necessary documentation, design calculations etc. required for

submission to statutory authorities like IBR, Chief Electric Inspector, Factory Inspector
etc.
12.05 Contract Stage Document Submission and Approval Procedure
12.05.01 Within fifteen (15) days of issue of LOA by the Purchaser/Consultant, the Bidder
shall furnish a schedule of drawings and design document to be submitted by him
to the Purchaser/Consultant indicating dates against each drawing/document.
12.05.02 The documents shall be divided into two categories: a) for approval and b) for
information/further engineering and co-ordination by the Purchaser/Consultant.
12.05.03 In preparing this schedule, the Bidder shall consider fifteen days from date of receipt of
drawings/documents for review and comments by the Purchaser/Consultant for each
submission of a document.
12.05.04 This document submission schedule shall require approval by the Purchaser/Consultant.
12.05.05 All contract documents shall be marked, without fail, with the name of the Purchaser,
the Consultant, the Project, the specification title and number and the unit designation.
i) All dimensions shall be in metric units.
ii) All notes, markings etc. shall be in English.
12.05.06 Documents/Drawings, submitted during tender stage, shall be revalidated or revised as

required and submitted as certified contract document for approval/information of the
Purchaser/Consultant.
12.05.07 Unless specified otherwise, the following categories of documents/ drawings would
require approval of the Purchaser/Consultant. The design calculation, drawings and
documents shall be approved by the consultants on behalf of the Purchaser.
i) System scheme and instrumentation diagrams.
ii) Design basis justifying selection of equipment & process parameters where not specified
in the Contract.
iii) Equipment data sheets and general arrangement drawings, Civil design, Civil
G.A. and R.C.C. drawings and structural drawings.
iv) Materials of construction with cross-sections.


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v) Layout drawings.
vi) Operation logic diagrams.
vii) Typical control circuit.
viii) Cable schedule and interconnection chart.
ix) Drive/feeder wise control scheme showing all external interfaces.
x) Drawings of Instrumentation and Control.
xi) Equipment foundation drawings and civil assignment drawings.
12.05.08 Unless specified otherwise, the following categories of documents/ drawings would be
treated for information/further engineering by the Purchaser/Consultant. The Bidder
shall, however, incorporate all additional information and clarifications in these
documents/drawings as and when desired by the Purchaser/Consultant.
i) Equipment GA drawings, Equipment cross-section drawings, product literature etc.
which are of proprietary nature.
ii) Predicted performance curves of equipment.
iii) Various bills of quantity, schedules etc.
iv) Piping fabrication drawings, isometrics etc.
v) Panel wiring diagrams.
vi) Instruction/ Operation manuals.
vii) Service manuals and troubleshooting guide for C & I system and instruments.
12.05.09 In essence, the Bidder is solely responsible for corrections and adequacy of design &
engineering for documents under this category.
12.05.10 Upon review, the Purchaser/Consultant shall put his remarks and one commented
copy shall be returned to the Bidder.
12.05.11 The Bidder's work shall be in strict accordance with the finally approved drawings and
no deviation shall be permitted without written approval of the Purchaser/Consultants.
12.05.12 Except key plan/general yard plan, any layout drawing requiring scrutiny shall not be
drawn to a scale less than 1:50.
12.05.13 Apart from required number of hard copies, all drawings/documents generated for this
project from the last tier of respective sub contractors shall be submitted also in soft
from.
12.06 Drawings/ Documents to be submitted by the Bidder along with the Bid
The Bidder shall submit along with his bid all documents/drawings as requested
in respective specifications. The documents shall include but not be limited to the
following:


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i) All Bid proposal sheets duly filled up. Editable soft copies for documents like data
sheets, list of mandatory spares, sub vendors, tools & tackles, etc. preferably in
word/excel format (additionally for compilation purposes), along with the copies of
signed non editable formats
ii) Scheme drawings indicating scope of supply and service as offered by the Bidder
indicating clearly exclusions, if any.
iii) List of terminal points of the package offered together with quality and quantity of
various input (i.e. water, air, electricity etc.) as required from the Purchaser at such
interfaces.
iv) Equipment GA, Layout, Design Calculations, interlock and other write- up,
catalogues/literature etc. as required for clear understanding of the bid submitted.
v) L-1 network indicating target dates for intermediate milestones and final commissioning
of equipment supplied; this network shall be supplemented by a detailed write-up on
proposal procedure of project implementation, deployment schedule for Key personnel
with their bio- data, schedule of construction machinery etc.
vi) List of proposed suppliers for all bought out items as listed
vii) Drawing showing termination point with Purchaser and relevant information
required from Purchaser.
viii) List of consumption of Utilities for the system covered under the scope of bidders.
12.07 Documents, Data and Drawings to be furnished by Bidder after Award of the
Contract
12.07.01 Each of the plant and equipment pertaining to the Sub-packages of FGD 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.
12.07.02 The Bidder shall furnish engineering data/drawings in accordance with the schedule of
information as specified in Technical Specification and data sheets.
12.07.03 The bidder shall furnish requisite number of copies/prints/CD-ROMs/manuals for

various types of documents.
12.07.04 The documentation that shall be provided by the Bidder is indicated in various sections
of specification. The documentation shall include but not be limited to the following:


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12.08 Basic Engineering Documentation
Bidder shall furnish for each sub-package Design basis Report, data sheets, drawings,
documents etc. The above documents shall contain the following as a minimum for each
sub-packages.
i) System description of all the mechanical, electrical, control &

instrumentation & civil systems.
ii) Technologies for each system / sub-system & equipment.

iii) Selection of appropriate technology / schemes for various systems/ subsystems
including techno-economic studies between various options.
iv) Sizing criteria of all the systems, sub-systems including various piping systems/
equipments/ structures/ equipment foundations along with all calculations justifying and
identifying the sizing and the design margins.
v) Schemes and Process & Instrumentation diagrams for the various systems/ sub-
system with functional write-ups.
vi) Operation Philosophy and the control philosophy of the FGD Plant.
vii) General Layout plan of the power station incorporating all facilities in Bidder's as well
as those in the Purchaser's scope. This drawing shall also be furnished in hard form as
well as soft form (Auto CAD format) in compact disc to the Purchaser/Consultant for
engineering of areas not included in Bidder's scope.
viii) Basic layouts and cross sections or various floor elevations for FGD areas included in
the scope of the Bidder.
ix) Documentation in respect of Quality Assurance System as listed out elsewhere in this
specification.
x) The successful Bidder shall furnish Design basis report for various sub packages.
xi) After approval of Design Basis Report for each sub-packages, Bidder shall furnish the
following detailed technical specification of all sub- packages.
(a) Layouts, general arrangements, elevations and cross-sections drawings for all
the equipment and facilities of the sub-packages.
(b) Flow diagrams, Process & Instrumentation Diagrams alongwith write-up and
system description.
(c) Piping isometric, composite layout and fabrication drawings.


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(d) Piping engineering diagrams, pipe and fittings schedules, valve schedules, hanger
and support schedules, insulation schedules.
(e) Technical data sheets for all bought out and manufactured items. Bidder shall use
the specifications as a base for placement of orders on their sub-vendors.
(f) Detailed design calculations for components, system/sub-system, piping etc.,
wherever applicable including sizing calculations for all auxiliaries as per criteria
specified elsewhere in specification.
(g) Comprehensive list of all terminal points which interface with Purchaser's
facilities giving details of location, terminal pressure, and temperature, fluid
handled & end connection details, forces, moments etc.
(h) Power supply single line diagram, block logics, control schematics,
electrical schematics, etc.
(i) Protection system diagrams and relay settings.
(j) Interconnection diagrams.
(k) Cable routing plan.
(l) Instrument schedule, measuring point list, I/O list, Interconnection & wiring
diagram, functional write-ups, and installation drawings for field mounted
instruments, logic diagrams, control schematics, wiring and tubing diagrams
of panels and enclosures etc. Drawings for open loop and close loop controls
(both hardware and software). Motor list and valve schedule including type of
actuator etc.
(m) Alarm and annunciation list and alarms & trip set points.
(n) Sequence and protection interlock schemes.
(o) Type test reports and power system stability study report.
(p) Control system configuration diagrams and card circuit diagrams and
maintenance details.
(q) Detailed software manuals & source software listing.
(r) Detailed flow chart for digital control system.
(s) Mimic diagram layout.

(t) Civil Task drawings, Design and Drawings for the Civil & Structural works
in the scope of the Bidder.


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(u) Model study reports wherever applicable.

(v) Functional & guarantee test procedures and test reports.
(w) Documentation in respect of Quality Assurance System as listed out elsewhere in
this specification.
(x) Documentation in respect of commissioning as listed out elsewhere in this
specification.
(y) The Bidder while submitting the above documents / drawings for approval /
reference as the case may be, shall mark on each copy of submission the reference
letter along with the date vide which the submissions are made.
12.09 Erection Manuals
The erection manuals shall be submitted prior to the commencement of erection

activities of particular equipment/system. The erection manual should contain the
following as a minimum.
i) Erection strategy.
ii) Sequence of erection.
iii) Erection instructions.
iv) Critical checks and permissible deviation/tolerances.

v) List of tool, tackles, heavy equipments like cranes, dozers, etc.
vi) Bill of Materials
vii) Procedure for erection.
viii) General safety procedures to be followed during erection/installation.
ix) Procedure for initial checking after erection.
x) Procedure for testing and acceptance norms.
xi) Procedure / Check list for pre-commissioning activities.
xii) Procedure / Check list for commissioning of the system.
xiii) Safety precautions to be followed in electrical supply distribution during erection


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12.10 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
Purchaser 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 equipments of each sub-packages of -FGD including,
operation, maintenance, dismantling and repair. 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 submitted to the
Purchaser.
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 Purchaser 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 for each sub-packages of -FGD.
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.
d) Various maintenance intervals, spare parts & man hour requirement

during such operations. The intervals for each type of maintenance namely
inspection of the furnace, inspection of entire hot gas path & the minor & major
overhauls shall be specified in terms of fired hours, clearly defining the spare
parts & man hour requirement for each stage
v) Detailed specifications for all the consumables including lubricant oils, greases,
and chemicals etc. system/equipment/assembly/sub D 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
Purchaser indicating lubrication method for each type/category of bearing.


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12.11 Plant Handbook
The Bidder shall submit to the Purchaser a preliminary plant hand book preferably in
A-4 size sheets which shall contain the design and performance data of sub-packages
including
i) Design and performance data.
ii) Process & Instrumentation diagrams.
iii) Single line diagrams.
iv) Sequence & Protection Interlock Schemes.
v) Alarm and trip values.
vi) Performance Curves.

vii) General layout plan and layout of main plant building and auxiliary buildings.
viii) Important Do's & Don’ts
The plant handbook shall be submitted by the bidder for Purchaser/Consultant

review/approval. After the incorporation of Purchaser/Consultant's comments, the final
plant handbook-sub packages wise complete in all respects shall be submitted three (3)
months before start-up and commissioning activities.
12.12 Project Completion Report
The Bidder shall submit a Project Completion Report after successful completion of
trial operation and at the time of handing over the plant for all the sub-packages of -
FGD package.
12.13 Drawings & Documents
i) All documents submitted by the Bidder for Purchaser/Consultant's review shall be

in electronic form (soft copies) along with the desired number of hard copies. The soft
copies to be supplied shall be through direct transfer via E-mail or throu management
System (CCMS), etc. The drawings submitted for approval could be in the Image form.
ii) Final copies of the approved drawings shall be submitted on CD-ROM along with the
requisite number of hard copies.
iii) The completed plant documentation with equipment drawings, data sheets, P&ID,
BOQ, schematics, logic diagrams, test reports and quality plan, etc. shall be


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furnished to Purchaser/Consultant.
iv) All documents/text information shall be in latest version of MS Office.
v) All drawings submitted by the Bidder including those submitted at the time of bid
shall be in sufficient detail indicating the type, size, arrangement, revision history,
reference drawings/documents, legend, weight of each component for packing and
shipment, the external connection, fixing arrangement required, the dimensions
required for installation and interconnections with other equipments and materials,
clearance and spaces required between various portions of equipment and any other
information specifically requested in the drawing schedules.
vi) Each drawing submitted by the Bidder (including those of sub-vendors) shall bear a title
block at the right hand bottom corner with clear mention of the name of the
Purchaser, Consultant, name of the Project, system designation, the specifications
title, the specification number, drawing/document number and revisions. If
standard catalogue pages are submitted the applicable items shall be indicated therein.
All titles, notes, markings and writings on the drawing shall be in English. All the
dimensions should be in metric units.
vii) The Bidder shall also furnish a “Master Drawing List” which shall be a comprehensive
list of all drawings/ documents/ calculations envisaged to be furnished by him during
the detailed engineering to the Purchaser/Consultant. Such list should clearly indicate
the purpose of submission of these drawings i.e. “FOR APPROVAL” or “FOR
INFORMATION ONLY”.
viii) Similarly, all the drawings/ documents submitted by the Bidder during detailed
engineering stage shall be stamped “FOR APPROVAL” or “FOR INFORMATION”
prior to submission.
ix) The furnishing of detailed engineering data and drawings by the Bidder shall be in
accordance with the time schedule for the project. The review of these documents/ data/
drawings by the Purchaser/Consultant will cover only general conformance of the data/
drawings/ documents to the specifications and contract, interfaces with the equipments
provided by others and external connections & dimensions which might affect plant
layout. The review by the Purchaser/Consultant should not be construed to be a
thorough review of all dimensions, quantities and details of the equipments, materials,
any devices or items indicated or the accuracy of the information submitted. The review
and/ or approval by the Purchaser/Consultant shall not relieve the Bidder of any of his
responsibilities and liabilities under this contract.
x) After the approval of the drawings, further work by the Bidder shall be in strict
accordance with these approved drawings and no deviation shall be permitted
without the written approval of the Purchaser/Consultant. Approved
drawings/documents by Purchaser/consultant, bearing stamp of approval, shall be


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distributed as per distribution list.
xi) All manufacturing, fabrication and execution of work in connection with the equipment /
system, prior to the approval of the drawings, shall be at the Bidder’s risk. The Bidder
is expected not to make any changes in the design of the equipment /system, once they
are approved by the Purchaser/Consultant. However, if some changes are necessitated
in the design of the equipment/system at a later date, the Bidder may do so, but such
changes shall promptly be brought to the notice of the Purchaser/Consultant indicating
the reasons for the change and get the revised drawing approved again in strict
conformance to the provisions of the Technical Specification.
xii) Drawings shall include all installations and detailed piping layout drawings. Layout
drawings for all piping of 65 mm and larger diameter shall be submitted for review/
approval of Purchaser/Consultant prior to erection. Small diameter pipes shall however
be routed as per site conditions in consultation with site authority/representative of
Purchaser/Consultant based on requirements of such piping indicated in approved /
finalized Flow Scheme/Process & Instrumentation Diagrams and/or the requirements
cropping up for draining & venting of larger diameter piping or otherwise after their
erection as per actual physical condition for the entire scope of work of this package.
xiii) Assessing & anticipating the requirement and supply of all piping and equipment shall
be done by the Bidder well in advance so as not to hinder the progress of piping &
equipment erection, subsequent system charging and its effective draining & venting
arrangement as per site suitability.
xiv) As Built Drawings
After final acceptance of individual sub-packages by the Purchaser/Consultant, the

Bidder will update all original drawings and documents for the respective sub-packages
to “as built” conditions.
xv) Drawings must be checked by the Bidder in terms of its completeness, data adequacy
and relevance with respect to engineering schedule prior to submission to the
Purchaser/Consultant. In case drawings are found to be submitted without proper
endorsement for checking by the Bidder, the same shall not be reviewed and returned to
the Bidder for re-submission. The Bidder shall make a visit to site to see the existing
facilities and understand the layout completely and collect all necessary
data/drawings at site which are needed as an input to the engineering. The Bidder
shall do the complete engineering including interfacing and integration of all his
equipment, systems & facilities within his scope of work as well as interface
engineering & integration of systems, facilities, equipment & works under Purchaser’s
scope and submit all necessary drawings/ documents for the same.
xvi) The Bidder shall submit the drawing/data/document in specified number of copies
in this specification for Purchaser/Consultant’s review and approval. The


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Purchaser/Consultant shall review the drawings and return one (1) copy to the Bidder
authorizing either to proceed with manufacture or fabrication, or marked to show
changes desired. When changes are required, drawings shall be re-submitted promptly,
with revisions clearly marked, for final review. Any delays arising out of the failure of
the Bidder to submit/rectify and resubmit in time shall not be accepted as a reason for
delay in the contract schedule.
xvii) All engineering data submitted by the Bidder after final process including review
and approval by the Purchaser/Consultant shall form part of the contract documents
and the entire works covered under these specification shall be performed in strict
conformity with technical specifications unless otherwise expressly requested by the
Purchaser/Consultant in writing.
12.14 Engineering Information Submission Schedule
12.14.01 Prior to the award of Contract, a Detailed Engineering Information Submission

Schedule shall be tied up with the Purchaser/Consultant. For this, the bidder shall
furnish a detailed list of engineering information along with the proposed submission
schedule. This list would be a comprehensive one including all engineering data /
drawings / information for all bought out items and manufactured items. The
information shall be categorized into the following parts.
i) Information that shall be submitted for the approval of the

Purchaser/Consultant before proceeding further, and
ii) Information that would be submitted for Purchaser/Consultant’s information
only.
12.14.02 The Engineering Information Schedule shall be updated month wise.

12.14.03 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.
12.15 Drawings/Document Distribution Schedule
The successful bidder will be required to furnish all the necessary Design basis reports
(DBR), drawings, data sheets etc. of package with appropriate “Status” stamp in
adequate number of copies as discussed and agreed upon during the first meeting after
acceptance of Letter of Award along with soft copy of the above mentioned
drawings/documents in NLC framed system DEMS.


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12.16. Engineering Progress and Exception Report
12.16.01 Report giving the status of each engineering information including

i) A list of drawings/engineering information which remains unapproved for more than
four (4) weeks after the date of first submission
ii) Drawings which were not submitted as per agreed schedule.
12.16.02 The draft format for this report shall be furnished to the Purchaser/Consultant within
four (4) weeks of the award of the contract, which shall then be discussed and finalized
with the Purchaser/Consultant.
12.17 Co-Ordination Meetings
12.17.01 The Bidder shall be called upon to organize and attend the Design/ Co- ordination
Meetings with the Purchaser/Consultant’s representatives, Project Consultant during
the period of contract. The Bidder shall attend such meetings at his own cost at
mutually agreed venue as and when required and fully co-operate with such persons and
agencies involved during the discussions.
12.17.02 The Bidder should note that Time is the essence of the contract. In order to expedite the
early completion of engineering activities, the Bidder shall submit all drawings as per the
agreed Engineering Information Submission Schedule. The drawings submitted by
the Bidder will be reviewed by the
Purchaser/Consultant as far as practicable within one month from the date of receipt of
the drawing.The comments of the Purchaser/Consultant shall then be discussed across
the table during the above co-ordination Meetings wherein best efforts shall be made
by both sides to ensure the approval of the drawing.
12.17.03 The Bidder shall ensure availability of the concerned experts / consultants/ personnel
who are empowered to take necessary decisions during these meetings. The Bidder
shall be equipped with necessary tools and facilities so that the drawings/documents can
be resubmitted after incorporating necessary changes and approved during the meeting
itself.
12.17.04 Should any drawing remain unapproved for more than six (6) weeks after it’s first
submission, this shall be brought out in the monthly Engineering Progress and Exception
Report with reasons thereof.
12.17.05 Any delays arising out of failure by the Bidder to incorporate Purchaser/Consultant’s
comments and resubmit the same during the TCM/ECM shall be considered as a
default and in no case shall entitle the Bidder to alter the Contract completion date.


(4X210MW)
FOR
VOLUME – II B
TECHNICAL SPECIFICATION
MECON LIMITED
RANCHI – 834 002
DOC. No: MEC/11/S3/10KP/TS/2569/R-0, Rev. 00 July, 2020


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INDEX TO VOLUMES
Volumes Title
Section 06.00 Quality Assurance system / Requirement


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Volumes Title
Volume -V General Civil, Architectural & Structural Works

SECTION 01.00
FGD TECHNOLOGY
DESCRIPTION


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01.00 FGD TECHNOLOGY DESCRIPTION
The FGD system shall be generally in line with the following or equivalent
proven technology.
The semi dry FGD flue gas treatment system is to be located after removal of
particulate matter from flue gas by existing electrostatic precipitator. The clean
gas is discharged to the stack. The FGD system shall be based on Circulating Dry
Scrubber (CDS) or Spray Dryer Absorption (SDA) technologies. Circulating Dry
Scrubber (CDS) type semi dry FGD system shall be the preferred technology for
4X210 MW MTPS-I plant.
Each units shall be provided with two nos. independent Booster fans (2 x 50%
capacity) at the downstream of the ID Fans. The connection between the boiler ID
fan outlet and stack also consists of a bypass bi-plane damper which is used to
bypass the complete FGD system, if needed.
Flue Gas from Booster fan discharge shall be taken to the inlet of the CDS reactor
inlet from bottom side. In the CDS reactor, SO2 in flue gas shall be removed by
injecting lime and water spray, or a prepared mixture of lime and water fed via
mechanical feeder. The hot untreated flue gas is introduced via venturi tube(s) at
the bottom of the reactor vessel. Enough water is sprayed to maintain the optimum
reaction temperatures above adiabatic saturation and overall dry reaction products.
To improve the utilization of reagent, a portion of the reaction product collected in
the downstream fabric filter is recycled back into the reaction tower.
Alternatively, in a Spray Drying Absorption technology, Hot, untreated flue gas
is introduced into the Spray Dryer Absorber via a flue gas disperser and
subsequently comes into contact with a highly reactive absorbent that will be
atomized by a rotary atomizer. An efficient contact between flue gas and absorbent
allows for rapid mass transfer of acidic components from the flue gas into the
alkaline absorbent. The absorbent neutralizes the absorbed acid. While this reaction
takes place, the water is evaporated, thus forming a dry powder. A fraction of the
dry powder will be deposited at the bottom of the absorber chamber whereas the
main part is carried to the downstream fabric filter while the cooled flue gas
leaves the chamber.
Clean gas from the scrubber / absorber shall be taken to Chimney through fabric
filter. Clean flue gas from the dry FGD s yst em shall be discharged through a
flue can located in the individual chimney’s of 4x210 MW MTPS-I units.
Both the above processes result in a stable and dry end product, mainly consisting
of fly ash and various calcium compounds.
Vol. – IIB, Section 01.00 TECHNICAL - FGD SYSTEM Page 1 of 30


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The FGD System shall be in operation when Steam Generator is in operation.

However, provision shall be made for facilitating operation of unit with FGD
bypass.
02.00 Design and Operating Conditions
02.01 General
a) The FGD system shall be installed downstream of the ID fans and shall be based
on semi dry FGD process to achieve the required SO2 capture. The FGD System
shall be designed to be in operation when Steam Generator is in operation.
b) The unit must be capable of handling its TMCR output with no limits as to
duration, with maximum availability, rapid load variations and frequent stops and
starts without suffering any damage to the equipment and to the fittings, other than
normal wear. The FGD system shall be designed and manufactured for a life span
of 25 years.
c) The FGD system shall be a semi dry hydrated or slaked lime-based system. The
system shall include a single reactor. A modular concept with multiple reactor
towers may also be proposed for CDS system. Two (2) nos. working booster fans
for each Unit shall be included downstream of existing ID (induced draft) fans. The
system shall be able to meet guaranteed SO2 as per performance guarantee
schedule.
d) The FGD and the ancillary facilities shall be suitable for unlimited operation
with all transients and at any load between the minimum and maximum load point
of the Steam Generator. Further, the FGD plant shall be suitable for an unlimited
operation at any pollutant concentrations between minimum and maximum without
exceeding the emission values of SO2 and emission as indicated in Vol. IIA ,
Section 3 under various operating conditions.
e) FGD system shall be capable of meeting emission while in operation from 25%
to 100% TMCR on sustained basis.
g) In case of failure of the Steam Generator and ancillary equipment, the FGD plant
shall be brought automatically to the off-load operation, without restriction by the
current load case, by suitable measures.
h) In case of a power failure all items of equipment which may cause

irreversible damage to the FGD system shall be connected to the emergency power
supply system to be provided by the Bidder.


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i) Draining and flushing which are required even during short time outages or an
emergency shutdown shall be started automatically and by remote control from the
Control Room.
j) The FGD system and all the associated auxiliaries shall be designed to comply with
the requirements stipulated under ‘Guarantee Point’ and ‘Design Point’
conditions.
k) The reagent injection system shall have the flexibility in capacity to cater to
improved SO2 reduction efficiency resulting from any future change in
environmental emission norms. Bidder to indicate the design margin and relevant
features included in his offer.
02.02 Service Conditions

The Steam Generators which are designed to burn pulverised coal will also
use diesel oil during start up and at low loads for warm up and flame stabilization.
The steam generator may also fire blast furnace gas equivalent to 10% of plant
capacity. Further, the frequency and duration for start-up and low loads operation
may be quite high during the first year of unit commissioning and operation.
Expected numbers of Steam Generator start-ups during 25 years of design life are
as follows
Table-6.1 Steam Generator start-ups
S. No. Description Criteria
Life Number of start-up during the

life span of 25 years
1. Cold Start (after the shutdown 150
period exceeds 72 hours)
2. Warm Start (after the shutdown 1000

period between 10 hours and 72
hours)
3. Hot Start (after the shutdown 4000
period less than hours)
The Bidder shall consider the entire characteristics of expected combination of
fuels to be fired and the expected numbers of Steam Generator start up while
designing the FGD system.
02.03 Justification of Proposed Design

a) All the design procedures, systems, and components proposed shall have


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already been adequately developed and have demonstrated good reliability under
similar or more arduous conditions elsewhere.
b) The Bidder shall submit with the offer, comprehensive information on how the
mass balance, lime consumption, by-product generation etc. of the proposed design
has been arrived at. The Bidder shall also submit along with the offer, a detailed
write up on the proposed design features with recent design modifications, if any,
and their specific advantages over the previous designs.
02.04 Statutory Approval

The engineering, design, supply and installation of FGD system and the associated
auxiliaries shall comply with the applicable safety code and regulation of the
locality where the system is being installed. It will be supplier responsibility to
obtain statutory approval related to the package.
02.05 Location & Layout Requirements
The Bidder shall offer the best design to accommodate the Flue Gas
Desulphurisation (FGD) System and Lime & by-product handling & storage
system within the confines of the space available. The location of FGD System has
been indicated in the Attached Layout Plan.
02.06 Capital Overhaul of FGD System
Owner envisages carrying out the capital overhaul of the unit once in five (5) years.
The design and materials for various equipment/auxiliaries etc. shall be selected by
the Bidder keeping in view the above requirement of the Owner, such that no
major repairs/replacements, requiring shutdown of the unit, are needed in between
the capital overhauls.
02.07 Maintenance
The Bidder shall provide adequate handling facilities & approach as for carrying
out on-line and off-line maintenance of the FGD system and its auxiliaries. In order
to carry out on-line maintenance, it shall be possible to access, isolate, readily
disassemble, repair and reassemble the equipment supplied in the shortest period.
Cage Ladder/Monkey ladder shall not be allowed. Only proper staircase shall be
provided
03.00 Equipment and System Design (Mechanical)
a) The complete FGD system and the associated auxiliaries shall be designed as per


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the bidder’s proven design and standard industrial practices. Only field proven
materials for similar application shall be used for the system.
b) The FGD System shall be designed to meet all the specified operating
conditions. The values indicated for FGD sizing shall be considered as minimum
design criteria. These shall be modified to more conservative values if Bidder
experience warrants the same. Utilization of these values in no way relieves the
Bidder of his responsibility to meet all the guarantee requirements. The Bidder
shall also furnish the detailed calculations and data along with his Bid to establish
as to how the Bidder will meet the performance and efficiency requirements both at
design/ guarantee points as specified in FGD sizing criteria.
03.01 Gas Ducts

a) All ducts with operating temperature above 60 Deg. C shall be insulated in
accordance with the Vol. IIC, Section 6 of the Technical Specification for
Thermal Insulation.
b) The duct layout shall ensure that there is no accumulation of acid mist on the duct
floor.
c) All ducts shall be made of Carbon steel of minimum 7 mm thickness. A
corrosion allowance of 1.5 mm shall be considered for stress calculation for the
flue gas ducting.
d) Wherever required, expansion joints of proven design shall be provided in the ducts
to take care of differential expansion in the system. The material chosen for
expansion joints shall be suitable for the duty conditions and the corrosive
atmosphere of the FGD system and shall be field proven for similar applications.
The expansion joints shall be guaranteed for faultless material and workmanship,
for a minimum guaranteed life of not less than 20000 hrs. of operation. During
guarantee period any defects noticed in the expansion- joints due to faulty material
and workmanship shall be rectified by the Bidder free of cost.
03.02 Gates & Dampers
a) Provision shall be made for facilitating operation of unit with FGD bypass.
This shall also facilitate the online maintenance of reaction tower/absorber system
and associated equipment. The arrangement of the flue gas system shall allow
complete isolation of the absorber from the gas side, with the unit in operation.
b) Pneumatic/ Motorized bi-plane damper shall be provided at inlet & outlet duct to
booster fan and in the bypass duct to chimney. Motorized Guillotine type gates
shall be provided at inlet & outlet duct to the reactor/absorber and fabric filter
bag house
c) The Gates & damper shall be provided with 2x100% seal air fans.
d) 2x100% electrical heaters shall be provided in seal air as per bidder’s
standard practice.
e) The Gates shall be designed for tight shut-off. The design of the gates shall
ensure 99.95% leak tightness, on flow basis, without seal air. The gates shall be


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100% leak tight with seal air fans under the above conditions.
f) The blade and other components of the bypass damper as per bidder’s
standard practice.
g) The gates & dampers shall be controlled from the control room. Provision shall
be made for automatic opening of the by-pass damper in case of emergency.
The gates shall have provision for manual operation, through a hand wheel. The
force required for manual operation of the gate shall not exceed 35 kg (max.) at the
rim of the hand wheel.
h) The isolating gates shall be provided with locking devices to permit locking in
fully closed position.
i) All gates shall be designed to withstand the operating air and flue gas
temperature without distortion.
j) All guillotine gates shall be located in horizontal duct to avoid fly ash build up
when in closed position and shall be of top entry type.
k) Bidders shall indicate opening/closing time for each damper in bid data
sheets. The biplane damper shall be capable of opening during emergency
conditions within a time of 15-20 secs. Bidder to select the proper damper
accordingly.
l) The operation of dampers shall be suitably interlocked with booster fans, ID fan
and existing controls of the unit to prevent mal operation leading to damage of the
unit or FGD system.
m) Weather hood to prevent rain water entry and accumulation shall be provided at
damper top. The seal air pressure always at least 50 mmwc (g) higher than
maximum flue gas pressure
03.03 Booster Fan
a) The Booster Fans shall be located downstream of the ID Fans (Induced Draft Fans)
in the inlet duct to reactor/absorber to take care of the additional pressure drop in
the FGD System, fabric filter bag house & ducting and maintain required chimney
inlet pressure over the entire load range with any one or both Booster fans in
operation (as applicable for the offered configuration), in conjunction with one or
both ID fans in operation while firing the specified range of fuels.
b) Fans shall be capable to cater to 100% BMCR (flow & Pressure). Adequate
margin (flow & pressure) shall be provided for test block condition.
c) Salient Design Requirement:
Table-6.2 Booster Fan Design Parameter
S. No. Description Design
1. Type of Fans Constant speed, axial or centrifugal type
2. Quantity 2x50% for each absorber, to match the
combined
flow of two ID Fans


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3. Fan Blade material Nodular CI or high wear resistance steel

with or without coating as per
manufacturer proven practices
4. Fan operating speed < 750 rpm
5. Margin over Booster fan flow rate range to match
100% existing ID fan flow rate range including
BMCR Flow test block margins, for Design coal
6. Margin on volume 20% minimum to match existing ID fan
flow rate flow rate range including test block
margins, for Design coal
7. Margin over 44%
100%
BMCR pressure
8. Fan casing material Abrasion and wear resistant, high BHN
& steel housing min 8 mm thickness or 22mm
thickness MS
9. Type of coal firing Design whichever gives maximum flue gas
flow.
10. Power Supply 47.5 Hz to 51.5 Hz
frequency
11. Fan inlet air/flue 125 - 150 Deg. C
gas
temperature range
12. Pressure at +20 mm WC
chimney
inlet
13. Type of blade Stream lined, aerofoil shape section
14. Fan critical speed Not less than 125% of fan maximum
operating speed
15. Fan component design To withstand torsional stresses three (3)
times the normal/full load motor torque at all
speed
16. Flue gas control Blade pitch control
17. minimum wear life 25000 hours of operation from the
of Booster fan date of commissioning
components
Note:
1. Booster Fan shall have a minimum stall margin of 10% over the design
duty points.
2. The bidder shall furnish the fan sizing calculations for approval of
Owner during detail engineering.
d) The booster fans of the axial, single stage shall be provided with variable pitch
type, renewable liners and vibration isolation system (VIS) foundation. In case of


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centrifugal fans, suitable inlet guide vane control shall be applied.

e) These will be designed to withstand high bending and axial load and a
temperature up to 200°C. However, the material of construction of fans, the blade
thickness, liner thickness etc. for fans as per manufacturer’s recommendation is
also acceptable.
f) Each Booster fan shall be provided with bearing lubrication and inlet vane
control each consisting of 2 x 100% redundancy for oil pumps, oil coolers, filters.
On-line bearing temperature and vibration monitoring shall be provided.
g) Size oil reservoir in bearing housing for maintaining lubrication for extended
periods in case of oil circulation system is out of service.
h) Adequate numbers of duplex pt-RTD (100 ohm at o degree Celsius) and
temperature indicator shall be provided for each bearing.
i) Capable of operating in automatic mode for all regimes of operation in a
steady & stable manner.
j) For mounting vibration pads/pickups flat surface shall be provided in X-Y
direction by the bidder in the bearing housing.
k) Monitoring shall be possible from remote as well as local. l) The fan shall be
balanced before shipment.
m) Natural frequency of all fan components shall be established by vibration
testing to ensure that no part of the wheel is adversely excited by any force
generated at operating speeds.
n) The fan casing shall be split or as per OEM standard to provide easy removal of the
fan hub/impeller for replacement and repair.
o) The section shall have gasket joint to ensure airtight sealing.
p) Access doors shall be provided in each suction chamber casing and diffuser.
q) Drain connections shall be provided in each suction chamber casing and
diffuser.
r) The booster fan flow control shall be suitably interlocked /integrated with existing
boiler control. Additionally, for flow matching between ID fan and Booster fan at
all loads, suitable flue gas pressure/ differential pressure secondary (trim) logic
shall be incorporated in FGD control system.
s) The following characteristic curves of the fan shall be submitted:
i. Flow v/s Total pressure
ii. Flow v/s power consumption
iii. Flow v/s efficiency
The system-resistance point at different loads shall be indicated in the

above performance curves.
03.04 Lime Storage Silo

a) One (01) no. Lime storage silo f o r e a c h u n i t shall be designed for 7 days
storage for maximum lime requirement. The storage silo shall be complete with
supporting steel structure, platforms, staircase, air canons, power operated gates,
level switches, air relief devices, etc.


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b) Lime shall be delivered to site primarily by trucks. Bidder to provide suitable

pneumatic conveying system to unload the Lime from truck. Lime Silos to include
fill line piping, Sch. 80 carbon steel with quick coupling type connections for
truck connection, with number of bends minimized, and utilizing long radius 90
elbows that are abrasion resistant. Access shall be provided to 90 elbows to
facilitate replacement.
c) The lime feeding shall be done from storage silo to absorber / reactor through
Pneumatic conveying system.
d) Silo and hopper cones shall be fabricated of minimum 10 mm thick carbon steel
(ASTM A36 steel plate) with a SS lining of grade SS304 of minimum 4 mm
thickness in the complete cones to ensure reliable discharge of material. The
design of storage silos shall confirm to IS 9178 or any other proven international
standards. Coating shall be provided as per bidder’s practice to avoid any chemical
reaction. The Silo bottom hopper shall be conical and minimum 60 degree from
horizontal.
e) Minimum free board of one (1) meter or based on requirements for accurate
operation of level instrumentation shall be provided.
f) Silo vent filters shall be provided to remove collected lime dust and return to the
silo using compressed dry air to pulse the bags or cartridges. Pulse control shall
be based on differential pressure and timed basis. Silo vent discharge location
and sound level shall be considered as to not impact residential receptors.
Provide pressure and vacuum relief devices.
g) Access to the top of the silos, doors or man holes, the dust collection
equipment, or any instrumentation or other equipment mounted on the silo, shall be
provided by stairs and platforms complete with hand railing. Weather tight roof
shall be checkered plate with an access manhole. Access shall also be provided
near the bottom of the silo.
h) Each silo shall be provided with minimum three (03) nos. of air canons at
necessary location, capable of removing the jamming/clogging/blockage in the
silo.
i) Silos shall have provisions for emergency rodding and air blasting equipment near
the discharge throat. Connections shall be capped.
j) A motorized knife gate type isolation valve shall be provided at discharge of silo
hopper. Valves shall be proven for this application.
k) Each Silo shall be provided with sufficient no. of level transmitters.
l) Bidder to provide staircase up to the top of the silos. Access and platforms shall
be provided for all instrumentation.
m) Access and platforms shall be provided for all instrumentation.
n) Lime silo with hopper may be fabricated at factory in segments, transported and
welded at site.
o) A silo outlet chute shall be provided for feeding lime from silo. The size of the
opening chute shall be sufficient to ensure proper flow of the lime. There shall be
no reduction of section in the silo outlet chute.
p) All parts of the gate in contact with lime shall be of stainless steel
construction.
q) Facility shall be provided to open/close the silo outlet gate, through actuator, from
remote as well as local. In addition, a hand wheel with proper access shall also be
provided.


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03.05 Gravimetric Feeders

a) The lime shall be transferred from the storage silo into the reactor system via a
gravimetric feeder.
b) Gravimetric feeder shall be sized to meet 110% of the maximum
requirement. 2X100% Gravimetric feeder shall be provided.
c) Bidder shall provide a local control panel for the control of gravimetric feeder
d) Gravimetric feeders shall be designed such that they can be calibrated for
operation and testing.
e) A motorized silo shut-off gate shall be provided at the inlet to feeder.
f) The feeder system shall be adjustable to provide a variable output based on
demand.
g) All parts in contact with lime shall be of stainless-steel construction.
h) The feeder shall have a motor/pneumatic operated gate at the outlet.
i) The feeder shall have adequate instrumentation to detect `loss of flow’.
03.06 Screw Conveyor

a) One screw conveyor shall be provided under each gravimetric feeder to
transfer lime into lime preparation system. Each conveyor shall be sized to meet
110% of the maximum capacity.
b) Bidder shall provide a local control panel for the control of each lime day silo
screw conveyors.
c) Bidder shall provide a local control panel for the control of screw conveyors.
d) Screw conveyors shall be designed such that they can be calibrated for
operation and testing.
e) A motorized silo shut-off gate shall be provided at the inlet to each Screw
conveyors.
f) The conveyors system shall be adjustable to provide a variable output based on
demand.
g) All parts in contact with lime shall be of stainless-steel construction.
h) The conveyor shall have a motor/pneumatic operated gate at the outlet.
The feeder shall have adequate instrumentation to detect `loss of flow’
03.07 Hydrated Lime Preparation System

The lime preparation system shall be sized to provide the required hydrated lime
for introduction into the CDS -Reactors based on the range of operating conditions.
The hydrated lime preparation system shall accept delivery of hydrated lime from
intermediate lime storage silo and produce, via the hydration process, hydrated
lime with a specific moisture content. The hydration process shall be as per
bidders/OEM’s standard practice and shall have past executed references.


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Some of the prevalent process technologies are described as below;
In the pneumatic process, measured quantities of lime, air and water are introduced
into the hydration reactor for intimate mixing and conversion to calcium
hydroxide. Hydrated lime product is separated from the hydrator exhaust vapours
in a downstream cyclone and then collected in an intermediate hopper. From the
hopper, the hydrated lime can be fed directly or via hydrated lime storage silo to
the CDS reactor. If hydrated lime is fed directly to the CDS reactor, then this
system does not require a dedicated fabric filter for de-dusting.
In the mechanical process, a double shaft stirrer pre- mixer followed by a hydrating
and maturing chamber can be used for controlled hydration process involving
lime and water. Bag filter shall be provided for de-dusting in this process. The
hydrated lime from hydrator shall be transferred to the hydrated lime silo located
near the CDS reactor via suitable pneumatic conveying system.
A dosing valve shall be provided at discharge of intermediate lime silo and
hydrated lime product hopper. The hydrated lime shall be fed to the CDS -
reactor/ recycle mixer at a controlled rate to meet the required SO2 removal.
If a modular type CDS FGD is offered, then each module of CDS reactor shall be
provided with a dedicated hydrator-mixer.
The hydrated lime preparation system shall be sized to produce and deliver the
required quantity of hydrated lime for SO2 removal as designed.
The lime preparation system design shall include the following:

a) The system shall be able to use process water as defined in the specification.
b) The system shall be able to use lime as defined in the specification
c) The system shall produce a hydrated lime with the proper size distribution and
moisture content. The hydrator shall minimize grit and inert.
d) A platform shall be provided at the level of water injection nozzles for easy
access to facilitate ease of maintenance.
e) Hydrator water injection nozzles shall be constructed of a stainless steel and
suitable for long term operation. Nozzle design shall include an air shield to
mitigate build-up at the nozzle tip. Spare hydrator nozzles shall be provided.
f) The hydrator shall be designed for continuous operation only (when operating)
and shall be operated at a steady state temperature. This temperature shall be
controlled by the addition of water.
g) Alarms and controls shall be provided to ensure that the reaction temperature does
not become excessive.
h) The hydrator shall prohibit fugitive dust emissions and be designed not to plug.
i) The motor amperage shall be monitored and alarm on high amperage.


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03.08 By Product Recycle System

The system shall be sized and designed to deliver reclaimed, dry by-product from
the fabric filter baghouse to Reactor, and allow for a slip stream of by-product
material to be transferred to the by-product storage system, based on the range of
One complete system shall be provided for one reactor with one offline
complete stand-by system
If a modular CDS design is offered, then one dedicated recycle system associated
with the hydrator/mixer may be offered for each modular reactor
The system shall include as a minimum:
a) Fluid troughs shall be constructed of a material, minimum of 5 mm thick steel,
suitable and compatible with the by-product material collected by the fabric filter
bag house. The fluid trough shall be sealed to prevent release of by- product or
fugitive dust emissions.
b) Fluid troughs shall be provided with heat fluidized air connections, including
manual isolation valves. Fluid trough connections shall have expansion joints, as
require, for thermal expansion.
c) Fluid trough shall be easily accessible for future maintenance and
replacement. Access or connections shall be provided to remove material due to
upset conditions or to re-introduce material for start-up.
d) Fluid troughs shall be provided with proven level detection devices which
control excess by-product material discharged to waste and maintain required
recycle operating levels. Each fluid trough shall be provided with high level
detectors.
e) Fluid troughs shall have glass inspection ports placed at key locations to
visually monitor by-product flow.
f) Air shall be supplied from the compressed air system. Alternatively, air blowers
may be provided with sound enclosure, and include motor, coupling, inlet filter,
inlet silencer, heater, valves, pressure gauge, pressure transmitter for blower
interlock and alarm, and base plate extending under both blower and motor. The
source of air for the blower shall be ambient air, though shall be drawn from
outside the process area if it is a potentially dusty environment. The intake
filter shall be designed to prevent abrasive or corrosive materials, from entering
the blower. The fluid trough shall be designed to ensure material cannot
accumulate on the side walls.
g) The Bidder and Bidder shall be responsible to ensure the Owner is able to
effectively operate and maintain the equipment.
h) The fluid trough system shall be designed to prevent dew point condensation
within the hopper.
i) The transition between the fluid trough and the by-product transport system shall


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be designed to ensure that the fluidized by-product is transferred from the fluid
trough to the by-product transport system without interruption, plugging, or
bridging, shall not impact the Owner's ability to effectively operate the
system, and provide necessary means for equipment maintenance.
j) Fluid trough shall have a minimum 250mm diameter outlet flange to connect to
by-product transport system.
k) In a modular system, each module may be provided with a dedicated rotary
feeder that receives by-product material from the Fluid trough. The rotary
feeder introduces material into the each dedicated Reactor mixer at the required
feed rate.
l) Reactor mixer shall be provided with a dedicated valve station for the mixer
process water and instrument air feed.
m) Platform shall be provided for easy access to water/air injection nozzle to
facilitate ease of maintenance. If temporary access is considered, e.g., rolling stairs,
design must consider safety and ease of use.
n) Mixer water injection nozzles shall be constructed of a stainless steel and
suitable for long term operation. Nozzle design shall include an air shield to
mitigate build up at the nozzle tip. 20% or minimum 5 numbers nozzles in spare
shall be considered.
03.09 CDS Reactor

The CDS Reactor shall receive recycled by-product and hydrated lime as required,
to react with and reduce the incoming flue gas SO2.
The CDS system, including Reactors shall be designed to operate with an average
temperature of the flue gas exiting the CDS from 40°C to 25°C above the adiabatic
saturation temperature of the flue gas, at all conditions of operation. Design shall
consider required materials of construction to protect against corrosion at lower
CDS approach temperatures.
The Bidder shall ensure that proper flue gas flow controls are included such that
the flue gas distribution to the multiple modular reactors (if offered) is not
compromised during boiler load swings. This shall be documented in the operation
procedures.
The Reactor design shall include the following:
a) The Reactor shall be all welded, gas-tight construction using the same
criteria and materials as specified for the ductwork in this Specification.
b) The metal thickness for the roof, walls, and the hopper of the Reactor shall be 5
mm, minimum. Reactor materials shall withstand the expected chlorides, sulphur
dioxide, sulphur trioxide, sulfuric acid, moisture, alkali, pH, wet/dry transients,
cold/hot transitions, vibrations, and any other conditions that can occur within the


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operation. The Reactors shall be designed to avoid corrosion, slurry solid build-up,
scaling, acid attack, moisture attack, vibration fatigue, chloride corrosion, erosion,
and cracking. A minimum 1.6 mm of corrosion allowance shall be provided,
though the Reactors shall be designed and constructed with enough erosion
resistant margin per manufacture's recommendations.
c) ASTM A-514 or equal steel in high wear vessel wall areas shall be provided as
required.
d) Vessel design shall minimize internal structural supports.
e) The Reactors shall be designed to support the weight of dry waste deposits on the
internal walls and the bottom section filled with waste deposits.
f) The Reactors shall be insulated to minimize flue gas temperature loss and noise
propagation.
g) A minimum of two access doors shall be furnished. Doors shall be placed to
allow for inspection and maintenance of key components, including turning vanes,
Reactor lower screw, or inlet teardrop venturi. Doors shall be furnished with
external latches and tightening devices, which allow for gasket shrinkage and still
maintain zero leakage. Doors shall be furnished with means to lock in the open
position to prevent accidental closing with maintenance personnel inside. All
access doors subject to high temperatures shall be insulated. Other inspection
access doors shall be included as required.
h) Un-entrained material in the Reactor will be conveyed to the by-product
handling system. Bidder shall provide a reactor screw conveyor from the bottom of
the Reactor to the by- product material handling system.
i) Bidder shall provide a local control panel for the reactor screw conveyor.
j) Material collected at the bottom of the Reactor that cannot be re-entrained in the
flue gas stream shall be automatically conveyed to the by-product handling
system, while the Reactor is in operation. The bottom of the vessel shall also be
equipped with a port and valve to allow for manual clean out.
k) The system shall be designed to prevent by-product build-up. The Bidder shall
ensure that there is no significant impact to the Owner's ability to effectively
operate and maintain the equipment.
l) The vessel shall be provided with necessary instrumentation, control, and
alarms to prevent over-addition of water to the recycle by-product and lime. Bidder
shall describe in operating description how the water injection system will react to
and assist to control• extreme flue gas temperature rise (e.g. caused by air preheater
failure).
m) An overhead monorail and trolley system shall be provided for easy removal of
the equipment during maintenance.
n) Provide turning vanes, as required, to provide uniform flue gas flow through the
Reactors and ductwork Material shall be A36 carbon steel or AR 350 (or equal)
abrasion resistant steel as required per previous operating experience.
03.10 Spray Dryer Absorber


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a) Provide one complete SDAs with all necessary internals, cone hoppers, and
attachments. Design to minimize flooding and scaling, solids deposition, or
erosion of interior surfaces. Provide supports for SDA inlet duct to carry the
load directly to grade.
b) Provide instrumentation and connections for monitoring process variables in
accordance with Seller's process design and as specified in this specification.
c) Provide rotary atomizers complete with all necessary accessories for one
SDA vessel designed for all the units of 210 MW to meet guaranteed
emission level. 1 standby spare atomizer complete with all necessary accessories
shall be provided.
d) Design the atomizer system(s) to operate continuously.
e) Provide rotary atomizer(s) complete with drive motor(s), gear drives, and the
following:
(i) Complete self-contained oil lubrication systems, including pumps,
reservoirs, cooling heat exchangers, cooling fans, and other accessories.
Lube oil piping shall be stainless steel.
(ii) Vibration monitoring systems (with local indication) including high
vibration alarm and shutdown features for each rotary atomizer
(iii) Quick disconnects at the atomizer for all electrical and process connections
to allow for rapid removal and replacement of atomizer.
(iv) System shall include a spare rotary atomizer complete with all accessories
required to allow expedient installation and operation.
(v) Independent dedicated atomizer support stands for each atomizer
supplied.
(vi) Provide corrosion and abrasion-resistant materials for atomizer disk.
f) Provide a system with:
(i) Ability to maintain guaranteed SO2 removal requirements during a normal
maintenance atomizer change-out (out of service) for the specified plant
(ii) Ability to operate continuously
(iii) Provisions for purging of the slurry and air lines to every nozzle assembly
to prevent pluggage, and provisions for low flow switches to alarm a
pluggage condition.
(iv) Provide maintenance access doors or manholes on each SDA vessel.
(v) Provide access doors that are leak tight and conveniently located.
(vi) Provide at the bottom of SDA vessel hopper, a 600 mm by 600 mm
opening.
(vii) Provide SDA hopper heaters (owner’s approved), attached to outer face
of hopper. Design and provide low watt density type heaters adequate to
maintain hopper outside surface at the operating flue gas temperature with
a thermostatic control located at the hopper bottom. Extend heating to the
hopper throat area.
(viii) Provide level detectors to alarm on high hopper level.
(ix) Provide hoppers with valley angles not less than 60 degrees from horizontal.
(x) Shield nuts, bolts, and other fasteners in the flow path from the


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abrasive flue gas.

(xi) Fabricate all roof gas disperser surfaces that are exposed to flue gas (e.g.,
ductwork beyond inlet guide vanes, scroll, walled top and bottom
plates, turning and non -adjustable vanes, etc.) of 25 mm- thick abrasion-
resistant (AR 350) plate. Hard surface all welds where AR350 plate is used.
03.11 Lime Slaking
a) Provide two parallel (2x100%) lime slaking trains with detention type slakers
sized based on worst case shall be provided.
b) Provide each slaker with size classification and recycle equipment, as
necessary, to produce lime slurry at a rate equal to at least the maximum of lime
consumption rate at 100% TMCR (210MW) load.
c) Design the system to accept the water as per specification.
d) Provide in-line water heaters and pressure regulators, as required.
e) Include provisions to flush and drain the slaker and to maintain all vents clear and
functional. Provide devices to prevent dust and vapour escaping from the slaker,
especially to the lime feeder located upstream of the slaker.
f) Provide solution with sufficient capacity to contain all liquid surges resulting
from slaker start-up and/or shut-down operations. Floor drains discharge to the
area trench and sump system provided by others.
g) Provide a slaker design capable of continuous or intermittent operation.
h) Provide covered inspection/access ports for the slaker. Provide an access port
for sampling lime feed in the inlet housing.
i) Provide all equipment and instrumentation required for automatic control of the
lime slaking system, through the DCS. The controls shall include lime feed,
water feed control, and classification system. Provide sufficient signals for
remotely assess the status of the slaking operation. Provide a pre-wired local
operator panel for the lime storage and slaking system with push- buttons,
switches, and lights, which are I/O to the control system, so control can be local or
remote. This panel interfaces to the DCS.
j) Provide a grit removal and storage system for each slaker that will facilitate
periodic removal of grit, if required. Discharge to the floor is unacceptable.
Design grit disposal system with weather protection, i.e., on a slab and under a
roof. Design for discharge of grit into portable containers.
k) Design the grit removal system to remove grit produced at the maximum
slaker capacity. Provide removable screens of stainless steel, wire mesh type.
l) Provide grit screens of welded heavy construction to avoid screen tearing.
m) Provide internal baffles such that incoming slurry does not impinge directly on grit
screen.
n) Strainers shall be provided.
03.12 Lime Slurry Storage Tanks


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a) Provide one lime slurry storage tank for slaking train to store slurry equal to 12
hrs consumption. Allow for a minimum of 300 mm free-board space in the tank
sizing criteria.
b) Provide tanks with all necessary internals, nozzles, and attachments.
c) Provide tanks of all-welded construction. Make all welds on tank interior full
penetration seal welds. Skip or stitch welding is not acceptable. Equip shop-
fabricated tanks or tank partial sections for field final assembly with at least four
lifting lugs.
d) Equip tanks with overflow and drain nozzles.
e) Provide manhole for cleaning and waste removal purposes.
f) Provide high and low level detectors and indicators with local and remote
alarm for each tank.
g) Provide tanks capable of isolation for cleanout and maintenance.
h) Additional corrosion allowance of 3 mm on the minimum tank shell thickness as
calculated by IS:803, latest edition shall be provided by the bidder.
i) Interior surface of the tank shall be lined with replaceable chloro-butyl /
bromo-butyl/ rubber lining of minimum 5mm thickness and outside surface shall
be painted as per painting specification.
03.13 Agitators
a) Furnish tanks containing solid slurries with top-mounted agitators. Provide at least
one agitator for each tank.
b) Agitator shall be of reputed manufacturers (approved by owner) have same
application references Provide agitators and supports of heavy-duty, high quality
construction, and complete with motors, gear drives, coupling guards, and
mounting baseplates.
c) Provide each agitator with sufficient mixing energy to maintain all solids in
uniform suspension without solids settling or size separation.
d) Size agitators and drives to provide re-suspension of solids following a
minimum 90-minute period without agitation. Two impellers on one shaft shall be
provided.
e) Design agitators and drives to start up and perform over the full range of tank levels
from overflow to low level.
03.14 Slurry Pumps

This clause covers the design, manufacture and erection of all slurry pumps for
the SDA system.
a) The Bidder shall offer only proven design in successful operation in similar
application at previous installations. The design, manufacture, installation and
testing of the pumps shall follow the latest applicable Indian / International
(ASME /EN / Japanese) Standards.
b) The pumps shall be designed for continuous operation. The pump shall be single
stage centrifugal type capable of delivering the rated flow at rated head with


& ITS AUXILIARIES
margins as specified in the respective clauses. The slurry concentration in the pump
shall be as per OEM’s standard technology with similar application.
c) All the slurry pumps shall be provided with motorized suction and discharge
valves. In addition, flushing water lines with motorized valves shall be
provided for each pump for automatic flushing of the pump after each shut down.
The flushing water for the pumps shall be taken from the process water
supply.
d) The pump casing should be radially split to allow easy removal of impeller.
e) All the pump wear parts in contact with the slurry shall be provided with
replaceable rubber/elastomer liners suitable for the fluid handled. The Bidder can
also offer a high chrome alloy lined pump if the Bidder has previous experience of
the same for similar applications. The material used by the bidder shall be proven
in previous installations.
f) The material and thickness of the liners shall ensure a minimum service life of 2
years before replacement. All the wear parts of the pump shall be guaranteed
for a minimum wear life of not less than 14000 hrs.
g) The design of the shaft shall ensure that the operating speed is at least 20% above
the critical speed of the shaft.
h) The pump shall be provided with seals of proven type and shall be designed for
minimization of seal water consumption. The shaft shall be supported on heavy
duty ball/roller bearings.
i) All rotating parts shall be statically balanced. Water & slurry pumps are
balanced per ISO 19401-1:2003 quality grade G 6.3. Water pumps and slurry
pumps have a maximum shaft run out of 0.002 inches.
j) Slurry pump impeller shall be closed type.
k) Bidder to consider minimum margin of 10% on flow and 15% on Frictional
Head.
Table-6.3: Slurry Pump Design
S.N Parameters Description

1. Description All slurry pumps for the FGD system
2. Type Horizontal, single stage centrifugal type (all
identical pumps shall be interchangeable)
3. Duty Continuous
4. Fluid to be pumped Highly abrasive slurry
5. Flow & Head As per design guidelines contained in
accompanying specifications
6. Pump speed (max.) 1,000 rpm
7. Impeller tip speed 1676 meters / min. (max.)
8. Type of coupling Variable speed Hydraulic coupling with speed
reduction by means of speed reduction gear box in
first stage. Speed variation +10% - 45% with
respect to rated design point
9. Material of Construction


& ITS AUXILIARIES

Casing Outer casing shall be of cast steel to ASTM-A216 or
spheroidal Graphite Ductile iron to ASTMA-
536, 65-45-12. Inner casing (Volute liners) shall
be of chrome nickel cast iron (composition to Ni
hard-IV) of 550 BHN.
Or 28% chromium (high chrome alloy) cast iron
of 550 BHN.
Impeller Chrome nickel cast iron (composition to Nl-hard
IV) of 550 BHN Or
28% chromium (high chrome alloy) cast iron of
550 BHN.
Wear plate / liners - do-
wear rings
Shaft Carbon steel to AISI -1040 / EN-8
Shaft Sleeve Hardened and ground stainless steel (550-BHN) SS
410 BHN
Base Plate Steel to IS: 226 up to 20mm thickness and
IS:2062 and over 20mm thickness.
10. Drive Motor Rating 20% margin over and above the maximum load
demand in the entire operating range of pump at
50 Deg. C.
Drive Motor Speed Not exceeding 1500 rpm
11. Slurry Pump To be selected by Bidder. However, for the purpose
efficiency of evaluation, no credit shall be given for the pump
efficiency in excess of 70%.
12. Margins 10% on flow and 15% on frictional head
03.15 By Product Storage Silo

a) Silo and hopper cones shall be fabricated of minimum 10 mm thick carbon steel
(ASTM A36 steel plate) The design of storage silos shall confirm to IS 9178 or
any other proven international standards. Coating shall be provided as per
bidder’s practice to avoid any chemical reaction. The Silo bottom hopper shall
be conical and minimum 60 degree from horizontal.
b) Minimum free board of one (1) meter or based on requirements for accurate
operation of level instrumentation shall be provided.
c) Silo vent filters shall be provided to remove collected dust and return to the silo
using compressed dry air to pulse the bags or cartridges. Pulse control shall be
based on differential pressure and timed basis. Silo vent discharge location and
sound level shall be considered as to not impact residential receptors. Provide
pressure and vacuum relief devices.
d) Access to the top of the silos, doors or man holes, the dust collection
equipment, or any instrumentation or other equipment mounted on the silo, shall be
provided by stairs and platforms complete with hand railing.
e) Weather tight roof shall be checkered plate with an access manhole. Access


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shall also be provided near the bottom of the silo.

f) Each silo shall be provided with minimum three (03) nos. of air canons at
necessary location, capable of removing the jamming/clogging/blockage in the
silo.
g) Silos shall have provisions for emergency rodding and air blasting equipment near
the discharge throat. Connections shall be capped.
h) A motorized knife gate type isolation valve shall be provided at discharge of silo
hopper. Valves shall be proven for this application.
i) Each Silo shall be provided with sufficient no. of level transmitters.
j) Bidder to provide staircase up to the top of the silos. Access and platforms shall
be provided for all instrumentation.
k) Silo with hopper may be fabricated at factory in segments, transported and
welded at site.
l) A silo outlet chute shall be provided for feeding from silo to rotary feeder.
The size of the opening chute shall be sufficient to ensure proper flow. There shall be
no reduction of section in the silo outlet chute.
m) Facility shall be provided to open/close the silo outlet gate, through actuator, from
remote as well as local. In addition, a hand wheel with proper access shall also be
provided.
n) Motorised telescopic chute shall be provided with motorised knife gate valve at
outlet of the feeder discharge to truck. The level of the outlet shall be suitable for
unloading the by-product in to the truck.
03.16 Slurry Lines and Valves

a) Slurry pipes shall be designed to keep the velocity above the settling velocity
under all operating conditions. The bidder may provide a recirculation line with
motorized isolation valve.
b) The slurry pipes shall be of Carbon steel lined with replaceable wear
resistant natural rubber of minimum 6 mm thickness. Additional thickness of 2
mm in rubber lining shall be provided at bends.
c) All the pipes handling slurry shall be provided with replaceable rubber lining of
proven quality. The Bidder can provide slurry pipes of size lower than 80 NB
made up of abrasion resistant FRP material (silicon carbide coating on slurry
exposed surface) if it has previous experience of providing the same.
d) The isolation valves provided in all the slurry lines shall be of knife gate
type/butterfly type unless specifically mentioned. Motorized actuators shall be
provided for valves requiring frequent operation as indicated in the relevant
scheme.
e) The valves shall be of proven type and the bidder shall submit a detailed valve
schedule for owner’s approval. Reference list for previous installations for similar
application shall also be furnished to the owner.
f) Bidder shall provide all necessary arrangements for purging & flushing of all the
process pipelines, equipments etc.
g) The metal to metal seated knife edge gate valves strictly meet the testing


& ITS AUXILIARIES
requirements of MSS-SP 81 code for seat leakages.

h) Valves shall be provided with a mechanical indicator and limit switches to
indicate open or closed position of the valve locally and remotely.
i) For working pressure up to 10 kg/cm2 - Metal to metal seated knife gate valve
shall be selected
j) For working pressure above 10 kg/cm2 – Plug type regular pattern valve or
resilient sealed knife gate valves shall be used.
k) Material of construction of valves shall be as follows;
S.No Parameters Description

1. Body/Cover Cast iron FG-260 to IS: 210 (min. 10 mm thickness) with Ni hard
deflection cone (minimum 400 BHN hardness) for knife edge gate
valves.
OR
Carbon steels to ASTM - A - 216 Gr. WCB (0.3% carbon
max.) for plug valves.
2. Gate/Plug Stainless steel with min. 350-400 BHN Hardness on wear
surface for knife edge gate valves (gate edge)
OR
Carbon steel to STM-A-216 Gr. WCB case hardened to
400-450 (port) and BHN suitably impregnated for low friction.
3. Stem Stainless steel (SS-304) for knife edge gate valves
OR
IS: 1875 Class C made out of ASTM-A-105 (forged carbon steel)
and will be suitably impregnated for low friction or BS:970-
709M40.
03.17 Water & Air Piping, Fitting and Accessories

a) All piping shall be provided with vents at the highest points and drains at the
lowest points along with vent valves and drain cocks. Vents shall not be less than
15mm in size. Drains shall not be less than 25 mm size. The piping shall be
arranged to provide clearance for the removal of equipment requiring maintenance
and for easy access to valves and other piping accessories required for operation
and maintenance.
b) Piping shall generally be routed above ground but where specifically
indicated/approved by the Engineer the pipes may be arranged in trenches or
buried. Bidder shall provide either coal tar or Bitumen tapes on conventional coat
and wrap system for corrosion protection of buried piping as per relevant codes and
standards.
c) Necessary drain lines with valves of adequate size for draining the system and
to achieve low pressure loss and low noise level shall be provided. The air release
valves shall be fitted with an inverted ‘U’ pipe on the outlet and drain piping to the
nearest drain. All drain and air release valves shall be located in positions


& ITS AUXILIARIES
convenient for operation. No drain line shall be sized below 25 mm ID. All drain
lines shall be provided with two isolating globe valves in series.
d) Pipe Size in pump suction side shall be at least one pipe size larger than the
corresponding pump discharge connection.
e) A margin of 10% to be considered on the actual friction drop for arriving at
pump head (considering Hazen-William).
f) Pipes sizing criteria to be considered as follows:
S.No Detail Value

A Velocity Considered in Pipes for Various Duties
1. Lime Slurry (Minimum/ Maximum) 2.3/ 2.8
m/sec
B Friction factor ‘ C ‘ to be considered:
1. Friction factor ‘ C ‘ for Slurry Lines 140
2. Friction factor ‘ C ‘ for Sludge Lines 130
3. Friction factor ‘ C ‘ for Water Lines 110
g) Pipe Support Spacing

Pipe Size 25 50 80 100 150 200 300 400 500
(NB)
Spacing in meter 2.1 3.0 3.7 4.3 5.2 5.8 7.0 8.2 9.1
03.18 Specification for Hangers/Supports

a) Design, selection and Manufacture of Hangers/Supports shall conform to
ASME B 31.1, MSS-SP-58, MSS-SP-89.
b) Rod hangers’ rigid supports shall generally be used for supporting piping
where the cold to hot vertical movement at pipe support point is practically zero or
negligible.
c) Where hanger rod angularity exceeds 4 degrees from cold to hot position (at rated
parameters), the hanger and structural attachments shall be offset in the cold
position in such a manner that the hanger rod is vertical in hot position unless
d) The Bidder shall furnish detailed arrangement sketches for each support,
restraints, anchor, etc. The sketches shall include the key plan identification no.,
bill of quantities, design load, operating load, spring stiffness, amount of
precompression, centre line elevation of pipe, spring box position/orientation, etc.
04.00 Approach and Handling Facilities
a) Proper approach shall be provided for access to all equipment during normal
operation and maintenance. Unless otherwise specified, platforms, staircase and
ladders shall follow the stipulations specified elsewhere in this specification.
b) Equipment requiring monitoring during regular operation shall be approachable
from the ground floor through staircase. Staircase with minimum width of


& ITS AUXILIARIES
1200 mm shall be provided for approach to elevated structures at 5m height

from the nearest platform. Below this height a vertical ladder with minimum clear
width of 600 mm may also be acceptable.
c) Platform with a minimum clear width of 1000 mm shall be provided all around the
lowest absorber spray levels and mist eliminators. Similar platforms shall be
provided at subsequent elevations if they are more than 3000 mm apart from each
other. An adequately sized manhole with platform (min. 2 sq. m) shall be provided
above each spray level. Ladders/staircase shall be provided for the access to the
platform.
d) A 1500 mm space shall be provided around all pumps.
e) Platform with a minimum width of 1500 mm shall be provided all around the silo
and feeders.
f) A 1000 mm wide platform with suitable approach shall be provided around each
hydro-cyclone.
g) A 2000 mm wide floor/platform shall be provided all around each belt filter.
h) Bidder shall provide motorized hoists for all items requiring maintenance and
weighing 500 kg or more. All auxiliary structures, monorails, runway beams for all
lifting tackles, hoists etc., are included in Bidder's scope of supply. Access ladders
with suitable platform shall also be provided for approach to all motorized
hoists/trolleys mounted on their runway beams for the maintenance of hoists. Items
weighing more than 50 kg and required to be replaced for maintenance shall be
provided with manual hoists with runway beams/supporting structure etc.
i) Basement floor is not acceptable in FGD area, further local pits/trenches shall be
avoided as far as possible
j) Approach for removal of equipment for maintenance shall be provided.
k) All other safety requirements as per the applicable Factories Act, Building Codes,
National Electricity code etc. shall be complied with while developing layout.
l) Each equipment room shall be provided with alternate exits in case of
fire/accidents as per requirements of Fire Safety Codes, Factories Act and Statutory
bodies/insurance companies.
m) Minimum Headroom (free height) under all floors, ducts, walkways and stairs shall
be 2.50 M.
n) Inter-connecting pipes/cables between various facilities of FGD plant shall be
routed on the steel trestles to be provided by the Bidder. The clear head room for
the same shall be minimum 8.5 M.
o) In case of any specific space constraint at site, the layout, clearance, approach etc.
shall be mutually agreed and subject to approval of the Owner.
05.00 Duct Work and Dampers
05.01 Duct Sizing Criteria

Allowable maximum gas velocity in the duct shall be 15 m/sec at Design point
condition.
All new ducts, fabric filter compartments, scrubber vessel and other equipment
exposed to flue gas shall also be designed for (+) 660mmWc & (-) 150 mmWC or
maximum conceivable pressure of the booster fan, whichever is higher at 67%
yield strength of the material.


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05.02 Loads for Duct and Structure Design

The duct design shall take into account following loads all occurring together:
a) Wind loads
b) Dead weight including weight of insulation, lining, wash water and the vertical live
load.
c) All ducts to be designed for one tenth of duct full of ash. The ash density for the
purpose of loading shall be at least 1300 kg/m3.
d) Expansion joint reaction.
e) Seismic Load
The following minimum load factors shall be applied to the design load.
Temperature (Deg. C) Load FACTOR
27 1
38 1.02
93 1.12
149 1.19
205 1.25
260 1.29
316 1.34
321 1.42
All ducts shall have a sufficient slope with respect to horizontal so that any chance
of accumulation of ash particles or water in the duct can be avoided under all
normal/abnormal operating conditions. The inlet duct shall be sloped towards the
absorber.
f) The Absorber inlet duct shall be of rectangular cross-section and shall be of all
welded construction.
g) Steel plates for gas ducts shall be minimum 7 mm thick & duct stiffening shall be
by means of rolled sections of duct material.
h) A corrosion allowance of 1.5 mm shall be considered for stress calculation for the
flue gas ducting.
i) Duct stiffening shall be by means of rolled sections. No internal stiffeners shall be
used for ducts from Absorber outlet to chimney inlet.
j) The stiffeners provided on the ducts walls shall be of such a design and layout that
no rainwater can accumulate on the duct surfaces.
k) The flanges at the bolted joints shall have adequate stiffeners to avoid
damages to the flanges.
l) All necessary wall boxes and floor collars shall be provided where the
ductwork pass through walls, floor and roof.
m) The floor collars shall be fitted with a high combing to prevent water and dust


& ITS AUXILIARIES
falling through the hole.

n) The ductwork shall be fitted with a steel hood to cover the opening.
o) Weatherproof flashing shall also be provided wherever necessary.
p) Duct plates shall be designed for one-way beam action over stiffeners and
considered fully continuous over all supports.
q) Bidder to ensure proper draining facilities for the complete system including proper
drainage of acidic fluids from the ducts so as to avoid any accumulation of
acidic fluids.
r) The deflection of the plate, assumed continuous, shall be less than one-half the
plate thickness.
s) Ductwork sections between expansion joints shall be investigated with regard to
their ability to transmit loads to supports.
t) Duct shape shall be maintained by providing internal stiffening elements at or near
supports. However, these internal stiffeners shall be used, if and only if, it is not
possible to provide external stiffeners.
u) Conceptual data of internal stiffeners (if any) of the ducting shall be furnished
along with the offer.
v) All openings in ducts shall be reinforced for all design loads.
w) Duct plates shall be designed for one-way beam action over stiffeners and
considered fully continuous over all supports.
x) Ductwork supports may be hangers or sliding bearing, guides and
anchorages. A coefficient of sliding friction of 10% can be used with self-
lubricated plates such as "LUBRITE" or "MECHANITE", a coefficient of
sliding friction of not less than 35% shall be used for steel-on-steel contact. The
allowable bearing stress for self-lubricated plates shall be 70 Kg/sq.cm.
05.03 Fabrication Requirements
a) Fabrication shall be as per IS specification for Design, fabrication and
erection of 'Structural Steel for Building.
b) Welding shall be in accordance with Section IX of ASME code.
c) Ducts shall be strength welded and seal welded to produce a gas tight duct.
Alignment holes shall be provided in mating flange sections.
d) Ducting shall be detailed and fabricated in a few pieces as practical, taking into
account, shipping and erection considerations.
e) Materials improperly detailed or fabricated necessitating extra work during
erection on field shall be the responsibility of the Bidder.
05.04 Safety Equipment

One (1) each automatic safety shower unit consisting of drench shower and eye
bath station shall be provided at the reagent preparation area, and by-product
storage area.
06.00 Noise


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a) All the plant, equipment and systems covered under this specification shall perform
continuously without exceeding the noise level of 85 dBA over the entire range of
output and operating frequency.
b) Noise level measurement shall be carried out using applicable and
internationally acceptable standards. The measurement shall be carried out with a
calibrated integrating sound level meter meeting the requirement of IEC 651 or BS
5969 or IS 9779.
c) Sound pressure shall be measured all around the equipment at 1.0 m
horizontally from the nearest surface of any equipment/ machine and at a height of
1.5 m above the floor level in elevation.
d) A minimum of 6 points around each equipment shall be covered for
measurement. Additional measurement points shall be considered based on the
applicable standards and the size of the equipment. The measurement shall be done
with slow response on the A – weighting scale.
07.00 Type Test

The type tests shall be conducted by the Bidder on the equipment mentioned
below:
a) Leak tightness testing of all dampers of each type and size at shop to
demonstrate the guaranteed gas tightness efficiency (on flow). The minimum
guaranteed gas tightness efficiency of dampers shall not be less than the value
indicated in the section of the dampers of this specification.
b) The Bidder shall include the charges for these type tests in his bid.
c) Irrespective of the requirement of conducting the type tests under this
contract, the Bidder may submit the reports of any other type tests, for
Owner’s information, not specifically requested but carried out within last five (5)
years from the date of bid opening. These reports should be for the tests conducted
on the equipment similar (model / type / size / rating) to those proposed to be
supplied under this contract and the test(s) should have been either conducted at
an independent laboratory or should have been witnessed by a client in the
State or Central Power Utility. Submission of these type test reports does not
absolve the Bidder of his responsibility to conduct other shop tests specified under
this Tender.
d) All other shop and site acceptance and routine tests as per the specification and
relevant standards shall be carried out as described in below sections or elsewhere
in the Tender Specification. Charges for these shall be deemed to be included in the
equipment price.
08.00 Shop Tests
Before shipping equipment from factory, perform the following tests as


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minimum:
a) All pipes, valves, steam traps, are to be subjected to hydraulic test as called for
under IS, BS or other approved codes. Copies of certificates covering all the
hydraulic tests shall be submitted to the Owner. The following shop tests shall be
conducted, as applicable according to the approved manufacturer’s test Procedures:
• Material Analysis
• Radiographic test at welds.
• Magnetic particle examination
• Dye penetrate examination
• Hydro static test.
• Dimension check
• Ultrasonic test (as required)
b) Conduct factory performance tests for pump and blowers (one for each type,
minimum) in accordance with HIS and other applicable standard.
c) Perform hydrostatic tests on pressure-containing component of the system at not
less than 150% of design pressure in accordance with applicable code and standard.
d) All pumps and fans are to be tested at manufacturer’s works. Complete
performance tests are to be carried out on each pump/ fan to verify its output (flow)
against total head, power input, efficiency and suction head. Head vs. Volume,
Suction head vs Volume, Volume vs Efficiency and power input curves corrected
for site conditions are to be provided.
e) All booster fans shall be tested at manufacturer’s works as per approved quality
plan. Full range and full-scale performance testing shall be conducted at shop on
one (1) number Booster Fan as per BS EN ISO 5801or AMCA. The performance
testing at shop shall be conducted using actual fan and job motor.
09.00 Site Tests
Bidder shall carry out the tests at site to prove to the Owner that each equipment of
the plant complies with all the requirements specified. Before the plant is put into
commercial operation, the Bidder will be required to conduct tests to demonstrate
to the Owner that each item of the plant is capable of correctly performing the
functions for which it was specified. These tests may be conducted concurrently
with those required under commissioning sequence. The tests required shall
specifically include the following:
• Checks on the operation of dampers including tests of gas tightness/ leak
proofing.
• Check on operation of all fans to ascertain level of noise and vibration.
• Test running of pumps and motors.
• Check free rotation of gas heater and adjust seals, if necessary when heater


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is up to working temperature.
• Check operation of all variable speed drives throughout their respective
ranges on lime feeders etc. where applicable.
• Check operation of all motorized isolating valves both locally and from
the FGD control room.
• Check operation of all individual control loops in the FGD control system.
• Check inter-relation between each separate control loops.
• Calibration of instruments before commissioning as required.
• Gas tightness test on FGD system.
• Calibration tests of monitoring, instrumentation and control system/
devices (permanent one) to be used for tests.
• Other tests shall be conducted if required by the Owner to establish that the
plant equipment is in accordance with requirements of specifications.
10.00 Field Operations
a) Provide technically component personnel, including representatives of his sub-

vendor, as required, to advise and consult during start up and putting the unit in
operation.
b) Provide technically competent personnel, including representative of sub
vendor as required to advice and consult during start-up and putting the unit in
operation.
c) Provide the following to facilitate field erection in a timely and efficient
manner.
• Thorough internal inspection of individual component to ensure foreign
object are removed and all piping assemblies are blown out with compressed
air prior to shipment.
• Preparation of all equipment for shipment to prevent rusting, weathering,
ingress of foreign matter, corrosion or other damage during transit and
storage area.
Air and Gas Tightness Test
After completion of installation of Booster fans, ducts & reactor/absorber for each
unit, and before commencement of application of thermal insulation, a test shall be
performed on the FGD system to prove and to establish the tightness of the erected
equipment. The procedure adopted for such tests shall have the prior approval
of the Owner. Normally physical leak detection method by pressurizing the
section under test by running Temporary blower is adopted. The bidder may adopt
any other better method of testing. All equipment including any temporary
blanking, if required, for the above test shall be provided. The air and gas tightness
test procedure shall be such that it shall enable conductance of air/gas tightness test
on the ducts in segmented manner (as and when these duct segments are ready), so
that these duct segments can be immediately released for application of


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insulation after their gas tightness tests. Bidder shall make all necessary
arrangement for conducting tests in this manner. Any blanking etc. on the duct
side required for testing of duct segments shall be provided by Bidder. Bidder
shall bring fan / blower (s) of adequate size / capacity and other necessary
instruments so that these tests can be conducted. The above equipment shall be
brought to site by the Bidder on temporary basis and shall be taken back after
successful completion of air / gas tightness test.
Any other pre-commissioning activity such as floating of safety valves etc. as
considered essential for readiness of facilities for commencement of commissioning
activities shall also be undertaken by the Bidder.
11.00 Method of Computing Site Performance Test Results of FGD
The performance tests of complete installed FGD system shall be carried out in
accordance with ASME PTC 40 (2017) code. The details of the test shall,
however, be mutually agreed upon between the owner and the bidder.
The FGD system shall be stabilized within permitted limits of operation prior to the
test, as specified under PTC 40. Necessary correction curves as per guidelines of
PTC 40 shall be used to compute performance test results in case of variation of
operating parameters from reference performance guarantee conditions.
12.00 Model Gas Flow Test
a) Computational Fluid Dynamics (CFD) modelling for gas flow is essential for the
complete FGD system.
b) The test procedure shall be submitted for Owner’s approval.
c) Bidder shall provide within the scope of supply, flow modelling to verify the
flue gas path design from the ID Fan outlet to the stack (within the terminal point),
using physical model.
d) The Bidder shall provide as implosion modelling study to be performed to
determine flue gas system design pressure is adequate.
e) Include three-dimension scale model of the FGD absorber (include inlet transition)
and interconnecting flue work. Conduct test to determine:
(i) The size, configuration and location of all the necessary gas
distribution devices.
(ii) Final configuration of flue work.
(iii) Appx. Pressure drop through the system.
(iv) Gas flow distribution in the absorber.
(v) Adequacy of the draining.
f) Modelling shall also be performed on the wet/dry interface of the absorber inlet
duct.


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g) The model shall address gas flows for the range of full load conditions from
minimum load flow to max design gas flow across the full range of fuels.
h) Bidder to give at least 30 working days advance notice to witness the model test.
i) Provide scale factor of model to prototype, test procedures and description of test
instrumentation to owner for review and written permission to proceed. Scale
factor shall be not less than 1:12.
j) Provide a complete model test report describing configuration tested,
recommendations and test results for each such configuration.
k) Obtain inlet flue velocity profiles and outlet flue velocity profile from a model
for 100% flow. Express and tabulate these velocities in the cross-section. Provide
vanes to limit fan inlet velocity/ volume readings to ±5% side to side.
l) Record inlet flue velocity profiles and outlet flue velocity profile on model for
100% flow.
13.00 Buildings
a) Bidder shall consider buildings for air compressor/air dryer, water pumps, slurry
pumps, hydrated lime preparation /lime slurry preparation building (as per
bidder’s technology) and FGD control cum electrical room. The buildings must be
complete in all respects specially facilitating the smooth operation and
maintenance of associated equipment of above systems by providing adequate
maintenance space, handling facilities, walkways, staircase etc.
b) Bidder shall consider corrosion protection painting for structures &
equipment as described in the specification.
c) All platforms, walkways, staircase, safety rails for access to each equipment,
valves, dampers, gates, instruments etc. handling facilities for each component of
FGD system shall be included for the building structures.

SECTION 02.00
TECHNICAL
INFORMATION / DATA


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02.00 TECHNICAL INFORMATION / DATA TO BE SUBMITTED ALONGWITH THE

BID
02.01 Technical particulars are to be filled up in this tender document or mentioned elsewhere in
other Volumes of , shall be valid for all makes proposed by bidder and shall not be altered
later by the bidder due to selection/ finalization of any sub-contractor by the bidder.
02.02 Bidder is requested to ensure that no contradictions amongst the information /

data/write-up/drawings enclosed herewith. In the event of any such contradiction, decisions
of Purchaser shall be final and shall be binding on Contractor.
02.03 The bidder shall ensure that all information, data performance curves, technical literature
(catalogues) and drawings furnished here and during detailed engineering fully describe all
equipment/ systems covered under this tender document and fully meet the requirements of
the present scope of work.
02.04 The purchaser reserves the right to ask for future details regarding technical features,
application particulars, performance, past experience for similar application or any other
information as may be required to fully satisfy himself regarding suitability, quality,
reliability and full compliance with this specification for all equipment and systems offered
by the bidder.
02.05 It may be noted that this technical data sheets section is for bidding purpose only. During
detailed engineering, the bidder will be required to furnish all additional data about the
equipment/ system being supplied, even if such details are not asked for this section. The
details furnished in the data sheets are preliminary and may be subjected to changes during
detailed engineering stage. However the requirements of TANGEDCO tender specification
and the agreements reached during the techno-commercial discussion and price negotiation
meetings will be met with.
02.06 General Technical Information / Data Drawings for Flue Gas Desulphurization
System (Separate for Each Unit)
Sl. No Description Units Specification Bidder Information

Requirement Guarantee Design point
point
1 Performance Data for
FGD
1.1 Characteristic/Correction
Curves for Absorber
Gas flow rate vs SO2
i) removal efficiency for all
specified coals (Guarantee
Point / Design point)
Inlet SO2 concentration vs
ii) SO2 removal efficiency for
all specified coals
(Guarantee Point/Design
point)
Vol. – IIB, Section 02.00 TDS - FGD SYSTEM Page 1 of 19


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point
Inlet dust concentration vs
iii) Dust Removal efficiency for
all specified coals
(Guarantee Point/Design
point)
iv) Gas Flow Rate vs Pressure
Drop
1.2 Supplementary Data for

FGD System
A complete list of all the
equipment requiring the
i) following shall be furnished
indicating parameters
continuous requirements and
the maximum requirement
together with schematic
diagrams
a) Process water m3/hr.
b) Service Water m3/hr.
d) Potable Water m3/hr.
ii) Schedule of power
consumption
Recommended mode of
iii) erection sequence and other
relevant particulars in
respect of installation of
a) Structural Steel
b) Rotating Equipment
c) Static Equipment
d) Others
A comparison and history of
iv) all FGDs in service of
similar design and size to
that proposed including
descriptions of operating
difficulties.
Schedule of dampers with
v) full particulars of dampers
and their actuators, such as
type of actuator, make,
torque rating, stroke and
stroking time, electrical
rating/ pneumatic
consumption limit


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point
vi) List of special maintenance
tools included in the
proposal
vii) Write up on complete FGD
system
Write up on Absorber & its
viii) Auxiliaries like reaction
tank, fabric filters,
compressors/blower, lime
unloading & supply
equipments , process water
transfer pumps etc.
Calculations for working out
ix) of gas temperature, inlet
SO2 concentration, SO2
removal efficiency, water
evaporation, stack inlet
temperature, lime
consumption, fabric filter
efficiency, byproduct
recirculation etc.
Calculation for process water
x requirement and lime
consumption etc.
1.3 Drawings
i) Process flow diagram and
material balance
ii) P & ID for dry FGD system

including lime handling,
storage
& supply system,
compressed air system,
process water system,
Pneumatic conveying system
etc.
iii) Major mechanical equipment
list of all the items
furnished, including
quantities, sizes, MOC, tag
nos, service condition and
manufacture name
iv) Major Mechanical
equipment data sheet


& ITS AUXILIARIES

point
v) Utilities consumption list (
maximum, minimum &
average basis with
parameters) including flow
rate, temperature,
vi) General
Arrangement/Outline
Drawings
• Dimension and Location
(plan & elevation) of all
equipment including
dimension.
• Maintenance area
requirement.
• GA (Plan & elevation) of
FGD Plant
• FGD Plant control room
(plan & elevation) details
vii) Auxiliary Power
Requirement of each
equipment
viii) Flue gas ducting
arrangement drawing
9 Sealing Efficiency with Seal % 100% leak tight
air fan
10 Seal Air Fan Flow / Head (m3/h/m
mwc)
11 Heater type provided
12 Heater rating (KW)
2.3 Guillotine Gates Dampers

(Absorber inlet & out let,
Fabric filter inlet & out let)
1 Manufacturer
2 Size (m x m)
3 Quantity no 1 no for each

type
4 Material / Thickness of plate, As per
frame & seals specification
5 Type Guillotine
Gates/Dampers


& ITS AUXILIARIES

point
6 Actuator Rating (KW)
7 Sealing Efficiency (without % 99.95% leak

Seal air fan) tightness
8 No. of Seal Air Fans nos 2x100% seal air
provided fans &
2x100%
electrical
heaters
9 Sealing Efficiency with Seal % 100% leak tight
air fan
10 Seal Air Fan Flow / Head (m3/h/m
mwc)
11 Heater type provided
12 Heater rating (KW)
2.4 Booster Fan
1 Manufacturer
2 Type Constant speed,

Axial type or
Centrifugal
Type
3 No. of fan for the 210 unit No. 2x50%
4 Flow rate NM3/hr as per

specification
5 Flow rate at test block NM3/hr
condition
6 Max. flow rate fan can NM3/hr
handle
7 Min. flow rate fan can NM3/hr
handle
8 Static Pressure, mmWC
a) At test block condition
mmWC
b) At shut off condition mmWC
c) Min safe pressure mmWC
9 Test Block margin provided
a) Flow rate % as per
specification
b) Static pressure % as per
specification


& ITS AUXILIARIES

point
10 c) Fan operating speed rpm < 750
11 Critical Fan Speed rpm Not less than
125% of fan
maximum
operating speed
a) First critical speed rpm
b) Second Critical speed rpm
12 Design tip speed of blades m/s
13 Fan efficiency %
At Test Block Condition %
14 Direction of rotation facing (clockwi
fan coupling se or
anti
clockwis
e)
15 Impeller details
a) Impeller diameter mm
b) Shaft diameter mm
c) Moment of inertia of shaft kg/m2
and impeller,
16 Overall dimensions of fan& m
motor
17 Size of motor provided, KW
18 Power Consumption KW
Test Block Condition KW
19 Type of coupling
Lubrication System(forced/
20 ring lubrication) for fan &
motor
21 Material of construction as per
specification
a) Casing
b) Casing Side plate
c) Casing Liner
d) impeller Blade
e) Inlet Cone
f) Outlet diffuser
g) Impeller Hub/shroud
h) Impeller wear plate
i) Shaft Sleeve
j) Coupling
k) Base plate & Foundation
Bolt
l) Inlet guide vane/Inlet
damper


& ITS AUXILIARIES

point
22 Shaft sealing arrangement
23 Hydraulic servo drive
24 Lube Oil System
a) Number of pumps per fan 2 x 100%
b) Type of pump
c) Number of oil cooler per
Fan
d) Number of oil coolers in
standby/service
e) Relief valves provided? yes/no
f) Pressure switches yes/no
provided?
g)Thermometers provided ? yes/no
h)Electric heaters with oil yes/no
tanks provided?
25 Accessories
Coupling guards provided? yes/no
Base plate and foundation yes/no
bolts provided ?
Forced lubrication unit with
pumps, filters, coolers, yes/no
connected piping etc.
provided ?
Local instruments provided? yes/no
Provision for vibration yes/no
sensors made ?
RTDs for fan and motor yes/no
bearings provided ?
CDS- DRY FGD SYSTEM
2.5 CDS - REACTOR
1 Manufacturer
2 Manufacturer’s model
number
3 Quantity & type no/nos One (1) No.
4 Absorber Cross Sectional area (m2)
5 Absorber Dimension (mxmxm
)/diaxhei
ght
6 Height between support level (m)
to top of support steel
7 Number of water spray
levels(Working + Stand-by)
8 Number of spray nozzles per no/nos
spray level (hydrated lime &
Water)


& ITS AUXILIARIES

point
9 Number of redundant spray no/nos
nozzles per level (hydrated
lime & Water)
10 Maximum byproduct (m3/hr)
recirculation flow
11 Efficiency of Venturi Nozzle %
12 Guaranteed SO2 removal (%)
efficiency
13 Dust Removal Efficiency (%)
14 Guaranteed pressure drop (mmwc)
across Gas System
15 Guaranteed oulet Temperature (oC)
16 Hydrated Lime Consumption (kg/hr)
17 Gas velocity through (M/sec)
Absorber
18 Gas Residence time in (sec)
Absorber
19 Proposed standard for
conducting the performance
tests
20 Material / Thickness (mm) of
base material & lining
21 a) Absorber mm
b) Spray Area mm
c) Spray Nozzles
i) spray piping etc.
Design pressure (mmwc)
22 Design temperature (deg C)
23 Max. temperature with stand (deg C)
capacity and duration
24 Number of inspection doors nos 2
25 Dimensions of access (mm x
openings of inspection doors mm)
Spray Nozzle for hydrated
26 lime a) Make / Model
b) Type
c) Spray cone angle
Spray Nozzle for water a)

27 Make / Model
b) Type
c) Spray cone angle
28 Spray Header Diameter (mm)
2.6 Fabric Filter 1 X100 % per
reactor/


& ITS AUXILIARIES

point
absorber
a) Manufacturer/Model
The fabric filter
bag house shall
b) Capacity NM3/hr be capable of
operating and
meeting
emission and
performance
guarantees with
one baghouse
compartment
off• line.
c) Pressure drop mmwg
d) Air/Cloth ratio
Max Particulate
e) Capacity (Guarant Matter PPM at
eed) outlet< 20PPM
Max Particulate
f) Inlet Solid Concentration PPM Matter 100
PPM at flue gas
when one ESP
cell out of
service + Dry
Lime Injection
quantity.
g) Outlet Solid Concentration ppm < 20
h)No. of filtration chamber
i) Design Pressure of each (kgf/cm2
Chamber /a)
j) Operating Pressure of each (kgf/cm2
Chamber /a)
k) Material Cloth
--Casing Material:PPS
--Cloth material
--Internals
l) Life of Cloth (hrs.)
m)Hopper storage capacity (if shall be of 8
required) hours minimum
n)Cleaning System Pulse jet type
cleaning system
shall be
provided.
o) Dimensions (m x m x Maximum
m) allowed Bag
Length


& ITS AUXILIARIES

point
should be
12m
Dry Lime storage & Handling
System
SDA - DRY FGD SYSTEM
2.6 SDA - REACTOR
1 Manufacturer
2 Manufacturer’s model
number
3 Quantity & type no/nos One (1) No.
4 Absorber Cross Sectional area (m2)
5 Absorber Dimension (mxmxm
)/diaxhei
ght
6 Height between support level (m)
to top of support steel
7 Number of water spray
levels(Working + Stand-by)
11 Efficiency of Venturi Nozzle %
12 Guaranteed SO2 removal (%)
efficiency
13 Dust Removal Efficiency (%)
14 Guaranteed pressure drop (mmwc)
across Gas System
15 Guaranteed oulet Temperature (oC)
16 Hydrated Lime Consumption (kg/hr)
17 Gas velocity through (M/sec)
Absorber
18 Gas Residence time in (sec)
Absorber
19 Proposed standard for
conducting the performance
tests
20 Material / Thickness (mm) of
base material & lining
21 a) Absorber mm
b) Spray Area mm
c) Spray Nozzles
i) spray piping etc.
Design pressure (mmwc)
22 Design temperature (deg C)
23 Max. temperature with stand (deg C)
capacity and duration
24 Number of inspection doors nos 2
25 Dimensions of access (mm x


& ITS AUXILIARIES

point
openings of inspection doors mm)
Spray Nozzle for hydrated
26 lime a) Make / Model
b) Type
c) Spray cone angle
27 Spray Nozzle for water a)
Make / Model
b) Type
c) Spray cone angle
28 Spray Header Diameter (mm)
2.6 Fabric Filter 1 X100 % per
reactor/
absorber
a) Manufacturer/Model
The fabric filter
bag house shall
b) Capacity NM3/hr be capable of
operating and
meeting
emission and
performance
guarantees with
one baghouse
compartment
off• line.
c) Pressure drop mmwg
d) Air/Cloth ratio
Max Particulate
e) Capacity (Guarant Matter PPM at
eed) outlet< 20PPM
Max Particulate
f) Inlet Solid Concentration PPM Matter 100
PPM at flue gas
when one ESP
cell out of
service + Dry
Lime Injection
quantity.
g) Outlet Solid Concentration ppm < 20
h)No. of filtration chamber
i) Design Pressure of each (kgf/cm2
Chamber /a)
j) Operating Pressure of each (kgf/cm2
Chamber /a)
k) Material Cloth
--Casing Material:PPS


& ITS AUXILIARIES

point
--Cloth material
--Internals
l) Life of Cloth (hrs.)
m)Hopper storage capacity (if shall be of 8
required) hours minimum
n)Cleaning System Pulse jet type
cleaning system
shall be
provided.
o) Dimensions (m x m x Maximum
m) allowed Bag
Length
should be
12m
Dry Lime storage & Handling
System
2.7 Dry Lime storage Silo
1 Quantity & Capacity Tons 1 no. & total 7
days storage for
each unit.
2 MOC of Silo Carbon steel
(ASTM A36
steel plate)
3 Thickness of main plate mm minimum 10
mm
4 Lining Material / Thickness SS lining of
grade SS304 of
minimum 4 mm
thickness
5 Size of Bottom Opening mm
6 Size of Top Opening mm
7 Height mm
8 Minimum Side Plate Angle Deg
9 Minimum Wall Angle Deg
vent filters shall
10 Vent be provided to
remove
collected dust
and return to the
silo using
compressed dry
air to pulse the
bags or
cartridges.
2.7 Surge Bin


& ITS AUXILIARIES

point
1 Quantity & Capacity Tones One No.
(ASTM A36
steel plate)
mm
grade SS304 of
minimum 4 mm
thickness
7 Height mm
vent filters shall
remove
collected dust
and return to the
silo using
compressed dry
air to pulse
the bags or
cartridges.
2.8 GRAVIMETRIC FEEDERS
1 Location at discharge of
surge bin
2x100%
gravimetric
2 Quantity nos/stora feeder shall be
ge silo provided for the
surge bin and
shall be sized to
meet
110% of the
maximum
capacity.
3 Size of Dry Lime to be mm
handled
4 Type of feeder Electro-
Mechanical
5 Design Capacity of Dry Lime tph
storage Silo to be handled
6 Design for operating hours hrs 24


& ITS AUXILIARIES

point
7 Drive margin over design % 15%
capacity
8 Constructional Features
stainless steel
a) MOC construction
b) Down slope of the tray 10° maximum
c) Type of mounting Foot mounted
type, mounted
on a number of
coil spring to
The feeder shall
d) Discharge arrangement have a
motor/pneumati
c operated gate
at the outlet.
2.9 Screw Conveyor
1 Location
2 Quantity nos/hydr 2x100%; each
ator of 110% of the
maximum
capacity
3 Material stainless steel
4 Type of feeder Electro-
Mechanical
5 Discharge The conveyor
shall have a
motor/pneumati
c operated
2.10 Hydrated Lime Silo
1 Quantity & Capacity Tones One (1) no.
(ASTM A36
steel plate)
mm
grade SS304 of
minimum 4 mm
thickness
7 Height mm
2.11 By Product Silo


& ITS AUXILIARIES

point
1 Quantity & Capacity Tones 1 no. & 1 days
storage
requirement for
the unit
(ASTM A36
steel plate)
mm
Freeboard m One (1) m
(min).
5 Silo bottom hopper mm conical and
minimum 60
degree from
horizontal
7 Height mm
vent filters shall
remove
collected dust
and return to the
silo using
compressed dry
air to pulse
the bags or
cartridges.
2.13 Air Compressors
1 Numbers (w+s)
2 Manufacturer/Model
AC motor
3 Type driven multi-
stage, oil free,
package type
rotary screw air
compressors
4 Rated Capacity
a) Flow (m3/hr)
b) operating pressure (kg/cm² 8.0 (Min)
(g))
c) Power (KW)
d) Efficiency (%)
5 Margin


& ITS AUXILIARIES

point
a) Flow (%)
b) Head (%) 10
6 Motor Rating (KW)
7 Design Ambient Conditions (oC / %)
(Temperature / Relative
Humidity)
8 Motor Details (volts/H2
)
9 Speed/Synchronous Motor (rpm)
speed/critical speed
10 Casing Type (mm)
11 Casing Material / Thickness (mm)
12 Casing Liner Materials / (mm)
Thickness
13 Weight of Rotating Parts (kgs.)
14 Weight of Static Parts (kgs.)
15 Type of Seal
16 Cooling Water Flow (m3/hr)
Requirement
17 Bearings
a) Number
b) Type
c) Lubrication
18 Type of Coupling
2.14 Process Water Tank
1 Quantity & Capacity m3 1 no.
2 Type Vertical
Cylindrical
3 MOC of Tank
4 Thickness of main plate mm
5 Lining Material / Thickness
6 Dimension (DXL) m
2.15 Process Water Supply Pumps
1 Numbers Each 2X100%
Unit
3 Type Horizontal
Centrifugal
4 Rated Capacity
a) Flow (m3/hr)
b) operating pressure (kg/cm²
(g))
c) Power (KW)
d) Efficiency (%)
5 Margin


& ITS AUXILIARIES

point
a) Flow (%)
b) Head (%) 10
6 Motor Rating (KW)
Humidity)
)
10 Casing Type (mm)
11 Material of Construction (mm)
a Casing
b Impeller
c Shaft & Shaft sleeve
d Base plate and foundation
bolts
e Wearing Rings
12 Type of Seal
Requirement
14 Bearings
a) Number
b) Type
c) Lubrication
15 Type of Coupling
2.16 Service Water Tank
1 Quantity & Capacity m3 1 no.
2 Type Vertical
Cylindrical
3 MOC of Tank
4 Thickness of main plate mm
5 Lining Material / Thickness
6 Dimension (DXL) m
2.17 Service Water Supply Pumps
1 Numbers 2X100%
3 Type Horizontal
Centrifugal
4 Rated Capacity
a) Flow (m3/hr)
b) operating pressure (kg/cm²
(g))
c) Power (KW)
d) Efficiency (%)


& ITS AUXILIARIES

point
5 Margin
a) Flow (%)
b) Head (%) 10
6 Motor Rating (KW)
Humidity)
)
10 Casing Type (mm)
11 Material of Construction (mm)
a Casing
b Impeller
c Shaft & Shaft sleeve
d Base plate and foundation
bolts
e Wearing Rings
12 Type of Seal
Requirement
14 Bearings
a) Number
b) Type
c) Lubrication
15 Type of Coupling
3.0 INSULATION AND
CLADDING
1 Area to be insulated per unit
b) Absorber Inlet Duct
c) Absorber
d) Absorber Outlet duct
f) Absorber Bypass Duct
g) Stack Inlet Duct
h) Total
2 Material Thermal
Insulation along
with aluminium
cladding
3 Insulating material standard
4 Thickness (mm) not be less than
25
5 Thermal conductivity of (Kcal/m/ as per IS : 8183
insulation material hr/


& ITS AUXILIARIES

point
deg.C)
4.0 FGD Sump Pump
a) Number 2x100%
b) Pump Type vertical sump
pump
c) Material of Impeller (mm)
d) Casing Material
e) Rated Flow Head (m3/hrs/
mWCI)
f) Slurry Solid concentration (w/w %)
g) Flow Margin % 10
h) frictional Head Margin % 15
5.0 Utility consumption list
a) Process water m3/hr.
b) Potable Water m3/hr.
c) Service Water m3/hr.

METTUR THERMAL POWER STATION-I

(4X210MW)
FOR
VOLUME – IIC
BALANCE OF PLANT
MECON LIMITED
RANCHI – 834 002


& ITS AUXILIARIES
INDEX TO VOLUMES
Volumes Title
Section 04.00 Special instructions to Bidder
Section 05.00 Scope of work, supply & Services
Section 08.00 Finalization of sub-vendors / sub-contractors
Section 10.00 Terminal points & Exclusion
Section 11.00 Layout and maintenance requirement
Volume -IIB Technical Specification
Section 01.00 Flue Gas Desulphurization System
Volume -IIC Balance of Plant (BOP)
Section 01.00 Water Supply Facilities System
Vol. – IIC INDEX TO VOLUME Page 2 of 3


& ITS AUXILIARIES
Volumes Title
Volume -VA Civil Works
Volume -VB Architectural Works
Volume -VC Structural Works
Volume -VI Mandatory Spares and Tools & Tackles
Volume -VII Tender Drawings
Vol. – IIC INDEX TO VOLUME Page 3 of 3

SECTION 01.00
WATER SUPPLY
FACILITIES

METTUR THERMAL POWER STATION- I (4X210MW)

& ITS AUXILIARIES
01.00 WATER SUPPLY FACILITIES
01.01 Scope of Work
The scope of work shall include design, engineering, fabrication, manufacturing,

assembly & supply, erection / construction / laying, commissioning, testing &
performance guarantee tests of plant & equipment and piping of complete water
supply facilities including technological structures, pipe-support structures, as
specified and required for the complete water system for the proposed FGD.
System as specified in this chapter as well as various chapters of this tender
specification complete in all respect on turnkey basis including civil & structural
works are included in scope of Bidder.
The scope of work shall include the following activities.
i) Design, engineering, manufacture / fabrication, assembly, shop testing, painting,

packing sequential delivery FOR site, unloading, unpacking, storage at site,
preparation & submission of all drawings for civil, mechanical, structural, piping,
construction & erection drawings, construction & erection as per approved
drawings, site-testing, painting, commissioning and fulfillment of guarantee
performance of all plant & equipment of water supply facilities for the proposed
FGD system including drinking water, process water system and water based fire-
fighting system.
ii) Supply of pipeline supports, R.C.C. pedestals etc. for overhead / on-ground /
underground pipelines.
iii) Supply of all technical literature, drawings & documents, general arrangement
drawings, assembly & sub-assembly drawings of all the plant & equipment,
construction & erection drawings, as-built drawings, operation & maintenance
manuals, manufacturing drawings, etc.
iv) Submission of all drawings at (iii) above, design calculations, data sheets for
various equipment, pipeline sizing calculation for approval of Purchaser/
Consultant and finalizing the same as per approval of Purchaser / Consultant. The
approval of the same however does not absolve the Bidder from his
responsibilities.
v) Supply of commissioning spares & consumables; a list there of shall be submitted
by the Bidder.
vi) Supply of special tools, tackles for construction, erection operation and repair &
maintenance of the plant & equipment.
vii) All necessary connections for hook-up with Purchaser’s system at battery limits.
Vol. – IIC, Section 01.00 WATER SUPPLY FACILITIES Page 1 of 42

& ITS AUXILIARIES
viii) Supply of erection, testing & commissioning equipment and material.

ix) Piping network flushing fluids, chemicals & consumables.
x) Inspection and performance testing of individual equipment and system as a
whole.
xi) Participation in design conference with the Purchaser & Consultant as and when
called for.
xii) The Bidder scope covers extension of fire-fighting line and drinking water line
from the battery limits to various consumer points of the proposed units.
xiii) Diversion of existing water pipelines if required for installation of the proposed
units covered under this package is included in the scope of work of the Bidder.
xiv) Supply of minimum 20% of valves and piping’s and other fittings etc., required
for minimum two years trouble free maintenance of the system.
01.02 Specification and Description of Work
Water System Facilities: Water system shall in general include the following
facilities for 4 nos. of FGD (Flue gas de-sulphurisation) system:
a) Process water system

b) Equipment bearing Cooling water system
c) Make-up/service water system
d) Portable water system
e) Water based fire-fighting system
f) Interplant pipelines
a) Process Water System
Process water (industrial grade) is for the consumptive water use of FGD system.
Process water for FGD system shall be tapped off from existing clarified water
network with an isolation valve and valve pit. For detailed TOP refer VOL-IIA/
Section 10.00
i) One number process water storage tank /FGD unit of 4 hours capacity has been
envisaged for each unit
ii) 02 nos. of process water pumps one working and one standby have been
envisaged for spray purpose of each unit
iii) Complete piping, fittings, supports, valves, instruments etc. will be provided.


& ITS AUXILIARIES
b) Equipments Cooling Water System
Each FGD system shall be having separate dedicated closed cooling water system
using DM water. Cooling water system shall consist of primary and secondary
circuits. Primary circuit shall be using DM water and secondary circuit shall be
using industrial quality water. For
secondary circuit, cooling supply water shall be tapped from existing auxiliary
cooling water (ACW) supply of each unit. Return water line from secondary
circuit shall be connected to existing hot water return header of that unit. DM
water re-circulating water pump sets (1 working+1 stand-by), plate heat
exchangers (1 working+1 stand-by), expansion tanks (MSRL), SS piping and
associated appurtenance etc. shall be envisaged for primary cooling water circuits
of each FGD system. DM water shall be tapped from the existing DM water
network with an isolation valve. Each tapping of ACW shall be from existing
corresponding ACW network with an isolation valve. For detailed TOP for both,
refer VOL-IIA/ Section 10.00.
c) Make up / Service Water System
Industrial water shall be required to meet the make-up water requirement of each
FGD system. This shall be common for all the FGD system. Make up water shall
be provided for the following:
i) Water tank . The capacity of service water tank shall be of approx. 1 hr.
ii) Air conditioning and ventilation system
iii) Process area viz, booster fan area, silo area, absorber area, etc.
iv) Miscellaneous water requirement viz. Plant washing, gardening etc.
In this circuit two pump sets (1W+1S) along with required associated
appurtenances shall be considered of adequate capacity & head to meet the
requirement.
Service water shall be tapped from nearby service water network with an isolation
valve and valve pit. For detailed TOP refer VOL-IIA/ Section 10.00.


& ITS AUXILIARIES
d) Portable Water System
Portable water is required to meet the drinking water needs of plant personnel.
Portable water shall be tapped from existing portable water network with an
isolation valve & valve pit. For detailed TOP refer VOL-IIA/ Section 10.00.
If the pressure, as indicated in battery limits parameters, is felt inadequate, Bidder

shall provide separate sump and drinking water pumps (1W+1S) along with
piping and electrics etc. to meet the requirement. Online booster shall not be
accepted.
Drinking water system shall be designed based on 30 persons/ shift catering two
different area having distance of approximately 500 meter.
e) Fire Water
Fire Water shall be tapped from existing fire header available at plant with an
isolation valve & valve pit. For detailed TOP refer VOL-IIA/ Section 10.00.
External hydrants will be Landing Valve type with single outlet 63 mm size as per
IS : 5290 Type A. Internal hydrant will be single outlet 63 mm size with
instantaneous female coupling as per IS : 5290 Type A.
Interval between two consecutive External hydrants: 45 m

Interval between two consecutive internal hydrants: 30 m
Minimum pressure required at highest / remotest landing valve: 3.5 Kg/cm²
Hydrant shall be provided with following.
Hoses:
(i) 2 nos. of 7.5 m long hose (RRL) as per IS: 636 shall be provided for each Landing
valves along with fittings.
(ii) 2 No. of 15m long hose (RRL) as per IS: 636 shall be Provided for each External
hydrant.
These will be kept in hose box (fabric reinforced plastic) along with branch pipe,
nozzle (20 mm bore size), spanner etc.


& ITS AUXILIARIES
Note:
1. All the hydrant valves, branch pipe, nozzles shall be of Stainless Steel.
f) Interplant Pipelines
Process water, Cooling water, Portable water &Service water network and fire
water network will be provided to various consumption points in the proposed
FGD plant. All the water lines including fire water, drinking water, will generally
be laid over-ground outside the buildings and on building columns inside the
buildings.
01.03 Design Criteria & Equipment Specification
Efficiency, reliability and flexibility of operation and maintenance will be the

guiding criteria of the design of the water system for the proposed plant.
01.03.01 Piping, Valves and Fittings
Cooling water pipes, Make-up water pipes, drinking water pipes and fire water
pipes shall be generally laid over- ground.
Make-up, fire and auxiliary cooling water pipes shall be of carbon steel with
beveled ends and drinking water pipes shall be of galvanized iron with threaded
ends & DM water pipes shall be of stainless steel (304L) with bevel ends.
Piping system shall be designed with high degree of reliability so that the systems
perform the duty of fluid handling without any failure under all conditions of plant
operation.
Piping layout must follow good engineering practice. Proper attention shall be
given to obtain full functional requirement of the piping system with a layout
which provides sufficient clearance for other equipment and operating personnel,
easy access for operation and maintenance, convenient supporting points and neat
appearance.
Complete design of piping system shall be subject to approval by the Owner/

Consultant.
The design shall take into account the effect of internal/external pressure, thermal
expansion, self weight of piping, support reactions, surge and water hammer,
earthquake and wind effects at site, corrosion and erosion etc. and any other
effects dictated by good engineering practices.
Piping systems shall not impose undue forces on equipment terminals.


& ITS AUXILIARIES
As far as possible all the pipelines shall be laid together along the piping corridor.
The piping corridor shall be parallel to and by the side of roads.
All pipes network shall be provided with manually operated valves for
isolation/controlling purpose. Valves for size 125 mm and above shall be gear
operated and valves of size above 450 mm shall be electrically operated.
The pipe network shall be provided with air release valves at high points and drain
valves at the lower points.
Pipeline passing under or through equipment foundations or walls of buildings or

any other inaccessible structure shall be provided with steel encasing pipes for
easy insertion and removal.
Valves provided on the over-ground pipe network shall be provided with steel
structural platforms and access ladders.
Pipe supports shall be capable of supporting the pipelines under all conditions of
operation.
Pipelines shall be generally laid over ground on the structural trestles as far as
possible, wherever it is not possible pipelines shall be laid in tunnels
/trenches/underground in this order of preference. All openings in the piping
shall be kept effectively closed until assembled in the system to avoid
foreign matter entering into the system.
Compensators shall be provided on the over-ground pipe network to take care

of thermal expansion.
Valves provided on the over-ground pipe network shall be provided with steel
structural platforms and access ladders.
As far as possible all the pipelines shall be laid together along the piping
corridor. The piping corridor shall be parallel to and by the side of roads.
Wherever over-ground pipelines are crossing roads and railway tracks, they
shall be laid on pipe bridges to provide the necessary clearance for the traffic
movement. This should take in to account the various type of vehicles likely to
move in the plant.
All the buried pipelines shall be laid with a nominal slope towards the drain point.
All the buried pipelines shall be laid as far as possible at a depth of about 1200
mm, below finished ground level (i.e. the top of the pipelines shall be 1.2 m below
the finished ground level).

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Isolation /control valves drain valves, air release valve provided on the buried pipe
network shall be housed in suitably sized covered valve pit and the valve pits shall
be of self draining type.
Wherever the buried pipelines are crossing the roads and tracks, they shall be
suitably encased with mild steel pipes or reinforced concrete casing pipes and the
different sizes of the encasing pipes shall be as given below:
Encased pipe Encasing pipe size, mm, Encasing pipe size,

diameter (for Flanged pipe) mm, (for welded pipe)
Upto 100 300 250
150 400 300
200 500 400
300 600 400
350 600 500
400 700 600
500 800 700
600 900 800
700 1000 900
800 1100 1000
900 1200 1100
1000 1400 1200
In case a number of pipes are crossing road or track, these pipes shall be laid in a
reinforced concrete culvert having easy access.
Coal tar based anticorrosion tape as per IS: 15337 – 2003 shall be provided for
protection of underground mild steel pipelines. The thickness of tapes shall be 3
mm upto pipe diameter DN 300 mm and 4 mm above pipe diameter of DN 300
mm.
01.03.02 Laying Buried Pipelines
All buried pipelines shall be laid with earth cover sufficient to avoid damage from
pressure of vibration caused by the surface traffic. Minimum earth covering over
the pipe shall be 1200 mm from the finished ground levels. For laying of buried
pipelines earth work in excavation, back filling and acceptance of trenches etc.
shall be as per IS: 5822-1994 and IS: 3114-1994 and IS: 12288-1987.
The trench shall be so dug that the pipe line can be laid to the required alignment
and at the required depth, proper leveling of the excavated surfaces is an essential
requirement.


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In case stones, boulders etc. are found at the bottom of the trench which cannot be
removed completely, the bottom shall be leveled by sand layer for a minimum
thickness of 150 mm.
If the depth of excavation is more, proper protection for side walls shall be
provided till the pipe leveling is completed.
The entire pipe trenches bottom shall be covered with local sand bed of 50 mm
thick layer.
After laying the pipelines, 150 mm thick layer of local sand shall be provided over
the sand bed.
Precautions shall be taken at all the times to prevent damage to the coating and
wrapping in the pipe lines and appurtenances as applicable by workmen or
trespassers during laying or at any other time. Pipe handling slung and any
blocking used in handling or storing the pipes must be well padded to avoid
damage to pipe and its coating.
After laying a pipeline on skids it shall be thoroughly cleaned, inspected and for
any damage to the protective coating, satisfactory repair work shall be performed
while the pipe is suspended above the trench.
Before laying the pipelines, the trenches shall be examined by the Owner and after
his approval only the pipes can be laid.
After the pipes are erected and tested, the back filling of the trenches shall be done
with loose soil free from stones, bricks and metallic pieces, in layers and shall be
well rammed and compacted.
RCC manholes with removable covers shall be provided for the buried gravity
network and the maximum distance between two manholes shall be 30 to 50 m
depending upon the pipe size. Manholes of adequate size shall be provided at all
pipe junctions.
Where the pipelines cannot be laid overhead on stockades and are crossing roads
and tracks at too many points in a given area, the pipeline may be laid in walk-
able tunnels.
Pipelines in tunnels shall be provided with isolating valves, air release valves and
drain valves, which are easily accessible for operation and maintenance. Gland
type of Compensators shall be provided on these pipelines wherever necessary.
Pipelines in tunnels shall be suitably ventilated and illuminated. There shall be

minimum two entries for the tunnel. Each tunnel shall be provided with at-least

& ITS AUXILIARIES
two vertical centrifugal, non-clog type drainage pumps (one working and one
standby) and these pumps shall operate automatically based on the liquid levels.
Each tunnel shall be provided with at least a monorail and hoist for erection and
maintenance purposes. Minimum height of the tunnel shall be of 2.2 m and
suitable walkway shall be provided for each tunnel.
Pipelines within the shop buildings shall be laid overhead supported form the
building columns/side walls/cranes girder etc. wherever this is not possible, the
pipelines shall be laid either in tunnel or in pipe trenches (covered with removable
slabs of chequered plates).
Wherever pipelines are crossing form one bay to another parallel bay, they shall
be laid in tunnel or supported from the gable end.
01.03.03 Pipe Specification
A) Black Pipes DN 15 to DN 50:
1. End condition : Bevel Ends

2. Class : Heavy
3. Material : IS:1239 (Part-I) 2004
4. Manufacturing : Seamless
B) Carbon Steel Pipes DN 65 to DN150:
1. End condition : Bevel Ends

2. Class : Heavy
3. Material : IS:1239-Part-I 2004
4. Thickness : As per IS: 1239
C) Pipes above DN 150 as per IS:3589-2001:
1. End condition : Beveled ends for butt welding

2. Material : Carbon steel, Gr. Fe 410
3. Thickness : DN200 – DN250: 6.35mm
: DN300 – DN450: 7.14mm
: DN500 – DN1000: 7.925mm
D) Carbon Steel G.I (Galvanised Iron) Pipes DN 15 to DN 150 as per IS:

1239-2004:
1. End condition : Screwed up to DN 50, Beveled ends for all the

Sizes above DN 50.
2. Grade : Heavy

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3. Material : Carbon steel, Gr. Fe 410
E) S S Pipe & Pipe Fittings
1. As per ASTM A 312 – Pipe, seamless ANSI B36.10, Schedule 40 (size

6mm-200mm)
2. As per ASTM A 358 – Pipe, welded, ANSI B16.9, Class 3000, Schedule 40,
Sizes more than DN250
3. SS butt welding fittings: ASTM A403 WP304, ANSI16.9
4. SS socket welding fittings: ASTM A182 WP304, ANSI16.11
Table for maximum Span of Supports
Nominal pipe size (mm) Maximum span for liquid services (m)
25 2.1
40 2.7
50 3.0
65 3.4
80 4.0
100 4.3
150 5.2
200 5.8
250 6.7
300 7.0
350 7.6
400 8.2
450 8.5
500 9.2
600 9.8
900 12.0
1000 15.0
Note: Vertical pipe work shall be clamped at intervals of 3.5m (approx.) and at
the base of each riser. Maximum span at the place of turning shall be 0.7 times of
normal span.
Dimensional Performance and End Finishes
Tolerance on outside diameter of the pipe and specified thickness shall conform to
the limits laid down in IS:3589-2001. Finish pipe shall not deviate from
straightness by more than 0.2% of the total length.


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Pipes to be butt welded shall be supplied with ends beveled to an angle of 30

degrees (+ 5 degree – 0 degree) measured from a line drawn perpendicular to the
axis of the pipe. The root face shall be 1.6 ± 0.8 mm.
Method of Quality Control in Welded Joints
Following steps shall be taken by the Contractor, besides controlling quality in

general, to make effective control in carrying out welded joints.
Welding procedures shall be prepared in line with IS: 7307 (Part – I) – 1974,
reaffirmed in 1991 and tests shall be carried out to quality procedures. Number of
procedures will depend on variables like positions of welding, thickness range etc.
Once a welding procedure is qualified, strict adherence to it shall be made during
actual welding.
Welders employed shall be qualified as per IS: 7310 (Part – I) – 1974, reaffirmed
in 1987 after passing necessary tests.
Welding consumables shall be of approved type. Such consumables are, however,

subject to qualifying initial check tests as per IS: 814-1991.
The Contractor shall strictly follow approved welding procedures during actual
welding. Besides, the following stages of inspection shall also be carried out:
Weld edge preparation before welding, proper fit up, position of welding, cleaning
of slag between the passes, proper weld profile etc., shall be checked visually
amongst others.
Non-destructive tests of weld of welded joints shall be carried out as per approved
procedures/ drawings.
Preparation of Joints
The Contractor shall prepare the edge correctly to the shape, size and dimensions
of the vee-grooves as per ANSI B-16.25 unless otherwise specified in drawings/
documents.
The welding surfaces shall be smooth, uniform and free from fins, tears, notches
or any other defect which may adversely affect welding and shall be free from
loose scale, slag, rust, grease, paint, moisture or any other foreign material. The
clean surface shall extend to about 10 mm beyond the welding faces to avoid
contamination of the weld metal with foreign material and to avoid unsound weld
deposit.
Assembly, Alignment & Welding


& ITS AUXILIARIES
The sequence of welding shall be so planned and followed that there shall be a
balance of welding about the neutral axis of the fabrication. The Contractor shall
employ sufficient number of welders working at the same time in diagonal
quadrants of the shell using back-step method of welding. The rate of progress of
each welder shall be more or less equal and quality uniform.
The general direction of welding shall be towards the free end of the joint, but in a
long joint as in shell fabrication, back-step technique shall be used to reduce
distortion.
To minimize internal locked up stresses due to welding, the vertical joints for the
shell shall be welded and completed to a circular course and then the horizontal
circumferential seam welded. However, before the welding of horizontal seam
started, the complete circular course shall be aligned and adjusted for their correct
axes.
Alternatively, the Contractor shall complete each course in all respect on ground
and then the pre-assembled course shall be listed and placed in position. In such a
sequence and planning, the same principle of balancing of weld about the neutral
axis shall be followed and the method of fabrication of each course shall be
similar to fabrication of penstock pipes of transmission/ industrial pipelines of
bigger diameter.
Pipe and attachment shall be aligned properly by accurate and permanent methods
prior to welding. If tack welds are used, the tack shall be either fused into the first
layer or weld or else chipped out.
Tests on welded joints
Visual examination
The Contractor shall conduct visual examination and measurement of external

dimensions of the weld for all joints. Before examining the welded joints, areas
close to it on both sides of the weld for a width not less that 20 mm shall be
cleared of slag and other impurities. Examination shall be done by magnifying
glass which has a magnification power of ten (10) and measuring instrument
which has an accuracy of ± 0.1 mm of by weld gauges. Welded joints shall be
examined from both sides. The Contractor shall examine the following during the
Visual examination: -
Check the correctness of shape and size of the welded joints
Incomplete penetration of weld metal
Influx

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Burns
Under cuts
Unwelded crates
Cracks in welded spots and heat affected zones
Porosity in welds and spot welds
Compression in welded joints as a result of electrode impact while carrying out

contact welding
Displacement of welded element.
The Contractor shall carryout any or all tests as specified hereinafter to satisfy the
Purchaser about the acceptability of the welded joints, as directed by the
Purchaser.
Liquid Dye-penetrant Test
Liquid dye-penetrant tests shall be carried out in accordance with IS: 3658-1981,
reaffirmed in 1991 for surface/ sub-surface defects.
Test by Blowing
The surface of the weld shall be covered with soap solution consisting of one (1)
litre of water and hundred (100) grammes of soap. Compressed air shall be blown
from the opposite side at pressure of 4 to 5 kg/cm2. The distance between the tip
of base and the weld shall not be more than 50 mm. Any formation of soap bubble
will indicate welding defects. Portable compressor shall be arranged by the
Contractor, if necessary, for this purpose.
Tolerance
Deviations for assembly of welded joints may be permitted to the following

extent:


& ITS AUXILIARIES
Tolerance
Sl.
No. Manual arc Automatic
a) Source butt-Joints
i) Gap between the ends of + 2.00 mm ± 1.00 mm
plates - 1.00 mm
1.00 mm 2.00 mm
ii) Stepping of one plate
over the other
b) Single Vee-groove Joints
i) Bevel angle ± 5 deg. ± 5 deg.
ii) Gap between two + 2.00 mm + 1.00 mm
- 1.00 mm
iii) Stepping of one plate 2.00 mm 2.00 mm
over other
c) Lap Joint
i) Overlap 5.00 mm 5.00 mm
ii) Gap between the surface 2.00 mm 1.00 mm
d) Tee-filler Joints
i) Gap between the edges of 2.00 mm 2.00 mm
the web and the surface of
the flange
01.03.04 Pumps
The pumps (horizontal as well as vertical centrifugal) will be designed,

manufactured and tested as per IS:1520-1980, IS:5120-1977 R.A.1991,
IS:9137-1978 R.A.1993 or as per international standards acceptable to the
Purchaser and will be suitable for the required duty conditions and capacities.
The pumps and their auxiliary equipment shall be suitable for the required duty
conditions and shall be designed and constructed for continuous duty at full load.
The centrifugal pumps shall be suitable for a capacity range of 25% to 125% of
duty point capacity.
The motor capacity shall have a margin over its BHP absorbed at the pump shaft
at duty point and the margin shall be 25% for motors of rating upto 15kW, 20%
for motors of rating 18.5kW to 160kW and 15% for motors of rating 200kW and
above.


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The equipment and auxiliaries shall be designed for quick and economical
maintenance. The equipment shall be easily dismantable without disturbing the
suction and delivery pipe connections.
The equipment design shall incorporate provisions for reduction in noise level.
The rotating elements of the pumps shall be checked for critical speed in bending
as well as torsion. The critical speeds shall be at least 30% away from the normal
speeds for units with flexible shafts and at least 20% away from the maximum
operating speed in case of stiff shafts.
All passages inside the pump casing and impellers, which may be inaccessible to
machining shall be ground to a smooth finish as far as practicable.
The direction of rotation shall be clearly marked either by incorporating it on the

casing or by separate metal plate arrow securely fitted to the casing.
The head – Vs – discharge characteristics of the pump shall be continuously rising

form the duty point to the shut off point without any zone of instability. The
required duty range for a pump shall be on the stable portion of its head capacity
curve close to the best efficiency point. The head developed at the best efficiency
point shall be close to the required differential pressure so that throttling is not
required at pump discharge. The power-Vs- discharge characteristics shall be non-
overloading type.
The pump shall be so selected and installed that the available NPSH is not lower
than the required NPSH even in the most adverse operating conditions.
The pump shall be of proven make and design having material of construction
which is the best of its kind for the particular application and shall be
manufactured using best engineering practices under strict quality control. Each
pump shall be tested as per the standards stipulated elsewhere in this document.
The test shall include hydrostatic test, static and dynamic balancing tests,
performance tests material tests and motor routine tests.
The pump shaft and bearing shall be adequately sized to take the unbalanced
forced due to mal-operation. The pump gland shall ensure proper sealing without
excessive tightening of the packing. Proper cooling and flushing arrangement for
the gland shall be provided wherever required.
All moving parts of the pump shall be adequately guarded to prevent any injury to
operating personnel.


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Pumps shall be designed and installed keeping in view the easy accessibility of its
parts for maintenance. All end suction pumps shall be of back-pull-out design and
shall be provided with spacer coupling of adequate length.
Mechanical seals shall be provided at all pumps envisaged for closed loop circuit.
Minimum no. of standby pump shall be provided for each group of clear water
pumps and drainage pumps as specified in the design criteria for pump house. The
group of Pumps for scale water or other abrasive slurries shall be provided with at
least two standby units. Special abrasion resistant material shall be used for these
pumps and the design shall allow easy replacement of parts subject to wear and
tear.
An isolating valve shall be provided on the suction line of each pump and another
isolating valve together with a non-return valve shall be provided at the delivery
line of each pump. Pressure gauges shall be provided at the suction and delivery
flange of each pump.
The suction pipeline shall be laid at a constant down ward slope from pump centre
line to the suction chamber. Reducers used in the line shall be eccentric type to
keep the top of the suction line straight.
Each pump shall be provided with adequate safety interlocks including overload
and dry running protection.
Dismantling joints shall be provided on the delivery side of large size pumps to
facilitate quick maintenance, wherever required.
All pumps shall be provided with suitable lifting attachments and each pump
installation shall have suitable handling facilities.
A clear minimum gap of 700 mm shall be maintained between the pump and the
adjacent piping, other equipment or structures for proper movement. In case the
height of the top most part of the pump from the working floor is more than 1.0 m,
the minimum clearance shall be increased to 1000 mm.
The details of pumps should match with the drive motors throughout the working
life of these equipments and to meet operational requirement. High-speed motors
of 3000 rpm shall not be used, as for as practicable. Working hour meter shall be
provided on control panels to monitor conditions and subsequent ageing / reduced
efficiency, etc.
Vibration readings, etc. of new installation shall be supplied.


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Pumps shall be installed and commissioned as per manufacturer’s instructions. A

continuous running for 72 hours shall be required before final acceptance is given
to the pumping installation.
Shop testing of pumps
All materials, casting and forging shall be of tested quality.
Pump casing shall be of robust construction and hydrostatically tested at 200% of

the rated pressure or 150 % shut off pressure, whichever is higher. The test
pressure shall be maintained for at least 15 minutes.
The impellers along with any other unmachined rotating parts shall be tested for
proper balancing in order to avoid undue vibration during operation.
Performance tests shall be carried on each centrifugal pump. Performance test

shall be made to determine the following.
The discharge against a specified head when running at a specified speed under a
specific suction head.
The power absorbed by the pump at the shaft (BHP) under the above-specified
conditions.
Efficiency of the pump under the above specified conditions.
Variation of required NPSH with discharge.
The pump accessories like bearings, couplings etc. shall be subject to shop tests as
per manufacturer’s standards.
The materials of construction of various components of all equipment and

material covered under the scope of his specification shall be certified by the
contractor with regard to their compliance to specifications laid down for them
under relevant clauses of applicable standards and /or the manufacturing drawings
of the contractor duly approved by the purchaser. Formal material test certificates
to the effect shall be issued by the contractor.
All test results and certificates including material test certificates shall be
submitted for approval to the purchaser before dispatch of equipment.
The vertical centrifugal pump sets shall be supplied with flange mounted vertical
motors, motor stool, base plate, coupling, column pipe, delivery pipe, suction
strainer, companion flanges, gaskets, bolts, nuts, washers, etc.


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A stainless steel name plate shall be furnished and securely attached by stainless
steel pins at an easily accessible point on the pump. The plate shall be stamped
with the following minimum information: -
- Name of Manufacturer
- Model No.
- Purchaser's item no. or tag No.
- Serial number of pump
- Capacity in cubic meters per hour
- Pumping head in meters of liquid column
- Specific gravity of liquid pumped
- Revolutions per minute
- Pump input power, kW
- Motor rating, kW
- Design code IS/IPSS:
Material of construction for pumps
A) Horizontal Pumps:

1. Description Water pump
2. Type Horizontal, single or multi stage centrifugal type

(all identical pumps shall be interchangeable)
3. Duty Continuous
4. Fluid to be Water
pumped


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5. Parameters:-Flow As per design guidelines contained in
& Head accompanying specifications
6. Preferred Speed 1500 (Synch)
rpm
7. Type of coupling Flexible coupling
8. Material of Construction
Casing Cast Steel , ASTM A 216 WCB
Impeller CF8M
Wear plate / LTB5
liners wear
rings
Shaft SS-410
Shaft Sleeve SS-410
Base Plate MS fabricated
Companion MS
flanges
9. Shut
\ off head Minimum 10
% above duty head.
10. Type of Mechanical packing in case of DM water &
packing Gland packing in case of IW/PW/FW
The above MOC is for guidance, MOC of all pumps will be subjected to
Purchaser’s / Consultant’s approval during detailed engineering.
Inspection & Testing
The tests to be conducted at shop for various sub-assemblies/ assemblies of

equipment shall include, but not limited to the following:
Material/ identification tests for all the components of the pump
NDT as indicated below:
(a) Impeller Dye Penetration Test (DPT)

(b) Shaft DPT and Ultrasonic test

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(c) Wearing rings DPT

(d) Impeller Dynamic balancing
(e) Pump assembly Visual inspection
III. Hydrostatic test:
Hydrostatic test shall be done for the following components at a minimum

pressure of 200% of shut-off head. The test pressure shall be maintained for at
least one hour.
(a) Bowl
(b) Suction bell
(c) Discharge head
(d) Column pipe
IV. Performance test:
Performance test shall be conducted on each pump with one of the actual drive
motors at the manufacturer’s works in presence of Purchaser’s representative as
per the requirements of the relevant test codes.
Performance tests shall be conducted at rated r.p.m. to cover the entire range of
operation of the pumps. These shall at least cover the range from shut-off point
upto 1.3 times the rated capacity of pumps. A minimum of 5 readings shall be
taken for capacity Vs Head, covering the above range. After performance test, the
pump shall be dismantled for inspection of internal components.
Mechanical run test shall be carried on all pumps to demonstrate smooth running
of the pumps, measurement of noise levels, vibration, etc. This test shall be
carried out at site also and the site test shall be taken for acceptance of the pump.
The noise lever shall not exceed 85 dB at 1.6 m distance from the pump of as per
the latest norm whichever is less.
The pumps shall be tested for vibration at the guarantee points. Vibration limit
shall be as per Hydraulic Institute Standard/ API 610.
The following tolerances shall apply for the performance tests: -
i) Rated capacity: +2.5% at rated head
ii) Efficiency at rated capacity: No negative tolerance
Test reports and manufacturer’s test certificates shall be submitted to the

Purchaser/ Consultant for approval.


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The final tests shall be conducted in the presence of the Purchaser’s

representative. Test certificates for different tests shall be made available to the
Purchaser during the inspection. Material test certificates for bought out items
shall be obtained from original manufacturer/ reputed test house. For all bought
out items, test certificates as relevant to the items shall be furnished by the
Contractor.
All the pumps shall be subject to stage inspection by the Contractor’s own
inspecting authority. However, Purchaser’s Inspector may visit the works from
time to time who should have free access to all the places of the manufacturing
premises where any part/ parts are under manufacture.
The Contractor’s inspecting authority shall have a close surveillance in respect of

the quality of job for the design dimensions, tolerances, surface finish, etc.
01.03.05 Valves:
Flow control /isolating valves, drain valves, air release valves and
Compensators, wherever necessary, shall be provided for the complete in-shop
pipe network.
All valves shall be suitable for service conditions i.e. quality of fluid, flow
temperature and pressure under which they are required to operate.
Valves shall be provided on pipe network for isolation of pipe section and
equipment, control of pressure and flow, venting, draining etc. They shall be
suitable located considering ease of operation and maintenance.
All valves shall be provided with hand wheel and position indictor. The face of
each hand wheel shall be clearly marked with words “Open” and “Shut” with
arrows adjacent to indicate the direction of rotation.
Valves shall be provided with suitable extension spindle and head stock
assembly wherever required. In case gears or bevel system are used , these
shall be of cast steel or suitable grade cast iron with machine cut teeth.
Non-return valves shall be Dual Plate zip check type and shall have a
permanent “Arrow” inscription on its body to indicate direction of flow.
Larger size valves shall be provided with by pass and drain arrangement.
Float operated valve shall be preferably be right angled pattern complete with
ball float, level and other accessories.


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Butterfly valves shall be of quotable flanged, tight shut of design with angular
travel of 90 deg. from open to shut off position.
MOC of valves for DM water service shall be suitably selected.
Specifications for Valves
The specification given below is for general guidance for selection of valves.
Final selection shall be subject to purchaser’s / Consultant’s approval.
A) Specification for cast steel butterfly valves
Manual Operation / Pneumatic Operation/Motor Operated
1 Type Wafer/flanged/lugged type Butterfly valve

for water supply pipe lines.
2 Body & Cover ASTM A216 Gr WCB
3 Disc SS, IS: 3444-1987, Gr 6/ 7 / A351 SS304
4 Seat, EPDM/ Neoprene integral with the body

Body/Disc
5 Pin Stainless Steel, AISI-410
6 Spindle SS, IS: 6603-72, 15 Cr 16 Ni 2
7 Bolting, internal SS
8 Bolting, Carbon Steel, (HT)

external
9 End connections Wafer /Flanged/ Lugged as per application
Motorised / Pneumatic valves shall be

flanged for all sizes.
10 Pressure rating PN = 1.6 N/mm2
11 Manufacturing IS-13095-1991/AWWA:C-504/ BS:5155/

Standard IPSS-1-06-012 / API 609
12 Hydro static Body:24 kg/cm2

testing Seat:16 kg/cm2
13 Test certificates Required for material/hydro test


& ITS AUXILIARIES
14 Service Water
15 Max. operating 60
temp Deg 0C
16 Type of Refer specification

operation
17 Operation Manual / Pneumatic(As and where
specifically mentioned)
Remarks- All valves above DN600 shall be supplied with SS 304 gaskets
with CAF fillers
B) Specification for Cast Steel Gate Valves
Manual Operation / Pneumatic Operation/Motor Operated
1 Type Non- rising type sluice valves for water

works
2 Body & Cover CS ASTM A216 Gr. WCB
3 Disc ASTM A216 Gr WCB Face fing 13% Cr
steel
4 Body seat ring 13% Cr. steel
5 Handwheel CI, IS: 210 FG 260
6 Pin Stainless Steel, AISI-410
7 Stem SS, IS: 6603, 12 Cr 13 04 Cr 18 Ni 10
8 Gaskets Neoprene rubber
9 Gland packing Rubber
10 Gear Alloy Steel, IS: 1570, 40Ni2Cr1MO28Gr B
11 Gear housing Cast Steel, IS: 1030, 230-450 W
12 Pinion & pinion SS, IS: 6603
shaft
13 End connections Flanged
15 Manufacturing IS-14846-2000 / equivalent international

Standard standard


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16 Hydro static Body:24 kg/cm2

testing Seat:16 kg/cm2
18 Service Water
19 Max. operating 100 Deg 0C
temp
20 Type of Upto DN125- Lever operated
operation Beyond DN125- Gear operated
21 Operation Manual / Pneumatic(As and where
specifically mentioned)
C) Specification for Pneumatic Actuator:
a) Pneumatic Actuators shall be of double acting type for on/off operation and shall
be directly mounted on the valve. Single acting type shall be considered for
fail/safe operation
b) Each pneumatic actuator shall be supplied with
 Single solenoid common for both open &close operation.
 Valve position indicator- Mechanical type.
 Facility for emergency manual operation.
 SS tubing of 3.00 m length along with isolation valve and suitable end
connections for connecting it to ½” MS pipe by welding complete with required
pneumatic tube fittings for connection to dump valve and ½” MS Pipe.
 Open and close position, proximity switch, 2-wire, universal type

(AC/DC),PLF,IFM make, wired up-to a junction box.
c) All the above accessories shall be mounted on / connected to the valve.
 Actuator shall be capable of operating the valve when the air pressure is 6 Kg/cm2
and shall be able to operate the valve even when the air pressure drops to 4.5
Kg/cm2.
 Each actuator shall be supplied complete with two or one way solenoid valves of
¼” pipe size. Material of construction for body shall be Brass.
 Solenoids for all solenoid operated valves shall be suitable for 20 to 240V AC/DC

& ITS AUXILIARIES
power (Universal type).
 The enclosure class of solenoids shall be IP65.
 For termination of cable to the solenoid, proximity switches junction box shall be
provided by supplier. Terminals shall be suitable for terminating 2.5 sq. mm
copper conductors. 20% spare terminals shall be provided in the junction box.
 Apart from other tests, performance test for pneumatically operated valves with
respective actuators mounted in position to show valves opening and closing and
observation of leakage shall be conducted.
D) Specification for Ball Valve / Full Bore / 2 Way / 3 Way
1 Type three piece, Reduced bore, floating ball, PTFE

seated
2 Body, Cover & Gland CS as per ASTM A216 WCB
3 Ball SS , ASTM A 351, Gr. CF 8M
4 Stem AISI 316
5 Fasteners HT, SS 304 only
6 Gland Packing 35% Carbon Filled PTFE/ Graphite

7 End connection Socket welded / Flanged ( Refer Detailed
Valve List)
9 Manufacturing BS 5353/API 599

Standard
11 Service For instrument fitting, air vent and for
regulation purposes.
12 Max. operating temp 100 Deg 0C

13) Remarks- Socket weld connection with nipple pipe of 100mm welded on all
openings
E) Specification for Air Release Valve
Air release valves shall be cast iron, single large orifice type, with flanged ends.
Air release valve shall conform to IS: 14845-2000.
1 Type Air release valves shall be cast iron, type S1 &

S2 upto diameter 50 mm and type DS1 above

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diameter 50 mm and upto diameter 200 mm IS:

14845-2000.
2 Body CI FG 210 as per IS:210
3 Body seat ring Gun metal IS:318 LTB-2
3 Float Timber core with vulcanite/ rubber coating
4 Disc Gun metal IS:318 LTB-2
5 Stem SS, IS: 6603, 04Cr17
6 Disc nut Gun metal IS:318 LTB-2
7 Bolts/studs, nuts Carbon steel IS:1367
8 Gland CI FG 200 as per IS:210
9 Gland packing Graphited asbestos/ jute/ hemp
10 Air release nipple Gun metal IS:318 LTB-2
11 Gasket Compressed asbestos Fiber 3 mm thick
12 Rubber ball Vulcanite Ebonite
13 End connection Screwed up-to DN40 and flanged for DN50 &
above
14 Pressure rating PN 1.6 N/mm2
15 Test pressure Body : 24 kg/cm2
Seat : 16 kg/cm2
Test duration : 30 minutes
F) Specification for Companion Flanges
1 Type Raised face plate flanges, Slip-on, welded,

plate fabricated, machined finish.
2 Dimensional Standard As per IS-6392-1971(RA'88), PN=1.6 /1.0

N/mm2 as per valve rating, Table-17/11, drilled
off centre, RF.
3 Material C.S as per IS-2062 -1992 GR.A.
Note: Valve flanges and matching flanges shall be drilled as per
IS:6392-1971 (RA'1988), table 17 for PN 1.6.
G) Specification of Actuator for Motorized Valve
1 MAKE ROTORK/AUMA/LIMITORQUE/
APPROVED
2 OUTPUTMOTION ROTARY
3 OPERATION TIME 90 SEC (MAX)
4 SERVICE INLET PR.-8.5 Kg/cm2 (MAX)/ as per System
CONDITION requirement
INLET TEMP.-40 deg.C max.
FLUID – WATER

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5 ACTUATOR SHALL BE SUPPLIED COMPLETE WITH THE

FOLLOWING
A HANDWHEEL FOR MANUAL OPERATION
B POSITION INDICATOR
C OPEN/CLOSE LIMIT SWITCHES
D TORQUE LIMIT SWITCHES
E EACH LIMIT SWITCH SHALL HAVE 2 NO / 2 NC CONTACT

SWITCH FOR 10 AMP. AT 240 V
F MOTOR TERMINALS AND LIMIT SWITCH CONTACTS SHALL
BE WIRED UPTO A TERMINAL BOX TO BE MOUNTED ON THE
VALVE ACTUATOR
H) Motor Specifications
1 Make & Type ABB/NGEF/BHARAT BIJLEE/KEC/

APPROVED & 3 PHASE,4 WIRE, SQUIRREL
CAGE, INDUCTION MOTOR
2 Supply Conditions 415 V AC + 10%, 50 C/S + 3% -6%
3 Control Voltage 240 V
4 Protection IP-65
5 Enclosure TEFC
6 Duty Condition S2, 30 MINUTES
7 Class of Insulation `F' Temperature rise limited to class-B
8 No. of Starts/hr 60
Allowed
9 Design Performance As per IS:325-1996
10 Breakdown Torque Minimum 2.5 TFL or higher
I) Specification for Cast Steel Dual Plate Zip Check Valve
1 Type Dual Plate Zip Check Valve

2 Body ASTM A 216 Grade WCB
3 Plate ASTM A 351 Gr. CF8 M (SS 316)
4 Stop Pin AISI SS 410
5 Hinge pin AISI SS 410
6 Spring INCONNEL
7 Retainer CF8M (SS 316)
8 Body Bearing AISI SS 316
9 Plate Bearing AISI SS 316

10 Spring Bearing AISI SS 316

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11 Eye Bolt Carbon Steel

12 Body Seal EPDM
13 Plate Seal Integral
14 Body Test Pressure 450 psi (g)
15 Seat Test Pressure 320 psi (g) (Max.) / 285 psi (g) (Mini)
16 Design Standard API 594
17 Dimensions As per API 594
18 Testing As per API 598
19 Special features 1. Arrow indicating the flow direction.
required 2.Embossed name plate giving details of tag No.
size, etc.
20 End Connections Wafer/ Flanged as per Valve list
J) Specification for Online Filter/ Duplex Filter
Duplex basket filter shall be of cylindrical MS fabricated construction with

manual change over mechanisms.
Duplex arrangement with built-in valves shall be such that one element will
always remain in operation ensuring continuous uninterrupted supply of filtered
water from each strainer. It should not be possible to isolate both the strainers
simultaneously due to even inadvertent rotation of hand wheels for movement of
valve disc during change over from one basket to another. The changeover valves
shall be manual.
Basket Filter bodies and internals shall be designed to withstand design pressure
with normal surges.
Pressure equalizing connections for both the chambers shall be provided for
smooth changeover.
Two nos. dial type pressure gauges size 150 mm dia shall be provided suitably
mounted at the inlet and outlet mains of each filter with 1.0% accuracy and 3 way
gauge cock. This will be purchased separately and not included in the scope of the
tenderer.
Differential pressure switch with alarm contacts shall be provided for filter unit of
the main strainer across inlet and outlet for operation at a differential pressure
adjustable within 0-1 kg/cm2.
Indication lamps shall be provided to indicate ON-OFF status, clogged condition

of filter element, completion of changeover, etc. Differential pressure switch shall

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be provided with 3-valve manifold. The dead band shall not exceed 60% of gap
between set value and normal operating value. This will be purchased separately
and not included in the scope of the tenderer.
Flush drain valve and vent shall be provided for each unit of the main filter. The
design of the filter shall be suitable for easy maintenance and replacement of the
parts and inspection.
Strainer shall be provided with basket opening area (six times of pipe cross
section area or bigger) to ensure high flow volumes at low pressure and a long
service life.
Provision shall be made for collection of drainage water from the strainers and
shall be suitably connected to the plant area drainage system.
Along with the offer the Tenderer shall furnish details of the basket filter such as
make, general arrangement and cross-sectional drawings, operating parameters,
materials of construction of various components supported by manufacturer's
literature and catalogues.
Carbon steel Valves to be supplied as part of the duplex filters shall conform to
the following standards. Pressure rating of all valves shall be 16kg/cm2.
Butterfly valves : BS 5155/ API 609/ IS-13095,1991/AWWA:C-504

Globe valves : IS: 778-1984 reaffirmed in 1990/ BS 1873.
K) Specification for Plate Heat Exchanger
The heat exchanger unit shall consist of gasketed plates supported in frame
capable of being opened and closed. The frame provides structural support as well
as pressure containment for the gasketed plates and consists of frame plate,
pressure plate, guide bar, & carrying bars, closing studs/nuts and carrying bar
supporting columns.
The frame shall be designed to permit future installation of 30% additional plates.
Individual channel plates of heat exchanger shall have to pressed / formed in
single mechanical operation.
Each plate heat exchanger shall be designed for full pressure in each stream
having no pressure on other stream.
The heat transfer coefficient in clean condition should not exceed 6500
K.cal/m2.hr.degC


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While designing heat exchange area and number of plates, cleanliness factor on
account of fouling shall be considered as 20%.
Carbon steel components in contact with fluid system shall have a corrosion
allowance of min 3mm. All the threaded hardware items like studs and nuts shall
be zinc coated.
Minimum thickness of stainless steel plate shall be 0.5 mm.
The heat transfer area per plate should not exceed 85% of the total plate area.
Frame plate is the primary stationary end of the plate heat exchanger. All nozzles
shall be located on frame plate.
Inspection openings shall be provided on the pressure plates. These openings shall
be blanked by providing blind flanges. Ball valves shall be provided on the
bottom blind flanges for drain purposes. Handles are to be provided on all the
blind flanges.
All nozzles on the frame plate and inspection openings on pressure plate shall be
provided with stainless steel sheet lining conforming to AISI 316.
Pressure plate shall be supported in a roller bearing hanger from the carrying bar.
Pressure plate shall move along the carrying bar and shall be guided by the
guidebar.
The carrying bar shall be welded /bolted to the frame plate and carrying bar
support column. A stainless steel tee section shall be welded /bolted to the
carrying bar to provide mounting member for the plates of the plate pack. A
smooth surface shall be provided for roller bearing carrying grove for the whole
length of the carrying bar. Carrying bar shall be designed to support 1.5 times the
weight of the flooded exchanger along with pressure plate, tie rods, nuts and
nozzles.
Guide bar shall be welded /bolted to the frame plate and carrying bar supporting
column. It shall be sheathed in stainless steel on the 3 surfaces coming in contact
with the plates and is a guide bar only for the plates.
The gasket material’s compressibility, recovery, adhesive to metal, hardness etc.

shall be consistent with design of the equipment to provide a leak tightness barrier
between the two streams. The Gasket arrangement shall be such that one side is
fixed to plates to received continues support & to avoid the displacement from
the gasket grove. The Heat transfer plate gaskets shall allow longer operating time
without replacement.
Minimum diameter of tie rod shall be 19 mm.


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Carbon steel plates shall be as per IS 2062 Gr.B or Equivalent.
Plates having thickness of 16 to 50 mm shall be examined ultrasonically as per

ASTM A 435.
The heat exchangers shall be designed, manufactured and tested as per ASME
code Section VIII, Div. 1 and shall be suitable for the duty conditions and
capacities as indicated in the Annexure-I .
The plate heat exchangers along with their auxiliary equipment shall be suitable
for the required duty conditions and shall be designed and constructed for
continuous duty.
The equipment and auxiliaries shall be designed for quick and economical
maintenance. The equipment shall be easily dismantle without disturbing the
inlet and outlet pipe connections.
A stainless steel name plate shall be furnished and securely attached by stainless
steel pins at an easily accessible point on each plate heat exchanger. The plate
shall be stamped with the following minimum information:-
Purchaser's item no. or tag in 15 mm high letters.
Serial number of plates heat exchanger
Capacity in cubic meters per hour both for primary & secondary sides.
Temperature ranges for primary & secondary liquids.
Pressure drop in Primary & Secondary sides
Design code.
Inspection & Testing
The tests to be conducted at shop for various sub-assemblies/assemblies of

equipment shall include, but not limited to the following:
Material test
Testing during manufacture/fabrication like dye penetration tests on randomly

selected plates, high intensity light check for plates
Dimensional checking

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Hydrostatic tests
Ultrasonic test for the plates used for frame and pressure plates.
All the plate heat exchangers shall be subject to stage inspection by the successful
Tenderer's own inspecting authority. However, Purchaser's Inspector may visit the
works from time to time who shall have free access to all the places of the
manufacturing premises where any part/parts are under manufacturer.
The successful Tenderer's inspecting authority shall keep a close surveillance in

respect of the quality of job for the design dimensions, tolerances, surface finish
etc.
Before giving call for final inspection, all the documents shall be furnished to the
Purchaser. The record of manufacturing details, inspection and tests carried out
by the successful Tenderer shall be made available to the final Inspecting
Authority. However, approval and final inspection at the manufacturing works
shall not relieve the successful Tenderer of responsibility of replacing at his cost
any defective part/material which may be detected by the purchaser during
erection and commissioning or guarantee period.
Hydrostatic test shall be carried out at 1.5 times the design pressure maintaining
test pressure for a minimum of 60 minutes. Testing shall be done by pressurising
each side separately.
The final tests shall be conducted in the presence of the Purchaser's representative.
Test certificates for different tests shall be made available to the Purchaser.
Material test certificates for bought out items shall be obtained from original
manufacturer/reputed test house. For all bought out items, test certificates as
relevant to the items shall be furnished by the successful Tenderer before the
equipment is offered for final inspection.
Wherever required, all tests shall be done as per relevant Indian Standards. In the
absence of the Indian Standard, the equivalent internationally reputed standards
shall be followed.
Painting
Surface of the heat exchanger frame work shall be cleaned to near white metal
conforming to Sa 2 1/2 of Swedish Std. SIS 055900 or German Std DIN 55928
(Part-4)
After surface preparation, the plate heat exchanger shall be painted as per the
manufacturer’s standard.

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Acceptance Tests
Acceptance tests shall be carried out by the successful Tenderer after

commissioning. These tests shall be performed according to code of practice of
HEI /HTRI of USA or other mutually agreed procedure in the presence of
Purchaser's representative. All instruments required for the test shall be arranged
by the successful Tenderer. In Case during the tests the heat exchanger
performance falls short of guarantee figures, the successful Tenderer shall bear all
expenses of improving the performance of the heat exchanger and shall carry out
another acceptance test at no extra cost. In case the performance is again
unsatisfactory, the successful Tenderer shall be liable to replace the subject
equipment by new and better equipment at no extra cost without affecting the
overall schedule of the commissioning of the Main Plant.
Guarantee
All equipment shall be guaranteed for good workmanship, no material defect and
the design parameters till a period of 12 months from the date of successful
commissioning or 18 months from the date of despatch whichever is later.
The successful Tenderer shall stand guarantee that the heat exchanger shall cool
the required quantity of primary water with the specified quantity of secondary
water to the temperatures stipulated in Annexure A of this technical schedule. The
successful Tenderer shall also guarantee the agreed pressure drops across the
primary & secondary sides of heat exchanger. In addition, all items of the heat
exchanger are to be guaranteed in respect of material and workmanship. Any
defects found during warranty period shall be rectified to the complete satisfaction
of the purchaser at the successful Tenderer's cost.
L) Specification for Expansion Tank/ Surge Tank
Vessel shall be designed to meet the operation and performance requirements as

furnished in respective Process Data Sheets.
Codes and Standards
The following codes shall be referred during the fabrication of pressure vessels
and tanks.
Boiler and pressure : ASME SECTION VIII DIV.1 Vessel Code
Welding : ASME SECTION IX
Pipe Flanges : ANSI B 16.5
NACE Standard : MR 01-75 (Latest Edition)


& ITS AUXILIARIES
And any other Codes / Standards / Specifications mentioned / furnished in the

subsequent clauses of this technical specification.
The design / engineering work related to preparation of fabrication drawings, weld

joint and weld details, etc. shall be in Tenderer’s scope of work.
Tenderer shall furnish the capacity and design calculations for thickness of all
major components like shell, head, nozzles etc. for approval prior to
manufacture/fabrication. In case of any alteration in material or thickness,
Contractor shall seek Purchaser’s written approval. For CS vessels, the shell or
head thickness exclusive of C.A. shall be taken, even if pressure/ load
requirements may suggest lower thickness. Non pressure carbon steel parts (e.g.
Skirt, lugs, Cleats, etc.) shall have a provision of 1.5 mm corrosion allowance.
Plates shall be bent along the direction of plate rolling for forming the cylindrical
components of vessel. Plates shall have only positive tolerances on thickness.
Carbon content of C.S plate shall not exceed 0.25%. One product analysis per
heat shall be supplied.
All vertical & horizontal vessels shall be provided with lifting lugs.
Reinforcing pads for internal or external structural attachments to vessels shells

shall be provided with a ¼”. NPT vent hole. External vent holes shall be plugged
with a plastic sealant after the vessel has been tested.
All pressure vessels weld joints of category A and B shall be welded with full
penetration and full fusion. Welds shall be as per ASME Code Section VIII
Division 1, Table UW-12, NO.1.
Vessel Supports
The type of supports for vertical vessels shall be as indicated in the specification.
Access opening in skirt, vent holes and piping opening shall be provided in
supporting skirt as per enclosed standard specification.
Skirt and adjoining vessel shell outside diameter shall be the same.
Nozzles and Manways
When the inside diameters of nozzles are specified, these shall be maintained.
When the inside diameters of manways are specified, it shall be considered as a
minimum.


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Nozzles, openings and their reinforcements shall be attached to the vessels with
complete penetration welds.
Nozzles upto and including 50mm NB in size shall be stiffened by 2 nos. 40 x

6mm thick flats welded at 90° apart.
Nozzle flanges shall be as per ANSI B 16.5 type and rating as specified.
Substitution of W.N. type flanges with Slip-on type will not be permitted.
All manhole covers shall be hinged or provided with a davit along with suitable
lifting handle. Bolts, Nuts, Gaskets including spares shall be in Tenderer’s scope.
External reinforcing pads shall have a minimum of one vent hole except those
pads for nozzles greater than 400 mm NB shall have a minimum of 2 vents and
nozzles in excesses of 900mm NB shall have 4 vents. Pads installed by sections
shall have at least one vent per section. All vents shall be tapped for future
plugging and plug shall have ¼” NPT connection (max).
Class 300 flanges shall be used as a minimum, unless mentioned otherwise for
pressure relief valve connection.
For heavy wall thickness vessels, integrally reinforced necks are preferred,
although long welding neck flanges and built-up construction are permissible.
Where 125 Ra is specified for flange surface finish, the range for acceptance shall
be 63 Ra minimum to 250 Ra maximum. Finishes shall be judged by visual
comparison with surface finish roughness standards conforming to ANSI B46.1.
Where flange surface finish is not specified, it is the responsibility of the Tenderer
for the gasket specified. Fabricator shall ensure suitable protection of flange faces,
threaded connection, and machined surfaces, during transit.
Lap joint flanges are not permitted in severe cyclic service. An example for sever
cyclic service is defined in paragraph 300.2 of ANSI / ASME B 31.3 piping code.
All flanges intended for use with spiral wound metal gaskets shall be designed
using the manufacturers minimum gasket seating stress or the ASME Code value,
whichever is greater.
The Contractor shall give special consideration for the prevention of over
stressing the flange or bolts during gasket seating, when class 300 and lower
flanges are used with spiral wound metal gaskets.
Nozzle and manways shall not be located in tray down comers.


& ITS AUXILIARIES
All opening shall be cut off flush with the inside on the shell and the inside edge
shall be rounded.
Threaded fittings of tapped holes are not permitted.
Internals like distributor piping, deflector, vortex breaker, tray support rings,
demisters etc. are in Contractor’s scope, including bolting and spares. Details of
demister such as make, make type etc. shall be subject to MECON / Purchaser’s
approval during detailed engineering.
Externals like manhole davit, pipe davit, insulation supports, Pipe supports,
stiffening rings, fire proofing supports, name plate, etc. are in Contractor’s scope,
unless mentioned otherwise.
Sizes of nozzles for safety valve shall be indicated during approval of G.A
drawings by MECON / Purchaser. Contractor’s scope shall include supply of
nozzles with flanges, etc.
Nozzle orientation shall be subject to MECON / Purchaser’s approval during

detail engineering.
Materials
All materials used in the vessels shall be new and of the type and grade specified
in the specifications / drawings. All plates shall be supplied in normalized
condition.
Materials of construction of vent stack and seat drum shall be selected as per the
requirement of NACE, MR-01-75.
Each plate or forging shall be legibly stamped or stenciled showing grade number
and plate or forging number. When metal stamping is done it shall preferably be
on the long edge of each component as it leaves the mill. Metal stamping on rolled
surfaces shall be done with a “low stress” stamp.
Internal support rings shall be of the same material as the shell in killed steel
vessels unless otherwise mentioned, except in lined portions of vessels where they
shall be alloy corresponding to the lining. They shall be continuously welded on
the top and stitch welded on the bottom when carbon steel and continuously both
sides when alloy.
Plates form 16 to 50mm shall be ultrasonically tested as per SA 435 and above
50mm as per SA 578 for an Acceptance Level-1. All bought out items by
fabricator shall meet the relevant inspection requirements and test certificates.


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Fabrication
Vessels heads may be deep torispherical or 2:1 semi-ellipsoidal. Plate thickness

selected for vessel heads shall include due allowance for thinning during the
forming operations.
Dished ends in vessels upto 2.0m shall be made in one piece. When a formed head
is made from more than one plate, it shall have a crown plate having diameter
greater than that of the reinforcing pad of any nozzle located at the center of the
head. The central part of cordial seam blank shall be atleast 50mm or 3 times plate
thickness away from the beginning of knuckle curvature. The inside and outside
surfaces shall be MP/DP examined for detection of cracks.
Fabricator shall check for possible fouling / clash or attachments with each other
and with weld seams. Such fouling shall be resolved in consultation with the
Purchaser.
Skirt and other attachment welds shall have complete fusion for the full length of
the weld, and shall be free from undercut, overlap, or abrupt ridges or valleys. All
internal attachment welds shall be continuous, unless otherwise mentioned.
Edges shall be prepared after cutting, machining or grinding to eliminate

defective material or discoloration. All welding edges of above 25mm thickness
and the welding edges of dish ends of all thickness shall be checked by MP/DP
examination for detection or cracks, bruntations or segregations.
Drawings and instruction for fabrication and installation or tray and mesh blanket
supports attached to the vessel shall be furnished by the appropriate supplier of the
vessels internals. The vessel attachments shall be installed in accordance with the
instructions, and specifications, by the vessel manufacturer. It is the responsibility
of the vessel manufacturer to supply, or cause to be supplied, all materials
required for the fabrication of the vessel attachments for the support of internals.
Insulation supporting lugs / rings / pins / studs at a pitch of 300 mm over vessel
surfaces shall be provided wherever applicable.
Welding
All welding shall be done by a metal arc process. Only approved WPS, and
qualified welders shall be engaged.
Covered welding electrodes for non-alloy welding shall be in accordance with

specifications AWS A5 . 1, ASME SFA-5.1.
Bare electrodes shall be in accordance with the following :-


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Welding Process Electrode
Submerged Arc Welding AWS A 5.17, ASME SFA-5.17
Inert Gas Welding AWS A 5.18, ASME SFA-5.18
Flux-cored Arc Welding AWS A 5.20, ASME SFA-5.20
Deposited weld metal mechanical properties shall conform to the ASTM

requirements for the base metal.
Backing up strips, if used, shall be removed. Circumferential welds shall be so

located that visual inspection can be made with all internal equipment in place.
Seams in supporting skirts shall be made with full penetration butt welds.
Connections between skirts and vessel heads shall be made with a smooth flat
faced weld, unless otherwise shown. The width of the weld shall be atleast equal
to the skirt thickness, and its height shall be twice its width.
All welding directly t the vessel shall be completed prior to final treatment.
All welded joints for vent stack & seal drum shall be 100% radiographed. As a
minimum requirement all other pressure vessels shall be spot radiographed
(minimum 10%). Each spot radiograph shall be a minimum of six inches (152
mm) in length and in accordance with the ASME code. All welds to be covered by
nozzle reinforcing pads and at least one weld intersection shall be radiographed.
Non-radiographable welds shall be examined by magnetic particle or dye
penetrant as a acceptable alternative.
For vessel shell thickness 2 inch (50 mm) and greater, 100% ultrasonic
examination is required in accordance with the ASME code, after final post weld
heat treatment.
Heat Treatment
Vent stack & seal drum shall be stress relieved after welding to meet the required
hardness etc. as per the NACE stipulations.
For carbon steel formed components, including dished ends, stress relieving shall
be performed as per ASME Section VIII Div. 1, (UCS – 79).
In addition, cold formed carbon steel heads and knuckles shall be stress relieved
when their thickness is 16 mm or greater. Hot formed heads shall also be

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normalised in case they are formed at temperatures below the normalizing range.
Hot formed dished ends or similar parts, which have not been uniformly heated in
the normalizing range in the final stages of manufacture shall be normalized.
Vessels in caustic service, amine or sour gas service shall be stress relieved.
Flange facings must be protected against oxidation during heat treatment.
Painting
Vessels shall be cleaned by sand blasting prior to painting to Sa 2 ½ grade.
All uninsulated carbon steel surfaces shall be given two coats of epoxy zinc
chromate primer (P-5) with min. DFT of 35 microns per coat followed by two
coats of acrylic polyurethane finish coat (F-2) with min. DFT of 30 microns per
coat.
For insulated carbon steel surfaces, (i.e. Test storage tank) two shop coats of red
oxide zinc chromate primer (P-1) with min. DFT of 35 microns per coat shall be
given.
Earthing lugs shall only be cleaned by wire brush and not to be painted.
Sand blasting is not required for internal surfaces of vessels. Only wire brush
cleaning is required for the same. However, wherever internal surface painting has
been specified, i.e. in Test storage tank, sand blasting will be required.
01.04 Erection, Testing and Commissioning for Utilities
1. The erection of all plant and equipment shall be carried out according to the latest
engineering practices and according to the drawings, specifications, Instructions
etc. duly approved by the Purchaser / Consultant.
2. The welding work should be carried out as per the approved WPS and PQR.
3. The Bidder shall supply all required manpower, tools and related equipment, all
hoisting equipment, all necessary scaffoldings, all necessary transporting
equipment, consumables. Construction and erection materials, petrol, diesel oil,
kerosene, solvents, sealing compound, tapes, brazing and soldering materials,
welding and brazing gases, erection bolts, nuts and packing sheets / compounds,
temporary supports, wooden blocks, spacers, templates, jute and cotton wastes,
sand/emery paper etc. as required for the satisfactory completion of work.
4. On completion of the work, the Bidder shall remove and dispose off all rubbish
and other unsightly materials caused by his working to a distance of five kilometer


& ITS AUXILIARIES
from the proposed Refractory store or as directed by the Purchaser and thereby
leaving the premises in good, clean, safe and operable condition.
5. Before giving call for final inspection, all the documents shall be furnished to the
Purchaser. The record of manufacturing details, inspection and tests carried out by
the successful Bidder shall be made available to the final inspecting authority.
However, approval and final inspection at the manufacturing works shall not
relieve the successful Bidder of responsibility of replacing at his cost any
defective part/material which may be detected by the purchaser during erection
and commissioning or guarantee period.
6. All materials required for fabrication, construction, testing and inspection shall be
supplied by the Bidder. No material shall be free issue to the Bidder.
7. No equipment or part item shall be dispatched without final inspection and
issuance of inspection certificate.
8. All equipment, assemblies, sub-assemblies shall be shop tested as per relevant
standards and the test certificates shall be submitted by the supplier.
9. Erection, testing & commissioning of various equipments and piping etc shall be
done also inline with details given in various chapters of GTS.
01.05 Painting
The Bidder shall follow the painting procedure as mentioned in GTS.
01.06 Drawings/Documents to be furnished along with the tender
The Bidder shall submit the following drawings/ documents along with the tender
1. Scheme of the complete water supply system with descriptive and illustrative
literature.
2. Process flow diagram indicating the water consumption figures complete with
temperature, pressure and quality requirements.
3. Duly filled in data sheets for various valves, fire-hydrants and other equipments as
applicable in line with in the GTS.
4. Pipeline materials and specifications considered for various systems.
5. Layout drawing showing the battery limits of drinking water, fire fighting water
and the pipeline route to various consumers including requirement of drinking
water and fire-fighting water at battery limits.
6. Catalogues, literatures and GA drawings of all equipments and valves.
7. List of special tools and tackles.
8. List of commissioning spares.

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9. List of spares for two years of normal operation and maintenance with item wise
prices.
10. Specification and capacity of all equipment, valves etc. offered by the Bidder.
11. Tentative Bill of Quantities covering all equipments, valves, strainers, pipelines,
etc. and associated civil, structural items etc.
01.07 Drawings/ Documents to Be Furnished by the Successful Bidder for Approval
1. Process flow diagram indicating the water consumption figures complete with
temperature, pressure and quality requirements.
2. Layout of piping system indicating pipe routing, location of supports, valves and
other fittings as required.
3. Data sheets and technical details of all the equipments, valves and piping.
4. Test procedures for preliminary and final acceptance tests.
5. Quality Assurance Plan.
6. All equipment and piping sizing calculations.
7. Test certificates for the following:
 Material test certificate for all major equipment and their components.
 Hydraulic test of equipment, pipe fittings & valves.
 Static and dynamic balancing of all rotary parts/ equipments
8. Any other drawing/ documents as required by the Purchaser.
01.08 Drawings / Documents to be furnished by the Successful Bidder for

Reference and Record
1. The successful Bidder shall submit required sets of all the approved drawings,
documents and manuals for Purchaser’s record and use. After erection of
equipment, the Bidder shall submit one set of linen tracings/ reproducible in
required number of prints along with soft copies in CD (in AutoCAD format) of
each “As built drawings”.
2. Operating and maintenance manual.
3. Spare parts recommendation and price list.
4. Instruction for erection, testing and commissioning.
5. Manufacturer’s test certificates.
6. Various equipment assembly drawings and bill of material.
7. Welding procedure.
8. Hydraulic test logs.
9. Equipment GA drawings and bill of materials.


& ITS AUXILIARIES
10. Operation and maintenance manuals for all equipments, valves and complete
water system along with soft copies.
11. Test and calibration certificates.
12. Warranty/ guarantee certificates.
13. Technical literature, catalogues and manufacturer’s drawings for all brought out
equipment, valves and other items.
14. All inspection/ test report/ certificates.
15. Any other drawing/ documents as required by the Purchaser / Consultant.
01.09 Battery limits
Sl.No. Description TOP detail Available pressure at

TOP (kg/cm2) approx.
a Process water system Shall be provided by Shall be provided by
b Equipment bearing Purchaser Purchaser
Cooling water system
c Make-up/service
water system
d Portable water system
e Water based fire-

fighting system

SECTION 02.00
AIR CONDITIONING &
VENTILATION
SYSTEM


SEMI DRY FLUE GAS DESULPHURIZATION(FGD) SYSTEM & ITS
AUXILIARIES
02.00 AIR CONDITIONING, VENTILATION AND AIR POLLUTION CONTROL

SYSTEMS
02.01 Introduction
To control the dust load in the flue gas coming out from the absorber and to maintain
stack emission within allowable environmental norms, bag filter based de-dusting (dust
extraction) system shall be considered. The scope of work, description of the systems,
equipment, design criteria, general instructions to tenderer, etc. are furnished below.
02.02 Scope of Work
The scope of work of the turnkey package executer shall also include the design,
engineering, manufacture / procurement, inspection, supply, transportation to site,
unloading and site storage, testing, erection, painting, commissioning and performance
guarantee of the complete dust extraction systems (DES) and Air conditioning &
Ventilation Systems (ACVS) including electrics, instrumentation, civil & structural
work as per the scheme drgs. The bin vent filters with fans and necessary pulsing
arrangement shall also be provided for the silos (lime storage silos, intermediate silo &
main silos).
02.03 Bag Filter Based De-Dusting (Dust Extraction) System
The bag filter based de-dusting (dust extraction) system shall comprise online pulse jet
bag filter unit, air dilution motorized damper at the inlet of bag filter, suction duct
carrying dusty air, clean / filtered air outlet duct connecting to stack, fabric expansion
joints at inlet & outlet, on-line bag cleaning system, dust transportation system from bag
filter hoppers to the intermediate dust storage silos, structural supports, electrics,
instrumentations and controls, etc. Air dilution damper shall be required to regulate the
inlet temperature of dust laden flue gas as per the requirement and to safe guard the
bags. The bag house shall have thermal insulation / cladding to take care of safety as
well condensation issues, if any.
Bag filter unit shall also have inlet/ distribution chamber, filtering chamber with filter
bags and fittings for the bags, outlet chamber, dust collection hoppers with heater,
vibrator, insulation, manual slide gate & rotary air lock valves, dust storage – cum –
disposal hopper with rotary air lock valve, slide gate (for alternate chute) & disposal
chutes, structural stair case & platform, electric hoist for handling top cover / bags /
cages, etc. The tubular cloth bags (filter bags) shall be held vertically in the cages in the
filtering chamber with the top face open to the outlet chamber of the bag filter unit. A
minimum distance of 75 mm (approx.) between the bags and between bags & the
surface such as walls or columns of the casing shall be provided. The outside surface of
the bags shall be exposed to the inlet/ distribution chamber of the bag filter unit.
Weather protection shed (rain proof), side sheeting, rain water pipe, digital instrument
as well as pressure transmitter for monitoring of pressure drop across bag filter and
Vol. – IIC, Section 02.00 ACVS Page 1 of 88

AUXILIARIES
across each module and its display provision in the control room / panel, etc shall be
considered. Each module of the bag filters shall have pneumatically operated dampers at
inlet & outlet. The filter & hopper shall be provided with heaters to allow for free flow
of dust. Proper insulation shall be provided for the de-dusting filters and ducting
systems. Dusty air entry to bag filter modules shall be from the bottom of the bags. In
case of side entry, necessary baffles shall be provided to direct the flow to the bottom
and ensure that the dusty air enters the bags only from the bottom. Uniform air
distribution in the bag filter modules shall be ensured and shall be demonstrated during
the testing / cleaning of bag filter. The design calculation for the sizing of compressed
air distribution line & its header shall be submitted along with the GA drg. of bag filters
during detailed engineering.
The bag cleaning system shall consist of compressed air main header piping (connected
to compressed air supply network of the plant), manual valve, pressure regulator, air
manifold tank, solenoid valves with timers and array of pipes with nozzles, sequential
timer, control panel, DP switches, pressure gauges & transmitters, etc. The main
compressed air header pipe coming from compressed air supply network shall be taken
into an air receiver and shall then be connected to the air manifold tank through manual
valve & pressure regulator, etc; the air manifold tank shall be connected to the array of
compressed air pipes with nozzles through solenoid operated valves with timers. The
network of timers for the solenoid operated valves shall be provided / set in such a way
that during operation of the de-dusting (dust extraction ) system/ plant, periodic pulse
jet cleaning of the filter bags is achieved by blowing compressed air into each bag
periodically. There shall be dedicated compressors, dryers & air receivers with 100%
standby (for compressor & dryer) for each bag cleaning system.
The dust collected at the dust collection hopper shall be taken into the dust storage silo
through dust transportation system. This collected/ stored dust shall be disposed off by
central pneumatic conveying system to the main storage silo.
02.04 Bag Filter
The bags shall be made of Nomex needle felt cloth with PTFE surface treatment for
main de-dusting system. However, Polyester needle felt cloth with PTFE surface
treatment shall be provided for silos. The minimum wt. of bags shall be 550gm/m2. The
filter bags shall be stitched with 3 rows of thread. The bottom shall be closed with fabric
disc and top shall be open with SS 304 snap band. Air permeability shall be 175
lpm/dm2/min @ 20mmWG. Fabric thickness shall be 2.1mm + 10%. Muller Burst
value shall be 35Kg/cm2 + 10%. PTFE laminated coating shall be provided on the bags
to ensure surface filtration. The PTFE membrane shall be thermally laminated on to the
bags without the use of adhesive. The bag shall withstand upto the temperature of
200°C.The outside surface of the bags shall be exposed to the inlet / distribution
chamber of the bag filter unit. The inside of bag house chamber, cages, tube sheets, etc.
shall have acid proof treatment. The length of bags shall be 6 m preferably.


AUXILIARIES
Bag cage shall be of 5mm galvanized steel wires. Wires shall of minimum 4mm
diameter. No bend of wires shall be allowed. Absolute straightness of wires shall be
ensured. Sufficient nos. of vertical wires shall be provided to give strength to avoid
collapse of cage as well as to prevent draw of fabric between wires.
Thickness of casing of bag house shall be minimum 5mm and that of hopper minimum
6 mm and these shall be suitably stiffened from outside and treated with acid proof
coating from inside. All bag filter hoppers and dust storage silos shall be provided with
2 motorized bin vibrators each.
The following specific aspects shall be particularly taken care of while designing and
executing the project :
1) Structural stair case and platform all around the bag filter shall be provided in such a
way that easy approach shall be made available for inspection and/ or maintenance of
the filter bags, compressed air piping with nozzles installed inside the filtering chamber,
air manifold tank, solenoid operated valves, timers and bag filter inlet & outlet dampers,
etc.
2) The minimum platform width shall be 1.2m. Railings should be provided on the
platform. Intermediate platforms shall be provided for the bag filters and hoppers for
inspection and cleaning purpose. Staircase shall be provided upto roof top of bag filter,
silo and chimney. Necessary maintenance platforms to attend the electric hoist of bag
filters, silo & stack shall also be provided. 1m wide spiral staircase shall be provided for
stack. Following minimum structural member shall be considered:
Hand rail : 25 NB, IS:1239

Post : 32 NB, IS:1239
Access grating : 40 depth, 6 thick
Stair : 40 C/C, 38” slope
3) All structures shall be designed in accordance with IS 800: 1984 (RA 1998). STAAD
analysis shall be provided for all supports, structures and stiffeners during detailed
engg. by the successful bidder.
4) Structures shall be fabricated from heavy sections. They shall be properly packaged and
transported in manageable lengths to avoid damage during transportation. The structural
design of the bag filter supporting structures shall be rigid with necessary cross bracings
as required.
5) Separate Differential Pressure (DP) gauges with diaphragm seals shall be provided for
individual bag filter modules and DP gauge with diaphragm seal & DP transmitter with
remote seal shall be provided across bag filter inlet/outlet.
6) Zero speed switches complete with controllers shall be supplied for RAVs. Only sensors
are not acceptable.


AUXILIARIES
7) Pulsing pipes on top of the clean air chamber of bag filter shall be supplied loose and
shall be erected at site after erection of the clean air plenum.
8) All platforms and stair supports shall be independent of casing. Separate stair tower
may be envisaged. All other places, staircases shall be provided. Minimum loading for
the platforms shall be considered as 600kg/m2.
9) Plenum chamber (inlet/outlet duct) shall be independently supported from the main
columns by horizontal members with air entry to individual modules by cross duct from
the main inlet/outlet duct. They shall not be supported directly from the casing since in
such a case, erection is difficult.
10) MS Gratings for platforms and staircases shall be suitable for heavy steel plant duty.
11) Base plates of columns shall match with the foundation so as to allow sufficient bearing
area for providing the pack plates below columns. Proper shear key shall be provided.
12) Erection drawings shall indicate clear-cut assembly details with tag nos. The structural
support members shall be supplied with erection bench marks, erection holes and
erection bolts.
13) BOM and total weights of the bag filter components and support structure shall be
clearly indicated in the erection drawings. In absence of these, it is not possible to plan
for required size of crane and generation of monthly plans and erection reports.
14) All columns shall be supplied for bolt type fixing. Columns with insert type fixing are
not acceptable.
15) Minimum 2.5m clear space below the bag filter hopper shall be kept for the equipment
of dust transportation system.
16) Access door at hopper shall be provided.
17) Adequate safety measures including the explosion vent shall be taken into consideration
for flawless operation of the bag house.
02.05 Bag Cleaning system
The cleaning operation of the bag filter shall be on-line and automatic with the help of
PLC system. One module of bag filter of similar capacity shall be kept isolated for
maintenance purpose so that at any moment of time, effective volume of working
modules vis-a-vis the air to cloth ratio shall remain same. The online cleaning shall be
accomplished by means of compressed air pulse jet through pulse solenoid valves
controlled through PLC software. Cleaning operation of different modules of bag filter
shall be in sequence with a preset interval time. The cleaning of bags in a module also
takes place in a sequence. The time interval of cleaning operation between modules and
compressed air pulse duration & frequency are adjustable to maintain pressure drop
across bag filter in the range of 140mmWC.
02.06 Design guidelines


AUXILIARIES
Tentative design parameters for pulse-jet fabric filter based DE System shall be as given
below:
Flue gas flow – 10,94,650 Nm3/hr @ 140 deg C having moisture content 12%
(approx.).
Inlet dust load to bag filter – 4000 mg/Nm3.
Outlet dust load from bag filter to be restricted to 70mg/Nm3
Duty – continuous operation.
Maximum pressure drop across the bag filter shall not exceed 150 mmWG.
Air to cloth ratio - 1.1 m3/min/m2 (max).
Electric hoist for handling of top cover / bag cage.
Explosion vent and pent house shall be considered.
The selection/ design and manufacture of plant and equipment shall be suitable for the
intended service and the atmospheric/ environmental conditions prevailing at Mettur,
Tamil Nadu. Design and selection of equipment shall be made with the following also
in view:
a) Safety of personnel
b) Uninterrupted operation
c) Long life of equipment
d) Easy maintenance at low cost
e) Lowest operating cost
f) Spares availability
g) Co-ordinates and location of the building.
h) Equipment, piping and ducting layout
The equipment shall be suitable to operate satisfactorily under variations of load,

pressure and climatic conditions as may occur during working at Mettur.
02.07 Dust storage silo
Bag filter hoppers and dust storage silo shall have 65 degree valley angle. Pneumatic
dust conveying system shall be provided to feed the dust from the intermediate dust
storage silo to the main storage silo. So, the clear height below the telescopic chute /
discharge valve of the intermediate dust storage silo shall be minimum 3.0m to
accommodate the downstream dust transportation system. The silo shall have minimum
24 hours dust storage capacity with 20% margin over its geometric volume. Thickness
of dust storage hopper shall be minimum 8 mm. One Rotary Feeder having capacity of
100 TPH direct coupled, one manual knife edge gate valve and telescopic chute shall be
provided under dust storage silo. Vibrator shall be provided for easy flowing and
unloading of dust from the storage hopper. Supporting column width of dust storage silo
shall be 5m to facilitate the movement / parking of heavy vehicle.

AUXILIARIES
An insertable type bag filter with other accessories (including fan) shall be provided at
the top of the silos to reduce the dust spillage to the atmosphere during feeding of dust
into the silos. High level switch and safety alarm arrangement shall be provided in the
silo so that in case of high level of dust, the safety alarm will get activated through the
PLC. Necessary interlock shall be suitably considered & provided. Additionally, a
safety valve at the top of the silo shall also be provided as a safety measure wherever
the silos are fed through pneumatic dust conveying system. Insertable type bag filter
with other accessories (excluding fan) shall be provided at the top of the silos (which
are fed through pneumatic dust conveying system). The pneumatic dust conveying
system shall be designed in such a way that the pressure of the pneumatically conveyed
dust at the entry of main dust storage silo shall not exceed 200 mm WC. In case, the
entry pressure exceeds the set value (to be finalized during the commissioning stage)
then the safety valve mounted on the top of the storage silo shall open & release the
excess pressure. Necessary instruments & interlocking to this effect shall be designed &
provided. An expansion joint shall be provided in between the contact surface of bag
filter & silo top. Bag filters for such silos shall be accordingly designed. Staircase with
intermediate platforms (1.2m width) shall be provided upto the top of silos.
02.08 Thermal insulation (applicable for both de-dusting and Air conditioning system)
Thermal insulation shall be provided for the bag house, hopper, ducting, intermediate
silo and the hot surfaces, if any. Thermal insulation system shall be selected so as not to
result in a residual heat loss exceeding 150 Watts/m2 under plant operating conditions
measured over insulated surfaces. For design, the following data shall be referred :
Ambient air temperature : 45 deg C (Max.)

Wind velocity : 1 m/sec.
Surface temperature : Not to exceed 15 deg C above ambient
Rock wool density : 150 Kg/m3
Thickness : To be decided during detailed engg.
Cladding over insulation : Aluminium (Emissivity : 0.2)
Design should include de-rating factors of direct conduction paths e.g. spacer rings and
stitching wires normally associated with blanket type insulation material.
Following Reference Standards shall be followed :
IS 8183: 1993 (RA 2004) Specification for Bonded Mineral Wool, Group – III &
IV
IS 9842: 1994 (RA 2006) Specification for pre-formed Fibrous Pipe Insulation,
Group– III
IS 14164 : 1994 (RA 2001) Industrial application and finishing of thermal insulation
material at temperature above -80 deg C and up to 700

AUXILIARIES
deg C - Code of practice
Application procedure :
a) Piping:
• For surface preparation wire brush shall be used to remove rust, dust or oil etc.
thoroughly.
• Fix the pre-formed pipe-section insulation of required thickness against each diameter
of pipe as per the thickness requirement for temperature class and pipe diameter.
Construction (upto 75mm thick – 1 layer thereafter 2 or 3 multi layer) joints should be
staggered so that complete breaks are minimum on single layer insulation and no
through joints occur in multi layout work. The insulation must be held in position by
strapping with 20mm x 24 SWG Aluminium Straps.
• When lightly bonded rock wool mattresses are used, they shall be wrapped around the
pipes without any under layer. On top of each layer, the wire netting already on top of
mattresses should be tightly butted against each other so that the fibers interlock both
along the longitudinal and circumferential joints. The pipe joints shall be stitched with
22 SWG soft GI lacing wire for pipes upto 400mm O.D. For pipes over 400mm O.D.,
the mattresses should be further secured by strapping with 20 mm x 24 SWG Al. straps
at 500mm intervals.
All un-insulated flanges, pipeline insulation shall be stopped off at a suitable distance
from the flange for facilitating withdrawal of bolts without disturbing insulation.
When supporting insulation of vertical pipelines it is essential that all the pipe insulation
(above 200 NB pipe) should be supported at minimum of 3.0 meters distance by
applying insulation support spider clamps. These clamps are fitted around the pipeline
bare surface with projecting legs whose length should not be more than 70% of
insulation thickness.
Flanges and Valves: Removable covers shall be provided over all flanges and valves
whenever they are insulated with preformed materials. These covers over valves and
flanges shall have provision for quick – release clips.
Sheet Metal Cladding: All pipes shall be covered with Aluminum sheet (24
SWG/0.56mm upto 325mm O.D. inclusive of insulation thickness and 22
SWG/0.71mm beyond 325mm O.D.) conforming to IS 737: 1986 (RA 2006), to the
outside of the insulation with minimum 25mm circumferential and longitudinal over
laps. The overlapping should be grooved so as to prevent ingress of water into the
insulation. In horizontal piping, joints shall be arranged at an angle of 30 to 40o from
the horizontal so as to shed rain water.


AUXILIARIES
When lightly bonded rock wool mattresses have been used as the insulation material,
spacer rings shall be required screwing the Aluminum sheet. The sheet metal shall be
secured to themselves by self-tapping screws at a pitch not exceeding 150mm.
After securing the Aluminum sheet, the overlapped joints of the sheet metal shall be
sealed with metal sealant to make joints perfectly waterproof.
b) Vessels & Equipment :
• The surface to be insulated shall be thoroughly cleaned by wire brushing to remove dirt,
loose scales, dust etc.
• Where welding is permissible, weld 10 SWG GI spokes at 300 – 400mm diamond
pitch.
• `L’ shaped lugs to be fixed to the spacer rings made of 25mm x 3mm MS flats at
450mm C – C with 25mm x 25mm x 3mm asbestos mill board washers and 4mm MS
rivets.
• The spacer rings shall be fixed around the tank at 900mm C – C by welding `L’ shaped
lugs to tank body.
• Impale Rock wool lightly bonded machine stitched mattresses with one side wire
netting of required density (upto 400o – 100 Kg/m3, above 400oC – 120 Kg/m3) and
thickness, with the ends of mattresses butted closely together with lacing wire of 22
SWG. In addition, mattresses shall be secured with tightly tensioned circumferential
Aluminium bands at approx. 450mm pitch.
• The ends of GI spokes shall be bent on the insulation.
• The Aluminium metal cladding (22 SWG/0.71mm) is to be fixed on the spacer rings
with self-tapping screws at 150mm C – C.
• All over lapped joints of Aluminum sheet metal shall be sealed with loidseal-94 to
make joints waterproof.
c) Expansion joint :
Expansion joints shall be provided in the insulation to allow for movement and
expansion of the pipe or vessel without producing random cracks. At the expansion
joints, there shall be complete cut and the cutout portion shall be 25mm wide and dry
filled with loose insulation material the density of which shall be equal to that of the
basic insulation. The expansion joints wherever necessary shall be installed by
overlapping the cladding material.
Pipe temp. oC Spacing of Expn. Joints in meters
Upto 200oC No Expn. Joint.

201 to 300oC 3.5
301 to 400oC 3.0
Above 400oC 2.0

AUXILIARIES
d) Design Criteria :
Ambient air 35oC or 45oC

temperature
Design surface Not to exceed 15oC above ambient air temperature
temperature
Wind velocity 1 meter/second
Cladding over Aluminium (Emissivity : 0.2)
insulation
Insulation material Rock wool density 144 Kg/m3 upto 350 mm NB, Rock wool
mattresses above 350mm NB pipes density 100 Kg/m3 upto
400oC and 150 Kg./m3 above 400oC
e) General Guidelines for insulation thickness :
Temperature: 100oC 200oC 300oC 400oC 500oC

Pipe NB Thickness of Insulation
100 25 40 70 100 140
200 25 45 80 115 160
300 25 45 85 125 170
400 25 55 95 145 190
500 25 55 95 150 195
600 25 55 100 150 200
Flat 25 60 115 140 255
Note: For piping upto 325 mm OD (including insulation thickness) aluminum sheet
thickness – 24 SWG (0.56mm) and beyond 325 mm OD (including insulation
thickness) aluminum sheet thickness – 22 SWG (0.71mm).
02.09 Rotary Air Lock Valve
Rotary air lock valve shall be made of cast iron with the carrying side hard faced. The
rotary air lock valve shall be complete with shaft of EN8, cast iron housing, rotor blade
(detachable type), etc. Rotary air lock valve is directly coupled to gear box & motor.
Rotary air lock valve capacity shall be based on 50% filling volume. Rotor blade shall
be of MS construction and hard faced. Face of blades shall be hard faced by 20x15
diamond weld beads (2 to 3 mm ht) to achieve 250-300 BHN hardness.
Casing thickness : 6 mm
Rotor blade thicknes : 5 mm
Capacity : Bidder to finalize as per system requirement
RPM of RAV : Not more than 20

AUXILIARIES
Manually operated slide gate shall be provided above RAV in the bag filter hopper for
isolation purpose for maintenance.
Telescopic Chute
Telescopic chute with knife edge gate valve above RAL shall be provided for
discharging the dust from the storage hopper into the closed truck.
02.10 Ducting for de-dusting
Ducting Network shall comprise ducting, duct support, measuring hatch, cleaning hatch
and duct line dampers as required along with necessary external stiffeners, flanges,
counter flanges, fasteners, gaskets and other accessories.
Construction
The duct sizing shall be so selected to maintain proper conveying velocity throughout
the system. Man holes/hand holes and dust outlets shall be provided at intervals to
facilitate cleaning of dusts and for disposal of dust. The ducting shall be fabricated from
M.S.(IS 2062: 2006) having thickness as follows unless otherwise specified in the job
specification :
Duct diameter Straight line duct thickness Bend Thickness

Upto 500 mm 3.15 mm 4 mm
Upto φ 900mm 4 mm 6 mm
φ 900mm to φ 1500mm 6 mm 8 mm
φ1500mm to φ 2000 mm 8 mm 10 mm
above φ 2000mm 10 mm 10 mm
At all duct bends (carrying abrasive dust) above 900 mm diameter shall have abrasion
resistant liners with caster wood / rock basalt / FRP in line with job specification
requirement.
Thickness of flanges shall be 12 mm. Necessary stiffeners shall be provided in the duct
depending on size. The ducts shall be laid vertical as far as practicable for dedusting
installations and horizontal ducts should be avoided.
For special application corrosion / abrasion resistant duct liner material of construction
of FRP / Liner material may be required to be installed in line with job specification
requirement.
Conveying velocity


AUXILIARIES
A conveying velocity of 18-25 m/s shall be maintained at all points in the ductwork to
ensure flow of dust laden air without settling of dust.
Expansion joints shall also be provided in the ducting network to reduce thermal stress
as required.
Provision of Flow Testing Points
Main duct and all major branch ducts shall have two 100mm diameter capped sockets
installed at 90° to one another at least 8D away from flow disturbance (bends, hood
inlets) for insertion of pitot tubes for flow measurement and system balancing during
commissioning. Test points are to be located in a readily accessible position in the duct.
However in any suction hood if flow appears to be on the lower then necessary flow
measurement and correcting device shall be made by the successful tenderer to suit site.
Straight Duct Runs
Interconnecting duct work shall be circular in cross section. The duct work shall be
fabricated from mild steel plate, IS 2062:2006 or be seam welded spiral wound duct
work as per job specification requirement.
Branches
Branch connections should be oriented to the top or side of the main with no two
branches entering at opposite sides.
Joints
Matching flanges are to be bolted together with asbestos rope gasket or rubber gaskets.
All bolts and gaskets for jointing shall be included in the scope of work of the
successful tenderer. All duct joints are to be air tight to minimize air leakage.
Duct Cleanout Doors
Clean-out doors will be provided on horizontal runs, before elbows and junctions. The
spacing between cleanout doors should not exceed 6 meters. Clean out doors will be
constructed to have a diameter of 600 mm or the duct diameter whichever is less for
ducts upto 1 meter diameter. Larger diameter ducts will have clean out doors sized 600
mm high by 600 mm wide.
Duct system hangers and supports
The ductwork support spacing and hangers will be designed for the weight of settled
dust plus a 25% design margin. Following dust load will be considered for designing
duct and duct support and duct stiffeners.

AUXILIARIES
Duct dia (in mm) % Cross section of duct filled up with dust.
500 and below 70 %
Above 500 to 1000 50 %
Above 1000 diameter 30 %
All duct inside buildings and duct along main structural building will be supported from
plant building structure or as approved during detailed engg. Details of duct supporting
members will be decided during detail engineering. To suit site condition, supporting
members may have to be modified by the successful tenderer without any commercial
implication to the purchaser. All outside ducting network shall have independent duct
supporting trestles.
Ductwork Layout
Ductwork will not interfere with fixed or mobile crane access to the plant. Horizontal
run of the ducting will be avoided to prevent settling of dust.
Minimum horizontal clearance from road center line is 5 meters. It is the responsibility
of the successful tenderer to effect the dedusting system ductwork arrangement in
accordance with the design requirements set down in the specification and to the
satisfaction of the purchaser / consultant.
Ductwork integrity
The successful tenderer shall design the ductwork in such a way to ensure that the
ductwork will not collapse at any point, should it be subjected to the maximum suction
capacity of the fan system. The design shall accommodate any variation in ambient
temperature.
It is the responsibility of the Successful tenderer to size all ductwork in detail as per
duct balancing calculation. Duct balancing calculation will be furnished by the
successful tenderer for approval of the purchaser. It is the Successful tenderer’s
responsibility to establish routes both inside and outside building. This is to be done in
conjunction with and to satisfy the Purchaser.
The duct work will be self pressure-balanced type. However, during testing and
commissioning if any throttle piece is required for adjustment of flow in any duct
branch, same will be carried out by the successful tenderer without any commercial
implication.


AUXILIARIES
Flexible connection / expansion bellows at inlet & outlet of bag filter and in the ducting
network shall be provided by the successful tenderer as required along with the back-up
calculation for fixation of such expansion joints / supports (sliding / fixed type).
02.11 Expansion joints
All expansion joints will be fabric type construction, mounted between flat face flanges.
Internal liners are required to prevent the dust laden air from coming into contact with
the fabric material and shall be designed so as not to reduce the nominal joint
dimensions. Flow direction shall be clearly identified on each expansion joint to ensure
correct installation. The Tenderer will define MOC and technical reasons for their use
for the following components of the expansion joint assemblies:
• Flanges and keeper plates

• Fabric material and Liner plates
• Bolting material for flexible member and retainer plates
02.12 Dampers
All damper components will be weatherproof construction mounted between flat face
flanges. Lifting lugs will be provided. Flow direction shall be clearly identified on each
damper to ensure correct installation. The dampers shall be suitable for installation in
both horizontal and vertical ducting. Suitable rubber packing / 3mm gasket shall be
provided at the flanged joint to make the system leak-proof. All dampers shall be
located with suitable approaches provided by the Tenderer. The design and material
selection of damper assemblies will be capable of meeting the process requirements. All
damper valves will be clearance or ribbed type butterfly dampers, shaft mounted on
frictionless bearing with flat face flanges. System will fail in the open position at loss of
pneumatic or electrical signal. Each limit switch will be supplied with open and closed
contacts. Rate of damper leakage in the fully closed position is to be given as a
percentage of the normal flow with the damper open and shall not exceed 1%.
Damper valve body, disc, and shaft and de-clutchable manual over-ride will be carbon
steel construction, suitable for the rugged service demands encountered during blast
furnace cast house operation.
Pneumatic design (Damper)
Spring return pneumatic actuator shall be provided for “open-closed" service dampers.
They shall be operated with compressed air to close and spring to open. Necessary limit
switches shall be provided for position control and indication for all dampers.
Actuator will be spring return, single acting, electrically operated for 0 to 90 degree
travel. The entire train will be totally enclosed within single cavity housing. Actuator


AUXILIARIES
will have external manual indication of valve and output shaft position. Indicator shall
be of corrosion resistant materials in contrasting colour to actuator body. Indicator shall
be the sole external moving part.
Actuator will be capable of being mounted directly to the damper. Actuator will be
complete with external de-clutchable manual over-ride which will have safety interlock
to exhaust air from actuator when manual mode is selected. All moving parts must be
totally enclosed. Actuator will be operable with valve installed in any position without
loss of performance and will be mounted parallel to the pipe.
Actuators are to be sized to operate with compressed air supply 5 to 7 Kg/ cm² pressure.
Actuator will be complete with position indicating switches. Switches will be totally
enclosed, in approved IP-65 enclosure, for corrosive environments. Switches will be
CAM operated and cams will be independently adjustable throughout the full actuator
travel range. Switches will have external position indicator to the same specification as
the basic actuator. Actuator will also be complete with electro-pneumatic valve
positioner, suitable for spring return, fail-open operation and manual over-ride.
Actuator housing will be hard anodized, extruded aluminum. End caps and pistons will
be pressure die-cast aluminum. Output shaft will be heat treated steel. All actuator seals
will be of Nitrile material and will be of O-ring construction.
Manual Over-ride
The de-clutchable manual over-ride mounted on the damper / valve will be of a worm
and segment actuator, in which the worm-drive shaft can be rotated eccentrically by the
worm-drive lever to disengage the worm from the segment. The segment is then free to
rotate when driven by the actuator.
The drive-shaft will have an internal locking device to lock it into the selected mode of
operation.
Normal operation is with the worm-drive lever in the "auto" position. In this position,
the worm-drive will be disengaged from the segment gear, and the actuator will be free
to rotate the valve shaft.
To engage the de-clutchable manual over-ride, the worm-drive locking button, mounted
on the unit, will be released allowing the worm-drive to rotate to the "manual" position.
02.13 Valves
The design, engineering, selection, manufacture, test and supply/fabrication of Valves

with all accessories required to be installed for the purpose shall conform to applicable
Indian Standards. All flanged valves and pipe fittings will be supplied with matching
flanges, bolts, nuts and gaskets. All valves will be suitable for required working

AUXILIARIES
pressure of the system served. The broad specifications for the different categories of
valves pertaining to compressed air & water line are as follows:
a) Isolation valves – for size 50NB and below, ball valve screwed as per IS 778 :
1984 (RA 2005) class 2. It will have SS ball & cast steel casing.
- For size above 50 NB, butterfly valve with SS disc & cast steel casing shall be
provided.
b) GM globe valves – screwed as per IS 778: 1984 (RA 2005) class 2 shall be used
for control valves.
c) Non-return valves – GM check valve (lift type) screwed as per IS 778 : 1984 (RA
2005) class 2 for NB – 50 and below. C.I. check valve flanged as per IS:5312 :
Part I : 2004 for NB 65 and above.
02.14 Instruments & controls for De-dusting system
The instrumentation system shall be designed using PLC based instruments unless
otherwise specified. Tenderer shall offer all the measurements, alarms & interlocks as
may be required for efficient & satisfactory operation of their offered system. Following
are the indicative list of measurements, alarms and interlocks for de-dusting system:
A. List of measurements and controls to be made available in PLC:
1. Alarm annunciation and interlocking for high level of dust in each bag filter hopper and
each storage hopper.
2. Indication of differential pressure across bag filter. Alarm and interlocking signal shall
be generated through PLC software. Purging arrangement shall be provided in the
impulse lines. Rotameter shall be considered for purging medium (compressed air) flow
regulation.
3. Indication and control of temperature for dust laden air at the inlet of bag filter. Alarm
annunciation and interlocking signal for high temperature shall be generated through
PLC software.
4. Indication of compressed air pressure at the compressed air header at the inlet of de-
dusting unit.
B. List of local Instruments:
1. Local indication of pressure & pressure low alarm for the compressed air header at the
inlet of each bag filter unit (through separate pressure gauge & blind type pressure
switch).
2. Local indication of pressure for the air at the outlet of bag filter of dedusting unit
(through diaphragm seal type pressure gauge)
3. Local indication of differential pressure across each bag filter. Purging arrangement in
the impulse line shall be provided.


AUXILIARIES
4. Any other measurement and controls, alarms and interlocks required for the safe and
reliable operation of the De-dusting System shall be provided by the Tenderer.
A. General:
All instrumentation equipment shall be suitable for operating continuously under the
environmental conditions indicated below:-
FIELD INSTRUMENTS PANEL INSTRUMENTS

Temperature: 0 – 60°C 0 – 50°C (minimum)
Relative humidity: 0 – 100% 0 – 95 % (non-condensing).
All measurements shall be in SI units.
Wetted parts of instrumentation equipment shall be properly selected so as to withstand

physical and chemical properties of the process medium. Instruments with diaphragm
type protection shall be used, if the process so demands.
In hazardous area applications, electronic/electrical instrumentation equipment shall be

suitable for hazardous area classification as per IEC. These equipment shall be
intrinsically safe conforming to CENELEC standard and certified by appropriate
statutory bodies (FM, BASEFA etc.). Intrinsically safe systems shall be designed using
zener/ IS barriers. Where intrinsically safe design is not feasible, ex-proof
equipment/enclosure, certified by statutory bodies (like CMRI, etc.) shall be supplied.
Other acceptable safety procedures (e.g. increased safety procedure, pressurization, etc.)
shall be used, wherever applicable. Required documentation/certificates shall be
submitted in conformance with all such features. Instruments installed in the open
environment shall be weatherproof, dust tight and splash proof. If such instruments are
not available, these shall be housed in weatherproof enclosures. Suitable canopies shall
also be provided for outdoor installations, wherever required. All field instruments shall
be provided with stainless steel tag plates with the following minimum information
engraved:
- Instrument tag no.

- Model no.
- End connections, ratings, etc., as applicable.
- Instrument range / set point.
- Input/output signal
Colour code applicable for the entire plant as per Client’s choice/ relevant standard shall
be followed for instrumentation pipelines, lamps, cables, panels, etc. Instrument power
supply shall be single phase 230V AC ± 10%, 50 Hz ± 5% as per prevailing condition at

AUXILIARIES
Mettur work / project site. All instrumentation equipment shall be suitably selected
accordingly. No instrument contact shall be used directly for alarm annunciation or
interlocking. Contacts after multiplication through relays shall be used for alarms and
interlocks. Instrument power supply shall be through circuit breaker (with adjustable
short circuit and overload release facility) and isolating transformer. Circuit breakers
shall also be provided on the secondary side of the isolating transformer for providing
power supply to a group of 2-3 instruments. All instruments shall also have individual
switch fuse units. Power supply equipment for instruments as may be required for Local
& Control panels shall be installed inside the panels.
B. Thermocouple and RTD:
The following types of primary sensing elements shall be used depending on

temperature of process fluid & application requirements:
i. Pt-Rh 13% / Pt ( ISA Type “R”)

ii. Pt-Rh 10% / Pt ( ISA Type “S”)
iii. Pt-Rh 30% / Pt-Rh 6% ( ISA Type “B”)
iv. Chromel – Alumel ( ISA Type “K”)
v. Nicrosil-Nisil (ISA type N)
vi. Chromel – Constantan ( ISA Type “E”)
vii. Copper – Constantan ( ISA Type “T”)
viii. Iron – Constantan ( ISA Type “J”)
ix. RTD ( Pt 100/ Pt 1000)
x. Radiation Pyrometers
RTD shall generally be used for measurement in the temperature range of -200ºC to
300º C and thermocouples for higher temperatures. For all control applications,
requirements involving duplication of temperature signals and plant specific
requirements, temperature transmitters shall be used. Head mounted type transmitters
shall not be provided. RTDs shall usually be three-wire type. Four-wire type RTDs shall
be used whenever specifically required.
Pt-100 or Pt-1000 RTDs shall have “;” of 0.00385 /ºC.
Thermocouples shall normally be mineral insulated (i.e., extruded MgO) type. RTD/
Thermocouple assembly shall be spring-loaded to ensure positive contact with thermo
well. Measuring junction of thermocouples shall be grounded or insulated depending on
the type of electric system or safety protection requirement. Thermo wells shall be
provided for all applications to enable maintenance work of thermocouple / RTD
without affecting production. Thermowells shall be bar stock type for upto 600 mm
immersion length and fabricated type for immersion length more than 600mm. AISI 316
shall be used as thermo well material, unless other special material is required due to
process fluid and conditions. Thermocouples shall be complete with compensating

AUXILIARIES
leads, installation fittings. The indicators, controllers shall have broken sensor
protection. Interconnections to / from thermocouples to temperature transmitters/
automation systems shall be made via compensating cables of thermoelectric
characteristics matching with thermocouples. In case, temperature elements, extension
cables, compensating leads are to be laid on the top of furnace /hot surface, suitable heat
insulation protection shall be provided. Use of asbestos shall be avoided. Mineral
insulated cables shall also be used for such applications. JB for connecting
compensating cables shall have terminal blocks suitable for type of thermocouples to be
connected. A protection tube consisting of a gas-tight ceramic sheath preferably
reinforced with stainless steel shall be provided with Pt-Rh/Pt thermocouples unless
some other special construction is specified.
C. Pressure Gauges & Pressure Switches:
Bourdon tube (spiral or helical), bellows or diaphragm type sensing element shall be
used in pressure gauges/ switches, depending on the process application. The gauges
shall be designed in accordance with IS 3624. Accuracy shall be ±1.0% of span for
pressure gauges and ±1.5% of span for DP gauges. Accuracy shall include the combined
effect of linearity, Hysterisis and repeatability. The element and other wetted part
materials of pressure gauges/ switches shall be of AISI 316, unless process media
necessitates use of other materials. Movement material of gauges shall be of AISI 316.
Outer casing and bezel material shall be either made of die cast Aluminium with epoxy
coating or of AISI 316. Pressure gauges shall have external zero adjustment facility and
minimum IP55 housing. These shall have a linear scale and dial colour shall be white.
Pressure gauges shall have dial size of 150 mm diameter. Gauges of smaller dial size
may be used for machine- mounting applications. Window material of pressure gauges
shall normally be toughened glass. However, where the pressure exceeds 40kg/cm2,
window material of the pressure gauge shall be shatterproof glass. Pressure gauges &
switches shall be provided with 3 – way/ 2-way gauge cocks. These items shall be
provided in addition to the isolation valves/ root valves at the process tapping point. The
working range of pressure switches shall be selected in such a way that the set pressure
is between 35% and 65% of the range. The switch enclosure shall be weatherproof to IP
65. Pressure switches shall have repeatability of at least ± 1% of span. These shall have
in-built scales.
D. Transmitters:
Pressure, flow, differential pressure and level transmitters shall be rugged, industrial,
microprocessor based ‘Smart’ type. Transmitters shall work on 24 V DC power supply
having 2-wire, 4-20 mA DC output & ‘HART’ protocol based or field bus based digital
communication. Accuracy of all transmitters shall typically be 0.1% or better of
calibrated span for turn-down ratio of minimum 10:1 and rangeability of 100:1.
Accuracy shall include the combined effects of linearity, hysterisis and repeatability. In
any application, the worst case error (WCE) consisting of static pressure effect,

AUXILIARIES
temperature effect, humidity effect and stability (1 year) shall not be greater than 0.75%,
unless specified otherwise. Zero and span adjustments shall be non-interacting to each
other. Transmitters shall be suitably compensated against any thermal effects in the
process medium. Transmitters shall be able to withstand a minimum over pressure of
150 % of the rated pressure. All the transmitters shall be weather-proof to IP-65 or
better. Zero suppression & elevation features, surge protection and provision for
selection of different damping levels shall be provided in each transmitter. Absolute
pressure transmitters shall have provision for compensation of barometric pressure. All
transmitters shall have integral local linear digital indicators calibrated in engineering
unit. DP transmitters for flow applications shall have built-in square root extractors.
Local indications shall be adjusted / calibrated through hand held calibrator. Pressure
transmitters shall be supplied with 2-valve manifolds of AISI 316 material. Flow; DP
and level transmitters shall be supplied with 3-valve manifolds of AISI 316 material
having suitable pressure and temperature rating. Standard zero suppression/ elevation
facilities and output reversal facility shall be available for all transmitters. All the
required accessories for mounting shall also be supplied with the transmitters. However,
for purging requirement, pressure transmitter shall be supplied with 2-valve (3 way)
manifold and DP type transmitter shall be supplied with 3-valve (5 way) manifold. All
transmitters shall be provided with traditional mounting arrangement along with
manifolds. For corrosive atmosphere, transmitter body, mounting accessories, nuts &
bolts etc. shall be of stainless steel. One hand-held calibrator with required software,
rechargeable battery and battery-charger shall be supplied for calibration checks of the
transmitters. For HART protocol based instruments or foundation field bus based
instruments. However, laptop based calibrator shall be supplied for profibus PA based
instruments, in case hand held calibrators are not available. Transmitters shall be
provided with external lightning protection devices, wherever required. Wherever
transmitters shall be installed in a room, proper ventilation shall be provided for that
transmitter room.
E. Level Switches:
External displacer type instruments with rotatable head shall usually be used for level
measurement up to 1200 mm (48”). Torque tube shall be made of Inconel and
displacers/float of AISI 316., unless otherwise specified. Side-side flange connection
shall normally be used for level switches. Heat insulator / finned extension shall be
used for temperatures above 230°C. All such instruments shall have drain valves and
vent plugs. Vibration fork type level switches shall be either external cage type
construction or shall be standpipe mounted type. Process connection to the cage shall
be 1“ socket weld type, unless otherwise specified.
Capacitance / conductivity type probes shall be as follows:
Rod type : for lengths up to 2000 mm.

Rope type with gravity weight : for length exceeding 2000 mm.


AUXILIARIES
For level measurement in non-conducting tanks or sumps or when the tank profile is
non-linear, capacitance type instruments shall be provided with a reference electrode /
ground probe. Capacitance type level probes may be used for both switching as well as
for continuous level measurement in liquids. Capacitance type level probe shall not be
used for level measurement in solids when there is likelihood of material build-up on
the probe. Capacitance type level probe shall not be used in liquid service where there is
a chance of di-electric value change (due to oil spillage etc.).
02.15 Air Conditioning & Ventilation Systems
Air-conditioning and ventilation systems are proposed to provide proper working

conditions necessary for maintaining environment compatible with human hygienic
requirement for the electrical premises, control / panel rooms, offices, conference room,
executive cabins, etc. and to maintain conditions necessary for working of equipment.
The Successful bidder shall clearly specify basis of design being offered along with heat
load calculations and back up guarantee on their design. Necessary IBR approval shall
be obtained by the bidder for the steam piping (from battery limit onwards). The details
of experience and credentials shall be furnished in the tender. Any other premises within
the battery limits of the successful bidder not specifically mentioned in schedule of
buildings in the specifications but are required to be provided with air conditioning /
ventilation (desired by the specific equipment manufacturer), shall be provided with
suitable air conditioning / ventilation systems by the Successful bidder to maintain the
required temperature and humidity.
Design criteria for Air conditioning and Ventilation systems
Following Indian Standards shall be followed for designing Air Conditioning System:
IS 655: 2006 HVAC System duct

IS-659-1964 (RA-2001) Safety code for air conditioning system
IS 778:1984 (RA 2005) Specification for Copper Alloy Gate, Globe and Check Valves
for Waterworks Purposes
IS 1239 : Part 1 : 2004 Steel Tubes, Tubulars and Other Wrought Steel Fittings -
Specification - Part 1 : Steel Tubes
IS 1239 : Part 2 : 1992 (RA Mild steel tubes, tubulars and other wrought steel fittings, Part 2
2002) Mild steel tubulars and other wrought steel pipe fittings
IS 1391 : Part 1 : 1992 (RA Room Air Conditioners - Specification - Part 1 : Unitary Air
1999) Conditioners
IS 1391 : Part 2 : 1992 (RA Room air conditioners: Part 2 Split air conditioners
1999)


AUXILIARIES
IS 2712 : 1998 (RA 1999) Gaskets and packings - compressed asbestos fibre jointing
IS 3588 : 1987 (RA 1999) Specification for Electric Axial Flow Fans
IS 3589 : 2001 (RA 2006) Steel Pipes for Water and Sewage
(168.3 to 2 540 mm Outside Diameter) - Specification
IS 3677 : 1985 (RA 2006) Specification for Unbonded Rock and Slag Wool for Thermal
Insulation
IS 4671 : 1984 (RA 2004) Expanded polystyrene for thermal insulation purposes
IS 4894 : 1987 (RA 1999) Centrifugal fans

IS 5312 : Part 1 : 2004 Swing Check Type Reflux (Non-Return] Valves for Water
Works Purposes - Specification - Part 1 : Single-Door Pattern
IS 5822 : 1994 (RA 2000) Code of Practice for Laying of Electrically Welded Steel Pipes
for Water Supply
IS 7613 : 1975 (RA 2001) Method of testing panel type air filters for air conditioning and
ventilation purposes
IS 7896 : 2001 Data for Outside Design Conditions for Air Conditioning for
Indian Cities
IS 8148 : 2003 Package air conditioner
IS 8183 : 1993 (RA 2004) Thermal Insulation – Bonded Mineral wool
IS 10470 : 1983 (RA 2000) Specification of air cooled heat exchanger
IS 11304 : 1985 (RA 2003) Code of practice for control of air pollution in iron and steel
plants
IS 11327:1985 Requirements for refrigerants condensing units
IS 11329 : 1985 Specification for Finned Type Heat Exchanger for Room Air
Conditioner
IS-11338-1985 (RA-1991) Specification for Thermostats for Use in Refrigerators, Air
Conditioners, Water Coolers and Beverage Coolers
IS 11446: 1985 Method of Measurement of Airborne Noise Emitted by
Compressor Units Intended for Outdoor Use
IS 11461 : 1985 Code of practice for compressor safety
ASHRAE Handbook ‘Fundamentals’
‘Equipment’
CARRIER Handbook Air Conditioning System Design by ‘Carrier Air Conditioning
Company’
ISHARE Handbook ISHRAE Handbook
The air-conditioning system will be designed to operate continuously round the clock
twenty four (24) hours a day for all seasons of the year and to take care of heat loads
due to equipment, lighting, solar radiation, occupancy and inside design condition. The
following design data shall be considered for selecting and sizing of various equipment
of air conditioning and ventilation systems :


AUXILIARIES
SEASON TEMPERATURE, 0 C (DBT) RELATIVE HUMIDITY (%)

SUMMER 39.4 38
MONSOON 33.9 50
WINTER 18.3 70
The temperature of the areas being ventilated by fresh filtered air supply system, push-
pull ventilation system or exhaust ventilation system shall not exceed 3°C above
ambient temperature at any part of the year. However, the ventilation system envisaged
shall be adequate to provide the desired ambience as required for the satisfactory
operation of electrical equipment / panels located in the ventilated premises. The same
(inside ambient temp.) shall be endorsed by the respective equipment / panel
manufacturer. If required, wet ventilation (i.e. air washer based pressurized ventilation
system) shall be provided to meet the inside requirement.
2-3 mm WC pressurization shall be maintained in the supply air pressurized ventilation

system. The ventilation systems shall be designed based on minimum 20 air changes/
hour or the heat loads of the premises whichever is higher in case of fresh filtered air
supply system & exhaust ventilation systems.
Detail heat load calculations of Ventilation and AC system shall be submitted first by
successful bidder for approval of the Client / Consultant before submitting any detail
engineering drawing. As a safety norm, all the steam piping has to be IBR approved and
the approval shall be obtained by the successful bidder.
Fire damper interlocking provision with fire detection system shall be considered for all
served electrical premises and susceptible fire hazard premises with the ACVS
equipment.
Unless otherwise specified in the technical specifications, all air conditioned premises
shall be maintained at 23±2 …C and 55±5 % RH.
All window glasses in air-conditioned premises shall be double glass type and airtight
double door entry provision shall be kept for these premises.
For improved water quality in refrigeration system, chemically treated water shall be
considered as make-up for corrosion protection. Necessary precautions shall be taken at
either side i.e. either the evaporator shall be selected to suit the available corrosion / pH
value of make-up water OR make –up water quality (pH / corrosion value) shall be
treated to match the fouling factor of given evaporator & condenser of VAM.
Chemically treated filtered water (soft water) shall be used as make-up to the expansion
tank and cooling tower basin.

AUXILIARIES
Chilled water pipe line shall be laid over ground. At the end of main supply and return
chilled water line, provision shall be kept with isolation valve for hooking up with
adjacent plant chilled water network. All pumps shall be vertical in-line pipe mounted
type with maximum RPM of 1500. Provision for monitoring of chilled water flow
quantity, temperature and served premises temperature shall be kept from central
control room station.
Fresh air supply as make up to AHU plant room shall be provided with pre-filter and
damper. AHU rooms shall be provided with necessary thermal (under deck) & acoustic
insulation.
Filter efficiency of pre-filter will be 90% down to 10 micron and fine filter will be 99%
down to 5 micron. High efficiency filter will be installed in the supply air duct at the
discharge end of blower / at AHU inlet.
Noise level generated in Central chiller plant, AHU room and duct line shall not be
transmitted to the served premises. Noise level in the served premises will not exceed
65 dB (A). Necessary acoustic insulation shall be provided to take care of the limit.
Noise level of individual equipment shall not exceed 85 dB(A) at 1m distance from the
equipment during peak load operation.
Local control of fan, pump, etc shall be provided near installation area for ON/OFF
operation as required.
For control of temperature and dehumidification of the conditioned premises, thermostat

and humidistat will be provided in the AHU Room.
Necessary handling facilities (electric hoist with monorails) shall be provided in chiller
plant room for handling pumps – impeller & motors, VAM inspection doors, etc.
Preferably exhaust fans of 900 rpm shall be provided in the chiller plant room &
compressor house.
All Equipment shall be provided with lifting attachments (wherever applicable) like
lugs, bolts, etc. to facilitate handling and lifting during erection and maintenance.
Strip heater box for humidity Control:
The strip heater will be installed in the supply air duct at the discharge end of blower for
dehumidification purpose and the strip heater will be interlocked with the blower unit to
prevent independent control/ switching of heaters. Safety thermostat shall be installed in
the duct line near strip heater for safety precaution. Strip heater box will comprise finned
heater, mounting plate, heater box/ casing made of 20 SWG G.I. sheet, cable terminal,

AUXILIARIES
terminal box with handle, 40x40x3 MS angle flange/ frame. Strip heater box will be
placed/ inserted in supply air duct. Safety thermostat will be mounted on strip heater
package to prevent overheating.
Humidification kit (Pan Humidifier) for humidity control:
Pan type humidifier shall be installed in the AHU room for adding moisture if required
for critical control of R.H. Level. The humidification kit will comprise a SS pan,
immersion heaters (3 Nos.), immersion heater cover box with handle, 15 NB pipe
connection with float valve for make up water, 15 NB pipe connection for over flow, 15
NB pipe connection with valve for drain, thermostat, earth stud, etc. Over flow pipe and
drain pipe will be connected together after/ below the valve of drain pipe. The
humidifier will be insulated with 50mm thick mineral wool (T.F. quality). Safety
thermostat will be provided in the pan humidifier to prevent it from dry heating.
Condenser cooling circuit.
Centrifugal pump and cooling tower for condenser cooling shall be supplied for water-
cooled type condensing unit. Rubber/Neoprene gaskets will be used on all bolted joints as
a seal against water leakage.
Water pipe line will be of MS Heavy ( C ) Class as per IS 1239 : Part 1 : 2004 upto a size
of 150 NB and for sizes beyond 150 NB MS, spirally welded, 6mm thick & conforming to
IS 3589: 2001 (RA 2006) shall be provided. Pipe fittings up to 150 NB will be as per IS
1239 : Part 2 : 1992 (RA 2002). Fabricated fittings manufactured from pipes shall be
provided for pipes of size 200 NB & above.
Velocity of water in pump suction line and delivery line will be within 1.2 and 2 m/sec
respectively. Y- strainer will be provided in suction line of pump. Butterfly valve/ ball
valve will be provided in water pipeline at condenser inlet & outlet, AHU cooling coil inlet
& outlet, pump inlet & outlet. For multiple consumer points, balancing valve in horizontal
line shall be provided at chilled water return branch line. Pipe supports will be fabricated
from mild steel and coated with appropriate rust preventive primer and finish paint. Where
pipe and clamp are of dissimilar material a gasket will be provided in between. All piping
will be tested to hydrostatic test pressure of at least one and half times the maximum of
operating pressure for period of not less than 2 hours.
The following control, instrumentation and necessary interlock shall be provided for air
conditioning system :
a. HP/LP cutout switch.

b. Cooling thermostat, heating thermostat, Operating and antifreeze thermostat &
Humidistat.
c. Pressure gauge & temperature gauge (150-mm dial type) with isolation cock.


AUXILIARIES
d. Water flow switch /differential pressure switch with interlock and signal in chilled &
condenser water systems.
e. Dry bulb & wet bulb thermometer for all major air conditioned premises.
f. Thermostatic expansion valve, sight glass, refrigerant strainer.
g. Flow meter to measure chilled water flow and condenser cooling water flow rate
h. Flow control valve in chilled & condenser water line
i. Any other instrumentation not specifically mentioned above but required for the air
conditioning system will be indicated & provided by the Tenderer.
Air conditioning facilities
Central AC with chiller plant at ground floor shall be envisaged for the entire air
conditioning premises. Air conditioning shall be provided mainly by VAM based chiller
with standby 100% being provided by Screw Chiller of identical capacity. VAM based
chiller consists of VAM (steam based) chiller, steam condensate pump, chiller pump,
condenser pump, pump for de-superheating station, cooling tower & AHU. Chillers
shall be selected after considering 20% margin over the cooling load. AHU rooms shall
also be taken into account while evaluating the overall cooling load of the entire AC
system. AHU rooms, cooling tower shall be planned at the roof top. The expansion tank
duly insulated and complete with motorized valve, interlock with low & high level
switch, etc. shall be located at the highest elevation level with suitable approach &
platform for maintenance. The following tentative premises shall be considered for
central air conditioning system:
Sl.
Tentative Premises Facilities
No.
1. Control room / Control operator 2xAHUs (1W+1S) served through common
desk room chiller plant to meet inside condition of 23 ±
20C, 55 ± 5% RH
2. Electrical panel room, office, 2xAHUs (1W+1S) served through common
conference room, cabins, etc. chiller plant to meet inside condition of 23 ±
20C, 55 ± 5% RH
However, the distribution of loads for selection of AHUs shall be finalized during
detailed engineering keeping the inventory for similar AHUs, pipes, valves, air filters,
dampers & fire dampers in view.
Split type air conditioners shall be envisaged for isolated premises, if any which will
generally maintain a temperature of 23 + 2 deg. C.
The Vapour Absorption Machine based chilled water plant shall include :
• The unit comprising generator, absorber, evaporator, condenser, heat exchanger
tubes, refrigerant pipe line, steam & chilled water piping with valves & safety


AUXILIARIES
devices, electrics, instruments and controls, etc.

• Auto PRDS system consisting of pressure reducing & de-superheating station with
metering pumps.
• Steam condensate disposal arrangement, steam condensate tank with pumps
(1W+1S), piping, etc. Steam condensate line shall be of SS.
• Steam pressure & temperature control system.
• Insulated steam piping network with valves (Shutoff, flow control, steam trap, etc),
fittings, strainers, instruments and safety devices.
• The vapour absorption machine shall be designed in such a manner to avoid
crystallization. In the rare chances of crystallization, the machine shall have de-
crystallization protection and auto de-crystallization operation control.
• Necessary interconnection of the vapour absorption units shall be provided for
flexibility of operation.
• All necessary safety & control switches shall be provided for normal and
satisfactory operation of chiller unit.
• Captive Soft water plant for treating make up water shall be provided.
• Monorail beam with chain pulley block (electrically operated) shall be provided in
the chilled water plant room for handling pumps and VAM inspection door.
• Chiller pump, condenser pump, pump for de-superheating station, vacuum pumps,
etc.
• Insulated chilled water piping network with valves (Shutoff, flow control, float,
etc), strainers, instruments and fittings.
• Thermal insulation over condensate drain line to avoid condensation over cold
surface
• Thermally insulated expansion tanks located at the top most location of the entire
chilled water piping network.
• Magnetic type flow meters in chilled & condenser water lines.
• Condenser cooling network comprising Induced draft FRP cooling tower with RCC
basin & PVC fills, pipes & fittings, valves (Shutoff, flow control, float, etc),
strainers and instruments. Cooling tower basin shall be at higher elevation for ease
of maintenance of drain valve.
• MCC, starter panel, electrics, instrumentation etc.
• Painting
• Multiple air handling units / Fan coil units as applicable with fan, filter, cooling coil
for different premises.


AUXILIARIES
• Ducting network with VAV box, damper, diffuser, acoustic and thermal insulation.
• Humidity control arrangement with strip heater, pan humidifier and humidistat.
• Make up air filter with damper in different AHU rooms.
In addition to the above, the standby packaged chilled water unit will be vapour
compression type chiller designed for continuous duty. Each package chiller unit will
essentially comprise of rotary screw compressor, shell & tube type water chiller,
refrigerant circuit, water cooled condenser, electric drives, instruments and controls
and other standard accessories assembled in steel cabinet. The compressor will be
semi-hermetic / hermetically sealed and mounted on anti-vibration pads &
dynamically balanced. Each chiller shall have multiple screw compressors with
independent refrigerant circuit.
Condenser shall be horizontal, shell & tube type construction dual refrigerant circuit
water-cooled type. Unit shall be equipped with integral finned type, solid drawn,
seamless copper tube of diameter approx. 19mm and thickness not less than 0.63mm.
The tubes shall have internal turbulator. Fins shall be made of Aluminium having 25
nos. per inch (min). Condenser shell will be constructed and tested in accordance
with section VIII, division I of ASME pressure vessel code. The shell shall be
capable to withstand refrigerant pressure of 300 psig, where as the tube side shall be
capable to withstand a water pressure of 150 psig. Cast iron water heads shall be
incorporated for easy removal, mechanical tube cleaning and/or tube replacement.
Condenser shall be provided with multiple pass to give optimum water velocity
through tubes combining efficient heat transfer and allowable pressure drop.
02.16 Technical specification of HVAC equipment
02.16.01 Description of VAM
VAM shall be completely factory assembled and wired in a single package complete with
evaporator, absorber, two stage generator, condenser, heat exchangers, solution pump,
refrigerant pump, vacuum pump for purging, starter panel (starting control), PLC based
control panel (safety & operating controls), all necessary sensors/ instruments, internal
cabling and piping work. Solution & refrigerant pump drive shall be hermetically sealed.
VAM shall be supplied with full operating charge of eco-friendly refrigerant (water),
lithium bromide solution (with non toxic inhibitor) and octyl alcohol for purging. Lithium
Bromide and Octyl Alcohol shall also be supplied for one year consumption. The
machine shall be factory tested under operating conditions. The absorption machine shall
be horizontal shell and tube with unit shell which shall be horizontally divided into two
parts. The upper part of VAM shall contain the condenser and the low temperature
generator. The evaporator and the absorber shall be housed in the lower part. The high


AUXILIARIES
temperature generator shall be provided either on the side of the machine or at the top
depending upon the type of the machine. The heat exchangers shall be horizontal shell
and tube type and fitted beneath the unit shell. The unit will be complete with all
necessary piping, valves, mountings, instruments, thermometers, etc. for normal and
satisfactory operation. Insulation of VAM unit shall be provided. The VAM shall be
double effect steam fired type with HTG having SS straight tubes as per job requirement
and availability of steam quality.
Vapour absorption m/c shall be chosen to operate normally with saturated steam in the
pressure range 0.5 to 10 kg/cm2(g) to deliver chilled water at 7 deg C with delta t of 5 deg
C (i.e. return water at 12 deg C). However, in specific cases, operation with Hot Water in
the temperature range 90 -135°C may be provided, if required.
Vapour absorption m/c shall be chosen not only to meet the full load design but also to
perform efficiently at lower loads and at lower condenser water inlet temperature
(particularly during winter season). Necessary condenser water temperature control shall
be provided. Tenderer shall furnish the inlet condenser water temperature range of their
machine.
Evaporator heat exchanger design shall meet the chilled water inlet & outlet temperature
required for air conditioning requirement as mentioned above in the job specification.
The following inputs are available for the purpose of steam based VAM system:
Temperature – 180 ◦C – 200◦C
Pressure – 12 kg/cm2
Flow – 2.5T/hr
Elevation of the header – 6 meter
Dia. of the header – 100 mm
Material of construction of different components of the vapour absorption machine shall

be as follows :
Shell & Tube sheet: MS (IS 2062)

Tubes - evaporator; absorber; condenser : high quality seamless grade SS 316 L
Tubes - low temperature generator: Stainless Steel
Tubes in high temperature generator: Stainless Steel
HTG Tube sheet: SS316 L
Impeller for Refrigerant & Solution Pumps: Stainless Steel
Casing for pump: CS
Fouling factor for condenser & evaporator shall be 0.001 & 0.0005 hr-ft² °F/ Btu
respectively.


AUXILIARIES
The evaporator portion and support structure should be painted with chloro-rubber paint.
High Temperature Generator with ‘U’ tube configuration for better thermal expansion
arrangement. High temperature and low temperature heat exchanger for improving cycle
efficiency. Sight glasses shall be fused type. Drain cooler to effectively cool steam
condensate & improve energy efficiency. Solution & Refrigerant pump with necessary
isolation valves. Imported high quality floats/relays for HTG & evaporator levels shall be
provided. All pressure and temperature gauges should be glycerin filled with shatter proof
glass and isolation valves for maintenance, calibration and replacement.
Pneumatically operated steam control valve complete with air set, regulator, valve
positioner, I/P converter, solenoid valve on air line complete in all respects shall be
provided. Compressed air lines shall be provided by the successful bidder as required for
AC system.
Following safety and controls will be provided with the vapour absorption machines:
Motor overload relay for solution, refrigerant and purge pump

Motor coil temperature cutout for solution and refrigerant pump
Low refrigerant temperature cutout
Chilled water flow failure cutout
First stage generator pressure cutout switch
First stage generator solution temperature cutout
Automatic start/stop temperature cutout
Solution dilution control
De-crystallization operation control
Solution pump start condition switch
Automatic start / stop arrangement
Automatic capacity control system consisting of steam control valve and automatic
temperature controller shall be provided to control the refrigerating capacity in
accordance with the load requirement. Capacity control should be smooth, stable and
step-less from 100% to 20% load. Automatic control of chilled water outlet temperature
shall be provided by controlling steam flow rate.
Necessary instruction manual, P&I diagram, control panel drawing, GA drawing, civil
foundation drawing shall be furnished.
The steam flow control valve should be installed at a maximum height of 1m from the
floor.
VAM shall have connectivity for communication, data logging, history charts and mimic
to PC at remote location.

AUXILIARIES
02.16.02 Description of Screw Chiller
The standby packaged chilled water unit will be vapour compression type chiller
designed for continuous duty. Each package chiller unit will essentially comprise of
rotary screw compressor, shell & tube type water chiller, refrigerant circuit, water cooled
condenser, electric drives, instruments and controls and other standard accessories
assembled in steel cabinet. The compressor will be semi-hermetic / hermetically sealed
and mounted on anti-vibration pads & dynamically balanced. Each chiller shall have
multiple screw compressors with independent refrigerant circuit.
Condenser shall be horizontal, shell & tube type construction dual refrigerant circuit
water-cooled type. Unit shall be equipped with integral finned type, solid drawn, seamless
copper tube of diameter approx. 19mm and thickness not less than 0.63mm. The tubes
shall have internal turbulator. Fins shall be made of Aluminium having 25 nos. per inch
(min). Condenser shell will be constructed and tested in accordance with section VIII,
division I of ASME pressure vessel code. The shell shall be capable to withstand
refrigerant pressure of 300 psig, where as the tube side shall be capable to withstand a
water pressure of 150 psig. Cast iron water heads shall be incorporated for easy removal,
mechanical tube cleaning and/or tube replacement. Condenser shall be provided with
multiple pass to give optimum water velocity through tubes combining efficient heat
transfer and allowable pressure drop.
Fouling factor to be considered while designing the condenser shall be

0.00025h-ft2F/Btu and temperature difference between inlet and outlet water shall be
approx. 7.50F. Integrally finned copper tube from outside having minimum 25 fins per
inch shall be expanded in to tube sheets for leak proof joints.
With special tube arrangement and the partition plate allowing cooling water to pass
through the condensed refrigerant and thereby sub-cooling the liquid. This produces
higher refrigeration capacity without increasing the power consumption.
Condenser shall be tested as per ARI standard 550/590 1998.
Condenser shall be provided with following accessories/safety devices:
Purge valve / drain valve

Charging valve
Relief valve/ Fusible plug
Liquid level indicator
Flanged hot gas inlet / water outlet connection.
Hand shut off valve for water inlet and outlet connection, Flow control valves
Magnetic type flow meter and flow switches in condenser water line

AUXILIARIES
Pressure & temperature gauges for water inlet and outlet

Vent valve
Cooler shall be Shell and tube type DX / FLOODED chiller with dual refrigerant
circuit.
Chiller shall be constructed from carbon steel plate with adequate number of baffles for
efficient heat transfer.
Copper tubes of minimum diameter 16mm shall be rolled in to grooves on tube sheet
for a water tight and air tight joint. Joints between the tube sheet and the shell shall be
water tight while those between the shell and boxes shall be airtight. Adequate sealing
gaskets shall be provided to prevent leakage of refrigerant and the infiltration of
moisture and air in to the system. Fouling Factor (water-side) 0.0001 hr-ft2F/Btu shall
be considered for design of cooler.
Cooler shell shall be capable of withstanding a pressure of 150 psig on shell side while
225 psig. on the tube side. Refrigerant shall pass through the tube while water through
the baffled shell. Refrigerant head is designed for proper number of passes to ensure
refrigerant pressure drop is within the limit and adequate velocity for proper oil
carry-over long with vapours.
The chiller assembly shall be thermally insulated with Armaflex / equivalent material of
50mm thick and finished with aluminium cladding.
Minimum superheat of 3o C under design condition shall be considered while selecting

the chiller.
Following controls and safety devices / accessories shall be incorporated in the chiller.
Cooling and Anti freeze thermostat.

Flanged water inlet and outlet connection with flanges and shut off valves, flow
control valves, including industrial type thermometer.
Relief valve, purge valve, drain valve .
Pressure and temperature gauges at the water inlet and outlet.
Refrigerant charging connection with valve .
Magnetic type flow meter and flow switches on the water line.
View port
• Pressure gauges


AUXILIARIES
Pressure gauge shall not be less than 150 mm diameter dial with appropriate working
range and be complete with shut off gauge cocks etc., duly calibrated before installation.
Pressure gauges shall be provided at the following locations.
A. Supply and return of Chillers and Condensers.

B. Discharge of pumps.
C Inlet and outlet of heat exchangers.
D Supply and return chilled water line of A.H.U.
• Thermometers
Thermometers shall be 150 mm dial type with capillary tube and protective sheets, duly
calibrated before installation.
02.17 Air Handling Unit
The AHUs shall be of fabricated construction & draw through type. The housing/casing
shall be of double skin construction. The frame work shall be of extruded aluminium
profile frames and peralluman nylon glass fibre reinforced corner joints. Double skin
sandwich panels shall be fabricated from inside with 22g galvanised sheet steel and
outside with 22g high polymer polyester coated (pre painted) galvanised sheet steel with
protection films on top. Minimum zinc deposition shall conform to Grade 275 of IS
277: 2003. The 25 thk. panels shall be PUF injected with PUF density of 40 kg/m3 to
ensure high rigidity and sound attenuation characteristics. The unit sections shall be
mounted on galvanized sheet steel channel & aluminium die cast legs. Panels shall be
fitted to Al frame work with neoprene gaskets & screws. The framework of AHU casing
shall be assembled by means of reinforced nylon corners. Necessary supports shall be
provided to slide the coil in the drain pan. Outlet shall be provided on both sides of the
drain pan. The fan section of the casing shall be provided with access door. Aluminium
die cast / Chrome plated hinges & handles shall be used in access door. The AHU shall
consists of the following sections :
Filter section.
Cooling coil section
Fan section:
Filter section shall house 48-50 mm thk. pleated filters having cleaning efficiency level
more than 99%. These filters shall be vertically arranged in the frame and all mounted
directly on AHU for ease of removal.
Cooling coil section shall have chilled water cooling coils constructed with copper tubes
and fins of aluminium. Thickness of Cu tubes shall be minimum 0.75 mm. Fin spacing
shall be minimum 10 fins per inch and minimum thickness of fins shall be 0.16 mm.
The fins of the coil shall have a mild ripple with die formed directional guide channels
to improve heat transfer efficiency. Cooling coil header shall be of GI. Chilled water

AUXILIARIES
coils shall be provided with suitable vent and drain connections. Drain pan shall be
fabricated from minimum 22 G stainless steel sheet and stainless steel nipple for drain
connection. Necessary slope shall be provided to facilitate fast removal of condensate.
Drain pans shall be thermally insulated. The entire assembly shall be mounted on PUF
insulated bottom panel. Condensate drain pipe of required length with sealing loop shall
be provided and insulated. The drain from drain pan shall be connected to floor drain.
Air velocity through cooling coil shall not exceed 2.5 m/sec and pressure drop across
the coil shall not exceed 15 mmWC. Water pressure drop through cooling coil shall be
limited to 5 mWC. Normally AHUs shall have 6 rows of cooling coil.
Fan section shall house centrifugal fan(s) which shall be forward curved, multiblade
double width double inlet type. Impeller blades shall be fabricated from heavy gauge
galvanised sheet steel or MS with spray galvanized. The wheel & housing shall be
fabricated from heavy gauge galvanised steel. The fan section shall be mounted above
the coil section. Fan speed shall not be more than 750 RPM. Flexible connection &
volume control damper (opposed blade type) shall be provided at fan outlet.
Blower fan shall be statically and dynamically balanced as per ISO1940 Gr 2.5. The
first critical speed of the rotating assembly shall be at least 25% above the operating
speed. The motor & blower assembly shall be isolated from the main frame by means of
spring. Motor & fan assembly shall be mounted on base frame and fixed on anti-
vibration rubber mounts. Motor shall be mounted on a slide rail to adjust the belt
tension. Fan shall be coupled to motor by V belts. V belts shall be provided with guards
that do not impede the air flow to the fan inlet. Fan static pressure shall be minimum 60
mmWC or more (as required based on pressure drop calculation). All the AHUs shall be
selected on the basis of min. 500 CFM/TR.
Typical AHU connection details shall be as shown below:
Drain to nearest Drain Point


AUXILIARIES
Temperature control in AHU shall be provided by modulating the chilled water flow in
the cooling coils by 3-way mixing valve. A bypass line around 3 way valves shall be
provided. Temperature switch and transmitter for monitoring of chilled water and served
premises temperature shall be provided. AHUs shall be offered with dehumidified air
quantity of at least 500 CFM/TR.
02.18 Cooling Tower

Cooling tower shall be power driven type and shall be selected to suit the requirement.
Induced draft type FRP cooling tower shall be provided for the cooling of condenser
water. Accordingly, cooling tower cooling capacity shall be selected with respect to
condenser capacity, which shall be min. 20% more than the chiller selected capacity (to
be endorsed with back-up calculation).
The capacity of the cooling tower shall be adequate to take care of the entire cooling
water required for the air conditioning plant.
The cooling tower with RCC basin shall be mounted on masonry pillars on the roof of
the building.
Cooling tower capacity shall be adequate to cool water basin temperature up to maximum
29oC as per prevailing ambient condition to meet the condenser cooling requirement of
screw chiller.
Cooling towers shall be provided with the following items and accessories :
• Type : Induced draft counter flow

• Frame Work : MS hot dip galvanized
• All the fasteners (Bolts, nuts, miscellaneous hardware) shall be of stainless steel
or hotdip galvanised steel. Rubber/Neoprene gaskets must be used on all bolted
joints as a seal against water leakage.
• Fills : PVC
• Nozzles : Brass
• Fan hub & blades : Cast Aluminium
• Fan type : Axial flow, direct drive (2X50%)
• Fan speed : 720 rpm
• Motor of induced draft fan shall be of weatherproof construction. Degree of

protection of motor : IP 55 (temperature rise limited to class B) unless otherwise
specified in the electrical specifications.


AUXILIARIES
• Ladder : Galvanised steel ladder with safety cage & hand railing up to the top of
tower to access fan, motor, nozzles, etc. Inclined to 300 to the vertical.
• Eliminators shall be provided in removable sections and installed in the cell of the
tower. The number of deflections in the eliminators shall be so arranged as to
limit the drift loss to within 0.01% of the circulated water.
• Level switch at cooling tower basin (to be interlocked with pump)
• Make up connection with float valve (float made of copper), back up ball valve
• Quick fill connection with ball valve
• Overflow connection
• Drain connection with ball valve
• GI wire mesh 18 gauge strainer
• Equalizing line of cooling towers with isolation valves
• Cooling tower basin (for chilled water plant) shall have minimum 5 minute water
holding capacity (of circulation water volume).
• Arrangement for handling fan – motor.
02.19 Thermal & Acoustic Insulation for HVAC
The insulation of water piping, air-handling units, ducting, chillers etc. shall be carried
out to maintain proper temperature of fluid / vapour in the conduits & to prevent surface
condensation on cold surfaces.
The materials to be used for insulation shall be as follows:
Closed cell Nitrile rubber/Polythene (CFC/HCFC free)
The thermal conductivity of the material shall not exceed 0.04 W/m deg. C. at 10 deg. C
mean temperature and density should not be less than 60 kg/ m3. Thickness of the
insulation shall be as specified below for the individual applications. The insulation
material can be readymade pipe section or precut sheets.
Polyurethane Foam (PUF)
The thermal conductivity of the material shall not exceed 0.04 W/m deg. C. at 10 deg. C
mean temperature and density should not be less than 40 kg/ m3. Thickness of the
insulation shall be as specified below for the individual applications. The insulation
material can be readymade pipe section or precut sheets as per application. The PUF
shall be CFC/HCFC free.


AUXILIARIES
Sl. Surface Material Insulation Type of Thk. Finish

material Section (mm)
No.
1. Chilled water PUF PIPE 50 Sand cement Plaster
piping (100 NB
and less)
Closed cell Nitrile Plain/Pipe 25 Al cladding
rubber/Polythene section
2. Chilled water pipe PUF PIPE 75 Sand cement Plaster
insulation (125
NB & above)
3. Chilled water PUF PIPE 75 Sand cement Plaster
pumps, valves,
flanges etc.
Closed cell Nitrile Plain section 31 Al cladding
rubber/Polythene
4. Expansion tank PUF Plain section 50 Sand cement Plaster
Closed cell Nitrile Plain section 25 Al cladding

rubber/Polythene
5. AHU drain pipe PUF PIPE 25 Sand cement Plaster

6. Acoustic Resin bonded Slab 12 Fiber glass tissue &
insulation glass wool board perforated Al sheet 26G
7. Under deck PUF Slab 50 --

thermal insulation
Ducting:
Closed cell Nitrile rubber/Polythene
The air handling ducts shall be insulated with closed cell Nitrile rubber / Polythene with
density 60±2 kg/m3. Duct insulation thickness shall be as follows :
AC Duct in conditioned space - 13 mm thickness

AC Duct in unconditioned space - 25 mm thickness
Cold adhesive or equivalent can be used for setting the insulation on the pipe/duct.

AUXILIARIES
Resin bonded glass/mineral wool:
The air handling ducts shall be insulated with resin bonded glass/mineral wool with
density not below 48 Kg/m3 with polythene back hessian on outer side. Duct insulation
thickness shall be as follows :
AC Duct in conditioned space - 25 mm thickness

AC Duct in unconditioned space - 50 mm thickness
Application Procedure (Resin bonded glass/mineral wool):
Clean the surface with wire brush to make it free from rust etc. Apply two coats of hot
bitumen 85/25 to the surface @ 1.0 Kg/m2 for first coat & in patches for second coat.
Wrap the duct with insulation blankets of the specified thickness. Apply PBH layer on
the outside and reinforce it by tying GI wire of 0.5 mm at interval of 450 mm.
Duct in outdoor areas exposed to weather shall be covered with 24 SWG Aluminum
sheet bent true to shape and secured with self-tapping screws and over lapped joints
sealed with Loidseal – 94.
Acoustic Lining:
The first 7 meter length of duct starting from each fan outlet shall be provided with
insulation for acoustic purposes. The insulation material shall be as specified under
“Insulation materials” above. Then it shall be covered with 0.56 mm perforated
Aluminium sheets.
Application Procedure:
The duct surface shall first be cleaned from inside. The insulation boards shall be
wrapped in Glass Cloth of 7 mil thick with ends stitched. The boards shall be fixed
inside the duct. The insulation shall then be covered with 0.56 (24 SWG) perforated
Aluminum sheets.
The sheet and the insulation, shall be secured to the duct by means of cadmium plated
bolts, nuts and washers and the ends should be completely sealed off so that no
insulation material is exposed.
Walls and Ceiling – Acoustic Treatment of equipment rooms:
Insulation material shall be resin bonded glass wool/mineral wool of density 48 Kg/m3
of 50 mm thickness.
Application Procedure:


AUXILIARIES
Fix 40 mm x 50 mm Deodar / Kail wood battens at 500 mm intervals longitudinally.

Then fix cross battens at 1.0 meter C – C using suitable gutties and brass / SS Screws.
Fill each rectangle with 50 mm resin bonded glass/mineral wool wrapped in glass cloth.
Then tie with 24 SWG GI wires at 300 mm intervals. Then cover with 24 SWG (0.56
mm) perforated Aluminum sheet having 3 mm perforations at 6 mm C – C. Overlap all
the joints and provide beads of 25 mm by 1.5 mm MS flat.
Extent of Acoustic Treatment : The entire ceiling covering the room.
Measurement : The measurement of insulation of vessels, piping and ducts shall be

made over the insulated surface area as per IS 14164: 1994 (RA 2001).
02.20 Ducting Network for HVAC System
The ducting network comprises ducting work, duct line dampers, down comer & supply
air diffuser with VAV box for HVAC system, supply air grill/ adjustable louver grill
duct supporting arrangement, flexible connections, etc. All GI / Aluminium ducting
work for airflow shall conform to IS 655: 2006. Galvanised steel sheet conform to IS
277: 2003 grade VII (i.e. zinc coating @ 200g/m2). As per job specification
requirement ventilation duct may be fabricated from steel sheet conforming to IS 2062
:2006.
Ducting work
Ducting work consists of main duct, branch ducts, bends, reducers, joints, access doors,
etc. Duct work shall be complete with flanges, gaskets, stiffeners, fasteners (nuts, bolts
& washers), hangers, etc. as required. Minor modification of ducting network may be
required to suit site condition. GI Ducts shall be fabricated at site to match with site
condition. All ducting work shall be properly reinforced to prevent sagging, buckling or
vibration. GI Ducting shall be provided with joints at 2.5 - 3m interval conforming to IS
655: 2006 as and where required. In case of flanged joints, the flanges shall be of angle
iron type riveted with GI sheet on duct perimeter. Flange joints should be made air tight
with use of felt gaskets. Duct supports shall be provided to keep the ducting in position
in aligned condition. Measuring hatch for measurement of flow / pressure shall be
provided in ducting network at convenient locations. For proper distribution of air in the
premises, supply air grills (adjustable louver grills) with volume control dampers shall
be provided in the ducting work for ventilation system and supply air diffusers with
volume control damper shall be provided in the ducting work for air conditioning
system. Sizing of the duct shall be done for pressure balancing as well as to
maintain the air velocities in the ducting work as given below: -
Description Air Velocity for Air velocity for Air conditioning

Ventilation System system


AUXILIARIES
Main supply air duct 8 – 10 m/sec. 6 – 8 m/sec.

Branch ducts 6 – 8 m/sec. 4 – 6 m/sec.
Supply air grills / diffuser 4 – 6 m/sec. 2.0 – 3.0 m/sec
Branch risers - 4 – 5 m/sec.
Return air duct (main) - 5.0 – 6.0 m/sec.
Fresh/Make up Air filter - 1.5 – 2.0 m/sec.
Fine filter - 1.0 – 1.5 m/sec
Return air grill - 1.5 – 2.5 m/sec.
Outside exposed supply/return air duct and indoor AC duct shall be thermally insulated
to avoid heating up of cold air duct and condensation. Ventilation duct which are
exposed to atmosphere shall be also thermally insulated with sand cement plaster finish.
Supply air diffusers (AC / ventilation) shall be provided at the supply air duct @ not
exceeding 3m centre to centre distance inside the served premises.
The following accessories shall be fitted in the duct line.
i) High efficiency filter

ii) Strip heater for dehumidification purpose
iii) Pan humidifier for humidification purpose
Joints : In line with IS 655: 2006 guide lines the type of transverse joints shall be
followed unless otherwise specified in job specification :
Sealing: All construction joints and duct seams shall be reasonably sealed with
bituminous cold emulsion or equivalent vapour seal.
Bends : The interior of all ducts shall be smooth for free flow of air. The radius to bend
shall not be less than 1.5 D. Turning guide vane shall be provided in all large duct bends
and bends with radius less than 1.5 D for proper air flow.
Access door : All main ductwork shall be accessible throughout using tight fitted
hinged access doors, provided with sponge rubber gaskets. Angle joints shall be
provided with felt or rubber gaskets for leak-tightness of the joints.
Access doors/panels are to be provided at following places:
• Near each fire damper

• Near each Reheat coil
• Near high efficiency filter/absolute filter
Any other place if envisaged by the owner about its essentiality during drawing
approval or construction period. In case access doors are to be installed in the insulated
ducts, the access door panel should be insulated too with overlapping, such that it can be

AUXILIARIES
operated without damaging the duct insulation and there should be no condensation
either on the access doors or on the duct when the plant is in running condition.
Adjustable louvers grill (Supply air grill) with volume control damper for
ventilation system:
1.25mm MS sheet shall be used for the manufacture of grill. All grills shall be true to
shape and shall be checked with a level gauge before being secured in position. No
distortion or warping is permitted.
All duct mounted grill shall be complete with rubber gaskets and flanged holding
frames of suitable design for the intended installation. They shall be mounted on collar
extending from the duct. No part of grilles shall project into the main duct. The
adjustable louver grill shall be provided with volume control damper as well as double
deflection flap/ grill for direction control.
Supply air diffuser (SAD) with volume control damper / VAV box for AC System:
SAD with VCD shall be provided where no variation of load is expected (Control room,
electrical panel room, drive room) and SAD with VAV box shall be provided where
there is load variation like in conference room, etc. Bidder shall ensure that automatic
temperature control at user end shall be governed.
Thickness of Grills, Diffuser, Damper shall be as follows:
(a) Frame 16 gauge

(b) Louvers 18 gauge
Supply air diffusers shall be circular/rectangular in shape as per detailed engineering

requirement. The throat of a diffuser shall be connected with collar piece provided at the
duct bottom for holding the diffuser as well as for supply of air. Each diffuser shall be
provided with volume control damper. Each diffuser shall comprise fixed plate, damper
blade, damper blade operating knob, spindle, connecting rod etc. The diffuser should
flush with the false ceiling. False ceiling shall not bear the load of any diffuser. The
load of diffuser shall be borne by the duct and collar. Each diffuser shall be painted with
appropriate colour to match with the colour of the false ceiling. Diffuser shall be placed
considering light fittings position and false ceiling runner position. Diffusers/grills shall
be of extruded aluminum powder coated / Anodized aluminum.
Variable air volume (VAV) box :
These shall of the low velocity variable air volume boxes without re-heat coils and shall
be of open protocol as marketed by a firm specializing in this field. The unit shall be
complete with damper, airflow ring, and solid-state electronic controls to provide
accurate room temperature control automatically with respect to the load available in the
premises at any point of time. The damper shall be aerofoil type construction with

AUXILIARIES
bearings. Boxes shall be supplied with all internal attenuation treatment and acoustical
damped casing necessary to achieve the required noise criteria. Casing shall be of 22G
GSS minimum fitted with a completely sealed, easily removable means of access to all
internal parts. Access to all boxes must be from the underside only.
The actuator shall be of 24V AC Bi-directional, direct coupled to the damper shaft. The
required transformer to step down of the voltage range from 230V to 24V shall be part
of the unit. The unit shall be complete with transformer, access panel and other
accessories as per the standard. The noise level shall be less than 35Dba.
Maximum allowable static pressure to the boxes for its satisfactory operation shall not
exceed 0.10WG, otherwise fan and motor selections may be affected. Boxes shall be
able to reset any air flow between 10% and the maximum air quantity that the boxes can
handle without changing orifices or other parts. Air quantity limiters will not be
accepted. Under shut-off conditions, all boxes shall not have air leakage more than 2%
of the maximum air quantity at 75mm static pressure.
The VAVs shall be used in standalone mode complete with its own temperature sensor
and controller and shall perform the function of maintaining the temperature and airflow
automatically as per the load. All boxes shall be electrically controlled. The boxes shall
be pressure independent. VAV Box shall have provision to support from floor/ wall/
ceiling and in vertical/horizontal condition.
Return air grill
Return air duct shall be provided above false ceiling in the served premises and AHU
plant room. The return air grill of suitable size shall be provided at the AHU plant room
side face for smooth flow of return air. The air supplied in the served premises shall
return above false ceiling through the return air duct of the served premises. From there,
it shall pass into the AHU plant room. The return air grill shall be painted with
appropriate colour to match with the colour of the false ceiling. Return air grills shall be
of extruded aluminum powder coated / Anodized aluminum.
Insulation: Sheet metal duct shall be acoustically and thermally insulated as per
requirement. For details of insulation refer respective equipment specification.
Flexible Connections: Flexible material shall be used for fabrication of flexible

connections. These shall be of at least 100 mm length and shall be provided at each
connection between duct work and fan units and any other places as asked for in the job
specification. Flexible connection material shall be selected considering the temperature
and pressure of the system.
Hangers & supports for ducting: All duct work shall be provided with adequate
supports as required to ensure rigid support and to prevent vibration. The fixing and
supports interval shall not exceed 3 meters. Hanger rods having U-bend at one end and

AUXILIARIES
threading at other end shall be hung from the ceiling by anchor fasteners / expansion
bolts. Duct angle supports from brick wall/RCC wall/ structural wall shall be grouted /
welded to suit site.
Make up air filter with damper: Make up air for AHU will be drawn from ambient
through filter and volume control damper.
Self Acting Damper: Self acting dampers shall be provided to maintain pressurisation
inside the ventilated premises. The damper shall be used in the premises being served
with pressurized plenum ventilation system. The damper shall be multi-blade type made
of Aluminium flaps of not less than 24G thickness and GI frame of 18G. These shall be
designed such that these shall operate when the pressure inside the premises exceeds 2-3
mm WC. It shall be possible to operate in fully open or partial open positions.
02.21 Centrifugal vertical in-line pump (pipe mounted):
The pumps shall be designed, manufactured and tested as per following applicable IS
standards (IS 5120: 1977 (RA 2001), IS:1520-1980, IS:5120-1977, IS 9137:1978 (RA
2002)).
In case any other international standards are used, the same shall be subject to approval
of the Purchaser and the pumps shall be suitable for the duty conditions and capacities
as indicated in the job specifications.
The centrifugal pumps along with their auxiliary equipment shall be suitable for the
required duty conditions and shall be designed and manufactured for continuous duty at
full load. All the pumps shall be capable of developing the required total head at rated
capacity for continuous operation. The pumps shall operate satisfactorily at any point on
the H-Q characteristic curve over a range of 25% to 130% capacity or capacity
corresponding to 75% of the total head whichever is lower.
Capacity vs discharge pressure curve for each pump shall preferably be continuously
drooping from the shut-off point to the rated operation point and be suitable for parallel
operation. The pumps shall be designed to avoid cavitations at any of the operating
points.
The required duty range for a pump shall be on stable portion of its head-capacity curve
close to the best efficiency point. The head developed at the best efficiency point shall
be close to the required differential pressure so that throttling is not required at pump
discharge.
The vertical centrifugal pump sets shall be supplied with flange mounted vertical
motors, motor stool, base plate, coupling, column pipe, delivery pipe, suction strainer,
companion flanges, gaskets, bolts, nuts, washers, etc. The equipment and auxiliaries
shall be designed for quick and economical maintenance. The equipment shall be easily
dismantleable without disturbing the suction and delivery pipe connections.


AUXILIARIES
The equipment design shall incorporate provisions for reduction in noise level.
The rotating elements of the pumps shall be checked for critical speed in bending as
well as torsion. The critical speeds shall be at least 30% above the normal speeds for
units with flexible shafts and at least 20% above the maximum operating speed in case
of stiff shafts. All passages inside the pump casing and impellers, which may be
inaccessible to machining, shall be ground to a smooth finish as far as practicable.
All pumps shall be centrifugal vertical inline type pipe mounted with maximum RPM of
1,500. However, mono-block type pump for wet ventilation system only in case on non-
availability of vertical inline pump may be provided.
Material of construction
Casing - C.I
Impeller - Bronze
Bearing Bracket - C.I
Shaft protection sleeve - Bronze
Wearing ring - Bronze
Shaft - EN8
Common base frame for pump & motor - M.S
The direction of rotation shall be clearly marked either by incorporating it on the casing
or by an arrow on a separate metal plate securely fitted to the casing.
A stainless steel name plate of 2 mm thickness shall be provided and securely attached
by stainless steel pins at an easily accessible point on the pump. The plate shall be
stamped with the following minimum information :-
a) DESIGN CAPACITY
b) TOTAL HEAD
c) SPEED
d) MOTOR RATING
e) MODEL NUMBER
f) MANUFACTURER’S SERIAL NUMBER
g) WEIGHT OF EQUIPMENT
h) TAG NUMBER
The total head-capacity curve shall be continuously rising towards the shut-off. The
shut-off head shall be at least 110% of the total head.
The velocity of vibration shall be within acceptable limit as per IS standard.
The power rating of the pump motor shall be larger of the following :
a) 110% of the power required at the duty point.


AUXILIARIES
b) For parallel operation, motor rating should be sufficient enough for running of
single pump also.
The casing shall be of cast iron and shall be designed for a pressure not less than the
shut-off pressure at the highest operating speed plus the maximum pressure that may be
encountered at the pump inlet. In addition, CI casing shall have corrosion allowance of
not lower than 3 mm. The casings shall be smooth, free from blowholes, cracks, fins
and other imperfections and thoroughly cleaned. Standard hydrostatic test shall be
conducted on the pump casing with water at 1.5 times the maximum discharge head or
twice the rated discharge head whichever is higher. The hydrostatic tests on the casing
shall be conducted for a minimum duration of 30 minutes.
Impeller shall be of bronze. Impellers and balancing drums (if provided) shall be
statically and dynamically balanced. Dynamic balancing shall be at the operating speed
of the pump. For multi stage pumps, all the impellers shall be assembled together for
balancing. Provision shall be made for adjusting the clearance between the impeller and
the casing to compensate for wear. The impeller shall be keyed or screwed on to the
shaft in such a way that it does not come-out due to reverse rotation of the pump.
The shaft shall be of EN-8 or equivalent and shall be designed for critical speed. The
ratio of critical speed to speed of shaft shall be not less than 1.3 for solid shafts. The
deflection in line shaft shall not exceed 1 mm per meter of length. All shafts above 150
mm diameter shall be ultrasonically tested. Shafts shall be checked for endurance and
strength. Change of sections in shafts if considered shall be made with due allowance
for stress concentration. Shafts shall be machined to close tolerance for mounting on
impeller bearings, shaft seal, shaft sleeve, shaft coupling etc. The magnitude of shaft
deflection at the face of the shaft seal shall not exceed 50 microns.
Long shafts shall be supported on bearings at 3m centre or less. Shafts shall be easily
accessible throughout their lengths and shall be designed as far as practicable in
interchangeable lengths. All steel shafting 150mm or less in diameter shall be hot rolled
and turned, forged and turned, cold rolled or cold drawn. All shafting above 150mm in
diameter shall be forged and machined to size. All forged shaft shall be annealed or
normalized before machining and then heat-treated, if necessary.
For vertical pumps when coupled with solid shaft motor, the coupling shall be of rigid
adjustable type. Removable coupling guards shall be supplied and mounted. Guards
shall be sufficiently heavy and rigid to provide adequate personnel safety.
Shaft seals shall be provided to prevent leakage out of or into a pump over the range of
specified operating conditions. The seals shall be suitable for variations in inlet
conditions that may prevail during start-up and shut down. They shall be accessible for
inspection and replacement without disturbing any part of the installation. An adequate
drain shall be provided so that liquid cannot collect on the drive support.


AUXILIARIES
Coupling shall be properly keyed in place and the cylindrical fit shall allow simple
removal of the coupling in the field. Removable coupling guards shall be supplied and
mounted. Guards shall be sufficiently heavy and rigid to provide adequate safety for
working personnel.
Two bearing assemblies shall be provided, one within the frame to carry radial load
only and the other to carry both radial and axial thrust. Bearings shall be of
manufacturer’s standard design. Water lubricated sleeve type bearings may be used.
Suitable thrust bearings shall be provided in the pump to take total thrust of the pump
including hydraulic thrust. Vertical motor shall be provided with separate thrust bearing
to take care of its own axial thrust. Motor thrust bearing shall be designed without water
cooling arrangement. Suitable tapped holes shall be provided for refilling of oil in the
bearing housing.
All the vertical pumps shall be provided with separate thrust bearings with proper
lubrication and cooling facilities as required so that the thrust and other vertical loads
due to the moving parts are not transferred to the prime mover.
All pumps shall be supplied with sturdy base plates as per manufacturer’s standard.
Base plates and pump supports shall be constructed so rigidly and the unit so mounted
on pipes as to minimize misalignment due to piping strain, internal differential thermal
expansion, etc. Base plates shall be fabricated from MS channels.
Plate flanges having raised face shall be provided at suction and delivery side of pumps
and they shall be of mild steel and conform to table 17 of IS: 6392-1971 (R.A.1988).
Slip on raised face flanges to 150 Lbs. class conforming to ANSI B16.5 shall also be
acceptable. Black bolts and nuts conforming to IS 1362-1992 shall be provided for the
companion flanges. CAF gaskets of 1.5 mm thickness conforming to IS: 2712-1979
(R.A. 1994) shall be provided for the companion flanges.
Following data sheet shall be followed for the pumps :
Sl. No. Parameters Details
1 No. of Pumps To be included by Tenderer
2 Application Industrial water
3 Type of Pump Vertical centrifugal Inline
4 Pump Tag No. To be included by Tenderer
5 No. of Stages one

6 Type of Motor TEFC
7 Capacity of the pump m3/h To be included by Tenderer


AUXILIARIES
8 Total head mWc To be included by Tenderer
9 Preferred Speed rpm 1500 (Synch)
10 Operation To be included by Tenderer
11 Duty Continuous
12 Shaft Seal Packed Gland
13 Material of construction
a Casing/Bowl CI FG 260
b Wear rings/Liner Bronze
c Impeller Bronze
d Shaft En8
e Shaft sleeve SS 410
f Strainer MS-Galvanised
14 Depth of sump Pipe Mounted
15 Companion MS flanges with nuts, To be included by Tenderer

bolts and gaskets
16 Foundation bolts To be included by Tenderer
17 Base Plate /Frame To be included by Tenderer
02.22 Valves:
Depending on the layout, the Tenderer will provide valves wherever required for ACVS
systems. All valves shall conform to applicable Indian Standards. All flanged valves
and pipe fittings will be supplied with matching flanges, bolts, nuts and gaskets. All
valves will be suitable for required working pressure of the system served.
Strainers will be provided in the condenser water supply / inlet line, washed air systems,
etc. Bypass line with valves will be included to facilitate cleaning the strainer without
affecting the functioning of the unit.

AUXILIARIES
Gate valves will be provided at pump outlets & at tank outlets whereas butterfly valves
shall be provided at pump inlets.
For dust suppression systems, pressure relief valves shall be provided at pump outlet to
divert water back to the tank in case downstream usage of water is reduced. Butterfly
valves shall be provided in branch headers to operate a particular group of nozzles.
Globe valves shall be provided on nozzle headers to control the flow through each
nozzle.
Butterfly valve
Butterfly Valves shall be provided in water line of size 65 NB and above and ball valve
shall be provided for pipe size below 65 NB.
Type : Wafer design

Body : SG iron with nitrile rubber/ EPDM lining
Disc : SG Iron with teflon (PTFE) coating
Stem : High tensile stainless steel
The valves shall be provided with integrally moulded & bonded body liner to provide
perfect seating and complete isolation of body material from fluid. The body liner shall
provide the seating to valve disc, primary seal to the stem & gasket joint with matching
pipe flanges. Valves shall be provided with self locking lever operation from open to
fully closed position with intermediate positions marked on the indicator plate mounted
on the top flange. The valves shall conform to BS 5155 / IS 13095: 1991, RA 2003.
Extended valve shaft shall be provided so that the lever can be operated without any
obstruction on the insulated pipes. Gear operated valves shall be provided for sizes
more than 150 NB.
Ball Valve
Body : Cast steel

Body liner : Nitrile rubber/ EPDM
Ball : ASTM A351 Gr CF8
The ball valve shall be of 3 piece design, socket welded type and be supplied with
200mm length of pipe on both sides.
Gate Valve
1. Type Gate valve with non-rising spindle & bolted bonnet

2. Body Below 50 mm Bronze. 50mm & above Cast iron as per IS:
210-1993 (RA 1999),GR.200


AUXILIARIES
3. Bonnet Bolted
4. Spindle SS as per AISI 410
5. Disc Cast iron as per IS:210-1993 (RA 1999),GR 200
6. Body seat ring & SS as per AISI 410
Disc facing ring
7. End connections Below 50 mm - Screwed. 50 mm & above flanged end, to be
drilled as per ANSI B.16.5
8. Pressure rating As per system requirement
9. Flange facing Flat Face
10. Manufacturing std. IS:778, 1984, RA 2007
11. Bolts & nuts Black Hexagonal bolt with nut as per ASTMA 307 Gr B.
12. Gaskets Compressed Asbestos Fibers to IS 2712: 1998 (RA 1999), 1.5
mm thick
13. Hand wheel CI Gr 200 as per IS : 210 – 1993 (RA 1999)
14. Packing Asbestos
15. Companion ANSI B16.5 Class 150
Flanges
16. Hydrostatic testing As per relevant IS & Pressure rating of PN 1.6
17. Test certificates For Physical/chemical analysis & metallurgical tests for body
parts , Hydro testing
18. Service Re-circulation water/ Make up water/chilled water
Globe Valves
1. Type Globe valve for water supply pipelines
2. Body/Bonnet Bronze As per IS 318: 1981 (RA 2001) Gr 2

3. Stem Brass as per FHTB 1 of IS 6912: 2005
4. Hand wheel CI FG 200 as per IS : 210 – 1993 (RA 1999)
5. Gland, Gland nut, As per IS 318 (RA 2001) Gr 2
spindle nut
6. Gland Packing Asbestos
8. Manufacturing std. IS : 778 : 1984 (RA 2007)
9. Max. Optg. temp 50 0 C
10. Operation Manually operated hand wheel with open and close direction
indication.
11. End connection Screwed as per IS-554 upto 40 mm unless otherwise mentioned
in job specifications. Flanged end for 50 mm and above.
12. Special features 1) Arrow indicating flow direction
2) Embossed nameplate-giving details of tag nos., type and
size.
13. Service Re-circulation water/ Make up water/chilled water


AUXILIARIES
14. Hydrostatic Testing As per relevant IS and pressure rating of PN 1.6
Non return valves
1. Type Dual plate check valve with two springs hinged on a central
hinge rod / Swing check type
2. Body SG iron / Cast iron as per IS: 210-1993 (RA 1999), GR. 200.
3. Body liner Nitrile rubber/ EPDM
4. Cover SG iron / Cast iron as per IS: 210-1993 (RA 1999), GR. 200.
5. Hinge Cast iron as per IS: 210-1993 (RA 1999), GR.220.
6. Hinge pin HT brass IS 320: 1980 (RA 2006) HT-2
7. Body Seat Ring & IS 318: 1981 (RA 2001) Gr 2
Disc ring
8. Disc ASTM A351 Gr CF8 / CI as per IS: 210-1993 (RA 1999),
Gr.200
9. Gasket CAF gasket as per IS 2712: 1998 (RA 1999) of thickness 1.5
mm
10. End connections Flanged end, drilling as per ANSI B16.5
12. Manufacturing Std IS:5312(Part-1)-2004 / BS-5153 1991
13. Bolts & Nuts Hexagonal type as per IS:1367-1967 Cl.-4.614.4
14. Companion ANSI B 16.5 class 150
Flanges
15. Hydro static testing As per IS : 5312 Part-1 -2004 / BS 5153 (1991) and pressure
rating of PN-1.6
16. Test certificates For Physical/chemical analysis & metallurgical tests for body
parts , Hydro testing
17. Service Water / chilled water
02.23 Air filter:
Dry panel type air filter shall be of high efficiency cleanable type, constructed out of
HDPE (6 ply) supported by layers of GI wire gauge. It shall be corrugated to the depth
of filter casing in order to increase the ratio of filtration area to frontal area. It shall be
covered by strong GI frame (14G) and shall have space to ensure uniform distribution
of air. Filtering panel shall be of standard size which can be mounted on angle frame in
multiple number as per capacity of the fan. Face velocity of air shall not exceed 1.5
m/sec. The resistance of air filter shall not exceed 10 mmWC when dirty. Efficiency of
the normal air filter shall not be less than 90% down to 10 microns unless otherwise
specified in the job specifications. Cleaning efficiency of the high efficiency air filter
shall not be less than 99% down to 5 microns unless otherwise specified in the job
specifications. Panel type air Filters testing shall conform to IS 7613 : 1975 (RA 2001).
02.24 Expansion Tank


AUXILIARIES
Steel tank of suitable capacity fabricated from 6mm thick MS plates (as per IS:2062) in
welded construction shall be provided at the highest point of the chilled water circuit for
chilled water expansion cum make up. This tank shall be complete with all accessories
like motorized ball valve and float valve for make up connection, quick fill, drain
overflow, low & high level switches, approach, platform, ladder, etc. Tank shall be
thermally insulated and aluminum cladded from outside and Zinc coated from inside.
Grade of Zn coating shall be 350g/m2. The tank capacity shall be 20% more than the
required volume of chilled water.
02.25 Split AC:
Split air conditioning unit shall comprise of two sections - Indoor and Outdoor. Indoor
section shall comprise of cooling coil, fan, supply air grill, filter. Outdoor section shall
comprise of air cooled condenser, condensing fan, hermetically sealed compressor.
Sealed refrigerant piping shall inter connect indoor and outdoor sections. Outdoor unit
shall be installed in open space for easy heat dissipation from condenser. Indoor section
shall be ceiling suspended or wall mounted type as per job specification requirement.
Remote control unit, thermostat and other standard accessories for successful
installation of split type air conditioner shall be included in the scope of successful
tenderer. Split air conditioner unit shall conform to IS 1391 : Part 2 : 1992 (RA 1999).
Eco-friendly refrigerant shall be used and the rating of the AC unit shall be 3 star
minimum.
02.26 Ventilation :
Depending upon the specific requirement, the premises envisaged in the project shall be
provided with either exhaust ventilation or pressurized ventilation. The system design
will take into account the requirement of air change as well as excess heat removal.
Filters will be provided with pressurized systems. The details and types of system
proposed are indicated in the equipment schedule.
Air Washer
Air washer unit comprises intermediate chambers at inlet and outlet and cell deck pad
chamber with water tank. Adapter section shall be provided for connecting air washer
unit with other equipment. There shall be 2 pumps (1W+1S) for the wet section. The
evaporative cooler shall be a self contained, single skin housing unit consisting of MS
intake louver of 75 mm deep with bird mesh, dry filter section, wet section and fan
section. The dry filters are 6 ply HDPE as specified. The wet section shall consist of
cooling media, water delivery system and sump including piping. The fan section shall
consist of fan with motor, drive arrangement to deliver specified air volume against
specified static pressure.
Housing


AUXILIARIES
The housing shall be constructed from 16G GSS whereas the tank shall be of SS304.
Hinged access panel shall be provided in the fan section of the housing on both sides.
The access panel shall be gasketed or formed to preclude air or water leakage into the
interior of the housing. The opening shall provide easy access to the blower to allow for
service of the motor, belt adjustment, bearing and possible shaft replacement. The
housing shall be airtight and waterproof.
The wet section shall consist of a sump, sides and top. A side lift – off or hinged panel
for media access and service of the float valve assembly for make up water shall be
provided. Removal and replacement of the media can be made through either a side lift
off panel, top removal, intake or discharge side of the section as the case may be . The
wet section shall be mechanically attached through the frame work to the fan section
housing and shall be supported across it’s entire width.
Internal components of the wet section shall be cooling media, water delivery system,
internal plumbing including a header pipe, make –up water, overflow and drain fittings.
Fan Section
The fan shall be heavy duty centrifugal type, DIDW backward curved impeller blades
with non- overloading characteristics and shall be capable of delivering air volume at
external static pressure as per requirement. The fan shall be AMCA certified for
performance, noise level with balancing grade of G6.3. The fan shall have solid, ground
and polished C45 steel shaft with self-aligning type bearing on both ends.
Vibration isolation shall be provided under the fan and motor and shall be of spring
type. Isolators shall be selected for minimum deflection. Flexible neoprene rubberized
steel impregnated connection shall be provided between the fan discharge and the
housing at the outlet duct connection.
Wet Section
Sump construction in wet section shall include TIG (fusion) welded corners and joints.
The sump shall be leak proof without the use of fillers, sealants or coatings. A media
support channel shall be included. This channel shall extend across the full width of the
media. The channel shall provide a minimum of 50% open area for water to flow freely
from the media into the sump.
An air bypass inhibitor plate shall be provided from the intake bottom of the media and
designed to preclude any untreated air flow under the media.
Stainless steel couplers with female pipe thread shall be welded into the sump and side
to provide for make-up water, overflow and drain. Make up, overflow and drain
connection of suitable size shall be provided.


AUXILIARIES
Water distribution system shall be pump re- circulating system with mechanical float
valve assembly to maintain water level in the sump. A bleed – off system shall be
provided. Bleed- off rate shall be minimum of 20% of evaporation rate. Pump shall be
sized to deliver water flow rate at the head and pressure required. Flow rate shall be
determined at three (3) times the evaporation rate plus the bleed-off rate. Pump shall be
vertical submersible type of SS construction. One working plus one standby pump shall
be provided for each air washer.
Water distribution system shall incorporate perforated SS deflector trough to redirect

the water from the header pipe discharging upwards back on to the media to attain even
distribution across the full width of the media. A union shall be provided in the riser
pipe below the header pipe to facilitate removal of the header pipe.
Cooling media shall be celdek or glacier-cor or approved equivalent imported makes

having rigid media12” thick . This media shall be cross- fluted pad of cellulose material
impregnated with anti-rot slats and rigidifying saturants and wetting agents with at least
123 square feet of evaporative surface area per cubic foot of media. The transverse
flutes shall be 60 degree and 30 degree with water flow in the direction of the 60 degree
flute against the air flow and air flow in the direction of the 30 degree flute with the
direction of air flow. Media shall have no more than 0.7” w.g. air pressure drop at 500
feet per minute face velocity and shall develop a saturation efficiency of not less than
95% for 12” thick media.
Media access and removal shall be accomplished through a removable side or top panel
provided for this purpose or from the intake or discharge side of the media by removing
retaining rails provided for media support and removal purposes as specified.
Dry Filters
A Dry filter stage will be provided to cover the entire intake face area of the cooling
module. Filters are extended surface, pleated type with 90% average dust arrestance
efficiency, 2” thick cleanable type with maximum velocity of 2 m/s. Filters shall be
removable from the intake side of the frame using bracketless lift and remove rack
system or side removable from a hinged panel provided for this purpose.
Low water level pump protection
A low water level protection system with float type level switch shall be used to
provide dry run protection for the pump.
Moisture drift eliminator
A moisture drift eliminator stage will be provided to prevent entrainment of water

droplet in the air stream from the cooling media. The mist eliminator shall be made of
HDPV


AUXILIARIES
Magnehelic Gauge
Magnehelic differential pressure gauge shall be provided to measure the pressure drop
across the cooling media to indicate the change in the resistance to air flow which
relates to the cooling media condition. The detector tubing shall be placed immediately
upstream and downstream of the media. Gauge shall be mounted externally on the unit
for manual reading of the pressure drop.
02.27 Centrifugal Fan
Generally the fans shall be of limit load design. Centrifugal Fan design shall conform to
IS 4894: 1987 (RA 1999). The fan shall be provided with drive motor, drive
coupling/V-belt, belt pulley, belt guard, fan inlet and outlet flexible connections, Guide
plate (to prevent direct contact of flexible fabric with air flow), slide rails, foundation
plates, gaskets, base frame, vibration isolators, Anchor / foundation bolts and nuts, fan
inlet protection screen and other standard accessories. In case standby fans or multiple
working fans are connected to the same duct line, fan outlet dampers shall also be
provided. All these items/materials and accessories shall be supplied with the fan.
The fan shall be of rugged steel construction, industrial duty type and suitable for the
proposed project/plant. Capacity and static pressure of fan shall be as per job
requirement. Fan housing shall be of welded construction and provided with flanges at
inlet and outlet sides for duct connections. The housing shall be provided with lifting
eye for ease of handling and bolted type access door. The equipment shall be designed
to permit ease of access during inspection, maintenance and repair.
The fan unit shall be free from undue noise and vibration during operation; normally the
fan speed shall not be more than 1500 RPM.
The fan shall be both statically and dynamically balanced as per ISO:1940. In general
HVAC system application balancing grade shall be of 6.3.
Casing & Impeller
Casing and inlet box shall be fabricated from mild steel (IS 2062: 2006) plate with
continuous welded joints and external stiffening to prevent vibration. Flanged, bolted
and gasketed access doors are to be provided in the equipment scroll and inlet box. The
casing and inlet box of each equipment / fan shall be split with bolted flange joints to
allow for removal of the impeller and shaft without removal of installed connecting
ductwork. The casing, inlet box, scroll and impeller shall be suitably designed to take
care of corrosive environment.
Shaft seals shall be provided at the casing and the inlet box. The housing shall be fitted
with a bottom drain, not less than 50 mm dia. The equipment units and drive motors


AUXILIARIES
shall be assembled on a common structural steel base plate wherever practical, to ensure
mounting rigidity.
Fan inlet / outlet velocity shall preferably be limited to 15 m/s.
The fan impeller may be backward curved for clean air application. The impeller shall
be of welded steel, designed for heavy duty and having non-overloading (limit-load)
power characteristics. The first critical speed of the rotating assembly shall be at least
25% above the operating speed.
Fans for ventilation systems shall have following minimum thickness of materials for
different parts unless otherwise specified :
a) Capacity below 20,000 m3/hr :
Casing : 3.15 mm
Back plate : 4 mm
Impeller : 2.5 mm
b) Capacity above 20,000 m3/hr and below 50,000 m3/hr
Casing : 4 mm
Back plate : 6 mm
Impeller : 3.15 mm
However, casing of 6 mm, back plate of 8 mm and impeller of 6 mm shall be considered

for fan capacity above 50,000 m³/hr.
Shaft
Shaft shall be steel bar stock or forging made of material conforming to EN 8 and
machined all over. The shaft with equipment impeller and half coupling mounted is to
be dynamically balanced.
Drive Coupling
The fan shall be directly driven. The drive coupling from the motor to fan shaft is to be
of flexible type suited for heavy duty and industrial application. A protective guard is to
be fitted over exposed drive shafts and coupling. Belt drive may be allowed only in case
of ventilation fans on specific approval of purchaser / consultant.
Bearings
The bearings are to be outside of the equipment casing and inlet box shaft seals and
shall be of heavy duty, self aligning, anti-friction, sump oil / grease lubricated type with

AUXILIARIES
readily accessible lubrication points. Adequate temperature protection shall be provided

for the bearings in order to avoid running the unit without lubrication. Bearings shall be
selected with ample safety factor for longer life. Bearing housings are to be split
horizontally, fitted with multiple seals to exclude dust while retaining lubricant and
shall have provision for mounting temperature and vibration sensors.
Guards
For all external rotating parts like coupling, belts, pulley etc., guards fabricated out of
sheet metal shall be provided.
Base Frame
Fabricated steel bracket of M.S. angles, channels and chequered plates shall be provided
to take static and dynamic load of the fan and motor assembly. The base frame shall be
fabricated of mild steel and shall support equipment housing, bearing pedestals,
coupling guards and drive motor where ever practical. All support mounting faces are
to be machined after all welding is completed. Jacking screws are to be provided
wherever necessary, to allow both lateral and longitudinal movement of equipment.
Vibration Standard
The fans and duct work shall be designed for minimum vibration. Maximum allowable
vibration level shall be as per VDI – 2056 guide lines. Sufficient number of suitable
vibration isolators of approved make shall be provided to ensure isolation of vibration
from the equipment to foundation as per requirement.
Vibration and Temperature Sensors
Vibration sensors and temperature sensors (RTD) shall be provided for each fan and
temperature sensors (RTD) shall be provided for each motor of centrifugal fan.
02.28 Tube Axial Flow Fan:
Tube axial flow fans shall be of heavy duty wall mounted type as per service
requirement. Axial fan design shall confirm to IS 3588: 1987(RA 1999).
The wall mounted supply / exhaust air fan shall be capable of withstanding the stresses
which may be experienced during normal operation under the condition which it is
required for and during over speed test. The noise level shall not exceed 85dB(A) at 1m
distance.
The first critical speed of the rotating assembly shall be at least 25% above the
operating speed. The speed of the fan shall preferably be limited to 1500RPM for fan
with diameter 600mm or less and 960RPM for fans with diameter more than 600mm to
limit the noise generation.

AUXILIARIES
Impeller:
The impeller shall be of cast aluminium alloy construction of high efficiency aerofoil
section blades. The fan impellers shall be cast in one piece, finished all over and
carefully balanced both statically and dynamically as per ISO - 1940. Finally the
assembled rotor shall be dynamically balanced.
Casing:
Axial flow fan casings and their components shall be suitable for outdoor installation.
The casing shall be minimum 2 mm thick. The casings shall be provided with flanges at
inlet and outlet. All nuts & bolts associated with it shall be of zinc or cadmium plated.
Easily removable inspection cover having galvanised fly nut shall be provided. The
covers shall be located such that the grease nipple for all bearings and also motor
terminals are easily accessible through the cover.
Hood and Cowl
Exhaust / Supply air fans shall be provided with hood for protection against rain and
other contingencies. It must ensure no dripping of rain water under any circumstances
and will have low pressure drop of air. The hoods shall be provided with a heavy gauge
(14G) expanded metal bird screen.
Rain protection cowls shall be designed for protecting fans from rain. The cowls shall
be provided with bird screen of heavy gauge expanded metal netting. The rain
protection hood & cowl shall be fabricated from minimum 14G thick MS sheet (Hot dip
galvanised).
Fan Drive
All direct drive axial flow fan impellers shall be directly mounted on extended motor
shafts.
Materials of Construction :
a) Impeller : Cast Aluminium Alloy

b) Shaft : EN-8 as per BS-900 or its equivalent
c) Fan Scroll : Heavy gauge M.S.
d) Fan Supports, Frames : M.S.
e) Coned inlet : M.S. 2mm thick
f) Dampers : M.S. of heavy gauge
g) Connection pieces : Galvanised M.S.
h) Bolts and Nuts : Galvanised M.S.
i) Rain protection cowls, : GI sheet
hoods and casing


AUXILIARIES
02.29 Erection, Testing, Commissioning & Performance Guarantee
Erection
Air Conditioning, Ventilation and Dust extraction / De-dusting systems shall be

assembled and erected at site with necessary allied facilities. The erection work includes
transportation of material from stores to site, making and making good of openings and
other civil work to suit equipment installation, installation of equipment, duct work,
piping and auxiliary items, trial run of equipment, cleaning of debris and waste material
and taking care of all defect points mentioned during preliminary acceptance tests
(PAT) along with adherence to the safety norms. Successful Bidder shall also take care
of watch & ward of equipment. Dismantling of assembled equipment/ system and re-
assembly/ re-erection, if required due to miss-communication among sub-vendors, shall
also be included in the scope of the Successful Bidder.
• Erection of structural steel work shall be carried out in an expeditious manner in

conformity with the drawings and specification.
• The Successful Bidder shall provide all construction and transport equipment, tools,
tackles, consumables, materials, labour, supervisors for erection.
• All items and fittings required for completion of systems shall be provided by the
Successful Tenderer.
• All erection work to be done in co-ordination with other tenderers working in that area
and under supervision of Purchaser’s representatives.
• The successful Bidder shall construct a temporary store cum office and shall dismantle
and make debris free the same after completion of work.
• Civil work of any nature required for duct & pipe support, opening in RCC / brick wall
for duct passage and making good of the same after completion of work, final grouting
of equipment, supply and fixing of anchor fasteners on RCC wall and roof for duct
support etc. shall be done by the Successful Tenderer.
Testing & Commissioning
The Bidder shall provide necessary supervisory personnel, all tools and tackles, testing
equipment and instruments, approach facilities, etc. required for complete checking of
installation, testing and commissioning of all equipment with auxiliaries and
accessories. After erection of equipment and all necessary allied work mentioned in
scope of work, ACVS and DE systems shall be tested and commissioned.
The equipment shall be tested and commissioned in accordance with the latest relevant
standards and codes of practice published by Bureau of Indian Standards, wherever
available. In case Indian standards are not available and requirements/ procedures not
mentioned, these shall be carried out in accordance with the latest standards and codes
of practice published by any other recognised National Standard Institution.


AUXILIARIES
The testing and commissioning of other equipment/ components shall be carried out by
respective equipment supplier/ manufacturer to avoid any unforeseen failure of the parts
/ system.
The testing of all sub-systems as well as the equipment as a whole shall be carried out to
ensure that the equipment and its components are in satisfactory condition and will
successfully perform its functional operation.
All tests shall be carried out by the successful bidder using his own instruments, testing
equipment (with valid calibration certificate) as well as qualified testing personnel.
At site, equipment shall be energised only after certification by the personnel

performing the test and that the equipment is ready for energizing and with the
concurrence of the Purchaser.
Results of start-up tests and commissioning shall be recorded jointly by the successful
bidder and the Purchaser.
After commissioning, 72 hrs continuous trial run shall be made before handing over the
plant to the Purchaser. Moreover, the guarantee clause and conditions stipulated under
the TS shall hold good even after taking over by the Purchaser. The required operators
and persons for watch & ward, testing & commissioning and for period between final
acceptance test and handing over the systems to Purchaser, shall be provided by the
successful bidder as per site requirement.
The equipment will be subjected to final performance tests and the Bidder shall
guarantee the performance of the equipment upto relevant standards and specifications
to meet the requirements as given in this specification in the presence of the Purchaser
or his representatives. Demonstration of PG parameters will be done by Bidder in an
integrated manner when main technological plants are in full operation. The tests /
checks to be demonstrated by successful bidder will be generally as under:
1. Performance of Air conditioning, Ventilation and De-dusting systems along with all
safety interlocks shall be demonstrated by the successful bidder in the presence of
Purchaser /Consultant.
2. During operations of the equipment at no load and at full load, performance of all the
drives will be checked in respect of current drawn by the motors etc. temperature rise,
vibrations, gear box noise and its heating, bearing heating etc. Consumption of power
and lubricants etc. will also be measured and compared with the respective rated values.
3. Indoor climate condition (temperature, relative humidity) of served premises shall be
measured for consecutive three days, twenty four hours duty condition at two hourly
intervals.
4. Any other observations / tests felt necessary for judging the performance of the system
after mutual agreement between successful bidder & Purchaser will be carried out.
Performance Guarantee (PG)


AUXILIARIES
The PG test will be conducted for three (3) consecutive days in the Summer season as
per the date mutually decided by employer/consultant/successful tenderer. However, the
Tenderer, Purchaser/ Purchaser’s representatives will jointly prepare the procedures to
be followed during PG test indicating the period.
Once the installation of ACVS & De-dusting systems are over, there will be a joint
survey with successful Tenderer and Client for total system during daytime. During this
survey, following points will be checked to the satisfaction of Client when the ACVS &
De-dusting systems are under full load operation:
1. Inside condition of air conditioned premises shall be maintained at temp. 23+2 deg C &
55+5% RH.
2. For ventilation system, fan capacity and performance of motors shall be tested at site.
Negative tolerance on unit capacity will not be allowed.
3. Pressure drop across bag filter shall not exceed 140 mm WC.
4. For each system, 3 sets of work area environment readings and emission data at the bag
filter outlet will be collected and the average of 3 readings will be considered as actual
performance of the system and it should be restricted to 70 mg/Nm3. Any abnormality
will be sorted out by mutual discussion at site.
In case unit capacities and design parameters guaranteed by the successful

Tenderer are not established during the performance guarantee testing, the Client
at his discretion may reject or accept the concerned system after due correction by
the successful Tenderer to achieve the guaranteed parameter.
Final Acceptance
All the equipment, plants and system under this TS will be taken over by the Client in
running condition and final acceptance certificate will be issued by the Client when :
a) Performance guarantee tests in respect of sub-units as well as the unit/ system as a
whole have been carried out and integrated performance guarantee values have been
achieved under normal & peak operation of process equipment.
b) All other supplies and services have been completed.
c) Supply of spares has been completed.
d) The successful Tenderer has met any and all other obligations including objections /
observations mentioned in the commissioning certificate.
e) The successful Tenderer has submitted all final documents incorporating latest
modifications in the As-Built Drawings.


AUXILIARIES
f) The unit has operated satisfactorily for a period of 12 months / as decided by client from
the date of commissioning certificate.
g) Warranty period has expired.
02.30 Documentation
The following minimum documents shall be provided by successful Tenderer after the
award of contract as per agreed schedule:
- Design Basis Report (with back-up calculation for equipment sizing)

- P & I diagram
- GA drawings along with Technical data sheet for chiller, AHU, pumps, fans,
cooling tower, electric hoist, MCC panel, Bag filter, Dust transportation system,
intermediate silo, etc.
- Equipment layout drawings for De-dusting system, chiller plant, AHU room, etc.
- Quality assurance plan (Mechanical & Electrical)
- Control philosophy
- Documents as per the approved QAP.
- Technical catalogues for bought out equipment.
- Erection drawings of the equipment / components with bench-markings to
facilitate smooth erection / assembly at site for DES & ACVS.
- Erection, testing, commissioning, special instructions and start-up manual.
- As built drawings
- Operation & maintenance manual
All the drawings shall be made in AUTOCAD and soft copies of all the drawings /
documents shall also be submitted in AUTOCAD (editable version).
02.31 Spares, Tools and Tackles
Mandatory spares, commissioning spares, special tools & tackles as required shall be
supplied by the Tenderer without any commercial implication till successful
commissioning of VAM, ACVS and De-dusting systems. Unused spares, if any shall be
handed over to the Client.
Recommended two years’ spares list for operation & maintenance of the ACVS & de-
dusting system shall be furnished as per the table given below:
Sl. No. Description of items Quantity

1. 1Bags 50% of total nos.
2. 2Cages 20% of total nos.
3. 3Solenoid Valve 15% of total nos.
4. Rotary Airlock Valve 5% of total nos.

AUXILIARIES
5. One (1) spare geared motor (having gear box

One no. of each size / type
& motor) for Telescopic Chute
6. Instruments (DP switch, level switch, pressure
One no. of each type
switch, PG, TG) for bag filters
7. 01 Set for each type /
AHU / Fan Bearings
capacity
8. Impeller along with shaft assembly For each AHU
9. PG, TG, strainer & balancing valve for AHU 01 set for each type
10. Absorbent For one year consumption
11. Inhibitor For one year consumption
12. Rubber expansion joints 01 set for each pump
13. Impeller along with shaft assembly For each pump
14. Cooling tower nozzles 20% of total nos.
15. Gland packing 02 sets for each pump
16. Mechanical seal, coupling, wearing ring &
1 set each
bearings for pumps
02.32 Painting
The complete paint system for any item shall include the following basic activities:
i ) Proper surface preparation
i i ) Application of primer coats
i i i ) Application of intermediate coats
iv) Application of finished coats
Surface preparation - All surfaces shall be cleaned of loose substances and foreign
materials, such as dirt, rust, scale, oil, grease, welding flux, etc. in order that the prime
coat is rigidly anchored to the virgin metal surface. The surface preparation shall
confirm to pictorial representation of surface quality grade of Swedish Standards
Institution SIS – 055900 or equivalent standards such as SSPC – VIS – 1.67 or DIN
55928(Part 4) or BS 4232 or IS 1477 – 1971 (Par t I).
Paint application - Paint shall be applied in accordance with paint manufacturer’s

recommendations. The work shall generally follow IS 1477 – 1971 (Par t II) for jobs
carried out in India and SSPC-PA-1 or DIN 55928 or equivalent for jobs carried out
outside India. Paint shal l be applied at manufacturer’s recommended rates. The dry film
thickness of painted surfaces shall be checked with ELCOMETER of measuring gauges
to ensure application of specified DFT. Paint shall not be applied when the ambient
temperature is 5 deg C and below or 45 deg C and above. Also paint shall not be applied
in rain, wind, fog or at relative humidity of 80 % and above unless the manufacturer’s
recommendations permit.
All fabricated steel structure, fabricated steel pipes, etc. shall have a minimum of two
coats of primer paint before dispatch to site. Total DFT shall be 170 – 200.

AUXILIARIES
02.33 General Instructions to Tenderer w.r.to ACVS & DES :
1. The Tenderer shall study this specification carefully and make themselves conversant
with the scheme and the site conditions for the execution of ACVS & Dust Extraction
systems.
2. The Tenderer shall submit the necessary credentials to satisfy the Consultant / Client that
they possess necessary technical know-how of the system and facilities to execute the
order.
3. All items of equipment in this specification shall be complete in all respect including
civil, structural, mechanical, electrical & instrumentation equipment / part as specified
including fasteners, foundation / anchor bolts and nuts, gaskets, base frames, stiffeners,
supports, canopy over the exposed motors, etc. Any item not covered in this specification
but essential for superior design, smooth & safe operation and to meet guaranteed
performance of the system shall be included by the Tenderer.
4. The equipment shall be designed, manufactured and tested in accordance with the
relevant standards prescribed by the Indian Standard Institution (Bureau of Indian
Standard) wherever possible. In cases where suitable Indian Standards are not available,
the equipment shall conform to generally accepted standards and codes acceptable to the
Consultant / Client.
5. All equipment supplied and work done shall be suitable for use under heavy duty
condition of MTPS plant. In the interest of standardization, Client reserves the right of
selecting a particular manufacturer of equipment/ component as indicated in this
specification.
6. The Tenderer shall not off-load the contract or part thereof to any sub-tenderer without
written permission of the Client. In the event of subletting the contract or any part thereof
is permitted by the Client, the fact that such permission has been accorded shall not
establish any contractual relationship between the approved sub-tenderer and the Client
and nor shall release/ free the Tenderer from the obligations under the contract. Facilities
shall be provided by the Tenderer to enable the Client's authorized inspector to inspect the
equipment and their auxiliaries at all stages of manufacture to satisfy themselves as to the
use of proper material and workmanship. Apart from this, the equipment shall be tested or
suitable test facility shall be provided by the Tenderer to enable checking of operational
parameters, if so desired.
7. The work shall be carried out strictly as per the specification and approved drawings and
as per the direction of Client. The Tenderer should quote for the complete job on turnkey
basis in line with the technical specification.
8. All moving parts of equipment which can conceivably cause injury to the operator or
otherwise authorized personnel within the vicinity of the working area, shall be suitably
guarded.
The tenderer shall strictly adhere to the safety norms during the site execution without
fail.
9. The Tenderer shall provide a complete new and unused set of all tools and tackles,
consumables, instruments and spares required for erection, testing & commissioning.

AUXILIARIES
10. The Tenderer shall furnish all technical data of the equipment along with layout &
schematic drawings of system during the tendering stage. However, these data shall be
finalized during detailed engg.
11. The tenderer shall also mention their utility requirement, if any in the technical offer.
12. The Tenderer shall ensure that each equipment is provided with non- corrodable name
plate engraved in English language with the details like supplier's address, operation and
design parameters, weight, precautions, etc.
13. Technical specifications and capacity of the equipment given are for general guidelines
and indicative only. However, the Tenderer will examine and select the equipment and
include other accessories to suit the duty requirements and other performance guarantee
parameter.
14. The Tenderer shall indicate the final kW and frame size for the motor after considering
15% (min) margin over the BkW for all systems (ACVS & De-dusting system) at the
operating condition. However, the tenderer shall ensure that motor rating will be more
than the derated kW at the temperature prevailing at site.
15. The Tenderer shall ensure that the speed of operation of all the mechanical and electrical
equipment shall be kept low enough to reduce noise, vibrations and wear.
16. All equipment supplied shall also meet/ comply with the statutory requirements of the
Government of India, the Government of Tamil Nadu and the latest version of Indian
Electricity Rules and Environment (Protection) Rules of Central/State Pollution Control
Boards, Factories Act etc.
17. No deviation in preferred makes is acceptable unless it is approved in advance by Client.
If any additional make is sought by the successful tenderer during detailed engineering,
then the delay occurred in getting approval of that particular make, shall be solely
attributable to the successful tenderer.
18. All equipment shall be shop tested according to the relevant standards. The particulars of
the proposed tests shall be submitted to the Consultant / Client who shall be given full
access to all the tests as per approved QAP. The client / consultant shall be informed by
the successful tenderer well in advance for the witness of tests / inspection at
manufacturer’s works.
In case, the client / consultant does not make himself / herself available due to some other
exigency for the witness of tests at manufacturer’s works, the supplier shall approach the
Client with all necessary documents for clearance for dispatch of equipment.
19. At the time of inspection, the Tenderer shall furnish internal routine inspection certificate,
material test certificates, approved drawings and QAP etc. to the inspector. Inspection at
different stages of manufacturing as desired by client may be done to satisfy them
regarding the quality of materials, used workmanship, etc. No equipment and material
shall be dispatched to site without inspection certificate / waiver in writing from the
Client. In the event of waiver, shop test certificate including internal inspection certificate
along with other document as per the approved QAP shall be furnished. Inspection shall
be regarded as a check only and shall in no way relieve the successful Tenderer of his/her
responsibility.
Generally, equipment from indigenous sources will be preferred. Imported equipment
shall be included only when absolutely necessary and shall be listed separately with their

AUXILIARIES
prices. In case of import, the Tenderer shall have to make his own arrangement to
procure and F.O.R supply. The supply of such material with 30% spare parts shall be
ensured only after ensuring availability of after-sales service of the equipment in India.
20. The quantity of items given in Schedule of Equipment and elsewhere in the technical
specification is indicative only. No additional payment is admissible for variation in
quantity of items after award of contract.
21. Language of drawings, name plates of the equipment and operation and maintenance
instructions shall be in English language. S. I. units shall be used.
22. Proper platforms, walkways, railings, toe guards, approach and access to manholes,
dampers, valves, instrument measuring points, etc shall be provided by the successful
tenderer.
23. The successful Tenderer shall make provision for all miscellaneous items required for the
proper operation of the system during demonstrations of all guarantees till final
acceptance test. These shall be made available at site along with the major equipment in
adequate quantities by the successful Tenderer.
24. All materials / equipment shall be properly packed to avoid rusting, pest attack and any
damage during transportation / site storage. However, all damages if any occurred during
transit / storage at site, the responsibility shall rest with the Tenderer only and
rectification of defects (to the satisfaction of client) / replacement shall be done by the
Tenderer without any extra cost to the client. The packing list and dispatch document
shall be included along with the packing.
25. After award of contract, no claim for extra payment submitted by the successful Tenderer
on ground of any special local working conditions or nature of subsoil for foundation
shall be considered.
26. All welding shall be of structural steel standard and only certified welders shall be
employed.
The tenderer shall ensure that 10% safety factor over the design of DES shall be
considered.
Equipment makes shall be as per the list of preferred makes mentioned herein.
27. Initial fill of lubricants, oils, grease and other consumables as may be required for smooth
operation of equipment and systems shall be provided by the successful Tenderer. Any
refill or replacement required upto the handing over of the system shall be provided free
of cost by the successful Tenderer.
28. Noise level generated by the equipment shall not exceed the permissible limit of 85 dB
(A) at 1m distance from the equipment during full load condition.
29. Calibration of all instruments, dimensions in drawings, technical data, weights and
quantities shall be in S.I units. All drawings, name plates of the machinery & equipment
and operation & maintenance instructions shall be in English language.
30. The expected life of plant and equipment shall be taken as 20 years on round the clock
operation basis. All plants and equipment shall be designed with this consideration in
view. Choice of materials, their sizing, surface treatments, etc. shall be decided
accordingly. As far as possible, environment friendly materials and consumables shall be
used.

AUXILIARIES
31. The Tenderer shall guarantee the satisfactory performance of the equipment/systems
supplied by them throughout the year. The Tenderer shall arrange for attending faults,
replacement of components etc. during commissioning of the system and till handing over
of plant to the Client. The Tenderer shall supervise the demonstration of the functioning
of electrical interlocks and control prior to offering the systems for FAT (final acceptance
test). The following reputed/ accepted publications, norms/ guidelines, standards, acts &
rules etc. shall be followed for execution of the work:-
a) B.I.S Publications
b) ASHRAE handbook
c) ACGIH publication, USA
d) ARI publication
e) I.S.O Publications
f) VDI stipulation for vibration level
g) Occupational safety and health act (USA)
32. In the cases where norms/ standards/ guidelines other than those listed above are
followed, the Tenderer shall furnish a copy of such document (s) in support for the
Client's perusal and acceptance. Wherever a contradiction is found between different
documents being followed, the decision of the Client will be final and binding.
02.34 Equipment Schedule for de-dusting/ dust extraction system
The tentative equipment/ components of the systems considered are furnished below.
However, the tenderer shall provide the system in line with the TS :
SL. Served System Equipment/ items of the system Quantity

NO. Building Considered
01. 870138 Nm3/hr capacity (approx.) bag filter unit 4 nos.
complete with inlet and outlet expansion joints, air
dilution motorized dampers, explosion vent, dust
collection hopper with rotary air lock valve, heater,
Bag filter silo with rotary air lock valve & slide gates,
Day Bin based dust structural platform, ladder and supporting
Building extraction structures, insulation, electric hoist, etc.
system of 4 x Ducting network with stiffeners, approach stairs, Lot
870138 inspection doors and supporting structures across
Nm3/hr the bag filter.
capacity Bag cleaning system complete with compressed air 4 sets
(approx.) header pipe, manual valve, pressure regulator, air
And silo manifold tank, solenoid valve with timers, array of
dedusting pipes with nozzles, etc.
Dedicated Compressors, dryers, air receivers, Lot

AUXILIARIES
piping & instrumentation as per the TS.

Dust transportation system upto intermediate silo. 4 sets
Electrics, instrumentations and controls etc. Lot
Hopper heater & hopper vibrator along with Lot
insulation / cladding for bag filter hopper &
intermediate silo.
Bin vent filter with fan for lime storage silos, Lot
intermediate dust storage silos, main by-product
silos.
02.35 Equipment Schedule for ACVS
SL. EQUIPMENT SPECIFICATIONS Heat loads, no. of QUANTITY

NO. persons and size of
room
I AIR-CONDITIONING :
1a Main Central A/C Chiller plant for control
room, electrical room, offices, conference room,
cabins, etc with vapour absorption machines
(steam based chillers -1W) , Standby vapour
compression screw chiller of identical capacity -1
(SB), induced draft cooling towers (1W+1S),
vertical inline centrifugal pumps with 100%
standby for both chilled water & condenser water,
steam piping with insulation, valves, electric hoist
with monorails, flow meter, thermally insulated
expansion tank with necessary valves &
accessories, safety devices & interlocks, etc. TO BE GIVEN TO BE
1b Double skin Air Handling Units – with 100% BY TURNKEY GIVEN BY
standby. SUPPLIER TURNKEY
1c Condenser cooling & chilled water piping with SUPPLIER
insulation, valves & fittings, supports, etc.
1d Ducting with necessary insulation, SA & RA grills
/ diffusers, supports, fire damper, etc.
1e VAV boxes with actuator, sensor, etc to control
temperature automatically.
1f Thermal (hot & cold) & acoustic insulation
1g Electrics and Instrumentation
2a Split A/Cs for isolated premises, if any with
necessary accessories to complete the system.
II VENTILATION SYSTEMS :
V-1 Pressurised plenum wet ventilation systems
(PPVS) for MCC cum switchgear rooms with

AUXILIARIES
centrifugal fan, motor, dry panel air filter, damper,

ducting, SAG, supports, electrics and other
accessories.
V-2 TA Exhaust fans of suitable capacity with louver
shutter and other accessories for A/C plant room,
pump houses, transformer room, compressor
room, cable cellars, toilets, etc.
N. B. : The above list is only tentative and for the guidelines purpose. Any other area
that needs Air conditioning or ventilation and not covered above will also be provided
with the necessary facilities of ACVS without any price implication.
02.36 Technical Data to be Furnished
1. VAM - General
a) Application
b) No. of units (working + standby)
c) AC plant capacity (TR)
d) Refrigerant & Absorbent
e) Type of VAM machine ( single effect/double effect)
f) Charge (Refrigerant & Absorbent) of all circuits (kg)
g) Overall size
h) Shipping & Operating weight
- Design & construction features
a) Make/Type
b) Model No.
c) Maximum power required (kW)
d) Type of capacity regulation
e) No. of steps of control
f) Type of drive
g) Range of load operation
h) No. & type of heat exchangers
i) MOC
• Condenser tube
• Chiller tube
• Shell
• HT generator tube /tube sheet
• LTG tube
• Casing / Impeller for pump
• Bolts /Nuts
• Base frame


AUXILIARIES
j) Auxiliaries
• High /Low pressure gauge (Yes / No)
• High /Low pressure switches (Yes / No)
• Water differential switch (Yes / No)
• RTD (Yes / No)
• Automatic unloading device (Yes / No)
• Solution pump (Yes / No)
• Refrigeration pump (Yes / No)
• Vacuum pump (Yes / No)
• Local control panel (Yes / No)
k) Performance :
• Design hydraulic /pneumatic test pressure (kg/cm2)
• Condenser cooling water side fouling factor
• Water fouling factor for evaporator
• Water fouling factor for absorption
l) Condenser
• Type /arrangement
• Manufacturer /model no.
• Fluid flow rate (m³/hr)
• Inlet/outlet temp (Deg. C)
• Fluid velocity (m/s)
• Pressure drop (allowable / calculated)
• Fouling resistance
• Bundle /Nozzle orientation
• Design (Hydrostatic) test pressure and duration
• No. of passes
• Corrosion allowances
• Connection size (inlet / outlet)
• Thickness (Min/Average)
• Length of tubes
• Thermo wells
• Pressure gauge
• Vent connection with valve
• Drain connection with valve
• Relief valve / fusible plug
• MOC – Shell & Tubes
m) Absorber
• Type arrangement
• Manufacturer / model no.
• Performance / selection chart furnished


AUXILIARIES
• Thermo wells
• Pressure gauge (manometer)
• Vent connection with valve
• Drain connection with valve
• Relief valve
• Anti freeze thermostat
n) Refrigerant piping, valves & fittings (Included / Not included)

o) Piping details
p) Valves (included / Not included)
q) Solenoid valves (Liquid line) - (Included / Not included)
r) Charging valve (included / Not included)
s) Sight glass (included / Not included)
t) All necessary supports for refrigerant piping provided (Yes / No)
Chiller data
• Chilled water inlet temp. (Deg. C)

• Chilled water outlet temp. (Deg. C)
• Chilled water flow (CMH)
• Steam pressure inlet to PRDS
• Steam pressure & temperature inlet to VAM
• Steam consumption
2. Cooling Tower
1 Make & Model

2. Type of Tower & Nos. of cell
3. Capacity per cell, m3/h
4. Overall dimension LXBXH
5. Rated water flow, m3/h
6. Design wet bulb temp., oC
7. Approach, oC
8. Cooling range at rated flow, oC
9. Evaporation loss at rated condition, %
10. Temperature of leaving air, DBT/WBT
11. Water flow area, m2/cell
12. Water flow rate/m2 of water area, m3/hr/m2(L)
13. Vibration level of Tower
3. Centrifugal Vertical In-line Pumps
1. Make & Model

2. Capacity in m3/h

AUXILIARIES
3. Total head in m of water column

4. Material of impeller & casing
5. Type of seal
6. Type of pump
7. Pump RPM
8. Static & dynamic wt. of pump & motor
9. Liquid to be handled
10. Drive details
11. Power consumption at pump shaft / Offered motor KW/P/RPM
12. Efficiency
13. Type and No. of bearings
14. Foundation bolt
4. Air Handling unit
1. Make & Model

2. Type (horizontal / vertical )
3. Capacity in m3/h
4. Fan pressure selected
5. Overall size
6. Inner skin / outer skin material
7. Outer skin surface treatment
8. Material & material thickness for copper coil
9. Material & material thickness for aluminum fins
10. Material & material thickness for drain pan
11. Material & material thickness for base channel
12. Type and Nos. of fan
13. Fan shaft power / fan RPM
14. Selected fan motor KW /P
15. Chilled water coil make / model
16. Nos. of coil per AHU
17. Water flow / coil tonnage
18. Air side & water side pressure drop
19. Coil rows selected
20. Fin spacing
21. Temp. & pressure at inlet & outlet of coil
5. Dry Panel Filter
1. Make & Model.

2. Capacity in m3/h
3. Pressure drop in mmWC.
- When clean
- When dirty
4. Effective cross sectional area in m2

AUXILIARIES
5. Velocity through filter in m/sec.

6. Material of filtering panel.
7. Cleaning efficiency Vs particle size
8. Methods of cleaning.
9. Filter box construction details.
10. Overall dimensions & no. of filters.
11. Fixing frame details
12. Total weight
6. Valves / Strainer
1. Type
2. Make & model
3. Nominal bore in mm
4. Working pressure/Test pressure in kg/cm2
5. Medium handled
6. Type of end connection
7. Material of construction
8. Type of drive (if any)
9. Total weight & quantity
7. Water Pipe & fittings
1. Material
2. Make and Class
3. Pipe size, thickness, length, weight & quantity
4. Type & quantity of fittings
5. Hydro -test pressure & duration
8. Ducting Including Supply Air Diffusers with Volume Control Damper
a) Ducting
1. m2 of duct work
2. Weight of duct work
3. Weight of support and flanges
4. Material and thickness of duct work & GI glass
5. Duct support type and material
6. Velocity of air for different section of duct
b) Supply Air Diffuser with volume control facility
1 Size
2 Quantity offered

AUXILIARIES
3 Material of construction & thickness

4 Provision of horizontal & vertical direction control
5 Weight
6 Velocity of air
7 Methods of volume control
c) Return air grills/intake air louvers
1. Size
2. Quantity offered
3. Material of construction
4. Weight
5. Velocity of air
d) Insulation (Thermal & Acoustic)
1. Make & Type

2. Quantity
3. Density in kg/m3
4. Thermal conductivity
5. Sound absorption co-efficient
6. Moisture absorption co-efficient
7. Material of construction and its thickness
8. Application procedure reference standard.
9. Vapour barrier material
10. Fire resistance property
11. Cladding material
9. Centrifugal fan
1. Make and Type

2. Model No.
3. Capacity in m3/h
4. Static pressure in Kgf/m2
5. Speed in rpm
6. Impeller diameter, Wt. & GD2 value
7. Characteristic curves for the given speed & dia
8. Shaft power
9. Total static efficiency
10. Fan characteristic curves
11. Drive details (Type, kW, pole, rpm & voltage/freq.)
12. Bearings
13. Thickness and material; in wheel, shaft, scroll etc.
14. Outlet / inlet velocity
15. Variable inlet vane damper (type & size)

AUXILIARIES
16. Static weight

17. Dynamic weight
18. Noise level at one meter distance
19. Vibration level
20. Vibration isolation arrangements
21. Supporting frame
22. Details of flexible connection at fan inlet & outlet
23. Sheet thickness of different parts of fan
24. Accessories included with specified detail
10. Air washer
a) Air washing chamber with water tank

1. Make & Model No.
2. Overall dimensions (mm)
3. Weight (kg) with and without water
4. Air flow capacity in m3/h & Air flow velocity in m/s
5. Total Pressure drop, kgf/ m2
6. MOC, diameter and numbers of spray header pipes and nozzles
7. Make up water requirement
8. Details of make up, over flow, drainage, supply and return water pipe
lines
9. Saturation efficiency
10. Amount of water and its pressure at the nozzle
11. Material of construction and thickness of casing, tank, air distributor
plate
12. Water tank capacity
13. Details of mist /droplet eliminator : MOC, material thickness and depth.
b) Intermediate chamber
1. Size, Material of construction & Thickness of material
c) Adapter section
1. Size, Material of construction & Thickness of material
d) Re-circulating water system

1. Pump capacity & head, motor KW
2. Details of piping, fittings, strainer, valves
3. Instruments – pressure gauge, temperature gauge, water flow switch
11. Tube Axial fan
1. Make & Model

2. Quantity
3. Capacity in m3/h.

AUXILIARIES
4. Total Pressure, mmWC

5. Characteristic curves for the given speed & dia
7. Speed in RPM
8. Drive details like make, kW rating, type & protection class, etc
9. Shaft Power consumption
10. Wheel diameter
11. Efficiency
12. Size of fan
13. Static & Dynamic weight of fan & motor assembly
14. Critical speed of fan
15. Noise level at 1m distance in dB(A)
16. Performance curve
17. Air flow direction
18. Fixing details
19. Vibration level
12. Bag filter
1. Make and type

2. Model No.
3. Type of bag filter
4. Capacity in m3/hr
5. Filtering area in m2 (including A/C ratio)
6. Fabric type
7. No. of bags & modules
8. Diameter & length of bags in mm
9. Filtering velocity m/sec.
10. Pressure drop in mm WC (during clean & dirty)
11. Weight of bag filter in kg (without dust)
12. Weight of bag filter in kg (with dust)
13. Efficiency of bag filter Vs particle size
14. Material / thickness of bag filter casing in mm.
15. Material / thickness of bag filter hopper in mm.
16. Compressed air requirement in Am3/hr & Nm3/hr.
17. Compressed air pressure
18. Compressed air quality
19. Velocity of air at inlet / outlet in m/sec.
20. Fixing arrangement of filter bags
21. Hopper – size, capacity & wt. per module
22. Overall space requirement (L x B x H) including accessories of B/F
23. Rotary feeder details
a) Quantity
b) Capacity in m3/hr (at 50% filling)
c) Speed in rpm

AUXILIARIES
d) Motor rating kW & Pole.

e) Material of construction of casing & blades & thickness
24. Storage Hopper
a) Volume in m3
b) Valley angle
c) Size (L x B x H)
d) Motor rating kW & Pole for RAL & bin vibrator.
e) Material / thickness of hopper
f) Weight in kg (with / without dust)
25. Telescopic chute for dust disposal

26. Support / Structure / Weathering shed for bag filter
27. Hoisting arrangement for bag
13. Expansion Joints / Flexible Connection
1. Make, Model & Type

2. Size
4. Total weight
5. GA drawing with dimensions
6. Fixing arrangement & Orientation
7. Sealing arrangement.
8. Fabric / Bellow details
9. Liner details
10. End connection
11. Temperature range
12. Technical details as per manufacturer’s data sheet
13. Any other information
14. Damper – Manual / pneumatic Operated
1. Make & Model & Type

2. Size
4. Total weight
5. Fixing arrangement
6. Details of actuator and power / compressed air requirement
7. End Connection
8. Rate of valve leakage in fully closed position. This leakage is to be given as a
percentage of the normal flow with the valve open.
9. Any other information
15. Insulation


AUXILIARIES
1. Make & Type

2. Quantity
3. Density in kg/m³
4. Thermal conductivity
6. Application procedure reference standard.
7. Vapour barrier material
8. Fire resistance property
9. Cladding material
16. Electric hoist
17. Motor
18. Instrumentation
19. Others, if any
20.00 Steam Facilities
20.01 General
Steam shall be supplied at the takeover point (TOP) by the Purchaser. The Bidder shall
make further connections from TOP.
Bidder shall make further connections for steam systems from the TOP complete with
isolation valve, metering devices, controls and instruments.
20.02 Scope of work
The scope of work of the Bidder under this specification covers design, engineering,
manufacture / procurement, assembly, inspection, testing, shop painting, supply,
transportation, delivery, storage at site, erection, testing, painting & commissioning of
steam service.
The supply shall include pipes, valves, supports, fittings, insulation, paint material etc.
for the completeness of the system.
Bidder shall also follow the instructions for design, engineering, supply, fabrication,
erection, testing, painting & commissioning of the pipeline as furnished elsewhere in
the technical specification.
• The Bidder shall furnish following drawing / document for information / approval.


AUXILIARIES
• Scheme drawing.
• GA and cross section drawing with binding dimension showing pipe dia,
supporting arrangement, location of valves etc..
• Data sheet catalogues for valves, equipment & fittings etc.
• Specification of pipeline.
• GA and detail of Pressure reducing station.
20.03 Design basis
20.03.01 Steam
Steam shall be available at the TOP from the new boiler at a pressure of 12 kg/cm2 &
temperature of 180 - 2000 C. The size of existing steam header at TOP is DN 100.
Steam will be required for steam based VAM system.
All condensate shall be discharged to drains at suitable interval through traps &
strainers.
General guideline for pipe sizing and other details to be followed are listed below:
For pipe sizing:
i) Pipelines shall be sized by limiting the gas velocity in the pipeline as per below
Table 1.
ii) Peak flow rate based on the distribution pattern shall be considered for sizing of
pipes.
iii) Sizing shall be based on actual flow rate at worst combination of

parameters i.e. lowest pressure and highest temperature.
iv) In case recommended velocity is dependant on diameter range, after initial

sizing, velocity should be re-checked and if required size should be recalculated.
v) Nearest higher standard pipe size shall be selected after calculation.
vi) Pressure drop calculation shall be carried-out in order to ensure the required pressure
at consumer end.
TABLE: 1
Sl. Fluid Condition Average Velocity, m/sec Remark

AUXILIARIES
No Up to DN 50 to DN 200mm s
DN 50mm DN 150 mm and above
1 Saturated At Sub- - 10 – 15 15 – 20
Atmospheric Pressure
2 Saturated At 1 To 7 15 – 22 20 – 33 25 – 43
kg/cm² (g)
3 Saturated Above 7 15 – 25 20 – 35 30 – 50
kg/cm² (g)
4 Superheated Upto 20 – 30 25 – 40 30 – 50
7 kg/cm² (g)
5 Superheated Above 20 - 33 28 – 43 35 - 55
7 To 35 kg/cm² (g)
All Pipe work shall be designed to provide sufficient flexibility against thermal
expansion to prevent development of undesirable forces and moments at points of
connection to equipment, at anchorage or at guide points. Whenever self-
compensation can not be achieved by pipe routing, provision for thermal
expansion shall be made by providing expansion loops. This shall be achieved by
providing U-loop in between two fixed support.
20.03.02 Valves and Isolating Devices

Isolating devices shall be provided in piping system for isolation of pipe sections
as well as for isolation of all other mounted accessories for the purpose of
operation and maintenance. They shall be suitable for the service conditions in all
respects and located suitably considering ease of operation and maintenance.
Isolation valves shall be provided at the following locations:
• On all pipe lines both at the source and at consumer ends

• On all branch pipes to individual buildings and shops
• On all bleeder / vent pipes
• On all by-pass lines for large valve, regulators, filters, moisture traps etc.
• Instrumentation tapping points.
20.03.03 Selection of Actuators for Isolating devices:
Manually operated shut-off gate valves of size upto DN 450 mm for low pressure
lines shall not have gear drive. For high pressure lines, gear operator shall be
provided as per manufacturer’s recommendations for limiting the operating torque

AUXILIARIES
to acceptable limits.
Gate Valves of size DN 500 and above shall be preferably provided with
pneumatic actuator to work with air / nitrogen at 3.0 Kgf/cm2(g).
Electrically operated gate valves for gas pipelines of smaller diameter are
recommended to be used only if they are incorporated in the automation scheme.
All valves located remotely, requiring frequent operation and / or with automatic
control shall be provided with electric drives, electro- pneumatic drive, solenoids
etc.
Check valves shall be used in piping system where unidirectional flow is required.
For small size pipes below DN 50, lift check valves shall be used. For DN 50 and
above, swing check valves or dual plate check valve shall be used. Lift check
valves shall be used only in horizontal pipeline. It should not be used in vertical
pipeline.
The Pressure Regulating valve shall be of globe / needle type, with material
specifications, dimensional standards etc. as per Piping Material Specification (PMS)
for the service for which the valve is intended.
For Steam service, sizes up to DN 50, pressure reducing valves of single seated
diaphragm type having in-built strainer, with screwed ends up to DN 20 for PN 10
and below and flanged ends for higher sizes and for higher PN. Body of main and
pilot valves shall be of carbon steel / alloy steel castings / forging, diaphragms
shall be of stainless steel, internal springs of stainless steel and pressure adjustment
springs of spring steel.
For higher sizes to meet larger flow rates, the pressure reducing valves shall be as
per manufactures standards, but capable of meeting the service conditions and duty
specified.
20.03.04 Fabrication and installation of pipe work

Pipe joints shall be assembled with the inside of all pipes and fittings smooth,
clean and free from burrs, scale, welding slag, sand and dirt. The inside edges of pipe
and tubing shall be reamed after cutting to remove burrs. Screw threads shall conform
to ANSI B 2.1 for taper pipe threads. All the threaded joints shall be made up with a
lubricant or compound suitable for the service under which the piping is to be used.
Welded joints shall conform to “Code for pressure piping ANSI B31 1.0 (power
piping) or approved equivalent, except where the welding of such joints is covered by
other code requirements such as IBR, ASME pressure vessel and boiler code or


AUXILIARIES
approved equivalent.
Branches shall, in general, be formed by welding standard fittings. Pipe bends and tees
shall be truly cylindrical and of uniform sections. Where permitted for certain
services, elbows or branch connections may be formed from steel pipe. Unless
otherwise agreed, slip-on welding flanges shall be used on pipe and for
connection to low pressure equipment. Weld neck flanges shall be used for butt
welding fittings as elbows, tees and reducers and for connection to high pressure
equipment. Where class 125 ANSI flanges are bolted to 150 ANSI steel fittings, the
1.5mm raised face on the steel flange shall be removed. When bolting such flanges, a
full face gasket shall be used. Equipment terminal flanges, if consist of a different
standard, a suitable companion flange shall have to be provided at the connecting
points.
Flange drilling shall straddle the natural centre line of pipe. Faces of all flanges
shall be 900 to the longitudinal axis of the pipe to which they are attached. Slip-on
flange when used, shall be welded in accordance with ANSI B31.1 or any other
equivalent code. If distorted after welding, the flange shall be refaced. In all cases,
flange faces, must be free from particles of weld metal. The flange face and the pipe
projecting end shall then be machined to permit both pipe and flange to bear against.
All welding by the electric arc and gas welding process for pipe joints and
fabrication shall be done by qualified welders and done according to appropriate
IBR, ANSI code / regulations as applicable for welding, subject to accompanying
code regulations and standards for filler metal, pressure, temperature and fluid
carried. The ends of pipe and welding fittings shall be beveled according to the
details shown in ANSI B31.1 or equivalent. All welds shall be made in such a
manner that complete fusion and penetration are obtained without an excessive
amount of filler metal beyond the root area. The reinforcement shall be applied in such
a manner that it will have a smooth contour merging gradually with the surface
of adjacent pipe and welded fittings.
20.03.05 Thermal Insulation of Pipelines

The tenderer shall furnish heat insulation for all necessary equipment and piping to
efficiently prevent abnormal heat loss from all exposed parts to limit surface
temperature within 60 deg.C. Resin bonded mineral wool/slag wool, fiber glass
asbestos ropes and preformed pipe sections, mats/mattresses form of insulation
conforming to IS:8183/IS:9842/IS:7413 will be acceptable. However, the grades
shall be selected considering respective temperature. In case of using loose
insulation, proper care shall be taken at site to get recommended density. Packing
density of the insulation wool shall be 150 kg/m3.
Insulated surface of all equipment, piping, valves and fittings shall be covered with

AUXILIARIES
aluminium sheet of 22 SWG (0.8 mm thick) held in place by self tapping screws of
nickel plated type. Apart from the screw, joints shall be further sealed with a
suitable sealing compound. All fastening materials such as clips, wires for field
weld to the equipment, galvanized wire mesh, metal corner bead shall be
provided. Where valves, pipes fittings, flanges, etc. occur, a clear space between end of
covering and flange shall be left of sufficient length, to permit withdrawal of flange
bolts without interference. Ends of the covering at those joints shall be leveled
from the outside covering to the pipe and sealed.
Flanges, valves bonnet, end flanges and fittings shall be effectively insulated.
Valve & flange insulation covers shall be made in two halves so that these may be
removed/ refitted readily without interfering with the adjacent covering. Protrusions
through the insulation which themselves do not require insulation such as pipe
clamps, supports, small piping, instrument take-offs, etc. shall be covered to the
same thickness as the adjacent insulation and be tightly sealed except at hanger rods.
Ample provision shall be made to prevent damage of insulation due to thermal
movement of the pipe or equipment. All the services to be insulated shall be cleaned
of all foreign materials such as scale, rust and paint by use of steel wire brushes and
steel scrapers. Anti corrosion painting (primer coat) shall be applied on hot surfaces
before application of insulation
20.03.06 Thickness of Insulation
Pipe size (outside Insulation thickness in mm for various temperature

dia) ranges
Pipe size (outside 1000C Between Between Between Between Above
dia) and 101 0and 201 0and 301 0and 401 0and 5000C
below 200 C 300 C 400 C 500 C
Upto DN 50mm 25 50 50 75 100 100
DN 65 to DN 25 50 75 100 125 125
100mm
DN 125 & DN 50 75 75 100 125 150
150mm
Note:
The metallic jacket over the insulation shall be galvanized steel sheet conforming to
IS: 277 with following thicknesses:
Pipe sizes up to 300 mm OD : 0.63 mm

Pipe sizes up to 300 mm OD
equipment, flanges, valves : 0.80 mm
Flexibility analysis shall be carried-out for steam pipeline.


AUXILIARIES
Steam line shall be designed to meet the requirement of IBR and necessary approval for
the same needs to be obtained by the Bidder.
20.03.07 Piping Material Specification
Service: Low Pressure Steam, Medium Pressure Steam
Service Conditions : Maximum Operating Pressure 18 kgf /cm², Temp 360 °C
Corrosion Allowance: 1.5 mm
Item Size Description Dimensional/ Material

Range Design
Standard
Pipe DN 15 To Carbon steel ANSI B 36.10 ASTM 106 GR.B
500 seamless pipe with or equivalent
bevel ends
Welded Fittings
Bends Below DN Bends fabricated ANSI B 16.11 ASTM A 105

50 from pipes by
cold bending with
3D radius and
socket
welded ends, 3000#
Forged carbon steel
elbow, 3000# with
socket welded ends.
DN 50 to Bends fabricated ANSI B 16.9 ASTM A234 Gr.
500 from pipes by WPB, Sch 40
cold/hot
bending with
3D radius,
3000# Forged
carbon steel
elbow, 3000#
with socket
welded ends.
Tees / Below DN Forged carbon steel ANSI B 16.11 ASTMA 105

Reducers 50 Tees / Reducers
with socket welded
ends

AUXILIARIES

Range Design
Standard
DN 50 to Forged seamless ANSI B 16.9 ASTM A234 Gr.
500 carbon steel Tees / WPB, Sch 40
Reducers with butt
welded ends
Bolting All sizes Bolts / studs / Nuts Bolts / Studs
ASTM A193 Gr
B7. Nuts ASTM
A194 Gr. 2H
Gaskets All sizes Non Asbestos IS 2712 Gr W/3,
Gaskets for 1.5 mm thick
condensate and LP
steam
All sizes Spiral wound
SS304 with graphite
filler for MP steam
Flanges All sizes SO/ WN / Blank ANSI B 16.5 IS 2002 Gr. 2A
flanges RF
125 AARH
made from ANSI B 16.5 A105 /
carbon steel A 234
plates / Gr.
Forged carbon WPB
steel flanges
Valves
Isolation Below Forged carbon API 602/BS 5352 Body / Bonnet
DN50 steel gate valve, to ASTM
Class 800/900 A105, Stem /
with rising stem trim SS to
and socket AISI 410
welded ends. (13% Cr)
DN50 and Cast carbon steel API 600 Body / Bonnet to
above gate valve, Class ASTM A216 Gr.
150/300 (for MP WCB, Stem /
steam) with rising Trim SS to
stem and BW/ AISI 410 (13%
Cr)
Flanged ends
Throttling Below Forged carbon BS 5352 Body / Bonnet
DN50 steel globe valve to ASTM
class 800/900 A105, Stem /
with rising stem trim SS to

AUXILIARIES

Range Design
Standard
and socket AISI 410
welded ends (13% Cr)
DN50 and Cast carbon steel BS 1873/ API Body / Bonnet
above globe valve class 600 to ASTM A216
150 / 300 (for MP Gr WCB, Stem
steam) with rising / Trim SS to
stem and BW / AISI 410
(13% Cr%)
Flanged ends
Non return Below Forged carbon BS 1868 Body / Disc /
DN50 steel swing check Cover to
/ piston lift valve ASTM A105,
class 800/900 Internals
with socket / Trim SS to
welded ends. AISI 410 (13%
Cr)
DN50 and Cast carbon steel BS 1868 Body / Disc /
above swing check valve Cover to ASTM
Class 150/300 A216, Grade
(for MP steam) WCB Internals /
with rising stem Trim SS to AISI
and BW / Flanged 410 (13% Cr)
ends
Strainer Strainer with cast Manufacturer’s
steel body and Standard
brass strainers of
16 G sheet with
1.25 mm diameter
perforation @ 20
per cm2 and SW /
Flanged ends.
Hose Metallic hoses of Manufacturer’s
assembly 15 m length Standard
complete with
screwed female
swivel couplings
at both the ends
Steam trap 50 and Thermodynamic Manufacturer’s Body / Cap / Plug
below steam trap with Standard A743 Gr CA 40
inbuilt strainer,


AUXILIARIES

Range Design
Standard
Class 800/900 and
SW ends
Note:
Class 150 for condensate and LP steam
Class 300 for MP steam
For feed water, schedule / thickness of pipe fittings and class ratings are to be
selected by the tenderer based on pressure and temperature of feed water.
20.03.08 Erection of Pipelines
i) General
Before erection, the equipment, valves and other fittings to be mounted on
pipelines/ equipment should be dismantled, (only if required), cleaned, oiled and
reassembled. Glands shall be packed with suitable materials as per approved
drawings.
• All elements of the pipelines system shall be erected at site strictly as per the
drawings approved by the / Consultant.
• Any modification to be carried out at site, shall have the prior approval of
/ Consultant’s representatives.
• While erecting, pipelines shall rest uniformly on each support. Yokes,
if provided, shall not allow lateral movement of pipes.
• Matching faces of flanges shall be perpendicular to the axis of pipelines. Use of
gaskets of unusual thickness to fill gap between flanges shall not be allowed.
• For horizontal pipes, the flanges shall be erected such that top two bolt holes
are displaced by half pitch from the vertical axis of the flange.
• Flanges of adjoining pipes shall be located in staggered manner.
• Flanged joints shall be laid as close to the support as possible.
• Bends for steam pipes shall have a radius of not less than three
times the nominal pipe dia unless otherwise specified.
• In general pipes are to be joined by butt welding. However, steam service
pipelines 40 mm & lower sizes shall be joined by socket welding.
• For insulated pipe, steel protectors for the insulation shall be provided at
points where the pipe is supported on rollers, slides or other equipment
where contact with such members is required outside the insulation.
• In case the location of spindle wheel of valves is not clearly shown in the
erection drawings, the same shall be located in a manner as to facilitate easy
operation from ground level of nearest operating platform.
• After erection of pipelines, the holes made in the walls shall be covered with

AUXILIARIES
bricks & mortar. A gap of 10 to 20 mm shall be kept between wall and the
pipe for the movement due to thermal expansion. The gap shall be filled with
felt/ asbestos.
• Holes made in the roof shall be covered with removable CGI sheets.
• The trenches for pipes shall be covered with removable chequered plate
covers/ concrete slabs as per the drawings.
• All pipeline branches not connected to equipment shall be closed using blank
flanges and gaskets.
ii) Welding of pipelines

• All pipelines shall be joined by welding. Flanged joints shall be used for
connecting the pipe with equipment, valve or fitting.
• Electric arc welding shall be used for joining pipes, support, structures, etc.
• Welding shall be done by qualified welders. Code of practice as per relevant
Indian Standards shall be followed for the welding procedure, use of electrodes,
etc.
• Proper edge preparation and preheating of edges to be welded, whenever
required, shall be ensured before welding.
• After every 50 butt welded joints of gas pipeline, one test sample shall be
welded by the same welder. Tensile teat and bend test shall be performed as per IS
:814 to check the strength of welding. Four test samples shall be made from the test
piece, two each for tensile and bend test.
• Tensile strength shall not be less than 34 kg / mm2 and elongation less than 12%.
• Angle of bend at the appearance of first crack shall not be less than 70 deg.
• Visual inspection shall be done for all welded joints to check for following
possible defects :
• Surface cracks on weld metal or parent metal.
• Fusion or cuts at the joining of weld metal and parent metal.
• Sponginess or porosity on the surface of weld.
• Non-uniform thickness or distortion in case of fillet welds.
• Deviation in the pipe axes or dimension of the joint.
• All defective spots found shall be chipped off and re-welded.
• For high pressure pipes, radiographic examination of welds shall be carried
out as per IS : 2825.
20.03.09 Testing of Steam pipelines

i) Preliminary acceptance test for erected pipelines shall be carried out as follows:
• Checking of metal marked as per manufacturer’s certificate/ approved drawings.

• Checking of test result of mechanical tests for welding/ radiographic tests.
• Visual examination of welds.

AUXILIARIES
• Dimensional checks as per the approved erection drawings.

• Checking of welded joints by chalk kerosene test.
• In case defects are found by visual examination, these shall be rectified prior to
leakage test.
• Checking of proper installation of supports, expansion joints, valves and fittings.
• The pipeline shall be cleaned from inside, all debris removed and pipeline blown
with air to remove all dirt, rust particles, etc.
ii) Strength and leakage test for Steam pipelines :
• Test fluid for Steam service shall be water.
• All mounted equipment / instruments, control valves, etc. on pipelines

shall be temporarily replaced by spool pieces. End connection near equipment
connection shall be temporarily disconnected and blanked.
• Test pressure shall be 1.5 times the maximum working pressure.
• The minimum duration shall also be 1/2 hour.
• Leakage test shall also be carried-out at 1.1 times the maximum operating
pressure to check the leakage by soap solution. Test duration shall be minimum 2
hours.
• Soap solution shall be applied to the weld surfaces / flanges to check for any
leakage.
• Any defect found shall be rectified after releasing the test pressure and after
rectification of defects the test shall be repeated.
• The maximum allowable pressure drop in all gas pipelines shall not exceed 1.0
% per hour for outdoor pipelines during pneumatic test. For pipeline subjected to
hydro test, no leakage is permissible
20.03.10 Commissioning pipelines

Pipelines shall be commissioned only after successful completion of
preliminary acceptance test, strength tests and leakage tests.
All valves and regulating devices shall be checked for smooth & proper operation.
All safety relief valves shall be checked and set at required pressure setting.
All instruments, interlocks, etc., shall be checked.
20.03.11 Charging of Steam.


AUXILIARIES
After pressure test steam pipeline shall be depressurised and drained of

water fully through drains/ by pass of steam traps. Subsequently, the pipeline
shall be charged with steam slowly by crack opening the steam supply valve
keeping all drain points open.
When steam is observed from all drain points and consumer ends then steam
valve at the inlet to the system should be fully opened and all by pass valve
on drains closed and isolation valve on steam traps are kept open.
20.04 Pipe work
• All pipe work from TOP upto various consuming points.
• Flow measuring, recording and controlling facilities.
• Pressure indicators and temperature indicators.
• Isolation valve at Take over point (TOP).
20.05 Pressure Reducing Station (PRS)
A Pressure Reducing Station shall be under the scope of Tenderer. This shall
include Pressure reducing valve with an isolation valve uptseam & downstream
PRV and a by pass throttle valve with an isolation valve uptseam & downstream
throttle valve. Futher, pressure measuring devise upstream & downstream shall
also be provided.

SECTION 03.00
ELEVATOR, CRANE &
HOIST


ITS AUXILIARIES
03.00 ELEVATOR, CRANE & HOIST

03.01 Passenger cum goods Elevator
03.01.01 General
i) The Elevator shall be designed in accordance with IS 14665 (Part 1 to 5) and any other
relevant specifications. The tenderer shall also take in to account local and state
regulations as in force for the design and installation of the lift. In case there is no local
lift act is in force, the Bombay lift act shall be followed.
All electrical works in connection with installation of electric lift shall be carried out in
accordance with provisions of Indian Electricity Act 1910 and Indian Electricity Rules
1956 amended up to date. The electrical works shall also confirm CPWD General
specifications for electrical works Part I (Internal) 1994 and Part II (External) 1994 as
amended up to date wherever relevant.
ii) The Elevator shall be suitable for 24 hours round the clock operation.
iii) All parts requiring replacement or inspection or lubrication shall be easily accessible
without the need for dismantling of other parts/equipment. All electrical cables shall be
so laid that they are not liable to damage and can be easily inspected and maintained.
Safe access for maintenance and removal of all mechanical and electrical parts shall be
ensured, without additional scaffolding.
v) The vendor shall furnish drawings for hoist way, arrangement required to fix gearless
machine inside the machine room, permissible vertical centre to centre distance
between supports for guide rail etc. and load data for guide rail, machine room & lift
well pit shall also be furnished to work out civil / structural design and preparation of
drawings.
Loading Hook/Monorail shall be provided in the machine room for handling of
machine.
03.01.02 General Principle
The motive power to the elevator shall be transmitted on electrical principle. For this
purpose gearless elevator, the hoisting equipment shall be kept inside the machine
room. The sliding assemble shall slide on a pair of guide rails during upward and
downward motion of the elevator car. All other systems i.e. elevator door operations,
car entrance, hoist way entrances, car enclosure, signalling and other controls etc. shall
be provided as specified below and indicated in the data sheet.
Vol. – IIC, Section 03.00 ELEVATOR, CRANE & HOIST Page 1 of 19


ITS AUXILIARIES
03.01.03 Hoist Machine

The hoisting machine shall be of the gearless type with a closed loop VF drive at speeds
indicated in data sheet, with motor, brake discs and drive sheave compactly mounted in
the machine room. Suitable Sound isolation arrangements shall be installed to reduce
vibration or air borne noise. The motor shall be reversible type particularly designed for
elevator variable frequency service with high starting torque and low starting current.
Sound reducing material shall be installed under machine. The hoisting machinery
shall be gearless type with 3 phase AC synchronous motor of suitable speed.
03.01.04 Emergency Cranking
The hoisting machines shall be provided with means of manual cranking and to allow
release of hoist brake and provide for manual movement of the car in case of
emergency.
03.01.05 Brake
Disc type Brake shall be spring loaded closed (mechanically applied) and shall open
electrically. Braking shall be by using variable input frequency to bring elevator to a
stop electrically.
03.01.06 Automatic Self -Levelling
The elevator shall be provided with automatic self - levelling feature that shall bring the
elevator car level to within ± 5 mm of the landing floor regardless of load or direction
of travel. The automatic self - levelling feature shall correct for over travel and rope
stretch.
03.01.07 Speed Governor and Safety Gear
The car safety shall be operated by a mechanical centrifugal speed governor. The
governor shall actuate a switch when excessive descending speed occurs, disconnecting
power to the hoist motor and applying the brake and actuate safety gear if necessary.
03.01.08 Pit Switch
An emergency stop switch shall be located in the pit accessible from the pit access door
which when operated shall stop the car regardless of position in the hoist way.
Adequate lighting shall be provided in the pit. Ladder shall be provided in the lift pit.
03.01.09 Buffers
Buffers shall be installed in the pit as a means for slowing and stopping the car and
counterweight at the bottom limits of travel, in compliance with local codes. Buffer
shall be designed for design speed + 15%. These shall conform to IS 14665 Part 4. Sec
1. Spring or oil buffers only shall be used. Spring buffers shall be capable of
supporting, without being compressed solid, a total load equivalent to two times the
weight of car and its rated load for car buffers and two times the weight of counter

ITS AUXILIARIES
weight for counter weight buffers. The oil buffers shall be self-resetting type. They will
also be provided with means for determining the oil level.
03.01.10 Guide Rails
Steel elevator guide rails shall be installed to guide the car and counterweight, erected
plumb and securely fastened to the building structure, filled and filled to ensure smooth
joints.
03.01.11 Roller Guides Shoes
Rubber encased coil spring tension adjusted roller guides shall be provided for
passenger elevators with speed of 1.00 m/sec or greater, mounted on top and bottom of
the car frame, and on top and bottom of the counterweight frame to engage their
respective guide rails.
03.01.12 Hoistway Operating Devices
Redundant series wired terminal stopping devices shall be provided to slow down and
stop the car automatically at the terminal landings. Resetting a tripped devices shall be
done manually only.
03.01.13 Compensating Rope
Compensating ropes shall be provided to compensate for the shifting weight of the hoist
rope. Compensating chain where provided shall be noiseless type polyurethane
enclosed chain.
03.01.14 Counter Weight
A structural steel frame with cast iron or steel plate filler weights shall be furnished to
provide proper counterbalance for smooth and economical operation.
03.01.15 Counterweight Guard
A metal (a suitable guided structural steel frame with suitable weights) counterweight
guard shall be provided and installed at the bottom of the hoist way, and shall wrap
around counterweight rails for a height of no less than 1.80 m in order to protect
accidental contact.
03.01.16 Belts/Wire Rope
Flat coated steel belts/Wire Rope of adequate size, construction to insure proper
operation of the elevator and give satisfactory and safety assurance. Belts/ropes shall
conform to governing codes or regulations. The factor of safety for belt system shall be
minimum 12.
The Lift shall be provided with inbuilt system to monitor the integrity of the belt
cords/Wire Rope for ensuring the safety.
03.01.17 Hoistway Materials

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All hoist way materials shall be non-flammable except travel cable cladding which shall
be flame resistant. All other electrical cables / wires shall be FRLS and housed in metal
conduit or other metal enclosures. Isolation pads shall be provided in hoist way Cable
shall conform to codes and shall anchor to the frame by means of an equalizing device
to insure uniform cable loading. Cable safety shall minimally conform to governing
code. Travelling cable shall be secured to the cars underside. Cable shall be clear of all
obstructions while car is in motion. Cable jacket shall be rated for immersion in water,
salt water and oil. Jacket restraint shall minimize strain on conductor.
03.01.18 Hoistway Entrances
For each landing served, a complete elevator hoist way entrance with stainless steel
baked enamel painted steel hoist way door frame shall be installed. Each entrance shall
have centre opening two speed horizontal sliding type doors suitable for a clear opening
as per above data sheet, and shall include flush doors of hollow metal pan type
construction, extruded aluminium sill with anti-slip grooving on the surface door,
hanger supports and hanger cover. Exposed surfaces of doors and frames shall be
finished as per building’s Interior Design. Corrosion resistant coating shall be applied,
wherever required, prior to completion of the installation.
03.01.19 Hoistway Doors
Sheave type two point suspension ball bearing door hangers and tracks complete shall
be provided for each hoist way opening and adjustable ball bearing rollers shall take the
up thrust of the doors.
Each car and hoist way door leaf shall be fitted with two Teflon or nylon Gibbs as
bottom door stabilizers.
03.01.20 Architraves and Doors
Doors, threshold, door hangers and electro mechanical locks shall be as a system, fire
rated for not less than 1 hour.
03.01.21 Car and Hoistway Door Operator
For each elevator door, a Variable Voltage Variable Frequency (with harmonic filter)
door operator shall be furnished to simultaneously open the car and hoist way doors
when the car is at a landing. The doors shall be closed simultaneously by motor power.
Emergency key provision shall be made to open doors at all landings from outside of
the hoist way. The door speeds shall be controlled independent of hydraulic cushioning.
In the event of interruption of electric power or failure of which shall prevent elevator
movement away from the landing unless the door is in the closed position. Each hoist
way door shall be equipped with a positive electromechanical interlock and auxiliary
door closing device so that the elevator can be operated only after the interlock circuit is
established.

ITS AUXILIARIES
The doors shall open automatically while the car is levelling at the respective landing.
The doors shall automatically close after a predetermined time interval has elapsed, but
the momentary pressure of the "door open" button provided in the car shall reverse the
motion and reopen the doors and reset the time interval unless over ridden by the infra -
red beams monitoring the open door.
The operation shall be possible with or without attendant with the provision of key in
the main operating panel. The emergency push button shall also be provided to
facilitate stopping of elevator at particular landing cancelling all the registered calls.
It shall not be possible for the car to be started or kept in motion until all the landing
doors and the car door are locked in the closed position.
It shall not be possible to open the landing door from the landing unless the elevator car
is within the particular landing zone.
03.01.22 Sheaves
Sheaves shall be mentioned, balanced and shall maintain cable / sheaves ratio well
within code requirements. Lubrication points shall be extended to a location that is
easily accessible.
03.01.23 Carframe And Safety
A car frame fabricated from formed or structural steel members shall be provided with
adequate bracing to support the platform and car enclosures. The car safety shall be
integral with car frame, and shall be of the flexible guide clamp type designed to stop
and hold a fully loaded car which exceeds descending speed. It shall withstand without
deformation the operation of safety gear.
The car shall be so mounted on the frame that vibration & noise transmitted to the
passengers inside is minimum.
The MS parts of the frame and the sheets exteriors within the shaft shall be painted with
approved quality Epoxy paints.
03.01.24 Platform
The car platform shall be checkered plate steel construction. It shall be equipped with
slip resistant threshold. The entire platform shall rest on rubber pads, so designed to
form an isolating cushion between the car and car frame. Platform deflection shall be
limited to maximum 3 mm under maximum normal operating conditions. Platform shall
conform to local codes. Approved coloured granite floor finish shall be provided. The
weight of the granite stone shall be considered as the part of dead weight of the car.
03.01.25 Infra - Red Beam Detector
An infra - red beam device with emitters & receivers shall be installed on passenger
elevator. This device shall monitor traffic across the threshold of the door and shall

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initiate door closing 2 seconds after last beam interruption, thus overriding door open
period. There should be minimum of 50 beams criss - crossing across door height.
There shall be no zone in the entire opening that is not monitored by the device.
03.01.26 Over - Load Feature
All elevators shall be fitted with over load warning indicator based on sensing relays
fitted in the platform of elevator cabin to illuminate and sound a buzzer to indicate "
Over - load " and subsequently defeat the car's operating circuits when car load reaches
110% or more of rated load. Car platform may require stiffening to minimize margin of
error resulting from excessive deflection.
When the load exceeds 80 % of the rated load, the car will bypass automatically all the
hall calls along the service direction. This feature shall be effective under full automatic
mode i.e. without attendant service.
03.01.27 Automatic Rescue Device
The elevators described in these standards must be equipped with an automatic rescue
device which will upon power failure, automatically move the elevator to the nearest
landing, opening of landing doors and facilitate the rescue of the passenger in the
elevator and parks with door open at that floor.
ARD shall activate rescue within 10 sec of power failure.
All the lift safeties should remain active during the ARD mode of operation.
The elevator shall be automatically switched over to normal operation as soon as
normal power supply returns.
Battery (Type Ni-Cd, maintenance free ) capacity shall be adequate so as to operate the
ARD at least seven times a day, provided the duration between usage is at least 30
mins.


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03.01.28 FIREMAN SWITCH
The elevators described in these standards must be equipped with fireman switch ( at
Ground Floor) which will upon manually operated key switch automatically move the
elevator to the ground floor/lobby. All floor and car buttons shall be rendered
ineffective until the system is manually reset. A key operated switch provided at the
ground floor to activate and reset the retrieval system manually. Self-testing facility
shall be provided for the entire Elevator after restoring mains power.
On initiation from the fire alarm system, all elevators travelling away from the lobby
floors shall stop and reverse with opening their doors indicating fire mode operation to
passengers, ignore all car and hall calls and express to the lobby or alternate landing
floor.
Cars travelling toward lobby shall express to lobby ignoring all car and hall calls. Cars
parked at intermediate floor shall close their doors and express to lobby. Cars parked at
lobby shall open their doors ignoring car and hall calls. At hall and car buttons shall
extinguish and shall accept no further hall or car registration.
03.01.29 Terminal & Ultimate Limit Switch:
Limit switches shall be provided to slow down & stop the car automatically at the
terminal landings & ultimate limit switches shall be provided to automatically cut off
the power & apply the brake, should the car travel beyond the terminal landing.
03.01.30 Acceleration / Decelaration:
Shall be linear and smooth. Stops shall be made without cable oscillations.
03.01.31 Noise Levels
Noise from all stationary equipment shall not intrude into adjoining public areas. Noise
from moving equipment including door operation, car motion, fan, wind, etc. shall not
intrude into adjoining corridors.
03.01.32 WIRING:
Al wiring and electrical interconnections shall comply with governing codes and
manufacturer standards. Insulated wiring shall have flame retardant and moisture proof
outer Covering, and shall be run in metal conduit, tubing or approved electrical
raceways. Travelling cables shall be flexible and suspended to relieve strain on

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individual conductors. A minimum of 10% spare conductors shall be provided in

travelling cable.
03.01.33 Car Position Indicator:
A scrolling alpha numeric car position indicator shall be installed above each operating
panel. The position of the car in the hoist way shall be shown by illuminating the
corresponding landing at which the car is stopped or passing.
03.01.34 Hall Lanterns:
Recessed surface mounted directional lanterns with stainless steel faceplates or finish
specified by architects shall be provided at all hoist way entrances, with up and down
indications at intermediate landings and single indication at terminal landings. When a
car is stopping at a landing, the lantern shall indicate the direction in which the car is
travelling and shall become illuminated prior to arrival of the car.
03.01.35 Car Operating Panel:
A full length car operating panel shall be provided in each passenger car. The car
operating panel shall contain a bank of Led illuminated push buttons of micro pressure
type (with Braille markings) with a maximum movement of 1.5 mm marked to
correspond to the landings serviced. It shall include a series of push buttons
corresponding to the floors served, along with an emergency stop and switches
required. Operating panel shall incorporate the following: floor buttons, door open /
close, emergency stop / alarm, up / down in manual mode, man / auto key switch and
fire operation.
A locked compartment integral with operating panel shall contain
a. Up / down button.
b. Open / shut button
c. Alarm Button
d. Floor Button
e. Emergency stop button
f. Car direction indicator
g. Car position indicator
h. Fireman’s service indicator

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i. Overload indication
j. Telephone
k. Key for with or without attendant operation.
l. Fire extinguisher as per IS codes shall be provided in the car.
A separate lockless cabinet shall house the emergency telephone.
03.01.36 Lighting & Ventillation
The cabinet manufacturer shall make all provisions for installation of lighting fixtures
including integration of emergency lighting fixtures. Car light shall be equipped with
Automatic sleep provision.
Cross flow fan with automatic sleep provision (size of fan minimum 300 mm dia) shall
be provided in the car.
03.01.37 Fixture Finishes:
The metal faceplates and required accessories for the operating as well as signal
devices in the cars and at the landings, shall be stainless steel as specified in data sheet.
03.01.38 Car Cladding and Finishes:

Walls shall be of hair lined stainless steel sheet as per Data sheet.
03.01.39 Inspection/Maintenanace Operation:

A switch shall be provided in the control panel and also on top of the car to permit
operation of the elevator from top of the car for inspection & maintenance purposes,
with car and hall buttons inoperative.
03.01.40 Independent Service:

A key operated switch shall be provided which, when actuated, shall disconnect the
elevator from the hall buttons and permit operation from the car buttons only.


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03.01.41 Safety and Installation Aspects

The placing of equipment in elevators well should be such as to allow free movement of
maintenance personnel inside and highest level of safety.
1. Only authorized persons shall be allowed to work on elevators installation and proper
record thereof during the tests, inspection and maintenance when necessary shall be
taken by in the presence of employer’s representative.
2. If during installation any safety or protection device is inoperative, due care must be
taken in order to avoid accidents.
3. The car & landing buttons shall be isolated from circuit by switching the maintenance
switch provided on the top of the car / emergency stop switch inside the car / attendant
control switch during maintenance of the elevator.
4. As a standard precaution, face plate between the door header and the corresponding
upper landing, sill on each floor must be provided.
5. Before any maintenance / repairing work checked that any electromechanical door
locks are not short circuited either from the controller or at the landings.
03.01.42 Testing and Commissioning:

1.0 After the supply has been connected and before the elevator is put into normal service,
the following tests as per IS:14665 (Part 3/ Sec 1 & 2) -2000 shall be carried out.
a. Test to determine that the insulation resistance between power and control lines and
earth is as per specified IS codes.
b. Test to determine that the earthing of all conduit, switch, casings and similar metal
works is continuous and of low resistance.
c. Test to determine that the motor, brake, control equipment and door locking devices
and limit switches function correctly.
d. Load test with 100% and 110% of rated load as per clause no.8.1.6 of IS 14665 (Part
2/Sec 1): 2000.
e. Brake to be tested to check whether it can sustained a car at rest with 125% of contract
load.
f. Test to determine that the lift car achieves the specified speed.
g. Test for rated power against actual power consumption under full load.
h. Check for current drawn by each elevator during starting and full load operation.
i. Sound level check for motors.
j. Visual inspection for all components.

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k. The contractor shall guarantee the smooth and noiseless performance of the elevators
System.
l. Any other test felt necessary by Purchaser and supplier to ensure proper functioning
and installation of the lift.
Test load & other equipment (stop watch etc.) shall be arranged by the contractor.
2.0 Vendor shall keep all his testing instruments duly calibrated against standard meters not
earlier than 6 months from the date of test of the equipment covered under this
specification, in the presence of Purchaser. Calibration certificates shall be made
available during inspection.
03.01.43 DOCUMENTATION
1. Information to be furnished by the Tenderer along with the tender:
The tenderer shall submit adequate sets of following technical drawings & technical
data/ information with tender
a) General Arrangement of the Elevator indicating load data, details of various

openings in machine room floor as well as lift well shaft, buffers etc.
b) Filled in questionnaire
c) List of commissioning spare,
d) List of spares for two (2) years normal operation and maintenance
e) List of insurance spare for each elevator
f) List of special/ maintenance tools & tackles.
2. List of drawings/ documents to be furnished by the successful Tenderer for

approval
a) General arrangement drawing of elevator showing full details in plan and sections.
b) GA, BOM & Data sheets for various electrical components like motor, Panels etc
c) Single Line Diagrams / Circuit diagrams
d) Quality Assurance Plan for inspection.
e) Test and inspection certificate.
f) List of spares for 2 years normal maintenance.
g) List of insurance spare for each elevator
h) List of special/ maintenance tools & tackles.


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3. List of drawings/documents to be submitted along with equipment by the

successful tenderer
a) GA drawings, complete assembly and sub assembly drawings of the

equipment.
b) Single line diagrams / Circuit diagrams.
c) Drawings of all equipment/component received from sub supplier.
d) Test and warranty certificate for each item of
equipment.
e) Test reports and inspection reports.
f) Instruction manuals for testing and commissioning.
g) Operation, maintenance and safety manuals.
h) Requirement of special tools and tackles, if any, for subsequent maintenance.
i) All other drawings and documents as stipulated in General Conditions of
Contract.
03.01.44 QUESTIONNAIRE
01. Name of manufacturer :

02. Nos. Off :
03. Type of elevator :
04. Capacity,
i. in Kg :
ii. Number of passenger :
05. Rated Speed (m /min) :
06. Total travel (m) :
07. Nos. of floor to be served :
08. Floor levels :
09. Size of elevator well / mast :
10. Internal size of elevator car :
11. Type of car / landing doors :
12. Landing/car door operation :
13. Car Enclosure :
14. Total Weight :
i. Mechanical component :
ii. Structural item :
iii. Others :
15. Headroom above top landing :
16. Elevator operation :
17. Method of control : Selective collective automatic
control
as per clause no. 3.41.3 of IS: 14665
(Part 2/Sec1): 2000 with or without
attendant.
18. Ambient temperature :
19. Quantity of Motor :
20. Power consumption :
21. Leveling accuracy :

ITS AUXILIARIES
22. Emergency power supply :

23. Intercommunication :
24. Electric power supply :
i. Power Voltage :
ii. (AC) Phase :
iii. Cycles :
iv. Wire system :
v. Control voltage (DC) :
25. Signals :
26. Motor Details

i. Make :
ii. Kw rating :
iii. Frame size :
iv. Speed :
v. Duty cycle :
vi. FL amperes :
vii. Class of insulation :
viii. No. of permissible starts per hour :
27 Special Feature :
03.02 Electric Hoist
03.02.01 General
a) The hoist shall be designed in accordance with IS: 3938-1983.
b) For outdoor hoists, motors, brakes & other equipment shall be covered to suit to
outdoor operations.
c) All Electric hoists shall be pendent operated.
d) Power supply shall be through flexible trailing cables, which shall be clamped with
PVC or non-metallic clamps or shrouded Bus bar.
e) Power isolator shall be provided at operating height.
f) Defects in the materials like fractures, cracks, blowholes, or laminations are not
allowed.


ITS AUXILIARIES
g) No cast iron parts shall be used except for electrical equipments and no wood or
combustible material shall be used unless specifically mentioned otherwise.
h) All working parts requiring replacements or inspection or lubrication shall be easily

accessible without the need for dismantling of other equipment or structure.
i) All bolts except those with nyloc nuts shall be provided with grip lock nuts or spring
washer.
j) All parts of the hoist shall be thoroughly cleaned of all loose mill scales, rust or foreign
matter & then painted as specified. All parts inaccessible after assembly shall be
painted before assembly & assembled while paint is still wet.
k) All Electric hoists shall be provided with maintenance / repair platforms with handrails
and ladder at one end wherever layout permits.
l) All parts except motors, resistors, thrustors, solenoids, etc. shall be de-rusted manually
& painted before assembly& assembled while paint is still wet.
m) All the hoists shall be provided with a maintenance platform with ladder approach at
one end of the monorail.
03.02.02 CONSTRUCTION FEATURES
Electrically operated hoist shall be a complete unit with travelling trolley, hoisting
motor, travel motor, rope drum, wire rope, necessary gearing, sheaves, brakes, hook,
pendent push button station, contactor panel, all wiring, conductor for travel motion ,
limit switches, end stops, buffers, earthing terminals and other accessories to make the
equipment complete in all respects.
03.02.03 Mechanical Details
01. Travelling Trolley
The travelling trolley shall be motor driven. Trolley frames shall be fabricated from
rolled structural steel sections. The side plates of the trolley shall extend beyond wheel
flanges, thus providing bumper protection for the wheels. The two side plates shall be
connected by means of an equalizing pin.
02. Wheel & drive
The electric hoist shall run on two pairs of wheels, a pair of which shall be driven by
motor through reduction gear. The wheels shall be of cast steel/forged steel, single
flanged with taper / parallel treads to suit to monorail. The wheels shall be machined on
their treads to match the profile of the monorail. The wheels shall be mounted on
anti-friction bearings & shall be easily removable for repair & replacement. The wheel


ITS AUXILIARIES
diameter shall be selected such that skidding does not take place even under unloaded
condition.
03. Hoist mechanism
The hoist mechanism shall consist of a bottom block fitted with a standard forged
swivel hook of the specified capacity, supported on 2 or 4 falls of wire rope. However,
non-spinning type of wire rope shall be used for 2 falls rope arrangement. The wire
rope shall be wound on a grooved drum which shall be sufficiently long to
accommodate in one layer the length of rope requisite for the specified lift & in
addition not fewer than two turns at each anchored end & one spare groove at the
opposite end. The hoist drum shall be motor driven through gears enclosed in oil filled
reduction gearbox.
04. Rope Drum
Rope drum shall be of cast steel or fabricated out of rolled steel plates. Fabricated rope
drum shall be stress relieved before machining. The grooves of the drum shall be
smooth finished.
05. Wire Ropes
The wire ropes shall be of regular right hand lay hemp cores as per IS: 2266-2002.
However, Ropes working under water and in corrosive atmosphere shall be galvanized
and shall have steel core. For rope arrangement with 2 falls wire rope, shall be of non
spinning type.
06. Rope Sheaves
Rope sheaves shall be of cast steel or fabricated out of rolled steel plates.
07. Rope Guides
Suitably designed rope guides with pressure ring/rope tightened shall be provided for
each lead of rope from the rope drum to prevent the rope from overriding, loosening or
rope coming off the groove.
08. Gearing.
Straight & helical spur gearing shall be used for all motions. Worm & bevel gears shall
not be used without specific permission from purchaser. Preferably all first reduction
gears shall have single helical teeth. All gears shall be hardened & tempered alloy or
carbon steel with machine out teeth. Surface hardening of teeth is not acceptable. All
gears shall be enclosed in oil filled gear box except when not possible.


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09. Lubrication
All gears & bearings shall be lubricated either by splash lubrication or by grease. If
possible, all the lubricating points shall be grouped together in easily accessible
positions.
10. Bearings
Ball & roller antifriction bearings of reputed make shall only be used, with minimum
bearing life as per IS: 3938.
11. Shafts and Axles
Shafts and axles shall be of forged steel and shall have ample strength, rigidity and
adequate bearing surface for intended duties. Shafts and axles shall be accurately
machined and properly supported. Shafts shall, as far as possible, be furnished straight.
If shouldered, these shall be provided with fillets of ample radius or shall be tapered to
avoid loss of strength and stress concentration. These shall be designed considering
allowances for keys and splines.
12. Motors/Couplings
For Hoists o f c a p a c i t y 5T & above, the motor (Foot mounted B3 type) shall
be connected to its gear drive by a flexible coupling. Flange mounted motors
(B5) may be used for Hoists of capacity upto 5T and also for all CT drives.
The number of poles of motor for hoist & CT drive shall be Minimum 6 & 4
respectively.
13. Lifting Hook
The lifting hook shall be single hook type, solid, forged, heat treated, of rugged
construction and provided with a standard depress type safety latch. Lifting hook shall
have swivels and operate on ball or roller thrust bearings with hardened races. Lock to
prevent hook from swivelling shall be provided. Lifting hook shall conform to IS
15560:2005 as applicable.
14. Brakes
DC Electro-magnetic Shoe brakes shall be provided for Hoist motion of capacity 5 T &
above. DCEM Disc brake may be provided for Hoist motion of capacity below 5 T. CT
Motion shall be provided with DCEM disc brake. Brakes shall be provided on the high
speed pinion shaft of the gear –train.


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15. Buffers, Stops and Sweeps
Spring or rubber buffers shall be provided on the trolley. Suitable end stops shall be
provided which shall be welded on the ends of monorail to contact the buffers mounted
on the trolley.
Trolley wheel stops shall be provided before the end stops. These shall match to wheel
radius. Stops to prevent trolley from running off the monorail shall be abutted against
ends of monorail. Stops shall be welded to the monorail.
Sweeps shall be attached to the trolley to remove foreign material from the rails.
16. Guards
All exposed couplings, shafts, gear wheels, pinions, drives etc. shall be safely encased
and guarded.
The sheaves of hook blocks shall be guarded to prevent trapping of hand between a
sheave and the in-running rope
03.03.03 Documentation
01. Drawings and documents to be submitted by the Tenderer with Tender
a. General arrangement drawings/clearance diagram of the Hoist

b. Filled in questionnaire
c. List of commissioning spare and list of spares for two (2) years normal operation
and maintenance of Hoist.
d. List of special/ maintenance tools & tackles
e. Other supporting documents e.g. Leaflets, catalogues etc.
02. List of Drawing/ Documents to be furnished by the Successful Tenderer

for approval / reference
a. General Arrangement drawings of hoists / attachments along with design

calculations .
b. Electrical Single Line Diagrams
c. GA, BOM & Data sheets for various electrical components like motor, Panels
etc
d. Quality assurance plan for inspection.
e. Specification of oils and lubricants and other consumables and their
quantity and frequency of change.


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f. Detailed layout plan and sections for power supply system. (Angle Bus
bar/Shrouded BusBar/ Festoon Cable etc.)
g. DSL / Trolley line arrangement layout.
03. List of Drawings/ Documents to be furnished along with equipment
a. Requisite no. of sets of all GA drawings, complete assembly and sub assembly
drawings of the equipment.
b. Drawing of all equipment/ component received from sub supplier.
c. Engineering and design calculations.
d. Test and warranty certificate for each item of equipment.
e. Detailed erection schedule and manuals, assembly/ erection drawings, erection
sequence, special precautions to be followed during assembly/ erection (these
shall be despatched three months prior to FOT/FOR delivery).
f. Test reports and inspection reports.
g. Instruction manuals for testing and commissioning.
h. Operation, maintenance and safety manuals.
i. Requirement of special tools and tackles, if any, for subsequent maintenance.
j. Detail drawing and specifications of all wearing out parts and parts subject to
breakage during normal operating conditions
k. List of spare parts with drawings, sketches, specifications and manufacturer’s
catalogue
l. All other drawings and documents as stipulated in General Conditions of
Contract.
03.03.04 Qusetionnaire
i/ Equipment No.
ii/ Nos. off
iii/ Type
iv/ Capacity (t)
v/ Height of lift (m)
vi/ Duty class
vii/ Location
viii/ Hoists :
a) Speed with safe working load, m/min
b) No. of rope falls supporting the load and specification of rope
c) Lift of hook above floor, m
d) Drop of hook below floor, m
e) Motor details like type, kW, Pole, %CDF, no. of start/Hr, Duty, POT, Insulation
& enclosure class, qty, Make etc.)
f) Make, type and size of brake
ix/ Cross – travel :
a) Speed with working load, m/min
b) Wheel base, mm
c) No. of wheels

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d) Moor details like type, kW, Pole, %CDF, no. of start/Hr, Duty, POT, Insulation
& enclosure class, qty, Make etc.)
e) Make, type and size of brake
x/ Power supply
xi/ Control voltage
xii/ Made and type of control
xiii/ Total weight of hoist (t)
xiv/ General arrangement drawing showing details as enumerated
xv/ List of deviations from the purchaser's specification in the format enclosed.

SECTION 04.00
FIRE PROTECTION
SYSTEM

TENDER SPECIFICATION FOR SEMI DRY TYPE FLUE GAS

DESULPHURIZATION(FGD) SYSTEM
& ITS AUXILIARIES
04.00 FIRE PROTECTION SYSTEM
04.01 Introduction
In order to combat any occurrence of fire in various areas/units of the proposed FGD
system for existing power plant of Mettur Thermal Power Station-I (4X210MW), an
elaborate system of fire protection will be provided. The system will be planned in
conformity with Tariff Advisory Committee’ guidelines,BIS and other relevant
standard/codes.
Major Facilities envisaged are as following:
i/ Fire detection and alarm system (Refer electrical chapter)
ii/ Fire Hydrant System
iii/ Automatic clean agent system
vi/ Portable fire extinguishers
vii/ Passive fire protection
04.02 Scope of Work and Services
The scope of work covers on turnkey basis design & engineering, supply, erection,
painting, testing, commissioning, and handing over of complete Fire Protection System
envisaged for the proposed FGD system for existing power plant. Two years operation and
maintenance spares, necessary tools, spanners etc. required for regular operation /
maintenance of systems will be supplied along with the equipment and will be mentioned
in the offer.
Major work comprises of following:
a/ Bidder will be provided firefighting water at a single point as indicated in the drawing;
however bidder has to tap water from this point and further design and supply of the
entire firefighting facilities under their scope of work.
b/ Fire Hydrant system consisting of internal as well as external hydrants for the area
earmarked for FGD system. Number of hydrant and monitor points shall be finalized at
detailed engineering stage as per Norms.
c/ Automatic Clean agent total flooding system for computer rooms/ PLC room/control
rooms.
Vol. – IIC, Section 04.00 FIRE PROTECTION SYSTEM Page 1 of 21


& ITS AUXILIARIES
d/ Microprocessor based Fire detection and Alarm system for electrical premises and
premises with automatic fire extinguishing system.
e/ Detector shall be multi criteria combination of rate of rise heat detectors and photo
electric smoke detector. Ionization smoke detectors are not to be accepted.
f/ Portable fire extinguishers.
g/ Piping, valves, sluice gates etc.
h/ All civil & structural works
i/ All electrics.
j/ Controls and instrumentation.
k/ Shop and site painting for all equipments, pipes etc.
l/ Fire-fighting facilities during construction period by installing fire extinguishers and

hydrant for protection of combustible material.
m/ Erection, testing, commissioning, PG test and Warranty for the complete fire protection
system.
n/ All the requirements of TAC for complete FPS will be incorporated by the bidder in
their scope irrespective of whether the details are described in specification and/or
shown in the drawings or not.
o/ Passive Fire Protection measures
04.03 The scope of work and services to be rendered by the bidder for installation of fire
protection systems will include but will not be limited to the following activities.
i/ Design & engineering, handling at site, preparation of erection drawings, fabrication

and erection as per approved drawings, site testing, painting, commissioning and
fulfillment of guarantee of all fire protection systems, sub-systems and integrated
systems as described above and also covered in general technical specification.
ii/ Miscellaneous materials and services will include but not limited to the following :
a/ All piping integral to and/or between any equipment furnished under this specification,
except as otherwise specified.
b/ Coupling guards for all exposed shafts and couplings.


& ITS AUXILIARIES
c/ Foundation bolts, base plates, thrust blocks, duck-foot bends, matching flanges,
supporting materials and shims.
d/ All necessary instruments, power and control wiring integral to any equipment
furnished under this specification. These will include terminal blocks and integral
wiring to the terminal blocks for equipment requiring external connection.
e/ Earthing strips of all panels, & other firefighting equipments supplied by the bidder will
be connected to the nearest earthing ring available at site.
f/ Digging of underground trenches, laying of cables, laying of protection slab/bricks over

the cable routes, back filling of trench and levelling of earth if required.
g/ GI pipes/ conduits and other accessories wherever required for laying of cables.
h/ Other erection materials like cable supporting structures, channels, brackets, clamps
and other hardware materials, as required, for laying of cables.
i/ All erection accessories, consumables and miscellaneous materials, though not

specifically indicated in this specification, but actually required for completing the job
in all respects.
j/ All necessary connections for hook-up with other system, if required as per instruction
of the purchaser.
k/ Erection, testing and commissioning materials.
l/ Initial fill of gas and other fire extinguishing media (including quantity required for PG
test) and demonstration.
m/ Valve chambers for all isolation valves.
n/ Cylinder battery racks.
04.04 Drawings and Documents
04.04.01 Drawings/documents to be furnished with offer
a/ Scope of work with general description of system and equipment offered specifying the
important features supplemented with scheme drawings. The bidder has to give a
confirmation with respect to the scope of work as detailed in this specification
excepting for the deviations, if any, to be listed in the schedule of deviation. The

& ITS AUXILIARIES
description to be accompanied by single line diagrams, and equipment layout to

enable the Purchaser to have a proper appreciation of the equipment offered and its
operation.
b/ Specification of equipment/material along with their makes/catalogues. Approval

certificate from authorizing bodies for various components of the systems.
c/ Time Schedule (Bar Chart L1) for implementation of jobs and number of persons to be
deputed at site along with their experience/ qualification and period of posting at site.
d/ Reference list of job executed.
e/ List of mandatory spares.
f/ List of special tools and tackles
g/ Certificate of approval from TAC and similar other authorizing body for various
component of the system.
04.04.02 Drawings / documents to be furnished for approval by purchaser/consultant after

placement of order
i/ Piping layout drawing with complete support detail, isometric layout for hydrant system,
clean agent gas system.
ii/ P& ID , Schematic drawing of proposed firefighting system
iii/ Detailed gas requirement calculation.
iv/ G.A Drg. for the system.
v/ GA and cross-sectional drawings showing all dimensions and materials of construction of

various components of portable fire extinguisher.
vi/ Distribution of extinguishers with respect to their type, capacity and numbers in various
premises will be decided in accordance with IS – 2190-2010. A drawing/table showing
such distribution shall be submitted for approval.
04.04.03 Drawings/documents to be furnished for information after placement of order
a/ Manufacturer's routine test and type test certificates for all equipment and cables.
b/ Detailed technical catalogues/data sheet/brochure for all the equipment.
c/ Instruction manuals for erection, maintenance and operation of all the equipment.


& ITS AUXILIARIES
d/ Pressure loss calculation of Isometric piping and erection drawing.
04.05 Refer Vol - IV/ Electrical Section for Fire Detection & Alarm System
04.06 Refer Vol - IIC/ Section 01.00 for Hydrant System
04.07 Clean Agent Inert Gas Flooding System (IG-541)
04.07.01 General
Clean agent Inert gas “CLEAN Agent Gas (IG-541)” total flooding system shall be
provided for the following areas including above false ceiling and below false floor areas.
The system shall be designed as per NFPA 2001 (Latest Edition).
The scope of work and services to be rendered by the Bidder for installation of clean
Agent total Flooding System shall include but not limited to the following activities:
i. Design, Engineering, manufacture, fabrication, assembly, shop testing and shop painting,
sequential packing, delivery for site, comprehensive insurance, unloading, unpacking,
storage at site, site handling, preparation of erection drawings, fabrication and erection as
per approved drawings, site testing, painting, commissioning and performance guarantee
of Clean Agent Total Flooding System in integration with complete fire protection system
required for below false floor, and above false ceiling for main control room, PLC room as
per NFPA 2001 (Latest Edition).
ii. Supply of mandatory spares required for two years operation and maintenance initial fill
consumables.
04.07.02 System Description
The Inert clean gas total flooding system is an engineered system consisting of fixed
nozzle and gas distributing network. The system shall be designed and installed in
accordance with the NFPA 2001 (Latest Edition). Inert gas clean agent system will
extinguish surface burning fire in Class – A, B & C hazards.
The system shall consist of various major components as listed below:
i. Gas
ii. Cylinder rack
iii. Gas Manifold
iv. Pressure reducing devices
v. Pilot Cylinder, cylinder valve assembly
vi. Cylinder Bank
vii. Electric Actuator

& ITS AUXILIARIES
viii. Manual release push button

ix. Directional valves
x. Inhibitors and safety relief valves
xi. Flexible Hoses
xii. Discharge Nozzles
xiii. Pipe and Fittings
xiv. Bracket Supports and Hangers
xv. Transportation trolleys However, Bidder shall provide one Trolley for each area for
transportation of cylinders.
xvi. Name plates
xvii. Digital Warning signs(Audio & Visual)
xviii. Hooters/siren
xix. Digital type static weighing machine for weighing one no. cylinder at a time.
xx. Bank of standby cylinders fitted with cylinder head, valves with manifold.
xxi. All the components of clean gas agent system shall be UL/FM/Vds approved only.
xxii. Gas cylinder shall be certified from PESO, INDIA.
xxiii. Fire detection and alarm system (Excluded from this package)
The Inert gas clean agent is stored in metallic cylinder in a pressurized condition at
200/300Bar. A master cylinder will be fitted with Electric Actuator & manual actuator.
Separate multiple cylinder bank dedicated for each risk area is provided close to the
protected area. No. of cylinders in each bank will be determined as per volume of gas
required for total flooding as indicated above. All the cylinders are connected to a
discharge manifold by means of flexible hoses. The manifold is connected to piping
network having discharge nozzles at the protected areas. All the piping is supported &
clamped suitably to avoid vibration.
The system shall consist of "independent engineered storage" system with 100% (one
hundred percent) connected reserve supply cylinders. The main or reserve supply
cylinders shall be designed for the requirement of largest risk with directional valves for
each of the zones. Suitable selector switches shall be provided for "Normal/Standby"
supply selection in the fire alarm system panel for each of the zone. The cylinders shall be
located in a separate room civil building near to unit control room. This room shall be
provided illumination facility, ventilation facility.
All the above areas are air conditioned, provided with false ceilings and false floor
separated from the adjoining areas (both the above and false ceiling spaces) by brick
walls.
Each zone shall be equipped with fire detection system. On receiving the fire signal from
the detection system agent gas shall be released automatically after a set time delay and
gas shall be discharged into the enclosed space.
The system shall comprise of the following mode of operation and actuation and

& ITS AUXILIARIES
cancellation facility etc. with necessary control panel.
System operation shall be possible by the following means:
a. Automatically due to fire detection in the protected area.

b. Operation of manual release push button located adjacent to protected area.
c. By operating manual lever provided on electrical / manual control head on pilot
cylinder.
d. By push button actuation at Clean Agent control panel in manual mode.
The clean agent shall be discharged / actuated automatically after an adjustable time delay
based on the detection signal received. The delay shall be minimum 30 seconds. In the
local control panel of clean agent system, there shall be one hooter, which shall operate
once the gas is released during time delay; there shall be pre-discharge alarm (audio +
visual). Hooter shall follow the alarm once the gas is discharged.
The release of gas shall be preceded by an audio visual alarm in the affected area for
alerting and evacuating the personal and for this purpose time delay of about 60 seconds
(which is settable from the panel) between the initiation of release and actual release of
gas. The exact time delay to be incorporated in the system shall be decided during detailed
engineering.
To avoid an inadvertent mal operation and release of gas, on either of the model release
operation (auto or manual), provision of manual interruption (i.e.) gas charge inhibition
facility through a suitable device from a local control unit at a suitable location or from the
panel shall be provided so that the agent release can be stopped within the time delay.
Positive material Identification test shall also be performed.
04.07.03 Design Criteria
Quantity of gas required for the system shall be based on the gas required to blanket the
volume of the area to be protected and time that the discharge must be maintained to
assure complete extinguishing of fire within 10 sec after actuation.
i. Complete design and all the system components/equipment shall be approved and listed
by UL/ VDS/FM.
ii. Design, manufacture and installation of inert gas fire extinguishing system shall be in strict
accordance with NFPA 2001 (latest edition) and certified by UL / VDS/FM.
iii. 200/300 bar clean agent extinguishing system shall be designed and installed for below
false floor, main room and above false ceiling of various risk areas.


& ITS AUXILIARIES
iv. The design concentration shall be as per NFPA 2001 if the system is UL/FM approved. If
the system is Vds approved then design concentration shall be as per vds standard only.
v. The Physical properties and its discharge characteristic of clean agent shall meet the
requirements of NFPA-2001 (Latest edition).
vi. The design calculation shall be supported by UL/VDS/FM listed software guidelines and
shall have their approval.
vii. The system shall be designed based on the single largest risk area. In order to optimize the
requirement of gas and considering the space for cylinder bank, it may be planned to club
together requirement of two or more adjacent premises. Bidder to ensure that appropriate
logic is followed for discharge of gas in respective premises.
viii. The system shall have 100 % Clean Agent filled standby cylinders along with manifold,
directional valves and automatic change over for each risk area.
ix. The complete volume of the rooms including the above false ceiling shall be considered
for estimation of quantity of gas and containers.
x. When determining the gas quantity, the leakage losses from the enclosure shall be taken
into account by the supplier. The exact amount of gas to compensate for leakage
compensation shall be designed by the Bidder taking into consideration the type and
features of enclosure, unclosable openings if any and other considerations so that design
concentration is achieved after stabilization of discharge. However, a minimum 20%
margin to be considered as leakage compensation and extinguishing efficiency.
xi. Further volume of re-circulating type air conditioning system & its ductwork (at least up to
the automatic fire dampers of the ducts) shall be considered as a part of the total volume so
that the design concentration is achieved throughout the hazard area. Further gas quantity
shall be adjusted for ambient pressure conditions.
xii. Both the main & reserve supply cylinders shall be permanently connected to the
distribution piping through manifold and arranged for easy changeover from the panel.
xiii. The discharge time period shall be that the design concentration can be achieved within 60
seconds. The flow calculations shall establish these criteria.
xiv. The quality of gas shall conform to relevant design standard ie: NFPA - 2001
xv. Bidder shall include automatic actuation of the system by Fire detection and alarm in the
premises concerned. Annunciation for system operated will be provided in MFAP and
annunciation panel. Bidder shall consider clean agent discharge panel (intelligent type) –
with battery charging facility. All signal & control of gas system shall be controlled from

& ITS AUXILIARIES
gas discharge panel. Signal shall repeat as main fire alarm panel. Interface unit between
gas discharge panel and MFAP shall be provided by the bidder by considering the
requirement of MFAP. Provision for fire delay and evacuation alarm shall also be given.
xvi. Concentration of gas shall not exceed the NOAL and LOAL level as per NFPA guide
lines.
xvii. All electrics including power supplies and control interlocking, provision of MRPS,
inhibitor, evacuation alarm, hooters, all components required for ventilation tripping etc
shall be considered in the design and supply.
04.07.04 System Requirements
04.07.04.01 Clean Agent gas
The quantity of clean agent gas provided shall be sufficient to protect the risk area with
100 % standby. Every individual risk shall have its own distributing pipe, nozzles, alarm
and actuation system etc. The physical properties of clean agent gas shall meet the
requirement specified in the NFPA 2001 (Latest Edition).
Both the main and standby cylinders shall be permanently connected to the distribution
piping through manifold and auto change over. The clean agent discharge shall be
substantially completed in a normal 60 seconds. For inert gases the measured discharge
time is considered to be the time when the measuring device starts to record reduction of
oxygen until the design oxygen reduction level is achieved. The min. oxygen
concentration shall be as per NFPA 2001 (Latest Edition).
04.07.04.02 Flow Calculation
System flow calculations shall be performed using a calculation method listed or approved
by UL/VDS/LPC/FM. The system designed shall be within the manufacturers listed
limitations. Bidder shall provide the sufficient measure facilities in the risk areas to
dissipate over pressurization due to release of clean agent and also provide calculation in
support of same for each protected area.
The Bidder shall provide the approval certificate of software from UL listed along with
design calculation.
04.07.04.03 Clean Agent Quantity
Minimum design concentration of Clean Agent gas shall be as per NFPA-2001 (Latest
Edition) at 700 F by volume for Clean Agent fire extinguishing system based on approved
/ listed flow calculation method and having design concentration approved by UL/FMRC
at 700 F (210 C) for the single largest risk.

& ITS AUXILIARIES
Clean Agent concentration requirement shall be computed considering the volume of the
class C high hazard area as specified. In addition to the concentration requirements as
specified, 20% of the gas quantity as computed above, shall be added to compensate for
leakages and extinguishing efficiency. The Bidder shall work out the quantity of Clean
Agent as per NFPA 2001. However, Bidder shall quote minimum quantity of clean agent
for the volume as given in the Scope of work.
04.07.04.04 Clean Agent Storage Cylinders
i. Cylinders shall have approval from PESO, Nagpur in addition of UL/VDS/LPC/FM.
ii. All the storage cylinders (cylinder bank) shall be provided under an enclosure. It shall not
be kept open to atmosphere.
iii. Cylinder bank : Required quantity of gas will be stored in seamless steel cylinders shall
have UL and CCE nagpur approval.
iv. The 200/300 bar Clean Agent storage cylinders shall be designed to hold Clean Agent at
ambient temperatures.
v. Minimum design level pressure of storage cylinder shall be 200/300 bar. The design
pressure for cylinder shall be suitable for the maximum pressure developed at 1300 F (550
C).
vi. The cylinders shall be charged to a fill density or super pressurization within the range
specified in the manufacturers listed manual.
vii. The total number of cylinders in the bank shall be determined depending on the volume of
the premises to be protected. Bidder shall select the capacity of cylinder based on the
storage space available and for effective replacement and inter changeability. All cylinders
in the Bank and reserve bank shall be interchangeable
viii. The cylinder shall be seamless and never retested, brand new never retested and month &
year of manufacture shall be latest.
ix. Each cylinder shall have a permanent name plate, specifying the agent, tare and gross
weight in addition to the pressurization level, nominal agent volume.
x. Cylinder shall bear the mark of manufacturer, serial number, single test certificate issued
by manufacturer and shall be duly approved by UL/FMRC/VDS/LPC.
xi. Cylinder shall conform to the requirement of NFPA 2001 (Latest Edition) and shall be
compatible with the engineered system being provided along with design analysis.


& ITS AUXILIARIES
xii. Each cylinder shall have pressure relief valve to protect the cylinders against excess
pressure conditions. Pressure gauges with isolation valves on manifold shall be provided.
xiii. Automatic means such as check valve shall be provided to prevent agent loss if the system
is operated when any cylinders are removed for maintenance.
xiv. Clean Agent cylinders shall be arranged in proper manner.
xv. In a battery of cylinders manifold together, leading to distribution piping and discharge
nozzles for the risk to be protected, including below false floor and above false ceiling
spaces, along with a reserve battery of Clean Agent filled cylinders with manifold and
directional valves, including arrangement for automatic change over to any of the two
banks after actuation of main cylinders to be provided in each risk area i.e. 100% reserve.
Reserve cylinders shall be connected to the main header, so that incase of successive fire
reserve bank can also be used.
xvi. The cylinder storage racks shall be provided for main as well as for reserve cylinders.
xvii. The manifold cylinders referred above shall be securely mounted on the floor and suitably
supported in a rack with provision for convenient individual servicing, according to the
manufacturers installation manual. Such servicing shall be possible without shutting down
the system.
xviii. The Bidder shall indicate the space provision for storage of Gas Cylinders and Manifold
Piping along with technical offer.
xix. The gas cylinders shall be provided with Base Plate, foundation bolts & nuts etc. so that,
the entire load is evenly spread out over the entire plan area. No concentrated load shall be
resulted from the mounting arrangement of the cylinder/containers.
xx. All the pressure, gauges/switches, manifold connections etc shall be easily removable for
servicing / maintenance without any loss of gas.
xxi. All cylinders in the bank shall be interchangeable
04.07.04.05 Discharge Nozzles
Discharge nozzles shall conform to NFPA 2001 (Latest Edition). The material of
construction shall be of Brass and shall be UL/FM/VDS/LPC approved. Discharge
nozzles used in the system shall be listed for the use intended for discharge characteristics.
The selection of nozzle orifice shall be such that 95% of the minimum design
concentration of gas is discharged within 60 seconds, through the nozzles of the system.
Each nozzle shall be permanently marked to identify the manufacturer as well as type and

& ITS AUXILIARIES
size of the orifice along with tag / part number, orifice code, or other suitable marking as
specified in relevant norms / codes.
04.07.04.06 Piping, Fittings
Pipes shall be of ASTM A53 or A106 type (seamless carbon steel high pressure Schedule
80 pipes and pipe fittings shall be provided as per the requirements specified in NFPA-
2001 (Latest Edition).
All the pipes &pipes fitting, testing pressure, brusting pressure, etc. shall be designed and
tested considering supplied cylinder pressure as per NFPA -2001 (Latest Edition).
The Clean Agent piping and nozzles shall have to planned clearing following facilities
coming on its route, in the areas where protection is being envisaged:.
 Path of AC ducts.
 Cabling in false flooring.
 Light fittings, detectors etc.
04.07.04.07 Operating Devices
i. Operating devices shall include Clean Agent releasing devices or valves, discharge
controls and shut down equipment necessary for successful performance of the system.
ii. The automatic Clean Agent system shall be of robust design and shall not be readily
rendered inoperative easily. The Clean Agent system shall be designed to function
properly for the temperature range specified in NFPA-2001.
iii. The Clean Agent cylinders shall be mounted on front and firmly supported in brackets in a
manner that they will not be easily subjected to mechanical, chemical or other damage,
which would render the system inoperative.
iv. In addition to Automatic actuation, there shall be a normal manual control for actuation,
which shall be located so as to be conveniently and easily accessible at all times including
the time of fire. This control shall cause the complete system to operate in its normal
fashion.
v. Manual controls shall not require a pull of more than 40 lbnor a movement of more than
14 inches to secure operation. Each remote manual control for activation shall be located
not more than 4 feet above the floor.
04.07.04.08 Gas release Panel
i. The local control panel shall be free standing, floor mounted type and shall be suitable for

& ITS AUXILIARIES
both auto and manual operation. The panel shall be naturally ventilated, totally enclosed,
dust and vermin proof, with IP-67 enclosure as a minimum. The Clean Agent system shall
be actuated automatically by the signal received from the fire alarm and detection panel.
Fire alarm and detection panel, after detecting the fire in the protected area / zone, shall
provide an actuating signal to Clean Agent control panel, which in turn shall energize the
solenoid valve to trigger the operation in the respective protected area / zone. The exact
location of local control panel shall be decided during the detailed engineering.
ii. Boosting up provision shall be done by the Bidder to get adequate power supply/ current/
voltage required to operate the solenoid valve, LDP and other component of FDA system
iii. The local control panel shall be equipped with adequate rating battery charger and Ni-Cd.
battery with 24 hour back up, for efficient operation of the system during mains power
failure.
iv. Control panel shall be provided with all alarms, indicators, caution/sign board and relays/
control switches meeting all the requirements of NFPA-2001 and shall include but not be
limited to the following:
a. Two alarms and one fault indicator lamp for each zone to be protected.
b. Combination of alarm silence and alarm off switch.
c. Combination of fault silence and trouble lamp switches.
d. Alarm test switch
e. Alarm re-set switch.
f. The system shall have a positive warning device by sounding alarm to alert
personnel of the impending discharge and also a positive indication to show that the
system has actuated.
g. Alarm indicating failure of devices /equipment shall be distinctive from alarm

indicating operation in hazard.
h. All indication lamps shall be LED type with minimum size of 10 mm.
v. Warning and instruction signs at entrance to and inside protection areas shall be provided.
vi. A Control Box /Clean Agent Release Panel shall be provided for manual control at the exit
doors of each risk area, comprising of selector switches for selection of Main/Reserve and
Auto/Manual Push buttons for Clean Agent release.


& ITS AUXILIARIES
vii. Potential free contacts shall be provided from the Clean Agent Control Panel to shut off
the fire dampers / louvers and Air Conditioning System.
viii. Supervision of automatic systems shall be provided and shall include electrical supervision
of the actuating device and the wiring connecting the actuation device and the detection
system.
ix. Visual display shall be flashing type and hooter system of distinct tone capable of being
heard in the range of 500m from the source.
x. Clean Agent extinguishing system shall incorporate a pre-discharge alarm with a time
delay, sufficient to allow personnel evacuation prior to discharge. The delay shall be
minimum 30 seconds. However it shall be adjustable from 30 to 120 seconds.
xi. Operating devices shall be by mechanical, electrical and pneumatic means conforming to
NFPA2001. The power supply to electrical actuators shall be backed up with reliable
battery supply. Such batteries shall be charged automatically by battery chargers. Power
supply is taken from the Fire detection alarm system panels of the respective units.
Required annunciation's such as "Gas released", "Failure of automatic actuation", "Gas
release aborted" etc shall be exhibited in the fire alarm panel.Gas release panel shall be
UL/FM/Vds approved
xii. Where pilot cylinders are employed for actuation of the cylinder banks, the number of
pilot cylinders shall be as per the listed design manual.
xiii. All manual operating devices shall be identified to the hazard they protect.
xiv. Manual abort switches for each of the area / zone shall be as per NFPA2001 or as
specified by listing authorities.
xv. The gas releasing devices at cylinder outlets shall be of reusable type after discharge at any
instant.
xvi. Supervision of automatic actuation devices, power supply, manual actuation circuits, and
complete wiring shall be provided through control system I panel and the healthiness shall
be reported or indicated in the panel automatically. Complete control system shall be listed
and approved by UL/FMRC/VDS.
xvii. Bidder shall consider the digital type static weighing machine for each cylinder. However
where system does not permit digtal weighing, then gas loss from each cylinder shall be
displayed on Local Gas Release Panel through actuation of pressure switch installed on
each gas cylinder as well as on Main Fire Alarm Panel. Bidder shall also provide one
trolley for each area.


& ITS AUXILIARIES
04.07.05 Materials of Construction
The material of construction shall be as per this specification for the items specified. For
other items, the materials of construction used in the system shall be in accordance with
NFPA-2001 or as specified by the equipment manufacturer for the intended use (if the
same is not specified in NFPA-2001). The material of construction shall be UL/FM/VDS/
approved. The approval of the same shall be submitted at the time of bid submission.
04.07.06 Electrical
Bidder to include power supplied and control interlocking. All wiring – junction boxes,
push button station, indication lamps, hooters etc. shall be included into scope of Bidder.
All areas shall have illuminated board “FIRE – EVACUATE, GAS WILL BE
FLOODED”. Each area shall have hooter adjacent to illuminated sign.
Main fire alarm panel shall have annunciation for fire in above areas and after confirmed
signal (operation of two detectors) signal will be initiated for tripping of A/C system and
visual indication ‘START – FLOODING’ shall be there. From main fire alarm panel
signals shall also be initiated for illuminated sign / hooters of respective area.
Manual pushbutton of each area shall be located near exit and shall be break glass type
with attached hammer. Manual push button shall operate valve for flooding in respective
premises and as well as for connecting banks of gas cylinders to main pipe.
Bidder to develop logic for above and submit working scheme along with the tender. Any
interface devices required to hook up this system with the main fire alarm panel shall be
included by the Bidder as part of the scope as a whole.
One no. wall mounted annunciation board near cylinder bank shall be provided for
(duplicate) annunciation to facilitate manual operation of valves.
04.07.07 Gas Manifold
Each cylinder in the bank shall be fitted with a discharge head, which shall be connected
to a common manifold through high pressure connecting pipes of tubes. In case rigid pipes
are used for the purpose anti-vibration coils shall be provided. Gas Manifold shall be also
UL/FM/VDS/ LPCB approved only.
All cylinders in the battery and the common manifold shall be mounted and suitably
supported in a rack provided for the purpose. The rack shall be designed in such a manner
that servicing and checking of individual cylinders shall be convenient and the cylinders
are rigidly held in position. The design shall ensure no change / minimum possibility of
accidental discharge of cylinders.


& ITS AUXILIARIES
04.08 Portable Fire Extinguishers
04.08.01 Special Instruction to Bidder
Types, Quantity, installation and distribution Portable fire extinguishers shall be as per IS
2190-2010. Extinguishers bearing IS marking shall only be supplied.
All the fire extinguisher shall be as per following specification only.
1. All the extinguisher shall be as per IS: 15683: 2018 and ISI marked.
2. Mechanical Foam gas cartridge (9 liters) capacity shall have minimum class B rating of
89B & minimum class A rating of 2A.
3. Water type 9 liter Capacity (gas cartridge) shall have minimum class A rating of 2A.
4. CO2 Extinguishers shall be 4.5 Kg capacity and shall have class B rating of 34B. As the
capacity of the extinguisher has been reduced to 4.5 Kg from 6.5 Kg, Proportionate
numbers of extinguisher has to be increased as Per IS: 2190:2010
5. DCP Extinguisher capacity 6 kg (filled with UL listed urea potassium bicarbonate powder)
, and shall have minimum class B rating of minimum 89B .
6. IS: 15683: 2018 also govern the clean gas agent fire extinguisher hence capacity of the
extinguisher shall be 6 Kg with minimum class A rating of 1A class B rating of 55B .(
(Halotron / NAF PV/ HFC-36 / Fluoro ketone) .
7. Distribution of fire extinguisher shall be as per IS 2190: 2010
8. Fire sand bucket shall be as per IS: 2546-1974 galvanised mild steel, capacity 10 litres.
9. All the fire extinguisher shall pass vibration test as per IS: 15683: 2018 & Fire
extinguisher shall be capable to mount in vehicles and moving equipment’s.
10. 2 no. Extra cartridge with each cartridge type fire extinguisher shall be provided.
11. Water, Foam & DCP shall be of cartridge type, Carbon dioxide and clean agent shall be
stored pressured type.
12. Additional 10% portable fire extinguishers of each categories shall be also included in
scope of supply for maintenance and replacement purpose
The following information shall be furnished with the tender.


& ITS AUXILIARIES
(i) GA and cross-sectional drawings of the equipment covered in the specification.
(ii) Catalogues for the above.
(iii) Name and address of manufacturer for various equipment.
(iv) Test pressure.
(v) Materials of construction of various components.
(vi) Weight of each item/ assembly.
(vii) Copies of ISI approval/TAC approval/or other statutory authority certificates & Test
Certificates
(viii) Reference list.
(ix) List of 2 years operation and maintenance spares as well as fast wearing item along with
unit rates
(ix) Additional 10% portable fire extinguishers of each categories shall be also included in
scope of supply for maintenance and replacement purpose
(x) All the fire extinguisher shall bear ISI marked and it shall be as per latest relevant IS
15683.
04.08.02 Necessary tools, spanners etc. required for regular operation/ maintenance of the
equipment shall be supplied along with the equipment and shall be mentioned in the offer.
04.08.03 All equipment shall be so packed to avoid any damage during transit.
04.08.04 The Bidder shall guarantee satisfactory performance of all the equipment supplied by him.
04.08.05 No deviations or exceptions from this Specification shall be permitted without the written
approval of the Purchaser / consultant. Intended deviations if any, shall be listed by the
vendor on a separate sheet of paper at the time of bids submission and supported by
reasons for consideration by the Purchaser / consultant.
04.08.06 Compliance with this Specification shall not relieve the Bidder of his responsibility of
furnishing equipment and auxiliaries of proper design, materials and workmanship to
meet the specific operating condition
04.08.07 All the equipment shall be provided with test certificates. A certificate shall be produced
from Chief/ Dy. Chief controllerof Explosives, PESO, Nagpur in case of Carbon dioxide
extinguishers. IS/TAC approval shall be required for all types of extinguishers.


& ITS AUXILIARIES
04.08.08 All portable extinguishers shall be supplied with mountings, accessories and installed
along the column/walls near entry/exits and at height of approximately 1000 mm from the
finished floor level. Wherever extinguishers are required to be installed on the steel
columns of the building, the welding of the supporting fixture to columns shall be done by
the successful Bidder. Necessary welding set for this job shall be arranged by the Bidder.
The Bidder shall mark / provide border around the fire extinguisher installing point / fire
point describing details as specified by fire officer in florescent paint. Self-explanatory
display board shall be provided depicting the type of fire & the type of suitable
extinguishers that is to be used.
04.09 Passive Fire Protection
04.09.01 Introduction
Passive fire protection is an integral part of a complete fire protection system and is
essential for prevention of spread of fire through openings in walls or floors. These
measures are intended to contain a fire in the fire compartment of origin, thus limiting
the spread of fire, excessive heat and corrosive, re-ignitable and fatal gases for a limited
period of time, as determined by testing, which must bound installed configuration in
all respects in order to comply with the law and regulations. Passive fire protection
system shall be provided as per indicated in Annexure-1 (refer electrical drawing indicated
in Sl. No. 3 to 7 in list of drawing enclosed portion).
04.09.02 Fire retardant coating/ Painting:
For vertical run of cables & PVC conduits, fire retardant coating will be provided for
the whole length. For horizontal run of cables, 1 m length of fire retardant coating will
be provided at every 5.0 m interval wherever cables cross any partition wall, floor or
pass through any opening, coating shall be provided for at least 1 m length on either
side. In addition to this all the cable joints shall be coated with fire retardant paint all
around and or 1 m length both the side of joint. Fire retardant coating/ painting of
cables having minimum 3 hours fire rating. The material shall be UL/FM/VDS/LPCB
approved and enlisted. Approval for the material shall be obtained from CBRI,
Roorkee.
04.09.03 Fire barrier / Sealing of Cable Openings:
Cable fire stops/barriers shall be provided in following cases:
 Entry/Exit area of cable/cable trays in various compartments of cable

gallery/basement/tunnels having different fire loads.
 Under control panel/any other panel where cables are entering or going out.
 In floor openings.


& ITS AUXILIARIES
The system shall have minimum 3 hours fire rating ( It should have approval from
CBRI, Roorkee).Fire Stop materials shall have approval and certification from UL/ FM/
LPCB/ VDS.
04.10 Erection, Testing, Commissioning & Performance Guarantee
04.10.01 Testing
All tests and inspection of the installation shall be done in conformity with the functional
and statutory requirement of the system. The bidder shall furnish a detailed testing and
commissioning procedure for all the systems for approval by the purchaser. As soon as a
given facility or a portion thereof is completed and ready to energize and start-up, the
purchaser may test run and operate it without relieving the Bidder of his responsibility or
guarantee.
04.10.02 Start-up and Commissioning
i. Bidder shall provide the services of all technicians, erection and start-up engineers
necessary to bring the complete installation of hydrant / clean agent system etc. into
operation.
The Bidder shall be responsible for the integrated commissioning of the plant &
equipment supplied by him including trials, commissioning and demonstration of
performance guarantee test.
ii. The Bidder shall render the following services:
a. Prepare equipment for trial runs and start-up

b. Start-up and commissioning of equipment.
c. Preliminary operation, initial operation, trial operation and Final acceptance test.
The Bidder shall be required to clean up the equipment and surrounding area and prepare
it for trial runs and operation.
The Bidder shall clean up dirt, remove any protective coating applied by the manufacturer,
clean ventilating open and remove all visible foreign bodies from the equipment erected.
Commissioning of entire fire protection system shall be done in presence of CFO of

METTUR-I& his representative.
Sequence checking of all control systems, pneumatic and cable connections, checking
operation of all interlocks and protective devices shall be done by the Bidder.
Blow down of all piping systems, installations and removing strainers in piping and
equipment, as required shall be done by the Bidder.

& ITS AUXILIARIES
Calibration and adjustment of relay settings, instruments etc., disconnecting and

reconnecting the driven and driving parts of any equipment and drives, as required, during
the trial runs and rectification, if any shall be done by the Bidder.
The Bidder shall provide personnel as required for assisting starting up and
commissioning of equipment as well as adjustments, repairs and rectifications of defects in
erection of the equipment during commissioning of the equipment and upto final
acceptance.
iii. Trial runs
Trial runs shall be carried out after completion of erection and shall determine function
ability and the readiness of equipment to operate the plant erected. The plant shall be
tested in all its functions and checked for proper performance. Any irregularities found
shall be remedied by the Bidder.
Trail run shall be performed during the shutdown period which will be discussed mutually
and informed to the Bidder.
iv. Commissioning
On completion of the trial operation, all the systems shall be under observation in
operative condition. The Bidder shall provide skilled personnel including necessary tools
and consumables wherever necessary to rectify the deficiencies observed.
04.10.03 Scope of Inspection of portable fire extinguisher
 Verify and certify the material (equipment) offered meets all the details mentioned in the
specifications.
 Welding materials/ rods shall be checked for meeting specifications/ standards. Wherever
radiography welding is required, the same has to be inspected (only for welding
applications).
 Extinguisher is as per relevant IS codes mentioned in the specifications.
 Checking performance of extinguisher on random basis.
 Check the fire extinguisher as per the design calculations.
04.10.04 Performance Guarantee
PG Test shall be carried out within 3 months from date of commissioning of the system in

& ITS AUXILIARIES
presence of METTUR-I and turnkey supplier of the system viz.hydrant system, Clean
agent gas system, Portable fire extinguisher, Passive fire protection.
The PG parameters shall be understood to be met if, the above mentioned system have
performed as per the technical requirement spelt out in TS.
Portable extinguisher shall be subject to WARRANTY for a period of 12 months from the
date of commissioning of the plant. The warranty shall cover defect, defect in material or
workmanship for sub-assemblies as well as the total assembled equipment Initial fill of
gas and other fire extinguishing media (including quantity required for PG test) shall be
under the scope of Bidder and quantity/item used for testing/PG shall be replenished by
the bidder free of cost.
In case it fails/deviates, from the TS, the bidder has to make it operable according to the
requirement of TS within a period of 2 weeks.
In absence of the above, Bidder shall be charged proportionate percentage of the L.D of
7.5% of the total contract price plus escalations, if any, paid or payable to the bidder
excluding taxes and duties.
The observations of each performance test shall be recorded and signed by the Purchaser
and the bidder. If such data conform to the performance test values, the performance
guarantee test shall be considered to have been successfully completed and a certificate to
this effect shall be issued by the purchaser.
The bidder shall be liable for the PG Test and meeting the requirement of
performance guarantee parameter of entire firefighting system as whole category
wise.
04.11 Equipment Preferred Make
Shall be as per Purchaser’s preferred make.

SECTION 05.00
PIPE, VALVES &
FITTINGS


ITS AUXILIARIES
05.00 PIPE, VALVES AND FITTINGS
05.01 GENERAL
Complete set of pipe, valves, fittings, specialties, accessories, instruments, pipe

supports, trestles etc. for the entire FGD system complete in all respects i.e. (Flue gas
system and absorber system, reagent conveying system with bunkers/silo, by-product
conveying system with bunker/ silo, water supply system, drain & sump system, etc.). It
shall include all water piping, air piping, recirculation lines, interconnecting pipelines,
flushing & purging pipelines etc.
All valves (isolation / gate / globe / control) required for the FGD system, actuators for
the actuated valves as required.
05.02 The material to be supplied for completing the pipe work shall include but not be
limited to the following:
05.02.01 Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing unions,
couplings, caps, blank flanges, saddles etc. necessary for making reliable piping
system.
05.02.02 Gaskets, ring joints, jointing material etc. as required.
05.02.03 Instrument tapping connections, stubs.
05.02.04 Gate / plug, globe and check valves to start/stop, regulate and to prevent back flow.
05.02.05 Anchors, hangers and supports as required including secondary steel embedment etc.
05.02.06 Bolts, nuts, fasteners as required for interconnection piping, valves and fittings as well
as for terminal points.
05.02.07 Painting, anti-corrosive coatings etc. for outside pipes as necessary.
05.02.08 Welding electrodes and welding rods.
05.02.09 The area around storage tanks, strainers, valves etc. (located outside pump house) shall
be paved
05.03 Water and Air Piping, Fitting and Accessories
All piping shall be provided with vents at the highest points and drains at the lowest
points along with vent valves and drain cocks. Vents shall not be less than 15mm in
size. Drains shall not be less than 25 mm size. The piping shall be arranged to provide
clearance for the removal of equipment requiring maintenance and for easy access to
Vol. – IIC, Section 05.00 PIPE, VALVES & FITTINGS Page 1 of 2

ITS AUXILIARIES
valves and other piping accessories required for operation and maintenance.
Piping shall generally be routed above ground but where specifically

indicated/approved by the Engineer the pipes may be arranged in trenches or buried.
Bidder shall provide either coal tar or Bitumen tapes on conventional coat and wrap
system for corrosion protection of buried piping as per relevant codes and standards.
Pipe Size in pump suction side shall be at least one pipe size larger than the
corresponding pump discharge connection.
Pipe Support Spacing
25 50 80 100 150 200 300 400 500

Pipe Size (NB)
Spacing in 2.1 3.0 3.7 4.3 5.2 5.8 7.0 8.2 9.1
meter
Vol. – IIC, Section 05.00 PIPE, VALVES & FITTINGS Page 2 of 2

SECTION 06.00
THERMAL
INSULATION, LAGGING
& CLADDING


ITS AUXILIARIES
06.00 THERMAL INSULATION, LAGGING AND CLADDING
06.00.00 General
Thermal Insulation along with aluminum cladding shall be provided for all the
equipments/surfaces having skin temperature more than 60 degree Celsius.
06.01.00 The specification of the insulation including type, density, thickness, heat
conductivity and finish shall be designed based on criteria specified below. The
insulation thickness shall be designed based on following criteria.
Sl. No. Criteria Design Conditions

1. Ambient Temperature 45 deg C
2. Surface Wind Velocity 0.25m/s
3. Emissivity of aluminium 0.2
4. Cladding Surface Temperature 60 deg (Max)
5. Thermal Conductivity of Not less than the Maximum values as
insulation material per IS:8183
6. Pipe/Equipment wall Maximum fluid design temperature
temperature
7. Overall heat transfer coefficient To be calculated as per ASTM C 680-
and insulation thickness 89
However, the minimum insulation thickness, however, shall not be less than 75 mm.
06.02.00 Material and application of insulation material, protective cladding, wire mesh
etc. shall be conforming to latest edition of following codes:
a) IS: 8183
b) IS: 3677
c) IS: 3144
d) IS: 14164
e) IS: 280
f) ASTM B-209
06.03.00 Insulation material for all equipments, ducting, etc. shall conform to following
requirements:
Parameters Requirement
i) Material a) Lightly resin bonded mineral
wool of best grade conforming to IS:8183.
(Handmade mattresses are not acceptable).
Material shall be rock wool only. Slag wool
Vol. – IIC, Section 06.00 THERMAL INSULATION, LAGGING & CLADDING Page 1 of 8

ITS AUXILIARIES
or slag wool inclusion shall not be accepted

b) Lightly resin bonded glass wool
mattress, having density 64 Kg/m³ (min.),
self stitched in shop can also be accepted
for temperature less than 400°C
ii) Bulk density of lightly resin
bonded mineral rock wool
mattresses
(a) For use upto 400°C 100 Kg/m3
(b) For use above 400°C 150 Kg/m3
iii) Physical requirements
Following shall be met by testing as
per relevant clauses of IS:3144.
a) Shot Content 5% by weight (maxm.), size of any shot
not to exceed 5 mm in diameter
b) Bulk Density To comply with 16.03.00(i) & (ii) above
c) Weight gain by moisture 2% (maxm.)
absorption
d) Sulphur Content Not exceeding 0.6%
e) Alkalinity as percentage of Not exceeding 0.6%
Na2O
f) Maximum oil content Not exceeding 0.3% by weight
g) Total carbon content Not exceeding 0.3% by weight
h) Settlement Nil (When tested as per Cl. 21.1 & 21.2
of IS:3144)
i) Handability Fully handable, without any lump
formation and disintegration of material
j) Loss of weight after Not exceeding 5% by weight
combustibility test
06.04.00 The Insulation mattress shall be rated incombustible when tested by the method
prescribed in clause 15 of IS:3144 and shall meet the requirement of the Mercantile
Marine department, Lloyd's Register of shipping, underwriter, fire hazards codes and
other International standards.
06.05.00 In addition to requirements as mentioned above, insulation material (and protective

covering) shall:
a) Be fresh, incombustible, rust proof, non hygroscopic.

b) Be capable of withstanding continuously and without deterioration the maximum
temperature to which they will be subjected.
c) Not react chemically, either to itself or with other components.
d) Not sustain any fungi, or vermin and must not pose health hazards.

ITS AUXILIARIES
06.06.00 The Mineral wool shall:
a) Pass standard combustibility test both immediately after application and after subjected
to maximum operating temperature for not less than 100 hrs.
b) Not suffer permanent deterioration as a result of contact with moisture due to
condensation and shall be free from objectionable odor.
c) Not cause corrosion of the surface being insulated or of cladding on it under normal site
conditions.
d) Not suffer any quality deterioration under specified service conditions (both
cold/hot face temp.) of use.
06.07.00 The use of insulation of finishing materials containing asbestos in any form is
not permitted.
06.08.00 Insulation mattress/section shall be supplied in thickness of 25,40,50 and 75 mm.

Insulation of higher thickness shall be made up in multiple layers using
mattress/slabs of thickness specified above. However, if the required thickness is
such that by using above mattress/slabs the calculated thickness is not achieved,
the mattress/slabs in increment of 5 mm shall be acceptable for outer layers.
The min. thickness however, shall not be less than 25 mm and number of layers shall be
minimum and innermost layer shall be thickest.
06.09.00 Sheathing Material
Sheathing material for all insulated surfaces, equipments, piping etc. confirming
to ASTM B-209-1060 temper H-14 or IS:737 Gr 19000/H2, shall be provided.
The thickness of aluminium sheathing to be used shall be 22 SWG (0.71mm).
06.10.00 Binding and lacing wires shall be 20 SWG Galvanised Steel wire
06.11.00 All Straps and bands shall be Galvanized Steel. Bands shall be 20 mm wide and 0.6 mm
thick. For securing Aluminum sheathing material, stainless steel or anodized
aluminum bends shall be used.
06.12.00 Screws shall be of galvanized steel, check headed, self tapping type. Above 400
degree Celsius temperature, screws shall be stainless steel.
06.13.00 Hexagonal wire mesh netting shall be 10-13 mm aperture and at least 0.56mm
diameter conforming to following Galvanized Steel wire.
06.14.01 Non metallic components like 3 mm thick mill board, aluminum pigment
sealant, white glass cloth, insulating cement, neoprene washer shall be provided.

ITS AUXILIARIES
06.15.00 Application of Insulation
06.15.01 General
a) All surfaces to be insulated shall be cleaned of all foreign materials such as dirt,
grease, rust etc. and shall be dry before the application of insulation.
b) Before applying the insulation the contractor shall check that all instrument
tapping, clamps, lugs and other connections on the surface to be insulated have
been properly installed as per the relevant erection drawing.
c) All flanged joints shall be insulated only after the final tightening and testing.
d) The insulation shall be applied to all surfaces when they are at ambient temp. Ample
provision shall be made for the maximum possible thermal movement and the
insulation shall be applied so as to avoid breaking/telescoping due to alternate periods
of expansion and contraction.
d) All cracks voids and depressions shall be filled with finishing cement, suitable for the
equipment operating temp. so as to form a smooth base for the application of
cladding.
06.15.02 All the refractory and insulation materials required for complete field application
of insulation, cladding etc. covered under these documents and specifications shall be
furnished with the equipment. They shall conform to the requirements of the various
relevant ISI standards or other approved equivalents. All items such as insulating
cement, sealing material, insulation material, screws, washers, etc., needed to
complete the work in the course of the application of insulation and refractory
shall be furnished. All insulating materials shall be chemically inert in both the dry and
wet state and shall withstand the full working temperature conditions to which
they are exposed without any deterioration. The gas ducts shall be insulated with
mineral wool block or mineral wool blanket and all other equipment operating at
elevated temp. not enclosed in the boiler casing shall be insulated with calcium
silicate blocks, mineral wool blocks or mineral wool blanket insulation.
06.15.03 Application on Piping
a) All vertical pipes shall be provided with the suitable insulation supports to
prevent collapsing/crushing of insulation due to its self weight. Support rings shall be
provided on all vertical piping with a difference in elevation of 4 meter or
above, and there shall not be more than 3 m straight length between support
rings.
b) Longitudinal joints of insulation mattress sections of horizontal piping shall be on the

bottom or at the sides of the pipe.

ITS AUXILIARIES
c) When more than one layer of insulation mattress/section is required on piping

the circumferential joints on adjacent layers shall be staggered by at least 150 mm
and longitudinal joints shall be staggered by at least 50 mm.
d) The mattress type insulation shall be formed to fit the pipe and applied with the
mattress edges drawn together at the longitudinal joints and secured by lacing wire.
Pipe section insulation shall be fitted on pipe using binding wires.
e) Where insulation is applied in two or more layers each layer of mattress shall be
backed with hexagonal wire mesh. For the first layer of insulation and in case of
single layer insulation, hexagonal wire mesh shall be provided on both the surface
of the mattress. For pipe sections, the sections shall be held in place by binding wires
without any wire mesh.
f) The ends of all wire loops shall be firmly twisted together with pliers, bent over
and carefully pressed into the surface of the insulation. Any gap in the insulation shall
be filled with loose mineral wool or finishing cement.
g) Insulation mattress/section ends shall be terminated at a sufficient distance from

the flanges to facilitate removal of bolts.
h) The insulation shall be held in place by fastening over with binding wire for
insulation surface with diameter upto and including 550 mm and with metal
bends for insulation surfaces with diameter over 550 mm. The fastening shall be done
at intervals of 250 mm except where specified otherwise. The ends of the binding
wires shall be hooked and embedded in the insulation. The straps shall be
mechanically stretched and fastened with metallic clamping seals of the same
materials as the strap.
i) Insulation for application on bends and elbows shall be cut into mitred segments,
sufficiently short to form a reasonably smooth internal surface. After the
application of insulation material place, insulating cement shall be applied as
required to obtain a smooth surface.
j) Weather hoods shall be provided for insulated piping passing through

floors/walls.
k) All pipe attachments coming on horizontal pipes, inclined pipes and bends shall
be insulated along with pipe such that there will be no insulation applied to hanger rod
and the component connecting hanger rod to pipe attachment. All pipe attachments
exposed to weather shall be provided with weather proof covering.
l) Upstream of all drain lines and the lines connected to steam traps, shall be
insulated upto and including first isolating valve for heat conservation. Rest of such

ITS AUXILIARIES
lines such as downstream of the drain valves, traps etc. and other lines such as
safety valve discharges, vents, etc. shall be insulated for personnel protection.
06.15.04 Application on Valves and Fittings
a) All valves fittings and specialties shall be insulated with the same type and
thickness of insulation as specified for the connected piping with the special provisions
and or exceptions as given below.
b) All valves and flanges shall be provided with removable box type of insulation covered
with box fabricated from aluminium sheets of thickness same as the connected pipe
cladding. Adjoining pipe insulation shall be bevelled back to permit removal bolts and
nuts or bands. The portion of the valve which can not be covered by box type
insulation shall be filled by loose insulating material of packing density at least
equal to that of the insulating material of adjoining pipe. The insulation for
valves/flanges shall be applied after the finishing has been applied over the
connected piping. The cladding shall be applied in such a manner that the bonnet
flange can be exposed easily without disturbing the complete insulation and cladding.
c) Flanges on lines having temperature upto and including 150 deg.C shall not be
insulated.
d) Union shall not be insulated.
e) Expansion joints, metallic or rubber, shall not be insulated unless otherwise

specifically indicated.
f) Safety valves shall be insulated.
06.16.00 While applying mineral wool blanket insulation:
a) Provide expended metal or hexagonal wire mesh on both sides for single layer
mattress and on first layer in case of multilayer insulation. Subsequent layers of
multilayer insulation to have only one side wire netting.
b) The edges of adjacent blankets to be leased together, by appropriate lacing wire.
c) Any gap between joints between insulation layers shall be filled by loose mineral
wool confirming to IS:3677.
d) All insulation to be secured by 1.63 mm dia wire netting over blankets with
ends of wire tightly twisted, and pressed in to insulation surface.
e) Impelling pins shall be placed on centers not exceeding 300 mm.

ITS AUXILIARIES
06.17.00 Flue Gas ducts with external stiffeners shall have first layer of insulation between the
stiffeners and a second layer of insulation over stiffeners so that stiffeners are also
insulated and a level surface is achieved. Other requirements are same as given in
Clause 06.09.00.
06.18.00 Application of Metal Cladding
06.18.01 All insulated surfaces of the FGD shall be provided with metal cladding in
accordance with the following requirements.
a) All insulation procedure of metal cladding shall have prior approval of the
Purchaser
b) All insulated surfaces of FGD shall be covered with aluminium cladding.
c) Cladding for FGD components are to be finished with plain aluminium sheeting
of thickness not less than the values specified. Wherever an inner casing plate is
necessary to effect a gas tight enclosure, the plate shall be of mild steel of required
thickness, but not less than four (4) mm suitably stiffened and supported.
d) Cladding on straight surfaces shall be finished with aluminium sheeting of at least 20

SWG thicknesses suitably pressed along diagonals to form diamond shape or otherwise
formed.
e) Cladding for insulated circular surfaces will be constructed from aluminium

sheets of thickness not less than 20 SWG.
f) Weather proof flashings shall be installed where the panels intersect with
columns and at other similar joints.
06.19.00 Application
All metal cladding shall be fabricated and installed to ensure a neat appearance and no
open ended sections of cladding shall be left uncovered. The following provisions shall
also be complied with:
a) All closures, flashings and seals required shall be provided and installed.
b) An asphalt and craft paper moisture barrier shall be provided to the aluminum
cladding for all out door applications. Such moisture barriers shall be fixed to the
inner surface of the cladding or shall be cemented to the outside surface of the
insulation before application of cladding.
c) All the used in the out door cladding shall be provided with Neoprene washers.

ITS AUXILIARIES
d) All openings and joints in outdoor cladding for piping connections, supports or
access shall be suitably flashed and weather-proofed. Where such flashings or
weather-proofing cannot effectively control the entry of moisture, then such openings
and joints shall be weather-proofed by application of aluminium pigmented sealer.
e) Cladding on the top surfaces of the FGD, duct work and equipment shall be suitably
reinforced to prevent damage by personnel walking thereon.
SECTION 07.00
COMPRESSED AIR
SYSTEM


& ITS AUXILIARIES
07.00 COMPRESSED AIR SYSTEM
07.01.00 General
Oil free screw type air compressors, desiccant type air dryers along with air receiver
having suitable capacity for the FGD plant shall be provided.
07.02.00 Scope of work
The scope of work of the bidder shall cover design, engineering, manufacture, shop
testing, painting, supply transportation to site, storage, handling at site, erection, testing,
commissioning, demonstration of performance parameters and final handing over of all
the plant & equipment and connected utilities of compressed air system.
The compressors, air dryer units and air receivers shall be complete with all materials
and equipment whether specifically mentioned herein or not but required for
satisfactory operation of plant & equipment individually as well as integrated manner.
At the outlet of compressor flow measurement shall be envisaged & same shall be
indicated in the control room or may be hooked up with PLC system, Suitable hoisting
facility for maintenance purpose shall be considered.
The compressors along with air dryer shall be located inside a structural building near
main plant.
Compressed air station shall comprise of but not limited to the following main units:
a) Oil free, air/ water cooled, rotary screw packaged type air compressor complete with
electric motor of suitable capacity and all its accessories & auxiliaries along with pipes,
fitting, valves, etc including the following accessories / auxiliaries to meet the
requirement of service/ instrument quality air for the entire FGD plant. The
specification of air compressor, air dryer unit and air receiver are indicated here in after.
i) Intercoolers, moisture separator with auto drain trap station,
ii) Suction air filter system
iii) Lube oil system.
b) Desiccant type of Air Drying unit of suitable capacity.
c) Air receiver of suitable capacity
d) All necessary interconnecting pipes, valves, fittings including supports and supporting
structures.
Vol. – IIC, Section 07.00 COMPRESSED AIR SYSTEM Page 1 of 5

& ITS AUXILIARIES
e) Drain pipelines from compressed air station to nearest drain / drain pit.
f) Necessary electrics, instrument & Controls for compressors, air drying unit and air
receiver & its auxiliaries.
g) A set of tools & tackles for repair and maintenance.
h) All anchor bolts & nuts, washers & base frame for equipment.
07.03.00 Equipment Specification
07.03.01 Air compressor:
No. of Compressors : Working + 100% Stand-by
Discharge flow : As per requirement
Discharge Pressure at outlet flange of : As per requirement

after cooler and moisture separator
Installation : Indoor
Service duty : Continuous/ intermittent
Environment : Dusty
Oil content : Nil
Dust particle size : Not to exceed 3 microns
07.03.02. Compressor shall be complete with motor of suitable capacity. Driving motor shall
have adequate margin not less than 10% over the maximum power requirement at
motor terminal (considering motor efficiency) at maximum capacity of the compressor.
07.03.03. Suitable lubrication system for bearings and other moving parts of the compressors
shall be provided. Lubrication system shall be complete with necessary filters /
strainers, oil coolers, level indicators, pumps, pipes, valves and fittings etc.
07.03.04. Compressor shall be provided with a dry type air intake filter system. The suction filters
supplied shall be of appropriate type such as to prevent ingress of dust into the machine.
07.03.05. The compressor shall have capacity control with constant discharge pressure over full
range. For this purpose suitable air intake control valve with other connected system
shall be provided.

& ITS AUXILIARIES
07.03.06. Compressor shall be provided with inter cooler, moisture separators etc..
07.03.07. Compressors shall be provided with adequate safety, protection and control system.
07.02.00 Air Drying Unit:
There shall be desiccant air drying unit of suitable capacity. Selection of dryer shall be
such that performance of the same shall not be affected at different loads of the system.
This dryer shall be installed adjacent to the compressor. The system shall be designed
such that under no circumstances the dry air supply shall be stopped.
The air drying and filtration shall be designed to continuously supply dry and oil free
air. Both manual and automatic change over from one mode to other should be possible.
The design, fabrication and materials of construction of various pressure vessels shall
be as per the pressure vessel code IS:2825 latest edition or ASME Section VIII.
Pre filters shall be provided to remove dust and any other contaminant from the air
stream. After filters located downstream of the absorber towers shall prevent carryover
of fine particles with the efficient air stream.
Both the pre filters and after filters shall have 100% standby unit. All filters shall have
individual isolation valves, safety valves and drains with trap stations and pressure
gauges.
The air drying plant shall be provided with dew point measuring devices.
Design considerations of the drying unit are indicated below:
Air flow rate (each) : Bidder to work out
Normal inlet pressure : Same as compressor outlet
Maximum air temp (inlet) : Same as compressor outlet
Dew point of outlet air : (-) 400 C

at atmospheric pressure
Maximum allowable pressure drop : 0.2 kgf/cm2 g.
Oil content in the outlet air : Nil
The dryer shall be supplied along with all necessary auxiliaries. The operation and
controls of the dryers shall be fully automatic.


& ITS AUXILIARIES
The dryers shall have built control panel with auto / manual operation. Indication of
outlet air temperature and pressure shall be provided at prominent place. Lifting eyebolt
shall be provided for installation and maintenance purpose. First fill of all consumables
shall be supplied along with the dryer unit.
07.03.00 Air receivers
There shall be suitable capacity of air receivers for service/ instrument air. Air receivers
shall be of carbon steel material, welded construction complete with all accessories.
The air receiver shall conform to IS:7938 latest edition. The air receivers shall be
designed, manufactured and tested according to IS:2825 latest edition and shall be
complete with pressure gauge, lifting lugs, manhole, safety valve and foundation bolts.
The material of construction of shell, header, nozzle, etc. shall be as per IS – 2002 – Gr.
– 2A or equivalent.
07.04.00 Pipe work, valves & specials
Piping layout must follow good engineering practices. Proper attention shall be paid to
obtain full functional requirement of air, water and oil piping with a layout which
provides sufficient clearance for various auxiliaries, other equipment and operating
personnel, easy access for operation and maintenance, convenient supporting
arrangement.
Except otherwise specified, all pipes shall be provided with butt welded connections
and with flanged joints only at the connections with equipment, vessels and valves.
Pipes laid inside the R.C.C. trenches shall be supported at intervals on steel sections
and the arrangement shall facilitate easy maintenance.
Valves in the air line shall be of shall be of cast steel / forged steel full bore, two / three
piece design ball valves with Stainless steel internals. For waterlines, either wafer type
butterfly valves sand witched between two flanges or double-flanged butterfly valves
shall be provided. In butterfly, gate, globe valves, face of the hand wheel shall be
clearly marked with word `open and shut' with arrows adjacent to indicate the direction
of rotation. In butterfly, non-return & globe valves, direction of flow shall also be
marked on the valve body.
All the globe valves shall be designed to prevent erosion of valve seats when the valves
are operated in throttled conditions. Design of valves shall be such that it shall permit
packing of glands while under pressure.
Non return valves shall be of double flanged and dual plate spring design.
The solenoid valves shall have heavy duty, double impregnated tropicalised coil and
shall be suitable for operating temperature and for operation continuously energised in
tropical climate. The solenoid valves shall be of bronze body with stainless steel trim.

& ITS AUXILIARIES
The coil shall be suitable for continuous duty. The enclosure shall be water tight, dust
tight and the valve shall be suitable for mounting in any position.
All the valves for water line and air line shall be of 150 class rating. The valves with
flanged ends shall be provided with flanged ends having raised face, serrated finish.
The drilling of the flanged ends shall be done as per IS:6392 - 1971 (RA 1988) .
Valves of size NB 125 - 400 shall be of gear operated type.
Ball valves shall confirm to BS:5351 / API 608.
Cast Iron Gate valves shall conform to IS:14846.
Cast Iron Globe valves shall conform to IS:9338
Gate & Globe valves below 50 NB shall conform to IS:778 - 1984(RA1990).
Non return valves shall conform to IS:5312 - 1984(RA 1990).
All pipelines shall be provided with drain connections, generally at the lowest point for
removal of accumulated condensate or water and also for draining of the water after
hydro testing of the erected pipe work. Vents with valves shall be provided at highest
point of the pipe line.
The drain piping shall have drain pocket followed by a connection of drain pipe with
isolation valve. Line shall be provided with slope towards the drain point.
MS Pipes of following specification shall be provided for industrial water and air
applications.
NB 15 - 150: ERW, Black, Heavy pipe having plain ends as per IS:1239 Part-I – 1990.
NB 150 & above: ERW, Black pipe of minimum thickness 6.35 mm having plain ends
as per IS:3589-1991
Pipe fittings conforming to IS:1239 Part-II - 1992 shall be provided for pipes of size up
to NB 150. Fabricated fittings manufactured from the pipes shall be provided for pipes
of sizes NB 200 and above.
Complete pipe network after erection shall be hydraulically tested at a pressure of 1.5
times the working pressure. The pipe network shall be subjected to the test pressure for
a minimum period of 4 hours.


(4X210MW)
FOR
VOLUME – III
CONTROL & INSTRUMENTATION
MECON LIMITED
RANCHI – 834 002


& ITS AUXILIARIES
INDEX TO VOLUMES
Volumes Title
Vol. – III INDEX TO VOLUME Page 2 of 3


& ITS AUXILIARIES
Volumes Title
Vol. – III INDEX TO VOLUME Page 3 of 3

METUR THERMAL POWER STATION-I (4X210MW)

& ITS AUXILIARIES
01.00.00 CONTROL AND INSTRUMENTATION SYSTEM
01.01.00 General
01.01.01 Introduction
Instrumentation & Control system for semi dry (hydrated lime) based FGD system for
MTPS-I (4 x 210 MW) has been envisaged with centralized, dedicated automated and
safe control system to achieve efficient and better reliability and availability of the plant
and equipment. This chapter covers the design criteria and concepts proposed for the
FGD System:
a. Micro - processor based dedicated Programmable Logic Control System (PLC)

including closed loop control system, open loop control system for the FGD plants
with Human – Machine Interface (HMI) system. (Each FGD shall be provided with
dedicated PLC. Control room is common for all the units. Operations of all four (4)
units of FGDs shall be done from any of the HMIs, housed in FGD common
Control room).
b. Smart type field instruments for the FGD plants & its auxiliaries.
c. Power Supply Equipment
d. Air Supply for pneumatic equipment.
e. CEMS Analysers
Flue Gas Desulphurisation (FGD) system and its auxiliaries shall be operated, monitored
and controlled through dedicated 1:1 hot redundant PLC system for each unit with all
closed-loop set in auto-mode. Sequencing, interlocking, protection and logic functions
shall be implemented in the PLC. No stand-alone PID controller for closed loop control
shall be envisaged. The C&I system shall be configured in fail-safe mode of operation.
This specification shall be read together with the Complete Technical Specification and
all the applicable clauses shall be complied by the Bidder while finalising the complete
scope of work & supply for this system.
Measurement and control equipment offered for the process shall be complete in all
respect in line with the broad requirement indicated in this specification. Any equipment
/ accessories not explicitly indicated in this specification, but considered essential for
proper functioning of process & equipment shall be included by Bidder in their scope of
work and supply.
CONTROL & INSTRUMENTATION SYSTEM Page 1 of 119


& ITS AUXILIARIES
Bidder shall refer the following clauses for the detailed technical specifications of
control and instrumentation facilities i.e. field instruments, analysers, cables, PLC,
control valves etc.
01.01.02 Scope of work and supply
i. The scope of supply & work shall be complete design, engineering, procurement,
manufacture, assembly, inspection, supply, packing, transit insurance, transportation
to site, storage, calibration, erection, testing and commissioning of the complete
control & instrumentation (C&I) system with all types of field instruments, cables,
pipes and erection hardware necessary for completion of C&I work for the FGD
system & their auxiliary units on a turnkey basis.
ii. The scope of work shall also be complete with all civil work like chipping, digging,
concreting, including filling material etc., and associated erection of instrumentation
equipment where ever required.
iii. Bidder shall consider and provide air conditioned and well ventilated rooms for all
analyzers including CEMS. Suitable enclosures (as applicable) shall be provided for
all outdoor analyser equipments.
iv. One number portable type gas analyser shall be supplied for each flue gas analyser
system.
v. Each flue gas analyser syetm shall be supplied with necessary softwares alongwith
Laptop for configuration and calibration and required Reference gas cylinders with
license.
vi. In the event of conflict between requirements of any two clauses in any
volume/part/chapters/section of the tender specification, the more stringent
requirements shall apply. Purchaser, however, reserves the right to relax this
condition at his discretion.
vii. Parallel redundant dedicated UPS 240V AC,50Hz system along with battery backup
for PLC, analyzers, field instruments and all C&I systems & equipments, along
with ACDB containing redundant adequate nos. of feeders for C&I system shall be
provided (For detail refer TS in Electrical Volume).
viii. Bidder shall provide vibration measurement system. Accelerometer type 4-20mA, 2
wire with vibration sensor for the HT drives of FGD system and shall be hooked up
with PLC.
ix. A minimum conventional (vertical) back–up panel mosaic grid type mounting of
miniature push bottoms, trip switches with LED indication for operation of

& ITS AUXILIARIES
start/stop of pump & motors considering major drives for safe operation & shut
down of the FGD plant.
x. All impulse pipes/Tubes after root valve shall be of SS as per application for field
instrument hookup.
xi. Any single failure of the field instruments or control equipment will not affect the
performance of the unit in any way. For field instruments /hardware configuration
following guidelines will be followed:
• For very critical application like for control & protection application of FGD unit
field instruments shall be provided 2 out of 3 hardware configuration.
• For balance control loops, protections, sequential logic and related measurement,
redundant hardware will be used.
• For balance measurement non-redundant hardware shall be used.
xii. Double root valve shall be provided if pressure >40 bar.
xiii. Close loop & open loop logics to be incorporated in Boiler logics due to
introduction of FGD system.
xiv. Maintenance platforms and access ladders for instrumentation equipment installed
at inaccessible heights.
xv. The purchaser reserves the right of selecting the manufacturer / model of control &
instrumentation items in the interest of standardization wherever necessary and the
Bidder shall agree to supply equipment/instruments of particular make if so desired
by the client within the list of approved vendors without any cost implication.
xvi. Any C&I equipment/instruments required during any stages for the efficient / safe /
reliable operation of the plant either during detail engineering / commissioning shall
be supplied, installed and commissioned by the successful Bidder without any
additional cost.
xvii. Providing engineering drawings, documents, licensed copy of software and

development tools, data, instruction, operation and maintenance manual etc. for
Purchaser / Consultant’s review / approval / record.
xviii. Arranging for Purchaser’s or his representative’s inspection and testing of

manufactured as well as bought-out items at the respective Works
xix. Master clock signal shall be provided by purchaser (MTPS-I) at the GPS panel
located in the main plant control room for time synchronization with the FGD


& ITS AUXILIARIES
systems. All the cables & hardware required for establishing the connectivity with
the main plant GPS shall be under the scope of the contractor.
xx. UPS power supply required for the FGD loads located at the main plant control
room (like RIO panel, OWS etc) shall be provided by purchaser (MTPS-I) in
ACDB. Further distribution from the ACDB including DB, Fuses, cable etc shall be
under the scope of the bidder.
xxi. Hardwire Signal exchange that is required with the main plant control system for the
critical signals shall be under the scope of the contractor including the cabling and
termination at both the ends.
xxii. It is envisaged that certain FGD drives shall also be controlled from the main plant
control system as decided during detail engineering in addition to the FGD control
system. IO’s required for these signals are also to be considered by the contractor.
Cabling & termination at both the ends i.e between FGD PLC & respective unit
control system shall be under the scope of the contractor.
Co-ordination with purchaser for software modification and development for
interfacing with main plant control system shall be under the scope of the bidder.
xxiii. The Bidder shall provide Air condition based PLC Equipment Room, FGD Control
Room, PLC RIO Room with granite flooring & metallic/metal plank false ceiling
with adequate lighting/LED bulb, emergency lighting etc. Control room shall be
aluminum framed, toughened glass partitioned for housing PLC control panels,
windows, main entrance double door and single door.
xxiv. Control room height shall be maintained minimum 3.5m upto the false ceiling and
over all height of control room shall be approx. 5.0 mts.
xxv. All instrument cables shall be routed through cable vault/gallery with maintaining
minimum height of 3.0meter.
xxvi. The measurements and controls indicated is the minimum requirement for the FGD
system. Bidder shall engineer the system and shall include additional measurements,
controls and protections required to make the system complete in all respects for
safe, efficient, reliable & ease of operation. Any measurement / control not listed
but essential for completeness of the process in total shall also be covered under the
scope of the Bidder.
01.01.03 Terminal Points
S.No. Description Terminal Point

1 OPC Main plant control room


& ITS AUXILIARIES
2 Master Clock Main plant control room

3 Hardwired Main plant control room
Signal Exchange
4 UPS power for Main plant control room ACDB
FGD loads in
main plant
control room
01.01.04 PLC system envisaged shall include but not limited to the following:
a) PLC for FGD system on seamless platform of hardware and software.

b) 1:1 hot redundant PLC controllers and its sub-systems as indicated in the
specification and system configuration drawings.
c) Remote IOs (RIO) and Marshalling racks wherever required.
d) Cabinets / panels with base frames (System Cabinet, RIO Cabinet, Marshalling
Cabinet, Relay Cabinet, PDB Cabinet, etc.)
e) HMI workstations, console desk, Hooters
f) All relevant software fully licensed
g) Electronic earthing required for field instruments and PLC system including
electronic earth pit.
h) Communication cable, special cables, etc.
i) Required mounting racks and furniture
j) Design and development of software for HMI functions
k) Erection hardware and accessories including cable tray and supports.
l) One (1) number FGD PLC’s operator work station (OWS) shall also be placed in
respective main plant unit Control Desk (UCD). MTPS-I FGDs shall be controlled
& monitor from OWS at respective main plant control desk apart from FGD
control room.
m) The soft data communication of FGD PLC with UCD (main plant control room)
Workstation shall be through FO cable.
n) Controllers of FGD system shall be provided with a RS485 communication ports to
facilitate communication with third party systems
Control Desk (CD) at control room
The bidder shall provide modular furniture including chairs for the work stations &
suitable tables for the printers supplied by them.
01.02.00 PLC system Overview
The FGD system shall be operated, monitored and controlled through dedicated 1:1 hot
bump less PLC controllers, located in the FGD common Control Room. PLC shall have
redundant in following level as per plant configuration.
• Controllers (CPU).

& ITS AUXILIARIES
• Communication modules
• Networks
• Power supply modules
• N/W switches, bus and connectivity including cables
• Critical I/O modules
This specification and PLC configuration drawing enclosed (Drg.No.:

MEC/TS/11/10KP/E5/MTPS-I/001) defines the minimum technical requirements of
plant control system comprising of PLC and its peripherals.
The plant control systems shall be capable of controlling and monitoring the entire
functional unit by executing all functional requirements. The control system shall have
provisions to allow the operations such as change-over of stream, valve operations from
the control room, without need to go to local.
The philosophy shall be such that the plant shall be operated and controlled from hot
redundant PLC controllers with all closed-loop set in auto-mode. Sequencing,
interlocking and logic functions shall be implemented in the PLC.
PLC shall have the data acquisition of the process parameters of various plant units,
which can also be used to generate various reports for Management Information System
(MIS).
The visual display of the workstation provides various colour graphics of the plant
process, which are dynamic and real time to plant operating conditions. The keyboard &
mouse of the workstation enables the operator to provide the set-points and commands
to control the process.
Remote Input-Outputs (RIO) concept has been envisaged. The RIO generally consists
of the field input-output cards, communication interface module, power supply unit
arranged in a cabinet. Redundancy shall be provided at communication module,
communication network, and power supply. RIO / remote controllers shall be located at
different geographical locations and shall communicate to the PLC located in the
control room, through dual redundant communication links. Failures of RIO shall be
annunciated in the PLC.
The number of RIOs and its location shall be decided during detail engineering.
The RIO / remote controller panels shall be located in the air-conditioned room.
However the remote I/O system shall be so designed that it functions well even when
there is no air conditioning.


& ITS AUXILIARIES
Operator’s interface to the plant and process is on Human Machine Interface (HMI)
which is a PC based workstation with HMI software. The Bidder shall provide
• Eight (8) nos. Operator work stations (2 nos. for each unit).
• Two (2) nos. Operator cum engineering station.
• One no. (1) Operator Station for each unit shall be placed at their respective
main plant control room
• Two (2) nos. A4 B&W laser printer.
• One (1) no Laptop with Engineering & HMI software loaded for FGD system.
• One (1) no A3 Colour Laser Printer.
• Two (2) nos. operator station with LVS 70”LED type common for all unit
• One (1 No.) Historian Station
• One (1 No.) OPC Station
01.02.01 PLC System Panel Hardware configuration Design for each FGD system
i) Separate Interposing Relay Cabinet with relays of 24V coil and contacts
(2NO+2NC) with LED indication.
ii) Power supply for SOV shall be 24V DC or 230V AC as per application and shall
be finalized during detailed engineering.
iii) For LT, HT, MOV drive control philosophy number of I/Os shall be considered as
per Electrical Technical specification.
iv) All DO signal shall be terminated through fuse TB.
v) Marshalling or Field wire shall be terminated through Field Termination Units
(FTU) for DI, DO, AI and AO shall be supplied separately. Alternatively, if it is
the standard practice of the PLC vendor to provide FTUs in the PLC cabinet, the
same shall be finalized during detail engineering.
vi) Mounting of cards on sides of PLC cabinet shall not be accepted.
vii) From base plate minimum 200-250 mm gap shall be provided in PLC cabinets.
viii) 24V DC, 230V AC UPS and 230V AC non UPS supply shall be provided
separately in Panel.
ix) A dedicated Panel (DB) for Power supply distribution shall be provided with
proper rating of MCB and shall be finalized during detailed engineering stage.
x) Dedicated Network panel shall be provided for switches and networking and
network switches shall be from approved vendors.
xi) For critical I/O consideration all Inputs shall not be located in same card and shall
be distributed in other cards.
xii) 20% spare installed I/O channels on each card level.
xiii) 10% spare installed I/O module
xiv) 20% spare TBs space for wiring in future
xv) No field wire shall be directly terminated to the I/O card (Like DI, DO, AI, AO)
without isolators/barriers/FTU (Field terminal units)
xvi) Multiple window facilities/face plate shall be provided in all the operating stations.
xvii) Separate modules shall be provided for RTD and Thermocouple.


& ITS AUXILIARIES
xviii) Software details shall be submitted along with Part no. and with latest version etc.
xix) Integral SOE in PLC (min.128 points) with 1msec time stamping at card level
shall be provided.
xx) SOE/Report/Long Term data archival package/self documentation/test
function/standard builder function/Alarms shall be provided for all operating
station as well as Engineering Station.
xxi) Online Auto/manual tuning of PID controller with plant performance monitoring
package shall also be facilitated.
xxii) SOE can be viewed from all the workstations and shall be time synchronized over
GPS master Clock.
xxiii) Logic chart, control loop display / Trending / Graphics / electronic documentation
History / Alarms software shall be provided for all operating stations as well as ES
cum operating stations.
xxiv) History for 3months shall be available in all OS as well as ES.
xxv) Desks / Boards / Panels / Cabinets / enclosures wiring and piping shall be arranged to
enable the removal of instruments/devices without unduly disturbing them.
01.02.02 PLC controller and I/O Modules
1.00 Power supply system

1.01 Power supply PLC system shall have two independent Input power
system supplies as described below :-
1) Two source of 240V AC single phase, 50 Hz
from UPSDB for CPU and each RI/O panel.
2) Two source of 240V AC single phase, 50 Hz
from UPSDB for control room equipment like
PCs, printers and other automation equipment.
3) Power supply unit for different types of cards as
described below shall have 100 % redundancy &
both power supply units shall have auto
changeover facility.
4) Power supply unit shall be of regulated power
supply to generate required AC or DC voltages
5) Separate power supply unit shall be provided for
Input interrogation voltage / power supply for all
types of inputs &outputs.
6) For CPUs and remote I/O racks, separate rack
mounted power supply unit shall be provided.
7) DP MCBs shall be used for protection of power


& ITS AUXILIARIES
supply system. Separate DP MCBs shall be used

at the incoming power & separate DP MCB for
input power supply to each card/hardware.
8) Separate power supply with suitable DP MCB
shall be provided for power supply of solenoid
valves, if directly fed from PLC.
9) DP MCBs shall be used for protection of power
supply system.
10) Separate power supply with suitable DP MCB
shall be provided for power supply of any field
instrument/devices, which shall be finalized
during engineering as per requirements
11) 20 % spare DP MCB shall be provided in each
panel
1.02 Built-in power Following features shall be provided in the power
supply units supply unit mentioned above.
- Insulation level 2.5 KV for 1minute.
- Protection against surge protection & short circuit
- Electronic over current protection with feedback
feature.
- Thermostat protection against over temperature.
- Over voltage protection.
- DPMCB protection in the input and output circuit.


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2.0 Central processor - Modular and plug-intype

unit - Minimum 64 bit microprocessor based
- PLC shall be able to scan and execute all close
loops in less than 100 milliseconds and scan
digital inputs in 50 milliseconds simultaneously.
- Execution time between 2 milliseconds to 5
milliseconds per 1K instruction or better.
- Provision to latch desired outputs.
- Provided with redundant hot standby CPU (with
appropriate communication module).
- The CPU system shall have facility of bumpless
transfer in case of failure of one.
- CPU shall have crystal clock generator.
- Peer to peer communication through I/O channels
shall be possible.
- Backup system communication (redundant
communication bus) shall be provided.
- The processor shall have proper communication
modules (for each CPU) for communicating with
redundant processor, remote I/O modules and for
communicating with other communication bus
protocols like ethernet bus / profibus / modbus /
controlnet / field foundation busetc.
- The processor shall have in-built provision for
software timers, counters, examining input
conditions, compare, compute, logical,
conversion from/ to BCD, bit manipulation, block
memory manipulation, diagnostic, shift,
sequencing, conditional jumping, subroutine
instructions etc.
- CPU shall be capable of handling PID functions
including mathematical functions ,weighing and
batching functions.
- CPU shall be capable of handling 30 % additional
(future) I/Os over and above 20 % spares
(installed) I/Os indicated in basic configuration
diagram.

& ITS AUXILIARIES
- Maximum CPU loading shall be limited to 60 %

for the intended applications.
- The CPU shall have the facility of generating a
synchronizing pulse to the server periodically
(Minimum once in aday).
3.0 Timers The timers shall be OFF delay, ON delay ,retentive

type timer with a range from few millisecond to few
hours. Accuracy shall be +/- 0.1% of the set value .
4.0 Counters The counters shall be of counter up and counter down
type. It shall have the range from 0000-9999.
5.0 Memory units - Modular and plug-intype
- Word length 64 bit(Minimum)
- Expandable in blocks of 4KWords
- Minimum size 20MB.
- EPROM/ RAM with batteryback-up
- Back-up battery shall be as follows:-
• Rechargeable Ni-Cd batteries with necessary
charging circuit / Lithium or any other
internationally acceptable type.
• Able to retain memory for a minimum of 1 year
with no power applied to the controller.


& ITS AUXILIARIES
6.0 Input Units - High density, modular.

- Insulation level of 500 / 1500 VAC/DC
- Input interrogation voltage 24 VDC.
- Individual DP MCB shall be provided in power
supply for eachcard
- Cards shall have diagnostic features
- Cards shall have Hot swapping features
6.1 Digital Input Digital input units shall have the following
Modules features
• 16 / 32 inputs per module.
• Time delay of about 10 millisecond to filter out
noise and contact bounce.
• Opto coupler to galvanically isolate each input
device from the decision making logic of the
controller
• LED status indication
• BCD input units suitable for four digit input
• Pulse inputs(Incremental encoder/digital tacho)
• Absolute / incremental encoder inputs.
• All the cards shall be compatible of receiving
digital signals from field sensors and switches
directly.


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6.2 Analog input Modules Analog input units shall have the following
features:
• Shall be 4 / 8 channels, rack based & plug–in
type..
• Suitable for 4-20 mA / 0-10V DC / RTD /
thermocouple / weighing signal inputs.
• With necessary A/D converter having at
least12
/ 14 bit resolution based on application.
• Suitable for J/K/S type thermocouples & for
PT100, 2- wire / 3wire
• Galvanically isolated differential inputs.
• For 4 – 20 mA analog inputs, fused T.B with
blowing fuse shall be provided.
• Healthiness of every input shall be monitored
& LED indication shall be provided.
• Analog module shall have the facility to be
configured in voltage or current mode and
differential or single ended inputs mode.
• All the cards shall be compatible of receiving
analog signals from field sensors and
switches directly . If not suitable converters
shall be provided.
7.0 Output units - High density, modular.
- Insulation level of 500 / 1500 VAC/DC
- Individual DP MCB shall be provided in power
supply for each card
- Cards shall have diagnostic features
- Cards shall have hot swapping features


& ITS AUXILIARIES
7.1 Digital Output modules Digital output units shall have the following
features:
• 16 / 32 digital outputs per module.
• High Density modular and plug-in type.
• Isolated outputs with two separate terminals
for each outputs.
• Rated for 24 VDC
• The output module shall be able to drive
interposing relays (24V DC coil) with 2
NO+2NC, solenoids, annunciation lamps,
LEDs, Instrumentation control equipmentetc.
• Power devices like contactors etc. shall be
actuated through interposing relays (2 NO+2
NC). The interposing relays shall be mounted
in the same panel. Proper surge suppressor
shall be mounted across the coil of the output
relays.
• Any special requirement e.g position control
to control field devices shall be met by using
separate interface modules.
- BCD output units shall be as follows:-
• Suitable for four-digit output.
• Rated to drive seven segment LED displays
7.2 Analog output modules Analog outputs shall have the following features:
• Shall be of 4 / 8 analog output channels.
• Suitable for 4-20 mA / 0-10V DC / +/-10V
DC outputs .
• With necessary D/A converters having 12 bit
resolution
• Each output shall be galvanically isolated.


& ITS AUXILIARIES
8.0 Additional features -On-line replacement of any module shall be

possible in such a way that the removal and
addition of any module shall be possible without
de-energizing the system. Further there shall not
be any interruption in the system while replacing
a faulty module except for the inputs / outputs
which are being handled by the module.
- The PLC system shall be immune to the
following:
• Radio frequency interference
• Electromagnetic interference
• Power system spikes
9.0 Mounted spares - Refer main specifications
10.0 Self diagnostic features - Parity errors, cycle errors and under voltage
- Failure in central processor unit, memory and
power supply.
- Indication of type of failure
- Automatic turning OFF of all outputs or
optionally holding of all outputs in their last state
on failure detection.
- Fault detection upto card level.
- Communication failures – allt ypes
- Fuse failure indication for outputs
11.0 Monitoring functions - Monitoring of internal voltages
- CPU Status monitoring
- Memory status monitoring
- I/O Status monitoring
- Address monitoring
- Bus & communication signal monitoring
- Broken sensor detection


& ITS AUXILIARIES
12.0 Terminations - All inputs and output wired up to easily

accessible terminal blocks rated for 1100V of
min 1 sqmm
- Screened cables for all analogue signals.
- TB shall be suitable for terminating up to 1.5sq.
mm. copper conductor industrial control cables.
- Fuse terminals with LED indications for all input
& output signals.
- Input and Output terminals shall be colour coded
i.e. separate colors shall be used for terminals of
Inputs& Outputs
13.0 Earthing - Separate earthing bus for power / panel earthing
and electronic earthing shall be provided.
Minimum two numbers of electronic earth pits
shall be provided for each set of PLC .
- Electronic earthing bus shall be suitably insulated.
Earthing requirements / earthing schemes for the
equipment supplied shall be clearly indicated in
appropriate drawings.
14.0 Constructional features - Unitised construction.
- Floor mounted, free standing and indoor type.
- Bottom cable entry through gland plate.
- Sheet steel clad
- Dust and vermin proof
- Anti vibration pads to be provided to withstand
vibrations as per application.
- Panel illumination with door interlocks limit
switch.
- Switch-socket outlet for maintenance.
- Suitable fans & inlet air filters shall be provided
at the bottom/top of each panel for proper air
circulation.
- Empty slots of the racks shall be provided with
dummy cards for protection against dust &
damage.


& ITS AUXILIARIES
- All panels shall be of preferred make of TS.
15.0 Enclosure - Conforming to IP-42 class in MCC room/control

room.
- Conforming to IP-54 class for remote I/O
cubicles located in shops/bays.
- Programmable controllers & RI/O panels, even
if housed in air-conditioned enclosure, shall be
suitable for normal industrial environment and
ambient temperature upto 50°C.
- Temperature while operating
• Lower limit :0 degree C
• Upper limit: 60 degree C
- Temperature while not operating(storage)
• Lower limit : 20 degree C
• Upper limit : 75 degree C
- Relative humidity
• Daily average 80 to 90% (8hrs.) and 65 to
90% (16hrs.)
• Maximum 98%, not occurring
simultaneously with maximum
Temperature


& ITS AUXILIARIES
01.03.00 List of Measurement & Control
Following are indicative list of measurement & control shall be provided by the Bidder
for this system. Any other measurement & control though not included in the list but
required for safe & proper operation of the process & equipment as per the offered
system of the Bidder shall also include in their scope and highlighted in their Offer.
Unless specified, all the measurement, control, alarm & interlock shall be achieved in
the PLC.
A. Absorber system (For 1 no.)
Following minimum remote signal at PLC
1. 2 Nos. of SO2 analyzers with Nafion dryer in each ID fan outlet (inlet duct to absorber)
duct
2. Pressure measurement (3 nos.) at the flue gas inlet (unclean) duct to absorber.
3. Temperature measurement at the flue gas inlet (unclean) duct to absorber.
4. Temperature measurement (3 nos.) at the top of absorber.
5. Pressure measurement (3 nos.) at the top of absorber.
6. RH (% H20) analyser offline (Lab).
7. Pressure measurement before recirculation slide 1 of absorber.
8. Pressure measurement (7 points.) at the bottom of absorber before discharge hooper.
9. Differential pressure measurement in between flue gas scrubber line and booster fan.
10. Pressure measurement at the inlet of booster fans.
11. Temperature measurement at the inlet of booster fans.
12. Pressure measurement at instrument air header line.
13. 2 Nos of SO2 analyzers with Nafion dryer in the clean gas duct at the outlet of absorber.
14. Level switch of each chutes below absorber hoppers.
15. Water tank level measurement & its control.
16. Water tank temperature measurement.
17. Differential pressure measurement across strainers (2 nos).
18. Pressure measurement at the common header of high pressure pump 1 & 2.
19. Flow measurement at the common header of water injection line to absorber.
20. Flow measurement of water tank return line.
21. Pressure measurement of water tank return line.
22. Instrument Air header pressure measurement.
23. Bearing temperature measurement of each Booster fans & its motors.
24. Bearing vibration measurement of each Booster fan & its motor bearing.
Following Local measurement shall be provided as minimum
1. Outlet pressure measurement of high pressure pump 1.

2. Outlet pressure measurement of high pressure pump 2.
3. Pressure measurement of water injection line before air mixing (4 nos.) at the absorber.
4. Pressure measurement of water injection line (4 nos).

& ITS AUXILIARIES
5. Pressure measurement of water tank return line.
B. Fabric Filter
Following minimum remote signal at PLC (Applicable for each compartment of

filter)
1. Dust concentration measurement for each compartment of fabric filters.

2. Differential pressure measurement for each compartment of fabric filters.
3. Level switches (3 nos.) of chutes for each compartment of fabric filters.
4. Temperature measurement of chutes for each compartment of fabric filters.
5. Temperature switch of chutes for each compartment of fabric filters.
Following Local measurement shall be provided as minimum (applicable for each

filter compartment):
1. Local pressure measurement of pulse header.

2. Local pressure measurement at the inlet and outlet of each fans to fabric filter
compartments
C. Re-circulation slide I
1. Level switch of recirculation inlet.

2. Level switches (3 nos.) of recirculation outlet.
3. Pressure measurement at common discharge line.
1. Local pressure measurement for each discharge line (Total 10 nos.).

2. Local flow measurement for each discharge line (Total 10 nos.).
3. Local pressure measurement at inlet and outlet of common discharge line pumps.
D. Re-circulation slide II
1. Level switch of recirculation inlet.

2. Level switches (3 nos.) of recirculation outlet.
3. Pressure measurement at common discharge line.
1. Local pressure measurement for each discharge line (Total 10 nos.).


& ITS AUXILIARIES
2. Local flow measurement for each discharge line (Total 10 nos.).

3. Local pressure measurement at inlet and outlet of common discharge line pumps.
E. Storage silo and conveying system
1. Level measurement & its control by regulating lime storage silos discharge gate.
2. Temperature measurement of lime storage silos.
3. Level measurement & its control by regulating by product silos discharge gate.
4. Temperature measurement of by product storage silos.
5. Necessary measurements and controls of lime conveying and compressor system.
6. Necessary measurements and controls of by-product conveying and compressor system.
7. pH and level measurement & control of mixing tank.
F. Chimney
Complete CEMS measurement system suitable for the semi dry flue gas parameters shall
be provided in the Chimney as per latest Central Pollution Control Board (CPCB) guide
line Aug, 2018 rev01. As a minimum Sox, Nox, CO, CO2, Hg, SPM, O2, Flow,
Temperature & Pressure measurement shall be provided.
01.04.00 All pump’s manual suction valves shall be provided with open limit switch. Automatic
starting of stand-by pump during any operational problem of the working pump shall be
considered, as applicable. To achieve the same, low header pressure alarm conditions
can be considered. Though not specified above, all process alarm & interlock functions
shall be suitably considered by the Bidder for safe & reliable operation of the process &
equipment. Make-up water pumps and waste water pumps shall have necessary
interlocking facilities including measurement of flow and pressure.
01.05.00 Technical Requirements
01.05.01 Pressure, Differential Pressure, Level (DP Type) and Flow (DP Type) Transmitters
(PT, DPT, LT & FT)
Smart Transmitters of the electronic type shall be provided.
Sealed capacitance / piezo resistive based SMART

Type/Construction
type
Material
Die cast Aluminum or Aluminium alloy with
- Body
epoxy coating for air &flue gas
- Diaphragm 316 SS or better
- Measurement element Teflon seal /Capsule/Diaphragm


& ITS AUXILIARIES
4 to 20 m Amp. DC (Two wires) With HART

Output signal
protocol
Local Indicator LCD indicator (5 digit) with scale of Engg. unit
+ 0.075% or better of FSR
Overall Accuracy
+ 0.2% for remote seal type transmitter.
10:1 for vacuum / very low pressure / very high
Turn down ratio pressure applications
25:1 or better for other services
Stability + 0.2% for 10 years
Power supply 24V DC nominal
Drive capability 600 Ohms nominal
IP-65 min. in general
Enclosure Class
Explosion proof for NEC Class-1, Division 1 area
Span Adjustment Remote or Locally adjustable
Zero Adjustment Externally adjustable
Zero suppression / elevation At least 100% of Span
Overpressure 150% of max. Operating pressure.
Adjustment/ calibration/ Port/provision for Centralized PC based system
maintenance maintenance
Ambient Temperature 60 Deg. C
Connection
- Process 1. Half (1/2) inch NPT (F)
2. Quarter (1/4) inch NPT With /without oval
flanges
½” NPT(F), two electrical connections and blind
- Electrical
plug
Accessories
Manifolds
Type Non-Integral type
Material of Construction SS
- For Absolute Pressure
Two (2) valve SS316 manifold
Transmitters
- For Gauge & Vacuum
Three (3) valve SS316 manifold
pressure Transmitters
For DP, level & flow
Five (5) valve SS316 manifold
transmitter
Snubber / Pulsation
dampners
shall be used where the process media is unstable
Application for measurement such as the discharge of a pump,
Compressor, Fan, etc
Material of Construction SS 316
Protective Diaphragm Seal
- Application For oil, corrosive, viscous, solid bearing or slurry

& ITS AUXILIARIES
type medium
- Type Flush Type
- Process Connection ½” NPT / Flanged SS316 Class 150
- Material SS316L
Capillary Length Minimum 10 m
Mounting bracket For all transmitters
Drain & vent points As per requirement
Transmitters shall be equipped with mounting brackets suitable for a mounting in

transmitter enclosures (LIE).
1 No. of universal type hand held/portable HART calibrators shall be supplied for
calibration / configuration of Transmitters & other HART based instruments.
01.05.02 PRESSURE SWITCHES (PS) & DIFFERENTIAL PRESSURE SWITCHES (DPS)
Applicable Standards IS3624 - 1966/ISA-RP-8.1 except as modified in

spec.
Type/Construction Bourdon / Sealed Diaphragm Piston Actuated
preferable.
Indicators with contacts are not acceptable.
Material
- Bellows 316 SS
- Bourdon tube 316 SS
- Movement 316 SS
- Case Material Die-cast aluminum. Epoxy coating shall be
provided for corrosive atmosphere
Accuracy +/- One (1) percent of span or better
Repeatability +/- 0.5 percent of span or better
Set Point & Differential Adjustable
Over range for Pressure / 130% of maximum pressure
Vacuum Switch
Contacts
- Number 1 DPDT / 2 SPDT
- Type Auto reset with internal Adjustable snap action
hermetically sealed micro switchwith silver vetted
shock & vibration proof
- Rating 5 Amp, 240V AC / 0.2 Amp, 220V DC/ 2 A,
24VDC
Connection
- Process Half (1/2) inch NPT Male
- Electrical Plug in type
Enclosure Class IP-65 or better for General services
andExplosion/Flame proof for NEC Class-1,

& ITS AUXILIARIES
Division 1 areaas applicable

Accessories
Manifolds
Pressure Switch 2 valve manifold
Differential Pressure Switch 5 Valve Manifold
on Steam & water Lines
Differential Pressure Switch 3 valve manifold
on Air & Flue gas Lines
Material SS 316
Snubber / Pulsation dampners
Application For Pump and compressor suction & discharge
lines and pulsating fluid application
Type Self Cleaning type
- Application For corrosive liquid lines.
i) Remote diaphragm seal with SS 316 armored
capillary for typical application. MOC of seal
material shall be as per process fluid requirement.
ii) Silver coated diaphragm for corrosive services
like chlorinated water.
- Type Flush Type
- Process Connection NPT / Flanged SS316 Class 150
Mounting In LIE. Retention ring and screws for surface
mounting
Mounting bracket / Clamp for 2 ‘’ pipe, bolt & nut.
Tag Tag Number, service engraved in SS tag plate
01.05.03 Pressure & Differential Pressure Gauges (PG & DPG)
Applicable standard IS:3602-1966, IS/3624, ASME B 40.1

Type/Construction
- (-) 760 mm Hg to 1. Kg/cm2 Bellows / Diaphragm
-Above1.Kg/cm2 Bourdon Tube
Suction Side of pumps Compound gauge
Materials
- Bourdon tube 316 SS
- Bellows 316 SS
- Movement 316 SS
- Case SS 304
- Protective Diaphragm Teflon
Dial 150mm size with toughened shatter proof glass
Scale Details Graduations in black lines on White dial, 270 Deg.
pointer deflection scales provided with glass cover.

& ITS AUXILIARIES
Smallest scale division shall be one (1) percent of

full scale value or smaller. Pointers stop for all
gauges
Anti parallax, glare free.
Accuracy + or - One (1) percent of Span or better
Connection
Process 1/2 inch NPT Male Bottom
Enclosure Class IP-65 or better & Explosion/Flame proof for NEC
Class-1, Division 1 area - as applicable
Zero adjustment For all gauges
External Micrometer screw for zero adjustment.
Internal micrometer screw for range adjustment.
Safety device
- Ranges 5 to 20 Kg/cm2 Rubber blow out disc with open front construction
- Ranges above 20 Kg/cm2 Neoprene safety diaphragm at the back with solid
front construction
- Over range protection One thirty (130) percent of full scale
Accessories
- 3 way gauge Cock For all gauges

Snubber / Pulsation dampners
Application For Pump and compressor suction &discharge
lines and for pulsating fluid applications
Type Self Cleaning type
Syphon / Pigtail For all Steam Lines
- Application For oil, corrosive, viscous, solid bearing or slurry
type medium
SS 316 Flange and Diaphragm, PTFE coated /
block, Silicon Oil filling fluid
- Type Flush Type
- Process Connection NPT / Flanged SS316 Class 150
01.05.04 Temperature Transmitters
Type Microprocessor type, 2-wire type temperature

transmitters (directly powered from 4-20mA input)
and fully compatible with thermocouples & RTDs
shall be provided by the bidder. Temperature
compensation of the thermocouples shall be
performed within the temperature transmitter itself.


& ITS AUXILIARIES
The transmitters can be either DIN rail mounted

type or field pipe / support mounted type.
Material
- Body Die cast Aluminum with epoxy coating
Pt-100 RTD, T/C – K types (Input type shall be
Input
selectable through HART terminal
2-wire with 4-20 mA output with superimposed
Output
HART protocol signal. 5-digit LCD display
Power Supply 24 VDC, 2- Wire Loop Power
Weather proof as per IP 65 with corrosion resistance
Enclosure Protection coating. For hazardous area explosion proof
enclosure as described in NEC article 500
i) DIN rail mounted types :
a) RTD = <0.4% of 0- 250 deg C

b) T/C K-type =<0.4% of 0-600 degC
Composite Accuracy
ii) For dual input type :
a) RTD = <0.25% of 0- 250 deg C

b) T/C K-type =<0.2% of 0-600 degC
CJC accuracy for T/Cs shall be <=1degC
Accessories Mounting brackets, SS Tag Plate, etc
.
01.05.05 Resistance Temperature Sensors with Thermowells
Applicable Standard ASME PTC 19.3 - Latest Revision

Element Platinum, R0=100 ohm 3-wire Duplex ungrounded
Sheath Material/ Insulation 316SS / Compacted Magnesium Oxide
Sheath O D 8 MM
Spring loaded Nickel plated brass-screw type/
Type of the Terminals
silver plated
Calibration As per DIN Standard – 43760, Class A
Material of construction of Die Cast Aluminum (Screwed) with galvanized
Head chain
10 Sec bare & 30 Sec. With protective
Response Time
sheath/thermo well
Accuracy + 0.35 degree C or Class-A whichever is better
Zero & span drift within 0.1% of span for a 6
Stability
month period
Connection
Process ½” NPT(M)


& ITS AUXILIARIES
Electrical ½” NPT(F) one unused entrywith blind plug

Enclosure Class IP-65
Thermo well
Applicable Standard ASME PTC 19.3 TW - 2010
Tapered drilled from Bar stock With Hex Head &
Construction Straight for Air & Gas systems
- 316 SS - water and steam and air services

- Inconel for flue gas services
For furnace zone, impervious ceramic protecting
Material
tube of suitable material along with Incoloy
supporting tubes and adjustable flanges.
- M33 x 2 in general
Process Connection - Flanged for Air & Gas systems with mating
flanges.
Within + 10 mm of center line of pipe subject to
sizing calculations such as frequency ratio, cyclic
Immersion Length
stress, dynamic stress, pressure limit. Etc. as per
PTC 19.3TW 2010
Minimum 100 mm above insulation of pipe and
Extension neck length Minimum 160 mm when there is no insulation on
pipe.
Thermo well Sizing Bidder shall provide sizing calculations for thermo
Calculation well as per ASME – PTC-19.3 TW 2010
01.05.06 Thermocouples with Thermowells
ASME PTC 19.3- Latest Revision,

Applicable standard ANSI-MC 96.1 – 1982,
IEC 584
Element Duplex ungrounded
i. Type K (Chromel - Alumel)
Type
Sheath 8 MM OD
Sheath Material 316 SS
Shall be spring loaded to ensure positive contact
with the well. Prevention of rotation of the insert
Terminals with respect to head and resultant twisting of leads
shall be ensured. Nickel plated brass-screw type/
silver plated
Nipple/Union required
Packed connector Compacted magnesium Oxide ungrounded
Element Size / Wire Gauge 16 AWG (for K type)

& ITS AUXILIARIES
Material of Head Die Cast Aluminum

As per ANSI MC 96.1 / IEC 751 / IS-2054 / 2055,
Accuracy
1974
For Type K T/C + 1.1 deg.C (for 0 - 277 deg.C)
+ 0.4 percent (for 277 to 1280 deg.C) Class-A
Linear with respect to temperature within +/- ½ per
cent of top range value.
Characteristic
For temperature vs. mV characteristics, following
IS shall be applicable :
Type K IS – 2054, 1974
Reference
Response Time (Bare
Thermocouple)
All other applications 10 Sec.
Connection
Process ½” NPT(M)
½” NPT (F) Double entry – one unused entry with
Electrical
blind plug
IP-65 or better (Explosion/Flame proof for NEC
Enclosure Class
Class-1, Division 1 area)
Thermowell
Applicable Standard ASME PTC 19.3 TW - 2010
Tapered Drilled from Bar stock for all other
Construction
application / Straight for Air & Gas Systems
- 316SS for water/steam air services
- Inconel for flue gas services
- For furnace zone, impervious ceramic -
Material protecting tube of suitable material along
with Incoloy supporting tubes and
adjustable flanges.
M33 x 2 in general
Process Connection SS316 Flanged, for Air & Gas systems, with
mating flanges.
Threaded union (SS316) 1/2" NPT (F) with two
Extension nipples of SS 316 having 1/2"NPT (M) threads at
both ends
Within + 10 mm of center line of pipe subject to
sizing calculations such as frequency ratio, cyclic
Immersion Length
stress, dynamic stress, pressure limit. Etc. as per
PTC 19.3 TW 2010
Minimum 100 mm above insulation of pipe and
Extension neck length
Minimum 160 mm when there is no insulation on

& ITS AUXILIARIES
pipe.
Bidder shall provide sizing calculations for thermo
Thermowell Sizing Calculation
well as per ASME – PTC-19.3 TW 2010
a) Adjustable nipple-union-nipple {1/2” Sch.
80 X1/2“ NPT (M)} with thermo well
connection
b) Compression fittings/union
c) Flanges etc. (For flanged connection
only), Bolts, nuts and gaskets for flanged
Accessories
connections
d) SS 316 forged/barstock thermo well as
per ASME PTC code. Process
connection M33X2 (M)in general or 1½”
Flanged for Flue gas/ Furnace air etc.
application
Thermowell
1. Thermowells shall, in general, be of SS 316 and shall be drilled from bar stock except
for air and flue gas services. However, selection of thermowell material shall as per
following guideline.
Flue gases Black steel, SS 446

Preheater Black steel, SS 446
Steam lines SS 316
Water lines SS 316
2. The thermowell immersion depth (U) shall be sufficient to eliminate conduction error. A
general rule, which may be followed, is to use an immersion length equaling a minimum
of 10 times the diameter of the protective tube or well. In general, immersion length of
thermowells for different line sizes shall be as follows:
Line size Immersion Length (U)

From 4” to 6” 280 mm
From 6” onwards 320 mm
Vessels 400 mm
Immersion length is based on 200 mm length between flange face and inner wall of pipe.
In vessels, where fouling with vessel internals is expected, the immersion length shall
suitably modified. Any pipe less than 4” nominal bore shall be blown to 4” size.
01.05.07 Temperature Gauges (TG)
Applicable standard : IS : 3602,BS:5235 ISA:RP:8.1 except as modified

in this specification

& ITS AUXILIARIES
Type/Construction
- Thermometer : Industrial type, Inert Gas Filled type with
separable thermowell Bimetallic & all angle
tiltable
- Thermowell : Bar stock
Material
Sensing material type : Bimetal strip helix
- Thermowell & Bulb : 316 SS

- Capillary : Armoured SS (Applicable or capillary Type)
- Casing : SS 316.Epoxy coating shall be provided for
corrosive atmosphere
Dial Size : 150mm with toughened/ shatter proof glass
Scale Details : 270 degree dial rotation/deflection.
Graduations in black lines on white dial provided
with glass cover. Smallest scale division shall be
1% of full scale value or smaller. Pointer stop for
all gauges Anti parallax heavy gauge aluminium
with white matte finish glare free
Accuracy : + One (1) percent of full scale or better

Response time : Maximum 15 seconds without thermowell, 30
seconds with thermowell
Dampener : Dampening pointer oscillation
Window : Toughened shatter proof glass
Connection
- Pipe : M33 x 2
-Thermowell : To suit instrument
Other Particulars
- Capillary length : Minimum 5 meters for local mounting & minimum
10 Meters for panel mounting
- Immersion Length : Within + ten (10) mm of center line of pipe with
adjustable nuts subject to sizing calculations as per
PTC 19.3 TW 2010
- Extension neck length : Minimum 50 mm above insulation of pipe/As per
approved hookup drawings.
- Stop or pointer at Maximum : For all gauges of scale with externally adjustable
value
: Contact type Temp. gauges are not acceptable for
interlock & protection.
- Over range protection : 150 percent (%) of full scale
Enclosure Class : IP-65 or better (Explosion/Flame proof for NEC

& ITS AUXILIARIES
01.05.08 Test Thermowells (TW)
Applicable Standard : ASME PTC 19.3 TW – 2010

Type/Construction : Machined from Bar Stock
Material : 316 SS
Connection
- Pipe : M33 x 2
- Test Instrument : To suit test instruments
Accessories : Plug with chain
Bidder shall provide calculation for thermowell as
per ASME –PTC-19.3 TW - 2010.
Test wells shall be provided on main steam, reheat steam, spray water lines and other
piping as required to meet ASME test requirements.
01.05.09 Radar type Level Transmitter
1. Radar type level Instrumentation shall be used when the physical properties of the
medium between the sensor and measured interface may vary.
2. The Radar type level Instrument shall be microprocessor based with HART protocol and
shall use digital signal processing techniques for signal conditioning and shall be
possible to calibrate through universal HART calibrator.
3. Radar type level transmitter shall have facilities for storing echo profile, manipulation of
the echo profile to remove noise, multiple profile-averaging etc.
4. Chemical compatibility of the sensor material with the process material shall be ensured
to avoid corrosion.
5. The sensor shall have in-built temperature sensor for ambient temperature compensation.
6. Necessary software, cables, connectors, HART to RS 232C converters etc shall be
provided.
7. Suitable protection box for mounting radar type level transmitters shall be provided for
mechanical protection & dust. Swiveling arrangement shall be provided for proper
aiming / focusing of radar type level transmitters.
Guided Wave Radar/ Radar Level Transmitter
Type : Guided wave Radar (Contact type)/ Radar (Non

contact type).
Application : Close Tank/Vessel
Environment Class : Highly abrasive with Gases and Fumes
Orientation : Vertical
Probe Type : Flexible Single lead with chuck
Probe Material : SS 316L


& ITS AUXILIARIES
Connection Size & Type : 2” Flanged ANSI 300 lb SS316L material

Connection material : SS 316L
Accuracy : +/- 5 mm
Resolution : +/- 0.1 % of range or better
Type (Transmitter) : SMART, 2 Wire
Operating Principle : Time Domain Reflectrometry
Output : 4-20 mA, DC with HART protocol and 600 Ω
output load.
Electrical Connection : ½” NPT
Enclosure Class : IP-65 or better (Explosion/Flame proof for NEC
Electrical Power : 24 V DC +/- 10%
Housing material : Die Cast Aluminum
Vent & Drain Plug material : SS
Side Flange Material : SS
Local Display : Provided (LCD Digital)
Units of Measurement : Length Mtrs
Accessories All weather canopies for protection from direct
a)
sunlight and direct rain.
For hazardous areas, explosion proof enclosure as
b)
per NEC article 500 shall be provided.
All mounting hardware and accessories required
c) for erection and commissioning. Mounting fittings
material shall be SS 316.
01.05.10 Level Gauge
1. Level gauges shall be steel armoured reflex or transparent or bi – colour type, top and
bottom connection as per pressure vessel standard of ASME PTC code and 15 mm NB
(1/2 inch NPT) Drain and vent connection.
2. Body material and cover material shall normally be forged carbon steel, 304 stainless
steel or other superior material.
3. Reflex type gauges shall be used for clean and colorless liquids and transparent type for
other liquids. For boiler and condensate services, treated water, the transparent type with
KEL – F shields shall be used to avoid their attack on the glands.
4. The gauge glass must have a rating equal to or more than the vessel design pressure and
temperature. The test pressure for the complete design gauge assembly shall be as per
Owner’ / Consultant’s recommendation.
5. The maximum length of a single gauge glass shall not exceed 1.4 meters. Where large
range is required, multiple gauges of preferably equal lengths shall be used with 50 mm
over – lapping in visibility.
6. The visibility shall cover the operating level range and the maximum and minimum
ranges expected considering start – up conditions as well as alarm and shut down points.


& ITS AUXILIARIES
Internal heating shall be provided for viscous liquids. Integral illuminators shall be used
for transparent gauges, if necessary.
7. Stand – pipes,shall be used for multi – gauge and level controller installation and on
horizontal drum or exchanger with top and bottom connections to have visibility of the
complete span. The standpipe shall not be used with block valves.
8. Primary isolation valves shall be used in addition to the gauge glass valves unless
otherwise specified. When the process fluid may create plugging or leakage problem,
gauge valves may be omitted. For low temperature liquid having high vapour pressure at
ambient temperature, isolation and gauge valves shall not be permissible. Safety valve
shall be provided at the vent connection of the gauge glass where isolation is required.
9. Level gauge shall be supplied as per the following specification:
Sensing Element &Material : Tempered toughened

Borosilicate Gauge glass steel armoured
Reflex or Transparent type
Body Material : Forged carbon steel /304 SS
End Connection : Process connection

as per ASME PTC and
drain / vent 15 NB
Accuracy : ± 2%
Scale : Linear vertical
Range Selection : Cover 125 % of max. of
Scale
Over range : Test pressure for the Assembly
shall be
Test : 1.5 to the Maximum
design pressure at 38 degree C
Housing : CS / 304 SS leak – proof
Zero / span : To be provided
Adjustment
Identification : Engraved with service legend or
laminated phenolic Name plate
Packing : PTFE Teflon
Illumination : 220 V, 50 Hz, 25 / 40
Watts either with deflector or Diffuser (for
transparent type level gauge) / 220V,
50 Hz,
Accessories : Gasket for all KEL – F
shield for transparent type vent
And drain valves of CS /
SS as per process requirement.
Others : Anti - Frost extension for


& ITS AUXILIARIES
low temperature service. Heating / cooling

arrangement.
10. Bi –colour level gauges shall have following features:
- Temperature equalizing column expansion bend and chain patterned hand – wheel
- Certification by Inspectorate of Boiler (If applicable)
01.05.11 Control Valve with Actuator
A. INTRODUCTION
1. The control valves and accessories equipment furnished by the biddershall be designed,
constructed and tested in accordance with the latest applicable requirements of codefor
pressure piping ANSI B 31.1, the ASME Boiler & Pressure Vessel code, Indian Boiler
Regulation (IBR) & ISA as well as in accordance with applicable requirements of the
“Federal Occupational safety and Health Standards, USA” or acceptable equal standards.
B. CONTROLVALVE DESIGN & SIZING
1. The design of all valve bodies shall meet the specification requirements and shall
conform o the requirements of ANSI for dimensions, material thickness and material
specification for their respective pressure classes.
2. The valve sizing shall be suitable for obtaining maximum flow conditions with valve
opening at approximately 80% of total valve stem travel and minimum flow conditions
with valve stem travel not less than 20% of total valve travel. All the valves shall be
capable of handling at least 120% of the required maximum flow. Further, the valve
stem travel range from minimum flow condition to maximum flow condition shall not be
less than 50% of the total valve stem travel. The sizing shall be in accordance with the
latest edition of ISA Handbook on control valves, While deciding the size of valves,
bidder shall ensure that valves outlet velocity does not exceed 8 m / sec. for liquid
services 150 m/sec. for steam services and 50% of sonic velocity for flashing services.
Bidder shall furnish the sizing calculations clearly indicating the outlet velocity achieved
with the valve size selected by him as well as noise calculations, which shall be subject
to consultation’s / owner’s approval during detailed engineering.
3. Control valves for steam and water applications shall be designed to prevent cavitations,
wire drawing, flashing on the downstream side of valve and down stream piping. Thus
for cavitations / flashing service, only valve with anti-cavitations trim shall be provided.
Detailed calculations to establish whether cavitations shall occur or not for any given
application shall be furnished.
4. Trim shall be multistage type having sufficient number of discrete pressure drop turns
(stages) to ensure elimination of vibration, erosive – action, cavitations. Bidder shall

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identity the number of pressure drop turns in proposed equipment and shall also provide
calculation demonstrating compliance to the trim exit velocity.
5. To prevent flow induced vibration and to protect the valve intervals from foreign
particles such as weld slag flow, direction shall be a flow to close (over the plug)
configuration for liquid applications. To maximize noise attenuating benefits and to
allow for constant fluid expansion, flow direction shall be under the plug for steam and
gas applications.
6. The control valve induced noise shall be limited to 85 dBA at 1 meter from the valve
surface under actual operating conditions. The noise abatement shall be achieved by
valve body and trim design and not by use of silencers.
7. The characteristic of the control valves shall be determined based on the application /
service.
8. On supply air or electrical failure for pneumatic/ electrical drive, the valve shall remain
full closed, open or stay – put position as per process safety requirement.
C. VALVE CONSTRUCTION
1. Proper selection of valve type and material of construction to meet operating

requirement.
2. All valves shall be of globe body design and straightaway pattern with single or double
port unless otherwise recommended by the manufacturer to be of angle body type.
Rotary valve may alternatively be offered when pressure or pressure drops permit.
3. Valves with high lift cage guided plugs & quick charge trims shall be supplied.
4. Cast iron valves shall not acceptable.
5. Bonnet joints for all control valves shall be of the flanged and bolted type for easy dis –
assembly. Bonnet joints of internal threaded or union type shall not be acceptable.
6. Plug shall be of one – piece construction either cast, forged or machined from solid bar
stock. Plug shall be screwed and pinned to valve stems or shall be integral with the valve
stems.
7. All valves connected to vacuum on down stream side shall be provided with packing
suitable for vacuum applications (e.g. double vee type chevron packing).
8. Valve characteristic shall match with the process characteristic.
9. Extension bonnets shall be provided when the maximum temperature of flowing fluid is
greater than 2800c.
10. Flanged valves shall be rated at not less then ANSI pressure class of 300 lbs.
11. Teflon shall be used for valve gland packing to suit process requirement.
12. The valve body shall be marked to show direction of flow.
D. VALVE MATERIALS
1. The control valve body material shall be
(i) Carbon steel as per ASTM – A216 GR WCB for non – corrosive, non – flashing and
non – cavitations services below 275 0C temperature above 275 deg C ASTM-A217 GR
WC 9

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(ii) Alloy steel as per ASTM – A217 GR WC 9 for severe flashing / cavitations services like
low load and full load feed water control, Heaters emergency drains, etc.
(iii) Alloy steel as per ASTM A – 217 GR WC 6 for low flashing / cavitations services like
Heaters normal drain control, drain cooler normal level control, gland steam cooler
minimum flow etc.
(iv) 316 SS for condensate service below 300 0C like condensate normal and emergency
make – up controls etc.
2. The control valve trim material shall be
(i) 17 – 4 PH SS for severe services listed under item D1,(i) ii) &(iii) above
(ii) SS 440-C for severe services listed under item D1 (iv) above
(iii) 316 SS for services listed at D.1 (iv) above and
(iv) 316 SS with stellite faced guide parts and bushings for remaining applications.
3. However, Bidder may offer valves with body and trim materials better than specified
materials and in such cases vender shall furnish the comparison of properties including
cavitations resistance, hardness, tensile, strength, strain, energy, corrosion resistance and
erosion resistance etc of the offered material vis – a – vis the specified material for
Consultant’s / Owner’s consideration and approval.
E. END PREPARATION
1. valve body ends shall be either butt welded / socket welded, flanged or screwed as
finalized during detailed engineering and as per Consultant’s / Owner’s approval. The
welded ends wherever required shall be butt welded type as per ANSI B 16.25 for
control valves of sizes 65 mm and above. For valves sizes 50 mm and below welded
ends shall be socket welded as per ANSI B 16.11. Flanged ends wherever required shall
be of ANSI pressure – temperature class equal to or greater than of the control valve
body.
F. VALVE ACTUATOR
1. All regulating control valves shall be furnished with pneumatic actuators . For
pneumatic actuators, compressed instrument air shall be used and for this, necessary
provision of Pressure Reducing Station (PRS) shall be considered. The bidder shall be
responsible for proper selection and sizing of valve actuators in accordance with the
pressure drop and maximum shut off pressure and leakage class requirements. The valve
actuators shall be capable of operating at 600c continuously.
2. Valve actuators and stems shall be adequate to handle the unbalanced forces occurring
under the specified flow conditions or the maximum differential pressure specified. An
adequate allowance for stem force, at least 0.15 kg / cm2 per linear millimeter of seating


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surface, shall be provided in the selection of the actuator to ensure tight seating unless
3. The travel time of the actuators/CV shall not exceed 10 seconds.
4. For quick opening / closing services the actuator shall be pilot solenoid operated
pneumatic drive, the rating of solenoid shall be 24V DC or 110 V AC shall be decided
during detail engineering. (If applicable)
5. Selection of actuator shall be such that it meets the requirements of thrust / torque, stroke
length, angular movement, full scale travel time, repeatability & accurate positioning for
successful operation of final control element.
6. All the actuators shall have also provision for manual operation during emergency /
maintenance along with graduated local position indicator.
G. CONTROL VALVE ACCESSORY DEVICES
1. All control valve accessories such as self reset type air lock valves with tubing, hand
wheels / hand jacks, SMART positioners, solenoid valves, volume booster, air filter &
regulator, diffusers, external volume chambers, position transmitters (capacitance or
resistance type only), tubing, fittings and junction boxers etc. shall be provided as per
the requirements.
Specification for Smart Positioners
S.N Feature Minimum Requirement

1 Input 4-20 mA DC
2 Power Supply 24 V DC Loop powered
Microprocessor based with self diagnostic facility
3 Type of Electronics & digital communication by means of HART
Protocol
Non-Contact type with 4-20 mA DC Output (2
4 Valve position sensing
wire)
Weather & Dust proof to IP-65/ Die cast
5 Enclosure Type/Material
Aluminium
Suitable for - 30 to +80 *C temperature & 0-95%
6 Ambient conditions
Humidity
7 Operating Range Suitable for Full range &SplitRange operation
8 Modes of operation Suitable for Direct & reverse valve action
Suitable for Linear & Equal percentage
9 Flow characteristics
Characteristics
10 Fail safe/Freeze feature Required
Sufficient to handle the Valves Selected/Boosters to
11 Air Capacity
be supplied if required.


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12 Air supply pressure To suite the Air Supply Pressure / Quality available
13 Process Connection 1/4“ NPT
14 Characteristic Deviation < =0.5% of span
15 Ambient Temperature effect <=0.01%/Deg C or better
Remote Calibration, Auto & Manual Calibration
16 Configuration
shall be possible
½” NPT, Side or Bottom Entry to avoid water
17 Cable Entry
ingress
Display with push buttons for
configuration and Display on the
a)
positioner itself (Password Protected /
Hardware Lock).
For Supply & Output Pressure, Filter
18 Accessories Regulator and other accessories shall be
b)
provided as on required basis for
making system complete
Valves Mounting Assembly For Sliding
c) Stem / Rotary / Single Acting / Double
Acting on required basis
1. SMART positioner shall preferably be of the same make as the Control Valve, toensure
repeatability in Calibration, serviceability and proper maintenance of the Control
System.
2. SMART positioner shall be a Double stage positioner. The first stage of the positioned
shall be typically a flapper-nozzle that serves as a high-gain pre-amplifier. This
sensitivity shall be maintained over a wide range of dynamic conditions. Second stage
shall be a power amplifier that provides power to drive the actuator. Preferably this shall
be a pneumatic relay. Spool Driven type SMART positioners are not preferred due to
Higher Dead Band and Poor responsiveness. The SMART positioner shall have pressure
sensors to measure the pneumatic outputs to the actuator.
3. The control algorithm for the positioner shall use feedback signal from the motion of the
pneumatic relay beam instead of pressure feedback to minimize pneumatic related
effects and for stable and smooth response of the control valve. The SMART positioned
shall have user adjustable tuning sets to identify the optimum tuning for the total valve
assembly. SMART Positioner with HART Communication facility shall communicate
all the valve diagnostics to Plant DCS.
4. All pneumatic tubing required to interconnect devices assembled together shall be

furnished complete with each control valve. The tubing shall be of Stainless steel
Specification for Air Filter Regulator (AFR)


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1 Type Constant Bleed type
2 Inlet Pressure 10 Kg/Sq. cm (maximum)
Adjustable from 0-2 Kg/Sq. cm or 0-7 Kg/Sq. cm
3 Output
(Continuous) as required
4 Filter Element 5 microns
5 Filter Element Material Phosphor Bronze
6 Bowl Material Metallic
7 Drain Automatic
Enclosure Protection class/
8 IP-65/ Die cast Aluminium
Material
9 Process connection ¼ “ NPT
All mounting accessories.
10 Accessories
2” dial size Pressure gauge.
Specification for Position Transmitter

1 Power Supply 24 V DC Loop powered
2 Type Non-Contact LVDT type/Optical type
3 Output 4-20 mA DC/ Linear
4 Accuracy +/- 1%
Enclosure Protection class/
5 IP-65/ Die cast Aluminium
Material
½” NPT, Side or Bottom Entry to avoid water
6 Cable Entry
ingress.
7 Accessories All mounting accessories
Specification for Limit Switch (Non Contact Type)

1 Type Non-contact type inductive Proximity/Namur type
2 Sensing distance 10 mm minimum
3 Hysteresis Maximum 10% of sensing distance
4 Indicator LED indication
5 Protection class IP 67
6 Integral Cable 1 mtr.
7 Power supply 24 V DC/ 8 V DC
8 Mounting Flush mounting with check nut
Explosion proof enclosures shall be provided
9 Other Feature wherever required by the application.
Shock & Vibration proof.


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H. TEST & EXAMINATION
1. All valves shall be tested in accordance with the quality assurance plan agreed between
the Owner / consultant and the vender which shall meet the requirement of applicable
codes.
The tests shall complete but not limited to the following:
i. Non-destructive test as per ANSI B – 16.34.

ii. Hydrostatic shell test in accordance with ANSI B16.34 prior to seal leakage test.
iii. Valve closure test and seal leakage test in accordance with ANSI B16.34 and as per the
leakage class indicated under clause no. B.4
iv. Functional test: The fully assembled valves including actuators control devices and
accessories shall be functionally tested to demonstrate times from open to close position.
v. All control valves shall be tested with the positioners for accuracy of positioning and
reproducibility over the full range of travel.
vi. CV Test : CV test shall be carried out as type test on each size, type and design of the
valves as per AISA 75.02 standard and test report shall be furnished for owner’s /
consultant’s approval.
vii. Magnetic particle inspection shall be performed on all machined surfaces of valves
having ASA rating of 1500 lbs ASA or greater. All carbon steel valves 1500 lbs ASA or
greater shall receive 100% radio graphic examination in accordance with ASTM – E71.
viii. Bidder shall submit test certificates for the tests mentioned in above paragraphs in
accordance with ASME and ASTM requirements.
I GENERAL REQUIREMENTS
1. Bidder shall furnish all the control valves as finalized during detailed engineering stage
without any price repercussions whatsoever depending on the process requirements
including the system under.
2. Following documents to be furnished by the bidder after the award of contract.
a. Final certificate data sheet for all control valves.
b. Detailed dimensional and cross-sectional drawing of control valves, indicating end to

end dimensions, various clearness required, weight etc.
c. Test certificate for the following:
i. Hydrostatic test for all control valves

ii. Magnetic particle inspection for all control valves.
iii. Radiographic examination of control valves.
iv. Seat tightness test for control valves
v. Materials test certificate for control valves.


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General Requirements for Control Valves
i) Control valves shall be furnished with applicable certification for FGD plant, wherever
required.
1. Noise: The maximum allowable noise level shall be 85 dbA or less at 1 m. distance from
the downstream bare pipe surface. The specified noise level shall be attained without
the use of orifices, mufflers, diffusers. No credit for thermal or acoustical insulations
shall be taken.
2. Valve Trim: Valve shall have quick change type trim utilizing top entry. No
components shall be screwed or welded into the body. The valve shall have equal
pressure distribution around the plug to avoid chattering / vibration.
Trim of severe/critical service valve shall be of multi stage & multi path design with
sufficient no. of discrete pressure drop stage to eliminate the chance of erosion,
cavitations, noise, vibration through out the control range of valve.
3. Leakage Class: The valve shall have minimum leakage class as per process application
4. The valve trim should be multistage, multipath design having sufficient numbers of
discrete pressure reductions (turns/stages) to ensure elimination of vibration, capitations,
erosion and noise effects.
5. Bidder should work out number of pressure drop turns in the trim of the valve and
should provide calculations of trim exit velocity.
6. Flow Vs. valve opening characteristics: the trim is to be so designed that the minimum
flow indicated in the bid specifications of the valve is achieved with minimum lift of
8mm. of valve plug from ‘close’ position. Subsequent characteristics should be ‘Equal
Percentage’ i.e. corresponding to the parabolic characteristics. Characterizing the cam of
the positioner to mimic the required flow characteristics is not acceptable.
7 angeability should be 50 to 1(minimum). Valve should be able to throttle even below 5%

opening without trim erosion.
8. Each pressure reducing element should have a uniform pressure distribution around the
plug to avoid mechanical vibrations(pressure equalizing rings/ grooves).
9. To prevent flow induced vibrations and the line trace damage to seat, the flow direction
should be over the plug for water and under the plug for steam.
10. During throttle opening of the control valve, flow should be diverted away from the
body seat.


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11. Required leakage of MSS-SP-61 better than ANSI/FCI-70.2Class-V equivalent class is

achieved with metal seat. Soft seat is not acceptable requisite calculations in support of
above leakage class to be submitted with the offer.
12. Leakage class for all the control valves required valves required is MSS-SP-61 better
than ANSI / FCI-70.2class-V or equivalent as the control valves are to work as block
valves when in `CLOSE” condition. The bidder should indicate how this will be
achieved in their valves and actuators.
13. Bidder to indicate the closing force on the seat in kgf/mm of seat circumference applied
for actuator.
14. Trim exit velocity in both minimum and maximum flow conditions should be less than
30M/Sec. in case of water and 22.5M/sec in case of flashing water conditions.
Calculation sheet should be attached demonstrating satisfactory compliance of this
requirement.
15. Noise level at 1 meter distance from the valve should be less than 85dB without
insulation, Orifices, silencers mufflers etc. Calculation sheet to be attached for each
valve offered.
16. Critical cavitations index (Kc) for all control valves should be approximately 10 (> 9.9).
This is specific requirement to avoid even remote possibility of cavitational damage to
valve internals.
17. To avoid problems associated with the piston rings provided in valves of balanced
design, unbalanced design for port size upto 25mm. is required. Bidder to indicate the
compliance clearly.
18. Material of the valve internals should be as under:
Guide : Inconel 718

Plug/stem : Inconel 718
Seat ring : SS 316 stellited
19. Valve actuators:
i) Piston actuators shall be used for all valves.
ii) Valve actuators shall be capable of operating at 70 Degree C ambient continuously.

iii) Castings shall be of the type to suite individual area environments.
iv) All fix connection size shall be ¼” NPT (Female)
v) Bidder shall guarantee that the size of the actuator is adequate to meet the operating
thrust requirement for the control valve under extreme condition. Bidder shall indicate
the stroking time of the valve assemblies with positioner.

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20. Accessories:
Control valve actuators shall be equipped with air supply filter regulator, gauges and
valve positioners along with boosters for typical applications wherever required, local
poison indicator with scale and pointer, position transmitter, limit switch and hand
wheel, air lock relay, solenoid valve etc.
01.05.12 Electromagnetic Flowmeters
Electromagnetic flow meters are to be used in clean liquid medium, having

conductivity ≥ 5µS/cm (≥ 20µS/cm for demineralised water). The flow meter consists of
sensor and transmitter. The system shall be capable of continuously measuring and
displaying the flow of the water in the pipe line.
The primary element shall have a flanged metallic tube with a non-conductive liner. The
tube liner material shall be PTFE or compatible with the process fluid. Liner shall be
extended over the full width of the flange face to the bolt circle. Liner thickness shall be
selected to suit the application.
Electrode material / shred material shall be best suited to the fluid, to minimize
corrosion or abrasive wear. Electrode shall be of self-cleaning type. Recessed electrode
faces are not acceptable.
The coils house shall be completely coated with an epoxy material and shall be rigid and
impervious to total immersion in water. Leads shall be adequately supported.
The transmitter shall be SMART, 4…20mA isolated output with integral LCD display
and HART protocol. Required cable between sensor and transmitter shall be provided
for remote type transmitter. The cable entry to the transmitter shall be ½” NPT. The
power supply to the transmitter shall be 240V AC and the transmitter shall power the
sensors. The transmitter housing shall be of die-cast aluminum.
The accuracy of the system shall be ±0.2% of FSD. System accuracy shall not be
affected by changes in process medium concentration, density, or particle size
distribution. The system shall be suited for outdoor installation and shall have IP65 or
better enclosure. The calibration range shall be easily changed without removal of the
flow meter from the process.
The meter shall be capable of attenuating noise induced by solids in the slurry bouncing
against the meter electrodes. For potential equalization, grounding rings shall be
provided. The calibration range shall be easily changed without removal of the flow
meter from the process. Straight length requirement shall be as specified by
manufacturer. If meter size is smaller than the line size, concentric pipe reducers shall be
used. Eccentric reducers shall not be used as they disturb the flow profile.


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Flow measuring accuracy shall not be affected by:

• Changes in fluid viscosity, density, temperature or conductivity.
• Changes in the percent of magnetic material in the solids suspended in the measured
fluid.
• Changes in the percent of solids in suspension.
• Changes in supply voltage within ±10% of the nominal voltage level.
01.05.13 Ultrasonic Flowmeters
Type : ULTRA SONIC, 2-wired

Sensing element : Non-contact
Output : 4-20mA with HART Protocol
Accuracy : + 0.1% FS
Supply : 24 V DC
Enclosure class : IP-65
Transmitter
Mounting : On Nozzle
Mounting position : Top mounted
Housing : Plastic
Display : Head mounted LCD Display and remote display
Accessories : As per process requirement
Process connection : NPT/Flanged
Electrical connection : 1/4” NPT
Turn Down ratio : 1:100
Measuring range : Adjustable (as per process requirement)
Totaliser : Required
01.05.14 Rotameter
Rotameter shall be provided with following features:
Type/Construction a) On-line type Rotameter for 50 Nb and below

lines
b) Bypass type Rotameter for above 50 Nb lines.
Material
- For On-line type
Metering Tube Borosilicate glass
Float 316 SS
Packing Teflon
End fittings 304 SS
-For Bypass type
Float 316 SS
Packing Teflon

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End Fittings 304 SS

Orifice Plate 316 SS
Carrier ring 304 SS
Flanges & Mating flanges Same as pipe material, 200 lbs ANSI - RF
Impulse pipe Same as pipe material

Fittings 2000 ANSI, SW ends to match with pipe material.
Dial Size/Scale length 250 mm

Scale Details Direct reading type engraved on detachable
Aluminum scale
Accuracy + Two (2) percent
Reproducibility Half (1/2) percent
Connection SCRD NPT
Accessories a)Isolating valves (for Bypass type only)
b)Bolts, Nuts and Gaskets as required
Tests Shall be tested at two hundred (200) percent of the

maximum process pressure
01.05.15 Sight Flow Glass Indicators
Flapper type.
Materials
Body Carbon steel/SS316 as per process
requirement
Glass Toughened Borosilicate
Gaskets Neoprene
Bolts & nuts SS
Flappers / Rotating Wheel 316 SS
Flappers / Rotating Wheel holder 304 SS
Process Connection SW (Socket Welded)
Accessories Scale, Bolts, Nuts, Cover plates and
Gaskets as required
Tests Tested at two hundred (200) percent of
the maximum process pressure.
01.05.16 Conductivity type Level Switches
1 Sensing elements Conductivity type

2 Probe Material SS 316with high purity ceramic
3 Repeatability ± 0.5 % of full range or better
4 Accuracy ± 0.5 % of full scale or better


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5 Working temperature As per process requirement

6 Probe length As per requirement
Probe rating Max. design pressure of vessel
7 Mounting Flanged- on external cage
Input Four independent channel with selectable
switching threshold for water conductivity
Relay Output Four isolated output relays for Hi, Lo, Hi-
Hi, Lo-Lo
No. of contact 2 NO. + 2 NC, 2 SPDT, snap action type
8
dry contact with silver vetted
Rating of contacts 5A, 240 V AC / 2A, 24 V DC / 0.25
9
A,220V DC
Local Display Coloured LEDs for Hi, Lo, Hi-Hi, Lo-Lo,
Power & fault
10 Enclosure IP 65
11 Housing Cast aluminum epoxy coated weather proof
12 Ambient Temperature 60*C (max.)
13 Electrical Connection Plug-in type
14 Cable connection ½ “ NPT with cable gland
15 Set point Adjustable
Accessories All mounting accessories, PTFE cable
16 from Probe to electronics, washer &
Gasket, etc.
01.05.17 CAPACITANCE TYPE LEVEL SWITCH

Type Capacitance type
Probe a)Rod or suspended electrode
b) Rope type probes may be used only where required probe
length is greater than 3 meters.
Probe Mounting Stainless steel 1-1/2 ANSI RF Flange / ¾“ NPT (M)
Material of 316 SS
construction
Insulation PTFE Part/Full as per service.
Enclosure Powder/Epoxy coated Die cast Aluminum with neoprene
gasket conforming to IP-65. (Explosion proof for NEC
Ambient 0-60 ºC
temperature
Mounting On Tap
Supply voltage 240V AC, 50Hz / 24V DC
Relay output 2SPDT
Contact rating 5A min. at 240V AC on resistive load
Response time 100 msec or better
Cable connection ¾” ET

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Accessories Counter flange, Cable gland, prefab cable and stainless steel
name plate engraved with alpha-numeric.
01.05.18 FLOAT / DISPLACER LEVEL SWITCH (LS)
Type/Construction a) External float cage type with magnetic switch actuator

for tanks and vessels
b) Displacer -Top mounted for all clean water sumps
Materials
- a) Cast Carbon Steel suitable for specified pressure and
Body temperature ratings.
b) For corrosive liquids suitable anti-corrosive coat/lining

shall be provided
- Float/Displacer 316 SS
- Wire rope 316 SS
Differential + 12 mm minimum (Adjustable)
Contacts
- Number DPDT/2 SPDT
- Type Snap action micro switch with silver vetted
- Rating 5 Amp 240V AC, 0.2 Amp 220V DC
Connection
- Process One (1) inch SCRD NPT Female Or One (1) inch ANSI
Flanged
Four(4) inch ANSI Flange for sump services
Electrical Suitable for gland 3/4 inch
Temperature/pressure As per service conditions
rating
Accessories Counter flanges, still pipe of requisite length with
anticorrosive coating for sump services.
01.05.19 ULTRASONIC LEVEL TRANSMITTER

(FOR WATER SUMP/TANK LEVEL MEASUREMENTS)
Principle of Operation Detection of reflected ultrasonic pulse
Measuring Ranges Up to 30 meters (typical)
Signal Processing Microprocessor Controlled Signal Processing
Operating Frequency 10 KHz to 50 KHz (typical)

Display Large alpha-numeric back lit LCD / LED
Calibration & Configuration Accessible from front of panel
Diagnosis On-line
Status For power, Hi / Lo / V. Hi / V. Lo- level indication,
fault etc.

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Construction Plug-on board

Power supply 240 V AC 50 Hz / 24V DC
Signal Output 4-20 mA DC (isolated) - 600 Ohm load.
Hysteresis Fully adjustable preferred
Output contacts 2SPDT Potential free changeover contacts @ 8A
230V AC.
Accuracy & Repeatability 0.25% of span or better
Resolution 0.1% of span
Operating temp. Transmitter-50 Deg.C and Sensor – 80 Deg.C
MOC Sensor Body- PVC and Face – Polyurethene
Humidity 1% to 95% non condensing.
Enclosure IP-65 Epoxy painted die cast aluminium or
Polycarbonate housing
Cable Connection 3/4" ET
Mounting 2” for sensor and Transmitter on panel.
Accessories Cable gland, prefab cable, mounting accessories.
01.05.20 LEVEL INDICATORS (LI)

Type/Construction : a) Reflex
b) Tubular (For tanks open to atmosphere only)
Material:
a) Glass : Tempered borosilicate resistant to thermal shock
b) Case : Carbon steel

c) Integral cocks and : i) Forged carbon steel with drain valves
stainless steel internals
ii) Rubber lined corrosion resistant 316 stainless
steel (for Demineralised and Osmosis water
service)
d) Fittings : i) Forged carbon steel
ii) Rubber lined 316 steel/PVC for corrosive
liquids Demineralised and Osmosis water
service)
iii) 304 Stainless Steel for non-corrosive liquids
e) Packing : Teflon
Scale details : Aluminum/SS316 scale Graduated in mmwc
Accuracy +/- 2 % of full scale
Connection : 25 Nb/40 Nb ANSI Flanged
Accessories : a) Integral cocks
b) Drain valves
c) Bolts, nuts and gaskets
d) Illuminating lamps as required
e) Periscope as required
Tests : Tested at two hundred (200) percent of the

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Other details : For larger lengths, additional gauge glasses shall
be provided with minimum of 50 mm overlap.
01.05.21 FLOAT & BOARD TYPE LEVEL GAUGE

Type of Instrument : Mechanical Type (Float Operated)
Service / Application : As per service requirement
Measuring Range : as per requirement
Material Specification
a) Float Material : SS316 having 2 nos. Guide wires
b) Float Wire Pulley : Shall comprise of 2 nos. Cast Aluminum Pulley
housing Assembly with SS 304 pulley and
pulley shaft. Steel ball bearings shall be
provided in pulley housing for easier float
movement. Float wire material shall be SS316L.
Between 2 pulleys, 1” NB G.I. short pipe with
tentative length as per P&ID
c) Guide wire Assembly : CS chamber with spring and adjuster having 1”
Class 150 ANSI RF MS flange. Guide wire rope
shall be SS316L.
d) Counter Weight : MS counter – weight with Aluminum Pointer
and Brass assembly Pull Chain.
e) Scale : Dial type of SS 316/Aluminum material
Accuracy +/- 5 mm
Nozzle Details : For float wire pulley assembly, one tapping and
for guide wire assembly two tapping at the top
of the tank; Size 1” NB (Top Mounting Type)
Process Connection : Flanged as per ANSI B 16.5 to suit 1” NB
nozzle
(Nozzle length - 150 mm for float wire, 100
mm for guide wire)
Accessories (to be supplied with
the instrument)
a) Counter flange : All mating Flanges, Nozzle
b) Mounting Accessories : All mounting accessories
c) Tag Plate : To be provided (material SS316)
01.05.22 RF TYPE LEVEL SWITCH

Electronic Controller
Input Supply : 240 V AC (+/- 10%), 50 Hz (+/- 5%)
Construction : Cast Aluminium Housing


& ITS AUXILIARIES
2 Nos. Relay Changeover Potential Free

Relay Output :
Contacts ( 2SPDT)
Contact Rating : 5A at 240 V AC & 0.25 at 220 V DC
Class of Protection : IP-66
Ambient Temperature : 55 Deg. C(Max)
Local Indication : Local LED Indications

Green : Normal Level
Red : Alarm Level
Yellow : Probe Healthy
3/4” ET(2 Nos.) for Supply and Output 5/8”
Cable Connection :
ET(1 No.) for Probe Connection
Repeatability : 100%
Sensing Probe
Type of Probe : Rigid
Material : Stainless steel SS 316
Probe Head Housing : Cast Aluminium
Insulation (B/W Active & Shield

: PTFE
And Shield & Ground)
Probe Head Protection : IP-66
Mounting : Side Mounted
Cable Connection : 5/8” ET(1No.)
Process Connection : 40 NB BSP THREADED
Coaxial cable for Connection Between Sensing

Signal Cable : probe and electronic Controller (min. 10 Mtrs.
Per Level Probe)
Application : Lime Stone hopper


& ITS AUXILIARIES
01.05.23 CORIOLIS PRINCIPLE based MASS FLOW METER

Sensor
Primary Element : Flow Tube of 316SS or better
Heating Arrangement : Integral with Flow meter.
Temperature Control : To be provided.
For Heating
Process Connection : ANSI RF Flanged and rating as per process
requirement.
Drain : Self-draining facility
Accessories : Counter flanges, Mounting nuts, bolts, gaskets
etc.
Transmitter
Measured quantities : Mass flow rate, Total Mass Flow, Density,
Temperature as minimum.
Input Signal Processing : Digital Processing.
Display : Digital Display (LCD).
Output : 2 Nos. isolated output of 4-20mA DC selectable
from four measured quantities.
Load : < 750 ohms.
Power supply : 240V AC, 50 Hz. From UPS
Accuracy : 0.15% of measured value for liquid
0.5% of measured value for Gas
Repeatability : 0.5%
Housing : IP 65 (Explosion proof for NEC Class-1,
Division 1 area)
Hazardous duty Version : FM Standards.
Nameplate : Tag number, service engraved in stainless steel
tag plate
Accessories : a) As required for field mounting,
Handheld configurator & complete Software,
External zero adjustment facility
b) Mounting U-bolts, nuts, bolts, prefab
cable etc.
01.05.24 FLOW TRANSMITTER (ULTRASONIC)
Type : ULTRA SONIC, 2-wired

Sensing element : Non-contact
Output : 4-20mA with HART Protocol
Accuracy : + 0.1% FS
Supply : 24 V DC
Enclosure class : IP-65

& ITS AUXILIARIES
Transmitter
Mounting : On Nozzle
Mounting position : Top mounted
Housing : Plastic
Display : Head mounted LCD Display and remote display
Accessories : As per process requirement
Process connection : NPT/Flanged
Electrical connection : 1/4” NPT
Turn Down ratio : 1:25
Measuring range : Adjustable (as per process requirement)
Totaliser : Required
01.05.25 FLOW GAUGES (FG) Rotameter

Type/Construction a) On-line type Rotameter for 50 Nb and below
lines
b) Bypass type Rotameter for above 50 Nb lines.
Material
- For On-line type
Float 316 SS
Packing Teflon
End fittings 304 SS
-For Bypass type
Float 316 SS
Packing Teflon
End Fittings 304 SS
Orifice Plate 316 SS
Carrier ring 304 SS
Flanges & Mating flanges Same as pipe material, 200 lbs ANSI - RF
Impulse pipe Same as pipe material
Fittings 2000 ANSI, SW ends to match with pipe material.
Dial Size/Scale length 250 mm
Scale Details Direct reading type engraved on detachable
Aluminum scale
Accuracy + Two (2) percent
Reproducibility Half (1/2) percent
Connection SCRD NPT
Accessories a) Isolating valves (for Bypass type only)
b) Bolts, Nuts and Gaskets as required
Tests Shall be tested at two hundred (200) percent of the
01.05.27 LIMIT SWITCH (Mechanical Type)


& ITS AUXILIARIES
Type : Heavy duty
Actuation : Bidirectional, Roller lever / Sealed plunger
Contact rating : Continuous 5 Amp.(240 V AC)with silver vetted
No. of contact : 2 NO + 2 NC
Mounting : Horizontal / Vertical / Inclined
Reset facility : Manual Reset
Switch body material : Die Cast Aluminium / SS
Degree of protection : IP-65
Cable Entry : ½” NPT / Sealed / Plug-in
Accessories : Fasteners (SS), Gaskets (Nitrile Rubber)
01.05.28 FLOW SWITCH

Type Vane Type
Materials
Sensing Element SS316
Case Die cast Aluminium
Mounting Online type
Switch Assembly
Type Micro switch with silver vetted
Form DPDT or 2 set of SPDT
Rating 5 Amp 240V AC / 0.2 Amp 220V DC
Enclosure Weather proof to IP65
Housing Aluminium alloy
Over range Protection 130% of FSR
Set point Externally adjustable over full range
Accuracy ± 1% of FSR
Repeatability ± 0.5% of span
Connection
Instrument Half (1/2) inch NPT Male Process
Electrical Suitable for Three fourth (3/4)” gland conduits.
Double compression type SS Cable gland shall be
included with instruments
Accessories i) SS tag Plate
ii) 1 no. blind Plug for unused electrical
connection

& ITS AUXILIARIES
01.05.29 SOLENOID VALVES
Principle Electromagnetic (noiseless)

Coil voltage rating 24V DC
Port Size ¼” NPT all ports
Body material SS Bar Stock ( Al anodized & Epoxy coating)
Trim Material SS440C – seal less
Manual Operation In-Built
Type of Duty Continuous
Sealing Air Tight & Leak Proof
Coil Enclosure SS, Epoxy coated,
Coil casing Protection IP-65 Weather proof
Class
Insulation Class Class ‘H’
Mounting On valve assembly
Cable Connection ½” NPT (F), or plug type or molded with minimum
5 meter cable length.
Accessories All mounting accessories such as brackets, nuts &
bolts
Special Features i) Temperature operated fuse at Explosion proof
enclosure
ii) Solenoid valve directly integral to actuator body
shall have NAMUR interface.
Solenoid valves shall be provided with control valves / pneumatic control valves hooked
up with process interlock requirements and where direct tripping is involved. The
number of ways for solenoid valve shall be provided as indicated below:
(a) Two (2) way solenoid valves shall be provided, where process line of less than 50 mm
with low pressure and temperature application.
(b) Three (3) way solenoid valve shall be provided commonly, where the pressure is
admitted or exhausted from a diaphragm valve or single acting cylinder, e.g, Pneumatic
operated spray water block valve.
(c) Four (4) way solenoid valve shall be provided for operating double acting cylinders, e.g,
Pneumatically operated on-off type dampers.
(d) Solenoid Valve coils shall be Class-H high-temperature or Class-F construction as
applicable and shall be designed for continuous duty. Three-way solenoid valves shall be


& ITS AUXILIARIES
designed for universal operation so that the supply air may be connected to any port.
Solenoid enclosures shall be NEMA-4.
(e) All solenoid shall be with varister, LED indication, surge suppress diodeand circuits.
01.05.30 POWER CYLINDERS (PNEUMATIC)
Mounting Type Fixed position mounting (End mounting).
Control Signal 0.2 to 1 Kg/Sq. cm. from I/P converter for modulating
purposes. 24Voperated solenoid valve operating on
pneumatic line. The Pilot solenoid will have separate
coils for open closing purpose.
Supply Air 0-7 Kg / Cm2.
Selection Based upon thrust / torque, stroke length, angular
movement, full-scale travel time, repeatability,
space factor etc. Provision for air-to-open and
air-to-close operation.
Casing IP-65.
Accessories (as required) a) Air lock relay
b) Hand wheel.
c) Air filter regulator with gauge.
d) Volume Booster.
e) Limit Switches (non-contact type).
f) Positioner with Input, Output and supply
pressure gauges.
g) Pilot Solenoid Valve (Double Coil type)
h) Position Transmitter (4-20 mA DC linear
output, LVDT or non contact type).
Fail-safe operation Stay put, open or close position on pneumatic
/electrical power supply failure as per process
safety criteria.
Repeatability Better than 0.5% of full travel.
Hysterisis Less than 1% of full travel.
01.05.31 JUNCTION BOXES (Outdoor/Semi outdoor application)
Type Flame proof/weather proof

Enclosure IP--65/Explosion/Flame Proof as per area
classification.(Single door) Specifically designed Z
bending type to drain water, such that moisture does
not collect against the seal -Prevents the ingress of
dust and dirt when the door is Opened -Additional
protection for the high-quality PU foam seal
arrangement

& ITS AUXILIARIES
Material SS 304, 1.5 mm thick with foamed-in seal for

outdoor and semi-outdoor applications
Rear panel , roof plate & 1.5mm SS sheet with foamed –in seal
bottom plate
Mounting plate To be provided
Gland Plate 3 mm flush type gland plate
Cable entry Bottom or Side
Cable glands Double compression type – Nickel plated brass with
PVC hoods.
Mounting Indoor/Outdoor
No. of terminals As required with standardization with 20% spare of
each size & type.
Terminals screw less cage clamp type
Grounding Two terminals for body and shield ground
Door Hinged, lockable type (IP type lock) with common
key
JUNCTION BOXES (Indoor application)
Type Flame proof/weather proof

Enclosure IP--65/Explosion/Flame Proof as per area
classification.
Material SS of 1 mm thickness
Mounting plate To be provided
Cable entry Bottom or Side
Cable glands Double compression type – Nickel plated brass with
PVC hoods.
Mounting Indoor
No. of terminals As required with standardization with 20% spare of
each size & type.
Terminals screw less cage clamp type
Grounding Two terminals for body and shield ground
Door Hinged, lockable type (IP type lock) with common
key
Suitable mounting clamps and other accessories shall be in scope of bidder.

The brackets, bolts, nuts, screws, glands, lugs required for erection shall be of brass,
included in bidder scope of supply. High voltage & insulation resistance test shall also
be conducted.
M6 Ni plated Brass earthing stud shall be provided (external 2 nos. internal 1 no.)
Gasket (Normal)- Neoprene thickness 6.mm


& ITS AUXILIARIES
01.05.32 INTERPOSING RELAYS (IPR)
Type plug-in, Electromagnetic type connections

with modular design
Mounting Channel / DIN rail
Coil rating 24V D.C
Contact 2NO + 2NC (SPDT)
Change over contacts 2 sets, rated for 0.5A 220 V DC / 5A 240 V
AC / 2A, 24V DC
Pick Up voltage 19.2 V
Test voltage shall not be less than 4 KV
Contact material Silver Plated
Relay Base Contact material Silver Plated
Features / Accessories LED &Freewheeling diode across relay coil
Self Reset Type LED indicator flag
(electronic)
Name Plate (SS) with tag & service
inscription.
All mounting accessories such as Relay base
for mounting on rail / channel, nuts & bolts
Operating temperature –20 deg. C to 60 deg. C.
Approvals V0 inflammability class in accordance with
UL94”, IEC60664, IEC60664A, DIN VDE
016
Note : Multiple Relay with single based board
shall not be acceptable
01.05.33 FLOW ELEMENTS
1 General Requirements
The design, material, construction features, manufacture, inspection and testing of flow
elements shall comply with all currently applicable statutes, regulations and safety
codes in the locality where the equipment will be installed. The equipment shall also
conform to the latest applicable standards. Nothing in this specification shall be
construed to relieve the Bidder of this responsibility.


& ITS AUXILIARIES
2 Technical Requirement
316SS long radius, weld in flow nozzles with D and D/2 pressure tapings; 316SS flow
orifice plate assembly with flange tap connections; Beta ratio of 0.6 to 0.7.Element
material of SS 316. The material of Flow nozzle shall be A182F91, where pipe material
is A335P91. The material of all type of accessories will be SS316. End connections for
flow elements will be butt welded except orifice plate on condensate return line to CST,
which will be flanged. The accuracy of the flow element shall be + 0.5% or better.
There shall be four(4) pairs of tapings, out of which three(3) pairs shall be used for
mounting of DP type flow transmitters for control & monitoring whereas the fourth pair
shall be used during performance guarantee test by of plant by Bidder.
Standards
The flow elements (Orifice plates) shall be designed in accordance with ASME PTC –
19.5 (Pt – II), ISA RP3.2or BS 1042/ISO 5167.
The flow elements (Flow Nozzles and Aerofoil/Venturi Nozzles) shall be designed in
accordance with ASME PTC – 19.5 (Pt – II), or BS 1042/ISO 5167.
Construction and installation of flow nozzles and orifices shall conform to the
requirements of ASME Performance Test Code PTC-19.5 as mentioned above and dis-
charge coefficients shall be predicted in accordance with data published in ASME
Research Report on Fluid Meters.
3 Orifice Plate
Concentric orifice plates shall only be provided for other flow measurements where
flanged construction and higher pressure losses are acceptable. Orifice plates shall be
made of SS316. The standard primary element shall be thin plate, square-edge
concentric. Orifice flanges shall be of the raised face weld neck type with dual sets of taps.
The minimum pressure rating for flanges shall be ANSI 300lbs. Thickness of Orifice plate
shall be 3 mm (minimum) for pipe diameter up to 300 mm and 6 mm (minimum) for pipe
diameter above 300 mm. Orifice plates shall be supplied with carrier rings as per process
requirements.
The length of straight pipe run required for metering accuracy shall be in conformity
with ISO. When it is extremely difficult to comply with the standard, a minimum
straight length of 1OD (D = pipe inner diameter) on the upper stream and a minimum
length of 5D on the down stream shall be considered
For pipeline sizes of 500 mm and less, the orifice plates shall be an integral unit
comprising of carrier ring assembly, tapping arrangement on both upstream as well
down stream side. For line sizes more than 500 mm, the orifice plate shall be disc type.
For disc type orifice plate, suitable corner tapping arrangement on both upstream as well
as downstream side shall be provided. All tapping arrangements shall be complete with
a piece of impulse pipe line and a shut – off valve suitable for specified line pressure

& ITS AUXILIARIES
For steam applications, orifice plate shall be supplied with a pair of steam condensation
chambers suitable for specified line pressure.
Feature Minimum Requirement
Concentric as per ASME PTC – 19.5 (Part III); ISA
Type
RP – 3.2; BS – 1042; ISO 5167
Material SS 316
3 mm for main pipe diameter up to 300 mm and 6
Thickness
mm for main pipe dia above 300 mm.
Beta ratio 0.4 to 0.7
Tapping Flanged weld neck 3 pairs of tappings.
Material of Branch Pipe SS 316
Root Valve type Globe
Root Valve material SS 316
Root Valve size 1” or ½ “
Accessories Root valves, flanges, vent / drain hole (as required)
1. Bidder to provide Beta ratio calculation, Assembly drawings & flow vs DP curves.
2. Each orifice plate shall be provided with a handle on which the orifice diameter, pipe
diameter and pressure tap distances are stamped. This information shall be so located that
it can be read without removing the orifice plate from pipe line.
3. Quadrant edge or quarter circle orifice plates shall be used for highly viscous liquids and
for pipe Reynolds Number below 10,000. Conical entrance type of orifice plates shall
preferably be used for very highly viscous liquids up to Reynolds Number below 250.
Vent and drain holes shall be provided wherever necessary.
4. Orifice diameter shall be selected, so that d/D ratio is between 0.40 to 0.70 for gas and
steam and up to 0.75 for liquids.
5. Restriction orifices and integral orifice transmitters do not require upstream or
downstream straight pipe runs.
6. The orifice plate shall be supplied and fitted in conformity with ISO. When the pipe
diameter is larger than the value specified in ISO, the restriction ratio will be decided by
extending the specific curve externally.
7. Performance
The Bidder shall submit type test certificate from a recognized test house
certifying evaluation of construction standard, accuracy of calibration.
8. Tests and Inspection
All equipment components shall be individually tested to ensure correct functioning.

Following tests shall also be conducted:
a) Calibration test
b) Dimensional check
c) Material test


& ITS AUXILIARIES
Wet calibration shall be carried out as on each size and design of flow element as per
ASME PTC or BS 1042/ISO 5167. The other tests shall conform to ASME-PTC 19.5.
The Biddershall submit the reports for all the tests carried out for Purchaser's review and
records. The functional test shall also be witnessed by customer as per approved
document.
9. Drawings & Documents

The supplier shall provide the following documents:
1. Design drawings
2. Data sheets & specification
3. Sizing calculation & flow Vs DP curves
4. Fabrication, assembly and installation drawings
5. Test Reports
01.05.34 TECHNICAL SPECIFICATION OF CONTINUOUS EMISSION MONITORING

SYSTEM (CEMS)
I. GENERAL
I.01 Bidder shall familiarize with the permit requirement of the plant and supply a
Continuous Emission Monitoring System complete in all respects to meet the
environmental monitoring requirements.
II. SYSTEM OVERVIEW
II.01 Flue gas analyzers shall be provided for FGD stack continuous emission monitoring
system (CEMS). Stack emission monitoring system shall comprise of CO, CO2, SOx,
NOx, O2 Analyzer, Dust / Opacity Analyzer, Stack Gas Flow, Pressure, Temperature and
Mercury Analyzer.
II.02 In addition to continuous environment monitoring system, manual sampling provision for
flue gas monitoring should be provided as per Emission latest Regulation of
CPCB/TNPCB in each stack along with necessary provision of platform, lighting facility,
safety rails and ladders etc. complete in all respect.
II.03 Type, quantity and locations of tapings in stack shall strictly follow the norms as
stipulated by the latest norms of MOEF / Central Pollution Control Board/ TNPCB. The
measurement shall also conform to EPA, TUV, MCERTS or equivalents regulations.
II.04 A dedicated Operating Station with calculations software, application software, report
generation software packages, diagnostics and data logging features & B/W A4 sized LJP
and Laptop for site calibration shall be provided along with the furniture for each unit.
Remote calibration of all analyzers shall be provided.


& ITS AUXILIARIES
II.05 Hardwired & soft signal exchange shall be envisaged between FGD PLCs & CEMS.
Provision shall be available at separate terminal block in CEMS cabinets for Hardware
interface of analyser signals for CPCB/ TNPCB interface.
II.06 Power supply to CEMS shall be from FGD Unit /Dedicated UPS. The bidder shall lay
necessary cable from ACDB in CER/CEMS room to CEMS Panel.
II.07 A permanent environmentally controlled (air-conditioned) room for each CEMS system,
with suitable electrification shall be provided to house all non-on-line mounted
components including calibration gases in the vicinity of the sampling location. Proposed
location of CEMS Room is zero mtrs. Elevation near stack.
III TECHNICAL PARTICULARS
III.01 Continuous Emission Monitoring system consisting of the following equipment

(Analyzers/monitors) shall be provided for measurement of emissions in the duct leading
to chimney / stack of each unit:-
• SOx, NOx, CO, CO2 analyzer,

• O2 analyzer.
• Opacity analyzer including Flue gas temperature/Pressure measurement
• Mercury (Hg) analyzer
• To estimate the emission quantities gravimetrically, a flow measurement system in
the stack shall be envisaged. Ultrasonic mass flowmeter shall be preferred.
III.02 All output signals of all stack monitoring analyzers shall be hardwired and connected to
FGD PLC system as applicable for monitoring, archiving and report generation for
environmental monitoring authorities.
CEMS OWS shall be equipped/ loaded with necessary Stack emission monitoring
system’s calculations and report generation software packages for generation of report for
submission to environmental monitoring authorities. This is specific application software,
shall be supplied by CEMS vendor.
Each Analyzer shall be provided with RS485 output required to connect with CEMS
operating work station, and port for calibration from Laptop.
Output of CO/ SOx/ NOx/ CO2/O2/ Dust monitors/ Stack flow analyzers shall be
normalized for temperature, pressure, water, vapour etc. This facility should be available
in respective gas analyzer.


& ITS AUXILIARIES
Weather protection against direct sun light, rain etc. for flow meter, local display / local
indicators shall be provided by Bidder.
Heated sampling line of PTFE material shall be provided from sampling point to panel
for measurement. Sample line shall be electrically heat traced. Power supply for heat
tracing tube shall be from UPS.
The common requirements to be met for all types of analyzers are as below. The specific
requirements to be met by each type of analyzer are detailed in the subsequent clauses.
III.04 Common Requirements of Analyzers:
Sl. No. Features Minimum requirements
1. Output Signals
Analog Two (2) numbers of 4-20 mA DC galvanically

isolated signals shall be provided.
One signal shall be connected to Data logger and

to CEMS OWS. From Data logger the signals
shall be connected to FGD PLC.
Other signal shall be connected to Pollution

control board system.
Binary 2 NO + 2 NC for high alarm
2. Zero & span To be provided with range selection facility.
Adjustment
3. Ambient temp. 50 °C
4. Indication Digital Alphanumeric Display. Display of reading

in engineering units shall be provided.
5. Enclosure Weather & Dust proof (IP 65) Die cast
Aluminum/SS.
Type/Material Weather protection for analyzer mounted inside
analyzer panel shall be IP-22 or better
6. Type of Electronics Microprocessor based with self diagnostic.


& ITS AUXILIARIES
Sl. No. Features Minimum requirements
7. Calibration Auto & Manual (from Remote)
8. Digital Signal HART / RS 485 Port Modbus Protocol / Ethernet

TCP/IP protocol for communication of stack
transmission emission data to CEMS OWS to be provided by
Bidder.
9. Power Supply UPS (Redundant Feeders) from Unit/ Dedicated
UPS
10. Compliance to USEPA, TUV, MCERTS, QAL or equivalent
Standards standards
11. Type of - SOx/ NOx/ CO/ CO2: Extractive sampling

type with Two stage Cooler
Technology - Stack Opacity: / Extractive type for Wet Stack
(Path) type
For Extractive sampling type systems, the entire

system including analyzers, sample handling/
conditioning system etc. offered shall be sourced /
assembled at Original Analyzer Manufacturer
(OAM) works i.e. all components involved shall
be imported or sourced from OAM only
12. Others i) All interconnection tubing and cabling
between probe and analyzer/ analyzer
panel and cabling from analyzer/ analyzer
panel to FGD PLC & Local Operator
Station (CEMS room) shall be provided.
ii) All the calibration gases required for one

year continuous operation shall be
provided. The calibration gas container
material shall not contaminate the
calibration gas.
(Calibration gases shall be provided by

Bidder after commissioning of the system)


& ITS AUXILIARIES
III.05 A data logger system shall be provided for acquiring the CEMS data from the analyses
and for transmitting the same to FGD PLC & CEMS OWS. A programmable controller
shall be provided for signal output, alarms, calibration cycle timers and measurement
indication for each analyzer. The controller shall be panel or rack mounted and furnished
with interconnecting cable to the field-mounted analyzer. Calibration cycle time shall be
set over fixed internals and sequenced by the controller.
Isolated DPDT contacts shall be furnished for the following alarms:
a) Two independently adjustable alarm levels for each constituent

b) Monitor range selection
c) Zero and span calibration
d) System faults
III.06 CEMS OWS station with application software shall be provided for the system.
Application software shall have the following minimum capabilities:
Visualization of acquired values of data from all analyzers

Average computation of data(programmable time like 30min, 1 hour, 24 hours, 48
hours or 1 week)
Trend representation of raw, and averaged data (trend time period shall be freely
selectable)
Archiving in simple formats like MS Excel etc.
Alarm setting and annunciation
Calibration procedures
Normalization of emission data
Annual cumulative mass of pollutants using flue gas flow and emission values
Capabilities of comparison of data w.r.t. standard/ threshold values.
Providing remote access to calibration and configuration.
Channel configuration for range, unit etc.
Data storage capacity.
Auto Report generation.
Diagnostics.
Data transmission.
All the necessary algorithms shall be provided to achieve system capability
All the data shall also be available on FGD PLC for analysis and monitoring from CEMS
OWS through redundant Bus (Modbus RTU or Modbus TCP/IP or OPC for soft link
interfacing). Interfaces shall be over optical fiber cable or Ethernet STP cables and shall
be decided during detail engineering stage based on Supplier’s standard practice
considering any distance limitation. Interfacing with FGD PLC shall be provided by


& ITS AUXILIARIES
Bidder. Workstation end hardware including LIUs, Modems etc. as required establishing
the connectivity with CPCB shall be also provided by Bidder.
The system shall be time synchronized with Master Clock System.
III.07 Extractive Sampling type SOx, NOx, CO2 & CO Analyzers:
Specification SOx NOx CO2 CO Analyzer

Requirements Analyzer Analyzer Analyzer
Sampling type Extractive Extractive Extractive Extractive with
with Two with Two with Two Two stage
stage cooler stage cooler stage cooler cooler
Principle of Radiation Radiation NDIR NDIR
Measurement absorption absorption absorption absorption
Measurement 0-300 ppm / 0-300 ppm / 0 to 40% 0-200 ppm to 0-
Range 0- 0- 1000 ppm
1500 ppm 1500 ppm (fully (Programmable)
(Selectable) (Selectable) selectable)
Measurement 0-300 ppm / 0-300 ppm / 0 to 40% 0-200 ppm to 0-
Range 0- 0- 1000 ppm
1500 ppm 1500 ppm (fully (Programmable)
(Selectable) (Selectable)
selectable)
Accuracy +/- 1% of +/- 1% of+/-2% of +/- 2 % of F.S.
F.S. F.S. measured
value
Linearity +/- 1% of +/- 1% of +/- 1% of +/- 1% of F.S.
F.S. F.S. F.S.
Repeatability ≤1% of Span ≤1% of Span ≤0.5% of ≤1% of Span
Span
Response time(up ≤ 5 seconds ≤ 5 seconds ≤ 5 seconds ≤ 5 seconds
to 90% of full scale)
Drift
a) Temperature +/- 2% / +/- 2% / +/-1% in 24 +/-2% /10˚C
Drift 10˚C 10˚C hrs
b) Zero Drift <1% <1% <1% <2% span/week
span/week span/week span/week
c) Span Drift <1% <1% <1% <1% measured
measured measured measured value/week
value/week value/week value/week

& ITS AUXILIARIES
Specification SOx NOx CO2 CO Analyzer

Requirements Analyzer Analyzer Analyzer
Operating Temperature 0-300˚C 0-300˚C 0-300˚C 0-300˚C
Filter Ceramic 3.5 Ceramic 3.5 Ceramic 3.5 Ceramic 3.5
Micron Micron Micron Micron
Accessories for Purging Purging Purging Purging System
Purging System System System System (Auto
(Auto (Auto (Auto Scavenging
Scavenging Scavenging Scavenging facility)
facility) facility) facility)
Temperature control Tempera-ture Tempera- Tempera- Temperature of
of the sample ture of the ture of the the sample shall
shall be sample shall sample shall be controlled
controlled be controlled be controlled before analyzer
before before before
analyzer analyzer analyzer
Power Requirements 240VAC, 50 240VAC, 50 240VAC, 50 240VAC, 50 hz
hz hz hz
Power Requirements 240VAC, 50 240VAC, 50 240VAC, 50 240VAC, 50 hz
hz hz hz
III.08 Ultrasonic Flowmeter for Flue Gas Flow in Stack
Type Transit time Ultrasonic meter

Mounting Style Transducers on the duct/ stack
Transducer Single pair of Corrosion resistant material to be provided
Zero and Span To be provided ( auto and manual)
Adjustment
Flow Measurement Instantaneous flow rate as well as totalized flow
Power Supply UPS (Redundant Feeders) from Unit/ dedicated CEMSUPS.
Distribution
Output: Isolated 4~20 mA linear outputs to PLC.
RS485 / Ethernet communication link with Modbus / OPC
Protocol to be connected to CEMS OWS
Hand held terminal port
Display/Indication Flow meter with LCD screen backlight based local display
and keypad. If required, transmitter shall be suitably located
away from the sensor for better access and visibility.
Recording / To be provided
Totalizing/Logging

& ITS AUXILIARIES
Type Transit time Ultrasonic meter

Diagnostics False signal tolerance , power supply failure etc.
Protection Class IP-65 or better, Weather protection against direct sun light,
rain etc. for flowmeter
Ambient -20˚C to +60˚C
Temperature
Accuracy <+/-2% for measurement ( zero uncertainty),
<+/-1% for measurement ( linearity)
Electrical Connection Plug & Socket
Accessories All mounting hardware required like clamping fixtures,
mechanism to remove the transducers online, interconnecting
cables, flexible conduits, junction boxes etc.
Purging arrangement (compressed air) for cleaning sensors

shall be provided (if required). Material of all fittings shall be
SS316
Software Features Compensation for temperature and pressure and any cross path
errors.
Programming, configuration shall be possible from front
panel.
III.09 Dust Monitoring (Opacity meter)/SPM
Type : In-situ Non contact cross duct type

Range : 0-100% ,0-999mg/m3
Min. detectable con. : 1 mg/m3
Measuring Averanging : Fully selectable in range 10 sec to 30 days
Response time : 90% in 5 seconds
Auto/manual calibration : In built
Accuracy : 0.2% Opacity of measurement
Resolution : 0.1% opacity
Linearity : 0.1% opacity
Power supply : 88-240V AC
Remote/local control Unit : Isolated 2x 4-20mA,500ohms outputs Configurable
Interface option : RS 232/RS 485
Compliance : EMC89/336/EEC, ASTMD6216
Display : Back Lit LCD
Ambient temperature : 0 - 50OC
Operating temperature : Transmitter & receiver- 0-150OC, Electronic unit – 0-70
O
C
Analog output : 4-20mA DC
Alarm output : 2 SPCO potential free rated at 230 VAC, 5A

& ITS AUXILIARIES
Power Supply : 240V AC, 50 Hz, 1 Phase UPS

Automatic misalignment : Required
detection
Automatic compensation : Required
of lens contamination
Purge air : Purge air to be provided
Span and Zero Check : Automatic periodic with manual override
Housing : Corrosion resistant painted aluminium rated at IP-65
Fail safe shutter : Automatic fail safe shutter against power and air failure
Input normalization : Correction for temperature, pressure, oxygen and water
vapour to be provided.
Preferred Features : “Power Supply On” LED visible from front
Accessories : All mounting accessories for mounting of all items to be
provided.
Application : At chimney
Interface : RS 232, RS 485, TCP/IP
Compliance : EMC89/336/EEC, ASTMD 6216, analyzers shall be
capable of online remote calibration requirement as per
latest CPCB guidelines .
III.10 Continuous Online Mercury Analyzer
Measurement Elemental, Ionic & Total Mercury

Measuring Range 0-100 µg/Nm3
Measuring Principle Cold Vapor Atomic Fluorescence
Flue Gas Temperature 0-250˚C minimum
Probe material shall be as approved by Owner
Measuring Outputs 4~20 mA, RS485 for CEMS OWS Interface
Digital Outputs 4 relay outputs
Digital Inputs 1 potential free outputs
Accuracy <1% of measuring range
Minimum Detectable <1 µg/Nm3
Limit
Temporary change of <±2% of measuring range/ month
sensitivity/ Reference
Point Drift


& ITS AUXILIARIES
Measurement Elemental, Ionic & Total Mercury

Temporary change of <±1.4% of measuring range per month, zero
zero offset/ Zero point correction (automatic)
drift
Power supply UPS (Redundant Feeders) from Station UPS.
Display LCD Display, IP 54 min

Special Requirements Non-interference with SOx, NOx, CO and any other
chemical components
MODBUS/TCP-IP protocol to be connected to
Bus Protocol
CEMS OWS.
Accessories Automatic purging System, Automatic Dilution
system, Automatic Calibration system, Filters etc.
Consumables For one year operations in addition to mandatory
spares.
III.11 Oxygen Analyzer:-
01. Type : In-situ, Zirconium sensor or extractive

paramagnetic or electrochemical cell,
micro-processor-based transmitter, field
repairable.
02. Range : 0.1-10% / 0.25-25% by volume
03. Output : 4-20 mA DC linear
04 Probe Length : 1800 mm (approximate depending on duct size)
05. Process Temperature : 850 DegC approx.
06. Measurement Reference : Instrument Air
07. Accuracy : ±1% of F.S.
08. Response Time : Less than 5 (five) seconds
09. Amplifier Housing : IP-65
10. Calibration : Automatic periodic
11. Calibration Frequency : Once every 24 hours
12. Power Supply : 240V, 50 Hz, 1 Phase

13. Material for Gas Carrying
Components : Stainless Steel
14. Read Out : LED/LCD Local indicating meter


& ITS AUXILIARIES
15. Protection : Automatic cell protection against reducing

atmosphere
16. Alarm Facility : 1 HI and 1 LO independently adjustable over
span. Contact rating 500 mA at 220 V DC
(minimum).
17. Preferred Features : a) HI and LO alarm LED visible from front.
b) Power Supply On/Failure LED visible
from front
18. Accessories : a) Mounting flanges, adaptor plate and
protection shield
b) Gasket, nuts and bolts
c) Cable with conduit from cell to amplifier
(as required) and other special cables (if
any)
d) Automatic calibration kit (complete with
all accessories and standard Gas
Cylinders)
III.12 The Technical Specification for Temperature Elements, Flowmeter,

Instrumentation Cables, Junction Boxes, Local Control Panels/ Cabinets,
Furniture, HMI hardware such as Workstation, Laptop etc., refer specification
mention elsewhere in this instrumentation tender specification.
01.05.35 Instrumentation cable
1. Instrumentation pair/triad cables shall conform to the following:

i) All cables shall be screened & armoured.
ii) Applicable standards: Latest revision of IS 8130, IS 5831, BS 5308 IEC 60092-376
iii) Conductor material shall be annealed, tinned, multi-stranded, electrolytic grade copper
of size 1.0 mm2. 1.5 mm2 cables shall be provided based on the requirement.
iv) Number of strands and strand size of conductor shall be 7/0.43 for 1.0 mm2 and for 1.5
mm2 , it shall be 7/0.53.
v) Primary insulation material shall be of Extruded HRPVC type C of thickness (nom) 0.6
mm.
vi) Individual pair/triad shall be shielded by aluminum mylar tape, helical type, 0.06 mm
thick (nom) with 100% coverage and 25% overlapping.
vii) Drain wire shall be of annealed tinned copper, 0.5 mm2, and 7 strands continuously in
contact with the shield. Drain wires shall be provided for each pair/ triad screen.


& ITS AUXILIARIES
viii) Inner sheath shall be Extruded HRPVC (ST2 type) / FRLS (as applicable)/ LSZH (as
applicable). Thickness (nom) shall be as per latest Indian standard. Inner sheath colour
shall be black.
ix) Overall shielding shall be helical type 0.075 mm thick aluminum Mylar tape with 100%
coverage and 25% overlapping.
x) Overall drain wire shall be of annealed tinned copper, 0.5 mm2, and 7 strands
continuously in contact with the shield.
xi) Ripcord shall be provided & shall be non-metallic type under sheath.
xii) Armour material shall be galvanized round steel wire.
xiii) Armour size shall be as per latest Indian standard.
xiv) Outer sheath shall be Extruded HRPVC (ST2 type) / FRLS (as applicable)/ LSZH (as
applicable). Thickness (nom) shall be as per as per latest Indian standard. Outer sheath
colour shall be blue.
xv) Tests shall be carried out according to following standards of latest revision:
a) General: IS: 1554 (Part I) except for thick nesses of insulation & sheath.
b) Insulation: IS: 5831except insulation resistance, Voltage and Spark tests,
which shall be as per BS 5308 Part II
c) Armour: IS: 3975
d) Armour Galvanisation: IS: 2633
e) FRLS properties test
• Oxygen Index According to: ASTM D2863
• Temperature Index According to ASTM D2863
• HCl Emission According to IEC 754-1
• Smoke density According to ASTM D2843
• Flame Retardant test According to IEC-332 Part III Cat A
xvi) Pair/ Triad shall be identified with numbers as per BS 5308. IEC 60092-376
xvii) Electrical characteristics, values like, resistance at 20 0C, Mutual capacitance (core to
core), mutual capacitance (core to screen), mutual inductance, L/R ratio shall be
indicated in the specification datasheets.
xviii) A durable marking provided on the surface of the cable at regular intervals not
exceeding 625 mm. The marking shall include manufacturer’s name, conductor
material and size, no. of pair, insulating material etc. as per IS: 1554 (Part I).
2. Instrumentation Power supply cable: -

i) All cables shall be armoured. For 240 VAC/ 110VAC power supply to field
instruments, directly 3-core cable from control room/ power distribution board to
individual instrument through individual MCB shall be used.


& ITS AUXILIARIES
ii) Conductor material shall be annealed, tinned, multi-stranded electrolytic copper of 1.5
mm2.
iii) Number of strands and strand size shall be min 7/0.53.
iv) Primary insulation material shall be of Extruded HRPVC type C. Thickness (nom) shall
be 0.8 mm.
v) Inner sheath shall be Extruded HRPVC (ST2 type) / FRLS (as applicable)/ LSZH (as
applicable). Thickness (nom) shall be 0.3mm. Inner sheath colour shall be black.
vi) Armouring shall be of galvanized round steel wire or galvanized steel strip as per IS
1554 (Part 1).
vii) Outer sheath shall be Extruded HRPVC (ST2 type) / FRLS (as applicable)/ LSZH (as
applicable). Thickness (nom) shall be 1.24 mm, 1.4 mm, 1.56 mm as applicable &
conforming to IS 1554. Outer sheath colour shall be black.
viii) Tests shall be carried out according to following standards of latest revision:
a) General: IS: 1554 (Part I).
b) Insulation: IS: 5831
c) Armour: IS: 3975
d) ArmourGalvanisation: IS: 2633
e) FRLS properties test
• Oxygen Index According to: ASTM D2863
• Temperature Index According to ASTM D2863
• HCl Emission According to IEC 754-1
• Smoke density According to ASTM D2843
• Flame Retardant test According to IEC-332 Part III Cat A
ix) Core identification shall be as per IS 1554 (Part 1).

x) Electrical characteristics, values like, resistance at 20 0C, Mutual capacitance (core to
core), mutual inductance, L/R ratio shall be indicated in the specification datasheets.
xi) A durable marking provided on the surface of the cable at regular intervals not
exceeding 625 mm. The marking shall include manufacturer’s name, conductor
material and size, no. of pair, insulating material etc. as per IS: 1554 (Part I).
3. Shield shall be kept open at the instrument end and to be connected to the electronic
earth pit at the control room end.
4. For shielded compensating cable the shield shall be earthed near the point of the circuit
ground. For grounded junction thermocouples, this means at the thermocouple head.
For ungrounded junction thermocouples this means at the control room end.


& ITS AUXILIARIES
5. Cross section of conductor of Compensating/Thermocouple extension cables shall be

minimum 3 X 22 SWG (1.19 mm2).
6. Insulation thickness of Compensating/Thermocouple extension shall be of Extruded
HRPVC type C of minimum thickness (nom) of 0.45 mm.
7. Compensating/Thermocouple extension cables to be used in high temperature zone or
are to be laid on the top of the furnace/hot surface, shall be sintered Teflon insulated
(0.45 mm minimum), sinter Teflon sheathed overall SS braided (0.15 mm, minimum
80% coverage) cables. Additional Glass fibre insulation shall be used for temperature
zone > 250 °C. Mineral insulated extension cables can also be used for such
application.
8. Compensating/Thermocouple extension cables having inner & outer sheath of
HRPVC/ FRLS (as applicable)/ LSZH (as applicable) and armouring; the thickness of
sheaths and armouring shall be provided as per the table indicated above for pair/ triad
cables.
9. All instrumentation cables (pair/triad) shall be numbered as per BS 5308, Part 1.
10. All cables, from field JBs to panels/ marshalling rack in the control room shall have at
least 10% (minimum 1 no.) spare core/pairs/ triads (as applicable).
11. Field bus cables shall be selected based on following:
a. Field bus cables shall be of Type A as per IEC 61158-2 or FF 844.
b. Single pair twisted type with overall shielding (100% coverage). Conductor size
shall be minimum 0.8 mm2 (18 AWG/7). Drain wire shall be tinned copper,
stranded and size shall be 20 AWG.
c. (+) core colour shall be orange and (-) core shall be blue.
d. Insulation shall be polyolefin/ polyethylene. Sheath material shall be PVC (+90
°C grade). Outer jacket colour shall be orange.
e. Field bus cables shall be either armoured type to be laid on trays or un-armoured
type to be laid in conduit.
f. Electrical characteristics: Impedance at 31.25 kHz shall be <100 Ω ± 20 Ω;
Max. DC resistance per conductor @20°C: 23.5Ω/km; Maximum attenuation at
39kHz: 3 dB/km; Capacitance unbalance: 4 nF/km max.; Nominal inductance:
623 mH/km.
01.05.36 Technical Specification of pH analyser and Transmitters
a. Applicable Standard pH electrodes shall conform to IS:
6804-1972 except as modified in this

specification
b. Type
i) Cell Measuring and Reference Electrode


& ITS AUXILIARIES
Combination with Flow through type

(Polypropylene flow chambers) for power
plant’s steam & water application. Sensor shall
not be affected by flow variation. Sensor shall
be designed for power plant applications.
ii) Monitors Single channel, Electronic (microprocessor

based)
indicating type with adjustable range facility.
c. Material:
i) Measuring & Toughened sensitive

reference
ii) Electrode pH glass
iii) Monitor body Die-cast aluminium
d. Monitor output: i) 4 to 20 m Amp, DC spare output
ii) 4 to 20 m Amp, DC isolated output for

DCS
iii) RS-232C / RS-485 Output for

diagnostics.
e. Power supply 240V, AC, 50 Hz
f. Accuracy/repeatability +/- 0.03 pH
g. Resolution +/- 0.01 pH or 1 mV. 1C
h. Stability 0.02 pH per week
i. Annunciation contacts for

monitoring
i) Number 2SPDT
ii) Type Relay
iii) Rating 5 amp, 240 V, 0.2 Amp, 220V DC


& ITS AUXILIARIES
j. Mounting
i) Cell On line/pipe mounted
(ON LINE in sample table)
ii) Monitors flush panel mounting
k. Connection:
i) Process 1/4 (Quarter) inch NPT(F) SCRD for on-line

type Three quarter (3/4) inch NPT (M) SCRD
for pipe mounted
ii) Electrical Half (1/2) inch NPT (F)
l. Accessories i) Automatic temperature compensation

with fast response integral temperature
sensors in the range 0-100°C
ii) Co-axial cable as required
iii) Sample coolers
iv) Flow and pressure regulators
v) Standard pH solutions
vi) SS impulse tubing fittings
vii) Isolation & drain valves as required
viii) Electrode holders
ix) Other accessories as required
x) Sample rate set valves
xi) Alarm settings and indications on

monitor.
xii) RFI/EMI shielded, weather and corrosion

proof casing


& ITS AUXILIARIES
xi) Diagnostic feature
m. Ranges As per sample stream detail table.
01.05.37 Vibration Measurement System
1. Accelerometer type 4-20mA 2- wire Vibration monitoring sensor will be provided for
all HT drive pumps & motors signals which will be connected to PLC.
2. Accelerometer type 4-20mA 2-wire sensors to be connected to be connected to DCS.
3. VMS will have necessary interfacing give output of 4-20 mA DC for each point
monitored. The signal will be suitable for use as an input to PLC as well as for trending
linear in proportion to vibration velocity as well as displacement.
Vibration Monitoring System (VMS) shall consist of the following items as a

minimum:
a. Vibration Sensors
b. Vibration transmitters with 4-20 mA DC output.
c. Cables, conduits & junction boxes.
d. Mounting Pads for sensors.
e. The above items are indicative only. Over and above any items & accessories, if
required, for completeness of vibration monitoring system shall be supplied,
even if it is not specifically indicated in this specification.
Specifications for Piezoelectric Accelerometer Sensor
Sl. No Features Minimum Requirements

1 Type Piezoelectric Accelerometer type
100mV/g + 5% (For machines operating at lower
2 Sensitivity speeds i.e. <700 RPM, the sensitivity of the
sensors shall be 500mV/g + 5%).
3 Measurement range +50g
4 Transverse Sensitivity 5%
5 Frequency Response 1 – 10 KHz
6 Output Impedance <200 ohms
7 Linearity +/- 1%
8 Temperature Range -55 OC to 120 OC


& ITS AUXILIARIES
Sl. No Features Minimum Requirements

9 Probe body material SS 316
10 Sealing IP-67


& ITS AUXILIARIES
Specification for Vibration Transmitter
Sl. No. Features Minimum Requirements
1. Type Maximum 2 channels
2. Output 4-20mA
3. Relay Outputs Minimum 02 nos. per channel
4. Input type Accelerometer and Velocity sensors
5. Supply Voltage 230V AC or 24V DC
6. Accuracy +/-2% of full scale
7. Display Yes
8. Interface Keypad or touch
9. Enclosure Aluminium (alloy or die-cast)
10. Protection IP-65
11. Mounting Field
12. Operating 0-60 OC

temperature
13. Humidity 90% (non-condensing)
01.05.38 Servers/Workstations/printers
Sr Servers / Engineering work Operator workstations/

Features
No. station Other workstations
1. Processor 64 bit with minimum 64 bit with minimum

spectp95 25 specint95-19 spectp95 – 20 specint 95-15
2. Memory 16 GB (Minimum) 16 GB (Minimum)

expandable upto 32 GB expandable upto 32 GB
3. Hard Disk 1 TB 500 GB ultra wide SCSI


& ITS AUXILIARIES
4. Monitor Min 24” LED Flat Monitor Min 24” LED Flat Monitor
(color) with resolution of 1920 x with resolution of 1920 x
1080 non-interfaced refresh 1080 non-interfaced refresh
rate min. 75 Hz. rate min. 75 Hz.
9. USB Port USB 3.0 - 4 nos. USB 3.0 - 4 nos.

Ethernet – 4 nos. Ethernet – 2 nos.
Parallel – 1 no. Parallel – 1 no.
Serial – 1 no. Serial – 1 no.
10. DVD ROM 40 x or higher 40 x or higher
12. Keyboard ASCII ASCII
13. Pointing Optical Mouse/Touch Screen Optical Mouse/Touch Screen

Device
14 Accessories Industrial grade furniture as Industrial grade furniture as

approved during detailed approved during detailed
engineering engineering
15. Additional Comprehensive disk

general maintenance utility for disk
purpose clean sweep/ crash
software (for guard/antivirus, etc. (like
using over "Norton System Works
network by 2000")
servers/workst
ations/PCs)
For NMS server, the dual CPU speed shall be 3.0 GHz or more, RAM shall be 8 GB or
more and the hard disk space shall be 500 GB or more.
The supervisory function of HMI like log, calculations, shall be implemented in
redundant Server/Information workstation, so that no functions are lost due to a signal
failure.
The mouse/keyboard/monitor shall have extra length of cable depending on the location
of CPU


& ITS AUXILIARIES
Printers
Colour Laser
Sl no. Features B&W Laser Printer (A4)
Printer (A3)
1 Paper Size A3, A4 A4
2 Printing Speed 8ppm (Color)

(min.)- in normal
mode for A4 size 24 ppm (B&W) 26 ppm
paper
3 Type Heavy duty (atleast Heavy duty (atleast 30000

50000 pages/month) pages/.month)
4 Resolution (black) 600 dpi 600 dpi

(min.)
5 First page out =<1 min for colour, =<<45 sec

time (with full <45 sec for BW
graphic display)
6 Paper input 500 sheets 500 sheets

capacity (min.)
7 Additional Automatic Duplex Automatic Duplex Printing

features Printing
8 Paper sheets (1 10 reams (A3) 20 20 reams (A4)

ream= 500 sheets) reams (A4)
with each printer
9 Additional 02nos. Black and 1 02 nos per printer

Cartridge/toner/ no. in each colour
ribbon of each per printer
type as used in
printer with each
printer


& ITS AUXILIARIES
Colour Laser
Sl no. Features B&W Laser Printer (A4)
Printer (A3)
10 Communication Ethernet Port (Network Ready Printer) in addition to

port 1no. USB 2.0 port.
01.05.39 Network Switches :
Layer-3 switches shall have the following features:
i 48 X Gigabit Ethernet Port
ii 24 or 48 x 10/100/1000 Base TX ports (STP)
iii SNMP, RMON, VOIP, VLAN, Multi link Trunk support
iv Broadcast/multicast storm control
v Supervisor Engine redundancy capability
vi Redundant Power Supply
vii Integrated Security features (IPS, ACL, Firewall)
viii 10 GB module support for future upgradeability
Expandability/ stackability through a dedicated high speed expansion port. Routable,

remotely manageable, configurable.
One intelligent SNMP manageable mini-UPS for 30 minutes backup shall be provided
with all accessories and software.
Secondary switches shall have the following features:
i) 24 or 48 X 10/100/1000 Base TX ports (STP)
ii) 2 or 4 X Gigabit Ethernet Port
iii) SNMP, RMON, VOIP, VLAN, Multilink Trunk support
iv) Support for stacking with high throughput
v) Broadcast/multicast storm control


& ITS AUXILIARIES
01.05.40 Firewall:
Firewall appliance should facilitate multi-vendor, multi-application environment and

should support third-party products on open alliance. It should support Active-Active
configuration.
The firewall should contain following features:
(a) Stateful inspection of packets.

(b) NAT functionality, including dynamic and static NAT translations
(c) Latest version of SNMP
The firewall must send log information to a separate log server via an encrypted
connection. Firewall logging must not impact firewall performance.
Remote network access to the firewall should only be possible through the
administration interface.
Firewall should also meet the following requirements.
The firewall must not support any unencrypted means of access to the firewall.
It should Monitor ALL network traffic-traffic at Firewalls (Internet and external
networks), in the DMZ and detect known threat through deep packet inspection.
Detect unknown threats via anomaly scanning.
Detect unknown threats via behavior pattern to protect from zero day attacks.
Keep up-to-date on new threats and vulnerabilities.
01.05.41 Specification for Co-axial Cables Cable-C
Co-axial cables are used for high frequency equipment and systems for transmission
and reception purposes and computers. Co-axial cable should have minimum following
characteristics:-
Construction : Solid silica coated, annealed copper conductor.
Low loss solid polyethylene foam, semi

Di-electric :
and spaced construction.
Braided or longitudinal tube of copper or Aluminum

Outer conductor :
giving 100% coverage with slight overlap.
Outer sheath : FRLS PVC


& ITS AUXILIARIES
Diameter over Di-electric : 7.24 sq.mm.
Outer diameter : 10.29 sq.mm.
Nominal impedance : 75 ohms
Nominal capacitance : 20.5 pF/ft.
Nominal attenuation : 8 dB at 1000 MHz Per 100 ft.
01.05.42 Fiber Optic Cable
1.1 This specification describes the minimum general requirements for the design,
manufacture, supply, inspection, installation, testing & commissioning of optical fibre
cable & accessories.
1.2. Bidder shall consider all related activities such as cable stripping, Cable entry in boxes
& panels, cable fibre splicing/fusion, cable performance testing & other services, to
achieve properly documented & operational cable network.
1.3. OFC shall be installed on cable tray, duct bank, cable trench installation as necessary.
For outdoor applications the cable shall be armoured with Poly Ethylene sheathing. In
all cases cable shall be routed through suitable grade HDPE permanently lubricated
protection pipe as per IS-4984, IS-12235 & TEC.G/CDS-08/01 of suitable size @ 53%
fill factor.
1.4. Fiber Optic cables shall be suitable for installation on cable tray, duct bank, cable
trench, racks and direct burial as necessary. Spliced / repaired cables are not acceptable.
1.5. Bidder to ensure that minimum 100% cores are kept as spares in all types of fiber optic
cables.
1.6 Fibre Optic Cables shall be separate for each service, Package, etc. and two (2) or more
services shall not be clubbed i.e. F O Cables for DCS signals, Video signals, any other
signals of CCTV shall not be through the same cable.
2.0 Fiber & Core
2.1 Fiber The optical fiber core shall be of ultra pure fused silica
glass coated with UV-cured acrylate suitable to
withstand temperature of about 80 Deg C continuously


& ITS AUXILIARIES
2.2 Type Fiber optic cables for outdoor applications shall be

single mode fiber type. However, for cable lengths less
than or equal to 1km, multimode fiber cable is also
acceptable subject to Purchaser’s approval.
2.3 Mode Multimode Multimode Single mode Fiber cable

Fiber Fiber cable
cable
2.4 Core Diameter 62.5 ± 2 50 ± 2 9 ± 1 microns

microns microns
(depending upon distance

between source &
destination)
2.5 Cladding Diameter 125 ± 2 125 ± 1 micron

microns
2.6 Cladding non- 1 % max.

circularity
2.7 Core / cladding 3 microns 3 microns 0.5 microns max.

concentricity error max. max.
2.8 Bandwidth @ 850 160 MHz- 500 MHz-Km -

nm Km min min
2.9 Bandwidth @ 500 MHz- 500 MHz-Km -

1300 nm Km min min
2.10 Attenuation @ 850 3.0 dB/Km 3.0 dB/Km -

nm max max
2.11 Attenuation@ 0.8 dB/Km 0.8 dB/Km -

1300 nm max max
2.12 Attenuation@ - - 0.37 dB/Km max

1310 nm (outside plant)
1 dB/Km max (inside

plant)


& ITS AUXILIARIES
2.13 Attenuation@ - - 0.22 dB/Km max

1550 nm (outside plant)
1 dB/Km max (inside

plant)
2.14 Numerical 0.275 + 0.200 + 0.015

Aperture 0.015
2.15 Number of Fibers 4 (minimum)

per core / tube
2.16 Fibre coloring Shall conform to EIA/TIA-598
2.17 Fiber Proof test As per IEC/EIA & other international standard.
2.18 Coating Diameter As per IEC/EIA & other international standard.

Test
2.19 Strength member Aramid Yarn to reinforce the integrity of data

transmission
2.20 Buffer Tube filling Thixotropic jelly or better material
2.21 Core wrapping / Water Swellable Tape / Suitable Water Blocking Gel
Moisture barrier
2.22 Loose tube Polyamide/PBTP or other acceptable Thermoplastic

material
3.0 Cable Construction
3.1 Design Loose Tube design
3.2 Type Dual jacket
Armoured with Poly Ethylene sheathing (for outdoor

applications)
3.3 Buffer Tubes Shall be stranded around the central member utilizing
reverse oscillating lay (ROL)
3.4 Interstices / Thixotropic jelly or better material

cable filling


& ITS AUXILIARIES
3.5 Blank fillers Shall be used as necessary to maintain circular cable

structure. Fillers shall be flame retardant and moisture
resistant.
3.6 Inner Sheath Flame retardant & UV resistant Polyethylene
3.7 Outer Jacket High density Polyethylene (HDPE) minimum 1.5 mm thick,
Flame retardant & UV resistant
3.8 Outer Colour Orange
3.9 Armour Co-polymer coated steel tape, corrugated and wrapped

around the inner jacket to provide additional compression
strength and termite & rodent protection
3.10 Ripcord Two highly visible ripcords shall be placed under the jacket
/ armour for easy outer jacket / sheath removal.
3.11 Central Shall be provided for outdoor/indoor application so as to

Strength prevent any physical damage. Consists of a dielectric Fiber
member Glass reinforced plastic (GRP) and Buckle resistant material
to provide both tensile and anti-buckling strength to the
cable
3.12 Spare Cores Minimum 100%
4.0 Cable Specifications
4.1 Details marked Manufacturer’s Name, Month and Year of Manufacturer,

at every meter Coded description of the cable based on telcodia’s (bell
on outer core) SR-2014 suggested optical cable code (SOCC),
sheath. Sheath identification Number, Sequential Length marking
in meter, A telephone Handset symbol to distinguish
communication from power cable as per NESC section-
35G.
4.2 Life Fiber Optic cable shall provide a long life expectancy of
Expectancy minimum 25 years under continuous operation without
degradation to optical or mechanical performance.
4.3 Stripping All layers easily removed with Commercially available

Ability tools


& ITS AUXILIARIES
4.4 Storage - 20 0 C to 60 0 C
Temperature
4.5 Operating - 20 0 C to 70 0 C
Temperature
4.6 Data Speed 1 Gbps minimum

performance
4.7 Drum The cables shall be supplied in non-returnable strong

wooden (or alternatively steel) drums provided with lagging
of adequate strength, constructed to protect the cable against
any damage and displacement during transit, storage and
subsequent handling and stringing operations in the field.
5.0 Installation / Mechanical characteristics:
5.1 Minimum 20 X D (D=core Diameter) - During Installation, Short

bending radius Term, loaded
(IEC 60794-1-
2-E11A) 15 X D (D=core Diameter) – Installed, Long Term, No load
5.2 Maximum During Installation: 2000 N at 0.25 % strain

Tensile
Load/Strength Installed: 1000N
(IEC 60794-1-
2-E1)
5.3 Method of Directly laid in cable trays / duct bank / clamped with
laying available structure
5.4 Pulling Ordinary cable grips
6.0 Test Specification (EIA/TIA – STD455 or Equivalent):
6.1 Impact 2000 Impacts minimum

Resistance
6.2 Crush 4000 N/10cm minimum

Resistance
6.3 Compressive 3000 N minimum


& ITS AUXILIARIES
Strength
6.4 Moisture/Water Water blocking layer, Cable shall withstand water

Resistance penetration when tested with a one meter static head or
equivalent continuous pressure applied at one end of a one
meter length of filled cable for one hour. No water shall
leak through the open cable end.
7.0 Tests Following minimum test as per any approved standard

shall be carried out on the cables:
a. Attenuation and Dispersion characteristics tests

b. Proof Tests
c. Macro-Bend resistance Test
d. Mechanical Test
e. Low and High Temperature cable Bend Test
f. Impact resistance Test
g. Compressive strength Test
h. Tensile strength Test
i. Cable Twist test
j. Cable cyclic flexing test
k. Environmental characteristics Test
l. Temperature cycling test
m. Colour permanence Test
n. Cable Aging test
o. Water penetration test
p. Lightning Test
q. Kink Test
r. Crush Test
8.0 Standards Optical cable shall conform to
i) IEC 60794/IEC 60793 & EIA/TIA 455.
ii) Low smoke (IEC 1034 –light transmittance of

80%)
iii) Halogen free (IEC 754: 1&2 - maximum acid gas

generation shall be 2% by weight and PH >4.3)
iv) Fire & flame retarded (IEC 331, IEEE 383)
v) Rodent resistant
vi) Crush Resistant (EIA -455-41)


& ITS AUXILIARIES
vii) Impact Resistant (EIA -455-25)
Bidder shall submit Type test report for review, conform to

IEC 60794, IEC 60793, IEEE 383, IEC 754: 1 & 2, IEC
331, IEEE 1034 and EIA/TIA standard.
Colour codes shall be as per EIA/TIA 598-A.
01.05.43 Fiber Optic splicer, terminator and tool kit box
Bidder shall provide 1 no. new unused Fiber optic splicer terminator tool kit with box
comprising of splicer and fusion jointer and tool kit shall comprise of cutter, stripper,
polishing tool, handheld microscope, heat shrinkable sleeve, scissor, knife etc as
required for maintenance and commissioning.
01.05.44 Twisted Pair Cable:
Cat - 5e cable Cat - 6 cable
Conductor
No of Pairs : 4 Pairs 4 Pairs
Material : Annealed Bare Copper Annealed Bare Copper
Size : 24 AWG 23 AWG
Insulation :
Thickness : 0.254 mm -
PO – Polyolefin / FRPE PO – Polyolefin / FRPE

Material :
(PVC) (PVC)
Outer Shield : Binder Tape Unshielded
Binder Tape :
Thickness :


& ITS AUXILIARIES
Aluminum Foil- Aluminum Foil-Polyester

Material :
Polyester Tape Tape
Coverage : 100% 100%
Drain Wire Yes NO
Stranded (7/32) , 24
Thickness :
AWG
Material : Tinned Copper
Outer Jacket
Material : Industrial Graded PVC Industrial Graded PVC
Outer Jacket Nominal

: 0.762 mm 0.24 mm
wall thickness
Outer Jacket Ripcord : No Yes
Mechanical
Characteristics
(Overall)
Installation Temperature
: -25 to +75 Deg.C -25 to +75 Deg.C
Range:
Operating Temperature
: -40 to +75 Deg.C -40 to +75 Deg.C
Range:
Tensile strength :
Max. Recommended
: 177.928 N 200.169 N
Pulling Tension


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Min. Bend Radius/Minor

: 12.700 mm 63.500 mm
Axis
Min. Bend/Installation :
NEC/(UL)
: CMR CMR
Specification
Electrical
Characteristics
Nominal Mutual
: 49.215 pF/m 50.8555 pF/m
Capacitance
Nominal Velocity of
: 70% 67%
Propagation (VP)
Max. Delay : 538 ns/100 m 538 ns/100m
Max Delay Skew : 45 ns/100 m 38 ns/100m
Max. Conductor DC
: 9.38 Ohm/100m 8.2 Ohm/100m
Resistance @ 20deg. C
Impedance :
Attenuation min. At
: 22 dB at 100 Mhz 18.9 dB at 100 Mhz
100m
EU Directive
EU Directive
2011/65/EU(RoHSII),
Applicable standards : 2011/65/EU(RoHSII), MII
MII Order # 39 (China
Order # 39 (China RoHS)
RoHS)


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Test
UL 1666 Vertical Riser, UL 1666 Vertical Riser,

Flame Test :
CSA FT4, IEEE 1202 CSA FT4, IEEE 1202
Pair Colour Code
White / Blue Strip &

1st Pair White / Blue Strip & Blue
Blue
White / Orange Strip & White / Orange Strip &

2nd Pair
Orange Orange
White / Green Strip & White / Green Strip &

3rd Pair
Green Green
White / Brown Strip & White / Brown Strip &

4th Pair
Brown Brown
01.05.45 NOTE: All cables near high temperature zone shall be high temp cables, which shall be
terminated at a junction box in normal temperature zone. Thermocouple extension
cables and copper conductor cables for high temperature applications shall be with
insulation of individual conductor and outer sheath of extruded FEP (i.e. Teflon) as per
VDE 0207 Part 6 and ASTMD 2116. The thickness of insulation shall be 0.5 mm
nominal (i.e. 0.4 mm minimum). These cables shall be single / Multipair twisted &
shielded.
01.05.45 CABLE GLANDS
Sno. Feature Minimum Requirement
1 Type Double compression
2 Entry Thread ½“ NPT
3 Material Brass
4 Finish Cadmium Plated


& ITS AUXILIARIES
5 Protection IP-54 or better
6 Accessories Neoprene gasket, Locknut, Reducer etc.
01.05.46 CABLE CONDUITS
1. Conduits shall be generally used for interconnecting cables from field instruments to
Local JBs. All unarmoured cables shall be installed in conduit. All rigid conduits,
couplings and elbows shall be hot dipped galvanized rigid mild steel in accordance with
IS: 9537 Part-I (1980) and Part-II (1981). The conduit interior and exterior surfaces
shall have continuous zinc coating with an overcoat of transparent enamel lacquer or
zinc chromate. Flexible metal conduit shall be heat resistant lead coated steel, water
leak, fire and rust proof. The temperature rating of flexible conduit shall be suitable for
actual applications. The flexible metal conduit shall be constructed with an interlocked
corrosion resistant steel & manufactured in accordance with UL1 & NEC Article 348.
2. The Bidder shall install conduits according to the general routing as approved by
Purchaser / Consultant and shall coordinate conduit locations with other works.
3. All grounding bushings within all enclosures shall be wired together and connected
internally to the enclosure grounding lug or grounding bus with 8 AWG bare copper
conductors. Conduit runs to individually mounted equipment shall be grounded to
the Purchaser’s cable tray grounding conductor with 12 AWG bare copper
conductors. All grounding bushings, clamps and connectors shall be subject to
approval of the Purchaser / Consultant.
4. All rigid conduit fittings shall conform to the requirements of IS: 2667, 1976.
Galvanized steel fitting shall be used with steel conduit. All flexible conduit fittings
shall be liquid tight, galvanized steel. The end fittings shall be compatible with the
flexible conduit supplied.
5. All individually mounted equipment and devices shall be connected to the supply
conduit, using not more than one meter of flexible conduit adjacent to the equipment or
device. Flexible conduit shall be installed in all conduit runs, which are supported by
both building steel and structures subject to vibration or thermal expansion .This
shall include locations where conduit supported by building steel or foundation
becomes supported by steam generator framing.
6. Special areas, such as Control Rooms in which external noise is to be minimized,

shall have flexible conduit in conduit runs where the runs cross from the main
building framing to the Control Room framing.

& ITS AUXILIARIES
7. Conduit supports shall be furnished and installed in accordance with these

specifications. Support material shall comply with the requirements.
a) Hanger rods shall be 12 mm diameter galvanized threaded steel rods.
b) Single conduit support shall be one-hole cast straps and clamp backs unless other types
are acceptable to the Purchaser. Multiple conduit bank supports shall be constructed of
special galvanized support channels with associated conduit clips.
8. Conduit sealing, explosion proof, dust proof and other types of special fittings shall
be provided as required by these specifications and shall be consistent with the area and
equipment with which they are installed. Fittings installed outdoors and in damp
locations shall be sealed and gasketed. Hazardous area fittings and conduits
sealing shall conform to NEC requirements for the area classification.
9. Bidder shall provide double locknuts on all conduit terminations not provided with
threaded hubs and couplings. Water tight conduit unions and rain tight conduit hubs
shall be utilized for all the application which shall be exposed to weather. Moistures
pockets shall be eliminated from conduits.
10. Conduits shall be securely fastened to all boxes and cabinets.
01.05.47 Cable Sub Trays & Support
1. The cable sub-trays and the supporting system, to be generally used between
Local/Group JBs and the main cable trays and the same shall be furnished and installed
by the Bidder. It is the assembly of section and associated fitting forming a rigid
structural system used to support the cable from the equipment or instruction enclosure
up to the main cable trays (trunk route).The material of cable tray shall be GI. For Main
cable tray details shall be as per Electrical Volume of the specification.
2. The covers on the cable sub-trays shall be used for protection of cables in areas where
damage may occur from falling objects, welding spark, corrosive environment, etc. &
shall be electrically continuous and solidly grounded. The cable trays shall not have
sharp edges, burrs or projections injurious to the insulation or outer sheath of the cables.
3. The supporting arrangement of cable tray system shall be able to withstand the weight
of the cable and cable tray system. The supporting interval shall not be more than the
recommended span for the above loading for the type of cable tray selected. The tray
shall not overhang by more than one meter from the support at the dead end. As far as
practicable the cable sub-tray system shall be supported from one side only, in order to
facilitate installation and maintenance of cables.


& ITS AUXILIARIES
4. The Bidder shall furnish and install the estimated quantities and size of sub trays /
troughs including all required fittings and adaptors on as required basis
01.05.48 INSTRUMENTATION CABLE TRAY
Sl.no. Feature Minimum Requirement
1 Material Mild Steel as per IS-2062
2 Thickness Not Less than 2 mm
Hot Dip galvanised as per IS-2629, 2633 & Zinc

3 Finish
Coating as per IS-4579
4 Length 2.5 Mtr. +/- 10 mm
5 Width W +/- 3mm
6 Inward Bend 25 mm
7 Coupler Plate Thickness 2 mm, length 100 mm, Width 50 mm
8 Coupler plate material MS with Hot dip galvanised
Nuts, Bolts, washer

9 As required/ Hot dip galvanised
etc.
10 Cover Dome Fixed type, Thickness 1.2 mm (Minimum)
11 Cover Material Hot dip galvanised MS sheet
01.05.49 Density Measurement
1. Following types of density meters shall be used based on process fluid and application
requirements:
i. Nucleonic type
ii. Ultrasonic type
2. For nucleonic type density meter, type of detector shall be selected to suit the
application and source strength.
3. The density meter shall include a source with housing, detector with housing control
unit and mounting hardware.
4. The radiation source shall be of sufficient intensity to provide an accurate signal and
response to meet the particular process and piping requirements. The nuclear source


& ITS AUXILIARIES
head shall meet the personnel safety requirements of the Nuclear Regulatory
Commission (NRC).
5. The radiation port of the source head shall have a manually operated mechanical shutter
with lock and key that can be opened and closed without removing the source head. The
shutter shall have a locking device to accommodate a padlock and to permit locking in
the closed position with visible indication of shutter position.
6. Type of detector shall be selected to suit the application and source strength.
7. Nucleonic Density meter shall be absolutely safe and reliable. The radiation source
shall be safely double encapsulated in a stainless steel with lead lining capsule so that
no radioactive material can escape from the protective source container.
8. In addition, independent security systems shall be included to ensure that gamma
radiation is only released from the source container when the measurement chamber is
closed and that the source containers are always locked and remains locked while the
chamber is open. This must not only be guaranteed under regular operating conditions,
but also in the case of false operation and power loss.
9. The Ultrasonic sensor shall be insensitive to gas bubbles and transmitters shall be
microprocessor based and shall use digital signal processing technique for signal
conditioning.
10. The Ultrasonic controller shall have data storage facility.
11. The Density meter shall be capable of temperature compensation automatically by
utilizing temperature sensor signal and in addition manually by entering temperature
value via keyboard entry.
12. The controller shall be SMART microprocessor based and have provision of all
required data of the tested part like material composition, absorption coefficients,
temperature compensation, selection of aperture and radiation source, measuring times
and tolerances of the compact density are pre-adjusted and recorded by the controller.
13. The Control unit transmitter shall be capable of processing gauge head signals,
temperature input, flow rate input. It shall have totalized display and individual
parameters display of selected variables.
14. All equipment necessary for standardization and calibration shall be provided.
15. The detector and the transmitter shall have IP65 or better enclosures.
16. The transmitter shall be suitable for surface mounting, with access to all terminals from
the front. Any required signal converter shall be within the transmitter enclosure.
17. The density devices and all associated equipments shall be as per manufacturer’s
standard, heavy-duty design, as required for the application specified herein.
18. Provision for the nitrogen/ compressed air purging facility in the sensor shall be
provided for cleaning the build-up of the material.
01.05.50 Oxidation Reduction Potential meter ( ORP)
ORP Range : +/- 999mV
ORP Resolution : 1mV
OPR Accuracy : +/-5mV


& ITS AUXILIARIES
Battery Life : approx 700hrs of continuous use
(Nicd re-Chargable)
Environment : 0-50*C; RH max 95%
01.05.51 LIE/LIR (Local Inst. Encloser/Local Inst. Rack)
LIE (Local Inst. Encloser)
Local Instrument Encloser conforming to IP-55 and is located outside area.

Transmitters local indication shall be visible through transparent (Acrylic) windows
slots. In LIE max. Transmitters shall be installed 3nos with 20% spare provision of
transmitter mounting shall be kept.
All Pressure and Differential Pr. Switches shall be mounted in LIE having suitable
isolation valves on Incoming lines and drain lines. All drain lines shall be connected to
suitable drain/blow down headers
LIR (Local Inst. Rack)
Inside Building other transmitters/switches shall be mounted in LIR fabricated of

angles and pipes having suitable /drain header and top/bottom entry through suitable
bulk head fittings Four type of LIR can be installed.
1no.- Type Transmitters rack
2nos. Type Transmitters rack
4nos.-Type Transmitters rack
6nos.- Type Transmitters rack
01.05.52 Control Panel
ALL PLC Panel dimensions, colour shall be uniform throughout the Control Equipment
Room (preferably size 2000 mm x 1200 mm x 800 mm with 100 mm black Base
channel and 15mm anti-vibration pad however same shall be decided during detailed
engineering. Colour of panels shall be follows as :
• Front & Rear and Top colour RAL 9002 (Grey white), End Panel side RAL5012(Light
Blue) Internal colour shall be Brilliant white
• All panels of width 800mm or more shall open with double door from front and rear
sides.


& ITS AUXILIARIES
• Panel thickness shall be Side & Top minimum 1.5mm, front and rear door thickness
shall be 2mm, bottom plate thickness 1.5/2mm and gland plate removable type
thickness 3mm.
• Inside Panel minimum 250mm height space shall be provided from bottom gland plate
to Terminal blocks (TBs).
• Panels shall be fitted with proper illumination with LED lamp at Front and at Rear
(2nos on each side for panel width > 600mm & 1 no. on each side for panel width upto
600mm ) with door interlock switches (. Proper cooling fans (1 no. fan at Front & 1no.
fan at Rear) with louvers shall be provided.
• Separat termination panels for control system shall be provided. for DI, DO/Interposing
relays.
• Dedicated Un-fused TB for 24VDC incomer for SOV shall be provided inside the
control system/ PLC Power distribution panel.
• Panel wire way channel shall be minimum dimension 60mm x 100mm, 40mm x 100 on
requirement basis and shall be decided during detailed engineering.
Inside panels side mounting card shall not be installed. Indoor located , free standing
vertical type system cabinets shall be provided with IP-42 enclosure, double doors with
neoprene gaskets
Sufficient number of power receptacles with disconnect switches shall be installed within
panels/desk/enclosure & racks
01.06.00 PROCESS CONNECTION PIPING

The bidder shall provide, install and test all required material for completeness of
Impulse Piping System, Sample Piping System and Air Piping System as per the
requirements of this Sub-section, enclosed installation drawings and source
connection drawings on as required basis for the connection of instruments and control
equipment to the process and make the system complete. The Bidder shall furnish during
detailed engg. all relevant drawings, material and tech. specifications of various items
service wise for Employer's approval.
All materials supplied under this Sub-section shall be suitable for intended service,
process, operating conditions and type of instruments used and shall fully conform to
the requirements of this specification. The material offered by the Bidder shall be from
reputed, experienced manufacturer whose guaranteed and trouble free operation has
been proven.


& ITS AUXILIARIES
01.06.01 Air Supply Piping
i. All pneumatic piping, fittings, valves, air filter cum regulator and other accessories
required for instrument air for the various pneumatic devices/ instruments shall be
provided.
ii. This shall include as a minimum air supply to pneumatically operated control valves,
actuators, instruments, continuous and intermittent purging requirements of Local
Instrument Enclosures (LIE) etc.
iii. For individual supply line and control signal line to control valve, 1/4-inch size light
drawn tempered copper tubing conforming to ASTM B75 shall be used. The thickness
of cu-tubing shall not be less than 0.065 inch and shall be PVC coated. The fittings to
be used with copper tubes shall be of cast brass, screwed type.
iv. All other air supply lines of 1/2 inch to 2 inch shall be of carbon steel hot dipped
galvanized inside and outside as per IS-1239, heavy duty with threaded ends. The
threads shall be as per ASA B.2.1. Fittings material shall be of forged carbon steel
A234 Gr. WPB galvanized inside and outside, screwed as per ASA 132.1. Dimensions
of fittings shall be as per ASA 1316.11 of rating 3000 lbs.
01.06.02 Purge Air Connection for Air and Flue Gas Applications
i. The continuous purging with instrument air shall be done, for all air and flue gas
measurements excepting instrument air and service air instruments, at the process
source connection end. Necessary arrangements required for continuous purging shall
be provided inside all the air and flue
ii. For intermittent purging with service air, necessary arrangement inside all the air and
flue gas enclosures shall be provided. The SS three way valve provided in the SS
tubing shall be used for isolating the transmitter & connecting the service air quick
disconnect line.
01.06.03 Installation and Routing
Instrument Piping System
For steam and liquid measurements, the impulse pipe should preferably slope
downward from source connection to instrument and instrument shall be installed
below the source point. If due to any reason instrument is installed above the source
point, the impulse pipe shold slope upwards continuously and a ‘pigtail’ should be
provided at the instrument to assure water seal for temperature protection. For vacuum
measurements, instruments shall be installed above source point and impulse pipe
should slope upwards.


& ITS AUXILIARIES
1. Impulse piping for air and flue gas shall slope upwards and instrument shall be installed
above source point. If this requirement cannot be met special venting or drain provision
shall be provided with vent & drainpipes. This drain is to be connected to plant drain
through open funnel also.
2. All impulse piping shall be installed to permit free movement due to thermal expansion.
Wherever required expansion loops shall be provided. Expansion joints shall be
provided wherever required especially for impulse piping coming in the furnace area.
3. Special accessories such as condensing pots/ reservoirs shall be provided and installed
wherever required. In any case condensing pots shall be provided for all level
measurements in steam and water services, all flow measurement in steam services and
flow measurements water services above 120°C. For drum/ separator level measurement
required balancing chamber shall be provided.
4. Colour coding of all impulse pipes shall be done by the bidder in line with the colour coding
being followed for the parent pipes.
01.06.03 Instrument Air & Service Air Piping/ Tubing System
Instrument air & service air headers and their branches with all associated fittings &
accessories shall be provided for giving supply to all consumers, as per the
requirements. Air piping shall be installed always with a slope of over 1/100 to prevent
accumulation of water within the pipe.
Single and multi tubes shall run with the minimum number of changes in direction.
Suitable identification tags shall be provided for easy checkup and for connections.
01.06.04 Piping/ Tubing Support
Impulse piping and sample piping shall be supported at an interval not exceeding 1.5
meters. Each pipe shall be supported individually using slotted angle mounted clamps
with necessary fixtures. Tubing shall run in proper perforated trays with proper
cover. Tubing shall be supported inside the trays by aluminium supports. Hangers and
other fixtures required for support of piping and trays shall be provided, either by
welding or by bolting on walls, ceilings and structures. Hanger clamps and other
fastening hardware shall be of corrosion resistant metals and hot dip galvanized.
01.07.00 INSTALLATION, CALIBRATION, TESTING AND COMMISSIONING –

INSTRUMENTATION WORK.
General Requirements


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(a) This specification covers the standards, scope of work, documentation, scope of
installation, testing and commissioning of instrumentation work and the various
requirements to be adhered during the execution of the instrumentation works.
Instrumentation works shall be performed in accordance with this technical
specification and various other drawings and schedules submitted and approved by the
Consultant during the execution and the instructions from the Consultant’s or
Purchaser’s Engineer-in-Charge or his authorized representatives during the progress of
the work. Any confusion in any clause should be pointed out by the Bidder and should
get clarifications prior to quoting, otherwise decision of the Engineer-in-Charge shall be
final. All consumables required for the job shall be supplied by the Bidder.
(b) Any recalibration of the instruments required during the loop checking and
commissioning shall be done by the Bidder free of cost during the commissioning of
PLC. All the control systems and protection & interlocking system supplied shall be
checked and commissioned by the Bidder.
(c) All materials fabricated and installed shall conform to the latest edition of applicable
codes and standards. Work shall be carried out in accordance with the various
International & Indian Standards and any local statutory regulations as applicable, listed
below, and though not limited to them:
ISA : Instrument Society of America, Standards & Recommended Practices.
ANSI : American National Standard Institute, B2.1 Pipe Threads B16.5 Steel
Pipe Flanges &Flanged Fittings.
ISI : Indian Standards Institute.
NEC : National Electric Code.
API : American Petroleum Institute.
ASME : American Society of Mechanical Engineers.
IBR : Indian Boiler Regulations.
NFPA : National Fire Protection Association.
BS : British Standards.
IS : Indian Standards.


& ITS AUXILIARIES
The work shall also conform to installation standards, approved hook up drawings, and
support standards. Layout drawings or any other drawings, documents or schedules
submitted by the Bidder and approved by the Purchaser / Consultant.
(d) Only the best trade practices shall be used and highly competent engineers, supervisors
and skilled workers shall be employed for execution of the job. Utmost care shall be
taken during execution of this work to avoid any untoward accidents. All safety rules
and precautions shall be taken care of. The Bidder shall carry out his work in neat,
workmanlike manner. Any substandard quality of job can be rejected by Engineer-in-
Charge. No extra charge can be claimed for such re-work.
(e) The Bidder shall protect all instruments, fittings, tubings and painting during
construction or while in storage from physical damage, contamination by dirt, sand,
water, and any other foreign material.
(f) All site-mounted instruments, junction boxes, air headers, tubing and wiring
terminations shall be labelled or tagged in a manner approved by the Engineer-in-
Charge. Terminals for electrical connections shall be numbered and identified to
indicate polarity, ground connections, test connections and any other pertinent
information.
01.07.01 Erection Practices and Guidelines
The specification provides the general guidelines to be followed for the warehousing,
handling, testing, erection, pre-commissioning checks and commissioning of various
types of instruments and accessories.
1. The guidelines provided shall not be deemed as an effort to describe the entire work
involved or to identify the steps and sequence to be adhered to in the erection of specific
work items.
2. The basic intent is to establish a sound engineering practice to be adopted throughout.
3. Equipment manufacturer’s recommendation, where available, shall prevail over the

guidelines furnished in this section and in case of any contradiction between the
stipulations.
4. For special instruments viz. analyzers etc., the specification furnished are of general
nature only and manufacturer's recommendation shall be strictly followed as guideline
for erection and commissioning.
5. The specification shall not be treated as comprehensive. Any activity, not specifically
mentioned but felt essential or advisable from good engineering consideration shall be
performed.


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01.07.02 Field Instruments
Guidelines provided herein shall be adhered to while erecting an instrument or

accessory in the plant beyond Control Room areas.
1. Care should be taken to avoid damage to the instruments during handling and
transportation. Special care shall be taken while handling breakable, spillable, fragile
and delicate items.
2. Before erection, all instruments shall be subjected to calibration and other functional
checks at Bidder's site laboratory. The instruments shall be unpacked with utmost care
and as per instructions furnished on the respective packages, using appropriate tools and
implements.
3. All instruments, jigs, tools and tackle for the purpose of performing the tests shall be
provided by Bidder.
4. All instruments shall be tagged with engraved aluminium / stainless steel tag plates
and shall be secured to the instrument with metallic wire fasteners, during the test.
5. For instruments found acceptable and conforming to the declared

performance parameters of the manufacturer, the test report shall be prepared.
6. Minor repairs and adjustments of the instruments shall be performed by Bidder.

Once the defective instrument has been successfully repaired, it shall again be
subjected to calibration and functional checks, as indicated above.
7. A record of such repairs and adjustments shall be systematically maintained by Bidder.
8. For instruments where the extent of damage is such that the same cannot be repaired at
site, a failure report shall be generated by Bidder, enumerating the nature of fault /
damage. Cases where the damages are only superficial and which does not affect the
appearance and performance of the instrument/s, the decision as to whether such
instruments are fit for erection shall solely lie with Purchaser / Consultant.
9. In no case, erection work shall be taken-up in areas where heavy equipment movement
is foreseen, major welding activity is under progress, heavy structural items are being
erected or any other major activity is being carried out or is anticipated, which may
cause damage to the erected instrument or its support.
10. If any erected instrument or its accessories are found to be vulnerable to damage or to
be fouling / interfering with progress of other activities in the area, same shall be
dismantled / removed. During re-erection of such instruments, all the necessary steps as
indicated in the specification for the erection of the instrument shall be carried out
afresh.

& ITS AUXILIARIES
11. After erection, the instruments shall be covered with transparent polyethylene sheets to
protect from unauthorized handling.
12. Coloured PVC adhesive tapes shall be put on the polyethylene cover to indicate various
stages of activities. Red tape shall indicate erection under progress. Yellow tape shall
indicate completeness of erection. Blue tape shall imply approval of erection and Green
tape shall signify the commissioning of the instrument. Adhesive paper tapes shall be
fixed on the respective tapes to inscribe the dates of completion of activities
13. Location of field instruments shall be consistent with tapping points on pipes and
equipment.
14. No field mounted instrument shall be installed in such a manner that it depends on
rigidity of the impulse piping or the electrical connection to it for support.
15. Handrails shall not be used, in general, for mounting or supporting instruments.
16. The place where the instrument is to be installed must be easily accessible from nearest
floor / platform level and there must be enough clear space to allow maintenance work
and lay-down.
17. The installed position must be such as not to cause any inconvenience to repair,
removal, observation, inspection and maintenance of the installed equipment and other
items nearby.
18. The nearby high temperature equipment or process piping shall not give rise to any
injurious effect to instruments.
19. There shall be no safety valve or effluent drain point which may cause injurious
effect near the instrument. In general, no instrument shall be erected in areas prone to
vibration.
20. Instruments which are outside the building or shed and are not located within
transmitter rack shall be provided with protective cover or canopy to provide effective
protection against dust, rain, sun etc. The cover shall be provided immediately after
mounting the instrument.
21. All clamps, supports, stands etc. required for installation and erection of instruments
and their accessories, shall be painted.
22. No field mounted instruments shall be installed without simultaneously taking up

impulse line work connected with the instrument.
23. Proper precaution is to be taken to protect the installations, instruments, accessories,

devices etc. by isolation / removal from possible damages during flashing, pressure
testing of main pipe lines, air headers, vessels, equipments etc.

& ITS AUXILIARIES
24. Wherever practicable the height of the instrument from its working floor / platform
shall be between 1000-1400 mm. The illumination at the locations where instruments are
located shall be adequate so that the scales can be read unassisted.
25. Sub-trays, where required, shall be erected for proper routing of the cables and tubes and
no cable shall be laid unsupported.
26. The indicating meters shall be oriented properly so that the scale can be read unassisted
and unobstructed from the approach floor / platform.
01.07.03 Pressure / Differential Pressure (DP) Transmitters / Level Transmitters
Pressure and DP transmitters shall in general be transmitter rack mounted or shall be

mounted locally on fabricated structures. Displacer type level and transmitters shall,
however, be mounted directly on the vessel / stand pipe attached to the vessel.
1. All manifolds, cocks and valves shall be pressure tested at rated hydraulic test pressure.
All air line and draft / vacuum service cocks and valves shall be leak tested.
2. Manifolds / valves shall be mounted on / connected to transmitter at Bidder's

workshop / site and the assembly shall be leak tested after completion of the
plumbing. The leak test shall be performed with compressed air and soap solution
at pressure not exceeding the maximum overload pressure of the transmitter.
3. All tests on the transmitters shall be performed after mounting / connecting of the
manifold / valve assembly.
4. For transmitters located in transmitter racks, the erection activities shall normally
include mounting of the transmitter with its manifold / valve assembly on appropriate
support structures in the rack with proper fasteners, viz. U-clamps, bolts etc.,
proper levelling of the transmitter, all pipe connections from process to the
transmitter, piping from transmitter to drain valve / vent valve, supporting / clamping
of the valve, pipe connections from transmitter / valve to drain pot / drain header /
nearest system drain, cabling from transmitter to the rack / external junction box
using flexible conduits, termination of the cable with appropriate lugs, sleeves
and markers, mounting and connecting all settling chambers / damper pots /
siphons etc., as applicable.
5. All cables shall be cross-ferruled at both the junction box and element head end.
01.07.04 Pressure Gauges / Switches, Differential Pressure Gauges / Switches
Pressure gauges / switches and differential pressure gauges / switches shall either be
directly mounted on the process pipeline or shall be mounted on local brackets, gauge
boards or open racks depending on accessibility and maintainability


& ITS AUXILIARIES
01.07.05 Junction Boxes and Pull Boxes
Bidder's scope of erection of junction boxes shall include mounting of junction boxes in
appropriate locations indicated in the drawings, fabrication of necessary supports,
pedestals, brackets, frameworks etc., for erection and final painting of the structures and
the junction boxes.
1. Junction boxes and pull boxes shall be provided for multi-pair / multi- triad / multi-
core cables and compensating cables.
2. Junction boxes shall be provided either with un-drilled removable gland plates or
with knock-outs. Before installation gland plates shall be drilled / knock-outs shall be
removed based on the cable schedule.
3. Ideally the height of junction boxes shall be 1000-1400 mm from the approach floor
level.
01.07.06 Transmitter Racks
1. The location of transmitter racks shall normally be pre-assigned. However,

depending on site conditions, some may have to be relocated at site
2. Impulse lines shall normally terminate at a bulk head union at the top or back side
of the closed type racks. In cases when bulk heads are not available, entry holes
shall be drilled (not gas cut) and properly sealed after installation.
5. Bidder shall suitably support the drain / vent valves, manifolds etc. With the necessary
clamps, bolts, washers etc.
6. Bidder's scope of work shall also include terminating all rack mounted transmitters
with electrical wires / cables in flexible conduits up to the terminal blocks with
necessary cable and conduit supports, clamps, glands, sleeves, conductor markers /
ferrules, lugs etc.
7. Cabling from transmitter rack-up to local junction box through flexible conduits,
supporting and fixing of conduits at both ends, glanding of cables, ferruling and
terminating are in Bidder's Scope of Work.
01.07.07 Conduits
Flexible and rigid conduits shall be used for connecting instruments to the junction
boxes or nearest trays / sub-trays. The activities shall include threading, plumbing,


& ITS AUXILIARIES
routing, supporting, connecting to cabinets, cleaning, sealing grounding, painting

and other related activities, as required.
1. Where threads are required to be formed they shall be cut and cleaned before
conduit reaming.
2. Ends of all conduits shall be reamed to remove all burrs and rough edges.
3. Cutting oil shall be used for threading operation and the dies shall be kept sharp.
4. Rigid conduits shall be installed in exposed runs either parallel or

perpendicular to dominating surface, with right angle turns made of
symmetrical bends only.
5. Conduit shall not be installed on the outside face of exposed columns but shall be
routed on the web or on the inside of the flange of column.
6. Metal conduits shall be joined by threaded conduit couplings.
7. A run of conduit shall not contain more than the equivalent of four quarter bends
including those immediately at the outlets or fittings of cabinets.
8. Precautions shall be taken to prevent accumulation of water, dirt, concrete, foreign

material etc. in the conduit.
9. Bending radius of the rigid conduits shall not be less than six times the internal
diameter of the conduits.
10. Rigid conduits shall be regularly clamped at intervals of not more than 600 mm.
11. Flexible conduits shall be installed in conduit runs across expansion joints.
12. All screwed joints shall be properly sealed with sealing compound to make them
thoroughly water proof.
13. Loop shall be provided in the flexible conduit while joining with rigid conduit,
enclosure or detector. Flexible conduit shall not be kept under tension.
14. Flexible conduits shall essentially be used for connecting instruments or equipment
subjected to vibration, expansion or thermal movement. In all such cases adequate loop
lengths shall be provided to allow free movement at the connected points.
15. Not more than 40% of conduit area shall be taken up by cables.
01.07.08 Sub-trays / Supports
Erection of sub-trays / supports shall include sub-tray sections up to the main trays. In
areas where main trays are not available, tray sections shall be laid up to the master
junction boxes / local panels / cable spreader areas. Bidder's scope of work shall include

& ITS AUXILIARIES
laying and supporting of trays, fabrication of trays wherever required, painting of trays
and supports and associated minor civil work wherever required.
1. Normally slotted GI trays or aluminium trays shall be used.
2. Trays shall be used to run SS / PVC coated copper tubes and electrical cables and shall
be mounted on steel structures and along the pipe racks wherever convenient. Special
stands / supports have to be fabricated wherever required.
3. The erection of trays shall include fabrication, welding and installation of racks
including supports from structural and installation of various sizes of tray in position.
Trays shall be screwed or bolted to the supports.
4. The supports shall be welded to the main structures, grouted in the walls / roof or
welded to the plate inserts. Welding of supports to main equipment / piping shall never
be allowed. Welding or gas cutting of trays shall not be allowed.
5. The scope of work shall also include the supply, fabrication and fixing of supports,
bends, offsets, corners, tees, crossings etc. as per requirement.
6. Civil / masonry works like grouting, providing inserts, chipping the concrete, bricks etc.
for providing supports etc. shall be included.
7. Bidder shall arrange to provide hangers, jigs, inserts and other fixtures on walls,
ceilings, structures and permanent scaffolding etc., for fixing racks. Fabrication and
fixing of necessary jigs, hangers, inserts and other fixtures, as required, shall be
considered a part of erection of structural steel work.
8. The trays shall be properly finished and laid to give neat appearance.
9. Cable trays shall be fixed on angle iron supporting racks fabricated at site.
10. All supports, clamps and other fixtures shall be painted.
11. All trays carrying SS tubes shall, in general, be vertical type.
12. If any erected tray or its supporting structures are found to be vulnerable to damage or
to be fouling / interfering with progress of other activities in the area, the same shall be
dismantled and re-erected.
13. The decision, whether to use rigid conduit or sub-tray shall be judiciously decided.


& ITS AUXILIARIES
01.07.09 Earthing
Bidder's scope of work shall include the earthing of all instruments / equipment,
enclosures and other metallic parts and objects. Necessary wires, lugs, sleeves, markers
/ ferrules etc. shall be supplied. In addition to the general guidelines given below,
Bidder shall remain responsible to follow the instrument / equipment manufacturer's
grounding recommendation.
1. Screens of all screened cables between field instruments to local junction box shall be
terminated to individual terminal blocks. The other end of the screen shall be left
disconnected and taped with adhesive vinyl tape. All screen terminal blocks at JB end
shall be shorted with shorting links. The screen of multipair / triad cables to cabinets
shall be connected to the screen terminal block in JB and the other end to be grounded
at panel end only.
2. Compensating cable screens shall be terminated at independent terminal blocks in

control panel end only. This terminal block shall, however, be wired up to insulated
screen bus bar integral to the panel.
3. All junction boxes, stands, stanchions, local panels, cubicles etc., must be connected to
the nearest riser of electrical earth mat by SWG 10 galvanized steel wire.
4. All control panels, desks, consoles, cubicles, cabinets etc. must be physically earthed
with the electrical ground mat inside the Control Room area.
5. All electrical ground terminals of local instruments shall be individually terminated up

to local junction box by one core of the signal cable and these terminal blocks shall be
shorted by links. The common earth point then may be led to local earth point by SWG
10 galvanized steel wire.
6. All local panel and central panel instruments shall be grounded to the common ground
bus available inside the panel. Normally the grounding wires shall be available as
wired-up inside the panels. Wherever grounding wires are not available inside the
panel, the same shall be provided by Bidder.
7. For terminating grounding wires only ring-tongue type lugs shall be used.
Regarding the earthing requirement of power supplies and electronic equipment,

manufacturer's recommendation shall be strictly adhered to. The earthing cables shall
be carefully sized not to exceed the specified earth impedance. Separate salt pit earth
and earth risers shall be created as required.


& ITS AUXILIARIES
01.07.10 Piping And Tubing
Instrument piping and tubing work shall include the impulse piping work between
Take-off valves on pipe lines or equipment / take-off nozzles and the instrument,
the drain piping to the nearby drain point, instrument air sub-header and main header
(wherever required) installation and testing and copper tubings between air header /
sub-header to different instruments / consumers.
01.07.11 Impulse piping / Tubing and Accessories
1. This section enumerates the basic guidelines for erection of primary impulse
piping, all associated fittings on primary impulse piping, piping for all instrument
drain and vent lines with all associated valves and fittings, impulse line support and
routing with accessories, all impulse line accessories viz. condensing pots,
temperature equalizing columns, seal chambers, settling columns, drain headers etc.
connections between instruments and valves / manifolds and their testing.
2. For impulse piping / tubing routing, Bidder shall develop a field routing sketch.
3. The pipes shall be cut with a hacksaw or high speed cutting emery wheel, squarely
and all burrs shall be removed. Roller type tube cutters shall not be used.
4. Cold bending of the pipes shall be performed with the use of a proper pipe bender
with radius of bends greater than five times the outside diameter of the pipe / tube.
Allowable deformation shall be within 4%.
5. Impulse piping shall always be installed with a slope greater then 10% in proper
direction for draining and shall never be installed in level horizontally.
6. Piping shall run with the minimum of changes in direction consistent with good
practice and neat appearance.
7. The bends / offsets must be smooth and regular. Bending shall not exceed 90 Deg.
in any case. Necessary couplings, unions, fittings etc. shall be provided on impulse
lines to facilitate removal and maintenance of instruments conveniently.
8. Drain lines shall terminate at approved drains only.
01.07.12 Instrument Air Distribution Piping
Erection of instrument air distribution piping include connection from nearest main air
header take-off valves to the vicinity of air consumers viz. control valves, pneumatic


& ITS AUXILIARIES
transmitters / controllers, I.P. converters, impulse line purge connections, power

cylinders, purge rotameters etc. Sub-headers shall be formed with GI pipes.
1. Supply and installation of all intermediate pipe fittings, isolation valves etc. including
supply and installation of necessary clamps and supports shall be considered as in
integral part of instrument air piping work.
2. For instrument air sub-header work, carbon steel hot-dipped, inside and outside
galvanized pipes shall be used. Only fittings of carbon steel galvanized threaded
type shall be used for GI application.
3. Outlets of air headers shall be provided with 1/2" isolation valves, for up to 7 consumers.
Bidder shall install GI sub-headers up to vicinity of the consumer and thereafter 6 mm
OD PVC coated copper tube shall be laid.
4. All headers and sub-headers shall be thoroughly cleaned before installation by means of
compressed air.
5. All headers and sub-headers shall be supported properly. The distance between any
two supports shall not exceed one meter unless otherwise required to suit site condition.
01.07.13 PVC Coated Copper Tubings and Fittings
Bidder's scope shall include PVC coated copper tubing shall be used for the signal
and supply air to transmitters, control valves, servo drives, impulse line purge
connections, solenoid valves, local controllers, I/P converters etc. with all necessary
fittings and air filter regulators, wherever required.
1. The tubes shall be thoroughly cleaned and flushed with air before
installation and defective tubes detected during checking, if any, shall be removed.
2. Single tube runs of PVC coated copper shall be joined together by means of straight
connector (double compression fitting) at every joint of the tube or shall be
telescopically brazed and sleeved.
3. The individual single run pneumatic signal tubing shall be run and connected from
the field mounted instruments to locally mounted controllers / indicators
mostly on tray work or on angles.
4. Tubes shall be run with the minimum number of changes in direction consistent
with good practice and neat appearances. Tube runs shall be properly dressed, neatly
laid and adequately clamped / supported on angles / trays. Distance between any
two supports shall not exceed one meter in any case.
5. Tubes installed but not connected shall have ends suitably closed to prevent the
entry of foreign materials.

& ITS AUXILIARIES
6. Tube runs shall be provided with suitable identification tags indicating the run
number for easy correlation and identification of connections. Identification ferrules at
both ends shall be provided.
7. Fittings shall be of brass flareless, of double compression type, and in accordance

with ASTM or similar standard specifications. All compression fittings shall be
provided by Bidder.
8. When tightening up the nuts of the compression type fittings, spanner of suitable
size shall be used. To avoid any deformation to the compression ring, adjustable
wrench shall never be used.
9. The bending radius for single tubes shall be more than five times the outside
diameter of the tubes. The tubes shall be bent with proper benders and care shall be
taken not to cause flattening of the bend.
10. The tubes shall be properly dressed on the trays to remove bends, dents etc. Tubes
shall not be directly hit by steel hammers.
11. Aluminium clamps or self-locking straps shall be used for clamping the tubes on trays
/ angles and same shall be supplied by Bidder at his own cost.
12. When connecting PVC coated copper tubings on servo-drives / valves mounted
on structures having thermal movement, sufficient expansion loops shall be formed
at the ends to allow for equipment movement without developing any stress on the end
fittings.
01.07.14 Flow Elements

Orifice Plate
For orifice plates with flange taps Bidder's scope shall include fixing of nipple and first
take-off valve, fixing and supporting condensation pot (wherever applicable) and
insertion of orifice plate with suitable gaskets, nuts and bolts. For orifice plates with D,
D/2 tapping, pipe welded stubs shall be available.
The general guidelines for installation of orifice plates are given below.
1. The length of the take-off nipples shall be sufficient so that the first take-off valve
protrudes beyond the thermal insulation.
2. The take-off nipples shall be screwed / welded according to the design requirement.
3. The hand wheel of the take-off valves shall be so oriented that they can be operated
conveniently from approach platform, ladder etc. Otherwise approach platform, ladder
shall be provided.


& ITS AUXILIARIES
4. For steam services, condensation pots shall be connected to the tapping point before or
after first take-off valves. Utmost care shall be taken to ensure that both the
condensation pots are at the same level. All necessary bracing, saddle etc. shall be
fabricated and used to support the condensation pots with the main pipe.
5. Orifice plates shall be inserted with proper orientation with respect to fluid flow in line.
6. Orifice plate should only be inserted in position for checking the alignment. Thereafter, it
shall be withdrawn and preserved till pre-commissioning activities are over.
7. Bidder shall supply suitable gaskets while fixing the orifice plates in position.
8. The orifice bar handle, shall be so oriented that the imprints are readable unassisted
from the access floor of platform.
9. Bidder shall ensure proper orientation of drain or vent holes
01.07.15 Flow Nozzles
Flow Nozzles shall normally be shop assembled in branch pipe and welded in position
with main pipe. The flow nozzles shall generally have D-D/2 tapping and shall be shop
assembled with take-off nipples and root valves. Bidder's scope of work shall include
connecting the condensation pots (for steam services) before installation of the
differential pressure instrument.
01.07.16 Control Room Control Panels / Desks, Consoles and Cubicles / Cabinets
This section provides guidelines for the erection of desks, panels, consoles,
cabinets etc., in the Control Room, Control Equipment Room, Local Control Room
and other such locations.
1. After Inter-sectional bolting with necessary nuts and bolts, inter-sectional wiring shall
be terminated at both ends.
2. Bidder shall arrange anchor bolts or grouting spikes and grout the same in the pocket.
Any civil job concerned with the proper installation of the panel shall be considered as
part of the panel installation work.
3. After installation, the main incoming fuse of each panel section shall be removed and
preserved till commissioning.


& ITS AUXILIARIES
01.07.17 Main Control Room / Computer Room Panels / Desks and Consoles / Local
Control Panels / Consoles and Desks
Bidder's scope of work shall include the installation of Operator's Terminals,

Engineering Terminals, Performance Calculation Terminals and other terminals,
consoles and some other peripheral devices in the Main Control Room / Computer
Room / Local Control Room wherever applicable. Associated activities shall include
laying, glanding and terminating prefabricated cables, related structural work and other
completing activities viz. modification of internal wirings, mounting and termination of
instruments / equipment supplied loose etc.
1. Erection of panels and desks in Control Room area shall involve precise alignment and
matching of surfaces. Bidder shall perform all related activities to achieve an aesthetic
completion of the job. All necessary realignment, foundation work, packing and filling
shall be done to compensate for shifting, waviness, misalignment etc.
2. When bolting the panel sections, care shall be taken not to leave excessive strain on any
of the surfaces. All necessary packing and filling materials shall be provided.
3. Instruments and accessories supplied loose for mounting on panels shall be installed
only after installation of the panels.
4. Tools and tackle recommended by the desk / panel / console manufacturer shall only be
used.
5. No element shall be forced or hammered into its slot.
6. If matching prefab connectors are available in pig-tail form the properness of

connection shall be checked by Bidder before plugging-in. Bidder shall be fully
responsible for improper connection of the connectors.
7. Bidder's activities shall also include splitting of gland plates, if required, to admit plug-
in connector, mounting of special cable clamps on the gland plates and dressing,
routing and clamping of the prefabs within the panel / desk / console.
8. All insulated conductors shall be tested with a 500 volt megger or an equivalent testing
device. Insulation resistance measurements shall be made between each conductor and
ground and between each conductor and all other conductors of the same circuit.
Minimum acceptance resistance values
01.07.18 Functional and Pre-Acceptance Test
The authorized quality assurance personnel of Bidder shall conduct all tests as per the
requirements of approved quality assurance program and fully satisfy in compliance
with specification requirements by all equipment / sub-systems and the system as a

& ITS AUXILIARIES
whole before sending notification for Factory Acceptance Test to Purchaser /

Consultant. Bidder shall maintain accurate records for all pre-acceptance test which
shall be properly documented and duly certified documents shall be furnished to
Purchaser / Consultant at least one month prior to Factory Acceptance Test.
01.08.00 DRAWINGS & DOCUMENTS
Bidder shall have to furnish system description, operational write-up, bill of materials,
drawings, data, information, technical catalogues, test certificates and other details
required to fully establish the capability and performance of the equipment and systems
offered. Any bid not containing sufficient details to fully describe the equipment and
systems offered may be treated as non-responsive and hence rejected. Bidder shall
submit the drawings and documents with good spiral binding. Loose documents /
drawings will not be accepted at any stage.
01.08.01 Following Drawings and Documents shall be submitted for conventional

Instrumentation. All communications / descriptions in the drgs., documents, technical
literatures and manuals shall be in English language.
01.08.02 Along with the offer
i) Process and instrumentation (P&I) diagrams for the FGD system and all auxiliary
equipment indicating all mounted instruments and PLC displayed measurement using
ISA symbols and using suitable tag numbers against each instrumentation equipment.
Alarm and interlock functions shall also be indicated in the P&I diagrams.
ii) Detailed technical literature of each C & I system and instrumentation equipment
offered.
iii) Write-up and Specification on FGD
iv) List of commissioning and recommended spares for all the equipment supplied along
with unit price
01.08.03 Drawings / Documents to be submitted by the successful Bidder during detail

engineering (in soft & hard)
A. For approval
i) Finalised process and instrumentation (P and I) diagram for FGD system and auxiliary
units indicating all local and remote measurements, controls, alarms and interlock


& ITS AUXILIARIES
functions, using ISA symbols and using suitable tag numbers against each
instrumentation equipment.
ii) Finalised instrument list for the entire plant indicating type of instrument, make, model
number, process conditions (max/operating pressure, temperature), scale range,
quantity, application and tag number (as per P and I diagram).
iii) Detailed specification datasheet for each instrumentation item/ equipment including
cables indicating finalised make, model no., application, scale range, quantity, tags no.
(as per P&I diagram), accuracy, power consumption etc. Data sheets for each
instrument as per standard format shall be submitted with all the required details filled
in.
iv) Instrument air distribution scheme with BOQ as applicable.
v) Instrument power supply diagram with specification and bill of quantities of electrical
accessories.
vi) General arrangement drawings and sectional views of various cabinets, panels including
gauge boards, transmitters cabinets & racks etc., showing internal disposition of all
components/ units with dimensional details and bill of materials.
B. For Information, Reference, Procedural Checking and Records.
i) Detailed technical literature/ catalogue for each instrumentation item and control
equipment, highlighting the selected model numbers.
ii) Design data, sizing calculation and selection criteria along with all related charts, curves,
tables and fabrication drawings of Flow sensors, control valves and actuators.
iii) Instrumentation layout drawing showing location of sensors, control valves, transmitters
etc. and route of cables from these up to Control Room.
iv) Cable schedules.
v) Wiring and termination diagrams with details of termination of field signals to local JBs/
panels and from JBs to panels/ marshalling racks/ cabinets and consoles including
internal wiring drawings.

& ITS AUXILIARIES
vi) Instrument Installation/ Hook up diagrams with bill of materials.
vii) Loop schematic drawings.
viii) List of commissioning and recommended spares for all the equipment supplied along
with unit rate.
ix) Manufacturer’s test, calibration and guarantee certificates for all instruments and control
equipment.
x) Operation and maintenance manuals for instruments and control equipment (In English
language).
xi) “As-built” documentation.
xii) Soft copy of all the above drawings and documents in CDs / DVDs/ suitable electronic
media.
Any other relevant data, drawings / documents and information necessary for review of
items whether specifically mentioned or not, shall be furnished by the Bidder. The
quantity of drawings and documents to be submitted to Purchaser / Consultant shall be
as per contract.
01.08.04 Following Drawings and Documents shall be submitted for PLC based automation
system. All communications in the drawings, documentations, technical literatures and
manuals shall be in English language.
Along with the offer
i) Proposed System configuration diagram
ii) Write-up and technical literature on the PLC system offered
iii) Technical specifications with literatures of all the units of the Control System viz.
Processing units, process I/O unit, sequence event recorder, device indicating operator’s
guidance message, data bus, communication unit etc. indicating make, model numbers,
features and application.
iv) List of reference of similar system already in service with complete performance record
details
v) Write-up and specification of FGD system.


& ITS AUXILIARIES
01.08.05 Drawings / Documents to be submitted by the successful Bidder during detail

engineering (in soft & hard)
A. For Approval
i) Finalized system configurations diagram for the automation system alongwith its
peripherals with list of hardware and write-up on the system.
ii) Bill of Material and final technical specification with detail data sheet for all PLC
equipments such Processors, Communication modules, Power supply cards, I/O unit,
panels, console, Operator stations, Engineering Station, Servers, printer, bus & N/W
cables, communication hardware etc indicating make, model numbers.
iii) Overall General arrangement drawings and sectional views of various cabinets, panels,
consoles, etc. showing internal disposition of all components/ units, with dimensional
details and bill of materials.
iv) Control room layout drawing showing disposition of panels, consoles, desks, etc with
dimensional details.
B. For Information, Reference, Procedural checking and Records
i) Control philosophy Functional description, control philosophy for the plant

indicating start up, shut down, control locations, interlocking and annunciation
system, mimic pages, report/data formats.
ii) Single line power supply diagram with specification and bill of quantities of
electrical accessories.
iii) Detailed technical literature/ catalogue for Automation system with peripherals,
highlighting the model number.
iv) Wiring and termination diagrams for all RI/Os, Marshalling racks, Cabinets, Consoles
etc.
v) Cable schedules.
vi) Input/ Output list.
vii) System grounding/ earthing scheme.
viii) Formats and work sheets for generation and display of overview, groups, loops,
graphics, alarms, operator’s guide messages, real time and historical trends, log and shift
formats.

& ITS AUXILIARIES
ix) Detailed listing of application software, system software, HMI software, etc and the
number of licenses with detail features and functional descriptions.
x) Manufacturer’s test, calibration and guarantee certificates for all instruments and
automation system.
xi) Operation and maintenance manuals for Automation system (In English
language).
xii) List of commissioning and recommended spares for automation system along with unit
rate.
xiii) As Built Drawings and documentations.
xiii) Soft copy of all the above drawings and documents in CDs / DVDs/ suitable electronic
media.
xiv) Factory Acceptance Test Procedure
Any other relevant data, drawings / documents and information necessary for review of
items whether specifically mentioned or not, shall be furnished by the Bidder. The
quantity of drawings and documents to be submitted to client / consultant shall be as per
contract.
01.08.06 Final Drawings
a) Before starting manufacture of the fabrication, Bidder shall secure approval on the
design drawings from Purchaser / Consultant for the drawings in writing. Any
manufacture done prior to approval of the drawings shall be rectified in accordance with
the approved drawings by Bidder at his own cost and the equipment shall be supplied
within the stipulated period.
b) Bidder shall submit within stipulated time from the date of receipt of approved drawings
as per GCC - eight (8) sets of final drawings along with one (1) set of soft copy for each
drawing & document loaded in suitable (CD/ DVD/ other) medium. Bidder shall also
provide fifteen (15) sets of latest version of Instruction Manuals along with one (1) set of
soft copy, loaded in suitable (CD/ DVD/ other) medium, for I & C system including its
various components, sub-assemblies, indicating the method of installation, check-ups
and tests to be carried out during erection and before commissioning of the equipment.
The manual shall also include instruction for step checking, trouble shooting and fault
rectification for different components and sub-assemblies.
c) Bidder shall also incorporate all modifications in the drawings carried out at site during
trial run, start-up performance and guarantee tests till hand over of the units to Purchaser

& ITS AUXILIARIES
and submit these final as-built drawings each in ten (10) copies along with one softcopy
loaded in suitable (CD/ DVD/ other) medium.
d) Care shall be taken to present all final documents in proper form. All catalogs and
literature (including sub-supplier’s catalogs), Datasheets, Instrument list, consolidated
I/O list for PLC system, Function Control diagram, Loop diagrams, PLC configuration
diagram shall be bound together in indexed volumes for keeping in plant library. All O
& M manuals shall be in handy size and neatly bound for carrying to the work place.


(4X210MW)
FOR
VOLUME – IV
ELECTRICAL SYSTEM
MECON LIMITED
RANCHI – 834 002


& ITS AUXILIARIES
INDEX TO VOLUMES
Volumes Title
and after award of Contract
Vol. – IV INDEX TO VOLUME Page 2 of 3


& ITS AUXILIARIES
Volumes Title
Vol. – IV INDEX TO VOLUME Page 3 of 3


& ITS AUXILIARIES
SECTION-I
GENERAL DESCRIPTION :
For 4x210MW units of existing power plants of Mettur TPS-1, semi dry limestone based
FGD (Flue Gas Desulphurisation) unit is proposed covering Absorbers, Booster Fans and
associated auxiliary systems.
Proposed Electrical system shall broadly comprise of the following, --
1. 6.6KV FGD HT Switchboard, 40KA, 3 sec. Al. Busbar - 2 nos.

2. 6.6/0.433KV, 2MVA (approx.) Transformer - 4 nos
3. 415V FGD LT PMCC, 50KA, 1 sec., Al. Busbar - 2 nos.
4. 415V LT MCC, 50KA, 1 sec., Al. Busbar - 4 sets / As required
5. HT Motors – 1 lot (to be considered as integral to respective mechanical
equipments)
6. LT Motors along with Motors for Electrical Actuators – 1 lot ( to be considered as
integral to respective mechanical equipments)
7. Local Push Button Station – 1 lot
8. HT Cables : 6.6KV (UE), XLPE insulated, , stranded Al. Conductor, Galvanised
Steel Wire Armoured and Overall FRLS, PVC type ST2 sheathed - 1 lot
9. HT Cable Termination Kits – 1 lot
10. LT Power Cables : 1.1KV, XLPE insulated, stranded Al. Conductor, Galvanised
Steel Wire Armoured and Overall FRLS, PVC type ST2 sheathed - 1 lot
11. LT Control Cables : 1.1KV, PVC insulated, stranded Cu. Conductor, Galvanised
armoured as applicable and Overall FRLS, PVC type ST2 sheathed - 1 lot
12. 415V LT Busduct (NSPBD) from Distribution Transformers (6.6/0.433KV) to
415V FGD PMCCs – 1 Lot
13. 220V DC, Lead Acid Battery Bank (2x100%) with MS Stand & accessories along
with Dual Float Cum Boost Battery Charger suitable for 220V Lead Acid Battery
(2x100%) and DCDB – 1 set
14. 240V AC UPS (2x100% parallel redundant), 3 phase/1 phase with Lead Acid
Battery bank (2x100%) for 60 minutes back-up, UPSDB - 1 set
15. ACDB/PDB – 1 lot
16. Illuminations (Building and Periphery, Approach Road/Street Lights including
Lighting Transformers, MLDB/LDBs, fixtures, Fittings, wirings) – 1 lot
17. Earthing and Lightning Protection – 1 lot
18. Telecommunication System – 1 lot
19. Fire Detection and Alarm system (in respective buildings) – 1 lot
20. Electrics associated with air conditioning & ventilation system of FGD building.
Vol. – IV ELECTRICAL SYSTEM Page 1 of 152

& ITS AUXILIARIES
21. Electrics associated with hoisting & handling system including cranes.
22. Electrics associated with elevators.
23. Erection Materials/Installation Hardware – 1 lot
24. Commissioning Spares as per OEM recommendations – 1 lot
25. Cable Supporting Structure, Cable Trays – 1 lot (For cable routing, existing
Trestle/Structure shall be utilised to the extent possible – in areas where the same
will not be available, suitable structures/trestles shall be provided by the bidder)
SOURCE OF INCOMING POWER SUPPLY

FGD system shall have two nos. of new 6.6KV HT Switchboards, each catering the
requirement of proposed FGD units for Unit-1 & 2 (2x210MW) and for Unit-3 & 4
(2x210MW) of the Power Plant.
For incoming power supplies for one of the 6.6KV FGD HT Switchboards, two nos. of
incoming feeders shall be made available by TanGedCo from available transformer
feeders (each 1250A VCB) in existing 6.6KV Station Switchgear (Station Bus C1, feeder
reference “ESP TRFR(Com)” and “PDFACS TRFR-1”).
Similarly, for incoming power supplies for another 6.6KV FGD HT Switchboards, two
nos. of incoming feeders shall be made available by TanGedCo from available transformer
feeders (each 1250A VCB) in existing 6.6KV Station Switchgear (Station Bus C2, feeder
reference “TIE TO C3” and “PDFACS TRFR-2”).
Maximum load (in MVA) for electrical operation of proposed FGD systems shall be
indicated in the offer by the Bidder. In this context, bidder shall note that maximum power
that can be made available from the existing station transformer viz. ST-1 & ST-2 (rating
31.5MVA each) is limited upto 10MVA each (i.e total 20MVA for proposed FGDs for all
four units of power plant) inclusive of all design and operational margins. Incase, the
connected load designed by the bidder exceeds 10MVA for FGD for each of 2x210MW
units, the capacity enhancement of existing station transformers viz. ST-1 & ST-2 and
allied HT bus C1 & C2 including busduct, incoming breaker and bus shall be in the scope
of the bidder.
POWER DISTRIBUTION SCHEME
1250A VCB feeders, two each from Station Bus C1 & C2 in existing 6.6kV Station
Switchgears, shall be used as two incomers to each of the new 6.6KV HT Switchboards to
be located in the proposed FGD Electrical Cum Control Room building. Replacement of
1250A VCB breakers by 2000A VCB breakers with necessary modification/changes in
power, control, protection, metering & associated components like new VCBs (2000A,
40KA, 7.2kV, floor mounted, bushing CTs, core balance CTs, relays, meters etc. including
retrofitting of the new 2000A VCB in the existing available breaker cubicle and achieving

& ITS AUXILIARIES
one to one interchangeability), two each from existing 6.6kV station bus C1 & C2 shall be
under bidder’s scope. Required HT Cables from these modified 2000A VCB panels up to
FGD 6.6KV new HT Switchboards, including laying and termination at both ends and
allied works, shall also be covered under the scope of the bidder of FGD package.
(Approximate distance 500meter each).
It is envisaged that from two nos. of new FGD 6.6KV HT Switchboards, total three nos. of
VCB, 1250A Transformer feeders (each restricted to draw a maximum load of 180A) shall
be allocated for use as power supply feeders viz. “ESP TRFR(Com)”, “PDFACS TRFR-1”
and “PDFACS TRFR-2” respectively. (Approximate distance 200meter each).
All HT motors of FGD (>160KW) shall be fed from new 6.6KV HT Board through 1250A
VCBs. New 6.6KV HT Board shall be housed in the Electrical building in new FGD area.
(‘SLD’ to be referred for details of HT drives)
Taking two feeders from new 6.6KV FGD HT Board, FGD LT PMCC shall be fed
through FGD LT Substation [6.6/0.433KV, 2.0 MVA (approx.)]. LV neutral shall be
provided with NGR and NDR and the neutral current shall be limited to < 1 Amp.
From PMCC, 415V LT supplies (ACB feeders) shall be made available to respective
MCCs in different load centres as well as to all LT drives rated above 90KW and up to
160KW. Further distribution of LT 415 V power to different drives shall be made through
different MCCs/PDBs.
Key Single Line Diagram (Drg. No. MEC/11/E1/10KP/TS/004, rev. 01, sheet 1 of 1) is
attached.
ELECTRICAL SYSTEM DESIGN CRITERIA

General : The design, manufacture, assembly and testing as well as performance of the
equipment shall conform to the relevant IS/IEC specifications (latest revision) and other
relevant standards.
Climatic Conditions : Electrical Equipment selection and derating shall generally be
based on ambient temperature of 500C. For specific hot areas the ambient temperature
conditions shall be taken into consideration and equipment suitably derated wherever
necessary. In hot areas of higher temperature conditions, the equipment shall be
adequately protected against damage from radiant heat and hot air. The equipment offered
shall be suitable for smooth, efficient and trouble free service in the climate prevailing at
site.
Standard Voltage levels :
Following power utilization standard voltage levels shall be adopted for various systems:
AC drive motors above 160KW 6600V, 3 phase, 3 wire, non effective

earthed.

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A.C. drive motors up to 160KW 415 V, 3 phase, 3 wire, with NGR earthed
DC drive motors 220 V, 2 wire, unearthed D.C.
Control and protection of LT 220 V D.C.
switchgears including VCBs of HT
board and ACBs of PMCCs
Control and indication voltage (other 240 V, 1 phase, line & neutral (through
than breakers) control transformers)
UPS 240 V, 1 phase, 2 wire
Metering 110 V, AC, PT supply
Plant illumination 240 V, 1 phase, line & neutral
Emergency illumination 220 V D.C.
Panel lighting and space heaters 240 V, 1 phase, 2 wire, 50 Hz, A.C. with
one point earthed
DCS/PLC/PLC power supply 240 V, 1 phase, 2 wire, 50 Hz, A.C. (UPS
supply)
Welding socket / power receptacles 415 V, 3 phase, 50 Hz, A.C. outlets
240 V, 1 phase, 2 wire, 50 Hz, A.C. with
one point earthed
Permissible variations :
The system/unit/equipment shall be designed suitably for following variations in voltage

& frequency
Voltage Frequency
+6% to –6%
+10% to -15%
Permissible variation with rated performance and (LT systems)
control effectiveness maintained +5% to –5%
(HT systems)
Permissible voltage dip at HT switchgear bus
(-) 15% ------
during starting of HT motor
Permissible voltage dip at LT switchgear bus
(-) 15% ------
during starting of LT motor
Symmetrical short circuit ratings :

The three phase symmetrical short circuit ratings of the switchgear at different voltage
levels envisaged are as follows:
Breaking Capacity Making Capacity
6.6 kV 40 kA 100 kA

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415 V 50 kA 105 kA
220 V DC 10 kA --------
[The rated short circuit withstand duration for 6.6kV switchboard will be 3.0 Secs,
whereas for 415 V switchgears including MCCs, it will be 1.0 sec.]
Voltage levels for Motors :
Criteria for selection of voltage levels for motors shall be as follows :

Motor ratings more than 160 kW and upto 2000 kW shall be fed from 6.6kV DOL
starting (with Soft Starter/VFD, if specified in write-up in other/technological section).
Motors ranging from 90 kW to 160 kW shall be directly fed from LT PMCCs through
ACBs with numerical motor protection relay and shall be provided with soft starters with
DOL By pass.
Motors below 90 kW shall be fed from LT MCCs.
Feeders catering to motors less than 90 kW capacity shall be consisting of MCCB /
MPCB, power contactor and O/L relay.
Separate starter panels shall be provided for DC motors.
Construction Power :
Two nos. 415V feeders at one location shall be made available by the purchaser
approximately 300meters from FGD battery limit. Further distribution to various loads of
the bidder shall be in the scope of the bidder. Bidder shall arrange necessary DBs,
capacitor banks along with APFCR, cables etc. for the distribution


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SECTION-II
TECHNICAL SPECIFICATION - ELECTRICAL
General :
In general, all the items/equipment shall be as per the general guidelines/technical

requirements described in various clauses of this document. However, in case of
discrepancies, if any, between this General Specification and that generally furnished
otherwise in various chapters of the bid document / bid specification, stringent of the two
documents/descriptions shall prevail unless otherwise referred to and concurred/finalized
otherwise by the customer/consultant suiting the requirement of the Plant.
AA. TECHNICAL SPECIFICATION FOR 6.6 KV SWITCHGEAR
01.01.00 General Requirement
In general, Circuit Breaker & Panels shall be supplied from the (same) unit / factory that
supplied the Circuit breaker/ panels on which successful type test was conducted.
Manufacturer of the switchgear panel shall be same as the manufacturer of Circuit Breaker. The
switchgear shall be of Indoor metal clad bolted/riveted design (with in house fabrication, pre-
treatment & powder coating facilities), single bus bar , self standing, dust proof construction,
internal arc tested for designed fault current for 1 sec., indoor cubicle type fitted with VCB in
fully truck mounted so that it directly rolls on to the floor when taken outside without usage of
any external breaker handling truck. Switchgear should be tested as per IEC for highest system
voltage for all short circuit duties.
01.02.00 Scope of Supply

01.02.01 Two (2) sets of 6600 V Switchgear, One each for (i) FGD systems of Units 1 &
2 and for (ii) FGD systems of Units 3 & 4 along with the systems/facilities which are common
for all the FGD systems for all four Units of 4x210MW Power Plant
1250A VCB feeders, two each from station bus C1 & C2 in existing 6.6kV station
switchgears, shall be used as two incomers to each of the new FGD HT switchboards to be
located in the proposed FGD electrical cum control room building. Replacement of 1250A
VCB breaker by 2000A VCB breaker with necessary modification / changes in power,
control, protection, metering & associated components like new VCBs (2000A, 40KA,
7.2KV, floor mounted, bushing CTs, core balance CTs, relays, meters etc., including
retrofitting of the new 2000A VCB in the existing available breaker cubicle and achieving


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one to one interchangeability), two each from existing 6.6KV station bus C1 & C2 shall be
under bidder’s scope.
Required HT Cables from these modified 2000A VCB panels up to FGD 6.6KV new HT
Switchboards, including laying of cable & termination at both ends and allied works, shall
also be covered under the scope of the bidder of FGD package. (Approximate distance
500meter each)
01.02.02 The base channel frame of the switchgears with hardware.

01.02.03 Set of accessories as detailed below :
a) Earthing truck for feeders : Two (2) Nos. for both 6.6 KV Switchgears
b) Earthing truck for bus : Two (2) Nos. for both 6.6 KV Switchgears
Separate earthing trucks (Two nos.) shall be provided by the Bidder for maintenance
work. These trucks shall be suitable for earthing the switchgear busbars as well as
outgoing / incoming cables or busducts. The trucks shall have a voltage transformer and
an interlock to prevent earthing of any live connection. The earthing trucks shall in
addition have a visual and audible annunciation to warn the operator against earthing of
live connections.
Interlocks shall be provided to prevent :
1) Closing of the earthing switch if the associated circuit breaker truck is in Service position.
2) Insertion of the breaker truck to Service position if earthing switch is in closed position.
3) Closing of the earth switch on a live connection. Three (3) nos. voltage capacitive dividers
shall be provided on each phase of the section intended for earthing and three nos. "RED"
neon lamps connected to these on the panel front for visual indication.
4) Energising an earthed Section:
Complete details of arrangement offered shall be submitted during detailed engineering ,
describing the safety features and interlocks.
The earthing device (truck / switch) shall have the short circuit withstand capability equal
to that of associated switchgear panel. 4 NO + 4 NC of auxiliary contacts of the
earthing device shall be provided for interlocking purpose.
All hinged doors shall be earthed through flexible earthing braid.
01.02.04 One set of special tools and tackles for 6.6 KV Switchgear.
01.02.05 Mandatory spares
01.02.06 All relevant drawings, data and instruction manuals.
01.02.07 In addition to all the outgoing feeders required for bidder’s own system,
bidder shall provide in each switchgear the following HT feeders as a minimum
a) Three (3) numbers 1250A transformer feeders (VCBs along with requisite control,
metering protection with associated components), One from one bus of HT switchboard


& ITS AUXILIARIES
for U1 & 2 and other two from each bus of HT switchboard for U3 & 4 for use by the
customer for “ESP TRFR (Comm)”, “PDFACS TRFR-1” and “PDFACS TRFR-2”
(max. load 180A each)
b) One (1) number highest rated motor feeder breaker as spare
c) One (1) number lowest rated motor feeder breaker as spare
d) One (1) number highest rated Transformer feeder breaker as spare

IEC : 62271
IS : 13118 , 3427
02.01.00 All equipment and materials shall be designed, manufactured and tested in
accordance with the latest applicable Indian Standards (IS) and IEC except where
modified and/or supplemented by this specification.
02.02.00 Equipment and material conforming to any other standards, which ensure
equal or better quality, may be accepted. In such case, copies of the English version of the
standard adopted shall be submitted.
02.03.00 The electrical installation shall meet the requirements of Indian
Electricity Rules as amended upto date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall also be followed.
03.01.00 The switchgear shall be used to supply power to HV motors, transformers and
other loads
03.02.00 Duty involves direct-on-line starting of large induction motors and also
under certain emergency conditions transfer of loads from normal to stand-by source
of supply.
The motor starting current varies from 6 to 8 times the full-load current, with a frequent
starts.
03.03.00 The switchgear shall be located in a clean but hot, humid and tropical
atmosphere.
03.04.00 For continuous operation at specified ratings, temperature rise of the various
switchgear components shall be limited to the permissible values stipulated in the relevant
standards and/or this specification.
03.05.00 The Switchgear and components thereof shall be capable of withstanding the
mechanical forces and thermal stresses of the maximum system short circuit current
without any damage or deterioration of material.
03.06.00 Circuit breaker shall not produce any harmful over-voltage during
switching off induction motors, unloaded lines and unloaded transformers. Surge
protection device shall be provided to limit over-voltage for motor & transformer feeders.

& ITS AUXILIARIES
03.07.00 The switchgear busbar rating shall be at least equal to the rating of
incomer. Each incomer of HV switchgear shall be rated to carry continuously minimum
120 percent of Name Plate rated current of all the connected equipments. Ratings of Bus-
coupler and Tie Breaker shall be equal to the rating of the incomer breaker of the
respective board.
03.08.00 For indicative requirement of power distribution scheme, the enclosed Single
Line Diagram (SLD) shall be referred. All the ratings, if shown in the above drawing
represent the indicative figures as a tentative requirement only. Exact rating, number and
type of feeders etc. shall be decided by the bidder and the same shall be indicated in the offer.
This shall be subject to review and approval by the purchaser/consultant based on relevant
sizing calculations along with SLD and List of Drives to be submitted along with the offer by
the bidder.
For easy interchangeability, number of ratings to be selected for breakers shall be of
two types. One for incomers, bus coupler & tie feeder (if applicable) and another common
rating for all other outgoing transformers, motors and board feeders
04.00.00 Specific Requirements
04.01.00 Construction
- Each transport unit not more than 3.2m.
- Removable lifting arrangement for each transport unit.
- Screwed wire mesh for busbar and CT chambers to prevent accidental contact with live parts.
- Explosion vents for different chambers
- Pressure relief flaps which can not be opened from outside to release pressure that builds up
in the event of arcing faults inside the cubicle.
04.01.01 The switchgear shall be indoor, metal-clad, floor mounted, draw
out type. Design and construction shall be such as to allow extension at either end.
04.01.02 The switchgear enclosure shall conform to the degree of protection IP:5X
for VT/relay compartment and IP:4X for other compartments. The minimum thickness
of CRCA / Alu zinc sheet steel used shall be 2 mm and gland plates shall be 2.5mm thick
made of hot/cold rolled sheets & 3mm for non-magnetic material .
04.01.03 The switchgear assembly shall comprise a continuous, dead-front, line-up of
free standing, vertical cubicles. Each cubicle shall have a front hinged door (with door
not forming part of the withdrawable truck) with latches and a removable back cover.
All covers and doors shall be provided with neoprene gaskets.
04.01.04 Switchgear cubicle shall be so sized as to permit closing of the front access
door when the breaker is pulled out to “rack out position”. The working zone shall be
restricted within 750 mm to 1950 mm from floor level.
04.01.05 Circuit breakers, instrument transformers, bus-bars, cable compartment etc.,
shall be housed in separate compartments within the cubicle. The design shall be such


& ITS AUXILIARIES
that failure of one equipment shall not affect the adjacent units.
04.01.06 All relays, meters, breaker control switches, selector switches and indicating
lamps shall be flush mounted on the respective cubicle door or on control cabinet built
on the front of the cubicle. AC/DC auxiliary supply switches / isolation switches for
cubicle space heater, cubicle lamp, spring charging motor circuit shall be located inside
metering compartment. For all the energy meters, Test terminal blocks shall be provided.
04.01.07 Dummy panel shall be provided in the switchgear line up, if required, for easy
termination access of power and control cables. Dummy panel / bus trunking panel shall
be of full cubicle with closed roof and rear door similar to enclosures for active
cubicles.
04.02.00 Bus and Bus Taps
04.02.01 The main buses and connections shall be of high conductivity
aluminum/aluminum alloy, control & auxiliary buses of electrolytic copper/copper wires
sized for specified current ratings with maximum temperature limited to :
a) For bolted joints (Plain or tinned) : 90oC (i.e. 400C rise over 500C ambient)
b) For bolted joints (Silver plated) : 105oC (i.e. 550C rise over 500C ambient)
c) For continuous busbars : 85°C (i.e 35°C rise over 50°C ambient)
04.02.02 Bus bars shall be of same size for the entire length of the switchgear.
Continuous current rating of bus connections / dropper shall be same as that of continuous
in panel current rating of associated breaker.
04.02.03 All bus connections shall be silver plated. Adequate contact pressure shall be
ensured by means of two bolts connection with plain and spring washers and locknuts.
Bimetallic connectors shall be furnished for connections between dissimilar metals.
04.02.04 Bus bars and connection shall be fully insulated for working voltage
with adequate phase/ground clearances. Insulating sleeves for bus bars and cast-resin
shrouds for joints shall be provided, suitable for maximum temperature rise of bus bars.
04.02.05 Bus insulator shall be high strength, hygroscopic, non- combustible arc
& track resistant type with creepage distance suitable for heavily polluted atmosphere.
Use of inflammable materials like hylam is not acceptable.
04.02.06 All buses and connections shall be supported and braced to withstand
stresses due to maximum short circuit current and also to take care of any thermal
expansion.
04.02.07 Bus bars shall be color coded for easy identification and so located that the
sequence R-Y-B shall be from left to right, top to bottom or front to rear, when viewed
from front of the switch-gear assembly.
04.03.00 Circuit Breaker
04.03.01 Circuit breaker shall comprise of vacuum type, three pole, identical single pole
type interposing units, operated through a common shaft.


& ITS AUXILIARIES
04.03.02 Circuit breakers shall be with horizontal isolation and horizontal draw
out type, having SERVICE, TEST and DISCONNECTED positions with positive
indication for each position. Circuit breakers shall be capable of racking in and racking
out with the door in closed condition
04.03.03 Circuit breakers of identical rating shall be physically and electrically
interchangeable.
04.03.04 Circuit breaker shall have motor wound spring charged trip free mechanism
with anti pumping-feature and shunt trip. In addition facility for manual charging of
spring shall be provided. Power supply to the spring charging motor shall be cut off when
closing spring is charged manually.
04.03.05 For motor wound mechanism, spring charging shall take place automatically
after each breaker closing operation. One open-close-open operation of the circuit
breaker shall be possible after failure of power supply to the motor.
04.03.06 Mechanical safety interlock shall be provided to prevent :
a) The circuit breaker from being racked in or out of the service position when the
breaker is closed.
b) Racking in the circuit breaker unless the control plug is fully engaged.
04.03.07 Automatic safety shutters shall be provided to fully cover the female primary
disconnects when the breaker is withdrawn.
04.03.08 Each breaker shall be provided with an emergency manual trip, mechanical
ON-OFF, indication, an operation counter and mechanism charge/discharge indicator.
04.03.09 Each breaker shall be provided with following :
a) Auxiliary switch, with 6 NO + 6 NC contacts, mounted on the draw out portion of the
switchgear.
b) Position/cell switch with 3 NO + 1 NC contacts, one each for TEST and SERVICE
position.
c) Auxiliary switch with 4 NO + 4 NC contacts mounted on the stationary portion of
the switchgear and operated mechanically by a sliding lever from the breaker in SERVICE
position. Alternatively electrically reset type latching relay may be used for the
purpose.
d) Spring charge limit switch with 2 NO + 2 NC contacts.
04.03.10 Switch contact shall be rated 10 A
AC and 2A DC at their respective operating voltage.
04.04.00 Control & Indication
The circuit breaker shall be wired up for local & remote operation. Each breaker
cubicle shall be equipped with following :-
04.04.01 One (1) local remote selector switch stay put type with pistol grip handle and

& ITS AUXILIARIES
key interlock.
04.04.02 Breaker control switch (T-N-C) shall be of spring return to normal and with
pistol grip handle.
04.04.03 Five (5) indicating lights on front of compartments :-
GREEN : Breaker Open
WHITE : Spring Charged
RED : Breaker Closed
BLUE : Trip circuit healthy
AMBER : Auto trip
04.04.04 Lamps shall be clustered type LED module pilot lights in
thermoplastic enclosure with polycarbonate lens and diffuser. LED shall be protected by
in-built fuse with surge suppressor and leakage voltage glow protection. Lamp and lens
shall be replaceable from front.
04.05.00 Current Transformer
04.05.01 Current transformers shall be cast resin type. All secondary connections shall
be brought out to terminal blocks where wye or delta connection shall be made.
Metering & protection CT secondary Terminal blocks shall be of link type with provision
for shorting.
04.05.02 Accuracy class of the Current Transformers shall be :-
a. Class PS for differential relaying (or as required depending on the type of relay
selected)
b. Class 5P20 for other relaying
c. Class 0.5 for metering.
d. Class 0.2S for performance / precision ABT metering.
e. Class of Insulation shall be ‘E’ or better.
04.05.03 Current transformer secondary shall be rated for 1A or 5A, depending on
requirement
04.05.04 Feeders requiring remote metering and/or current monitoring shall be provided
with current transducers with calibration for full-scale reading.
Other particulars of the CTs, like ratio, burden, knee point voltage, excitation current
and secondary resistance shall be decided by the bidder and shall be furnished for
review/acceptance of the client/consultant during detail engineering.
Core balance CTs (CBCT) having CT ratio of 50/1A shall be provided on outgoing
motor and transformer feeders. These CBCTs shall be mounted inside the switchgear panel.


& ITS AUXILIARIES
The window size of CBCT's shall be based on the overall diameter of the cables, to be
finalized during detailed engineering.
The CBCT and earth fault relays shall be properly coordinated to ensure:-
(a) Proper operation and entire range of earth fault current
(b) Prevent inadvertent operation due to motor starting current, transformer switching
inrush current and short circuit current.
04.06.00 Voltage Transformer
04.06.01 Voltage Transformer (VT) shall be cast-resin, draw out type and shall have an
accuracy class of 0.5/3P Bus PTs. BUS PTs and Line PTs shall be mounted in
separate vertical panel. Class of Insulation shall be ‘E.
04.06.02 High voltage windings of voltage transformer shall be protected by
current limiting fuses. The voltage transformer and fuses shall be completely
disconnected and visibly grounded in fully draw-out position.
04.06.03 Low voltage winding of voltage transformer shall have MCB, installed in
all ungrounded secondary leads. MCB shall be suitably located to permit easy
replacement while the switchgear is energized.
04.07.00 Relays
04.07.01 Relays shall be of draw out design with built-in testing facilities and
flush mounted at the front of panel. Small auxiliary relays may be in non-draw out
execution and mounted within the cubicle.
04.07.02 Relays shall be rated for operation on 110V secondary voltage and 1A or
5A secondary current to be decided by the bidder. Number and rating of relay contacts
shall suit the job requirements.
04.07.03 All protective relays shall be micro processor based multifunction type
numerical relays. All relays shall be able to communicate with DCS/PLC/Plant Control
System through IEC 61850 communication protocol.
Numerical relays of all modules in a switchboard shall be serially interfaced to plant
DCS/PLC/Plant Control System. Each breaker shall be monitored from DCS/PLC/Plant
Control System
Numerical relay shall have communication on three ports, local front port to laptop and
dual ports on IEC 61850 to connect to data concentrator through LAN.
Serial communication link shall have 100% redundancy.
Numerical relays and DCS/PLC/Plant Control System shall have common protocol for
proper communication.
Control of the Breakers shall be from DCS/PLC/Plant Control System through interposing /
Coupling relays which shall be located in the respective panels.


& ITS AUXILIARIES
04.07.04 Multifunction numerical relays shall be selected to provide an integrated

protection, continuous measurement and monitoring functions. These relays shall
communicate with the DCS/PLC/Plant Control System through an open protocol like
IEC 61850. Features such as self-diagnosis and external testing, disturbance recording,
sequence of event recording, time stampings and energy management shall be available
with the relay. It shall be possible to store relevant data in non-volatile memory backed
up by battery. The relay shall have multiple setting groups, optically isolated input /
output, front LCD display and menus, fixed function and programmable LEDs, keypad
and password protection. All functions including protection, automation,
communication, LEDs, input / output shall be programmable and can be modified, if
required, using the front panel user interface. The relay shall be provided with two
redundant IEC61850 compatible communication ports with parallel redundant protocol
at rear for communication to EMS / station DDCMIS and one front port suitable for
laptop connection. Two (2) numbers laptops loaded with support software (complete
version) shall be supplied for local off line programming, measurements, extracting and
viewing of events, disturbance etc. The relay shall be housed in dust tight enclosure,
suitable for IP52 degree of protection. All the printed circuit boards of the numerical
relays shall be provided with "conformal coating”.
04.07.05 The Bidder shall furnish, install & co-ordinate all relays to suit the
requirements of protection, interlock and bus transfer schemes.
04.08.00 Meters
04.08.01 Incomers, Bus PT & Line PT shall have Ammeters and voltmeters (as
applicable) with selector switches in addition to metering in Numerical Relays. Metering for
all other feeders shall be through Numerical Relays. Indicating instruments (96 x 96 mm)
shall be switchboard type, with 90- degree scale, anti-glare glass and accuracy class 2.0
or better. Each meter shall have zero adjuster on the front.
04.08.02 Motor ammeter shall have extended suppressed end-scale range to indicate
starting current (6-8 times full load).
04.09.00 Transducer
Transducers shall be provided for incomers and bus couplers for conversion of AC
electrical quantities such as voltage, current and power. Transducers shall be of low
burden type having 4 - 20 mA DC linear galvanically isolated output compatible
with secondary indicating instrument. Transducer shall be dual channel type.
04.10.00 Switch
04.10.01 Switches shall be dust protected, heavy duty, switchboard type complete with
escutcheon plate. Contacts shall be rated 10A at operating voltage.
04.10.02 Lockable stay-put type switchgear / field / remote selector switch shall be
provided as per requirement and mounted on switchgear cubicle.
04.10.03 Meter selector switches shall be maintained contact, stay put type with knob
handle. Ammeter& voltmeter selector switches shall be four position type. Ammeter

& ITS AUXILIARIES
selector switches shall have make before break feature to prevent open circuiting of CT
secondary.
04.11.00 Fuse & MCB
04.11.01 Fuses shall be HRC, link type, with minimum interrupting capacity equal
to the listed short circuit current. Fuses shall be furnished complete with fuse bases and
fittings.
04.11.02 MCBs shall be three/four pole, trip free, with manual close / open
mechanism. Automatic tripping provision for over load and short circuit shall also be
provided. MCBs shall be rated for full fault level of the system. MCB shall be provided
with required number of auxiliary contacts as per circuit requirement.
04.12.00 Push Button
Push button shall be heavy duty, shrouded, push to actuate type with colored button
and inscription plate. Each push button shall have 2 NO + 2 NC contacts, rated 10A
and 0.5A at their respective AC and DC operating voltage.
04.13.00 Secondary Wiring
04.13.01 The switchgear shall be fully wired at the factory to ensure proper functioning
of control, protection, transfer and interlocking schemes.
04.13.02 Fuses and links shall be provided to permit individual circuit isolation from
bus wires without disturbing other circuits. All spare contacts of relays, switches and
other devices shall be wired up to terminal blocks.
04.13.03 Wiring shall be done with flexible, 660V grade, PVC insulated switchboard
wires with stranded copper conductors of 1.5 Sq. mm. Flexible wire of 2.5 mm2 shall be
used from CT to relay chamber.
04.13.04 Each wire shall be ferruled by plastic tube with indelible ink print at both end
having terminal block no., terminal numbers, destination no. as per approved Wiring
Diagram.
04.13.05 Wire termination shall be made with crimping type connectors with
insulating sleeves. Wires shall not be spliced between terminals.
04.13.06 All spare contacts of relays, timers, auxiliary switches shall be wired up to the
terminal block.
04.14.00 Terminal Blocks
04.14.01 650V grade, multi way terminal block complete with mounting
channel, binding screws and washers for wire connections and marking strip for circuit
identification shall be provided for terminating the panel wiring. The terminals shall be
screw or screw less (spring loaded)/cage clamp type with lugs. All panel wiring for
external connections shall terminate on separate TBs which shall be suitable for
connecting two stranded conductor of 2.5 sq mm on each side or alternatively TBs shall
have the possibility of double shorting space to facilitate looping (typical). Terminals for

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C.T. secondary leads shall have provision for shorting and grounding. For CT wiring,
Disconnecting type TBs shall be provided.
04.14.02 Not more than two wires shall be connected to any terminal. Spare terminals
equal in number to 20% active terminals shall be furnished. Separate terminal blocks shall
be used for AC/ DC wiring termination.
04.14.03 Terminal blocks shall be located to allow easy access. Wiring shall be so
arranged that individual wires of an external cable can be connected to consecutive
terminals. All terminals going out of the switchboard shall be connected /wired to a separate
terminal block marked “External Termination”. These shall be easily accessible.
04.14.04 Terminal blocks used for interface with DCS/PLC/Plant Control System via
termination cabinet shall be suitably sized to facilitate proper termination of interconnecting
cables.
04.15.00 Cable Termination
04.15.01 Switchgear shall be designed for cable entry from bottom. Sufficient space
shall be provided for ease of termination and connection.
04.15.02 All provisions and accessories shall be furnished for termination and
connection of cables, including removable gland plates, cables supports, crimp type
tinned copper/ aluminum lugs, brass compression glands with tapered washer (Power
cables only) and terminal blocks.
04.15.03 Gland plates shall be minimum 3 mm thick. The gland plate and supporting
arrangement for Incoming power cables shall be of aluminum.
04.15.04 Sufficient space shall be provided between the power cable termination and
gland plate. Core balance CTs wherever specified, shall be accommodated within this
space, inside the cubicle. Sufficient space and support arrangement shall be available inside
each panel to accommodate HT cable termination kits and sealing kits suitable for the size
and number of XLPE, Aluminum cables to be terminated.
A minimum clearance of 600 mm shall be kept between cable lug bottom ends and gland
plates for stress cones for XLPE cables.
Dummy panels shall be provided adjacent to the switch panel where the required
number of cable termination can be accommodated in the cabling chamber of the main
panel. Rear extension not acceptable.
04.16.00 Bus Duct Connection
04.16.01 Bus duct connections, wherever provided shall be furnished along with
transition panel if required. Bus duct connections shall be generally from the top without
exceeding allowable temperature rise.
04.16.02 All connecting bus work shall have the same continuous rating as associated
switchgear bus and shall be fully braced for the listed short circuit current.
04.16.03. All provisions such as matching flange and other accessories required for

& ITS AUXILIARIES
proper connection to bus duct shall also be supplied.

04.17.00 Ground Bus
04.17.01 A ground bus, rated to carry maximum fault current, shall extend for the
full length of the switchgear.
04.17.02 The ground bus shall be provided with two-bolt drilling with G.I. bolts and
nuts at each end to receive 75 x 10 mm G.I. flat.
04.17.03 Each stationary unit shall be connected directly to the ground bus. The frame
of each circuit breaker and draw out VT unit shall be grounded through heavy multiple
contacts at all times except when the primary disconnecting devices are separated by a safe
distance.
04.17.04 Wherever, the schematic diagrams indicate a definite ground at the
switchgear, a single wire for each circuit thus grounded shall be run
independently to the ground bus and connected thereto.
04.17.05 CT and VT secondary neutrals shall be earthed through removable links so
that earth of one circuit may be removed without disturbing other.
04.18.00 Earthing Truck (Rating of the earth truck shall be in line with the associated
board)
Earthing trucks shall be provided for earthing the switchgear bus bars or
outgoing cables. The trucks shall have a voltage transformer and an interlock to prevent
earthing of any live connection. The trucks shall have audio-visual annunciation to warn
the operator against earthing of live connections. It shall not be possible to use bus-
earthing truck for cable earthing & vice versa. Earthing truck shall be non- fault making
type. Circuit breakers provided with integral earth switch, as an alternative, is not
acceptable. Rating of the earth truck shall be in line with the associated board.
04.19.00 Name plates
04.19.01 Each switch board shall have a name plate for its identification. All
enclosure mounted equipment shall be provided with individual engraved name plates for
clear equipment identification. All panels shall be identified on front as well as backside
by large engraved name plates giving the distinct feeder description along with panel
numbers. Back side name plates shall be fixed in panel frame and not on the rear
removable cover.
04.19.02 Name plate shall be of non-rusting metal or 3-ply lamicoid with white
engraved letterings, on black background. Inscriptions and lettering shall be subjected to
owner's approval.
04.19.03 Suitable stenciled paint mark shall be provided for identification of all
equipment, located inside the enclosure, as well as for door mounted equipment, from the
back side in addition to plastic sticker labels, if provided. These labels shall be located
directly by the side of the respective equipment, shall be clearly visible and shall not be
hidden by equipment wiring. Labels shall have device number as mentioned in wiring

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drawings. Type of labels and fixing of labels shall be such that they are not likely to peel
off / fall off during prolonged use.
04.19.04 Caution notice on suitable metal plate shall be affixed at the back of each
vertical panel.
04.20.00 Space Heaters and Plug Sockets
04.20.01 Each cubicle shall be provided with thermostat controlled space heaters and
5A, 3 pin plug socket.
04.20.02 In addition, motor feeder cubicle shall be wired-up for feeding the
motor space heater through suitable rated breaker auxiliary NC contact and/or
contactor.
04.20.03 Cubicle heater, Motor heater, Plug/socket circuits shall have individual
switch fuse units.
04.21.00 A.C/D.C Power Supply
04.21.01 Necessary 415V AC and 220V DC power supplies as required for control and
service, shall be arranged by the bidder. Duplicate feeders shall be arranged for AC
and DC supply.
04.21.02 MCCB/MCB shall be provided at each switchgear for the incoming
supplies, 4-pole, for AC and 2-pole, double throw and off for DC. Automatic changeover
scheme shall be provided for the two incoming feeders for DC supply.
Provision for Alarm/annunciation at remote shall be provided for ‘DC supply failure’ for
each of incoming feeders.
04.21.03 Bus-wires of adequate capacity shall be provided to distribute the incoming
supplies to different cubicles. MCCB/MCB/Isolating switch fuse units shall be
provided at each cubicle for AC/DC supplies. Provision for Alarm/annunciation at remote shall
be provided for ‘panel AC supply failure’ & ‘panel DC supply failure’
04.21.04 AC load shall be so distributed as to present a balance loading on three-phase
supply system.
04.21.05 DC Sub circuits (Control, spring charging motor , indication etc.,) of each panel
shall be protected by HRC fuses.
04.21.06 Control Supply Arrangement
(a) DC feeders of adequate rating shall be used for DC control supply of each
switchboard. DC feeders shall be terminated in bus-coupler breaker or bus PT module or
central panel of the switchboard with facility for auto changeover for DC supply.
(b) Isolating MCB of adequate rating shall be provided for incoming DC Control supply
feeders.
(c) DC control bus wire shall run throughout the length of the switchboard and DC
power supply for each cubicle shall be tapped through isolating MCBs of adequate rating,
for control, signaling, protection and motor circuit. Each incoming and sub-circuit shall be

& ITS AUXILIARIES
provided with separate MCBs. Main and sub-circuit MCB shall be selected to ensure
selective clearance of sub-circuit fault.
(d) Availability of DC control supply shall be supervised by auxiliary relay with
adequate number of NO/NC contacts for DC supply healthy indication on the switchboard
and failure of DC supply annunciation in DCS shall be provided.
(e) Auxiliary relays shall be provided instead of contactors wherever there is a
continuous application of 220V DC control supply. The auxiliary relays shall be rated for
240V DC.
(f) Similar arrangement shall be made for 240V single phase AC auxiliary power
supply for space heater, 240V inter panel illumination and plug point circuit for hand lamp
connection.
04.22.00 Tropical Protection
04.22.01 All equipment, accessories and wiring shall have fungus protection,
involving special treatment of insulation and metal against fungus, insects & corrosion.
04.22.02 Screens of corrosion resistant material shall be furnished on all ventilating
louvers to prevent the entrance of insects
04.23.00 Painting
4.23.01 All surfaces shall be sand blasted, pickled and grounded as required to
produce a smooth, clean surface free of scale, grease and rust.
4.23.02 After cleaning, the surfaces shall be given a phosphate coating followed by 2
coats of high quality primer and stoved after each coat.
4.23.03 The switchgear shall be finished in light gray color with two coats of
powder paint. The coating shall be done electro statically followed by stoving.
4.23.04 Sufficient quantity of touch-up paint shall be furnished for application at site.
04.24.00 Accessories
Following accessories shall be furnished along with each Switchgear :
a. Earthing equipment suitable for earthing the bus.
b. Earthing equipment suitable for earthing the outgoing cable.
04.25.00 Each board shall be supplied with
1 set of test plugs.
Any other special purpose tools for maintenance.
5.00.00 Tests
5.01.00 The switchgear shall be completely assembled, wired, adjusted and tested at
the factory as per the relevant standards.
5.02.00 Routine Test
The tests shall include but not necessarily limited to the following :

& ITS AUXILIARIES
a) Operation under simulated service condition to ensure accuracy of wiring,

correctness of control scheme & proper functioning of the equipment.
b) All wiring and current carrying part shall be given appropriate High Voltage test.
c) Primary current and voltage shall be applied to all instrument transformers.
d) Routine test shall be carried out on all equipment such as circuit breakers,
instrument transformers, relays, meters etc. as per relevant standard.
5.03.00 Type Test
Following minimum tests shall be performed on a representative sample of 6.6 KV
switchgear bus assembly, even if the equipment is already type tested.
a) Impulse Test
b) Temperature rise Test
c) Internal Arc Test
5.04.00 Test Witness
All
tests shall be performed in presence of Owner/ Purchaser’s Consultant
representatives, if so desired by the Purchaser/Consultant.
5.05.00 Test Certificate
5.05.01 Certified reports of all the tests carried out at the works shall be
furnished in requisite number of copies for approval of the Purchaser/Consultant.
5.05.02 The equipment shall be dispatched from works only after receipt of Owner
/ Purchaser's acceptance/approval of the test reports.
5.05.03 Type test certificate on any equipment shall be furnished. Otherwise the
equipment shall have to be type tested, free of charge, to prove the design.
6.00.00 Special Tools & Tackles
6.01.00 A set of special tools & tackle which are necessary or convenient for erection,
commissioning, maintenance and overhauling of the equipment shall be supplied.
6.02.00 The tools shall be shipped in separate containers, clearly marked with the
name of the equipment for which they are intended.
07.00.00 Microprocessor based Numerical Relay ( 6.6 kV SYSTEM)
The Numerical Relay for 6.6kV Switchgears shall comply with but not limited to the
following technical requirements.
1 Purpose Protection, Metering and Monitoring of Incomer,

Tie/Board, Motor and Transformer feeders.
2 Auxiliary Supply 220V DC
3 CT Secondary 1Amp.
Current
4 PT Secondary 110V AC, 3 Phase
Voltage
5 Ambient Temperature 50oC
6 Communication The relay shall be provided with two redundant
IEC61850 compatible communication ports with
parallel redundant protocol at rear for

& ITS AUXILIARIES
communication to EMS / station DDCMIS and one

front port suitable for laptop connection
7 Input & Output Required number of analog and digital
inputs/outputs as per scheme requirement with
spare.
8 Metering Complete metering for Incomer, Tie/Board, Motor
and Transformer feeders etc. as per Annexure-B
9 Protection Complete protection for Incomer, Tie/Board, Motor
and Transformer feeders etc. as per Annexure-B
10 Monitoring Self-diagnostic facility.
11 Facility to be made • Programming keys for complete access
available in the with out computer (built in)
Numerical relay. • Provision for external programming unit
through suitable software and communication ports.
• Display unit.
• Read/Write set points.
• Current & Voltage actual values and any
other analog measurement.
• ON/OFF/TRIP indication.
• Event recording with Pre-trip data with
starting characteristics.
• Statistical data.
• Output relays.
• Tamper proof security system.
8.00.00 Drawings, Data & Manuals
8.01.00 To be submitted for Owner / Purchaser’s Approval and Reference
(A) : ‘Approval Category’
(R) : ‘Reference Category’
8.01.01 Guaranteed Technical Particulars (A)
8.01.02 General Technical Particulars (A)
8.01.03 Dimensional General Arrangement drawing of the equipment (A), Foundation
Plan with Loading / Load data (R), Heat Load per cubicle/panel (R)
8.01.04 Single Line Diagrams (A)
8.03.05 Control schematic (R) and wiring diagrams (R)
8.01.06 Bill of material (R)
8.01.07 Type test certificate of the offered model of the circuit breaker
and switchboard for the specified type tests (R)
8.01.08 Routine Test Reports (R ) / Internal Test Reports

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8.01.09 Back up calculation for selection of

i) Busbar size and rating (A)
ii) CT, VT & Breaker ratings (A)
8.01.10 Quality assurance plan (R)
8.01.11 Cable schedule & cable termination chart (R)
8.01.12 Earth Truck Drawing (R)
8.01.13 Relay setting charts/drawings with back up calculations and co-ordination
curves. (R)
8.01.14 Instruction manuals on circuit breakers and its accessories (R)
The manual shall clearly indicate method of installation, check up and tests to be carried
out before commissioning of the equipment.
8.01.15 Leaflets on equipment and other accessories explaining their constructional
details, principle of operation, special features etc (R)
8.02.00 The drawings and document marked with (A) above are of
‘approval’ category and are subject to review by Owner / Purchaser. Those marked (R) are
for ‘reference’ category.
The bidder shall note that the approval of drawings & documents by the Owner /
Purchaser does not relieve him of his contractual obligation and responsibilities for smooth,
trouble-free satisfactory functioning of the offered equipment and accessories
8.03.00 All drawings shall be prepared by using Auto CAD, approved version
and documents shall be generated using MS Office. All final drawings and
documents shall be submitted in CD in Auto CAD (approved version) and MS office
format as applicable for Owner / Purchaser’s future reference.
8.04.00 As built drawings and documents incorporating changes/revisions, if any,
during erection, commissioning and testing of the equipment and accessories shall be
submitted by the bidder after successful commissioning of the system/equipment
8.05.00 The bidder may note that the drawings, data and manuals listed herein are
minimum requirements only. The bidder shall ensure that all other necessary write-ups,
curves and information required to fully describe the equipment and accessories are
submitted. Any relevant drawing or data necessary for satisfactory installation,
commissioning, operation and maintenance of the equipment and accessories shall be
submitted by the bidder for purchaser’s/consultant’s reference/review.


& ITS AUXILIARIES
ANNEXURE-A
RATINGS AND REQUIREMENTS
1.0 SWITCHGEAR 6.6 KV

1.1 General
Type Metal-clad , drawout
Service Indoor
Enclosure IP:5X for VT/ relay compartment and
IP:4X for other compartments
1.2 System
Voltage 6600 ± 10%
Phase 3
Frequency 50 Hz +/- 5%
System ground Non-effectively earthed through resistance
1.3 Rated Current at 50 Deg.C
Bus bar To be decided by bidder after furnishing &
approval of relevant calculations / As per SLD
Circuit breaker To be decided by bidder / As per SLD
1.4 Short Circuit Rating
Short time for 3 Secs 40 KA
1.5 Insulation level 60/20KV (peak/r.m.s)
1.6 AC/DC Power Supply
Control voltage 220 V DC
Service voltage 240 +/- 10%, 1 Ph, 50 Hz +/- 5%
2.0 CIRCUIT BREAKER
2.1 Duty Cycle -0 - 3' - CO - 3' - CO-
2.2 Breaking Current
A.C. Symmetrical 40 KA
A.C. Asymmetrical As per IEC
2.3 Making Current 100 KA peak
2.4 Operation Time
Opening time (ms) Not more than 60
Closing time (ms) Not more than 100
2.5 Auxiliary Voltage
Closing 220 V DC (187-242V )
Tripping 220 V DC (154-242V)
Spring Charging 220 V DC (187-242V )
3.0 Current transformer details
(i) Type Cast resin bar primary
(ii) Class of Insulation Class E or better

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4.0 Voltage transformer details

Type Cast Resin
Rated Voltage - Primary 6600 / 3 V
Rated Voltage - Secondary
110 / 3 V
Rated Voltage Factor 1.2 continuous and 1.9 for 3 sec. for Y
connected VTs
Class of insulation Class E or better
5.0 Meters (If provided separately)
Accuracy Class 1.0 or better, 0.2 for station & unit incomers


& ITS AUXILIARIES
ANNEXURE-B
PROTECTIONS
01.00.00 In case any trip function is not available in a single relay, separate
numerical relays shall be provided to achieve the requirement.
02.00.00 All protective relays shall be provided with self reset type of contacts.
03.00.00 Apart from protection relays, each breaker shall be provided with
separate discrete auxiliary relays for anti-pumping (94), trip
annunciation (30), trip supervision (74), electrically reset type
breaker contact multiplication (52X) relay and lockout (86)
functions. Lockout relay shall be hand reset type. For
multifunction relays however, trip circuit supervision function as
an integral feature of the relay is acceptable. Individual trip circuit
supervision function shall be provided with respect to each trip coil of
circuit breaker.
04.00.00 Numerical under voltage relays (27) with time delay relay
including VT fuse failure relay shall be provided for Bus VTs.
05.00.00 IDMTL relay version shall be decided as per system requirement and
the same shall be finalized during detail engineering.
06.00.00 Zero-sequence CT and associated relay combination shall be
such as to ensure a pick-up sensitivity of 10A primary ground fault
current.
07.00.00 Separate locked rotor protection relay (50 LR) with auxiliary relay
(50 LRX) shall be furnished, if required.
08.00.00 Separate numerical differential relay to be provided for motor 1000
KW and above , Transformer 10MVA and above with separate C.T. of
P.S. Class.
09.00.00 DETAILS OF METERING AND PROTECTION
Numerical relays shall have following protection / metering for the

switchgear panels. The minimum protections / metering required for
various typical feeders shall include, but not be limited to the
following:
(a) Incomers
Protections Metering / Local Indication

• Inverse time Overcurrent protection Remote Metering
• Inverse time Earthfault protection • KW, KWh
• DC supply failure protection • Voltage – phase to phase (all the


& ITS AUXILIARIES
three phases), phase to neutral

• Trip Circuit supervision relay • Current in all the three phases
• Trip Lockout relay Local Indication
• Under Voltage Protection • Current in all the three phases
• No Voltage protection • Voltmeter with Selector Switch
• Restricted Earth Fault Protection (64R)
• Standby Earth Fault Protection (51NS)
• Check synchronising relay
• VT Fuse failure protection
(b) Buscoupler

• Inverse time Earthfault protection • Current on all the three phases
• DC supply failure protection • Voltage – phase to phase (all the
• Trip Circuit supervision relay • KWh
• Trip Lockout relay Local Indication
• No volt & check synchronising relays • Voltmeter with Selector Switch
shall be provided. for Bus A and Bus B
• Current in all the three phases
(c) Tie breakers/Board feeders (as applicable)

• Inverse time Earthfault protection • Current on all the three phases
• Core balance protection • Voltage – phase to phase (all the
• DC supply failure protection • KWh
• Trip Circuit supervision relay Local Indication
• Trip Lockout relay • Voltmeter with Selector Switch
for Bus A and Bus B
• Check synchronising relay • Current in all the three phases
• No volt relays shall be provided.
(d) Bus PT Feeders

• Under voltage protection Remote Metering

& ITS AUXILIARIES
• Fuse failure protection • Voltage – phase to phase (all the

• No Voltage protection Local Indication
• Voltmeter with Selector Switch
for Bus A and Bus B
(e) Motor feeders

• Composite motor protection (99) to Remote Metering
cover a minimum of protections such as
Thermal Overload Protection (50I),
Restart Inhibit Protection (49), Short
Circuit Protection (50), Earth Fault
Protection (50N/50N2), Negative Phase
Sequence Protection (46), Locked
Rotor Protection (50 L/R), Number of
starts limitation (66),Under Voltage
protection with timer (27 M), Circuit-
breaker failure protection (50 BF), Fuse
fail protection (60) etc.
Winding temperature
Bearing Temperature
• Differential protection for motor • kW, KWh, Current in all the three
feeders (rated 1000kW or above) phases.
Local Indication
• KW, Current in all phases
(e) Transformer Feeders

• Overcurrent protections Remote Metering
• Earthfault protection • kW
• Short circuit protection • kWh
• Winding temp trip • Current on all the three phases
(for both dry type and oil filled)
• Buchholz relay (for oil filled) Local Indication
• Oil Temperature trip for oil filled Current in all phases
transformer.
• Core balance protection
• Pressure Relief Device trip
• Conservator oil level low (for oil


& ITS AUXILIARIES
filled)alarm
• Differential protection (for transformers
rated 10MVA and above)
• Restricted Earth Fault protection (64R),
Stand by earth fault protection (51N)
(f) Line VT Feeders

• Voltage supervision • Voltage – phase to phase (all
the three phases), phase to
neutral
Local Indication
• Voltmeter with Selector
Switch for Bus A and Bus B
(g) LED indicating lamps indicating voltage healthiness in all the three phases for Bus PT & Line
PT shall be provided.
The above list (for metering & protection) is indicative only. Bidder shall provide all
metering and protection features necessary for smooth, trouble-free, satisfactory
functions of the equipment and accessories


& ITS AUXILIARIES
ANNEXURE – C
INTERFACE WITH DCS
A. HT SWITCHGEAR - ELECTRICAL
1. Incomers – 1 & 2
a. Breaker Close DO
b. Breaker Trip DO
c. Breaker ON DI
d. Breaker OFF DI
e. Switchgear Disturbance (Control Supply DI
Fail)
f. Numerical Relay Unhealthy DI
g. Trip Coil Healthy DI
h. DC Supply-1 Fail DI
i. DC Supply-2 Fail DI
j. Switchgear Available (Breaker in service / DI
Spring Charged / Switchgear in Remote)
k. Electrical Trip (Lockout relay operated) DI
l. Interface through IEC
Numerical Relay
61850 protocol
2. Line PT – 1/2
a. Line PT under voltage DI
b. Line PT Fuse Fail DI
c. PT in service position DI
3. Bus-coupler
a. Breaker Close DO
b. Breaker Trip DO
c. Incomer-1 Check Syn DO
d. Incomer-2 Check Syn DO
e. Bus Coupler Check Syn DO
f. Breaker ON DI
g. Breaker OFF DI
h. Switchgear Disturbance (Control Supply DI
Fail)
i. Numerical Relay Unhealthy DI
j. Trip Coil Healthy DI
k. DC Supply-1 Fail DI
l. DC Supply-2 Fail DI
m. Switchgear Available (Breaker in Service / DI
n. Electrical Trip (Lockout Relay Operated) DI

& ITS AUXILIARIES
o. Numerical Relay Interface through IEC

61850 protocol
4. Bus PT – 1/2
a. BUS PT under voltage DI
b. BUS PT Fuse Fail DI
c. PT in service position DI
5. Outgoing Feeder
a. Breaker Close DO
b. Breaker Trip DO
c. Breaker ON DI
d. Breaker OFF DI
Fail)
h. Switchgear Available (Breaker in Service / DI
i. Electrical Trip (Lockout Relay Operated) DI
j. Numerical Relay Interface through IEC
61850 protocol
6. Transformer Feeder (Dry Type)
a. Breaker Close DO
b. Breaker Trip DO
c. Breaker ON DI
d. Breaker OFF DI
Fail)
h. Winding Temperature High (A) DI
i. Winding Temperature High (T) DI
j. WTI Surveillance Unit unhealthy DI
k. Switchgear Available (Breaker in Service / DI
l. Electrical Trip (Lockout Relay Operated) DI
m. Numerical relay Interface through IEC
61850 protocol
BB. TECHNICAL SPECIFICATION FOR L.T. TRANSFORMERS

01.01.00 The scope of supply shall include dry type transformers. Number and

& ITS AUXILIARIES
ratings shall be finalized based on selection criteria given in this specification

and in line with the actual requirement to be finalized during detail engineering
stage.
01.01.01 Each transformer shall be furnished complete with :
a) Fittings and accessories
b) Auxiliary equipment
IEC : 60076, 60354, 60726
accordance with the latest applicable Indian Standards (IS) and IEC except
where modified and / or supplemented by this specification.
02.01.02 Equipment and material conforming to any other standard, which ensures
equal or better quality, may be accepted. In such case, copies of the English
version of the standard adopted shall be submitted .
02.01.03 The electrical installation shall meet the requirements of Indian
Electricity Rules as amended up to date and relevant IS Code of Practice.
In addition, other rules and regulations applicable to the work shall be
followed.
03.01.00 Sizing Criteria
03.01.01 The transformers shall be used to supply power to other units and auxiliary
L.T. loads of FGD plant.
03.01.02 Power at 6600V level shall be transformed to 415V level through L.T
transformers at load centre to cater to the L.T. loads of plants and systems
at and near the respective load centres.
03.01.03 Each of the main L.T. boards which are directly connected to the L.T.
transformers shall be fed from 2x100% capacity transformers. During normal
operation each transformer shall cater for about half of the total load of the
L.T. board with the bus section breaker in open condition. In emergency
condition of one transformer being out of service the other transformer shall
cater for the total load of the corresponding L.T. board.
03.01.04 20% spare margin shall be considered while selecting the transformer.
Diversity factor with a minimum of 0.9 for continuous running loads and 0.4
for intermittent loads like cranes, hoists, elevators, sump pumps etc. shall be
considered.

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03.01.05 Voltage at load terminal

a) Under full load condition of the L.T. board, the voltage shall not drop
below 90% on the load voltage base.
b) At light load condition, the voltage shall not exceed 110% on the load
voltage base.
c) During largest motor starting the voltage shall not drop below 80% on the load
voltage base with an initial load on transformer equal to full load on L.T. board
minus the running load of the motor which has been started.
03.01.06 With a view to standardize the rating, the following transformer sizes &
impedances ( impedance subject to tolerance as per IS) may be chosen :
a) Capacity 2500/2000 KVA

b) Voltage HT : 6600KV LT : 0.433KV
c) Impedance 12% / 10 %
03.01.07 All L.T. transformers shall be Dry type suitable for indoor use and shall be kept
near the switchgear
3.02.01 One no Transformer Temperature scanner with RTD Duplex type winding
temperature assembly shall be provided for winding temperature measurement.
These shall give alarm at 120 deg C and give trip signal to trip the transformer
incoming breaker at 140 deg C through the RTDs. Additionally, the signals shall
be taken to the PLC / Plant Control System for surveillance/ trending.
03.02.02 Two numbers Earth fault CTs, one back up and one restricted E/F shall be
provided.
03.03.00 The transformer shall be capable of continuous operation at specified rating under the
following condition :
a) Voltage variation : ± 10%
b) Frequency variation : ± 5%
c) Combined voltage and frequency variation (absolute sum) : 10%
03.04.00 The transformer shall be capable of withstanding the short circuit stresses due
to a terminal fault on one winding with full voltage maintained on the
other winding as per the relevant IS.
03.05.00 The transformer shall be free from annoying hum or vibration. The design shall
be such as not to cause any undesirable interference with radio or
communication circuits.
03.06.00 The noise level shall be limited to the value specified by NEMA
Standard Publication No. TR-1-1993 when measured in accordance with
conditions outlines in ANSI/IEEE C57.12.90-1999/IS13964/CBIP publication.

& ITS AUXILIARIES
03.07.00 The transformer shall be installed in hot, humid and tropical atmosphere.
All equipment, accessories and wiring shall be provided with tropical
finish to prevent fungus growth.
03.08.00 The dry type transformers shall be epoxy cast resin/ resin encapsulated
type. They shall be naturally cooled (AN) and moisture proof. Insulating
materials used in construction shall be of low smoke emitting type, less
flammability and free from toxic gas emission.
04.01.00 Enclosure for Dry Type Transformer
04.01.01 The transformers shall be housed in enclosures fabricated from sheet steel of
minimum 2mm thick. Degree of protection of the enclosure shall be at least
IP33. Screens shall be perforated sheet steel type. Mesh size shall be such that
lizard, rats etc. cannot enter inside the enclosure.
04.01.02 The enclosure shall be adequately reinforced to ensure rigidity so as to permit
transportation of transformer within enclosure. Base frame for mounting the
transformer shall be minimum 4 mm thick and shall be provided with
bi-directional rollers/mounting skid.
04.01.03 Double leaf access, both at front and at rear end, shall be provided with
concealed hinge and neoprene gaskets for easy access and also for withdrawal
of core and coil assembly if required. Enclosure door shall have provision of
padlocking in door-closed position.
04.01.04 Enclosure shall be provided with lifting eyes and pulling lugs Heavy removal
parts shall be provided with eyebolt for ease of handling.
04.01.05 Each transformer shall be provided with one set of bi-directional rollers
for rolling the transformer parallel to either centre line.
Enclosure temperature during full load operating condition shall be limited to below
70ºC.
04.02.00 Core & Coils
04.02.01 The transformer may be of core or shell type. The core shall be built up with
high grade, non-aging, low loss, and high permeability grain oriented cold-
rolled silicon steel laminations especially suitable for core material.
04.02.02 The coils shall be manufactured from electrolytic copper conductor and fully
insulated for rated voltage. For dry type transformer of encapsulated design,
HV & LV coils shall be separately encapsulated under vacuum in cast resin
compound.
04.02.03 Insulating material shall be of proven design, Coils shall be so insulated that
impulse and power frequency voltage stresses are minimum. For dry type
transformer the insulating material shall be glass fibre reinforced conforming
to class `F’. Coils shall be so insulated that impulse and power frequency

& ITS AUXILIARIES
voltage stresses are minimum and are suitable to withstand even the
severest of temperature fluctuation.
04.02.04 All leads from the windings to the terminal board and bushings shall be
rigidly supported to prevent injury from vibration or short circuit stresses.
Guide tube shall be used where practicable.
04.02.05 The core and coil assembly shall be securely fixed in position so that no shifting
or deformation occurs during movement of transformer or under short circuit
stresses.
04.03.00 Tappings
04.03.01 Off-circuit taps as specified shall be provided on the high voltage winding.
04.03.02 The transformer shall be capable of operation at its rated KVA on any tap
provided the voltage does not vary by more than ±10% of the rated voltage
corresponding to the tap.
04.03.03 The winding including the tapping arrangement shall be designed to maintain
electromagnetic balance between HV and LV windings at all voltage ratios.
04.03.04 The tap changing shall be effected manually by change of copper link at the
terminal board inside the enclosure.
The HV winding of the transformer shall be brought out through suitably rated
bushing mounted on non magnetic material in separate air insulated cable box.
The cable box shall also be provided with facility for supporting from ground.
04.04.00 Safety Interlock
For all dry type transformers following safety interlocks shall be provided :
a) A safety interlock shall be provided to ensure that the enclosure door can be
opened only when transformer is de-energised.
b) Safety limit switches operated by door-handle shall be provided for tripping
HV & LV side breaker.
04.05.00 Bushing
04.05.01 Transformer HV bushings and LV bushings can be either solid porcelain or
epoxy type. Bushing shall be suitable for satisfactory operation in the high
ambient temperature inside Bus Duct enclosure (if applicable). LV flange
area shall be of non-magnetic material.
04.05.02 Bushings shall be provided with terminal connectors of approved type and size.
04.05.03 Bushing location shall provide adequate phase and ground clearances.
04.05.04 The bushings shall be suitable for a heavily polluted atmosphere.
04.06.00 Terminal Arrangements
04.06.01 The physical position of terminals and markings shall be as per the relevant

& ITS AUXILIARIES
standards.
04.06.02 Terminals for bus duct connection shall be brought through top cover mounted
bushings with matching flange.
04.06.03 Bushing terminals and flange shall be coordinated with bus duct.
04.06.04 Terminals for cable connection shall be brought out through top cover/side wall
mounted bushings to a detachable cable-end box with disconnect link.
04.06.05 Cable-end box shall be self-supporting, weatherproof, air filled type
with sufficient space inside for termination and connection of cables.
04.06.06 Cable-end box shall be furnished complete with removable gland plate, double
compression brass glands, tinned copper lugs, armour clamps and necessary
hardware.
04.06.07 In general, the arrangement shall be such as to permit removal of the
transformer and core/coil assembly without dismantling the bus duct/cable
installation.
04.06.08 Low voltage winding neutral shall be brought out thru' top cover mounted
bushing. Two ground conductors 75x10 G.I. flats shall run from
neutral bushing to the bottom of the tank over pin insulators for connection
to two different neutral earth pits.The earth pits shall be treated type.
04.07.00 Marshalling Box
04.07.01 For Marshalling Box the sheet steel used shall be at least 1.6 mm thick cold
rolled. The box shall be tank mounted type.
04.07.02 The degree of protection shall be IP-55.
04.07.03 Wiring Scheme shall be engraved in a stainless steel plate with viewable font
size and the same shall be fixed inside the Marshalling Box door.The
marshalling box shall be provided with cubicle lamp with door switch,
space heater with thermostat and removable cable gland plate. All terminal
blocks shall be located in this box.
Three (3) Nos. resistance winding temperature detectors / thermistors/PT-100 shall be
provided in LV winding of each transformer. Transformers shall be provided
with adequate No. of embedded temperature detectors/temperature scanners
for remote indication in DCS and necessary indication instruments (WTI) in
local.
The temperature detectors shall be wired through terminal box mounted on

transformer and from there, shall be taken to the marshalling box WTI etc.
transformer mounted protective devices shall be provided and wiring from all
these devices shall be brought to one terminal box with cables for connection
to plant protection and controls. The cables should not touch transformer body
to avoid heating.

& ITS AUXILIARIES
Epoxy moulded Neutral CTs (2 Nos.) of required ratings for REF and Backup
earth fault protection shall be provided
04.08.00 Wiring
04.08.01 All control, alarm and indication devices provided with the transformer shall
be wired upto the terminal blocks.
04.08.02 Wiring shall be done with 650V PVC wires in conduit or PVC armoured
cable. Minimum wire size for control wiring shall be 1.5 sq.mm stranded
copper and for CT/PT wiring the size shall be 2.5 sq.mm stranded copper.
Not more than two wires shall be connected to a terminal. 10% spare terminals
shall be provided.
04.08.03 Multi-way terminal block complete with mounting channel, binding screws
and washers for wire connections and marking strip for circuit identification
shall be provided for terminating the panel wiring. Terminals shall be stud
type, suitable for terminating 2 nos. 2.5 mm2 stranded copper conductor
and provided with acrylic insulating cover.
04.08.04 All devices and terminal blocks shall be identified by symbols corresponding
to those used in applicable schematic or wiring diagram. Each wire shall be
identified, at both ends, with interlocking type permanent markers bearing
wire numbers as per Bidder's Wiring Diagrams. AC/DC wiring shall have
separate color-coding. 20% spare terminals shall be provided.
04.08.05 Wire termination shall be made with crimping type connectors with
04.09.00 Grounding
04.09.01 For dry type transformers a ground bus rated to carry the maximum fault current
shall extend full length of the enclosure.
04.09.02 The ground bus shall be provided with two bolt drilling with GI bolts and nuts
at each end to receive the GS flats for earthing. Each flat shall be designed for the
earth fault current as specified in this specification.
04.09.03 The core coil assembly shall be directly connected to this ground bus by
removable bolted link for effective grounding.
04.09.04 Ground terminals shall be also provided on marshalling box to ensure its
effective earthing.
04.09.05 For continuity of earth connection, all gasketted joints shall be provided with
braided copper wire jumpers.
04.10.00 Painting
04.10.01 All steel surfaces shall be thoroughly cleaned by sand blasting and/or chemical
agents, as required, to produce a smooth surface free of scales, grease and
rust.

& ITS AUXILIARIES
04.10.02 The external surfaces, after cleaning, shall be given a coat of high quality red-
oxide or yellow chromate primer followed by filler coats .
04.10.03 The interior and exterior surfaces shall be finished with specified color shades
as per IS-5.
04.10.04 Sufficient quantity of touch up paint shall be furnished for application
after installation at site.
04.10.05 The paints shall be carefully selected to withstand tropical heat, rain etc. The
paint shall not scale off or crinkle or be removed by abrasion due to normal
handling.
04.10.06 All supporting structures and hardware shall be hot dip galvanized.
05.00.00 Tests
5.01.00 Routine Tests
During manufacture and on completion, all transformers shall be subjected to
the routine tests and acceptance test in accordance with latest IS/IEC in
presence of the purchaser or his representative.
5.02.00 Type Tests
Type test certificates shall be furnished for similar type and rating of
transformers. If certificates are not available or not meeting the
requirements , they have to be type tested, free of charge, to prove the
design.
However, following type tests shall be performed on one of each rating of
transformer, even if type test certificates are submitted by the Bidder for
Purchaser's approval:
a) Impulse withstand test
b) Temperature rise test
5.03.00 Miscellaneous
All component parts and auxiliary equipment such as bushings, etc. shall be
routine tested as per relevant Indian Standards.
06.01.00 Drawings, data & manuals to be Submitted.
06.01.01 Typical general arrangement drawings showing enclosure, core coil assembly
and terminal arrangement etc. for dry type transformers.
06.01.02 Transport/shipping dimensions and weights, space required for handling parts
for maintenance.
06.01.03 Technical leaflets on major components and fittings.


& ITS AUXILIARIES
06.01.04 Type test certificate on similar transformer.

06.01.05 Write-up on insulating material used and process of application/method of
construction followed for dry type transformer.
06.01.06 Backup calculation for selection of sizes and quantity of transformers
06.02.00 To be Submitted after Award of Contract
06.02.01 Dimensioned general arrangement drawing showing enclosure, core coil
assembly, terminal arrangement, marshalling box and various fittings.
06.02.02 Transport/shipping dimensions with weights, wheel base detail etc.
06.02.03 Foundation plan & loading
06.02.04 Heat Load
06.02.05 Bus duct/cable termination arrangement.
06.02.06 Control schematics and wiring diagrams.
06.02.07 Test reports and QAP
06.02.08 Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance.
06.02.09 Instruction manuals on Transformer and its various fittings The manual shall
clearly indicate method of installation, checkups and tests to be carried out
before commissioning of the equipment.
06.03.00 The Bidder may note that the drawings, data and manuals listed are minimum
requirement only. The Bidder shall ensure that all other necessary write-ups,
curves and information required to fully describe the equipment are
submitted.


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ANNEXURE-A
Ratings And Requirements
1.0 Application : Auxiliary transformer(dry type)
2.0 Service : Indoor, step-down

3.0 Type : Dry type transformer
4.0 Reference standard : IS 11171, IS 2026 & IEC60076
5.0 Rated power (indicative) : 2000KVA
6.0 Rated voltage ratio (line to line) : 6.6 / 0.433 KV
7.0 Number of phases of each unit : 3
8.0 No. of phases : 3
9.0 Rated frequency : 50 Hz
10.0 Type of cooling (AN or AN/AF ) : AN
11.0 Insulation Class : Class F
12.0 Temperature rise
12.1 Design ambient temperature : 50 degree Centigrade
12.2 Temperature rise above design : 70oC
ambient temperature (in winding
by resistance)
Temp. rise of enclosure by : 20oC
thermometer method
13.0 Insulation level ( LI : Lightning :
Impulse Voltage,
AC: Short duration induced &
separate source AC withstand
voltage)
HV- (LI/AC) : 60 KVp/20 KVrms
LV- (LI/AC) : -KVp/3KVrms
14.0 Vector group : Dyn11
15.0 Short-circuit impedance on : 10% on 2MVA
principal tap
16.0 Parallel operation of transformer : Momentarily
17.0 Type of taps provided : OCTC, full capacity
17.1 Taps provided on : H.V. winding
17.2 Range of taps : +/- 5 % in steps of 2.5%
17.3 Method of Tap charge control- :
a) Manual local : Yes
b) Electrical local : No
c) Electrical remote : No
d) Automatic : No
18.0 Enclosure protection class : IP32 or better
19.0 System earthing :
H.V. : Non-effectively earthed
L.V. : With NGR and ND relay; Neutral current

& ITS AUXILIARIES
shall be limited to < 1 Amp.

20.0 Terminal arrangement :
H.V. : Cable
L.V. : Non-segregated phase busduct
Neutral for earthing : 75x10 mm GS flat
21.0 Transformer bushing : HV LV LV-1
21.1 Voltage class KV(r.m.s.) 7.2 1.1 1.1
21.2 Material : Epoxy cast resin/resin encapsulated
21.3 Creepage distance mm :
: HV LV
21.4 Min. Ph-Ph clearance mm : As per IS As per IS
21.5 Min. Ph-Gr clearance mm : As per IS As per IS
Bushing Neutral CT : Two cores : one for Standby E/F and other
21.6
for REF protection
22.0 System fault Level :
HV Side : 40 KA (r.m.s.)
LV Side : 50KA (r.m.s.)
23.0 Max. Noise level : As per NEMA std. TR-1
24.0 Auxiliary supply : 415 V, 3 ph AC, 50 Hz
220V +10%, -15% 2 wire DC


& ITS AUXILIARIES
ANNEXURE-B
FITTINGS AND ACCESSORIES
Each transformer shall be equipped with fittings and accessories, as listed below:
1. Digital winding temperature scanner with electrical separate contacts of alarm and trip.
2. Handling & lifting lugs for both enclosure and core-coil assembly.
3. Jacking pad for core-coil assembly.
4. Flat type bi-directional rollers with locking arrangement for core-coil assembly.
5. Inspection cover for cable end box.
6. Door handle operated safety limit switch with 1 NO + 1 NC contact.
7. Ground bus.
8. IP-55 marshalling box.
9. Rating and terminal marking plate.
Note:
All indication, alarm, trip contacts provided shall be rated for 0.5A at 220 V DC and 5A
at 240 V AC.


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CC. TECHNICAL SPECIFICATION FOR 415 V PCC/PMCC, MCC, DB,

STARTER PANELS
01.01.00 This specification covers the following equipment complete with all
accessories:
a) 415V Power Control Centers(PCCs)/Power Cum Motor Control Centre(PMCCs)
b) 415V Motor Control Centers(MCCs)
c) 415V Distribution Boards(DBs) / ACDBs
d) DC starter panels
e) 220 V DCDB
f) Miscellaneous panels as per system requirement
The exact number of boards shall be finalized by the bidders based on actual
engineering requirement to be finalized during detail engineering stage.
01.02.00 Base channel frame of all boards along with necessary mounting hardware is
included.
IEC : 60947, IS : 13947
where modified and/or supplemented by this specification.
version of the standard adopted shall be submitted .
02.03.00 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended up to date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
03.00.00 System concept and Design criteria
03.01.00 415V power distribution in the Plant area shall be by means of PCCs,
MCCs and DBs
03.02.00 The PCCs/PMCCs/MCCs/DBs shall be used for providing power to various
LT loads of the plant. PCCs, PMCCs, MCCs, distribution boards shall be
planned as per requirement in various load centres.


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03.03.00 Bidder shall include and provide requisite PCCs, PMCCs, MCCs and
distribution boards for feeding all AC & DC loads including loads like welding
transformers, lighting loads, power sockets, maintenance sockets etc.
03.04.00 The equipment shall be located in a hot, humid, and tropical atmosphere,
heavily polluted at places with coal dust and/or fly ash.
03.05.00 Duty involves direct-on-line starting of large induction motors and also under
certain emergency conditions, automatic transfer of loads from one source of
supply to another.
Motor starting current shall be as per relevant IS for the IE3 motors subject to
tolerance (+20%) as per .IS. PCCs/ PMCCs /MCCs shall be designed
accordingly..
03.06.00 Busbars of PCCs/PMCCs shall be sized to carry continuously the LV side
current of the transformer plus a 20% margin.
Busbars of MCCs/DBs shall be sized to carry continuously the total running
load of the system (including anticipated future load, wherever applicable) plus
a 20% margin.
All busbars shall be capable of withstanding the mechanical forces and thermal
stresses due to maximum short circuit current.
03.07.00 In-cubicle ratings of incomer and bus-section breakers/switches shall be
identical to the associated busbar rating.
03.08.00 For continuous operation at specified ratings, the temperature rise of various
equipment/components shall be limited to the permissible values specified in
relevant standards and/or this specification.
03.09.00 Circuit breakers shall not produce any harmful over voltage during switching
off of induction motors. If required, surge protective devices shall be
included in the scope of supply to limit over voltages.
03.10.00 MCCs shall be used to supply power to contactor controlled motors rated
upto 90kW, local panels, local starter panels etc.
03.11.00 PCCs / PMCCs shall be used to supply power to motor of ratings above 90 to
160KW through ACBs.
03.12.00 Incomers and bus couplers of MCC’s of rating 630Amps and above shall be
through Air Circuit Breakers while incomers & bus couplers of lower rating
shall be through MCCBs.
03.13.00 All Outgoing feeders (non-motor feeders) of PCC/PMCC rated 630A &
above shall be Air Circuit Breakers while rated below 630A shall be MCCB.
03.14.00 Motors upto 90KW shall be provided with MCCB / MPCB, contactors


& ITS AUXILIARIES
03.15.00 Motors rated above 90KW shall have comprehensive motor protection
relays. They shall be numerical type and shall communicate with DCS /Plant
Control System through open protocol (IEC 61850).
04.00.00 Technical Requirements

04.01.00 POWER CONTROL CENTRE(PCC)/ POWER CUM MOTOR
CONTROL CENTRE (PMCC)
04.01.01 PCCs/PMCCs shall be used to feed Motor Control Centers and motors rated
from 90 KW up to and including 160 KW. All PCCs/PMCCs shall have
duplicate incomers and a bus-section, each section rated for 100% of the loads
connected to the switchgear. Incomers, bus-section, and all outgoing feeders of
a PCC/PMCC shall be breaker controlled. Non-motor feeders that are rated
below 630A may have MCCBs. Distribution of outgoing feeders shall be such
as to ensure uniform loading on each section of the PCC/ PMCC.
04.01.02 The switchgears shall be provided with suitable number and type of outgoing
feeders for the respective auxiliary loads of the system/area, power supply
feeders to various panels, lighting, space heating panels, control cabinets and
all other loads encountered in the plant. In addition, following feeders shall
be provided in each bus section of each switchgear.
(a) Spare feeders: 20 % or minimum of one no. feeder of each rating and type
(above quantity is the minimum requirement, at the time of handing over the
plant. Any additional quantity required for any increase/changes during
detailed engineering stage also shall be duly considered.)
(b) Bus VT module: 1 No. for each bus section
(c) Switchgear 240V, 1 phase space heating: 1 No.
(d) Line VT module 1 No. for each Incomer for synchronising purpose.
04.01.03 Short Circuit Currents
The short circuit current of 415V bus is 50kA for 1 sec. The momentary
current rating shall be 2.1 times this value.
04.01.04 Continuous Currents
The continuous current rating of the bus bars, their incomers, bus couplers of
the switchgear which are fed by the transformers shall be rated at the LV side
full load current of the corresponding transformers with 20% margin rounded
off to the next higher standard rating.
The continuous current rating of the bus bars, incomers, bus couplers of the
switchgear fed from other switchgears shall be the maximum load on the bus
due to all the running auxiliaries during any operation condition plus 20%
margin rounded off to the next higher standard rating. For the load
calculation, load factors to be considered shall be 0.9 for continuous loads,
0.4 for intermittent loads.

& ITS AUXILIARIES
04.01.05 Constructional Features

Metal clad Indoor type, single front, floor mounted, free standing design,
single/double tier panels, with dust Proof construction. The construction
shall be compartmentalized with metal / insulation partitions between
compartments.
Cold rolled sheet steel of not less than 2mm thickness for load bearing
members and 1.6mm thickness for other members.
Circuit breaker shall be mounted on fully drawout truck with service, test and
isolated positions and complete with following safety interlocks and safety
shutters with padlock facility:
Truck cannot be moved in or out of cubicle when the breaker is closed.
CB compartment door shall be mechanically interlocked so that it shall not
be possible to close the CB in plug position when the door is open.
Insertion of breaker into service position not possible if the shutters are not
free.
Name plate for each incoming, buscoupler and outgoing at front and back on
the fixed portion of the panel.
All panels shall have space heater with switch and cubicle illumination lamp
with door switch.
The back door shall be hinged type.
Enclosure shall conform to IP52 (min.). For busbar chamber of switchboards
rated above 1600A, degree of protection may be IP-42 (min.).
Busbars:
Three phase, neutral (with at least 50% rating of main bus bar) and
continuous earth Bus. Bus bar and tapping shall be provided with PVC
Sleeve.
Bus bars shall be provided with colour-coded sleeves.
Rating of horizontal buses shall be in line with incomer rating and vertical
bus bar for the compartment shall commensurate with all outgoing feeders.
Temperature rise of bus bars shall not be more than 40 deg C above ambient
of 50 deg C
Bus bar and connection shall be of high conductivity Aluminium alloy /
copper of suitable hardness and purity complying with as per IS 5082.
04.01.06 Air Circuit Breakers: Electrical Features:
Air break triple pole draw out type conforming to IS 2516-1980.

Rated continuous current as specified.

& ITS AUXILIARIES
Symmetrical interrupting capacity shall be 50kA.
Auxiliary contacts : 6 NO + 6 NC minimum convertible from NO to NC and

vice-versa at site.
Make and Continuous current : 10 amps.
Breaking current
AC - 4 amps at 240 V
DC - 0.5 amps at 220 V

Operating Mechanism:
Motor operated mechanism as applicable. Spring charged stored energy
mechanism to ensure high speed closing and tripping independent of the
operating forces.
Anti pumping and trip free feature.
Emergency tripping by mechanically operated trip push button (shrouded to
prevent accidental closing) acting directly on the trip bar.
Mechanical indication to show:
a) Closing spring charged.
b) Breaker ON / OFF / TRIP indication.
Breaker to close only when spring fully charged.
Non-reset type operation counter.
Charging of closing spring by motor.
Closing by closing coil (operating range 85% to 110% of rated voltage).
Spring charging motor and closing & tripping coil suitable for rated control
voltage (220 V DC). Tripping by trip coil (operating range 70% to 110% of
rated voltage).
One opening and one closing operation without control supply.
Provision also for manual closing with spring charging motor automatically
decoupled as soon as charging handle is inserted.
Suitable LOCAL/REMOTE selector switch (lockable type) shall be provided
for all breaker modules.
Drawout Features:
3 distinct position viz. service, test, and isolated with the door closed.
Mechanical position indication and locking / latching facility for all 3
positions.


& ITS AUXILIARIES
Power connections – self aligning, plug-in type contacts.

Control connections – sliding or plug socket type, mechanically coupled, to
prevent wrong insertion, continuous rating 16 amps minimum.
Automatic safety shutters to prevent accidental contact with live parts when
the breaker is withdrawn.
The break contact shall be on the breaker side.
Safety Interlocks:
Breaker cannot be closed in any intermediate position other than the 3 fixed
positions.
With the breaker closed, it cannot be racked in from any of the 3 position to
another.
Mechanical stopper to prevent accidental falling while withdrawing.
Breaker cannot be racked in from isolated to ‘test’ position with the door
open together with provision for defeat of this interlocking, however, the
door can be closed only when the breaker is brought back to ‘isolated’
position.
Door can be opened only when breaker is OFF and is in ‘Isolated’ position.
Remote closing of breaker not permitted with door open.
Insertion of breaker into ‘Service’ position not possible if the shutters are not
free.
Internal Control Wiring
Control Wiring by 660 V grade PVC insulated, single core stranded copper
conductor of min. cross section 1.5 sq.mm. CT/PT wiring shall be of 2.5 sq.
mm cross section.
Flexible wire, protected against mechanical damage for wiring to door-
mounted devices.
Wires identified at each end in accordance with schematic diagrams by
interlocked type ferrules.
All connections external to a feeder, all the auxiliary contacts of the LT
breaker and at least 1 NO + 1 NC spare contacts of the relays brought to
terminal blocks.
Interconnection between panels of adjacent shipping sections to be brought
out to a separate terminal block, wires for interconnection properly labelled,
looped and bunched inside the panel for connection at site.
Not more than two connections on any one terminal.
All spare contacts wired upto terminal block of the panels.

& ITS AUXILIARIES
650V grade multiway terminal blocks of non tracking moulded plastic

complete with insulated barriers, stud type terminals, washers, nuts and lock
nuts and identification strips.
Power and control terminals segregated.
Open type control terminals of minimum rating 10 A suitable to receive 2.5 /
4.0 sq.mm copper conductor. It shall be ensured that there is free access to
the control terminals after termination of all cables.
20% spare terminals in each control terminal block.
Power Terminations:
Suitable for accepting cables / bus trunking as specified.
Protective Devices
The circuit breaker shall be provided with the following protective devices
with suitable setting ranges.
• All required protections as per system requirement and as indicated
in various part of this specification.
• Shunt Trip coil for remote tripping rated for 220V DC. It should trip
at minimum 70% of rated voltage.
All the control, protection and signalling circuits of each circuit breaker
(incoming and outgoing feeders) shall be fed through MCBs and the
individual circuits may be protected by HRC fuses.
Control Supply
Two 220 V DC feeders shall be provided in each board for power supply of
control, shunt tripping and annunciation purpose.
Control supply shall have supervision facility, alarm shall be provided for
non-availability of any one of the control supply.
MCCBs/MCBs shall be provided on incoming sides of supplies. Control
buses of two sections shall be connected through auto changeover scheme.
LEDs shall be provided for the indication purpose.
Isolation arrangement shall be provided on each panel to facilitate fault
location and testing. Separate fuses shall be provided for spring charging
motors, for indication lamps and for closing / Tripping circuits of each
cubicle.
Breaker Handling Truck
One for each switch board, for withdrawing the breakers from the switch
board.


& ITS AUXILIARIES
Height of platform adjustable to suit the levels at which the breakers are
mounted.
Adequate mechanical strength for handling the largest breaker.
Guide rails and stops.
Truck shall be hydraulic operated.
04.02.00 LT MOTOR CONTROL CENTRES
04.02.01 Motor Control Centers (MCCs) shall house breaker panels, MCCB &
contactor operated modules etc. All MCCs shall have duplicate incomers and a
bus-section. All incomers and Bus-coupler shall have ACB’s for MCCs rated
630 Amps and above and shall have MCCB’s for MCCs rated below
630Amps. Suitable interlock shall be provided to satisfy the condition of two
out of three closing. All outgoing feeders shall be breaker/MCCB operated
with or without contactor depending upon the rating and application. All motor
feeders other than those operated through breakers shall have Bi-metal
overload relay with single phase preventor for protection. All motors above 30
kW shall have CT operated overload relay with single phase preventer for
protection. All breaker operated motor feeder modules shall have numerical
motor protection relays that can be interfaced with the DCS/PLC/Control
System. Distribution of outgoing feeders shall be such as to ensure uniform
loading on each section of the MCC.
04.02.02 Constructional Features
General:
Fully drawout type with modules having service, test and isolation positions.
Floor mounting, free standing with base channel for fixing on the inserts on
the floor.
Single front, totally enclosed, dust and vermin proof. However, for extreme
space constraint and/or to suit the overall layout for a chosen space/premises,
bidder may propose, in their offer, double front MCCs for review and
acceptance of the purchaser/consultant. In general, double front MCCs shall
be avoided unless prior intimation by bidder is done and subsequent
acceptance by the owner/consultant is obtained.
Degree of protection IP-54 or better.
Sheet steel with thickness not less than 2.0mm for load bearing and 1.6mm
for other members.
Provision of extension on either end of MCC.
Removable lifting facilities for each transport unit.
Designation plate for each MCC and Inscription plate for each module.


& ITS AUXILIARIES
Length of each transportable unit not more than 2.4 M

Compartment design
Pilot devices operable from the front.
Operating height not to exceed 1800mm.
Vertical wire way to accommodate all cables.
Components and devices accessible from front.
Protection against accidental contact with live parts while maintaining a
compartment and keeping others in service.
Anti rusting, undrilled removable gland plates to be provided.
Cable entry from bottom unless otherwise specified.
Compartment door interlocked with the main power isolating device for
safety with provision for defeating it by authorized person.
All compartments to have covering at the bottom to preclude entry of dust,
rats, lizards etc.
Space of about 200mm to be left vacant at bottom throughout the length of
the MCC for ease of cabling.
Power circuit isolation device to have facility for locking
In test position module control supply shall be disconnected and provision
shall be available to test the control circuit through test bus, obtained from
separate control transformer provided for this purpose.
04.02.03 Busbars
Busbars shall be of aluminium alloy / copper.
Power busbar joints shall be bolted type with spring washers. Bolts and
washers shall be cadmium plated.
Busbars shall be 3 phase and neutral running horizontally or vertically.
Busbar sizes to be selected in accordance with nominal current rating of
incoming Circuit breaker for full short-circuit power.
All bus connections shall be provided with anti-oxide grease. Adequate contact
pressure shall be ensured by means of two-bolt connection with plain and
spring washers and locknuts.
Bimetallic connectors shall be provided for connections between dissimilar
metals.
Busbars shall be insulated by colour coded PVC sleeves,
Neutral bus shall run on insulators with facility for connection to earth
busbar.

& ITS AUXILIARIES
Earth bus shall run throughout the length of MCC at bottom and for each
vertical section.
Busbar configuration shall be red-yellow-blue for three phase AC power and
red - blue for DC control supply from front to back or top to bottom or left to
right as viewed from front.
Temperature rise not to exceed 40 degree C above the peak ambient
temperature of 50 deg C.
Removal of busbars shall be possible without disconnecting external cables.
04.02.04 Control transformer
415/110 dry type – one for each module and one for test bus.
04.03.00 POWER DISTRIBUTION BOARD (PDB) / ACDB
PDB/AC Distribution Board (DB) shall house MCCB modules only. They
shall have duplicate incomers and a bus-coupler. Wherever bus-couplers are
provided, distribution of outgoing feeders shall be such as to ensure uniform
loading on each section of DB. Board shall be single/double front, metal
clad, front matched, dust and vermin proof, draw-out fully,
compartmentalized and extensible on both sides with IP52 type enclosure.
Shall have base channel of size ISMC 75.
Shall have isolated busbar chamber for main busbar at the top, running
throughout the length of the board. Chamber shall have removable cover.
Cable alley shall have sufficient space for aluminium power cables and
bottom cable chamber shall be left free completely isolated from the vertical
busbar.
Busbars shall have same cross section throughout the length. Rating of the
neutral busbar shall be 50% of the main busbar. Earth bus bar shall run in
bottom chamber throughout the length of the panel.
The number of PDBs/ACDBs and their locations shall be decided based on
consumer and shall be finalized during details engineering / drawing
approval stage.
20% of the total feeders shall be kept as spares.
04.04.00 DC DISTRIBUTION BOARDS (220V)
For feeding the 220V /48V DC loads, the DCDBs shall be provided.
DCDBs shall have two incomers and a bus section with suitable interlock
(one out of two logic) between the two incomers. Incomers of DCDBs shall
be breaker operated and outgoing shall be MCCB modules. They shall be
fixed type and floor mounted. Other constructional features shall be similar
to ACDB.


& ITS AUXILIARIES
The switch boards shall be provided with suitable quantity and type of
outgoing feeders for the auxiliaries, control supplies to various panels /
systems. For each load and auxiliary, one separate feeder shall be provided.
The feeder rating and quantity shall be as per requirement.
The continuous current rating of the bus bars and incomers for 220V DCDBs
shall be the maximum DC load (excluding the momentary load) on the bus
plus 20% margin rounded off to the next higher standard rating.
04.05.00 AC DISTRIBUTION PANELS
AC Distribution panels, shall have switch fuse units as incomer. Distribution
panels may be fed from DBs and shall have two incomer. AC distribution
Boards shall be of two types - one with 415V, 4-wire, triple pole- and-neutral
(TPN) outgoing feeders and the other with 240V, 2- wire,
single-pole-and-neutral outgoing feeders. The board shall be wall mounted
type and other constructional features as given in above specification for
PDB/ACDB except that fixed type module are accepted for such DBs.
For small loads, MCB boards with TPN MCB as incomer and TPN/SP
MCBs for outgoing may be considered. However, to bring down the short
circuit level to safe limits, isolation transformer shall be provided wherever
necessary. Details of such loads shall be finalized in consultation with the
owner/consultant.
The feeder rating and quantity shall be as per requirement.
04.06.00 A.C. STARTER (CONTACTORS)
a) The contactors shall be three pole, air break type with non-bouncing
silver/silver alloy contacts. The contactor shall be designed for duty as per
Annexure-A attached with this section.
b) Each contactor shall be provided with minimum (2) normally open and two (2)
normally closed auxiliary contacts rated 10A at 240V A.C. The exact
requirement of contacts shall be decided by the bidder taking into account the
scheme requirements and spares.
c) Contactors for forward and reverse direction of reversible drives shall
preferably be both electrically and mechanically interlocked.
d) Delayed dropout contactors, if required and provided for some essential
auxiliaries, shall not dropout on power failure if the voltage is restored within
three seconds.
e) It shall be the responsibility of the Bidder to fully coordinate the overload
and short circuit tripping of the circuit breakers with the upstream and

& ITS AUXILIARIES
downstream circuit breakers / fuses / motor starters, to provide satisfactory

discrimination. Further the various equipment supplied shall meet the
requirements of Type II class of Co-ordination as per IS: 8544..
f) Contactors shall break without damage 10 times rated current up to 100 amp
rating and 8 times rated current for above 100 amp rating.
g) Continuous current shall not exceed 2 amp and initial pick up shall be
limited to 9 amp. Class of insulation shall be E or better.
h) Contactors shall not drop at 70% but it should definitely drop at 20% of rated
volatge.and pick up shall be 85 to 110%. Contactor duty shall be as per
requirement.
i) Coil shall be designed for the control voltage without economy resistors.
j) Insulation for coils shall be class E of better.
04.07.00 DC STARTER PANELS
General
DC starter panel for Control of DC motors shall be provided. DC starters
shall be complete with switch-fuse units, DC contactors, resistors, overload
relays, meters, push-buttons, lamps, etc.
DC contactor shall be provided with adequately rated magnetic blow out coil
for effective arc quenching.
DC resistance in suitable steps shall be provided.
Contactors DC2 for shunt motor, DC4 for series motors.
Required shunt for current measurement.
DC shunt cable used in DCDB, DC starter panels etc. shall be included
Necessary transducers shall be provided for taking current signal to the PLC /
Plant Control System.
Starters shall be furnished in totally enclosed floor-mounting, sheet steel
cubicles complete with a hinged front access door. Minimum thickness of
sheet steel shall be 2mm.
The cubicle enclosure shall provide dust and humidity protection, the degree of
protection being not less than IP-54.
The resistor enclosure shall be provided with ventilating louvers and wire
mesh guard and shall have a degree of protection IP-23.
Cubicle space heater shall be provided to maintain internal temperature above
dew point. Heater shall be furnished with switch-fuse unit and thermostat
control.
04.08.00 SPECIFIC REQUIREMENTS FOR PCC/PMCC/MCC AND VARIOUS
OTHER BOARDS/PANELS

& ITS AUXILIARIES
04.08.01 Incomers and Bus couplers of 415V Switchgears, MCCs and outgoing
feeders of 415V switchgear having ACBs shall be provided with
Microprocessor based numerical relays.
04.08.02 Numerical relay shall have the following functions
• Protection
• Metering
• Monitoring
User Interfaces :
The Numerical relays shall have IEC 61850 communication. It shall be

possible to set the settings of Numerical relays from the front key pad. Also it
shall be possible to configure the settings of the numerical relays from the
DCS/PLC/Control System..
Numerical relays of all modules in a 415V switchboard / MCC shall be
interlinked and shall be interfaced to plant DCS/PLC/Control System on IEC
61850 protocol. For this purpose, necessary gateway shall be provided. Each
module shall be controlled and monitored from DCS/PLC/Control System
through this communication link.
Dual redundant network/data bus/Data concentrator/power supply units shall
be supplied. It shall be possible to add/replace/remove any Numerical relays
from the data bus without affecting communication. In the event of one of
the conductors breaking, the data transmission changeover should be
bumpless. The protocol and hardware shall support dual redundant data
concentrator and upward serial communication.
Software for numerical relays shall be supplied and loaded in DCS/PLC/Control
System.
04.08.03 The switchgear manufacturer shall coordinate with the DCS/PLC/Control
System manufacturer for protocols/mapping, procedures, interface and
testing.
04.08.04 All the switchgears / MCCs shall be designed for bottom entry of cable.
04.08.05 For breaker control in each switchgear 2 Nos. 220V DC control supply shall
be provided with auto-change over to either supply.
04.08.06 20% spare terminals shall be provided for each module.
04.08.07 Insulation Level:
- Rated insulation voltage 1100 V
- One minute power frequency withstand voltage.
• 2.5 KV for power circuits

& ITS AUXILIARIES
• 1.5 KV for control circuits.

04.08.08 Clearance in air (minimum)
• Phase to phase – 25 mm
• Phase to earth – 25 mm
04.08.09 Module Details
Incomers & Bus Couplers
All the switchgears & MCC shall have two incomers and a bus coupler
arrangement.
The incomer modules shall be interlocked with their upstream breaker such
that they can be closed only when upstream breaker is closed and trip
automatically when upstream breaker is tripped.
The following minimum protections shall be provided for incomers and bus
couplers.
• 3 phase inverse time over current protection
• Earth fault protection
CTs, PTs shall be provided for protection and metering.
Feeder Modules :
Feeders for all drives shall consist of ACB/MCCB/with contactor as
applicable according to the details described elsewhere.
Open/Close/Trip or ON/OFF/Trip indication lamps (LED) for each drive
shall be provided.
Control supply of each module shall be taken through dedicated control
transformer of ratio 415 / 110V. Test supply shall be obtained from Test Bus.
The short circuit release of MCCBs shall be selected such as to avoid
tripping during starting of drives.
Warning markers shall be provided for ‘caution external voltage’
At least 20% of feeder modules of each type & rating subject to a minimum
of one module shall be provided as spares. Spare modules shall be
completely wired up.
20% of control terminals in each module shall be provided as spare subject to
a minimum of 2.
Motor Modules
90KW and above capacity motors shall be fed by ACBs.


& ITS AUXILIARIES
Less than 90kW capacity motors shall be fed by MCCB and contactors
through MCC.
More than 30kW capacity motor feeders shall be provided with 240V, 1-
phase space heater. Also ammeter shall be provided locally with display in
DCS/PLC/Plant Control System.
Each motor feeder of MCC shall be provided with suitably rated 415/110V
control transformer, for arranging control supply for the module. All the
necessary auxiliary and main contactors shall be provided suitable for this
control supply.
Control
Close & Open control of the Incomer & Buscoupler breakers and start/stop
control of all motors/outgoing feeders shall be from DCS/PLC/Plant Control
System through the interposing relays.
All Modules shall have ON, OFF & TRIP indications through LED
indication lamp
04.09.00 REQUIREMENTS FOR THE SWITCHBOARD COMPONENTS
04.09.01 Switches
Switches shall be triple/double pole, air break type and designed for duties as
specified in Annexure-B. Motor duty switches shall be capable of safely
making and breaking the locked rotor current of the associated motor circuit.
The switch shall have a quick-make, quick-break mechanism operated by a
suitable external handle, complete with position indicator. This handle shall
have provision for padlocking in ON and OFF position.
The compartment door shall be interlocked mechanically with the switch such
that the door cannot be opened unless the switch is in OFF position. Means
shall be provided for releasing this interlock at any time.
Switches shall be capable of withstanding the let-through fault current of
back-up fuses or circuit breakers.
Wherever two incoming switches and one bus-section switch/breaker are
provided for an assembly, these shall be mechanically/key interlocked to
ensure that only two out of the three can be closed at time.
Wherever two incoming switches are provided for an assembly, these shall
be mechanically/key interlocked to ensure that one of the two can be closed
at time.
04.09.02 Fuses (as applicable)
Fuses shall be HRC, cartirdge link type, with a minimum interrupting capacity
equal to the short circuit current of the LT system.


& ITS AUXILIARIES
Fuses shall be furnished complete with fuse bases and fittings of such design
as to permit easy and safe replacement of fuse element.
Visible indication shall be provided on blowing of the fuse.
Motor fuse characteristics and ratings shall be chosen to ride over starting
period without blowing. The fuse on incoming feeder wherever provided, shall
be chosen to provide discrimination with motor/feeder fuses.
04.09.03 Meters and Meter Selector Switches
All indicating instruments (96 x 96 mm) shall be flush mounted on panel front,
with 90 Deg. scale, anti-glare glass and accuracy class of 1. Each meter shall
have zero adjuster on the front.
Where Numerical Relays are not envisaged, Ammeters shall be provided for
motor feeders of rating above 30 KW. Motor ammeters shall have an extended
suppressed end-scale range to indicate starting current (6 to 8 times full-load
current).
Meter selector switches shall be maintained contact, stay-put type, with knob
handle. Ammeter and voltmeter selector switches shall be four position type.
Ammeter selector switches shall have made before break contacts, to prevent
open circuiting of CT secondary.
Incomers, Bus PT & Line PT shall have Ammeters & Voltmeters (as
applicable) with selector switches in addition to metering in Numerical
Relays. Metering for all other feeders shall be through Numerical Relays.
04.09.04 Transducer( Wherever Numerical relays are not envisaged)
Feeders requiring remote metering and/or current monitoring shall be
provided with solid state current transducers with calibration for full scale
reading. The dual output shall be 4-20 mA DC of which shall correspond to
the normal range. Transducers shall be duplex type.
04.09.05 Thermal Overload
a) Thermal overload relays shall be three element, positive acting, ambient
temperature compensated with adjustable settings.
b) Single phasing preventor shall be provided as an inbuilt feature of the thermal
overload relay.
c) Relays shall be manual reset type with changeover contacts, Resetting of
relays shall be possible with compartment door closed. Colour of the
resetting button shall be BLACK.
d) Relays may be direct acting or C.T. operated, depending on current rating.
C.T.s shall be included in the scope of supply. C.T. operated relays shall be
used for L.T. Motors having rating 45 KW and above.


& ITS AUXILIARIES
e) Relays for fan motors having long starting time shall be saturable case C.T
operated.
04.09.06 Secondary Wiring
All boards shall be fully wired at the factory to ensure proper functioning of
control, protection, transfer and interlocking schemes.
Fuse and links shall be provided to permit individual circuit isolation from bus
wires without disturbing other circuits. All spare contacts of relays, switches
and other devices shall be wired up to terminal blocks.
Wiring shall be done with flexible, 660 V grade, PVC insulated switchboard
wires with stranded copper conductors of 2.5 mm2 for current and voltage
circuits and 1.5 sq.mm for other circuits..
Each wire shall be ferruled by plastic tube with indelliable ink print at both end
having terminal block no., terminal nos, destination no. as per approved
Drawing.
Wire terminations shall be made with crimping type connectors with solderless
04.09.07 Terminal Blocks
Terminal blocks shall be 650V grade clip-on type with marking strips.
Terminals for C.T. secondary leads shall have provision for shorting.
Terminal blocks used for interface with PLC / Plant Control System via
termination cabinet shall be suitably sized to facilitate proper termination of
interconnecting cables.
Not more than two wires shall be connected to any terminal. Spare terminals
equal in number to 20% active terminals shall be furnished.
Terminal blocks shall be located to allow easy access. Wiring shall be so
arranged that individual wires of an external cable can be connected to
consecutive terminals.
04.09.08 Cable Termination
Generally, all assemblies shall be designed for cable entry from the bottom.
Sufficient space shall be provided for all the cables as per cable schedule, for
ease of termination and connection.
All provisions and accessories shall be furnished for termination and
connection of cables as per cable schedule, including removable gland plates,
cable support, crimp type tinned copper lugs, double compression brass glands
with tapered washer (Power cable only) and terminal blocks.
Gland plates shall be minimum 3 mm thick. The gland plate and supporting
arrangement for single core power cables shall be non-magnetic type to
minimise the flow of eddy current.

& ITS AUXILIARIES
04.09.09 Bus Duct Connection

Bus duct connection, wherever provided, shall be furnished along with
transition panel, if required. Bus duct connections shall be from the top.
All connecting bus work shall have the same continuous rating as associated
PCC/MCC/DB bus and shall be fully braced for the LT system short circuit
current.
All provisions such as matching flanges and other accessories required for
proper connection to bus duct shall also be supplied.
04.09.10 Ground Bus
A ground bus, rated to carry maximum fault current, shall be provided which
shall extend the full length of the assembly.
The ground bus shall be provided with two-bolt drilling with G.I. bolts and
nuts at each end and shall be suitable to receive 50 x 6 mm G.S. flat.
All stationary units shall be directly connected to the ground bus for effective
grounding.
The frames of all circuit breakers and drawout V.T. units shall be grounded
through heavy multiple contracts at all times except when the primary
disconnecting devices are separated by a safe distance.
The frames of all other drawout modules shall be grounded at all times except
when the power disconnects are separated by a safe distance.
Wherever the schematic diagrams indicate a definite ground at the switchgear;
a single wire for each circuit thus grounded shall be run independently to the
ground bus and connected thereto.
C.T. & V.T. secondary neutrals shall be earthed through removable links so
that earth of one circuit may be removed without disturbing others.
All hinged doors shall be earthed by flexible copper braid.
04.09.11 Nameplates
Nameplates of approved design shall be provided on each cubicle, at the top
of the assembly and on each instrument & device mounted on or inside the
cubicle.
The material shall be lamicoid or approved equal. 3 mm thick with white
letters on black background.
The name plates shall be held by self-tapping screws. Name plate size shall be
minimum 20 x 75 mm for instrument/devices & 40 x 50 mm for panels.
Caution notice on suitable metal plate shall be affixed both at the front and
back of each vertical panel.


& ITS AUXILIARIES
04.09.12 Space Heaters and Plug Sockets

Each vertical section shall be provided with thermostat controlled space
heater and 5A, 3 pin plug socket.
In addition, motor feeders rated 30 KW and above shall be wired-up for
feeding the motor space heater through suitably rated breaker auxiliary NC
contact and/or contactor.
Cubicle heater. Motor heater, and Plug-socket circuit shall have individual
switch fuse units.
04.09.13 Current Transformer
The thermal and dynamic stability current of CTs shall be same as for ACB.
CT ratio shall be as per requirement. CT shall be bar/window type conforming
to IS-2705,Part-II&III-1992. Current Transformers shall be cast-resin type. All
secondary connections shall be brought out to terminal blocks where wye or
delta connection shall be made.
Accuracy class of the current transformers shall be:
a) Class PS for differential
b) Class 5P20 for other relaying
c) Class 1.0 for metering
Other CT particulars like ratio, burden knee-point voltage, excitation current
and secondary resistance shall be decided by the bidder.
Feeders requiring remote metering and/or current monitoring shall be provided
with current transducers with calibration for full scale reading, where
numerical relays are not envisaged. The output shall be 4-20 mA DC of which
shall correspond to the normal range.
CT secondary shall be rated for 1 A for metering & protection.
04.09.14 Voltage Transformer
Voltage transformers shall be cast-resin and shall have an accuracy class of
0.5. Voltage transformer mounted on breaker carriage is not acceptable.
High voltage windings of voltage transformer shall be protected by current
limiting fuses.
Low voltage fuses, sized to prevent overload shall be installed in all
ungrounded secondary leads. Fuses shall be suitably located to permit easy
replacement while the switchgear is energised.
Line PTs and Bus PTs with synchro check facility shall be provided for
Incomers. Two sections of the PCC / MCC shall be suitable for momentary
parallel operation. Paralleling shall be done through use of synchro check
relay.

& ITS AUXILIARIES
04.10.00 Changeover Scheme

All the switchgears with sectionalised buses shall be normally operated with
the bus coupler breakers open.
Manual changeover/auto changeover between the two normal incomers and
their bus-coupler shall be provided with the following features.
Manual changeover from one incomer to another with momentary paralleling
of the two supplies after checking through synchrocheck relay.
Auto changeover from one incomer to another after trip of first incomer.
If there is a prolonged under-voltage on any one of the bus sections, the
respective incoming breaker shall trip and the bus coupler breaker shall close
provided voltage is available on the other bus section. Total changeover time
shall not exceed 1.5 seconds. This auto changeover shall be blocked if the
incoming breaker had tripped either on a bus fault or manually. Changeover
back to the normal source of supply shall be effected manually.
The automatic transfer circuit shall be controlled over by an auto-manual
change-over switch. The bus section breaker shall be allowed to close only if
there is no earth fault or O/C fault on affected section of the 415V
switchboard bus-bars.
Manual live changeover facility shall be provided for all the switchgears.
When planned outage of one of the normal incoming supplies is required, the
respective incomers shall be tripped automatically after the bus section
breaker is closed manually. For this purpose, a selection shall be provided on
the CRT in DCS/PLC/Control System for selecting the incomer to be tripped.
Thus, depending on the selection made, incomer to bus section – A or to bus
section – B shall be tripped once bus section breaker is closed manually, thus
maintaining continuity of supply.
Manual dead bus closing of a bus-coupler after an intentional manual
trip/outage due to under voltage of any one incomer shall be possible.
However, restoration to normal shall be manual.
A timer with a time delay on pick up of 0.5. - 5 sec. for annunciation of the
running breaker failing to trip within a preset time (i.e. If the two sources
remain paralleled for more than a preset time) shall be provided.
When the normal supply is to be brought back into operation, the incomer
breaker shall be closed whereupon the bus coupler shall trip automatically.
Latest breaker tripping provision shall be included in the changeover scheme
in addition to annunciation.
04.11.00 Metering, Protection & Alram, Indication, SER points
04.11.01 The minimum protections / metering required for various typical feeders


& ITS AUXILIARIES
shall include, but not be limited to the following. Additionally protections /

metering considered necessary during detailed engineering stage shall also be
provided by the bidder
(i) Numerical relays provided for ACB controlled modules shall have following
protection / metering.
(a) Incomers :
Protections Metering
• Over current protection Current on all the 3 phases
• Earth fault protection Voltage – phase to phase, phase to neutral
• Under voltage KW
• REF protection (For incomers kWhr
through transformers)
• Synchronising check relay
(b) Buscouplers :
• Over current protection Current on all the 3 phases
Earth fault protection KW
Synchronising check relay
(c) Motor feeders :
• Composite motor protection Current
to cover a minimum of Voltage
protections such as over kW
current, short circuit, earth KWh
fault, locked rotor, Negative
phase sequence, thermal
alarm etc.(for large
motors>=90kW
(ii) The minimum protections/metering required for the following feeders shall include, but
not limited to:
(a) Bus PT /Line PT Modules


& ITS AUXILIARIES
• Under voltage protection Voltage – phase to phase, phase to neutral
• Fuse failure protection
(b) Motor feeders( MCCB with Contactors)
• Bimetallic Thermal Overload Phase current (for motors of rating above
relay (with single phase 15kW)
preventor), short circuit
protection (MCCB)
(c) Incoming feeders for ACDB
• Short circuit protection (if Phase Current (1 phase)
MCCB )
(d) Outgoing feeders of ACDB
• Short circuit protection Phase Current (1 phase) for modules rated
(MCCB ) 63A and above.
04.11.02 Alarms/Indication/ SER Points

Following indications/alarms are the minimum to be provided in the CRT in
control room. Additionally indications/alarms considered necessary during
detailed engineering stage shall also be provided.
All these indications/alarms shall be selected for the sequential event
recording.
The control/interlock schemes for various types of feeders shall commensurate
with their application.
Single Line Diagram of all 415V switchgear and MCC shall be available in
CRT.
(a) Breaker Panel
(i) Status indication :

& ITS AUXILIARIES
Breaker ON, Breaker OFF, Breaker in remote, Breaker in service, Breaker in

test, Spring charged, Panel AC supply failed, Breaker not available, Protective
relay faulty, Trip circuit healthy
(ii) Alarms :
Protective relay/ O/L Relay operated, Trip circuit unhealthy
(iii) Control on CRT for breakers
(b) VT panel
Bus under voltage relay operated, Bus P.T fuse failed, DC supply-1 failed, DC
supply-2 failed, Bus PT-DC not available alarm
(c) Motor feeders (Breaker controlled)
Comprehensive motor protection numerical relay operated, Breaker ON,
Breaker OFF, Breaker in remote, Breaker in service, Breaker in test, Spring
charged, Panel AC supply failed, Breaker not available, Protective relay faulty,
Trip circuit healthy
Alarms :
Protective relay/ O/L Relay operated, Trip circuit unhealthy
Motor feeders (without Numerical relay)
Drive running Forward/Reverse, Drive stopped, Bimetal overload relay
operated
(d) Service Transformer Feeders
Winding temperature high alarm, Power supply failure to temperature
surveillance unit, Buchholz relay alarm (for oil type transformer), Oil
temperature alarm (for oil type transformer), Pressure relief device operated
(for oil type transformer)
(e) Analogue parameters
All the parameters indicated above under metering and protection shall be
displayed in the CRT in control room.
(f) Control
ON/OFF control and ON/OFF & fault/discrepancy indication for each of the
breaker shall be provided in the CRTs.
Note:
1. For incomers and bus couplers, voltmeters with selector switches and
ammeters on all phases shall be provided on the boards in addition to
metering through numerical relays.


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2. Apart from protection relays, each electrically operated breaker shall be

provided with anti-pumping (94), trip annunciation (30), lockout (86) and
trip circuit supervision (74) relays. Lockout relay shall be hand reset type.
3. Fuse failure relay shall be provided on the secondary side of voltage
transformer to monitor H.V. & L.V. fuses.
05.00.00 TESTS
Switchgear/MCC/Boards shall be subjected to all tests as per relevant

standards along with following tests:
(a) Temperature rise test on power circuits
(b) Short time current tests on power circuits.
(c) Mechanical operation test
(d) Insulation resistance test before and after 1 minute HV test
(e) Electrical control, interlock and sequential operation tests
(f) Verification of wiring as per approved schematic
Bidder shall submit type test reports of similar switchgear and associated
equipments. In case type test certificates for similar equipments are not
available, the same shall be conducted in presence of Purchaser or his
representative.
All Routine tests and acceptance tests shall be carried out in presence of the
purchaser or his representative.
06.00.00 DRAWINGS, DATA & MANUALS
06.01.00 Drawings, data & manuals to be submitted as indicated below
a) General arrangement and cross-sectional drawings showing constructional
features, space required in front and rear, power & control cable entry points
etc.
b) Bill of Materials
c) Typical foundation plans with load data
d) Heat Load for each Switchgear/MCC/Board/Equipment
e) Board-wise single line diagrams.
f) Typical control schematics
g) Drawings of matching flanges and terminals for bus termination
h) Calculation for selection of CT and VT rating
i) Bus bar sizing calculation

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j) Reports for all type tests of representative sections of panel assemblies.

k) Technical Data sheets (in specification format)
l) Technical leaflets
06.02.00 To be submitted after Award of Contract
a) Outline dimensional drawings showings general arrangement, space
requirements and bus duct/cable entry points.
b) Cross-section with parts list
c) Foundation plan & loading
d) Board-wise single line diagrams
e) Control schematics
f) Cable Schedule / Wiring diagrams with Termination details
g) Consolidated Bill of Material
h) Relay setting calculation.
i) Test Certificates and QAP
j) Bus bar sizing
k) CT/VT sizing
l) Technical leaflets
m) Technical Data Sheets (in specification format)
06.03.00 The bidder shall also submit all instruction manuals clearly indicating the
installation method, check-up and tests that are to be carried out before
commissioning the equipment.
06.04.00 Bidder shall note that the drawings, data and manuals listed herein are
minimum requirements only. The bidder shall ensure that other necessary
write-ups, curves and information required to fully describe the equipment
are submitted .
07.00.00 Ratings & Requirements
415V Switchgears/MCC/Boards
415V switchgears shall comply with the particulars indicated in the

following table:
SLNO. DESCRIPTION SPECIFICATION REQUIREMENTS

(a) Rated voltage, phases and 415V, 3 phase, 3 wire, 50 Hz.
frequency

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SLNO. DESCRIPTION SPECIFICATION REQUIREMENTS
(b) System neutral earthing Solidly earthed
(c) Reference Ambient air 50oC

temperature
(d) Material of bus bars High conductivity Al. Alloy
(e) Maximum temp. of bus 40oC

bars joints, droppers and
along the run at site
reference ambient of 50oC
(f) Short time rating for 1.0 50
Sec. (kA rms)
(g) Momentary rating (kA 105
peak)
(h) Degree of protection for as IP-52
per IS:2147
(i) Thickness of sheet steel in

mm
(i) Load bearing 2.0
members
(ii) Non-load bearing 1.6
members
(j) Colour finish shade as per Interior Glossy white
IS :5 Exterior As indicated in Section-1
Air Circuit Breaker
1. Service : Indoor
2. Type : Air – break
3. Rated service voltage : 415 v + 10%
4. Rated Current : As per requirement
5. Rated frequency : 50 Hz + 5%
6. System earthing : NGR grounded
7. Rated short time withstand : 50 KA (r.m.s.)
current for 1 sec.
8. Rated Symmetrical : 50 KA (r.m.s.)
breaking current at rated
voltage


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9. Rated making capacity : 105 KA

(min)
10. Rated operating duty : The duty of circuit breaker for motor
feeder involves direct-online starting
of motors. The motor starting current
varies from 6 to 8 times the full load
current at a very low power factor
Frequency of starts of motors:

Three (3) Starts per hour & Two (2)
Consecutive Cold starts and one (1)
hot restart.
11. Duty cycle : O-3 min-CO-3 min-CO
12. Operating mechanism : Stored energy type
a) Closing : motor wound spring operated
b) Opening : shunt trip coil
c) Latching arrangement : Mechanically & Electrically trip free
13) Auxiliary Voltage :
Closing : 220V D.C. (85% - 110%)
Tripping : 220V D.C. (70% - 110%)
Spring charging motor : 220 V + 10% D.C.
Space heater & lamp : 240 V+ 10% AC 50 Hz
14. Anti-pumping feature : Electrical anti-pumping feature shall
be provided.
15. No. of poles : 3
16. Aux. Switch contact (as per : Min (6 NO + 6 NC)
requirement)
17. Mounting : Drawout type transfer truck within
switchgear cubicle
18. Limits of temp. rise : As per IS:2516 part I & II / Sec I
19. Termination :
Incomer : Cable or Busduct
Outgoing : Cable
20. Static built in release : To be provided
21. Finish paint : 631 of IS-5
HRC fuses
1. Type : HRC cartridge type link fuse

2. Reference standard : IS : 13703
3. Rated current : As specified
4. Operation indicator : Required
5. Fuse characteristics : Bidder to furnish

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Contactor
: AC DC
1. Service : Indoor within steel Indoor within
cubicle for steel cubicle
maximum system for maximum
voltage, starting of system voltage,
motors and starting of
miscellaneous motors and
loads. miscellaneous
loads.
2. No. of Poles : 3 2
3. Rated service voltage : 415 V + 10% 220 V (190-
240V)
4. Rated frequency : 50 Hz + 5%
5. System earthing : Solidly grounded Ungrounded
6. Short time rating : To be coordinated To be
with fuse coordinated
Preceding it. with fuse
Preceding it.
7. Continuous current : To suit motor To suit motor
continuous current continuous
rating Conditions current rating
specified. Conditions
specified.
8. Short circuit level : 50 KA (rms) at 415 20 KA at 220V
V
9. Control circuit : 110V ±10% 1-ph 220V tapped
50 Hz ± 5% from power
derived from circuit.
415/110V control
transformer to be
provided in each
cubicle. In
addition, One
number Control
Transformer in
each bus section
shall be provided
for Testing


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10. Utilisation category : AC 3 for uni- DC 2 for shunt

directional motors motors
AC 4 for Bi- DC 4 for
directional Motors. series motors.
11. Duty Class: : 0.1 0.1

Intermittent class for Uni-
directional motors (IS:2959)
Intermittent class for Bi- : 0.3 -
directional motors (IS:2959)
12. Aux. Contact requirement : Min. 2 NO & 2 NC Min. 2 NO &
contacts 2 NC contacts
13. Limits of operation :

Closing (pick-up) : 85% to 110% 190-240 V
Dropout : 45 - 65% of rated 45 - 65% of
rated
14. High voltage test values :
(one Min. value)
a. Main power circuit : 2.5 KV 1.5 KV
b. Control & auxiliary : 2.0 KV 1.5 KV
circuit volts
15. Limits of temperature : As per IS:2959 As per IS:2959
Current Transformer
1. Service : Indoor
2. System : 415V, 3 phase, 3 wire, 50Hz, Solidly
earthed neutral
3. Type : Resin cast
4. Rated voltage : 415 V +10%
5. Quantity required : As per requirements of individual
feeders and as mentioned in the
specification drawings.
6. Ratio and burden : As required, C.T. secondary rating
shall be 1 Amp.
7. Accuracy : 5P10 or better for protection and
class-1 for metering.
8. Power frequency withstand : 2.5 KV (r.m.s) for one minute
voltage
9. Rated short time current :
Short time withstand : 50 KA (r.m.s)
current for 1 sec

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Dynamic current : 105 KA (peak)

10. Mounting : Inside switchgear cubicle in stationary
portion.
Potential Transformer
1. Service : Indoor
2. System : 451V, 3 phase, 4 wire, 50 Hz, Solidly
earthed neutral
3. Type : Cast resin
4. Rating- Voltage ratio : 415/√3 / 110/√3
5. Rated burden : As specified
6. Accuracy class : As per requirement
7. Power frequency withstand : Primary: 3.0 KV for one minute
voltage Secondary : 2.0 KV for one minute
8. Mounting : Fixed type
9. Quantity : As per requirement
Numerical Relays
Microprocessor based numerical relays with communication facility ( For ACB

operated incomers, Bus couplers and motor feeders (90 kW to 160 kW)
The numerical relays for 0.415KV Switchgears shall comply with but not limited to the
following technical requirements.
1 Purpose : Protection, Metering and Monitoring of

all switchgears and MCCs with synchro
check facility for Incomers, Bus couplers.
2 Auxiliary Supply : 220V DC for ACBs and 110V AC for
MCC only.
3 CT Secondary Current : 1Amp.
4 PT Secondary Voltage : 110V AC, 3 Phase
5 Ambient Temperature : 50oC
6 Degree of protection : IP 54
7 Communication : Compatible with PLC / Plant Control
System through IEC 61850 Protocol
8 Input & Output : Required number of analog and digital
inputs/outputs as per scheme requirement
with spare.
9 Metering : Complete metering for Incomer, Tie, Bus
coupler, feeders as indicated.
10 Protection : Complete protection for Incomer, Tie,
Bus coupler, feeders as indicated.

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11 Monitoring : Self-diagnostic facility.
12 Facilities to be made : • Programming keys for complete

available in the relay access with out computer (built in)
• Provision for external programming
unit through suitable software and
communication ports.
• Display unit.
• Read/Write set points.
• Current & Voltage actual values and
any other analog measurement.
• Event recording with Pre-trip data
with starting characteristics.
• Statistical data.
• Output relays.
• Tamper proof security system.


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Annexure – A
Selection of Switches & contactors
Motor Feeders
Type Motor Rating Switch Fuse Contactor Cable size
Rating / MCCB
A 0 - 5.5 KW 32A 16A 3/c – 2.5 Sq.mm - Cu
B 5.6 - 11 KW 63A 32A 3/c - 16 Sq.mm - Al
C 11.1 - 22 KW 63A 63A 3/c - 35 Sq.mm - Al
D 22.1 - 50 KW 100A 100A 3/c - 95 Sq.mm - Al
E 50.1 - 75 KW 200A 160A 3/c - 185 Sq.mm - Al
F 75.1 - 89 KW 400A 300A 2x3/c - 185 Sq.mm - Al
NOTE :
1. Rating of MCCBs, thermal overload relay and Contactors are to be coordinated
with motor rating by the bidder.
2. MCCBs with E/F protection to be considered for motors above 45 KW.
Outgoing Feeders
Type Switch Fuse Rating / MCCB Cable Size
AF 32A 4/c – 16 Sq.mm – Al
BF 63A 4/c – 35 Sq.mm – Al
CF 100A 3.1/2c – 95 Sq.mm – Al
DF 200A 3.1/2c – 300 Sq.mm – Al
EF 400A 4 x 1/c – 630 Sq.mm – Al
FF 630A 7 x 1/c – 630 Sq.mm – Al
Note: Selection of switches, contactors and cable sizes indicated above are for general
guidance of the bidder and the exact requirement shall be as per the detail engineering by
bidder.


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DD. TECHNICAL SPECIFICATION FOR MOTORS

1.00.00 Scope
1.01.00 This section covers the general requirements of the drive motors.
1.02.00 Motors shall be furnished in accordance with both this general
specification and the accompanying driven equipment specification.
1.03.00 In case of any discrepancy, the driven equipment specification shall
govern.
2.00.00 Standards
2.01.00 All motors shall conform to the latest applicable IS, IEC and CBIP
Standards/Publications except when otherwise stated herein or in the
driven equipment specification.
2.02.00 Major standards, which shall be applicable, are listed below. Other
applicable Indian Standards for any component part even if not covered in
the listed standards shall also be followed :
IS : 12615
IEC : 60034-30
IS : 3177
3.00.00 General
3.01.01 The motors shall be installed in hot, humid and tropical atmosphere, highly
polluted at places with coal dust and/or fly ash..
3.01.02 All motors shall be either totally enclosed fan cooled (TEFC) or totally
enclosed tube ventilated (TETV) or closed air circuit air cooled (CACA) or
closed air water cooled (CACW) type. Temperature rise shall be limited to
70deg.C by resistance method for class F insulation
All motors shall be rated for continuous duty (S1). They shall also be suitable
for long period of inactivity. However, hoist, crane and elevator motors shall
be rated for (S4) duty i.e. 40% cyclic duration factor.
All LT motors of S1 duty cycle shall conform to minimum efficiency
performance standards (MEPS) of IE3 mentioned in IS: 12615. All HT
motors shall have efficiency and power factor higher than 90% and 0.83
respectively. However this is not applicable for geared motors (motors
completely integrated with driven equipment) which are specifically
designed to suit the driven equipment duty.
3.01.03 For motor installed outdoor and exposed to direct sunrays, the effect of solar
heat shall be considered in the determination of the design ambient
temperature.

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3.01.04 Motors open to the atmosphere shall be protected with rain canopy. Rain canopy
provided for the HT motors shall be removable type in order to enable handling
of these motors by using the hoists provided for the purpose.
3.01.05 All motors shall be provided with jacking bolts with its foundation frame for
alignment.
3.01.06 All HT motors shall have individual dedicated electrically operated hoists for
maintenance of motors. Control panels for the Crane/hoist shall be located at
the ground level for ease of maintenance.
4.00.00 Type and rating
4.01.00 A.C. Motors
4.01.01 Motors shall be general purpose, constant speed, squirrel cage, three phase /
single phase, induction type.
4.01.02 All motors shall be rated for continuous duty (S1) unless stated otherwise.
4.01.03 The motor name-plate rating at 50°C shall have at least 10% margin for HT
and 15% margin for LT system over the input power requirement of the driven
equipment at rated duty point and also covering the 10% margin on maximum
load demand of the driven equipment under entire operating range, including
voltage and frequency variations, unless stated otherwise in driven equipment
specification or in general electrical specification. For S4 duty motors 10%
margin on maximum load demand of the driven equipment shall be
considered.
4.01.04 The motor characteristics shall match the requirements of the driven equipment
so that adequate starting, accelerating, pull up, break down and full load torques
are available for the intended service.
4.01.05 Frequent starting HT motors shall be fed through vacuum contactors and fuses.
4.01.07 Motors up to 160KW shall be LT (415V). Motors above 160KW shall be of 6.6
KV voltage rating.
4.01.08 All motors shall be supplied with foundation bolts (if applicable), drain holes
with plugs.
4.01.09 Motors in the explosion hazardous areas shall be explosion proof.
4.02.00 D.C. Motors
4.02.01 D.C. motor provided for emergency service shall be shunt/compound wound
type and rated for 220V DC.
4.02.02 Motor shall be sized for operation with fixed resistance starter for maximum
reliability. Starter panel complete with all accessories shall be included in the
scope of supply of the bidder.
5.00.00 Performance

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5.01.00 Running Requirements

5.01.01 Motor shall run continuously at rated output over the entire range of voltage
and frequency variations as required for the driven equipment.
5.01.02 The motor shall be capable of operating satisfactorily at full load for 5 minutes
without injurious heating with 75% rated voltage at motor terminals.
5.02.03 Starting Requirements
Motor shall be designed for direct on line starting at full voltage. Starting
current shall be
i) HT Motors upto 750 KW : 600% subject to IS Tolerance of plus 20%
ii) Motors (above 750KW upto 1000KW) : 600%. Not subject to any positive
tolerance.
iii) Motors above 1000 KW : 450%. Not subject to any positive tolerance.
iv) For LT motors the starting current shall be as per the limit mentioned in the
relevant standard with IE-3 efficiency class. For D.C. Motors the starting
current shall be limited to 2 times full load current
5.02.04 The motor shall be capable of withstanding the stresses imposed if started at
110% rated voltage.
5.02.05 H.T Motor shall start with rated load and accelerate to full speed with 80%
rated voltage at motor terminals. L.T Motor shall start with rated load and
accelerate to full speed with 85% rated voltage at motor terminals
5.02.06 a) The motor shall be capable of three equally spaced starts in an hour, the
motor initially being at a temperature not exceeding the rated load operating
temperature.
b) The motor shall be capable of two starts in succession with coasting to rest
between starts and the motor initially at rated operating temperature.
5.02.07 Pump motor subject to reverse rotation shall be designed to withstand the
stresses encountered when starting with non-energized shaft rotating at 125%
rated speed in reverse direction.
5.03.00 Stress During Bus Transfer
5.03.01 The motor may be subjected to sudden application of 150% rated voltage
during bus transfer, due to the phase difference between the incoming
voltage and motor residual voltage.
5.03.02 The motor shall be designed to withstand any torsional and/or high current
stresses, which may result, without experiencing any deterioration in the
normal life and performance characteristics.
5.04.00 Locked Rotor Withstand Time


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5.04.01 The locked rotor withstand time under hot condition at 110% rated voltage
shall be more than motor starting time by at least 2.5 seconds for motors
upto 20 seconds starting time and by 5 seconds for motor with more than
20 seconds starting time.
To prevent unwanted tripping of a high inertia load at start-up, there may be
need to shunt out the motor’s overload trip device. Speed switches mounted
on the motor shaft may be provided in such case. Heating experienced during
start-up must still be considered when sizing the motor
Hot thermal withstand curve shall have a margin of at least 10% over the full
load current of the motor to permit relay setting utilizing motor rated
capacity
Accelerating torque at any speed with the lowest permissible starting voltage
shall be at least 10% motor full load torque.
Pull out torque at rated voltage shall not be less than 205% of full load torque
5.04.02 H.T Motors Starting time mentioned above is at minimum permissible
voltage of 80% rated voltage.
5.04.03 Hot thermal withstand curve shall have a margin of at least 10% over the
full load current of the motor to permit relay setting utilising motor rated
capacity.
6.01.00 Enclosure
6.01.01 All H.T & L.T motor enclosures shall conform to the degree of protection
IP-55 for outdoor & indoor unless otherwise specified. Motor for outdoor
or semi-outdoor service shall be of weather-proof construction.
6.01.02 For hazardous area approved type of increased safety enclosure shall be
furnished.
6.02.00 Cooling
6.02.01 The motor shall be self ventilated type, either totally enclosed fan cooled
(TEFC) or closed air circuit air- cooled (CACA).
6.02.02 For large capacity motors, closed air circuit water cooled (CACW) may be
considered for acceptance.
6.03.00 Winding and Insulation
6.03.01 All insulated winding shall be of copper.
6.03.02 HT and LT motors shall have class F insulation but temperature rise shall be
limited to class B (as measured by resistance method).
6.03.03 Windings shall be impregnated to make them non-hygroscopic and oil resistant.
6.04.00 Tropical Protection

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6.04.01 All motors shall have fungus protection involving special treatment of
insulation and metal against fungus, insects and corrosion.
6.04.02 All fittings and hardware shall be corrosion resistant.
6.05.00 Winding & Insulation
: Non-hygroscopic, oil resistant, flame resistant copper windings
motors : Thermal class 155 (F) insulation, Temperature rise shall be limited to
Class B. Winding material shall be of copper. The winding insulation
process shall be total Vacuum Pressure Impregnated i.e resin poor method.
The lightning impulse & interturn insulation surge withstand level shall be
as per IEC-60034 part-15
415VAC & 220V DC motors : Thermal Class(F )
6.06.00 Bearings
6.06.01 Motor shall be provided with antifriction bearings, unless sleeve bearings are
required by the motor application.
6.06.02 Vertical shaft motors shall be provided with thrust and guide bearings. Thrust
bearing of tilting pad type is preferred.
6.06.03 Bearings shall be provided with seals to prevent leakage of lubricant or
entrance of foreign matters like dirt, water etc. into the bearing area.
6.06.04 Sleeve bearings shall be split type, ring oiled, with permanently aligned, close
running shaft sleeves.
6.06.05 Grease lubricated bearings shall be pre-lubricated and shall have provisions for
in-service positive lubrication with drains to guard against over lubrication.
6.06.06 Oiled bearing shall have an integral self cooled oil reservoir with oil
ring inspection ports, oil sight glass with oil level marked for standstill and
running conditions and oil fill and drain plugs.
6.06.07 Forced lubricated or water cooled bearing shall not be used without prior
approval of Owner.
Greased ball, roller and /or sleeve bearing shall be rated for minimum standard
life of 40,000 hours taking bearing and driven equipment loads in to account.
6.06.08 Lubricant shall not deteriorate under all service conditions. The lubricant shall
be limited to normally available types with IOC equivalent.
6.06.09 Bearings of HV motors rated 1000 KW and above shall be insulated as
required to prevent shaft current and resultant bearing damage.
6.07.00 Noise & Vibration
6.07.01 The noise level shall not exceed 85 db (A) at 1.5 meters from the motor.
6.07.02 The peak amplitude of the vibration shall be within IS specified limits.

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6.08.00 Motor Terminal Box

Motors shall be provided with separate terminal boxes for main, space heaters,
embedded temperature detectors, bearing temperature indicators and moisture
detectors terminals, Neutral CT terminals. When it is not possible to provide
LT motors with separate terminal box for space heater terminals, space heater
terminals shall be adequately segregated from the main terminals in the single
box. Terminal boxes shall be weatherproof and water-tight confirming to
minimum IP-55 degree of protection with removable front cover for making
connections. IP-55 degree of protection shall be achieved without application
of compound.
6.08.01 Motor terminal box shall be detachable type and located in accordance with
Indian Standards clearing the motor base- plate/ foundation
6.08.02 Terminal box shall be capable of being turned 360 Deg. in steps of 90 Deg.,
unless otherwise approved. However,in the case of rectangular type,Terminal
Box shall be rotatable in steps of 180 Deg.
6.08.03 The terminal box shall be split type with removable cover with access to
connections and shall have the same degree of protection as motor.
6.08.04 The terminal box shall have sufficient space inside for termination/ connection
of or XLPE insulated armoured aluminium cables as the case may be.
6.08.05 Terminals shall be stud or lead wire type, substantially constructed and
thoroughly insulated from the frame.
6.08.06 The terminals shall be clearly identified by phase markings, with corresponding
direction of rotation marked on the non-driving end of the motor.
6.08.07 The terminal box shall be capable of withstanding maximum system fault
current for a duration of 0.25 sec.
6.08.08 For HT motor, the terminal box shall be phase-segregated type. The neutral
leads shall be brought out in a separate terminal box (not necessarily phase
segregated type) with shorting links for star connection.
6.08.09 Motor terminal box shall be furnished with suitable cable lugs and double
compression brass glands to match with cable used.
6.08.10 The gland plate for single core cable shall be non-magnetic type.
6.08.11 In case no differential protection is required star point of the winding shall
be formed in the neutral terminal box to be provided on one side of the
motor. The phase segregated terminal box shall be placed on the other side
of the motor.
Neutral terminal box for HV motors rated 1000 KW and above shall be
suitable for mounting of three (3) Nos. wound/bar primary/ring type cast
resin insulated current transformers for differential protection. These CTs


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shall be mounted in the motor neutral terminal box

6.08.12 All terminal boxes shall be provided with earthing studs for termination of
protective earth conductor.
6.09.00 Grounding
6.09.01 The frame of each motor shall be provided with two separate and distinct
grounding pads complete with tapped hole, GI bolts and washer.
6.09.02 The grounding connection shall be suitable for accommodation of ground
conductors as follows:
Motor above 50 x 6 mm GS Flat

90 KW
Motor above 35 x 6 mm GS Flat
30 KW up to
90 KW
Motor above 5 25 x 3 mm GS Flat
KW up to 30
KW
Motor up to 5 6 SWG GI Wire
KW
The above size is the minimum. Higher size shall be used if found necessary as
per earthing calculation. Calculation to be submitted by the bidder.
6.09.03 The cable terminal box shall have a separate grounding pad.
6.10.00 Rating Plate
In addition to the minimum information required by IS, the following
information shall be shown on motor rating plate :
a) Temperature rise in Deg.C under rated condition and method of
measurement.
b) Degree of protection.
c) Bearing identification no. and recommended lubricant.
d) Location of insulated bearings.
7.00.00 Accessories
7.01.00 General :
7.01.00 Accessories shall be furnished, as listed below, or if otherwise required by
driven equipment specification or application.
7.02.00 Space Heater :

& ITS AUXILIARIES
7.02.01 Motor of rating 30 KW and above shall be provided with space heaters, suitably
located for easy removal or replacement.
7.02.02 The space heater shall be rated 240 V, 1 phase 50 Hz and sized to maintain the
motor internal temperature above dew point when the motor is idle. Heaters to
be automatically OFF when the motor is switched ON.
7.03.00 Temperature Detectors :
7.03.01 In HT motors, at least four numbers simplex / two numbers duplex platinum
resistance type temperature detectors shall be provided in each phase stator
winding.
7.03.02 Each bearing of HT motor shall be provided with dial type thermometer with
adjustable alarm contact and 1 no. duplex platinum resistance type temperature
detectors.
7.03.03 The temperature detector mentioned above shall be resistance type, 3 wire,
platinum wound, 100 ohms at 0 Deg.C.
7.03.04 Leads of all duplex type motor winding RTDs and motor bearing RTDs shall be
wired up to respective switchgear metering & protection compartment. From
which one set of RTDS shall be connected to numerical protection relay and
another set shall be kept free for PLC / Plant Control System connectivity.
7.04.00 Vibration monitor :
All HV motors shall be provided with vibration pads for mounting vibration
detectors. Vibration monitors shall be provided for all HT motors and shall be
suitably connected to the PLC / Control System of the Plant.
7.05.00 Indicator/Switch :
7.05.01 Dial type local indicator with alarm contacts shall be provided for the following :
a) Hot and cold air temperature of the closed air circuit for CACA and CACW
motor.
7.05.02 Flow switches shall be provided for monitoring cooling water flow of CACW
motor and oil flow of forced lubrication bearing, if used.
7.05.03 Alarm switch contact rating shall be minimum 0.5 A at 220V D.C. and 5A at
240V A.C.
7.06.00 Current Transformer for Differential Protection :
7.06.01 Motors of rating 1000 kW and above shall be provided with differential
protection. Matching CTs shall be provided by the bidder for the same. The 3
nos. current transformers, one for each phase shall be mounted in a separate
compartment in the neutral side terminal box. The three phases shall be
connected to form the star point after they pass through the CTs. The CTs shall
be of relay accuracy and CT characteristics shall be compatible with the
differential relay . The additional 3 nos. CTs of identical characteristics shall be

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provided in the 6.6 kV switchgear panel.

7.06.02 The arrangement shall be such as to permit easy access for C.T. testing and
replacement.
7.07.00 Accessory Terminal Box :
7.07.01 All accessory equipment such as space heater, temperature detector, current
transformers etc., shall be wired to and terminated in terminal boxes, separate
from and independent of motor (power) terminal box.
7.07.02 Accessory terminal box shall be complete with double compression brass
glands and pressure type terminals to suit owner's cable connections.
7.08.00 Drain Plug :
7.08.01 Motor shall have drain plugs so located that they shall drain the water, resulting
from the condensation or other causes from all pockets of the motor casing.
7.09.00 Lifting Provisions :
Motor weighing 25 Kg. or more shall be provided with eyebolt or other adequate
provision of lifting.
7.10.00 Dowel Pins :
The motor shall be designed to permit easy access for drilling holes through
motor feet or mounting flange for installation of dowel pins after assembling
the motor and driven equipment.
7.11.00 Painting :
Motor including fan shall be painted with corrosion proof paints as per IS-5.
8.00.00 TESTS
8.01.00 Routine & Type Tests :
“All routine & acceptance tests shall be conducted on HT motors as per
relevant IS in presence of Purchaser or his representative. With regards to type
tests as per IS, copy of test certificates (TC) for test conducted on similar
motors for earlier projects shall be submitted. If type test certificates are not
submitted, type tests shall be conducted free of cost.”
The following tests also shall be conducted on HT motors as routine tests.
a) Polarisation Index test (on each motor)
b) Noise level measurement. (on representative sample for each rating)
For LT motors and DC motors, if type test certificates are available for the
same type & rating of the motors offered, same shall be furnished; else shall be
conducted. All routine and acceptance tests shall be conducted in all LT motors
in presence of Purchaser or his representative.


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In addition, any special test called for in the driven equipment specification
shall be performed for all motors.
9.01.00 Drawings, data & manuals for the motors shall be submitted as indicated below
List of the motors
Individual motor data sheet as per format of the proposal data sheets.
Scheme & write up on forced lubrication system, if any
Type test report
9.02.00 After award of the Contract
a) Dimensional General Arrangement drawing
b) Foundation Plan & Loading
c) Cable end box details
d) Space requirement for rotor removal
e) Thermal withstand curves hot & cold
f) Starting and speed torque characteristics at 80% & 100% voltage
g) Complete motor datasheet
h) Erection & Maintenance Manual
i) Test reports
j) QAP


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EE.TECHNICAL SPECIFICATION FOR ELECTRIC MOTOR ACTUATORS
1.00.00 Scope
1.01.00 This Section covers the general requirements of Electric Motor
Actuators for valves, dampers and gates.
1.02.00 All electric motor integral type actuators shall be furnished in accordance
with this general specification and the accompanying driven equipment specification.
2.00.00 Standards
2.01.00 All electrical equipment shall conform to the latest applicable IS, ANSI
and NEMA Standards, except when stated otherwise herein or in driven equipment
specification.
2.02.00 Major standards, which shall be followed, are listed below. Other
applicable Indian Standards for any component part even if not covered in the listed
standards shall also be followed
i) IS-9334
ii) IS-12615
iii) IEC:60034
3.00.00 Service Conditions
3.01.00 The actuator shall be suitable for operation in hot, humid and
tropical atmosphere, highly polluted at places with coal dust and/or fly ash.
3.02.00 Unless otherwise noted, electrical equipment/system design shall be based
on the service conditions and auxiliary power supply given in chapter-1.
4.00.00 Rating
4.01.00 For isolating service, the actuator shall be rated for three successive open-
close operation of the valve/damper or 15 minutes, whichever is longer.
4.02.00 For regulating service, the actuator shall be suitably time-rated for the duty
cycle S4 - 600 cycles or better.
5.00.00 Performance
The actuator shall meet the following performance requirements:
5.01.00 Open and close the valve or damper completely and make leak-tight valve
closure without jamming.
5.02.00 Attain full speed operation before valve load is encountered and impart an
unseating blow to start the valve in motion (hammer blow effect).
5.03.00 Operate the valve stem at standard stem speed and shall function against
design differential pressure across the valve seat.

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5.04.00 The motor reduction gearing shall be sufficient to lock the shaft when the
motor is de-energised and prevent drift from torque switch spring pressure.
5.05.00 The entire mechanism shall withstand shock resulting from closing with
improper setting of limit switches or from lodging of foreign matter under the valve seat.
6.00.00 Specific Requirement
6.01.00 Construction :
6.01.01 The integral actuator shall essentially comprise the drive motor, torque/ limit
switches, gear train, clutch, hand wheel, position indicator/ transmitter, in-built close / open
contactors, thermostat for over load protection, space heater and internal wiring.
6.01.02 The actuator enclosure shall be totally enclosed, dust tight, weather-proof
suitable for outdoor use without necessity of any canopy.
6.01.03 All electrical equipment, accessories and wiring shall be provided with
tropical finish to prevent fungus growth.
6.01.04 The actuator shall be designed for mounting in any position without any
lubricant leakage or operating difficulty.
6.02.00 Motor :
6.02.01 The drive motor shall be three phase, squirrel cage, induction machine with
minimum class F insulation having temperature rise limited to Class-B.and designed for
high torque and reversing service. Enclosure shall be IP—67 or better.
6.02.02 The motor shall be designed for full voltage direct on-line start, with starting
current limited to 6 times full-load current.
The motor bearing shall be double shielded, grease lubricated and antifriction type.
6.02.03 The motor shall be capable of starting at 85 percent of rated voltage and
running at 80 percent of rated voltage at rated torque and 85 percent rated voltage at 33
percent excess rated torque for a period of 5 minutes each.
6.02.04 Earthing terminals shall be provided on either side of the motor.
6.03.00 Limit Switches :
Each actuator shall be provided with following limit switches: -
6.03.01 2 torque limit switches, one for each direction of travel, self-locking,
adjustable torque type.
6.03.02 4 end-of-travel limit switches, two for each direction of travel.
6.03.03 2 position limit switches, one for each direction of travel, each adjustable at
any position from fully open to fully closed positions of the valve/damper (wherever
applicable).
6.03.04 Each limit switch shall have 2 NO + 2 NC potential free contacts. Contact
rating shall be 5A at 240V A.C. or 0.5A at 220V D.C.

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6.04.00 Hand Wheel :

Each actuator shall be provided with a hand wheel for emergency manual operation. The
hand wheel shall declutch automatically when the motor is energized.
6.05.00 Position Indicator/Transmitter :
The actuator shall have:
6.05.01 One (1) built-in local position indicator for 0-100% travel.
6.05.02 One (1) position transmitter, potentiometer type, for remote indicator
Close Open Power contactors
Close / open Power contactors 1 No each of suitable rating shall be provided for
energizing the motor.
6.06.00 Space Heater :
A space heater shall be included in the limit switch compartment suitable for 240V, 1 phase,
50 Hz supply.
6.07.00 Wiring :
All electrical devices shall be wired up to and terminated in a terminal box. The internal
wiring shall be of sufficient size for the power rating involved but in no case less than 1.5
Sq.mm copper. All wiring shall be identified at both ends with ferrules.
6.08.00 Terminal Box :
The terminal box shall be weather proof, with removable front cover and cable glands for
cable connection. The terminal shall be suitable for connection of 2.5 Sq.mm copper
conductor
7.00.00 Interfaces:
i) Open/Close command termination logic with position & torque Limit Switches,
positioner circuit shall be suitably built in the PCB inside the actuator
ii) For Binary Drive (both ON-OFF and Inching type) :- Open/Close command & status
thereof and disturbance monitoring signal (common contact for Overload, Thermostat,
control supply failure, L/R selector switch at local & other protections operated) shall be
provided.
iii) Interface with the control system shall be through hardwired signal only. Inter posing
relays provided in the actuator shall be energized to initiate opening and closing, by 24V DC
signal from the external control system.
iv) For Modulating drive: - the command to actuator shall be in form of 4-20mA signal.
The necessary positioning circuit and motor protection shall be provided.

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v) Open/close command termination logic shall be suitably built inside actuator.

8.00.00 Test
The actuator and all components thereof shall be subject to tests as per relevant Standards. In
addition, if any special test is called for in equipment specification, the same shall be
performed.
9.01.01 Drawings, data & manuals to be Submitted :.
Data sheet for each type of actuator shall be furnished along with internal wiring diagram,
suggested control schematic and torque limit switch contact development and
manufacturer's catalogues.
9.01.02 To be Submitted after Award of Contract :
Actuator Data Sheet
Internal wiring diagram and suggested control schematic
Torque switch and limit switch contact development
QAP
Test reports
Manufacturer's Catalogue
Instruction manual indicating clearly the installation methods, check ups and tests to be
carried out before commissioning of the equipment.
9.02.00 The Bidder may note that the drawings, data and manuals listed herein are
minimum requirements only. The Bidder shall ensure that all other necessary write-ups,
curves and information required to fully describe the equipment are submitted with the bid.


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FF.TECHNICAL SPECIFICATION FOR UNINTERRUPTED POWER SUPPLY
1.00.00 Scope of Work

The scope of supply shall include Uninterruptible Power Supply (UPS) System : One (1)
set .
a) Each UPS System set shall comprise the following :
i) 100% UPS System battery banks : 2
ii) 100% Static Inverter banks : 2
iii) 100% Static switches : 2
iv) Manual bypass switch/breaker : 3
v) 100% Float-cum-boost charger : 2
vi) Static Voltage Regulator (SVR) with step : 1

down transformer and back up source static
switch
vii) UPS A.C. Power Distribution Board with : 1 set
MCCB
b) One (1) set of special tools and tackle.

c) All inter-connecting cables including those required for inter-connection within UPS
equipment as mentioned in (a) above.
d) Mandatory Spare parts.
e) List of recommended spare parts for three (3) years satisfactory and trouble- free
operation of the equipment for Purchaser’s consideration.
f) All relevant drawings, data and instruction manuals.
1.02.00 UPS System shall be adequately designed to cater the entire UPS loads of each
system / sub system.
Note: 10% cushion to be kept in UPS system/set and UPS-DB for Purchaser’s
future use.

a) All equipment and materials shall be designed, manufactured and tested in
accordance with the latest applicable Indian Standards (IS) except where modified
and/or supplemented by this specification. In case Indian Standards are not available

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for any equipment, Standards issued by IEC/BS/VDE/IEEE/NEMA or equivalent

shall be applicable.
b) Equipment and materials conforming to any other standard which ensures equal or
better quality may be accepted. In such case, copies of the English version of the
standard adopted shall be submitted .
c) The electrical installation shall meet the requirements of Indian Electricity Rules as
amended up to date and relevant IS Codes of Practice. In addition, other rules or
regulations applicable to the work shall be followed. In case of any discrepancy, the
more restrictive rule shall be binding.
2.02.00 Annexures
2.02.01 All annexures appended to this specification shall form part of this specification and
supplement the requirements specified herein.
2.02.02 This specification shall be read and construed in conjunction with the drawings and
annexures to determine the scope of work and terminal points.
2.03.00 Completeness of supply
2.03.01 It is not the intent to specify completely herein all details of the equipment.
Nevertheless, the equipment shall be complete an operative in all aspects and shall
conform to the highest standard of engineering, design and workmanship.
2.03.02 Any material or accessory which may not have been specifically mentioned but
which is necessary or usual for satisfactory and trouble free operation and
maintenance of the equipment shall be furnished.
2.03.03 The bidder shall supply all brand new equipment and accessories as specified herein.
2.04.00 Guaranteed Performance
2.04.01 The proposal data sheets given in another volume of this package specification shall
be filled in without any ambiguity by typing in appropriate place on each page.
2.05.00 Drawing Approval
2.05.01 Before starting manufacture of any equipment, the bidder shall have to take approval
of relevant drawings and data from Owner/Consultant in writing.
2.05.02 Any manufacture done prior to the approval of drawings/data shall be rectified in
accordance with the approved drawings/data by the bidder at his own cost and the
equipment shall be supplied within the stipulated period.
2.06.01 Design Basis

a) UPS System provides a regulated and uninterrupted single phase A.C. power, within
specified tolerances, to critical FGD loads during normal and emergency operation.


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b) The UPS system excluding its battery shall be installed indoors in A.C. environment.
DC supply to Inverter shall be provided from Common Battery System / DCDB
c) UPS system shall be compatible for satisfactory and well-coordinated operation with
other related equipment as well as with input and output systems.
d) Energizing or de-energizing any portion of the system serviced by the UPS shall not
cause output changes which shall affect the operation or integrity of the remaining
portions of the system in any way.
e) The equipment shall be self-protecting against all A.C. and D.C. transients, voltage
surges, and steady state abnormal voltages and currents.
f) The circuit protection shall be coordinated with UPS short circuit capacity and
protective device characteristics so that a fault on any circuit shall result in minimum
loss of function.
g) All non-interrupting components of UPS system shall be capable of withstanding the
prevailing short circuit current without damage.
h) All circuit interrupting components shall be capable of withstanding and interrupting
the prevailing short circuit currents without damage.
i) For continuous operation at specified ratings, temperature rise of the various
components of UPS system shall be limited to the permissible values stipulated in
the relevant standards and/or this specification.
k) The inverters, static switches, regulating transformers and voltage stabilizers should
be arranged in such a way that any equipment shall be fully isolated for maintenance
without affecting in any way the operation of other panels/ components.
l) In the A.C. Distribution Board, the bidder shall provide 10% or minimum one (1)
no. spare feeder of each size and type of the outgoing feeders.
m) The UPS system supplied shall have provision to transfer UPS parameter/data to
PLC/Control System. Necessary data transfer software & hardware shall be
incorporated in the system for this.
2.06.02 System Concept
a) 2 (Two) nos. of independent A.C. power sources will be available to the UPS
system. The system is so designed that its load shall be served without
interruption as long as one of the above power sources is available within
specified limit of voltage and/or frequency.
The UPS shall consist of two physically separate sets of equipment streams
consisting of the following :
i) Two sets of Rectifier Charger Sets with Battery Banks, Two sets of inverters
to produce high quality 240V, 1Ph 50 Hz A.C. output power.
ii) Two sets of static switches, synchronizing circuit to parallel the above-
mentioned Inverter output and bypass stabilized power stream.
v) One set of standby bypass stream consisting of suitable transformers, Static
voltage regulator etc. to produce regulated 240V, 1 Ph. 50 Hz A.C. power
from the 415V, 3 Ph. 50 Hz A.C. input from FGD LT supply.


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vi) One UPS A.C. power distribution board with suitable no. of outgoing
feeders.
Two sets of equipment streams as mentioned above shall constitute the UPS
system.
One set of synchronizing equipment and high performance static switch shall
parallel the above two streams and common output shall be taken to loads
which can accept only single non-redundant power input source.
The system shall ensure highest system availability around 99%.
b) Each of the two UPS streams shall be of 100% capacity and shall normally
work, each sharing 50% load. On failure of any stream, its load gets
automatically transferred to the other inverter through static transfer switch.
c) If one UPS stream is out of service for any reason then the second UPS
stream shall be working with 100% UPS load.
d) Inside each stream on failure of its inverter assembly the standby DC source
shall back up to supply the 100% UPS load automatically through static
transfer switch.
2.06.03 Layout Criteria
a) The UPS system shall be located indoor in FGD building .

The rectifier, inverter, static switches and distribution panels shall be located
in the UPS room.
The rectifiers, inverters, static switches, regulating transformers & voltage
stabilizers should be arranged in such a way that any equipment can be fully
isolated for maintenance without affecting in any way the operation of other
panels/components.
The equipment of the two UPS streams shall be physically isolated with
reasonable space between two installations.
3.01.00 Static Inverter
a) The static inverters shall be static type consisting of IGBT PWM type
inverter, static filters, integrated control modules including necessary
oscillators, voltage regulators, current limiting and surge suppression.
b) The inverter equipment shall include all necessary circuitry and devices to
conform requirements like voltage regulation, soft start, transient recovery,
protection, automatic synchronisation, wave shaping etc. as specified herein.
c) Upon transfer of full load, the inverter output voltage shall not drop below
80% of nominal voltage during the first half cycle after transfer and 90% of
nominal voltage in the next half cycle. The recovery to within ± 2% of
voltage shall be in less than 50 milli-seconds.

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d) On occurrence of a fault in branch circuit, the inverter shall be capable of

clearing the highest rated branch circuit fuse in 4 milli-seconds or less.
e) The inverter shall be protected against overload, short circuit, 100% loss of
load, as well as excursions, loss or restoration of D.C. input voltage and
synchronising voltage. The overload capacity shall be 125% for 10 mins.,
150% for 60 secs. and 300% for 4 msecs.
f) The D.C. input current shall never exceed twice the full load current except
for a short circuit within the inverter.
g) For any value of the load and load power factor drawn by the equipment
served, the inverter shall not impose on D.C. source any voltage oscillations
in excess of 5 volts (RMS total all frequencies) or any current oscillations in
excess of 3 percent (RMS total all frequencies) of the D.C. current at full
load.
h) The inverter shall be self protecting against A.C. and D.C. Transients,
voltage surges and steady state abnormal voltage and currents likely to be
encountered in the plant.
i) Under voltage(u/v), Over voltage(o/v) and earth fault protections shall be
provided for UPS (either separate relays or achieved electronically)
3.02.00 Automatic Synchronisation
a) Inverter equipment shall include stable solid state oscillator devices designed
to automatically maintain the inverter output in phase and in synchronism
with the standby A.C. source.
b) Facility shall be provided for automatic transfer to internal oscillator
operation when the standby source frequency is beyond specified limits and
the frequency shall be automatically controlled within 50 Hz plus or minus
0.5 Hz when the inverter operates in this mode.
c) Retransfer to standby A.C. source for synchronisation shall be automatic
after the standby source frequency is restored to permissible limits and
remains within this limit for an adjustable time delay period (up to 5
seconds).
d) Provision shall be made for stepless adjustment of synch- disconnect
frequency range from 50 Hz ± 0.5 Hz to 50 Hz ± 2 Hz.
e) Automatic adjustment of phase relationship between inverter output and
stand-by A.C. source shall be gradual at a controlled slow rate, which shall
not exceed one hertz per second.
3.03.00 Static Transfer Switch
a) The static transfer switch shall be solid-state type using SCR for
automatic/manual transfer of load from "inverter" to "stand-by" source and
vice-versa.


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b) Stand-by source can be either of the inverter or A.C. source depending on

whether both the inverters are supplying 50% load each or one of the inverter
is carrying 100% load.
c) The transfer time including sensing shall be less than 4 m.secs. Further the
transition shall be make- before-break in both directions.
d) The capacity of static transfer switch shall be equal to the continuous
full-load capacity of the inverter. The switch shall be provided with
protective devices in both normal and alternate power source.
e) Static transfer switch shall be furnished with contact to alarm failure of the
alternate source or opening of any fuse protecting the static switch.
f) Static transfer switch shall include all necessary circuitry and devices to meet
the functional requirements of transfer initiation, transfer inhibit and
re-transfer back to normal as detailed below :
g) Transfer Initiation
i) The transfer of static switch from normal 'Inverter' position to 'stand-by'

position shall be initiated by one of the following causes.
• Inverter failure and UPS system trouble.
• Inverter output voltage failure.
• Manual push button operation.
ii) The UPS bus shall be monitored by two voltage detectors. One fast acting
circuit shall be used for detecting a complete and instantaneous voltage loss
while the other slower acting averaging circuit with adjustable trip level shall
be employed to detect voltage deviation beyond selected limits. Both voltage
detector circuits shall automatically initiate operation of transfer switch.
iii) The static switch shall automatic transfer the load from inverter to standby
2
source when the maximum I t capability of the inverter is reached and when
the inverter output drops below 90%.
h) Transfer Inhibit
Automatic or manual transfer from inverter to stand-by A.C. source vice
versa shall be inhibited when the inverter frequency is not synchronised to
the alternate source.
i) Retransfer to Normal
i) The return to inverter mode shall be manual in all cases.
ii) Manual transfer shall be initiated by push button actuation.
3.04.00 Manual By-pass Switch
a) Manual by-pass switch is used to isolate any static transfer switch for
maintenance or repair without interruption to the UPS load.
b) The switch has also the facility of by-passing both the static transfer switches
during start-up at the option of the operator.


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c) Switch contact shall be make-before-break type.

d) The switch shall have current rating equal to the full load inverter current and
necessary short time load carrying and interrupting capacity to meet the
requirement of UPS system.
e) Breakers may be used instead of By-pass switch maintaining the same
philosophy of operation.
3.05.00 Step-down transformer and Static voltage regulator (SVR)
a) A three phase to single phase transformer along with associated voltage

stabilizer shall be furnished with the UPS system.
b) The transformer and SVR hall be sized for 100 per cent UPS load and shall
coordinate with the largest branch circuit protection device for feeder short
circuit current without sacrificing voltage regulation.
c) The SVR shall employ silicon solid state circuitry. It shall maintain the
specified output voltage within +/- 1.5% through out the load variation from
0 to 100% with maximum input voltage variation of +/- 10%. The make and
rating shall be subject to Purchaser's approval.
3.06.00 A.C. Distribution Boards
a) The DB shall have one section with MCCB as incomer and shall have bus
healthy lamps, volt meter and ammeters. Outgoing feeders to the loads shall
be protected by semiconductor fuses with fuse monitoring devices, MCCBs
and feeder ‘ON’ LED indication with glass fuse. Each load shall be fed by
two independent feeders terminated into a change over switch at the load
point. The gland plate of the distribution board shall be non-magnetic type
having thickness 3mm.
Interposing relays / transducers /potential free contacts required for DDCMIS
system shall be mounted on the UPS distribution board.
b) The distribution boards shall be fixed type, of modular design in freestanding
gasketted sheet steel enclosure conforming to IP-54. Sheet steel thickness
shall be 2 mm minimum.
c)Each module shall be housed in a separate compartment complete with individual
front access door. Working height shall be limited to 1800 mm from floor
level.
d) A full height vertical cable alley shall be provided in each panel to facilitate
module wiring. The alley shall be liberally sized and shall have removable
cover at the front. Removable back covers shall be provided at the back of
the panels.
e) Switches shall be double pole, air break, heavy duty type, capable of safely
making and breaking the full load current of associate circuit.


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f) Switch handle shall have position indicator and provision of padlocking in

ON & OFF positions. Further it shall be interlocked with access door for
safety.
g) Fuses shall be HRC, preferably link type, design to permit easy & safe
replacement. 20% spare feeders shall be provided in the DB.
Visible indication shall be provided for indication of fuse.
3.07.00 UPS Cabinets/Enclosures
a) The UPS system components shall be housed in a sheet steel freestanding
IP-31 enclosure with all access from the front. Sheet steel thickness shall be
2 mm minimum.
b) The enclosure shall consist of vertical cabinets housing modules in rack type
sub-assemblies, connected mechanically and electrically to form a rigid, self-
supporting, metal enclosed structure.
c) The modular units shall be mounted in pull out and/or swing trays. Each
module shall be capable of being easily removed to provide for the ready
inspection of major solid-state devices.
d) Vertical wiring trough shall be provided for the entire height of the UPS
cabinet. Cable entry shall be from bottom only.
e) Adequate ventilating louvers and screens shall be provided. The top of the
panel shall be protected by a suitable drip cover to prevent entrance of falling
liquid and foreign material.
f) If the equipment supplied requires forced air cooling, the cooling system
furnished shall meet the following requirement :
i) Two (2) nos. 100% cooling fans shall be provided for each vertical panel.
ii) Completely independent duplicate protection, control and wiring systems
shall be provided for the cooling fans for redundancy.
iii) The cooling fans shall be powered from the output of the associated
inverter.Normally one fan shall be running while the other is on stand-by.
iv) Each cooling fan shall be equipped with an airflow switch having an alarm
contact that closes upon failure of airflow.
3.08.00 Alarms
a) Solid state audio-visual annunciation system shall be provided for inverters,
static transfer switch
b) Alarm facia shall be provided on each inverter panel, complete with proper
actuating devices, circuitry and legends.
c) The arrangement shall be such that on occurrence of a fault the
corresponding window shall light up and stays lighted until the fault is
cleared and reset button pressed.


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d) Each time a window lights up a master relay shall get energized to provide
group alarm signals for remote PLC/Control System alarm system.
e) The requirements of indication/metering/alarms are given in the annexure -B
f) Alarm contacts shall be rated 0.5 A at 220 V DC and 5A at 240 V A.C.
g) Electrically independent, potential free alarm contacts for each of the points
mentioned in Annexure-B shall be wired up to the terminal block for
Purchaser's use.
3.09.00 Lamp / Space Heaters / Receptacles
a) The panels shall be provided with :
i) Internal illumination lamp with door switch.
ii) Space heater with thermostat control.
iii) 3-pin 6A receptacle with plug.
b) Lamp, heater and receptacle circuits shall have individual switch fuse units.
3.10.00 Wiring / Cabling
a) The panels shall be completely wired up. All wiring shall be done with
flexible, 1100V grade, PVC insulated wires with stranded 2.5 Sq.mm copper
conductors and routed through wiring troughs. Each wire shall be ferruled by
plastic tube with indelible ink print at both end having terminal block No.,
terminal number as per approved wiring diagram.
b) Panels shall have removable 3mm. gland plate for cable entry. All
incoming/outgoing cables shall be terminated in suitable terminal block.
c) Control terminal blocks shall be box-clamp type, minimum 10 Sq.mm. 20%
spare terminals shall be furnished.
3.11.00 Nameplate
a) Engraved nameplates shall be provided for each panel and for each
equipment/device mounted on it.
b) The material shall be anodised aluminium / lamicoid, 3 mm thick, with white
letters on black background.
c) Nameplates shall be held by self-tapping screws. The size of nameplates shall
be approximately 20 mm x 75 mm for equipment and 40 mm x 150 mm for
panels.
d) Nameplates for panels shall be provided both on the front and rear.
e) Control and meter selection switches shall have integral nameplates.
Nameplates for all other devices shall be located below the respective devices.
f) Instruments and devices mounted on the face of the panels shall also be
identified on the rear with the instrument/device number. The number may be
painted on or adjacent to the instrument or device case.


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g) Caution notice on suitable metal plate shall be affixed at the back of each
panel.
3.12.00 Grounding
a) Normal 3-phase A.C power supply shall be grounded at the source. For
grounding other than this, isolation transformer shall be furnished with the
U.P.S.
b) The inverter D.C. input and A.C. output shall be electrically isolated from
each other and from cabinet ground.
c) Panels shall have fully rated ground bus with two ground terminals, one at
each end.
d) Each terminal shall comprise two-bolt drilling M10 G.I. bolts and nuts to
receive Purchaser's ground connection of 50 x 6 mm G.S. flat.
e) Separate electronic grounding shall be provided for each UPS system.
3.13.00 Tropical protection
a) All equipment accessories and wiring shall have fungus protection, involving
special treatment of insulation and metal against fungus insects and
corrosion.
b) Screens of corrosion resistant material shall be furnished on all ventilating
louvers to prevent the entrance of insects.
3.14.00 Painting
a) The panels shall be finished in light grey shade (shade 631 of IS-5) with two
coats of synthetic enamel paint. The panels shall have a matt finish to prevent
any glare from surface due to illumination.


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4.00.00 Tests
4.01.00 All equipment and components thereof shall be subject to shop tests as per relevant
IEC/BIS Standards. The tests shall include, but shall not be limited to :
4.02.00
Tests on UPS System
a) Type & routine test for various components.
b) Burning test on PCBS - Assembled PCBS shall be tested at 70 Deg.C for 72
hours in loaded condition.
c) Rapid temperature cycling test at 70 Deg.C and 0 Deg.C for 30 minutes at
each temperature - 5 such cycles.
d) Functional tests to demonstrate compliance with all specified requirements
and published. Specifications such as frequency, regulation, voltage
regulation, current limiting, fuse clearing capability of inverters,
demonstration of phase and frequency control of inverter for synchronisation
with range of adjustments transfer and retransfer of static switches under
influence of under voltage and over current, tests on chargers, batteries and
other system component to confirm compliance with specification.
4.03.00 Type test certificates of any equipment shall be furnished, if so desired by the
Purchaser. Otherwise, the equipment shall have to be type tested, free of
charge, to prove the design.
5.01.00 Drawings, data & manuals to be submitted.
5.01.01 Technical data sheet (in the specification format)
5.01.02 UPS panels, and layout drawing with dimensions.
5.01.03 General Arrangement drawing of UPS panels.
5.01.04 Bill of Material.
5.01.05 Schematic drawing of UPS circuits.
5.01.06 Technical leaflets on :

a) UPS System
b) Rectifier/Converter
c) Inverter
d) Static Switch
e) Manual bypass Switch
5.01.07 Sizing calculation of UPS system.

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5.01.08 Type test certificates for similar equipment.
5.02.01 Manufacturer’s Quality approval plan & technical data sheet
5.02.02 Dimensional UPS, layout diagram in plan & section.
5.02.03 Connection details of take-off terminals.
5.02.04 Dimensional general arrangement drawings of UPS, clearly showing device

dispositions, cable entry, space requirement, etc.
5.02.05 Sectional views of UPS System panels.
5.02.06 Panel foundation plan and loading.
5.02.07 UPS system schematics and wiring diagrams.
5.02.08 Test reports
5.02.09 Detailed bill of materials.
5.02.10 Any other relevant drawing or data necessary for satisfactory installation,
operation, and maintenance.
5.02.11 Cable schedule & Inter-connection charts.
5.02.12 Instruction manuals of UPS system

The manual shall clearly indicate method of installation, check-ups, and tests
to be carried out before commissioning of the equipment.
5.03.00 The bidder may note that the drawings, data and manuals listed above are
minimum requirement only. Bidder shall ensure that all other necessary
write-ups, curves and information required to fully describe the equipment
are submitted .
6.00.00 Special Tools and Tackles
The bidder shall quote any special tools and tackles needed for his
equipment or stated herein.


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ANNEXURE-A
RATINGS & REQUIREMENTS
1.00.0 STATIC INVERTER
1.01.00 Application : UPS System for FGD control system, DDCMIS

and other essential loads
1.02.00 Type : Static
IGBT PWM type
1.03.00 Duty : Continuous
1.04.00 Enclosure : Sheet steel, IP31
1.05.00 Cooling : Natural convection or forced cooling using
redundant fans
1.06.00 Ambient temperature : 50 Deg.C
maximum,
8 Deg. C minimum
1.07.00 Inverter capacity : To be decided by the
bidder
1.08.00 Overload capacity : 300% for 4 m
secs.
150% for 60 secs
125% for 10 mins
110% for continuous
1.09.00 Voltage
a) Inverter input, DC/Battery output :
220V DC
b) Nominal output : 240 V, 50 Hz,
1-phase
1.10.00 Voltage Regulation :
a) Steady state (0-100% load at all input : ± 1.5%

voltages and all power factors)
b) Transient voltage : ± 10%

(On application or removal of 100% load)
c) Time to recover from transient to normal : 50 milliseconds.

voltage
1.11.00 Wave form :
a) Nominal frequency : 50 Hz

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b) Frequency range for all conditions of input : ± 0.05 Hz.

supplies, loads and temperature occurring
simultaneous or in any combination
(automatically controlled)
c) Synchronisation limits (for maintenance of : 49 Hz to 51 Hz

synchronism between inverter and standby (factory set)
A.C source)
d) Field adjustment range for (c) above : 50+

_ 0.05 Hz to 50+
_
2 Hz
e) Total Harmonic Content : 5% maximum at

rated load
f) Harmonic content for any single harmonic : 3% maximum
1.12.00 Rated output current at rated output voltage with current limit not operating
a) Current : 200%
b) Duration : 100 milliseconds.
1.13.00 Efficiency at full load :

90% or better.
(Watt output/watt input)
1.14.00 SCR derating from peak voltage
and peak rating : 50%
1.15.00 Short time rating : 1 second for short circuit at inverter
output
terminals
2.00.00 STATIC SWITCH
2.01.00 Type : Solid-state, SCR
2.02.00 Duty : Continuous
2.03.00 Enclosure : Sheet Steel, IP31
2.04.00 Cooling : Natural convection or forced cooling using redundant

fans.
2.05.00 Ambient Temperature : 50 Deg.C
2.06.00 Capacity

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a) Continuous : Equal to full load capacity of the inverter.
b) Overload : 300% for 4 m secs.

150% for 60 secs
125% for 10 mins
110% for
continuous
c) Peak : 1000% of
continuous rating for 5 cycle.
2.07.00 Normal Voltage : 240V, 50 Hz, 1-phase.
2.08.00 Transient Voltage Tolerance : 340V

peak above the nominal line voltage.
2.09.00 Transfer Time : less than

4 m secs.
2.10.00 Short time rating : Short circuit rating of the inverter for 1
second and 150% of Full load current for 2
minutes.
3.00.00 MANUAL BY-PASS SWITCH/BREAKER
3.01.00 Type : Maintained,

make before break.
3.02.00 Voltage : 600V
3.03.00 Rated Current : To meet the requirement

as specified in
clause no.: 3.04.00
3.04.00 Short time rating : Short circuit rating of the inverter for 1
second and 150% of Full load current for 2 minutes.
4.00.00 DISTRIBUTION BOARDS
4.01.00 Type : Fixed, Modular.
4.02.00 Enclosure : Sheet Steel, IP54


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4.03.00 Mounting : Free standing

(can be attended from both front &
back)
ANNEXURE-B
a) The alarm points shall be as follows :

i) AC supply failure
ii) DC voltage low
iii) DC voltage high
iv) DC system ground
v) SCR fuse blown
b) Indicating meters
Meters shall be 96 x 96 mm switchboard type, with 250 deg., antiglare glass, ± 2%

accuracy with zero adjuster on the front.


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GG. TECHNICAL SPECIFICATION FOR BATTERY AND BATTERY

CHARGER

1.01.01 220 V DC system
The 220V DC system is designed to cater the control, protection, interlocking,
annunciation and emergency DC drives and DC lighting for FGD area.
220 V DC System shall be provided with two (2) x 100% rated battery banks.
Each battery bank shall have 1 No Float charger , 1 No Float cum boost
charger and 1x100 % sectionalized DCDB with all other related equipment &
accessories.
1.01.02 One set of special tools and tackle.
1.01.03 Mandatory spares.
Note : Ratings, requirements, fittings and accessories of the equipment have been
further detailed in this specification and annexure. Equipment shall be
furnished in strict accordance with the same.

Major standards, which shall be followed, are listed below. Other
applicable standards for any component if not covered in the listed standard
shall also be followed:
Indian Standards Title International &

Internationally
Recognized
Standards
IS : 1652 Stationary cells and batteries, Lead acid IEC896-1
batteries with Plante’ positive plates
IS : 266 Sulphuric acid

IS : 8320 General requirements and methods of tests
for lead-acid Storage batteries
IS : 1146 Specification for rubber and plastics container
for lead acid storage batteries


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IS : 6071 Synthetic separator for lead acid batteries

BS-6290 Lead acid stationary cells and batteries.
Specification for High Performance Plante’ cells
IS : 1885 (Part-15) Electrical vocabulary, primary cells and
batteries
IS : 1069 Quality Tolerances for Water for storage IEC-60050
batteries
IEEE Recommended practice for sizing for IEEE-485
lead acid batteries for stationary application
IEEE Recommended practice for installation IEEE-484
design and installation of vented lead acid
Batteries stationary application

3.01.00 Design Basis and Sizing Criteria for 220 V Battery
3.01.01 220 V D.C. system provides reliable sources of D.C. power for
control, indication, protection and annunciation of the plant equipment. In
addition, it provides for the emergency loads/services on failure of A.C.
supply.
3.01.02 Each 220 V D.C. system comprises of two (2) sets of storage battery
banks, Each battery bank shall have 1 No Float charger , 1 No Float cum
boost charger and 1x100 % sectionalized DCDB with all other related
equipment & accessories.
All sets of batteries mentioned above shall be lead acid PLANTE type
and complete with associated float charger and float-cum-boost chargers. The
two charger & battery systems shall be of same capacity and rating.
3.01.03 The batteries shall be installed indoor in a clean but hot, humid and tropical
atmosphere. Battery chargers shall be installed in Air conditioned room.
3.01.04 The battery and charger combinations shall be such as to ensure continuity
of D.C. supply at load terminals without even momentary interruption.
3.01.05 For continuous operation at specified ratings, temperature rise of the
various components of battery and charger shall be limited to the permissible
values as stipulated in relevant standards.
3.01.06 Battery shall be sized to cater for the following loads with minimum
duration as indicated.
a) For duration 0 minute to 1 minute
Tripping breakers.
Starting current of all automatically started DC drives.
Solenoid valves.

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Indicating lamps, Protective relays, Auxiliary relays on switchgears and control panels
Emergency lighting
Supplies to UPS Inverters
b) For duration 1 minutes to 179 minutes duration
Running currents of DC motors.

Emergency lighting
c) For duration 179 minutes to 180 min duration
Closing and spring charging of breakers

Running currents of DC motors.
Emergency lighting
The sizing of the lead acid with plante batteries shall be as per IEEE-485. Following Factors
to be considered for Battery Sizing:
Design Margin: 1.15
Aging Factor: 1.0
The No. of cells, end cell voltage shall be considered based on the minimum and maximum
voltage windows and cable drop etc. as per system requirement.
DC scheme shall ensure that each critical consumer is fed from two different bus sections.
DCDBs shall be provided with adequate number of feeders on each section.
3.01.07 Ampere hour capacity (minimum) shall be as specified in Technical
particulars for design for 10 hours discharge rate with final voltage per cell
1.85V.
For faster discharge rate, the permissible continuous load with final
discharge voltage 1.85V / Cell shall be based on the following :
Discharge Time AH capacity in % of rated 10 Hr. capacity
10 hrs.
3.01.08 While estimating battery capacities, an ageing factor of 1.0 may be kept as per
IEEE -485 guidelines.
3.01.09 Additionally, 5% margin to be kept for future use.
3.01.10 For the purpose of estimating battery capacities and to arrive the
temperature compensation , the maximum and minimum temperatures shall
be considered as 50 Deg.C and 5 Deg.C respectively.


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3.01.11 The procedure for estimating battery capacities shall be as per

guidelines stipulated in IEEE-485.
3.01.12 The battery shall be sized such that the voltage at any time during the duty
cycle shall not be less than 1.85 volt per cell.
3.01.13 During float mode, charger shall be rated to cater to the following:
a) Trickle charging current of the battery
b) Continuous load on the DC system
c) 25% spare capacity over above loads
The output voltage of the float mode charger shall be adjustable between
230-240 V.
The charger shall also be capable of delivering the rated load even under
the specified voltage and frequency variations.
3.01.14 The float charger and float-cum-boost charger shall be sized to restore
the fully discharged battery to full charge condition in eight (8) hours
with 25% margin over maximum charging rate and also to operate as a
float charger.
3.02.00 The batteries & chargers shall be so designed that the maximum fault level
on DC DB is limited to 25KA (Indicative only; the actual value shall be
decided by the bidder after substantiating the same by calculation.)
3.03.00 System Concept for 220 V DC
3.03.01 DC system shall be parallel redundant with load sharing type. Normally the
chargers connected to the battery shall supply the DC loads and also keep the
battery under float charge. On failure of supply from charger, the battery shall
take over the DC loads without any interruption.
3.03.02 When the battery require boost charging, the first charger shall operate on boost
charge mode while the second charger shall supply the DC load on float mode
through automatic changeover arrangement.
3.03.03 Interlock shall be provided to ensure that the battery can be taken to boost
mode only if the second charger is healthy and running. Interlock
defeat arrangement shall also be provided for initial charging of battery.
4.01.00 Layout
4.01.01 The battery and battery charger shall be located indoor.
4.01.02 Battery room ventilation shall be under the scope of the Bidder.
4.01.03 Sufficient clear space shall be provided for attending individual cells.
4.01.04 Room floor shall be acid proof type.

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4.02.00 Battery
4.02.01 General
a) The battery shall be Plante type
b) The plates shall be designed for maximum durability during all service
conditions including high rate of discharge and rapid fluctuation of load.
a) Each cell shall be assembled in sealed type, heat resistant, shock
absorbing, robust, clear view SAN container.
b) Electrolyte level shall be marked on the clear view container or
level indicators as applicable. The markings shall be for upper and
lower limits.
c) Sufficient sediment space shall be provided so that the cells shall
not have to be cleaned out during normal life.
d) Vent plugs for sealed in type cells shall be anti-splash type.
e) Separator between plates shall permit free flow of electrolyte.
Separator shall be wood or other acid resisting material. Proper
arrangement to keep end plates in position shall be furnished.
f) The cells shall be supported on porcelain insulator (if required) fixed
on to the rack with adequate clearance between adjacent cells.
g) The cell terminals posts shall be provided with connector bolts and
nuts, effectively coated with lead to prevent corrosion
h) Lead or lead coated copper connectors shall be furnished to connect
up cells of battery set.
i) Positive, negative and 84th tap terminal posts shall be clearly and
indelibly marked for easy identification.
j) Lead-coated bent copper plate, tubular copper lugs, teak wood
clamp,bolts, nuts, washers, etc. shall be furnished for connection of
outgoing stranded copper cables from battery to charger.
k) The battery shall be shipped uncharged with the electrolyte
furnished in a separate non-returnable container.10% extra electrolyte
shall be furnished to cover spillage in transit or during erection.
4.02.03 Racks
a) The racks for supporting battery cells shall be constructed of best
quality teakwood with acid resistant insulation between the cells and
the rack and shall be painted with at least three (3) coats of anti-acid
paint, the shade of which shall be subject to approval of the Purchaser.


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b) Racks shall be freestanding type, mounted on porcelain insulators.

c) Numbering tags for each cell shall be attached on to the racks.
d) not more than two tires or two Tiers should normally be considered
for smaller batteries. Batteries above 300 AH shall have only one tier
and Lower shall have either two tier or one tier.
4.03.00 Battery Charger
4.03.01 General
a) The charger shall be natural air cooled, solid-state type, with full
wave,fully controlled, bridge configurations.
b) The charger shall be provided with automatic digital voltage
regulation, current limiting circuitry, smoothing filter circuit and soft-
start feature.
c) Voltage control shall be stepless, smooth and continuous.
Voltage control shall be possible either in "Auto" mode or in "Manual"
mode. An Auto-Manual selector switch shall be provided for this
purpose.
d) The charger shall be self-protecting against all A.C and D.C
transients and steady state abnormal currents and voltages.
e) Charger A.C input and D.C output shall be electrically isolated from
each other and also from panel ground.. Isolation shall also be provided
between power and control circuits.
f) Each battery charger shall be provided with one (1) no. voltage
transducer and one (1) no. current transducer for monitoring the D.C.
output. These transducers shall have twin-channel output of 4-20 mA
and shall be used for analog inputs to DDCMIS.
a) The charger shall comprise a continuous line up of free-standing,
floor mounted sheet steel panels, with access from both front and rear.
b) In between the float-cum-boost charger panels, a central panel
shall be provided. This panel shall house the battery terminals, load
terminals, battery blocking diodes, and a few meters, annunciators and
indicating lamps.
c) The panels shall conform to the degree of protection IP-42.
Minimum thickness of sheet metal used shall be 2 mm.
d) Access doors shall be with concealed hinges and neoprene
gaskets. Ventilating louvers shall be covered with fine wire mesh. Doors
over 600 mm width shall be of double-leaf design.


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e) All equipment within the panels shall be arranged in modular

units and laid out with sufficient space for easy maintenance.
f) Switches, meters, relays, etc. shall be flush mounted on the front
of the panels. Adequately sized name plates shall be provided for all
circuits and devices both at front & inside of the panel.
g) All busbars and bus connections shall be of high
conductivity aluminium/aluminium alloy and adequately sized to limit
the maximum temperature rise to 40 Deg.C under rated load condition.
The maximum allowable temperature rise shall be 50 Deg.C at joints.
The ambient temperature in either case shall be 50 Deg.C.
h) All bus connections shall be silver-plated. Adequate contact
pressure shall be ensured by means of two bolt connection with plain
and spring washes and locknuts.
i) Heat-shrinkable Insulating sleeves shall be provided for busbars.
All bus connections shall be shrouded. Busbars shall be colour coded
for easy identification.
j) Busbars shall be supported and braced to withstand the stresses
due to maximum short circuit current and also to take care of any
thermal expansion.
4.03.03 Charger Equipment
a) All power diodes and control rectifiers shall be silicon type.
Rectifier transformers shall be dry type, double wound, with copper
conductor and class-F insulation. The maximum temperature of the
class-F insulation shall be limited to that of class-B insulation.
b) Blocking diodes shall be fully rated and redundant so that failure
of a single diode shall not incapacitate the system in any way.
c) MCCBs with built in Short circuit and Overload release shall be
provided at input and output for isolation.
d) Changeover switch shall be 3 position, 4 pole, load break type
with minimum 2 NO + 2 NC auxiliary contacts. The switch shall be
installed in such a manner that the operating handle shall be accessible
only after opening the front door.
e) Contactors shall be air-break type. Thermal overload relays shall
have in-built single phasing preventor.
f) Fuses shall be HRC type and arranged for easy replacement.
Semi conducting device fuses shall be fast-acting.
g) Indicating Lamps shall be LED type. LED lamp shall be made in
accordance with InP Technology (Aluminium Indium Gallium


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Phosphide Technology). The body shall be made of Poly Carbonate

Unbreakable Lens. LED shall be protected by inbuilt fuse with surge
suppressor or leakage voltage glow protection. LED circuit shall be
PCB mounted. Intensity shall be greater than 200 med.
h) Meters shall be 96 x 96 mm switchboard type, 90 deg scale,
antiglare glass, +_ 1% accuracy with zero adjuster on the front.
i) Rectifier transformer for float-cum-boost charger shall be
provided with+_2x2.5% taps on the primary side.
4.03.04 Alarms
a) Solid-state, audio-visual annunciation system shall be
provided for battery chargers. Annunciation system shall operate on
220 V D.C.
b) One (1) minimum ten-point alarm facia shall be provided on each
float charger and float-cum-boost charger panel, complete with
proper actuating devices, circuitry, legend, push-buttons (Accept, Reset
and Test), and hooter.
c) Each central panel shall be provided with one (1) minimum eight-
point alarm facia, complete with proper actuating devices, circuitry,
legend, push buttons, (Accept, Reset and Test) and hooter.
d) The arrangement shall be such that on occurrence of a fault, the
corresponding window shall light up and stay lighted until the fault is
cleared and the reset button is pressed.
e) Each time a window lights up, a master relay shall get energised
to provide group alarm signals to remote control panel.
f) The requirements of indications/alarms are given in Annexure-B.
g) Some of these important alarms shall be hooked up to
PLC/Control System .
4.03.05 Meters
a) Each float charger panel shall be provided with the following
meters :
i) One (1) D.C. ammeter (for charger output)
ii) One (1) D.C. voltmeter with selector switch (for charger
output/battery voltage).
iii) Necessary shunts for local and remote metering shall be provided.
iv) Measurement for AC input voltage and current (through
Voltmeter/Ammeter selector switch)
b) Each float-cum-boost charger panel shall be provided with the

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following meters :
i) One (1) D.C. ammeter (for charger output)
ii) One (1) D.C. voltmeter with selector switch (for charger
output/battery voltage)
iii) Necessary shunts for local and remote metering shall be provided.
iv) Measurement for AC input voltage and current (through
Voltmeter/Ammeter selector switch).
c) Each central panel shall be provided with the following :
i) One (1) D.C. ammeter (for load circuit)
ii) One (1) A.C. voltmeter with selector switch (for main
A.C.supply)
iii) One moving coil center zero ammeter, with shunt to read
discharge/charge current of the battery, with suitable range .
Battery trickle charging current(through amplifier)
DC bus voltage (through selector switches) to measure between positive
to earth, negative to earth and positive to negative.
4.03.06 Controls
The following manual controls shall be provided on the front of each
charger panel :
a) Selection of float, equalising, or boost charge.
b) Voltage setters for setting the output of float/equalising/ boost charge.
Setting shall be independent of each other so that setting of one voltage shall
not require resetting of the others.
c) Current limit setter.
d) Acknowledge-Reset-Test push buttons for annunciation system. The
colour of reset buttons shall be BLACK.
4.03.07 Lamp/Space heaters/receptacles
a) The charger panels shall be provided with :
i) Internal illumination lamp with door switch
ii) Space heater with thermostat control
iii) 3 pin 5A receptacle with plug
iv) Communication plug
b) Lamp, heater and receptacle circuits shall have individual switch fuse
units/MCCB.

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4.03.08 Wiring/Cabling
a) The panels shall be completely wired-up. All wiring shall be
routed through wiring troughs. Wires shall be ferruled at both ends for
identification.
b) Internal wiring of the panels shall be done with 1100 V grade PVC
insulated cables with stranded copper conductor of minimum size 1.5 Sq.
mm.
c) Panels shall have removable gland plates at the bottom for cable entry.
All incoming/outgoing cables shall be terminated in suitable terminal
blocks.
d) Control terminal blocks shall be box-clamp type, minimum 10
Sq.mm. 20% spare terminals shall be provided.
4.03.09 Grounding
a) The charger panels shall have fully rated ground bus with two ground
terminals, one at each end.
b) Each terminal shall comprise two-bolt drilling with M10 G.I. bolts
and nuts to receive Purchaser’s ground connection of 50 x 6 mm GI.
4.03.10 Tropical protection
a) All equipment accessories and wiring shall have fungus protection,
involving special treatment of insulation and metal against fungus,
insects and corrosion.
b) Screens of corrosion resistant material shall be furnished on all
ventilating louvers to prevent entry of insects.
4.03.11 Painting
The panel shall be chemically cleaned,phosphated and sprayed with two
coats of high quality premier and stoved after each coat.The panels shall be
finished in light grey shade (shade 631 of IS-5) with two coats of synthetic
enamel paint. The panels shall have a matt finish to prevent any glare from
surface due to illumination. Inside panels painting shall be as per IS-5 (shage
632 of IS-5).
4.03.12 Name Plate
a) Nameplates shall be provided for each panel and for each
equipment/device mounted on it.
b) The material shall be anodised aluminium/lamicoid, 3 mm thick,
with white letters on black background.
c) Nameplates shall be held by self-tapping screws. The size of
nameplates shall be approximately 20 mm x 75 mm for equipment and 40

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mm x 150 mm for panels.

d) Name plates for panels shall be provided both on the front rear and
also inside of the panels.
e) Control and meter selection switches shall have integral nameplates.
Nameplates for all other devices shall be located below the respective
devices both inside & outside of panel.
f) Instruments and devices mounted on the face of the panels shall also
be identified on the rear with the instrument/ device number. The
number may be painted on or adjacent to the instrument or device case.
g) Caution notice on suitable metal plate shall be affixed at the back of
each panel.
5.00.00 Tests
All equipment and components thereof shall be subject to shop tests as per
relevant IS standards.
5.01.00 The above tests shall include but not be limited to :
5.01.01 Following type tests on two cells of the Battery, even if type test certificates
of these tests are submitted by the bidder for Purchaser's approval :
a) Test for capacity - test for voltage during discharge
b) Ampere hour & watt hour efficiency test
c) Endurance test.
5.02.00 Tests on battery charger
a) Dielectric tests.
b) Voltage regulation check from 0 to 100% load with +_10% input
voltage
variation.
c) Ripple content measurement.
d) Functional tests.
e) Heat run test on current limiting value.
5.03.00 Routine tests on component parts
5.04.00 a) Burning test on PCBS - Assembled PCBS shall be tested at 70 Deg.C
for 72 hours in loaded condition.
b) Rapid temperature cycling test at 70 Deg.C and 0 Deg.C for 30 minutes
at each temperature - 5 such cycles.
5.05.00 Type test certificates of any equipment shall be furnished to the Purchaser.
Otherwise, the equipment shall have to be type tested, free of charge, to
prove the design.


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6.01.00 Drawings, data & manuals to be submitted .
6.01.01 Battery and battery charger layout drawing with dimensions.
6.01.02 General Arrangement drawing of charger panels.
6.01.03 Bill of Material.
6.01.04 Schematic drawing of float and boost charge circuits.
6.01.05 Battery cell voltage characteristics and data for different discharge rates.
6.01.06 Technical leaflets on :
a) Battery
b) Battery charger
6.01.07 Duty cycle diagram and battery sizing calculation in the format of IEEE-485.
6.01.08 Sizing calculation of charger main equipment, viz. Battery,SCRs, rectifier
transformers etc.
6.01.09 Type test certificates for similar equipment.
6.01.10 Data sheet in ( the specification format )
6.01.11 Manufacturer’s Quality assurance plan.
6.02.01 Dimensional battery layout diagram in plan & section.
6.02.02 Connection details of take-off terminals.
6.02.03 Dimensional general arrangement drawings of battery charger, clearly
showing device dispositions, cable entry, space requirement, etc.
6.02.04 Sectional views of battery charger panels.
6.02.05 Charger foundation plan and loading.
6.02.06 Charger schematics and wiring diagrams.
6.02.07 Test reports
6.02.08 Detailed bill of materials.
6.02.09 Any other relevant drawing or data necessary for satisfactory
installation, operation, and maintenance.
6.02.10 Instruction manuals of battery and battery Charger. The manual shall clearly
indicate method of installation, check-ups, and tests to be carried out before
commissioning of the equipment.
6.03.00 The bidder may note that the drawings, data and manuals listed above are
minimum requirement only. Bidder shall ensure that all other necessary

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write-ups, curves and information required to fully describe the

equipment are submitted .


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ANNEXURE-A
RATINGS & REQUIREMENTS
1.0 BATTERY
1.1 Applicationl Unit battery
1.2 Ambient temperature
a) Maximum 50 Deg.C
b) Minimum 5 Deg.C
1.3 Type Lead Acid Plante
1.4 Nos. of Cells per Battery 110
1.5 Battery nominal voltage 220 V
1.6 Ten hour rating to 1.85V/Cell at 27 deg C To be decided by Bidder with
proper calculation
1.7 Proposed Method of working
a) Float charging (normal) 2.25 Volt per cell.
b) Equalising Charge (occasional) 2.36 Volt per cell
c) Boost charging 2.75 Volt per cell (maximum.)
(after complete discharge)
1.8 Intermediate tapping 84th Cell.
1.9 Mounting Teakwood
1.10 Terminal Connection 1/C, copper cables of adequate
size
2.0 BATTERY CHARGER
2.1 Charger Float charger
2.2 Type Solid-state, full wave, fully
controlled, three phase bridge.
2.3 Enclosure Sheet steel enclosure, IP-42
2.4 A.C. Input
a) Supply 415 V, 3 phase, 50 Hz, 4 wire
b) Voltage variation +/ - 10%
c) Frequency variation +/ - 5%
d) Combined volt and frequency variation 10% (absolute sum)
e) Short-circuit level 50 KA r.m.s. symmetrical.
f) System earthing Solidly earthed
2.5 Performance Requirements
a) The output voltage of the charger shall be regulated within +_ 1% of the set
value for any load variation from 0 to 100% and A.C. input voltage and
frequency variations as indicated above in 2.5.
b) The ripple content in charger D-C output shall be limited to +_ 1% of the D.C.
output voltage, at nominal A.C. voltage
2.6 Terminal Connection

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a) A.C. Input AYWY cable of adequate size

b) D.C. Output
To battery 1/C, copper cables of adequate size.
To load 1/C, AYY copper cables of adequate size
FITTINGS & ACCESSORIES

Each battery shall be furnished complete with the following :
1.0 BATTERY
1.1 First charge of electrolyte plus 10% extra
1.2 Teakwood racks with 3 coats of anti-acid paint.
1.3 Stand insulators plus 5% extra
1.4 Cell insulators plus 5% extra
1.5 Cell inter-connectors with 5% extra and end take-off with one no. extra
1.6 Lead-coated connection hardware plus 5% extra
1.7 Cell numbering tags with fixing arrangements
1.8 Teakwood cable clamps with hardware.
1.9 Six (6) extra cell with all accessories but without acid.
In addition to above, each battery shall be furnished with a set of following
accessories
1.10 One (1) inter-connector bolt wrench
1.11 One (1) hydrometer syringe
1.12 One (1) thermometer with plug & cap and with specific gravity correction scale
1.13 One (1) cell testing voltmeter with leads
1.14 Pocket thermometer
1.15 Acid resisting funnels
1.16 Acid resisting jugs of adequate capacity
1.17 Rubber aprons
1.18 Rubber gloves
1.19 Cell lifting straps
1.20 PVC spill trays under the battery cells
1.21 Bridging clamps
1.22 Spanner for cells
1.23 Float type level indicator
1.24 First aid box
2.0 LIST OF ALARMS
2.1 Each Float charger and Float-cum-Boost charger panel shall be provided with one
(1) minimum twenty -point annunciation facia. Alarm points shall include
a) A.C. supply failure
b) D.C. Voltage low
c) D.C. Voltage high
d) D.C. System ground

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e) Charger overload
f) SCR fuse blown
g) Filter fuse blown
h) D.C. output fuse blown
i) Float bus over/under voltage
j) Boost bus over voltage
k) Boost over current for each charger
l) Failure of thyristor/diodes for each charger
m) Failure of blocking diodes
n) Output MCCB open for each charger
o) Battery MCCB open
All above alarms shall be duplicated to DDCMIS for operator interface at Control
Room
2.2 The central panel shall be provided with one (1) minimum eight-point
annunciation facia. Alarm points shall include :
a) Battery on boost charge
b) Float charger fail
c) Float-cum-boost charger in float mode.
d) Battery earth fault
e) Main A.C. fail
2.3 Initiating contacts, wired to two terminals, shall be provided for group
annunciation of "Battery Charger Trouble" in remote control room.
2.4 Initiating contacts for all alarm points shall also have electrically separate spare set
of contacts wired to the terminal block for future use.
2.5 All alarm contacts shall be rated 0.5A at 220V D.C. and 5 Amp. at 240V A.C.
2.6 In addition to the alarm points mentioned above, any other alarm point, if required
for battery and charger, shall be provided. In addition to above requirement, each
section of battery charger shall have at least two (2) nos. spare annunciation channels
and window facia.
3.0 LIST OF INDICATIONS
3.1 The indications to be provided on each float charger and float-cum-boost charger
panel shall include but shall not be limited to:
a) Charger power supply ON
b) Charger D.C. output healthy
c) Control supply ON
3.2 The indications to be provided on the central panel of each charger set shall
include but shall not be limited to:
a) Annunciation D.C. healthy
b) Float-cum-boost charger in equalising mode.
c) Float-cum-boost charger in boost mode
d) Float-cum-boost charger in float mode.
e) Float charger selected
f) Float charger tripped on fault


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HH. TECHNICAL SPECIFICATION FOR FOR CABLES
1.00.00 Scope
This section covers the general requirements of Power cables, Control

Cables and trailing cables. The cables shall be furnished in accordance
with this specification. Other cables including special cables, if any,
which are necessary as per proven engineering practice for satisfactory
& trouble free operation of the entire cable system of the main plant shall
also be within the scope. These shall include all such cables for electrical
integral with mechanical equipment systems and sub-systems.
2.01.00 Cables shall be generally laid on ladder type trays or drawn through rigid
steel conduits. For interplant connection cables shall be laid on overhead trays
supported on trestles. In some cases the cables may be directly buried in
ground with the specific approval of the purchaser.
2.02.00 For continuous operation at specified rating, maximum conductor
temperature shall be limited to the permissible value as per relevant
standard and / or this specification.
2.03.00 The insulation and sheath materials shall be resistant to oil, acid and alkali
and shall be tough enough to withstand mechanical stresses during handling.
2.04.00 Armouring shall be single round wire/flat wire of galvanised steel for
multicore cables as specified under various clauses of this specification. For
single core cables, armouring shall be of aluminium.
2.05.00 The outer sheath as well as the inner sheath shall have flame retardant low
smoke (FRLS) characteristics and shall meet the requirements of additional
tests specified for this purpose.
2.06.00 Core identification for multi-core cable shall be provided by colour coding.
2.07.00 For 6.6 KV and above rating cables shall be dry cured in pressurised
nitrogen atmosphere.
3.01.00 General Description
All Cables shall be furnished in strict compliance with ratings and
requirements and sizes as given in Annexure to this Specification.
3.02.00 Drum Length and Tolerance
The cables shall be supplied in wooden drums, each containing minimum
500 meters length for power cables and 1000 meters for control cables.
Allowable tolerance on individual drum length is +_ 5%.

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3.04.00 Packing
3.04.01 Cables shall be supplied in non-returnable drums. The drums shall be of heavy
construction. All wooden parts shall be manufactured from seasoned wood.
All ferrous parts used shall be treated with suitable rust preventive finish or
coating to avoid rusting during transit or storage. Wooden cable drum shall
be treated by immersing in copper-nitrate solution.
3.04.02 The ends of each length shall be sealed before shipment. Heat shrinkable cable
cap shall be used for this purpose.
3.04.03 A label shall be securely attached to each end of the reel indicating the
Purchaser's order number, Owner’s identification mark i.e. “TanGedCo”,
length, type, voltage grade, conductor size and number of cores of the
cable. A tag containing the same information shall be attached to the
leadings end of the cable inside. An arrow and necessary instructions shall be
marked on the drum indicating the direction in which it should be rolled.
Drum numbers are to be indicated on the cable drums.
3.05.00 Joints and Terminations
Materials of construction for a joint/termination shall perfectly match with
the dielectric chemical and physical characteristics of the associated cables.
The material and design concepts shall incorporate a high degree of
operating compatibility between the cable and joints. The protective
outer covering (jacket) used on the joints/terminations shall have the same
qualities as that of the cable outer sheath in terms of ambient/operating
temperature withstand capability and resistance to hazardous environments
and corrosive elements.
3.06.00 Selection Criteria
3.06.01 In cable sizing the following are to be taken into consideration.
a) Short circuit current and duration
b) Continuous current.
c) Installation conditions.
d) Voltage drop under normal running and starting condition.
3.06.02 Apart from above, consideration shall also be given to limit the cable to
some standard sizes instead of using too many types.
3.06.03 The standard cable sizes, capacities, de-rating factors, etc. as given in IS shall
be generally followed.
3.06.04 a) For breaker protected circuits minimum size shall be determined by
short circuit rating.
b) For motor circuits the selection of size shall be made ensuring that the cable
shall withstand a short circuit fault directly following a second hot start.

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3.06.05 For power circuits, the conductor size shall depend on full load current
subject to voltage drop not exceeding 3%. For practical purposes, the
minimum size chosen is as below :
Alu 10 Sq. mm
mini
um
Cop 2.5 Sq. mm
per
All drives of small rating where terminations with 10 Sq. mm. cables are
not feasible, shall have copper cable.
3.06.06 All control cables shall be 1.5 Sq. mm. copper cable. CT/PT cables shall be
2.5 sqmm copper cable.
3.06.07 Multi-core control cables shall generally have 20% of the total number of
cores as spare.
3.06.08 Separate cables for each type of following services / functions as applicable
shall be used for each feeder. Same multi-core cable using different services
shall not be acceptable.
a) Power.
b) Control, interlock and indication.
c) Metering and measuring.
d) Alarm and annunciation.
e) C.T. Cables.
f) V.T. Cables.
3.07.00 Cable Identification
Cable identification shall be provided by embossing the following on the
outer sheath:
a) Manufacturer's name or trade mark
b) Voltage grade
c) Year of manufacture
d) Type of insulation
e) Type of inner and outer sheath e.g. "FRLS" etc.
f) ISI marks
g) Nominal cross sectional area of the conductor & no of cores


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h) Sequential marking
i) Owner’s identification mark
3.08.00 Sizes of power and control cables for guidance are given in Annexure-B.
However, the bidder shall go for detailed sizing calculation and furnish the
same.
4.00.00 Trailing Cables (Power & Control)
Trailing cables shall be as per Annexure-A.
5.00.00 Tests
5.01.00 Shop Tests
The Cables shall be subject to shop tests in accordance relevant IS/IEC
standards to prove the design and general qualities of the Cables as below: -
5.01.01 Routine tests on each drum of cables.
5.01.02 Acceptance tests on drums chosen at random for acceptance of the lot.
5.02.00 Additional Tests
Following additional acceptance tests shall also be performed on each type
of cables having outer sheath with improved fire performance (category C1,
Type FR/ Category C2, Type FRLSH)
5.02.01 Oxygen index test (for both C1 & C2)
The Oxygen index shall not be less than 29
5.02.02 Temperature Index Test (for both C1 & C2)
The measured value of temperature index shall be 21 at a temperature of
250°C
5.02.03 Flame Retardance test on single cable and on bunched cables (for both C1 &
C2)
After the test, there should be no visible damages on the test specimen
within 300mm from its upper end.
After burning has ceased, the cables should be wiped clean and the charred or
affected portion should not have reached a height exceeding 2.5 meter above
the bottom edge of the burner, measured at the front and rear of the cable
assembly.
5.02.04 Halogen acid gas evolution test (for category C2). The level of HCL evolved
shall not exceed 20 per cent by weight
5.02.05 Smoke density test (for category C2)
The cables shall meet the requirements of light transmission of minimum
40% after the test.)

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5.02.06 Test for rodent & termite repulsion property

The test shall be carried out to note the presence of rodent and termite
repelling chemical in PVC compound. Normal procedure is that a few
chippings of the PVC compound are slowly ignited in a porcelain dish
or crucible in a muffle furnace at about 600°C. The resulting ignited ash is
boiled with a little ammonium acetate solution (10%). A drop of
aqueous sodium sulphide solution is placed on a thick filter paper and it
is allowed to soak. The spot is touched with a drop of above extract. A
black spot indicates the presence of anti-termite & rodent compound.
5.03.00 Test Witness
All the above tests shall be performed in presence of purchaser or his
representative.
5.04.00 Test Certificates
5.04.01 Type test certificates
Type test certificates of similar type & size of cables shall be furnished. If
type test certificates are not available, same shall be conducted in presence of
the purchaser or his representative.
5.04.02 Certified reports of all the tests carried out at the works shall be furnished
for approval of the Owner/Purchaser.
5.04.03 Test reports shall be completed with all details and shall also contain
IS specified limit values, wherever applicable, to facilitate review.
5.04.04 The cables shall be dispatched from works only after receipt
of Owner/Purchaser's written approval of the test reports.
6.01.00 To be submitted as indicated below
a) Manufacturer's catalogues giving cable construction details and
characteristics.
b) Cable current ratings for different types of installation, inclusive of
derating factors for ambient temperature, grouping etc.
c) Write-up on Manufacturer's recommended method of splicing, jointing,
termination etc. of the cables.
d) Type test report on all specified cables.
e) Proposal Data as per Annexure.
6.02.00 To be furnished after award of contract
a) Cable datasheets
b) Cable sizing

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c) QAPs & Test Reports.

d) Relevant catalogues


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ANNEXURE-A
RATINGS AND REQUIREMENTS (POWER AND CONTROL CABLE)
1.0 H.V. Power Cables 6600 V Grade

Heavy duty XLPE power cable suitable for use in 6600V non-effectively
earthed system conforming to following requirement and in line with IS-7098,
IS-8130, IS-5831 & IS-3975.
1.1 Conductor : Stranded and compacted aluminium conductor of grade
H2 and class 2 for all sizes, generally conforming to IS:8130.
1.2 Conductor Screen : Extruded semi-conducting compound.
1.3 Insulation : Extruded cross linked polyethylene (XLPE)
1.4 Insulation Screen : Extruded semi-conducting compound with a
layer of non-magnetic metallic tape. For single core armoured cables, the
armouring shall constitute the metallic part of screening. The semi-
conducting tape shall be easily strippable.
1.5 Core Identification : By coloured strips applied on (For three
core cables) cores or by numerals.
1.6 Inner Sheath : Extruded FRLS PVC compound conforming to
Type ST2 of IS:5831. Filler material shall also be of type ST2 PVC.
1.7 Armour : Galvanised single round steel wire armour for twin
and multicore cables.
Non-magnetic hard drawn aluminium single round wire conforming to
H4 grade for single core cables.
1.8 Overall Sheath : Extruded FRLS PVC compound conforming
to type ST2 of IS:5831.
2.0 L.V. Power cables 1100 V grade
1100 V grade, power cable conforming to following requirement and in line with
IS-1554, IS-5831, IS-8130 & IS-3975.
2.1 Conductor : Stranded and compacted plain aluminium of grade
H2 and class 2/stranded, high conductivity annealed
plain copper as per Annexure, generally conforming
to IS:8130
2.2 Insulation : Extruded cross linked polyethline XLPE.
2.3 Inner Sheath : Extruded FRLS PVC compound conforming to type ST2 of
IS:5831 .
2.4 Armour : Galvanised single round/ strip steel wire armour for twin and
multicore cables.


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Non-magnetic hard drawn aluminium single round wire

conforming to H4 grade for single core cables.
2.5 Overall : Extruded FRLS Black PVC compound conforming to type
Sheath ST2 of IS:5831.
3.0 Trailing Cables (Power & Control)
Trailing cable, 1.1kV grade with highly flexible stranded tinned copper conductor,
insulation of EPR (Ethylene-propylene Rubber) each individual core protected and
covered and overall outer cover of poly-chloroprene rubber cable shall conform to IS 9968
part-1.
4.0 Control Cables 1100 V Grade
1100 V grade, 700 C rating, PVC Control cable conforming to
following requirement and in line with IS-1554, IS-8130, IS-5831 & IS-
3975.
4.1 Conductor : Stranded, non-compacted & circular, high
conductivity annealed plain copper, generally
conforming to IS:8130.
4.2 Insulation : Extruded PVC compound conforming to type A of
IS:5831.
4.3 Inner : Extruded FRLS PVC compound conforming to
sheath type ST1 of IS:5831
4.4 Armour : Galvanised single round steel wire for twin and
multicore cables.
4.5 Overall : Extruded FRLS PVC compound conforming to
sheath type ST1 of IS:5831


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II. TECHNICAL SPECIFICATION FOR LT NON-SEGREGATED

BUSDUCT
1.00.00 Scope
1.01.00 This specification covers the 415V Non-segregated phase busduct and
accessories
IEC : 60947, IS : 13947
where modified and/or supplemented by this specification.
version of the standard adopted shall be submitted.
2.03.00 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended up to date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
3.00.00 System concept and Design criteria
3.01.00 415V power distribution in FGD area shall be by means of PCCs,

PMCCs, MCCs & DBs.
3.02.00 PCCs, PMCCs and MCCs shall be provided in FGD area and associated
premises for catering to the loads of the respective areas.
3.03.00 PCC/PMCC/MCC in fire hazardous areas (wherever applicable) like
Hydrogen Handling, lubricant handling etc. shall be explosion proof.
3.04.00 LT transformer and PCC along with interconnecting bus duct shall be
provided by the bidder for these areas.
3.05.00 The equipment shall be located in a hot, humid, and tropical atmosphere,
heavily polluted at places with coal dust and/or fly ash.
4.00.00 Technical Specification
4.01.00 General
4.01.01 The busduct shall serve as interconnection between L.V. terminals of
L.T. Transformers to their respective PCC/PMCC and also for trunking
connection between each set of PCC if any.
4.01.02 The busduct shall be non-segregated type, self cooled. The cooling medium inside


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the duct shall be air.

4.01.03 The busduct shall be installed in a hot, humid and tropical atmosphere.
4.01.04 For continuous operation at specified rating, maximum temperature rise of the
busduct shall be limited to the following over ambient temperature of
50 Deg.C :
Conductor/Bus Connection : 40 Deg.C.
Enclosure/Supports : 20 Deg.C.
4.01.05 It shall be capable of withstanding the mechanical forces and thermal
stresses of the specified short-circuit currents without any damage or
deterioration of material.
4.01.06 Wherever expansion joints are required neoprene rubber bellows shall be
provided for enclosure and flexible connectors for conductor.
4.01.07 Same phase disposition shall be maintained throughout the run of the bus
duct. Phase cross-over units, if required, shall also be provided at the switchgear
end.
4.01.08 Outdoor portion of the busduct, if any, shall have continuous rain hood of non
magnetic material.
4.01.09 Insulation level
Rated voltage – 415 V
Rated Insulation voltage – 1100 V
1 min dry power-2.5 KV
4.01.10 Clearances
Phase to phase(mm):- 25.0
Phase to earth(mm):- 25.0
4.02.00 Enclosure
4.02.01 All the three phases shall be enclosed in a weather proof, dust tight enclosure.
Outdoor section of the busduct shall be completely rain proof. For bus
rating including and above 3000 A, enclosure shall be of aluminium of 3
mm thick and for bus rating below 3000 A, enclosure shall be of 2.5mm
sheet steel fabricated type. Minimum Degree of protection of busduct
enclosure shall be IP-52 for indoor and IP-55 for outdoor section.
4.02.02 Weather resistant type circumferential gaskets shall be provided for making the
joints with adjacent enclosures dust-proof and imperious to moisture.
4.02.03 The connection flanges shall be sufficiently stiffened so as not to bend while
tightening the bolts.


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4.02.04 Suitable inspection opening with gaskets shall be provided for access to
support insulator, bus joints etc.
4.03.00 Bus Conductor
4.03.01 The conductor shall be of high conductivity aluminium /aluminium alloy as per
IS:5082 sized for the same rating as associated PCC / PMCC bus.
4.03.02 Joints made at the factory shall be welded type and the joints to be made at
site shall be bolted type.
4.03.03 For bolted rigid/expansion joints, necessary bolts, nuts, (cadmium plated) washers
and other hardwares shall be supplied.
4.03.04 Busbars shall be colour coded at regular intervals for easy identification. The
markings on the bars shall be Red for R-phase, Yellow for Y-phase, and Blue
for B-phase.
4.03.05 For each shipping section, the bus conductor shall be supported at
minimum two positions.
4.04.00 Bus-Bar Support
4.04.01 All buses and connections shall be supported and braced to withstand stresses
due to maximum short circuit current.
4.04.02 The bus conductor supporting insulators shall be flame retardant, non-hygroscopic,
high impact and high dielectric strength material with an anti tracking contour.
Material shall be Epoxy SMC moulded/FRP/porcelain. Spacing of the bus
support insulators shall be considered by giving due factor of safety to
withstand the forces due to the short circuit current assigned to the bus duct.
4.04.03 The insulators shall be so located that they can be easily removed and
replaced without dismantling the busduct installation.
4.04.04 Space heater shall be provided near each insulator to avoid moisture condensation
within busduct.
4.04.05 Silica gel breather shall be provided for the indoor and outdoor portions of the bus duct
for the absorption of moisture. Provision for draining moisture shall also be
provided.
4.04.06 The number and wattage of space heaters shall be decided by the Bidders.
4.05.00 Supporting Structures
4.05.01 All supporting structures required for hanging and/or supporting the complete
busduct shall be furnished. These include all members, indoor/outdoor posts,
bolts, shims, base plates, beams, hangers, brackets, bracings and hardware.
4.05.02 All buses shall be adequately supported and braced to successfully withstand
normal operation, vibration, thermal expansion, short circuit forces, and all
specified design loads.

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4.05.03 All steel members shall be hot-dip galvanised after fabrication. All hardware
shall be of high strength steel with weather resistant finish.
4.05.04 For each shipping section, the enclosure shall be supported at minimum two
positions.
4.05.05 The enclosure supporting arrangement shall be such that the busduct
load is not transmitted onto the terminations.
4.05.06 Connections and Terminations
4.05.07 All matching flanges, seal-off bushings, gaskets, fittings, hardware, and
supports required for termination of the busduct at PCC, transformer, and
any other equipment shall be supplied.
All hardware used at conductor points shall be of non-magnetic, high tensile
material.
4.05.08 Expansion joints for both conductor and enclosure shall be provided as follows:
i). At all equipment terminations
ii) On either side of seal-off bushings
4.05.09 Expansion joints shall be provided on bus conductor and enclosure to take care of
thermal expansion.
4.05.10 Seal-off bushing with wall frame assembly shall be provided wherever the
busduct penetrates the building wall from outdoor to indoor.
4.05.11 Equipment terminal connection shall be readily accessible and shall provide
sufficient air gap for isolation of equipment during testing.
4.05.12 If the material of bus conductor and that of the equipment terminal
connectors are different, suitable bi-metallic connectors shall be provided.
4.06.00 Ground Bus
4.06.01 A ground bus rated to carry maximum fault current shall be provided running the
entire length of the busduct, grounding all parts of the supporting
structure and each enclosure section.
4.06.02 The ground bus shall be provided with two-bolt drilling with G.I. bolts and
nuts at each end to receive the G.S. earthing flats. Earth bus size shall be 50x10
mm minimum.
4.07.00 Finish
4.07.01 Bus conductor shall be given a coat of black matt paint to facilitate efficient heat
dissipation. However, effect of painting shall not be taken into consideration
while sizing of the bus conductor.
4.07.02 Inside of the bus enclosure shall be treated with a matt paint of dark colour,
preferably black to facilitate efficient heat dissipation. The shade of exterior

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surface finish shall be light grey IS Shade # 631 for indoor and battle ship
grey IS Shade # 632 for outdoor.
4.07.03 All supporting steel structures shall be finished with an undercoat of high quality
primer followed by two coats of synthetic enamel paint.
4.07.04 Pre-treatment consisting of degreasing, derusting etc. shall be done on all
fabricated parts before painting or galvanising.
4.07.05 Paints shall be carefully selected to withstand heat and weather conditions. The
paint shall not scale off or crinkle or get removed by abrasion due to normal
handling.
4.07.06 Sufficient quantities of all paints and preservatives required for touching up at site
shall be furnished.
4.08.00 Tests
4.08.01 Routine tests

All routine tests as per relevant standards shall be carried out at manufacturer’s
work in presence of the purchaser or his representative.
4.08.02 Type test
Type test certificates shall be furnished for similar type and rating of bus
duct. If certificates are not available, they have to be type tested, free of
charge, to prove the design.
Technical Particulars (415 V BUSDUCT)
1. Applicable Standard : IS:8623
2. Rated system voltage and frequency : 415V/50HZ
3. System earthing : Solidly grounded
4. System short-circuit level kA (rms) : 50kA
5. Type of busduct : Indoor/outdoor

Phase non-segregated
3 phase
6. Maximum voltage at which the busduct : 660V

can operate continuously
7. Busbar material (Conductor) : Aluminium alloy
8. Busduct support structure : To be provided


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:
9. Current ratings
Rated continuous current : As per requirement
Rated short time withstand duration : 1 second
Rated peak withstand current kA (peak) : 105 kA
:
10. Insulation level
Rated voltage : 415 V
Rated insulation voltage : 1100
1 min dry power frequency withstand : 2.5 kV
Impulse with stand :
:
11. Support insulators
Type : Non hygroscopic Epoxy

SMC
moulded/FRP/porcelain
Max. distance between supports : To be worked out based On
short circuit calculation
12. Clearances :
Phase to Phase (in mm) : 25.0

Phase to Earth (in mm) : 25.0
13. Earth bus :
Material : Galvanised steel

Size : 50 mm X 10 mm
:
14. Enclosure
Degree of protection : IP 52(indoor)

IP 55 (outdoor)
Material of enclosure : Aluminium / sheet steel
Thickness of material : Minimum 3 mm/2.5mm
Shade of paint : Inside surface - Matt paint
of dark colour
Outside surface :
Outdoor - 632 of IS:5
Indoor - 631 of IS:5


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15. Max. temperature rise over ambient

temp of 50 deg. c
Bus conductor : 40 deg.C
Bus enclosure and support structure : 20 deg.C
JJ. TECHNICAL SPECIFICATION FOR ILLUMINATION SYSTEM
01.00.00 General
01.01.00 This specification covers the general description of design, manufacture and
construction features, testing, supply, installation and commissioning of
FGD lighting System/Area Lighting system equipment.
Areas to be covered in this package are entire FGD buildings including FGD
and its auxiliary systems operational areas/platforms/buildings , Mill premises
including Mill maintenance, Transfer towers & Conveyor galleries, control &
switchgear room, Switchgear/MCC room, Compressor building, Piping gallery,
cable gallery, all roads within battery limit and area illumination of the above
premises.
Illumination of Transformer and switchgear building/area adjoining roads etc.
are also included in the scope of the bidder.
Any other area/premises roads not specifically mentioned here but which fall
under the battery limits of this package are also included in the scope.
02.01.00 All work shall be carried out as per the codes & standards chapter of this
volume
03.00.00 Lighting System Description
The illumination of various indoor and outdoor areas in the FGD Plant and
off site areas shall be provided as described here. The lighting system of
various areas shall comprise of one or more of the following systems:
(a) Normal AC Lighting System
(b) Emergency AC Lighting System
(c) DC Lighting System
03.01.00 Normal AC Lighting System

Normal AC lighting system 415V, 3Phase, 4wire, shall be fed from lighting
panels (LPs) which in turn shall be fed from the lighting distribution boards
(MLDBs)/Switch board MCC.
03.02.00 Emergency AC Lighting System


& ITS AUXILIARIES
This system shall be provided for certain important areas in the main plant.
The lighting fixtures connected to this system shall be normally "ON" along
with the normal AC system. These shall be fed from emergency lighting
panels (ELPs) which in turn shall be fed 3-phase, 4-wire supply from the
emergency lighting distribution boards (ELDB'S). These lights shall go off
for a few seconds in case of AC supply failure at Emergency Switchgear,
but shall be automatically restored when Emergency power supply is
provided from the DG supply.
03.03.00 DC Lighting System
03.03.01 At strategic locations in the FGD Plant, a few lighting fixtures fed from
220V, DC supply, shall be provided to enable safe movement of operating
personnel and access to important control points during an emergency,
when both the normal AC and Emergency Lighting system fail. These
lighting fixtures shall be fed from 220V DC LDBs which in turn shall be
fed from DC lighting panels
03.03.02 The supply to the DC lighting panels shall be automatically switched ON in

case of loss`of AC supply. The DC supply shall be automatically switched
OFF after about 3 minutes following the restoration of supply to normal AC
lighting system.
03.03.03 In auxiliary /off site buildings, emergency DC lighting is to be provided

through self contained DC emergency fixture at strategic locations. The
fixtures shall be switched 'ON' automatically in case of failure of AC
supply.
04.00.00 Design Philosophy
1. A comprehensive illumination system shall be provided in the entire project
2. All outdoor lighting system shall be automatically controlled by

synchronous timer or photocell. Provision to bypass the timer or photocell
shall be provided in the panel.
3. In the Off site area / buildings DC lighting shall be provided by self

contained 3 hours duration Emergency lighting fixtures.
4. The system shall include distribution boards, normal/ emergency lighting

panels, lighting fixtures, junction boxes, receptacles, switch boards, lighting
pole/masts, conduits, cables and wires, etc. The system shall cover all
interior and exterior lighting such as area lighting, including Transformer

& ITS AUXILIARIES
yard, Street lighting, security lighting, etc. The constructional features of

lighting distribution boards shall be similar to AC/DC distribution boards
described in chapter of LT Switchgear. Outgoing circuits in LPs shall be
provided with MCBs of adequate ratings.
5. The illumination system shall be designed on the basis of best engineering

practice and shall ensure uniform, reliable, aesthetically pleasing and glare
free illumination. The lighting fixtures shall be designed for minimum
glare. The design shall prevent glare/luminous patch seen on VDU/ Large
video screens, when viewed from an angle. The finish of the fixtures shall
be such that no bright spots are produced either by direct light source or by
reflection. The diffusers/ louvers used in fluorescent fixtures shall be made
of impact resistant polystyrene sheet and shall have no yellowing property
over a prolonged period. The Lux levels to be adopted for various area are
indicated at Annexure - A. (placed at the end of this Chapter).
Further Lighting System shall be designed considering maximum utilization

of natural light. To achieve this lighting circuit may be designed with
segregation and usage of lux control philosophy. Energy efficiency codes
shall be followed in principle.
6. Different Lighting Systems envisaged for various plant areas are indicated
in Annexure-B: While finalizing the detailed layout of lighting fixtures, the
position/location and layout of equipments should be taken into account to
have adequate illumination at desired locations.
7. LED Luminaires:
LED Luminaires shall be used for the lighting of all the Control Rooms and
& Control Equipment areas, all HT & LT Switchgear rooms and all Street
lights in Bidder's scope. In false ceiling area LED luminaires shall be
recessed mounting type & in non-false ceiling area the LED luminaires
shall be surface mounting type.
The individual lamp wattage for LED shall be min 3 watt. The LED chip
efficacy shall be min 120 Lm/W. The luminaire efficacy shall be not less
than 70 Lm/W. Suitable heat sink shall be designed & shall be provided in
the luminaire. The LED used in the luminaires shall have colour rendering
index (CRI) of Min 65. Colour designation of LED shall be “cool day light”
(min 5700K) type. The LED luminaire shall have minimum life of 25,000
burning hours with 80% of lumen maintenance at the end of the life. The
beam angle for LED chip shall be 120 degrees. The max. junction
temperature of LED shall be 85 deg C, further the lumen maintenance at
this temperature shall be min 90%. The THD of LED Luminaires shall be

& ITS AUXILIARIES
less than 10%. Further the EMC shall be as per relevant standards. The
power factor of the luminaire shall not be less than 0.9. The marking on
luminaire & safety requirements of luminaire shall be as per IS standards.
Suitable heat sink with proper thermal management shall be designed &
provided in the luminaire. The connecting wires used inside the system,
shall be low smoke halogen free, fire retardant PTFE cable and fuse
protection shall be provided in input side specifically for LED luminaires.
Care shall be taken in the design that there is no water stagnation anywhere.
The entire housing shall be dust and water proof protection as per IS 12063.
Driver Circuit: LED modules and drivers shall be compatible to each other.
The LED module driver’s ratings and makes shall be as recommended by
corresponding LED manufacturer.
LED Drivers may have following control & protections :-

• Suitable precision current control of LED.
• Open Circuit Protection
• Short Circuit Protection
• Over Temperature Protection
• Overload Protection
8. Apart from maintenance factor as given below, Temperature correction

factor shall be considered in the lighting design for flourescent fixtures
located in non air conditioned area.
(a.) Office area air-conditioned : 0.8

(b.) Office area non airconditioned and other indoor area : 0.7
(c.) Dust prone indoor and outdoor area : 0.6
(d.) Mill/LS Handling Plant, : 0.5
Conveyor /Transfer Points etc.
9. All lighting fixtures and control gears shall be powder coated. All outdoor
fixtures shall be weather proof and of IP55 degree of protection.
10. Lighting panels shall be powder coated with color shade RAL9002.
Lighting panels shall have IP55 degree of protection.
11. Wires of different phase shall normally run in separate conduit.
12. Power supply shall be fed from 415 / 240 V normal AC supply, emergency
AC supply (wherever available) and 220V DC supply through suitable
number of conveniently located lighting distribution boards (LDB) and
lighting panels (LP). AC lighting supply shall be isolated from main supply
by isolation transformers of max. rating of 100KVA and fault level
restricted to 3 KA at Lighting Panels.

& ITS AUXILIARIES
13. At least one 6/16A, 240V AC universal socket outlet with switch shall be
provided in offices, cabins, etc. Further 20A, 240V AC industrial receptacle
with switch shall be provided strategically in all industrial areas (For
conveyor gallery at 30m interval on both sides and for yard conveyor at
50m interval on one side). Suitable number of 63A, 3ph, 415V AC
industrial receptacles shall be provided for entire plant for welding
purposes, particularly near all major equipment and at an average distance
of 50m. Atleast one 63A, 3ph, 415V AC receptacle shall be provided in
each floor of off-site buildings/ structures, at 50m interval (starting from
one end) on both sides of the conveyor galleries and at 50m interval on one
side of the yard conveyor. In LS handling plant, One no 10A, 24V AC
receptacle with IP55 DOP shall be provided in each switchgear/ MCC
room, Pump house, TPs, crusher house. 24 V single phase industrial type
switch & socket(3 pin) of rating 20A shall be provided at specific areas of
FGD plant, LS handling Plant transfer points and conveyor gallery, all other
areas by 1-4 way & suitable loop-in loop-out of 2 core -16 sq.mm
Aluminium cable shall be used and maximum distance between two
adjacent points shall be 50 Mtrs.
The welding receptacle shall be wall mounted type. It shall be interlocked

such that
a) Switch can be put ON only when the plug is fully engaged
b) Plug can be taken out only when the switch is in OFF position.
c) Cover can be opened only when the switch is in OFF position.
14. In the hazardous areas like gas/ liquid fuel storage/ handling areas lighting
shall be flame proof.
15. All fluorescent fixtures, shall have energy efficient 'T5' type fluorescent
lamps except the fluorescent fixtures used for division 2 hazardous area.
The louvers of these fixtures shall be designed for 'T5' type fluorescent
lamps. All fluorescent lamps shall be have "Cool day light" colour
designation. The mirror optics type fluorescent fixtures shall have no
iridescence effect. Fixtures with better efficiency and upgraded proven
system may also be considered
For the DC Lighting. Tube light fittings with electronic choke suitable for
220V DC operation shall be considered.
04.01.01 In general, Illumination for all other areas/buildings within the boundary
limit of FGD Plant and accessories, even if not specifically mentioned here,
shall be provided.


& ITS AUXILIARIES
04.02.00 All luminaires and their accessories and components shall be of type readily
replaceable by available Indian makes.
04.03.00 Fans & Regulator
04.03.01 Ceiling Fans, to be provided in all the office area (irrespective of Air
conditioning) and non-air conditioned control room area, shall be suitable
for operation on 240 V +/-10%, 50 Hz, AC supply comprising of class ‘E’
or better insulated copper wound single phase motor, 1200mm sweep,
aerodynamically designed well balanced AL blades (3 Nos.), down rod, die
cast aluminium housing, capacitor, suspension hook, canopies etc. finished
in stove enameled white or with electro static powder coating. Power factor
of fans shall not be less than 0.9. Fan regulators shall be stepped electronic
type suitable for operation on 240V +/-10% AC supply.
04.04.00 Junction Boxes, Conduits, Fitting & Accessories , Pull Out Boxes
Junction box for indoor lighting shall be made of fire retardant material.
Material of JB shall be Thermoplastic or thermosetting or FRP type.
Junction boxes for street lighting poles and lighting mast shall be Fiber
glass reinforced polymer junction boxes. The degree of protection shall be
IP55. All switches and receptacles upto 16A shall be modular type. These
shall be provided with pre-galvanized/galvanized modular switchbox &
plate. Conduits, Pipes and Accessories Galvanised heavy duty steel
conduits for normal area and galvanised heavy duty steel conduits with an
additional epoxy coating for corrosive area shall be offered. Alternatively
glass reinforced epoxy conduits with comparable compressive and impact
strength with that of heavy duty steel conduits may be offered. Rigid steel
conduits shall be heavy duty type, hot dip galvanised conforming to IS :
9537 Part-I & II shall be suitable for heavy mechanical stresses, threaded
on both sides and threaded length shall be protected by zinc rich paint.
Conduits shall be smooth from inside and outside. Flexible conduit shall be
water proof and rust proof made of heat resistant lead coated steel. Pull out
boxes shall be provided at suitable interval in a conduit run .Boxes shall be
suitable for mounting on Walls, Columns, Structures, etc.. Pull-out boxes
shall have cover with screw and shall be provided with good quality gasket
lining. Pull out boxes used outdoor shall be weather proof type suitable for
IP :55 degree of protection and those used indoor shall be suitable for IP :52
degree of protection. Pull out box & its cover shall be hot dip galvanised.
04.05.00 Lighting Wires
04.05.01 Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed,
stranded copper/aluminium wire for fixed wiring installation. colour of the

& ITS AUXILIARIES
PVC insulation of wires shall be Red, Yellow, Blue and Black for R,Y,B
phases & neutral, respectively and white & grey for DC positive & DC
negative circuits, respectively. Minimum size of wire shall not be less than
1.5.sq.mm. for copper and 4 sq.mm. for aluminium.
04.06.00 Lighting Poles
04.06.01 The Street Light system and peripheral lighting shall be designed generally
in line with design guidelines. The Poles shall be mounted above ground
using base plate and minimum height of pole shall be 8 mtrs The poles shall
be hot-dip galvanized as per relevant IS2629/ IS2633/ IS4759. The average
coating thickness of galvanizing shall be min. 70 micron. The System shall
be capable of withstanding the appropriate wind load etc as per IS 875
considering prevailing soil/ site condition considering all accessories
mounting on pole. The street light poles shall have loop in loop out
arrangement for cable entry and light fixture / wiring protected with
suitably rated MCB.
04.07.0 Lighting Masts
04.07.01 Lighting Mast shall be of continuously tapered polygonal cross section hot
dip galvanised. The Mast shall be of 20 M or suitable height with lantern
carriage to enable raising/lowering for ease of maintenance, including the
Head Frame, Double Drum Winch, continuous stainless steel wire rope, in
built power tool, luminaires, suitable aviation warning light, lightning
alongwith necessary power cables within the mast. The mast shall be
delivered in not more than three sections & shall be joined together by slip
stressed fit method at site. No site welding or bolted joints shall be done on
the mast The Mast together with the fixtures shall be capable of
withstanding the appropriate wind loads as per IS:875. The Mast shall be
fabricated from special steel plates conforming to BS-EN10-025 and folded
to form a polygonal section. Suitable feeder pillar with TPN MCB,
contactors, timer, MCB and other necessary accessories for operation &
protection of the mast and fixtures shall be provided. Each mast shall be
provided with 8 Nos 400W metal Halide lamps with suitable control gears.
Minimum 4 Nos Lighting masts shall be considered.
04.08.00 Lighting fixtures shall generally be group controlled directly from lighting
panel. However, in office areas, control shall be provided through switch
boxes. Each switch shall control a maximum of three fluorescent fixtures.
04.09.00 A.C. normal, AC emergency and DC system wiring shall run throughout in
separate conduits. Wires of different phase shall run in different conduits


& ITS AUXILIARIES
04.10.00 Lighting panels, etc. shall be earthed by two separate and distinct
connections with earthing system. Switch boxes, junction boxes, lighting
fixtures, fans, single phase receptacles etc. shall be earthed by means of
separate earth continuity conductor. The earth continuity conductor 14
SWG GI wire shall be run alongwith each conduit run. Cable armours shall
be connected to earthing system at both the ends.
04.11.00 Alternately Vendor may offer technically superior and proven product
subject to approval of owner.
05.00.00 Tests
05.01.00 All equipment to be supplied shall be of type tested design. During detail
engineering, the bidder shall submit for Owner's approval the reports of all
the type tests as listed in this specification. 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.
05.02.00 However if the bidder is not able to submit report of the type test(s) or in
the case of type test report(s) are not found to be meeting the specification
requirements, the bidder 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.
05.03.00 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.
05.04.00 Selection of samples for type test, acceptance test & routine test and
acceptance criteria for all the items shall be as per relevant I.S
05.05.00 Type test reports of the following items as per relevant standards shall be
submitted for approval.
i. Lighting fixtures of each type

ii. Lamps of each type and rating.(life cycle and rating test only)
iii. Lighting panel of each type (Degree of Protection)
iv. Junction Box of each type
05.06.00 Acceptance Test and Routine Test
05.06.01 All lighting fixtures, lamps and other items shall be subjected to acceptance
and routine test, as per relevant specified standards.

& ITS AUXILIARIES
05.06.02 Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to
physical and dimensional checks.
05.07.00 Galvanizing Tests

05.07.01 The quality of galvanizing shall be smooth, continuous, free from flux
stains and shall be inspected visually.
05.07.02 In addition following tests shall be conducted as acceptance tests.
(a) Uniformity of coating - The coating of any article shall withstand four
1minute dips in standard copper sulphate solution without the formation of
an adherent red spot of metallic copper upon the basic metal.
(b) The quality of cadmium/zinc plating on items with screw threads shall be
free from visible defects such as unplated areas, blisters and modules and
shall be inspected visually.
(c) In addition, the plating thickness shall be determined microscopically/
chemically or electronically.
06.00.00 Commissioning Checks
1. On completion of installation work, the Bidder shall request the Project

manager for inspection and test with minimum of fourteen (14) days
advance notice.
2. The Project manager shall arrange for joint inspection of the installation for
completeness and correctness of the work. Any defect pointed out during
such inspection shall be promptly rectified by the Bidder.
3. The installation shall be then tested and commissioned in presence of the
Project manager.
4. The bidder shall provide all, men material and equipment required to carry
out the tests.
5. All rectifications, repair or adjustment work found necessary during
inspection, testing and commissioning shall be carried out by the Bidder
without any extra cost. The handing over the lighting installation shall be
effected only after the receipt of written instruction from the Owner/his
authorized representative.
6. The testing shall be done in accordance with the applicable Indian
Standards and codes of practices. The following tests shall be specifically
carried out for all lighting installation.
(a) Insulation Resistance.
(b) Testing of earth continuity path.
(c) Polarity test of single phase switches.
(d) Functional checks.


& ITS AUXILIARIES
7. The lighting circuits shall be tested in the following manner :

(a) All switches ON and consuming devices in circuit, both poles connected
together to obtain resistance to earth.
(b) Insulation resistance between poles with lamps and other consuming
devices removed and switches ON.

7.01.00 Drawings, data and manuals will be submitted in triplicate and in quantities
and procedures as specified in the General Condition of Contract and/or
elsewhere in this specification for approval and subsequent distribution after
the issue of Letter of Intent.
7.02.00 Contractor will submit the following for approval
7.02.01 Make, type and catalogue number of lighting fixtures, lamps and
accessories along with technical leaflets, data sheets, polar curves etc.
7.02.02 Typical outline drawings, showing constructional features, cable/ conduit
entry, fixing arrangements etc of :
a) Lighting Distribution Board & Panel/receptacles/junction boxes.
b) Street light pole.
c) Flood light towers.
7.02.03 Technical leaflets and data sheet on each piece of equipment / device such as
MCB, switch fuse, receptacle etc.
7.02.04 Type test certificates on lighting fixtures and lighting panels,
transformer, ballast, power cables.
7.03.01 Detail dimensional drawing showing constructional features, cable/ conduit
entry, grounding, fixing arrangement etc. of :
a) Lighting panels & distribution boards.
b) Receptacles & Junction boxes.
c) Street light poles & towers.
d) Lighting fixture complete with lamps and accessories.
e) Non-integral/separate type control gear box for lighting fixtures, as
applicable.
f) Lux level calculations for each area.
7.03.02 Data sheets for lighting fixture, lamps, accessories with light distribution
curves, co-efficient of utilization charts etc. Type and routine test
certificates of transformer and cables.

& ITS AUXILIARIES
7.03.03 Control schematic and wiring diagram of 415V AC/220V DC lighting panel
with automatic changeover from AC to DC and vice-versa,415V
normal AC street/area lighting panel with automatic ON/OFF feature.
7.03.04 Technical leaflets and data sheet on each piece of equipment/ device such as
MCB, switch, fuse, receptacle etc. Type and routine test certificates of
transformer and cables.
7.03.05 QAP and relevant test certificates
7.03.06 Lighting layouts showing the disposition of fixtures, lighting panels/boards,
circuit distributions, conduit & wire routing.
7.03.07 Key Single Line Diagram for lighting distribution, board wise single line
diagram with feeder loading, cable schedule and interconnection chart,
design calculation for lighting.
7.03.08 AS-BUILT lighting layout and erection drawings, properly incorporating the
changes/alterations/field modifications, if any, as carried out at field along
with circuit distribution schemes of all lighting panels, conduit and cable
routing and as acceptable to the Owner.
7.03.09 Any other relevant drawings, data and manuals necessary for satisfactory
installation, operation and maintenance.
7.03.10 The contractor may note that the drawings, data and manuals listed are
minimum requirement only. The contractor will ensure that all other
necessary write-ups, curves and information required to fully describe the
equipment are submitted.


& ITS AUXILIARIES
ANNEXURE-A
Sl. No Location Average Type of Fixture

Illumination
Level(Lux)
1 FGD Area operating floor 200 LED luminaire equivalent to
HPSV high/medium bay
2 FGD Area Other Platforms 200 LED luminaire equivalent to
HPSV high/medium bay,
HPSV well glass fixtures
3 Switchgear rooms, Charger, 200 LED luminaire equivalent to
Rectifier room Industrial trough type
fluorescent fixture
4 Control room, computer 350 LED luminaire equivalent to
room, control equipment Mirror optics with anti-glare
room features type fluorescent
or CFL down lighter
5 Offices, conference rooms, 300 Decorative mirror optics

etc. Type LED Luminaire
6 Battery rooms 100 Totally enclosed corrosion
Proof LED Fixtures
7 Compressor room, pump 150 LED Fixtures
house etc.
8 Cable galleries/vault 50 LED Fixtures
9 Street lighting- street lights 20 LED luminaire equivalent to
primary roads, secondary HPSV Street Lights
roads
10 Outdoor storage handling 20 LED Fixtures
and unloading area
11 Chemical stores/House 150 Corrosion proof LED
Fixtures
12 Laboratory LED Fixtures
Analysis area 300
13 Garage/Car Parking 50 LED Fixtures
14 DC Lighting- Control room - LED Fixtures
15 Transfer Points, Crusher 100 LED Fixtures
House, Sheds, Bunker
House etc.
16 DC Lighting- Other Area - LED Fixtures
17 Corridors, Walkways 50 LED Fixtures
18 Building Periphery Lighting - LED Fixtures
ANNEXURE-B


& ITS AUXILIARIES
Sl. Plant Areas Normal AC Emergency 220 V DC Portable

No. Lighting AC Lighting Lighting DC
System System System Fixtures
1. FGD Building, 80% 20%
switchgear room √
etc)
2. Platform 80% 20% √
3. Compressor Room 100% √
4. Unit Control Room 70% 30% √
5. Battery Room 80% 20%
6. Cable Spreader 80% 20%
√
Room/ Vault
7. Chemical House 100% √
8. Area Lighting 100%
9. Street Lighting 100%
10. Storage Yard 100%
11. LS Handling Plant 100% √
DC Emergency Lighting:
Sl. Area
Average Lux Level
No.
1. Unit Control Room 100
2. Control Equipment Room 100
3. Electrical Panel/Switchgear Control Room 100
4. Strategic Control Points ( In FGD Building 20
& Area, Battery Room, UPS Area, etc
5. Cable Vault & Galleries 1 fixture at every 20 metres
spacing along walkways
6. Stair Case 1 fixture at every 20 metres
spacing along walkways
7. Exit/ Entry of Main Plant Building 1 fixture
8. Fire Exit Sign 1 fixture
9. LS Handling Plant Control room - 50
Switchgear room - 50
Strategic control points - 20
Others areas - 20
KK. OTHER MISCLLANEOUS REQUIREMENT


& ITS AUXILIARIES
1.00 Plant Telephone Cables & Accessories
1.01 Scope of Work
The scope of work includes complete design, engineering, supply, storage at

site, erection, installation, laying of cables, testing, and commissioning of
FGD Plant Telephone Cables & Accessories as per the system described in
this specification & handing over of the system in ready to switch on condition
to purchaser on TURN KEY basis.
1.02 The scope shall broadly cover the following and shall include such of those
items and accessories not mentioned here but required for satisfactory
operation of the system.
1.03 The integrated cable network for FGD plant shall be designed by the package
vendor keeping 100% spare cable pairs and will terminate all cables in the
Distribution box (D.B) inside the FGD plant building. From this D.B the
package vendor shall bring the cable to Small Auto Telephone Exchange
(SAX) and terminate the cable at the subscriber side of Main Distribution
Frame (MDF) of the SAX including jumpering of cables & commissioning of
the plant telephone system. The telephone handsets shall be provided by the
bidder.
1.04 The Bidder shall indicate the size/space for a separate room for above system.
The room shall be suitably airconditioned & illuminated.
1.05 Telephone connections shall be provided at each room of the office building,
shift offices, Control rooms cum switch gear rooms, ECRs, MCC’s, cable
basement, laboratory etc.
1.06 The number of telephones to be considered at FGD plant is 30 (thirty) lines
2.00 Intelligent Fire Detection and Alarm System
2.01 Scope of Work
The scope of work includes complete design, engineering, supply, storage at

site, erection, installation, testing, and commissioning of microprocessor based
analogue addressable type fire detection and alarm system (FDAS) as per the
system described in this specification & handing over of the system in ready to
switch on condition to purchaser on TURN KEY basis.
2.02 FDA system will be designed based on the following broad parameters:


& ITS AUXILIARIES
i) All electrical premises, cable galleries/ tunnels, control rooms, offices etc.
will be provided with fire detection & alarm (FDA) system. The system
will have a network of detectors with a central control panel and
communication panels.
ii) Detection system will be microprocessor based intelligent one. All

detectors / manual call points will be self addressed intelligent type. Complete
system will be designed as per NFPA 72-E and IS: 2189.
2.03 The scope shall broadly cover the following and also shall include such of
those items and accessories not mentioned here but required for satisfactory
operation of the system.
Automatic fire detection and alarm system comprising of smoke detectors,

heat detectors and other types of detectors as chosen per the design criteria.
Break glass type manual call points with chain & hammer (with or without
hand set) / Pull down type manual call point.
Central control panel. Minimum 2 loop panels shall be provided.
Power supply equipment & battery back-up.
Power supply from UPS system for Local Graphics computer and printer.
Provision for interlocking with automatic fire fighting system in the panel.
Fire Alarm System shall be supplied along with HMI & required software
loaded.
The fire alarm panel shall have auto dialer facility to inform to central fire
station of Aloke Steel through plant telephone network. However the FDA
panel shall have Ethernet connectivity port with TCP/IP protocol to connect
plant LAN in future. The supplier of this package shall keep necessary
software & hardware in his scope of supply.
Provision for tripping of ventilation system (in cable tunnel, cable basement,
switch gear room etc. as defined in ACVS chapter) in the panel.
Siren and Accessories.
All types of cables keeping 20% spare cable core in the cable and cabling
accessories.


& ITS AUXILIARIES
Erection materials
Earthing Materials & Earthing.
Supply of commissioning & erection spares.
Minor civil works required for installing FAS equipment.
GI pipes /GI conduits /PVC rigid conduits and other accessories wherever
required for laying of cables.
Trench work, if required, for cabling.
Furniture, Racks etc
All erection accessories, consumables and miscellaneous material not

indicated in specification but required for completing the job in all respects.
Preparation of Design and detailed engineering drawings and specification.
Training of Purchaser’s personnel shall be provided by the bidder at their

works for operation & maintenance of the equipment / system offered. The
details shall be finalized during DE stage.
NOTE: Bill of quantities to be prepared by The Bidder and shall be submitted

for purchaser’s approval.
3.00 Local Control Station
Near all drives local control stations shall be provided. Local stations shall
have sheet steel construction, dust and vermin proof, and wall/structure
mounting. Push buttons shall be mounted on front hinged gasketted and
lockable door. For HT motors, start, stop, and emergency stop push button and
for LT motors, open/close/trip or start/stop, as applicable, shall be provided
along with Local/Remote Selector switch, ON/OFF indication lamps, ammeter
for motor rated 30 kW and above..
Suitable knockouts with glands shall be provided on the bottom or top cover
for cable entry. Terminals shall be suitable for 2 cores of 2.5 sq.mm
conductors with 20% spare terminals. Stop push button to be lockable type
with mushroom head and key to release. Enclosure conforming to IP-54 class
for indoor and IP55 with canopy for outdoor. Explosion proof/increased safety
type shall be provided in hazardous areas.


& ITS AUXILIARIES
All LPB stations shall be made of Cast Aluminium with minimum thickness of
2.5 mm. Press to stop and press to release (red colour) shall be provided for all
the motors. All LPBS for HT Motors shall be provided with Ammeters.
LL. LIST OF PREFERRED MAKE FOR MAJOR ITEM/EQUIPMENT
Item Description Make

HT Switchgear ABB/ SIEMENS / BHEL / AREVA/ SCHNEIDER
Protective relays AREVA / ABB / SIEMENS
Auxiliary relays ABB / ER / SIEMENS / AREVA/ BCH
Distribution Transformers (AN INTRA VIDYUT / VOLTAMP / BHEL/IMP/
Type) RPG/ ESENNAR
6.6 KV Isolator A BOND STRAND / SIEMENS / DREISCHER
PANICKER
Busduct STARDRIVE / SIEMENS / L&T / ALSTOM /
BEST & CROMPTON/ GEPOWER/ECC
HT Motors BHEL / CGL / KEC / ABB / SIEMENS
/ ALSTOM
LT motor BHEL / CGL / KEC / ABB / ALSTOM / BBL /
SIEMENS
DC motor CGL / KEC / IEC
Local control station (LCS) ECC/ BCH/ GEMCO/ ALSTOM/ L&T/
MEDITRON / SIEMENS/ SWITCHING
CIRCUITS/ TECHNOCRAT ENGINEERS
PMCC/MCC SIEMENS / L&T / GE POWER / ABB
LT Air Circuit Breaker L&T / ABB / SIEMENS / GE POWER
Current transformers ABB / SILKANS / PRAGATI / AE / KAPPA /
SIEMENS / L&T / JYOTI / AEP
Potential transformer ABB / BHEL / SILKANS / PRAGATI / KAPPA /
SIEMENS / ABB
Moulded case circuit breaker SIEMENS/ ABB/ L&T/ GEPOWER/ ALSTOM/
(MCCB) MERLIN GERIN
Motor protection circuit L&T/ GEPOWER/ SIEMENS/ MDS/
breaker (MPCB) SCHNEIDER
Miniature circuit breaker HAVELLS / MDS LEGRAND / HAGAR (L&T) /
ABB / SIEMENS
Control desks/panels, control devices and field devices:
Push buttons BCH/ L&T/ SCHNEIDER/ SIEMENS/ GE

POWER
Control transformers INDCOIL/AE/GYRO/BCH


& ITS AUXILIARIES
Indicating/monitoring/annunciating devices:
Indicating lamp ( led type) BINAY/ ESSEN/ VAISHNO

Solid state annunciator ADVANI OERLIKON / AREVA / APLAB /
CONTROL & DYNAMICS / DIGICON
INSTRUMENTATION LTD / L&T / MINILEC
Meters IMP / AE / MECO / SECURE METERS /
CONZERV / L&T / RISHAV
Digital type multifunction CONSERVE / L&T / SECURE / ER / RISHAV
meter
Watt-hour meter BHEL/SIMCO/ABB
Cables and cabling accessories:
H T Power cables ASIAN CABLES (RPG) / CCI/ / NICCO/ / FORT

GLOSTER/ INCAB
LT Power & Control Cables CCI/ UNIVERSAL/ NICCO/ RPG CABLES
(ASIAN)/ POLYCAB (XLPE)
HT Cable termination kits/ RAYCHEM
straight through joint (XLPE)
Terminal block ESSEN/CONNECT WELL/ ELMEX/ PHOENIX
UPS, BATTERY & BATTERY CHARGER :
UPS Hi-Rel / TATA LIBERT (EMERSON) / FUJI/ DB

ELECTRONICS/LIFELINE
Transducer ABB / MECO / RISHAB
Battery CHLORIDE/ Exide/AMARA RAJA
Battery charger / DCDB HBL NIFE/ CALDYNE/ ELNOVA
ILLUMINATION :
Lamps BAJAJ/ CROMPTON GREAVES/ GE
LIGHTING/ PHILIPS
Light fitting (fixtures) BAJAJ/ CROMPTON GREAVES/ GE
complete with all accessories LIGHTING/ PHILIPS
except lamp
Lighting wire (pvc) CCI/ DELTON/ FINOLEX/ NICCO/ UNIVERSAL
5A/15Aa piano switch ANCHOR/ ELLORA/ MDS LEGRAND/
PRECISION
Flame proof light fitting BALIGA
Exhaust fans CGL/ KHAITAN/ BAJAJ
Ceilling fans CGL/ KHAITAN
FIRE DETECTION & ALARM (F.D.A) SYSTEM
DEVICES MAKES

& ITS AUXILIARIES
Complete System including SIMPLEX / NOTIFIER / EDWARDS

Intelligent Detectors (Photo
Electric, Heat, Thermal, Multi
Detector)
Ul/Fm Approved
F.D.A. SYSTEM SUPPLIERS 1. ELECTRONICS CORPORATION OF INDIA
LTD.
2. M/S. TECHNICO INDIA
3. SIEMENS
ELECTRONIC PRIVATE 1. M/S. INDIAN TELEPHONE
AUTOMATIC INDUSTRIES LIMITED.
BRANCH TELEPHONE 2. M/S.AVAYA GLOBAL CONNECT LTD.
EXCHANGE 3. M/S. SIEMENS LIMITED
(EPABX SUPPLIERS) 4. M/S. ALCATEL
5. M/S. B.P.L. TELECOM PVT. LTD.
6. M/S. CROMPTON GREAVES LTD.
LOUD SPEAKER TALK 1. PHI-AUDIOCOM
BACK (LSTB) / LOUD 2. M/S. BYTE COMMUNICATION
SPEAKER
INTERCOMMUNICATION
(LSIS) SYSTEMS
SUPPLIERS
TELEPHONE CABLE 1. DELTON CABLES
SUPPLIERS 2. TELE-LINK NICCO
3. FINOLEX
NOTE : For items not indicated above, bidder shall have to obtain prior approval from the
purchaser / consultant.


(4X210MW)
FOR
VOLUME – V
CIVIL, ARCHITECTURAL & STRUCTURAL WORKS
MECON LIMITED
RANCHI – 834 002

METTUR THERMAL POWER STATION – I (4X210MW)

& ITS AUXILIARIES
INDEX TO VOLUMES
Volumes Title
Section 01.00 Flue Gas Desulphurisation System
Vol. – V INDEX TO VOLUME Page 2 of 3

METTUR THERMAL POWER STATION – I (4X210MW)

& ITS AUXILIARIES
Volumes Title
Vol. – V INDEX TO VOLUME Page 3 of 3

VOLUME VA
CIVIL WORKS


& ITS AUXILIARIES
01.00 CIVIL WORKS
01.01 Introduction
This section covers entire civil engineering work including design, supply and
construction for all buildings, structures and facilities for all production, auxiliary units,
foundations for all buildings, structures and equipments, pavings, roads, water supply
and sanitary system for FGD system and all other miscellaneous civil engineering work
that will be necessary for completing this package on a turnkey basis for Flue Gas
Desulfurization (hereafter, FGD) and Auxiliary system to be used in the 4x210 MW
MTPS-I Project, at Mettur, Tamil Nadu in line with scope of works specified elsewhere
of this specification, All civil, works including design as per FGD & Auxiliary system
requirements are in Bidder’s scope. Description of various civil items of work under
this specification and nature of work in detail are given hereinafter.
a) It is not the intent to specify herein all the works in the scope of the contract. The scope
also includes all other buildings, structures and works necessary, which are not
specifically mentioned here but required for construction, operation and maintenance of
all structures covered under the EPC package, are deemed to be included in the scope of
the Bidder. All works shall conform to the relevant specifications. The works shall
conform to high standards of design, engineering and workmanship. Design and
construction shall conform in every respect to all local and state regulations governing
such works and to stipulations of Indian Standards unless stipulated otherwise in detail
specification. The Bidder's detailed design and scope of supply shall include all
components and systems, whether included in the system descriptions or not, required
to provide a complete and fully functional facility. This shall include all type of Civil,
Structural & Architectural work required for successful completion of scope of work of
the bid document.
b) The work to be performed under this specification consists of design, engineering as

well as providing all labour, materials, consumables, equipment, temporary works,
temporary labour and staff colony, construction of plant, fuel supply, transportation and
all incidental items not shown or specified but reasonably implied or necessary for the
completion of this package, all in strict accordance with the specifications, including
revisions and amendments thereto as may be required during the execution of the work.
c) All materials including cement, reinforcement steel, foundation bolts, inserts, structural
steel etc. and all other construction materials required for successful execution of civil
works shall be supplied by the Bidder at his own cost.
d) The scope shall also include setting up by the Bidder a complete testing laboratory in
the field to carry out all relevant tests required for the civil works for the project.
Vol. – VA CIVIL WORKS Page 1 of 54


& ITS AUXILIARIES
e) The work shall be carried out according to the design/drawings to be developed by the
Bidder and approved by the Owner/ Consultant. For all buildings and structures,
foundations, etc., necessary layout and details are to be developed by the Bidder
keeping in view the statutory & functional requirements of the FGD plant and facilities
and providing enough space and access for operation, use and maintenance. Certain
minimum requirements are indicated in this specification for guidance purpose only.
However, the Bidder’s offer shall cover the complete requirements as per the best
prevailing practices and to the complete satisfaction of the Owner.
f) Bidder shall inspect the site, examine and obtain all information required and satisfy
himself regarding matters and things such as access to site, communications, transport,
right of way, the type and number of equipment and facilities required for the work,
availability of local labour, materials and their rates, local working conditions, weather,
flood levels, subsoil conditions, natural drainage, etc. Ignorance of the site conditions
shall not be accepted by the Owner as basis for any claim for compensation or
extension of time. The submission of a bid by the Bidder will be construed as evidence
that such an examination was made and any later claims / disputes in regard to price
quoted shall not be entertained or considered by the Owner on account of ignorance of
prevailing site conditions.
g) The Bidder's detailed design and scope of supply shall include all components and
systems, whether included in the system descriptions or not, required to provide a
complete and fully functional facility.
h) Some of the existing structures or facilities of power plant may be utilised during
construction of FGD system works, based on prior permission obtained from Owner’s
Engineer in charge at site. The Bidder to note that they shall have to dismantle and
remove the staging and other temporary facilities on completion of work, clear and
clean the site and make good any damages caused to the structure and restore to original
condition at his own cost.
i) The works covered in this section consists of collection of all site related data,
conducting site investigations, design, preparation of all construction drawings, supply
of all labour, supervision, all materials, slip form equipments, scaffolding, fuel, water,
construction equipment, tools and plant supplies, transportation, storage, construction,
fabrication, erection and testing where necessary, of all structures required for housing
all equipment and civil works for all services required for the package as defined in the
specification document. The Civil works shall include those required for Installation,
Commissioning, testing, operation and maintenance of structure/ system required for
the package.
j) The Site System shall provide roadways inside the plant boundary, micro grading
levelling and storm water runoff drainage up to the boundary wall terminal point.


& ITS AUXILIARIES
01.02 SCOPE OF WORK:
All Civil Works including design , related to all facilities required for the completeness
of this Package, shall be within the scope of this package.
The civil works for the buildings, structures, equipment foundations, facilities and
miscellaneous civil works to be provided for the project shall include but not limited to
the following:
a) Cable trenches, cable racks, duct banks, manhole and pipe trenches, Cable sleeper etc.
b) Supporting structures and platforms with access for utility pipelines, ventilation ducts,
Bus ducts and other equipments.
c) All roads, culverts, drainage & connecting the same to the existing nearest/ suitable
plant roads/ facilities. The roads shall be of similar type as of the main connecting roads
i.e. either R.C.C or Bituminous depending on the main connecting roads.
d) All water supply, plumbing and sanitary works including all fixtures for sewage
disposal for buildings / units / shed covered within the battery limit.
e) Collection & disposal of industrial effluents collected from buildings / units / shed
covered within the battery limit.
f) All necessary waterproofing, damp proofing and anticorrosive treatment with epoxy
coating to all reinforced bars, structures and foundations, including underground
construction.
g) All necessary civil works for crossing pipes/cables below for roadways and other
services within the battery limit and reconstructing of existing damaged utilities/
structures/roads etc.
h) Construction of all temporary facilities, building, offices, labour colonies, staff quarters,
roads and services required for this package.
i) Removal of debris, micro levelling of the site, included in the scope of contract prior to
completion of work.
j) Dismantling of buried/semi-buried structures, if any, encountered within the plant limits

and disposal of it from the site as directed by the Owner. Any facility / structure/
utilities dismantled shall be re-constructed by Bidder on his own Cost.
k) Blasting shall not be permitted for excavation of foundation any other purpose near the
chimney and other main structures.


& ITS AUXILIARIES
l) Site clearing, dressing, levelling and grading of formation to required levels and soil
compaction as necessary within the battery limits as shown in the bid drawing or as
directed by Owner.
m) Earthwork for buildings and equipment foundations, tanks, trenches, pits, sewers and
other underground / above ground construction work. Dewatering of the underground
works.
n) Back filling, soling and sub-grade work for all foundation, grouting, flooring, trenches,
pits for all structures/equipment included in the scope.
o) Encasing structural steel column bases as well as structural steel wall beams in RCC at
various locations as required.
p) Reinforced concrete work and PCC work in foundations, sumps, pits, trenches, tanks,
silos, all equipment, bucket elevators and other underground structures.
q) Reinforced concrete work and PCC work in foundations, columns, tie beams, beams,
staircases, slabs frames and other superstructures.
s) All masonry work in sub structure and super structure including plastering as required.
t) All finishing work to flooring, walls, ceiling, false flooring and false ceiling as required.
u) All finishing and painting work to masonry, concrete structures, steel works and wood
works.
v) All fencing and gates as required.
w) Doors, windows, ventilators, rolling shutters, fire check doors, gates shutters etc.
x) All necessary Buildings / Units and equipment supporting structures and their
foundation system.
y) All Handrails, inserts, kerb angles, bolts, cage ladders, platforms and other
miscellaneous steel works.
01.03 Engineering related Special Requirements
a) Approval of the Bidder’s design drawings / documents means that these are checked for
conformity with applicable specifications and general conformity with the engineering
requirements covered in the specifications. Approval of the Bidder’s design drawings
and documents shall not relieve the Bidder in any way whatsoever of any of his
responsibilities under the Contract and the Bidder shall remain wholly responsible for
any error in his design drawings, unapproved disagreements with contract technical
specification.

& ITS AUXILIARIES
b) The Bidder shall not make any change in the approved design drawings without the
prior written approval of the Owner/Consultant. Owner is not liable for approval of
document having additional changes on the design/ drawings already approved.
Manufacturing / procurement / fabrication prior to approval of design drawings shall be
solely at the Bidder’s risk.
c) In case of any deviations from the approved design drawings being called for at site due
to any reason, Bidder shall take approval on such change from Owner/ Consultant
before carrying it into effect at site. However, Owner is not liable for re-approval of
design/ drawings already approved.
d) In general no foundation shall rest over back filled soil. However, small foundation may
rest over the back filled soil after asserting the designed bearing capacity.
e) All facilities to be functionally & operationally connected, wherever process requires,

to the facilities of other package areas / MTPS-I at interface points.
f) All design calculations and drawings shall be in English and shall be in SI units.
g) Designs, drawings and other documents submitted by the Contractor shall be

thoroughly checked and approved by the authorized Contractor’s engineer. Any
unchecked / unsigned documents will not be reviewed by the Owner/Consultant. Also
design calculations not accompanied by supporting engineering drawings, incomplete
or shabbily done design calculations, design calculations without adequate reference or
backup data and documents where previous comments have not been incorporated will
not be reviewed by the Owner/Consultant. No claim from the Contractor for extension
of time or extra cost on this account shall be entertained by the Owner/Consultant under
any circumstances.
h) No check will be specifically carried out by the Owner/Consultant to verify arithmetical

/ numerical accuracy of the calculations, input data, compatibility of dimensions among
various drawings or between drawings and design calculations. Fouling of foundations
with any existing foundation shall be checked by the contractor before submission of
the drawings.
i) The Contractor shall submit copies of designs / drawings prepared by him, as

mentioned elsewhere in the bid document.
01.04 General work requirement
The Bidder shall make the layout and levels of all structures from the general grid of
the plot and the nearest GSI benchmark or other acceptable benchmark as per the
directions of the Owner.
All levels have to be established with respect to the permanent bench and reference
bench mark shall be indicated by the Owner.

& ITS AUXILIARIES
The bidder shall be solely responsible for the correctness of the civil works.
01.05 General Concepts for Buildings
Design and construction of buildings, structures etc. shall take into account requirement
for operation and maintenance of all equipment and its users. The buildings will have
good architectural features. The surrounding areas shall be properly micro levelled and
graded. The architectural design concept of buildings structure shall be evolved
considering the functional, technological and other requirements for efficient operation
ensuring comfortable working environment for personnel, satisfying the aesthetic
requirements. Special care shall be taken to provide elegance and aesthetics, with
effective use of appropriate treatment, materials fittings and finishes.
 Due consideration shall be given for adequate natural lighting and ventilation for plant
and non-plant buildings both.
 Internal finishes shall be provided with latest available materials as per finishing
schedule with due consideration of the functional aspect of the area.
 External finishes shall be provided with latest materials as per finishing schedule for
improving the aesthetics.
 Each building shall have its own identity. However, a total homogeneity shall be
maintained in the design of all buildings.
 Adequate frontage shall be provided to all important buildings to create a better visual
impact.
 Drainage of rainwater from roof shall be ensured by rainwater down comers with
necessary fittings & fixture and proper slope.
 All concrete roofs exposed to weather shall be provided with water proofing treatment
using latest Polymer based cementatious material of approved reputed manufacturer
like CICO, SIKA, FOSROC or equivalent consisting of minimum 2 coats of acrylic
polymer based cementatious slurry coating with one layer of fiber glass cloth in
between over screed concrete laid to required slope. 50mm thick PCC (1:2:4) shall be
cast over water proofing treatment, in panel not exceeding 1.2M X 1.2M size with
0.56mm diameter galvanized chicken wire mesh reinforcement. Joints shall be sealed
with sealing compound.
 All buildings shall be provided with 1000mm (minimum) wide apron along with
garland drain all round the periphery of the building. Apron shall be of minimum 75mm
thick PCC(M 20) finished with 15mm thick cement mortar (1:4) and neat cement
(chequered).
 Separate ladies and Gents Toilet & rest room facilities in all major buildings
 Separate fire exits shall be provided in all buildings as per requirements.
 Equipment foundations for all the systems specified in mechanical, electrical section of
this specification.


& ITS AUXILIARIES
 All other civil and structural buildings shall be developed in conjunction with the above
aspects.
 The architectural design concept of building structure shall be evolved considering the
functional, technological and other requirements for efficient operation, ensuring
comfortable working environment for personnel, satisfying the aesthetic requirements.
Special care shall be taken to provide elegance and aesthetics, with effective use of
appropriate treatment, materials fittings and finishes. To achieve above objective the
Contractor shall employ a qualified Architect / Architectural firm. The Contractor shall
submit all the architectural drawings for approval of Owner. The decision of Owner
shall be final and binding, in all respect of functional requirements to Contractor.
 The Contractor shall obtain and be conversant with all laws, by-laws, regulations of
local and Statutory Bodies as applicable to the project. The architectural concept
evolved should also take care of these requirements. The Contractor shall provide the
drawings and documents for such statutory approvals.
01.06 Terminal points
 All new structures shall be connected by roads and the roads shall be terminated up to
the nearest existing MTPS-I roads. Any damage to existing road/ facilities shall be
refurbished by Bidder.
 Water supply pipelines to FGD structures:

Water supply for new structures shall be taken from existing potable and service water
supply pipe lines.
 Drainages:
Discharge point shall be nearby existing nallah or existing drains. If discharge is
planned into the existing drainage system, proper drainage study for the carrying
capacity and design parameter of existing drains shall be done and submitted to the
owner for approval.
 Sewage:
Sewage discharge point shall be nearby existing STP or existing sewage line/manhole.
If discharge is planned into the existing sewage line/ manhole, proper sewage study for
the carrying capacity and design parameter of existing sewage shall be done and
submitted to the owner for approval.
01.07 Documents to be submitted by Bidder after the Award of Contract
The following documents are to be submitted for the approval of the Owner/Consultant,
prior to commencement of fabrication & erection / construction. All drawings shall be
of standard sizes (Metric system). The list is not exhaustive but indicative only.


& ITS AUXILIARIES
a) Layout drawing with co-ordinates of roads, buildings and facilities, piping / cable
corridors, pipe and cable trestles, provision of landscaping, diversion drains, equipment
lay down areas etc. within the battery limit.
b) Drawing showing underground facilities with co-ordinates of these facilities like buried
pipes, buried cables, trenches, ducts, sewer, drains, sumps, pits, culverts, foundations
etc.
c) Geotechnical investigation Methodology along with layout of various proposed tests
and Geotechnical investigation report along with foundation recommendation for
various buildings / structures / facilities.
d) Storm water drainage study furnishing levels of various terraces arrangement and
details of drains, culverts etc. for storm water drainage system.
e) Design basis memorandum for all buildings, facilities, services and structures.
f) Landscaping scheme, scheme for supply of potable and service water to all buildings.
g) Architectural floor plans, elevations, cross sections and perspective view in colour for
all buildings.
h) Design calculations and drawings for foundations/substructure and superstructure of all
structures within scope
i) Design calculations including dynamic analysis and drawings for all foundations
subjected to dynamic loads. Design and drawing of vibration isolation system shall also
be furnished.
j) A write up on dewatering system proposed at the time of construction where deep
construction such as for Conveyor tunnels and pump house etc. are to be executed
where water table is encountered.
k) Design calculations and drawings for all facilities and services like roads, culverts,
bridges, paving, road crossings, drainage pump house (if required), drains, sewers,
water supply, water tank, sumps, tunnels, trenches, ducts, equipment, DG,silos etc.
l) Drawings of all architectural works including finish schedule, colour scheme (both
internal and external), doors and windows, flooring and false ceiling, etc.
m) Design calculations and drawings for plumbing and building drainage.
n) All other designs, details / drawings or any other submissions as indicated elsewhere in
this specification and as required by the Owner/Consultant.
o) Design calculations and drawings for structures and foundations in switchyard,
transformer yard, etc.
p) All drawings / prints shall bear a stamp at a prominent place indicating whether the
drawings are submitted for approval or for information. Drawings supplied by the
Bidder shall bear the date and signature of a responsible person of the Bidder.
q) Details of corrosion protection measures for all structures
r) Total quantity of concrete (grade wise), reinforcement steel (diameter wise) and
structural steel (section wise) in all construction drawings.
s) Write up on various statutory requirements and their compliance for various buildings
and facilities.


& ITS AUXILIARIES
t) Copies of all reports on investigation and studies carried out by the Bidder as per the
scope.
u) Field Quality Assurance plan for Civil, Structural and Architectural works.
v) Structural analysis/ design shall be carried out using STAAD.Pro software. All
loads applied on structural frame work in STAAD.Pro input shall be clearly shown
in load calculation. Soft copies of design calculations in editable format, sources and
validation report for software, drafting (AutoCAD), shall be submitted for Owner’s
acceptance.
w) All relevant civil/structural materials shall be brought to site along with necessary test
certificates and should be submitted to the Owner at site for approval. Bidder shall
submit a list of preferred makes as given in the format for the materials.
x) List of all sub-contractors that the successful Bidder proposed to employ, indicating
their addresses with telephone number, experience on similar jobs, name, qualification
and experience of persons who shall be employed in the job on behalf of the sub-
Bidders etc. shall be submitted to the Owner/Consultant. Only the sub-contractor
approved by the Owner/Consultant shall be engaged on the job by the contractor.
Bidder to note that subletting of work on back to back basis shall not be permitted.
01.08 Specific requirement for site work
In addition to Scope of work specified in Mechanical / Electrical volume of this Tender

specification site specific requirements are listed below:
 Site related investigations.

 Site development work.
 Site clearance including diversion of existing services if any.
 Temporary roads/drains required for construction/pre-commissioning purpose.
 Construction enabling works.
 Ground preparation including minor grading, if required shall be done by the Bidder.
 Paving, trenches, tunnels, channels, duct banks, etc. involved in all system.
 Non shrink free flow grout for equipment foundations and grouting below all Steel
structure, Skids, etc.
 Plinth protection all around buildings.
 Sewage System: connection with existing sewage line/ manhole or as per system
requirement.
 Waste Oil Disposal (paving/pits etc., for all systems and final disposal.
 Drinking & service water distribution network for complete FGD area.
 All roads, culverts, drainage and street lighting for the FGD & connecting the same to
the existing nearest/ suitable plant roads/ facilities. The roads shall be of similar type as
of the main connecting roads i.e. either R.C.C or Bituminous depending on the main
connecting roads.

& ITS AUXILIARIES
 Plant storm water drainage system including connecting to the nearest nallah/existing
storm water drains. In case of connection with existing storm water drains, water
carrying capacity of such drains up to final disposal point to be checked by Bidder and
if the drains are not capable to carry storm water of FGD area, new drains with suitable
layout or up gradation of existing drains as per design requirements considering storm
from power plant area and FGD area.
 Rain water harvesting for the complete package within the battery limit.
 Construction water will be made available at one point near the proposed FGD system
by the owner. Pumping, Storing, providing pipe line for distribution etc. complete for
construction water for the construction shall be part of Bidder’s scope.
 Construction power shall be arranged by the Bidder by arranging from the Owner
approved power distribution source available in the vicinity of the site. All works
involved for substation, transmission lines and further distribution etc. complete for
construction power for the construction shall be part of Bidder’s scope.
01.09 Site Related Investigation/ SURVEY
01.09.01 Topographical Survey
The Contractor has to carry out survey as per requirement such as for layout of
buildings, foundations, fixing centre lines, fixing layouts etc.
The Contractor has to verify the topography and any other additional information
required by conducting survey at his own cost.
01.09.02 Geotechnical Stipulation
Refer ANNEXURE-1 for detail geotechnical stipulations
01.10 Site Development Work
01.10.01 Site Clearance
The Bidder shall be deemed to have visited and carefully examined the site and
surroundings and to have satisfied himself about the nature of the existing structures,
underground services, general site conditions, the site for disposal of surplus materials,
debris, surplus earth etc. and all other items affecting the work. Claims due to ignorance
of site conditions will not be considered after submission of Bid.
Ground preparation including minor grading, shall be done by the Bidder. However the
Bidder of the package shall consider removal of grass, shrubs, plant & its root from the
proposed area which are likely to grow again after first cut cleaning by site grading
work done by Owner. Certain amount of cutting, filling, and removal of top layer of
expansive soil, if any, shall be included in the scope of this bid document. Where earth

& ITS AUXILIARIES
fill is intended, the area shall be stripped of all loose / soft patches or top soil containing
objectionable matter before filling commences. Any structure or services existing at the
site shall be removed / re-routed with the permission of the Owner. Existing wells, pits,
marshy areas etc. shall be filled up with earth of approved quality.
01.10.02 Road, Drains and Culverts
Mainly all the roads shall be in line with existing type of roads and designed and
constructed as per relevant IRC codes/MORTH specification. Vehicular parking areas
shall be of flexible pavement type with wet mixed macadam (WMM) base and
bituminous topping on prepared surface. The roads shall be of similar type as of the
main connecting roads i.e. either R.C.C or Bituminous depending on the main
connecting roads.
On either side of the roads, open drains shall be provided. Minimum clear width of the
drain shall be 450 mm. All the drains shall be in RCC. Drainage lines and other
underground services shall be located at least 1.2 m clear from the edge of the road. All
service and utility lines crossing the roads shall be taken up through NP3 class RCC
pipe designed for impact loading. Culvert shall also be generally using NP3 class pipe.
The Contractor may adopt option of providing RCC box culvert.
01.10.03 Storm water Drainage
The storm water drainage of the FGD and Auxiliary system area is included under the
scope of the Bidder.
Hence, the Bidder shall carry out the drainage study in coordination and consultation
with the other Contractor who will be carrying out road & storm water drainage work of
other packages. All the drains shall be suitably connected to either existing power plant
drains or finally connect to outside plant boundary existing or propose drainage outlets.
01.10.04 Sewage/ Waste water drainage
The scope of Bidder shall include collection of the entire sewage form toilet, wash area,
etc. in a catch pit located just outside individual building / unit.
Carrying out the work of Sewage routing, shall provide the network of underground
sewage collection in gravity flow and shall arrange to lead the sewage to nearest
existing Sewage line/ manhole.
All paving works shall be carried out after successful installation of underground
sewage system.


& ITS AUXILIARIES
01.10.05 Paving/Plinth Protection
Entire paving area shall be provided with RCC paving over metal/ laterite soling. Plinth
protection around all buildings shall be provided to a min width of 1000 mm or the
distance between the brick wall to the garland drain.
Paving shall be carefully planned such that maintenance access roads minimum 4 m
wide to all major equipments are available. This area shall be designed for heavy loads
similar to design of roads. All drain / trench covers in these areas shall be designed to
withstand truck loading. All drain / trench covers in these areas shall be designed to
withstand truck loading.
01.10.06 Water supply
Plumbing and fixing of fixtures within the battery limit shall be provided in line with
the technical specification.
01.10.07 Rain Water Harvesting
All the buildings will be provided with rain water harvesting system approved by
relevant state govt. authority for entire FGD area.
01.11 Design Requirements
01.11.01 Climatic Condition
a) Ambient Temperature
Absolute Maximum : 40°C

Absolute Minimum : Min. 22°C
For design purpose, maximum temperature to be considered: 40.0°C
b) Rain fall
Annual average: 1123 mm (Avg.) During 2005
01.11.02 Seismic Zone
The site is located in Zone III as per IS: 1893-2016.
01.11.03 Wind Zone
The site is located in basic wind speed zone of 47 m/s as per IS: 875 (Part 3).

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01.11.04 Loads and Load Combinations
All structures shall be designed for the most critical combinations of dead loads,
imposed loads, equipment loads, wind loads, seismic loads, temperature loads, forces
developed due to differential settlement and any other loading conditions which can
occur during the design life of the facility.
(a) Dead Loads
Dead loads consist of the weights of the complete structure with finishes, fixtures,
partitions, wall panels and all equipment of semi-permanent nature including storage
structures (tanks, silo etc.), partitions, roofing, piping, cable trays, bus ducts etc. The
content of storage structures etc. shall be measured at full capacity for this purpose.
The piping loads, cable tray loads and the contents of the storage structures shall be
listed separately so that they can be excluded from dead load when dead loads are
acting as stabilizing load for uplift.
The following unit weight of material shall be considered for computation of loads.
Loads given in IS: 875 (part-I) shall be made use of for material not listed below.
Table 1.1
Weights of Material
Material Unit weight (kN/m3)
Plain cement concrete 24.0
Reinforced cement concrete 25.0
Brick work 20.0
Cement plaster 21.0
Floor Finish 24.0
(b) Superimposed Live Load (SILL)
Listed below is the minimum SILL for the areas involved. Floors and supporting
members subjected to heavy equipment live loads shall be designed on the basis of the
equipment loads specified by vendor or specifically defined SILL whichever is greater.
The specific minimum floor SILL is listed below:


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Table 1.2
Superimposed Live Load (SILL)
Sl. No Description SILL Value
a) Roof
Flat accessible roof 1.5 kN/m2
Flat accessible roof with HVAC 5 kN/m2
equipments, etc.
Flat inaccessible roof 0.75 kN/m2
Sloped Roof As per code IS: 875 (Part-2)
b) All building floors & Stairs 5 kN/m2
c) Walkways of Conveyor Galleries 5 kN/m2 or Concentrated Load
of 3 kN at centre which ever is
critical
d) M.C.C. Floor 10 kN/m2
e) Equipment Load As applicable
f) Culverts & its allied structures Class “A” / Class “70R” as per
including Concrete pipes IRC standard whichever is
higher / load due to bull dozers
g) Underground basement, Surcharge of 10 KN/m2
h) Vehicular traffic Surcharge of 20 KN/m2
i) Covers for Channels Surcharge of 10 KN/m2
j) Pump Houses
Operating Floor Slab 15 KN/sqm or as required by
equipment supplier whichever
higher
Workshop 10 kN/m2
k) Other areas:
 RCC floors (Offices, laboratories, 5 kN/m2
conference rooms and general
floors)
 Balconies 5 kN/m2
 Chequered plate / gratings 5 kN/m2
 Walkways 3 kN/m2
 Toilets 2 kN/m2
 In addition to LL, Hung loads for electrical, ventilation & air conditioning minimum of
0.5 kN/m2 shall be considered.
 For other areas LL shall be considered as per IS: 875 (Part-2).

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 Ponding effects due to framing deflections for roofs, if any shall be considered.
(c) Seismic Load
The various structures for the project are to be designed as per codal provisions of
IS:1893 for earthquake loads. The loads due to Earthquake are generated by the
response of the structure to design spectrum as specified in IS1893 (Part 1): 2016. The
site is located in Earthquake zone III and factors corresponding to that zone are taken in
calculation of response. The mass to be considered in seismic analysis shall comprise
of full dead load and the reduced percentages of live loads for calculating inertia
masses as given in Table 1.
Table 1 – Live load reduction factors under seismic condition
 Sl.  Description  Percentage of Design

No. Live load
 1 Uniformly distributed Live loads on floors  25
up-to and including 3 kN/Sq.m.
 2 Uniformly distributed Live loads on floors  50
above 3 kN/Sq.m.
 3 Roof  0
Following values are used for the defining Design Basis Earthquake (DBE) which is
considered for the analysis:
Zone factor, Z = 0.16

Damping (R.C structure) = 5%
Importance factor I = 1.5
Response reduction factor is considered as 5 for based on IS:1893.
(d) Wind Load
Wind load calculation shall be as per IS: 875 (part-3) 2015 where Basic wind speed
(Vb)shall be taken as 47 m/sec with Risk coefficient k1 as 1.07 ( important building
having mean probable life of 100 years, k2 as Terrain roughness and height factor for
Terrain Category –2 and depending upon the height of the building,k3 as topography
factor with a value of 1 and k4 as 1,
Wind pressure at any height above mean ground level,
pz = 0.6 Vz2 (clause 7.2 of IS 875 (Part-3) – 2015)


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Vz=k1.k2.k3. k4.Vb (clause 6.3 of IS 875 (Part-3) – 2015)
Design wind pressure, pd = kd.ka.kc.pz (clause 7.2 of IS 875 (Part-3) – 2015
where kd=Wind directionality factor
ka=Area averaging factor
kc=Combination factor
The value of pd, however shall not be less than 0.7 pz
For the design of structures, wind force on Equipment, supported on frame including all
fixtures, piping, staircase, ladder, etc., exposed to wind shall be considered.
Design of structures shall be checked for the condition of wind load with gust factor.
(e) Earth Pressure Loads
For earth pressure the worst condition with dry / submerged and active, passive or at
rest condition shall be considered. (The pressure coefficient shall be adopted as
recommended in Soil Report or for the backfill material used.)
(f) Temperature Loads

The total temperature variation shall be considered as 2/3rd of the average maximum
annual variation in temperature. The average maximum annual variation in temperature
for this purpose shall be taken as the average between the mean of the daily minimum
ambient temperature during the coldest month of the year and mean of daily maximum
ambient temperature during the hottest month of the year. The structure shall be
designed to withstand stresses due to 50 % of the total considered temperature variation
with temperature load applied with positive and negative sense.
Coefficient of thermal expansion of steel shall be taken as per IS: 800 where the value
is given as 12x10-6/°C. Coefficient for thermal expansion for concrete shall be taken as
per IS: 456.
(g) Thermal Loads (during operating condition)
When thermal loads (such as produced by temperature changes in piping, equipment

and structures) results in friction between equipment and supports (exchangers) or


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piping and supports, the friction force will be taken as the operating load on the support
multiplied by the applicable friction coefficient given below:
Table 2.4
Thermal Loads
Description Value
Surfaces Friction coefficient
Rolling supports 0.05
Concrete to steel 0.30
Any other bearing namely stainless steel, PTFE etc. can also be used.
(h) Equipment Loads
Static and dynamic loads of major equipments shall be based on the manufacturer’s
data of the specified equipments and shall be considered in design in addition to the live
load. However, where the uniform floor live load adequately accounts for the
equipment moving weight, the weight of such equipment as a dead load shall not be
considered e.g. control room floors are usually designed for a live load that includes the
equipment weight also.
All equipments, tanks and piping design loading shall include hydraulic test loading.
Weight of equipments, ducts, tanks, pipes, conduits, etc. supported by structure shall
include maximum possible loading conditions i.e. flooded conditions and associated
impacts, test loading, anchorages and constraint effects.
Air and gas duct loads shall include weight of insulation, duct attachments, dust
accumulation loads, seismic, wind and other loads applicable.
(i) Hoists, Monorail and Elevator loads
All lifting beams and monorails shall have their design loads increased for impact
factor. Loads for hoists, monorails and elevators shall be taken as per IS: 875.
100 % of the lifted load including elevator live load plus the cab weight shall be
considered for the elevator support beam design. Pedestals in elevator pits shall be
designed assuming 100 % impact factor.


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(j) Vibration and Noise
The design shall ensure that vibrations from any moving machinery transmitted from its
immediate foundations to adjacent buildings or areas of the same building shall be
suppressed in accordance with the recommendations of relevant codes of practice. Any
control room, administration facility and other permanently occupied office area shall
be structurally isolated from plant areas subject to frequent shock loads or containing
large oscillating or rotating plant and equipment.
(k) Other Loads
 Dust loads: All buildings / structures shall be designed for a dust load of 1 kN/m2.
 Construction Loads: The integrity of the structures shall be maintained without use of
temporary framing struts or ties and cable bracing as far as possible. However,
construction or access considerations may dictate the use of temporary structural
systems. Special studies shall be made and documented to ensure the stability and
integrity of the structures during any periods involving use of temporary bracing
systems.
 Future Loads: Loads from future expansion shall be considered when so directed by the
Owner/Consultant. Future loads may include any of the loads listed above.
 Surge Loads: Surge loads may occur in some vessels or equipment. In such cases, the
magnitude and direction of the load shall be given by the equipment supplier.
(l) Basic Load Cases
Following basic loads shall be considered for analysis and design:
Dead load : DL
Superimposed dead load : SIDL
Self weight of permanent equipment : EL
Live load on floor / walkway : LL
Superimposed live load : SILL
Live load on roof : LLR
Hoist, monorail loads : MR1
Wind load : WL
Seismic load : SL
Load due to soil pressure : SP
Load due to surcharge : SCL

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Load due to hydrostatic pressure : HP

Load due to temperature : TL
Special loads : SPL
Cable loads : CL
Piping loads : PL
(m) Load Combinations
The individual members of the frame shall be designed for worst combination of forces
such as bending moment, axial force, shear force and torsion. Permissible stresses for
different load combinations shall be taken as per IS: 456, IS: 800 & IS: 875 (all parts)
and other relevant IS codes.
Wind and seismic forces shall not be considered to act simultaneously.
Criticality of erection / maintenance loads shall also be checked separately in

combination with other simultaneously occurring loads for possible design loading.
(n) Load Combinations for underground structures
 For the design of sub structure only liquid pressure from inside and no earth pressure
and ground water Pressure and surcharge pressure from outside (applicable only to the
Structures which are liable to be filled with water or any other liquid) shall be checked.
 For the design of sub structure combination of earth pressure, surcharge pressure and
ground water pressure from outside and no water pressure from inside shall be applied.
 Ground water at ±0.00 level.
(o) Silos
The concrete silo shall be designed generally as per the criteria laid down in IS: 4995
(Part I & II).
(p) Switchyard Structures (If required)
The loading for the design of switchyard structures shall be as per IS: 802 Part 1/Sec
1:1995. Following loads shall be considered.


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 Dead load due to equipment and structure

 Temperature effects consisting of effect of temperature variation and sag tension as per
clause 10 of IS: 802
 Climatic loads as per Clause 11.2 of IS: 802
 Anti cascading loads as per clause 11.3.1 of IS: 802
 Torsional and longitudinal loads caused by breakage of conductor as per Clause 11.3.2
and 16 of IS: 802.
 Construction and maintenance loads
 Seismic loads as per IS: 1893
 Short circuit forces including “snap effect” in the case of bundled conductors
Switchyard structure shall be designed for the worst combination of above loads. The
factor of safety for design of members shall be considered as 2 for normal & broken
wire conditions and 1.5 for combined short circuit and broken wire conditions. Short
circuit forces and Seismic forces shall not be considered simultaneously.
Foundation shall be designed for a factor of safety 2.2 for normal and broken wire
condition and 1.65 for combined short circuit and broken wire conditions. Design of
foundation shall be carried out as per IS: 4091.
(q) Lime stone Handling System

In addition to the loads specified in (b) above, following additional loads shall be
considered for design of various structures of LSHS.
Flat roof
Accessible : 1.0KN/sq. m dust load
Non accessible : 1.25 KN/sq. m dust load
Building floors : 5KN/sqm +1KN/sqm spillage load and

10KN/sqm or equipment load whichever is
high +1KN/sqm spillage load (Where
equipment is located) for Building floors
with Equipment.
Load due to material on belt : 1.6 times design weight of the material on
belt
Spillage load
Gallery walk way : 1KN/sq. m
Seal plate : 1KN/sq. m

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Belt tension for twin conveyors : One belt at starting condition and one in
running condition
01.12 Building & Structures
All civil works for the buildings, equipment foundations, facilities and miscellaneous
civil works to be provided for the project will include but not be limited to the
following:
a) Control cum MCC room building
b) Compressor house
c) Pump house(if required)
d) Booster fan,
e) Absorbers
f) Fabric filters
g) Lime conveying air compressor,
h) Dryer for lime conveying air compressor,
i) Fluidizing air blower with heater for lime storage silo,
j) Fluidizing air blower with heater for intermediate by-product silo,
k) By-product conveying air compressor,
l) Dryer for by-product conveying air compressor,
m) Fluidizing air blower with heater for main by-product silo,
n) Spray water pump,
o) Pulse jet compressor for bag filter,
p) Instrument air compressor,
q) Desiccant type air dryer for instrument air compressor,
r) Electric hoist with monorail,
s) RCC silos(lime storage silo, Main by-product silo, intermediate by-product silo)
t) Pipe supports
u) Rack & pinion type elevator
v) Foundation for steel water tanks
w) Passenger lift
01.13 Earthwork and Rockwork
01.13.01 General
This section applies to all earth and rockwork required for the construction of buildings,
any types of structure and burying service lines in the ground.
The Bidder shall satisfy himself as to the ground conditions on the site including the
nature of the strata to be excavated, obstructions, possibilities of flooding and such like
and shall allow for all provisions necessary to carry out the work in the most suitable
manner when submitting his tender.


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Generally, all buildings and structures must be founded on bearing strata which means
that all excavation work for foundations shall meet the requirements of structural
analysis based on the results obtained from the soil investigation and of the available
information and instruction given in writing by the Owner/Consultant.
Furthermore, this division applies to excavation works in connection with pavement,

roadwork and landscaping as far as earth and rockwork is concerned and deals with the
handling and disposal of the materials to be re-used or taken to soil dumps on or off
site.
Excavation shall be done to the required dimensions and shall be finished according to
the specified lines and slopes, in a way acceptable to the Owner/Consultant. All
necessary precautions shall be taken to cause the minimum possible alteration or
disturbance to the material lying under and adjacent to the excavation final lines.
01.13.02 Fill Materials
The fill materials used and source are to be examined and approved. Excavation
materials can be used if they fulfil the requirements.
a) Select fill shall have the following properties:
Well graded (uniformity index not less than 5), non-cohesive and nearly silt free (silt
content not greater than 5%; up to 10% tolerated, except below footings of structures),
salt free (content less than 3%), soils free of organic matter (limit 2%).Decomposing or
compressible materials shall not be used.
All materials shall be of such nature and character that it can be compacted to the
specified densities in a reasonable length of time. It shall be free of highly plastic clays,
of all materials subject to decay, decomposition or dissolution, and of cinders or other
materials, which will corrode piping or other metal.
The intention is to use select fill below plinth, floors, roads, parking areas etc.
b) Ordinary fill shall have the following properties:
c) Natural inorganic soils: salt content not greater than 5%, organic matter less than 3%.
For other properties see under ‘Select fill’.
d) The intention is to use ordinary fill for non-built areas.
e) Special fill:


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f) Special fill material shall be gravel or crushed rock (for other properties see under
‘Select fill’). The intention is to use special fill e.g. as sub-base material for tanks and
roads.
g) Rip-rap/Rock fill:
h) Riprap must be of a size suitable for the place where it is to be used, as determined by
the speed of the current, wave height and depth of water. Riprap shall be of deformable
and yielding construction, using round stones if the intention is to safeguard the
underlying ground against scour. If the rock infill is to be used as a foundation for
structural components, the aim should be to secure effective bedding of angular stones
under water. The stones must be weather and waterproof.
01.13.03 Excavation in hard rock
Where hard rock is met, the Contractor shall intimate the Engineer in writing.
Excavation in hard rock shall be done by chiseling or by such other agreed methods as
may be required. Levels of hard rock surface shall be taken and got approved by
Engineer before start of excavation.
The excavation shall be carried out by chiseling, wedging or such other agreed
methods. All materials excavated from, chiseling or any such methods shall be stacked
for measurement as directed by Engineer.
01.13.04 Excavation
i) The works shall be excavated either by hand or by use of excavating plant and tools
acceptable to the Owner/Consultant.
Excavation by hand may be required close to existing installations and/or underground

services, but subject to special instruction of the Owner/Consultant.
The Bidder shall carry out all kind of earth and rockwork for the following particular
works as defined hereafter (where applicable)
i) Clearing and grubbing

ii) Excavation of topsoil
iii) Open cut excavation
iv) Backfilling
v) Safety precaution during earthwork
vi) Mining or underground excavation (if required)
vii) Grading
viii) Replacement of material

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ix) Trench excavation for service lines

x) Embankments
xi) Archaeological findings
01.13.05 Safety Precautions
The Bidder shall be responsible for all necessary safety measures.
Proper strutting, sheeting and bracing, including re-arrangement of the installations

when necessary, stabilization and protection of slopes, methods of excavation to reduce
risks of slides etc. shall be to the Bidder’s debit. The additional moving of soil resulting
from such damages will not be paid for. Blasting shall not be permitted near chimney
and other main structures. All necessary hand railing around open cut excavation shall
be provided by the bidder.
01.13.06 Over Excavation
If somewhere, and for any reason, excavation is executed beyond the established design
level, the Bidder shall at his own expenses backfill with lean concrete to
Owner/Consultant’s approval, the volume corresponding to over-excavation. He shall
not receive payment for over-excavation not ordered.
01.13.07 Stockpiles and Disposal
Excavated material from the works selected by the Owner/Consultant for re-use shall be
placed immediately in its final position, if possible, or otherwise may be stockpiled or
deposited on site as directed by the Owner/Consultant.
The Bidder shall not have the right either to additional payment or to claim because of
work involved in stockpiling materials, re-use of for carting to the waste disposal areas.
Soil unfit for re-use shall be removed to sites approved by the Owner and shall not be
permanently deposited elsewhere. The Bidder shall trim and form the edges of spoil to
profiles and levels as directed by the Owner/Consultant.
The placing of materials within the waste disposal areas shall be made in layers not
exceeding 0.50 m in thickness in order to obtain an appreciable degree of compaction
by means of transportation equipment and/or if required by appropriate compaction
equipment.
All traffic to or from the waste disposal areas shall run over the surface of such areas in
order to achieve compaction.
01.13.08 Preparation of Foundation


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All rock surfaces on which or against which concrete is to be poured shall be carefully
cleaned and roughened to the Engineer’s satisfaction.
The rock surface shall be free of oil, stagnant or running water, mud, loose rock, residue
and impurities or any other improper material. Rock faults, depressions and fractures
shall be cleaned to a depth equal to their widths and to sound rock at both sides.
Immediately before concrete placing, all rock surfaces shall be thoroughly cleaned by
means of air and water jets, wire brushes, sand jets or by any other devices necessary to
clean the foundation and keep it free of water, but shall be moistened prior to placing
concrete.
All earth surfaces against which concrete is to be poured, shall be clean and free of any
detrimental impurities, organic matter or unsuitable material. Immediately after
excavation, all such surfaces shall be moistened and treated as directed by the
Owner/Consultant and then protected by means of a lean concrete layer, 7.5 cm or PCC
thickness as shown in the design drawings, whichever is greater. No concrete is to be
poured until formation is inspected and approved by the Owner/Consultant.
01.13.09 Backfilling
Foundations and structures, pits, trenches etc. shall be backfilled with approved
material compacted in layers not exceeding 150 mm by suitable equipment until
optimum stability has been obtained to the satisfaction of the Owner/Consultant.
Compacting shall be carried out with special care by means of pneumatic or mechanical
rollers or other compactors of a type previously approved by the Owner/Consultant.
Density requirements as per standard Proctor Test shall be in accordance with relevant
parts of IS: 2720 and all tests shall be made by/on under the supervision of
Owner/Consultant at Bidder’s own expenses, at optimum moisture content:
a) Backfilling of foundations - 95%

b) Under grade slabs - 98%
c) Under roadways and parking areas - 95%
d) Embankment - 95%
The thickness of fill layers, number of passes and type of equipment to be used shall be
proposed to the Owner/Consultant after compaction tests have been made.
Surfaces receiving fill layers shall, if smooth, be previously scarified to obtain a good
key between the new fill layer and the sub-grade.


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Backfilling of foundation work with approved materials shall be carried out only after
foundations have been inspected by the Owner/Consultant.
01.13.10 Soil Replacement
The material to be used for replacement of soil shall not contain soluble or swelling
components such as clays, or organic matters. Sand gravel mixtures of favourable grain
size distribution shall be used in exchange.
Prior to the commencement of work, three samples shall be taken from the anticipated
borrow area and tested in respect of IS: 2720 for Proctor density, optimum moisture
content, grain size distribution and content of soluble matters.
These three samples shall cover the approximate variation of materials to be expected
within the borrow area.
The fill material shall be placed in horizontal layers of not more than 15 cm in
compacted thickness. The fill moisture content shall be controlled and adjusted in order
to achieve a maximum of compaction. Fresh water shall be used for watering of soils.
The fill material shall be compacted by vibratory roller (min. weight 20T.). The
minimum required degree of compaction should be as defined under “Tests and
Properties”. One Proctor and three density tests shall be made at every fourth fill layer
prior to continuation of filling work. The testing location will be indicated by the
Owner/Consultant. The Bidder shall either provide all required laboratory facilities and
staff to perform the tests or he shall co-operate with an experienced soil testing
laboratory, subject to the approval of the Owner/Consultant.
The results of the tests shall be made available to the Owner/Consultant within 24 hours
of the tests. Filling work may be continued in case all tests performed show satisfactory
results.
01.13.11 Pipe Bed Preparation
Pipe beds shall be constructed to guarantee the uniform transmission of loads. The
bearing section for supported profiles shall cover at least an arc of 90.
Pipes shall be bedded in an earth foundation of uniform density and carefully shaped by
means of a template supported at the desired grade, to fit the lower part of the pipe
exterior.
Where rock in either ledge or boulder formation is encountered, it shall be removed

below grade and replaced with suitable materials in such a manner as to provide a

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compacted earth cushion having a thickness under the pipe of not less than one quarter
of outside pipe diameter with a minimum allowable thickness of 20 cm if not otherwise
specified.
Where a firm foundation is not possible at the grade established due to soft, spongy or
other unstable soil, all such unstable soil under the pipe and for a width of at least one
diameter on each side of the pipe shall be removed and replaced with suitable selected
materials as approved by the Owner/Consultant, properly compacted to provide
adequate support for the pipe.
01.13.12 Protection of Existing Utilities and Services
During construction, the Bidder shall provide all protection for existing utilities and
services as may be required for his construction operations. Permanent protection of
certain items shall be as included under other sections or as instructed by the
Owner/Consultant.
In addition to the requirements as specified, herein the Bidder shall comply with the
following requirements:
a) Use all necessary precautionary and protective measures required to maintain existing
utilities, services and appurtenances that must be kept in operation. In particular, the
Bidder shall take adequate measures to prevent undermining of utilities and services
presently in services.
b) Protect existing or new utilities and services where required by the Bidder’s operations
and/or as directed by the Owner/Consultant. The Bidder shall be responsible for bracing
and supporting utilities and services to prevent settlement, displacement or damage.
01.13.13 Dust Control
The Bidder shall use all means necessary to control dust on roads, construction areas
and borrow pits.
Surfaces shall be regularly watered to prevent dust becoming a nuisance for the public
and interfering with the proper execution of the works.
01.13.14 Dewatering/Ground Water Control
This division applies to the methods and techniques of ground water control. Prior to
the decision for the method and technique to be applied, a comprehensive knowledge of
the soil and ground water conditions have to be obtained from the results of the soil
investigation and/or information given in writing by the Owner/Consultant.

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All costs for ground water control for keeping the construction pits dry shall be
included in the scope of the bidder except otherwise indicated.
The method and technique shall be based on the IS: 3764.
The scope of supply includes the installation of all equipment, plants, pipes, machinery,
etc. and its removal after completion including operation & maintenance of the
equipment during the construction period.
Where necessary, cofferdams, sheet piles, pump sumps, equipment and channels,
troughs, inlet gutters, pipes, well points and any other works required for the water
control and discharge shall be part of the scope of supply. The dewatering system shall
be designed and installed in such a way that alterations and extensions can be made at
any time throughout the operating time, if necessary. Reserve units shall be kept ready
for service when failure of any of the installed units occurs.
The Bidder has to consider the possibility of a temporary failure of any pump, diesel
engine and/or the electric power service and shall install emergency power units with
sufficient capacity to feed the necessary power to the installed unit at the moment of
failure. The Bidder shall submit to the Owner/Consultant, the detailed method of the
envisaged pumping system for dewatering, the pump capacity and the standby reserve
units. The Bidder shall adjust the system if required by the Owner/Consultant.
The Bidder must ensure that any dewatering works will not cause any interference to
his own work and to those of other Bidders working elsewhere on site or at structures
under construction. Any damage occurring during the above mentioned period should
then be made good by the Bidder at his own expense.
During the foundation works, the excavated areas, foundation levels, and pits are to be
kept free of water down to at least 0.50 m below the foundation level.
01.13.15 Equipment
All equipment, instruments, machineries, tools, pipelines, etc. required for execution of
the water control shall be kept in good working condition throughout the operation
period.


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01.13.16 Execution
The Bidder shall keep records of all data of importance occurring during operation of
the water control system. The records shall be submitted to the Owner/Consultant for
information and checking every working day. For that purpose, the lowering of the
water table shall be controlled by piezometers. The numbers and position of them shall
be submitted to the Owner/Consultant’s approval. The Bidder shall provide and
maintain these piezometers at his own expenses during the dewatering works or as long
as the Owner/Consultant requires it.
Pump operations shall not be stopped nor pipes, channels and equipment for dewatering
and water control removed or altered in any way, except with the express permission of
the Owner/Consultant. The Owner/Consultant will stipulate the time of removal. Until
then, the pumps and water drainage facilities shall be kept in proper working order
without extra payment being granted.
Pump sumps and channels:
Provision of pump sumps and channels of the dimensions required for each particular
case shall include all necessary excavation of any kind of soil above and under water,
backfill and consolidation, sheeting, bracing, stiffening, sealing, scaffolding accesses,
as well as the disposal of water and all auxiliary works.
Routing of channels or pipes for discharge water shall be such as not to impede or
obstruct any of the other works and/or operations.
The same shall be applicable for pump sumps. Prior to the determination of any
arrangement of pump sumps, the Owner/Consultant’s approval shall be obtained.
Routing and location of water discharge lines shall be submitted to the relevant
authorities and to the Owner/Consultant’s approval.
Difficulties during dewatering:
The Bidder shall consider all difficulties and additional work due to the presence of
unexpected ground water during subsequent construction work. Where it is possible to
keep off or divert such water without special dewatering arrangements or where work
can be carried out normally under or in water, such a
method may only be applied after approval from Owner/Consultant has been obtained.


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Ready for service condition:
The Bidder shall maintain ready for service and regularly clean all dewatering
equipment and accessories and shall keep all access clear so that they can safely be used
without risk of accident. Any recommendations made by the Owner/Consultant in this
matter shall be carried out immediately.
Leakage:
Blockouts and pipe connections through structures and their closure, proper grouting of
joints, etc. or repairs in the event of leakage shall be the responsibility of the Bidder.
Piezometers:
The ground water lowering effect is to be checked by piezometers in unfavourable

positions (e.g. in the middle of the building pit) before starting the excavation. The
piezometers are to be installed at unfavourable positions or in more permeable layers
(in stratified sub-soil) below the bottom of the excavation. They serve to check whether
or not the water pressure (head) has been sufficiently reduced in those layers below the
bottom of the excavation, which are more permeable. Security against hydrostatic uplift
is to be demonstrated by calculation.
01.13.17 Tests and Properties
a) General
The control of working and tests operations shall be carried out by the Bidder in the
presence of the Owner/ Consultant.
The Bidder shall prepare sheets for statistical analysis of the field and laboratory tests,
and shall submit the sheets to the Owner/Consultant for approval. Controlling will
consist of field and laboratory tests, such as compaction and density tests, grain size
distribution and shear tests.
If not otherwise specified under relevant items, the following min. tests have to be
carried out:
 One (1) test analysing the ingredients of the water used for performance of the work.
 Three (3) tests for specific gravity of soil as per IS: 2720.
 One (1) test for bearing capacity of soil for static load as per IS: 1888.
 Three (3) tests for grain size analysis of soils, if “Replacement of Material” is required
as per IS: 2720.


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 Three (3) tests of density of soil in place of sand cone method for each second layer of
“Backfilling and/or Replacement of Material and/or Roadwork” are required as per IS:
2720.
 All tests shall be recorded in forms acceptable to the Owner/Consultant.
 Tests shall be performed for each 500 m3 of fill but not less than once per shift.
b) Testing of Select Fill
Select fill, as specified herein, shall be provided as follows:
 As fill or backfill within the limits of the structure/building and below basement floors
as shown on the drawings to bring the sub-grade up to the required elevation or for
filling or backfilling against foundations walls and around footings.
 As fill beneath grade slabs or basement floors either to bring local low areas to grade or
to replace disturbed or unsuitable soil. Place select fill in approx. 15 cm layers
(compacted thickness) and compact to 98% of maximum dry density (IS: 2720).
 Quality control shall establish all of the following values:-
 Unit dry weight
 Standard penetration test: 20 blows per 10 cm penetration.
 Plate load test as per IS: 1888.
c) Testing of Ordinary Fill
Ordinary fill, as specified herein above, is required for all fill and backfill where special
fill or select fill have not been specified on the drawings. Place ordinary fill in 15 cm
layers (of compacted thickness) and compact to 95% of maximum dry density at
optimum moisture content as per standard Proctor Density Test.
Quality control shall establish all of the following values:
 Unit dry weight

 Standard penetration test: 16 blows per 10 cm penetration.
 Plate load test as per IS: 1888.
01.14 Reinforced Concrete Structures and Foundations
01.14.01 General
All structures, building foundations, machines / equipment foundation, water retaining


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structures, trenches, pits, etc. shall be designed as per latest relevant IS codes in general.
Construction in general shall follow provisions of IS: 456 and IS: 3370 for normal and
water retaining structures respectively.
01.14.02 Design Methodology
General
All designs of RCC structures shall be carried out by limit state method as per IS: 456
unless use of working stress method is specifically mentioned. Design strength of
materials and design loads shall be calculated using appropriate partial safety factors
over characteristic strength and characteristic loads as per IS: 456.
IS: 11384 shall be followed for design of steel concrete composite beams. For
reinforcement detailing IS: 5525, SP: 34 and IS: 13920 shall be followed.
The walls shall be provided with reinforcement on both faces for sections 150 mm or
more, even if not required from design consideration.
01.14.03 Settlement and Expansion Joints
Joints are to be arranged in such a way that stresses and strains caused by shrinkage,
settlements, temperature, differential settlement, etc. do not adversely affect the
structures. This primarily applies to differently loaded areas and structures having
different foundations or foundations of different depths. The settlement joints shall run
through the complete structure down to foundation level, the expansion joints however
shall stop on the top level of foundations.
The joint width is to be planned considering all relevant factors (settlements, tilting,
movements, aspects etc.).
Settlements of all relevant structures shall be measured, recorded and shown in

diagrams according to IS: 8009 – “Code of Practice for calculation of settlement of
foundation”.
01.14.04 Foundations at Different Depths
Foundations at different levels should be based beyond a load-spread angle of 30

(against the horizontal). Otherwise, the load influence (e.g. earth pressure) of the
higher-level structures on the lower ones must be taken into consideration.


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01.14.05 Replacement
If unsuitable soils are encountered below the grade slabs or basement floor, they are to
be replaced by suitable layer wise compacted material down to the good bearing soil.
Materials and compaction method as well as quality control are described in clause
‘Earth and Rockworks’ of this section. Selected fill is to be employed below all grade
paving and basement floors.
01.14.06 Liquid Retaining Structures
RCC water retaining structure like storage tanks shall be leak proof and designed as un-
cracked section in accordance with IS: 3370 (Part 1 to IV) by working stress
method/Limit state method. However the parts of such structures not coming in contact
with liquid may be designed according to IS: 456.
Substructure of pump houses shall be designed as IS 456
All water retaining / storage structures shall be designed assuming liquid upto the full
height of wall irrespective of provision of any over flow arrangement. No pressure
relieving devices shall be permitted in underground structures.
In all liquid retaining structures, PVC water bar shall be provided at each construction /
expansion joint. The sequence of construction shall also be specified on drawings
showing construction joints.
The walls shall be designed for a surcharge load of 2000 Kg/m² or actual whichever is
higher.
Liquid Retaining Structure shall be checked for two loading conditions. With water
inside up to operating level and no earth fill outside or water in one compartment and
no water in the other compartment (where two compartments are provided).
Base slab / raft of all liquid retaining structure shall be designed to withstand the uplift
pressure in tank empty condition.
01.14.07 Tank Foundation
In general tank foundations shall be circular type ring foundations provided along the
periphery of the tank. Inner side of the ring foundation shall be filled with well
hydraulically compacted clean river sand, in 500 mm thick layers, over this next layer
shall be 150 mm thick PCC (M-10), over this 50mm thick anti-corrosive layer of screed
coarse sand mixed with 8% to 10% of bitumen by volume and compacted over this next
layer is 50 thick pre-mix carpet in two layers of 30mm and 20mm respectively with 12
mm and down broken stone chips and 80/100 grade bitumen at 52 kg/cum. Design of

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the foundation shall be as per Limit state method. Follow other details provided under
clause 7.0 above.
01.14.08 Machine Foundations
General
The design of machine / equipment foundation shall be as per IS: 456 and IS: 2974. The
provisions of DIN 4024 may also be followed for machine foundations. All machine /
equipment foundations and structures subject to vibrations shall be suitably
proportioned so that amplitude and frequency of the foundation / structures are within
permissible limits.
Dynamic analysis shall be carried out to calculate natural frequencies in all modes
including coupled modes and to calculate vibration amplitudes. Frequency and
amplitude criteria as laid down by the relevant codes or machine manufacturers shall be
satisfied. Minimum reinforcement shall be governed by IS: 2974.
For the foundations supporting minor equipment weighing less than one ton or if the
mass of the rotating parts is less than one hundredth of the mass of the foundation, no
dynamic analysis is necessary. However, if such minor equipment is to be supported on
building structures, floors, etc. suitable vibration isolation shall be provided by means
of springs, neoprene pads, etc. and such vibration isolation system shall be designed
suitably. All such foundation shall be separated from adjoining part of building and
other foundations. Joints at floor/ slab shall be suitably sealed. All appendages to such
foundations shall be reinforced suitable to ensure integral action.
Loads
All static and dynamic forces / loads which equipment supplier considers applicable
shall be considered for analysis and design of machine foundations.
Foundation Sizing
The outline plan dimensions of foundations as given by the machine supplier will be
adopted. The height of foundation will be selected after taking into consideration soil
strata and operating level of the machine. The eccentricity of common CG of machine
and foundation with respect to the centroid of base area should not exceed 5 % of the
corresponding base dimensions of foundation. Partial contact between the foundation
and soil strata shall be considered wherever applicable. The footing will be checked for
minimum contact area of 80 % and maximum bearing pressure will be calculated for
the actual contact area only.
Analysis and Design
The minimum grade of reinforced cement concrete shall be M30, unless specified
otherwise.

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 The analysis and design of machine foundations will be carried out to ensure the
following:
 Compliance with the manufacturer’s requirements and relevant standards
 No resonance phenomenon of a disturbing nature to machine operation should exist at
the normal running speed
 Calculations to be performed for dynamic as well as static cases for reinforced concrete
block type pedestal
 Soil bearing capacities
 Deep foundation capacities
 Lateral earth pressures
 Allowable settlements
 Structure, equipment and environmental loadings
 Equipment performance criteria
 Access and maintenance requirements
 Temporary construction loadings
The foundation will be designed for the most critical combinations of forces and
moments, resulting from all possible combinations of the various loading from the
equipment system. The foundation sections will be sized and reinforced adequately for
bending moments and shear stresses and uplift.
The foundation shall be checked for overturning, sliding and uplift as per relevant IS
Codes. The foundation will be checked for overturning with minimum and maximum
vertical loads.
For analysis of machine foundation following data will be furnished by the equipment
manufacturer:
 Loading diagram showing static and dynamic loads and points of application of loads
 Operating speed of machine
 Weight of rotating parts, maximum eccentricity of rotating mass from the geometric
axis of rotation
 Location of C.G. of machines in all three axis
 Mass moment of inertia
 Allowable amplitude / velocity of vibration at machine bearing points
 Temperatures at various areas during operation
While designing following aspects shall also be taken care of:
 All dynamic foundations shall be isolated from building foundations. The isolation gap
shall be of minimum 25 mm.


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 Natural frequencies of structures and components shall be away from running speed of
equipment by at least 20 % and preferably 50%
 For design of foundation of large fans etc., provision shall be kept in the foundation for
addition of mass / area for retaining of the foundations if required at a later date
However following minimum factor of safety shall be followed:
 Factor of safety against overturning due to wind, seismic or other lateral loads shall be
1.5
 Factor of safety against sliding shall be 1.5
 Factor of safety against uplift due to hydrostatic forces shall be 1.2 and due to any other
loads shall be 1.5. Uplift check shall be carried out during construction stage also.
Specific requirements for machine foundations
 Booster Fan Foundation
 Booster fans foundation shall be of Reinforcement concrete foundation supported on

vibration Isolation system comprising of steel helical spring units and viscous damper
 Miscellaneous Machine Foundation
For miscellaneous machines, most suitable type of foundation shall be provided.

Foundation for pumps, and minor rotating equipment etc., are usually in the form of
solid block foundations, resting on the ground or on a floor of the building. At such
machine supports, floor may be thickened and extra reinforcement may be provided.
Also the machines, which are almost vibration free, light to moderately heavy, may be
supported in the above manner. Rubber or neoprene pads under some of these machines
to reduce transmission of vibrations to the supporting floor will be provided if required.
All block foundations resting on soil shall be designed using the Linear weightless
spring method(Barkan method) as per IS 2974.Alternately, Elastic half space theory can
also be used by referring to specialized literature. The mass of the RCC block shall not
be less than three times mass of the machine. Dynamic analysis shall be carried out to
calculate natural frequencies in all modes including coupled modes and to calculate
vibration amplitudes. Frequency and amplitude criteria as laid down by the relevant
codes or machine manufacturers shall be satisfied. Minimum reinforcement shall be
governed by IS: 2974.


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01.14.09 Temperature Control of Concrete
The temperature of fresh concrete shall not exceed 25C when placed. For maintaining
the temperature of 25C in the top decks of machine foundations, crushed ice shall be
used in mixing water.
01.14.10 Non-Shrink Grout for Equipment Foundations
Special non-shrinking grout of approved make shall be provided in strict accordance

with the manufacturer’s instructions / specifications. Ready mix non-shrink grout of
GP2 brand or equivalent, of approved make shall be used for base grouting of major
rotating equipments.
01.14.11 Stability of Structures
Design shall be checked against buoyancy due to the ground water during construction
and maintenance stages for structures like underground storage tanks, pits, trenches,
basements, etc. Minimum factor of safety of 1.2 against buoyancy shall be ensured
considering empty condition inside and ignoring the superimposed loading. For the
purpose of calculating downward load due to any overburden, only the mass located
vertically above the projected area of the base slab shall be taken in to consideration.
Maximum 500mm widening/Extension/projections all around in foundation to take
advantage of soil weight in uplift check is permissible.
All building sub-structures including pump houses shall be checked for sliding and
overturning stability during both construction and operating conditions for various
combination of loads. Factor of safety for these cases shall be taken as mentioned in IS:
456 and other latest relevant IS codes. However following minimum factor of safety
shall be followed:
 Factor of safety against overturning due to wind, seismic or other lateral load shall be
1.5 minimum
 Factor of safety against sliding shall be 1.5 minimum
 Factor of safety against uplift due to hydrostatic forces shall be 1.2 and due to any other
loads shall be 1.5
 Stability of the structure shall also be investigated for loading conditions during
construction, repair or other temporary measures. Lower factor of safety may be used
for such loading conditions as per relevant IS codes.
 In cases where dead load provides the restoring force, only 0.90 times characteristic
dead load shall be considered. Imposed loads shall not be considered as restoring force.


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01.14.12 Minimum Thickness of Concrete Structural Elements
The following minimum thickness shall be followed:

Table 2.5
Minimum Thickness of Concrete
Sl. No Description Thickness, mm
a) Suspended floor / slab / walkways /canopy slabs, etc. 125
b) Ground floor slab (non-suspended) 150
c) Water Retaining slabs / walls, partition wall 200
Cable/pipe trenches/underground pits/Launder walls
d) 125
and base slab
e) All footings (including raft foundations) 300
f) Parapets 125
g) Sunshades 75 at edge
h) Precast louvers / fins 50
i) Precast trench cover slabs / louvers 75
j) Paving 150
k) Basement walls and base slab 200
l) Silo / bin walls 200
Underground tank:
m) Below ground water table 200
Above ground water table 150
n) Metal deck floor slab (top of crest) 125
o) RCC Road 300
 From fire resistance point of view minimum cover to reinforced concrete members shall
be as per Table 16A of IS:456.
01.15 Specification of Concrete Works
i) General Description, Proportions and Mixing
Mix Design
At the commencement of the contract the Bidder shall make preliminary tests to
determine the proportions by weight of cement, fine aggregates, coarse aggregates and
water necessary to produce required grades of concrete. The mix proportions shall be
selected to ensure that workability of the fresh concrete is suitable for the conditions of
handling and placing and when concrete hardens, it shall have the required strength,

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durability and surface finish. The Bidder shall get approval of Owner/Consultant to
such proportions before he starts concreting. However, such approval shall not relieve
the Bidder of his responsibility to produce concrete having compressive strengths as
laid down in the foregoing Table.
No departure from the approved proportions will be permitted during the works unless
and until the Owner/Consultant gives written authorisation for any change in
proportion. The Owner/Consultant shall have authority at any time to check whether the
mixing of concrete is being carried out according to the approved proportions.
For the all major and important R.C. works and for all special works, the design of
mixes shall be made by the Bidder at his own cost, for each grade of concrete as well as
for various workability. The design of mixes shall be made according to I.S. 10262 or
any other approved standard methods.
The concrete made by designing the mix is termed hereinafter as "Design Mix
Concrete".
The cement content for various grades of concrete shall be based on design mix.
Minimum cement content shall be as per table 5 of IS 456.
ii) Water Cement Ratio
Where a particular water cement ratio is stipulated in the design or drawing along with
the characteristic grade of concrete the design of mix shall be carried out by adjusting
the other variable factors to obtain the characteristic strength of concrete with stipulated
water cement ratio.
In the structures where the impermeability and shrinkage of concrete have an important
bearing on the durability and serviceability of the structures, such as water retaining
structures, basements, underground premises, tunnels, pump houses, pre-stressed
structure, thin precast members etc. the water cement ratio shall be kept low and
preferably not exceeding 0.45.
The water cement ratio, as achieved in the Mix Design, or as specified in the drawings
shall be adhered to strictly and shall not be varied without the permission of the
Owner/Consultant.
iii) Workability
The workability of fresh concrete shall be such that the concrete is just suitable for the
conditions of handling & placing so that after compaction if becomes completely
consistent and homogeneously surrounds all the reinforcement and completely fills the
formwork.


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The workability of fresh concrete at the place of batching/mixing shall be measured by

compacting factor test and at the place of disposition by means of slump test. During
the finalisation of Trial Mixes, the relationship between compacting factor and slump
test shall be established for each grade of concrete as well as for various levels of
workability. The workability tests shall be carried out in accordance with IS: 1199.
Normally, in the condition of low water cement ratio as well as for medium/high
workability, the workability shall be achieved by increasing the cement content, in
consistent with added water.
In cases where the cement content is to be limited to reduce the heat of hydration, and
the water/cement ratio is also to be kept low to reduce the permeability or due to other
requirements the desired workability may be achieved with use of limited doses of
plasticiser orair entraining agent. In such cases the method of mixing and dosage of the
plasticiser/air entraining agent shall be according to the manufacturer's specification
and with the approval of the Owner/Consultant.
The usual limits of consistency for various types of structures are given below:
iv) Limits of consistency
Degree of Slump in mm with Standard Use for which concrete is suitable as

Workability - Cone per IS : 1199
Minimum Maximum
Very low 0.0 25.0 Large mass concrete structure with
heavy compaction equipment, roads
and the like.
Low 25.0 50.0 Uncongested wide and shallow
R.C.C structures
Medium 25.0 75.0 Deep but wide R.C.C structures with
congestion of reinforcement and
inserts
High 75.0 125.0 Very narrow and deep R.C.C
structures with congestion due to
reinforcement and Inserts
Note: Not withstanding anything mentioned above, the slump to be obtained for work
in progress shall be as per direction of the Owner/Consultant. With the permission of
the Owner/Consultant, for any grade of concrete, slump shall be maintained with the
usage of Plastisizers/ Superplasticizers as per the requirement. No extra payment will be
made for this addition.


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v) Durability
The durability of concrete, depending on the exposure condition, is to be taken into

account while designing the mix. For given aggregates, the cement content should be
sufficient to make sufficiently low water cement ratio and Appendix A of IS: 456 shall
be taken as guideline for durability considerations.
Minimum fire rating of 2 hours shall be considered where fire hazard is expected and
accordingly minimum cover shall be taken as per Table 16 A of IS: 456. For structures
below ground level which are exposed to sulphate attack, requirement of cement shall
be as per Table 5 of IS: 456. Intermixing of different grades of concrete in the same
structure shall not be allowed in a particular element.
Mix design concrete shall be used for all areas other than plain concrete work used for
lean concrete, screeds and backfill.
The following minimum grades of concrete as per IS: 456 shall generally be used for
the type of structures noted against each grade.
Table 2.7
Grades of Concrete
Concrete
Type of structure
mix/Grade
M10 Fill concrete
1:4:8 Blinding layer below foundations, trenches and underground
structures, foundation below brick wall, etc.
Minimum thickness of layer shall be 75 mm
1:2:4 For screed layer below water retaining structures.
M20 Plinth protection work around buildings
M25 Encasement of structural steel work, all PCC paving work,
M25 All RCC structures and equipment foundations, super structure,
grade beams, columns, roof slabs and all underground RCC
structures, cable and pipe rack foundation, pedestals, cable and pipe
trenches etc. water retaining structures below and above ground,
mill foundations, ground floor slabs, precast concrete work etc.
M-30 Water retaining structures
M-40 RCC road
Reinforcing bars shall be HYSD/TMT of grade Fe-500D conforming to IS : 1786. Test

certificate for reinforcement steel shall be obtained from required agency, before
using. All reinforcement bar shall be epoxy coated. If the steel is purchased by the
Bidder, Owner may desire to check the testing of the same & the Bidder shall
arrange it in approved laboratory at his own cost.

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01.15.01 Fine Aggregate

Fine aggregate shall be natural river sand, excluding fines. However, However, in case
of non-availability of natural river sand, manufactured/crushed sand confirming to IS:
383 and IS:2386 may be used in RCC and PCC works only, For all other purpose (e. g.
sand filling, plaster, mortar for masonry etc.) natural river sand shall be used. All sand,
unless otherwise directed by the owner, shall be graded from fine to course with the
coarse sizes predominating to give maximum density.
The amount of fine particles as ascertained by the laboratory sedimentation method
shall not exceed 4% for natural river sand and 10% for manufactured/crushed stone
sand.
The amount of material passing a 75 micron sieve (IS test sieve) shall not exceed the
following limits:-
i) Concrete subject to abrasion 1% by weight

ii) All other concrete 3% by weight
There shall be no clay or fine silt present.
The amount of hollow shells like to form voids or remain partially unfilled and present
in material retained on an IS 2.36 mm sieve, determined by direct visual separation,
shall not exceed 3% by weight of the entire sample.
Fine aggregate shall not contain appreciable amounts of flaky and/or elongated
particles.
The water absorption of fine aggregate, determined in accordance with BS 812 shall not
exceed 2.0% by weight.
Fine aggregate subjected to five cycles of the soundness test, specified in IS: 2386
(Part-5), shall not show a loss exceeding 10% when sodium sulphate solution is used
and 15% when magnesium sulphate solution is used, except where approved otherwise.
Tests are to be executed in accordance with IS: 2386. The grading of fine aggregate for
concrete work shall comply with the requirements of IS: 383.
The grading of the aggregates should be such as to produce a concrete of the specified
proportions, which shall work readily into position without segregation and without the
use of excessive water content. The grading should be controlled throughout the work
so that it conforms closely to that used for the preliminary tests.
A check on the moisture content of sand should be made at least once a day before
concreting. The amount of water to be added to the concrete mix should be adjusted
accordingly. Any washing, screening, classifying and other operations on the fine
aggregate required to meet this specification shall be done by the Bidder. Washing is

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required if the content of silt adhering to the aggregate is found to be unacceptably

high.
Sand for masonry mortar shall conform to IS 2116 and sand for plaster shall conform to
IS 1542. Sand when used as fine aggregate in concrete shall conform to IS 383. For
filling medium, grained sand (having fines less than75 microns not exceeding 20%)
shall be used.
Fine Aggregate (M-Sand) : Aggregate smaller than 4.75 mm and within the grading
limits and other requirements set in IS:383 (latest revision) is termed as Fine
Aggregate or Sand. Only Fine Aggregate from approved sources and conforming to
the above IS Specification shall be allowed to be used on works.
In case of unavailability of normal specified river sand the M sand or Crushed stone
sand shall be used with the approval of the Owner /Consultant as per given
criteria/specifications below .
i) As per Cl. 3.1.4 , of IS-383 (latest revision) the terminology of M-sand (manufactured
sand) as defined as fine aggregate manufactured from other than natural sources , by
processing materials using thermal or other processes such as separation, washing,
crushing and scrubbing. Generally the M sand or Crushed stone sand for the fine
aggregate are produced by crushing the hard stone.
The Crushed stone sand or M sand conforming to the following shall only be used as
fine aggregate in making concrete for sub and superstructures.
The Crushed stone sand is to be manufactured using VSI crushers only and not with
HSI crushers. In order to remove the fines , Crushed stone sand manufacturer should
have mechanized washing facility unit. Crushed sand stone conforming to Grading zone
–ll as per IS-383 (latest rev.) shall only be used. The M sand shall comply all the
parameters and recommendations of IS: 383 (latest rev.)
ii) The M sand shall be used only after the following tests are to be conducted by the
bidders at the NABL accredited laboratories with proven track records of performing
such type of tests by sending sealed samples of the materials -
a) Gradation Test.
b) Petrography.
c) Silt content.
d) Permeability test.
e) Adulteration test.
f) Design Mix Report.
g) Chemical Analysis Report


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Using of M-Sand/Crushed Stone Sand based on the Test reports shall only be done after
written approval of Engineer –In-Charge.
iii) The Crushed stone sand in general shall not be used for the following
structures/facilities :-
a) Structures constructed using slip form technology
b) All internal & external plastering works.
The structures where the slip form construction is envisaged the M sand or Crushed
stone sand may be used for casting its foundations only as they are not constructed
using slip form Technology.
c) Special care for design mix, cement content and necessary curing in the initial stage
shall be taken care of while using M sand /Crushed stone sand. However if the results
are not satisfactory , the use of crushed stone sand shall not be allowed for all RCC
floor slab upto and including 150 mm thickness, which are directly exposed to the
atmosphere immediately after casting. In such cases the ordinary river sand shall be
used.
d) The M sand/Crushed stone sand manufacturing locations shall be inspected by the

Owner before giving approval for supply. The bidder shall ensure that the
manufacturing process is done using only VSI crushers & shall have mechanized water
washing unit for removal of fines in the Crushed stone sand manufactured.
Aggregates smaller than 4.75 mm and within the grading limits and other requirements
set in IS-383 (latest rev.) as termed as fine aggregate . Only fine aggregate from
approved sources and conforming to IS- 383 (latest rev.) shall be used for execution.
The bidder shall have well developed site laboratory and quality control team to take
extra care while manufacturing and casting concrete using M sand/ Crushed stone sand.
Normally, any particular structure shall be constructed by using any one type of sand
(fine aggregate) only as per the direction / approval of engineer-in-charge. In general, it
is not permitted to use different types of sand in any particular structure.
01.15.02 Coarse Aggregates
Stone chips shall be used as coarse aggregate. It shall be crushed or broken from hard
stone obtained from approved quarries of igneous or metamorphic origin. The stone
chips shall be hard, strong, dense, durable and angular in shape. It shall be free from
soft, friable, thin, flat, elongated or laminated and flaky pieces and free from dirt, clay

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lumps, and other deleterious materials like coal, lignites, silt, soft fragments, and other
foreign materials which may affect adversely the strength & durability of concrete. The
total amount of deleterious /foreign materials shall not exceed 5% by weight according
to relevant clause of IS: 383-1970. If found necessary the stone chips shall be screened
and washed before use.
01.15.03 Cement
Ordinary Portland cement / Portland slag cement complying with the requirements of
IS:269-2015 and I.S. 455-2015 respectively shall be used for making plain and
reinforced concrete, cement grout and mortar.
Other types of cement may be used depending upon the requirements of certain jobs
with the approval of the Engineer. These shall conform to the following standards :
Testing of samples:
The Contractor shall supply a copy of the manufacturer's test certificate for each
consignment of cement supplied by him and consignments shall be used on work in the
order of delivery. The Contractor shall supply samples of cement to the Engineer as
frequently as he may require for testing. The sampling of cement for testing shall be
according to IS: 3535-1986. All tests shall be in accordance with the relevant clauses of
IS: 4031 (Part-I to Part-15) 1988 to 1991 & IS: 4032-1985.
Contractor's responsibility:
From the time a consignment of cement is delivered at site and tested and approved by
the Engineer until such time as the cement is used on the works, the Contractor shall be
responsible for keeping the same in sound and acceptable condition and at his expense
and risk. Any cement which deteriorates while in the Contractor's charge and is
rejected as unsuitable by the Engineer, shall be removed from the site to outside the
limits of work at the cost of contractor within two days of ordering such removal by the
Engineer.
Stock of cement:
In order to ensure due progress, the Contractor shall at all times maintain on the site at
least such stock of cement as the Engineer may from time to time consider necessary.
No cement shall be used upon the works until it has been accepted as satisfactory by the
Engineer.
Storage of cement:
The cement shall be stored in such manner as to permit easy access for proper
inspection and in a suitable weather-tight, well ventilated building to protect it from
dampness caused by ingress of moisture from any source. Different types of cement


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shall be stored separately. Cement bags shall be stacked at least 15 to 20 cm clear of

the floor leaving a space of 60 cm around the exterior walls. The cement shall not be
stacked more than 10 bags high. Each consignment of cement shall be stacked
separately to permit easy access for inspection.
01.15.04 Water
Water used for mixing concrete and mortar and for curing shall be clean and free from
injurious amounts of oil, acid, alkali, salts, sugar, organic materials or other substances
that may be deleterious to concrete or steel. The pH value of water shall generally be
not less than '6'. Water has to meet the requirements mentioned in clause 4.3 of IS:
456-1978. Water shall be obtained from an approved source.
Where it is obtained from a source other than a supply main, it shall be tested to
establish its suitability. Water for construction purpose shall be stored in proper storage
tanks to prevent any organic impurities getting mixed up with it.
01.15.05 Admixture for Concrete
Approval
Admixtures to concrete shall not be used without the written consent of the Engineer.
When permitted, the Contractor shall furnish full details from the manufacturer and
shall carry out such test as the Engineer may require before any admixture is used in the
work.
Types
Integral water proofer
Admixtures used as integral water proofer shall be free of chlorides and sulphates and
shall conform to IS: 2645-2003. The application and doses shall be as per
manufacturer's specification.
Interval of Routine Test
The routine tests of materials, delivered at site, shall be at the following intervals:
Aggregates - Fortnightly or for every 200 m3 for each aggregate

whichever is earlier and in other respects generally as per
IS : 2386 (Part 1 to 8)-1963.
Cement - Fortnightly or for each consignment, within 4 days of

delivery and in other respects generally as per IS : 4031.


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Water - Once in two months for each source of supply and in other
respects generally as per IS : 456-2000.
Reinforcement - For each consignment within 4 days of delivery in

accordance with I.S. 1786-2008, I.S. 1599-2019 and I.S.
1608-2018.
01.15.06 Steel
For Reinforcement
Reinforcing bars for concrete shall be round steel bars of the following types as may be
shown on the drawing:
i) Plain mild steel bars conforming to Grade-I of IS : 432 "Mild Steel & Medium Tensile
Steel for Concrete Reinforcement".
ii) High strength deformed steel bars/TMT bars conforming to IS : 1786 for Concrete
Reinforcement.
iii) Reinforcement fabrics conforming to IS:1566 "Hard Drawn Steel Wire Fabric for
Concrete Reinforcement"
All reinforcement bars shall be of uniform cross sectional area and be free from loose
mill scales, dust, loose rust, coats of paint, oil or other coatings which may destroy or
reduce bond. Unit weight of reinforcement bars conforming to I.S. 1786 is as given
below.
Nominal Size (Dia) Mass Per Metre Run

(mm) (Kg)
6 0.222
8 0.395
10 0.617
12 0.888
16 1.580
18 2.000
20 2.470
22 2.980
25 3.850
28 4.830

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32 6.310
Binding wire
Binding wire for reinforcement shall be annealed steel wire 20 BWG conforming to IS :
280 -2006 "Specification for Mild Steel Wire".
Light structural work and inserts
Steel for light structural work and for preparation of inserts and embedments shall
conform to IS: 2062-2011 "Steel for general structural purposes - Specification."
Steel Tubes
Steel tubes for use in light structural work and inserts shall be of light or medium class
(as may be specified in drawings or the schedule of items) and of grade YST 25
conforming to IS : 1161 - 2014"Specification for Steel Tubes for Structural Purposes".
Foundation Bolts
Bolts to be embedded in concrete shall, unless otherwise detailed in drawings, conform

to IS : 5624-1993 "Specification for Foundation Bolts". Material for bolts, shall, unless
otherwise mentioned in drawings or the schedule of items, be of steel conforming to IS :
2062-2011.
Nuts and locknuts shall conform to IS : 1363 (Part 1 to 3) -2018 "Specification for Black
Hexagon Bolts, Nuts and Lock Nuts (Diameter 6-39 mm) and Black Hexagon Screws
"Specification for Hexagon Bolts and Nuts (M-42 to M-150)".
Plain washers shall conform to IS : 2016 "Specification for Plain Washers and spring
washers shall conform to IS : 3063 "Spring Washers for Bolts, Nuts & Screws".
Steel Tubes for Non-structural use
Steel tubes for non-structural use shall conform to IS : 1239 (Part-I) "Specification for
Mild Steel Tubes, Tubular and Other Wrought Steel fittings, Part-I : Mild Steel Tubes".
Fittings for steel tubes used for non-structural purposes shall conform to IS : 1239 (Part-
II) "Specification for Mild Steel Tubular and Other Wrought Steel Pipe Fittings".
Threaded Fasteners
Bolts and nuts for fastening shall conform to IS:1367 (Part 1)-2014 "Technical Supply
Conditions for Threaded Fasteners".


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Testing
Test certificates from manufacturer shall be submitted for each consignment. Any
additional test which the Engineer may require shall be done according to IS : 1786,
1566, 280, 2062, 1161, 3063, 1239 (Part 1 and 2) and 1367.
Cast Steel
Quality
Cast steel shall conform to IS : 1030 "Carbon Steel Casting for General Engineering
Purpose". Unless otherwise specified, it shall conform to Grade2.
Conduits
Steel for electrical wiring
Rigid steel conduits for electrical use shall conform to IS : 9537 (Part 2) for rigid pipes
and to IS : 3480 for flexible conduits. Fittings for conduits shall conform to IS : 2667.
All conduit pipes shall be finished with galvanised or stove-enamelled surface. All
accessories shall be of threaded type and pipes shall be jointed by means of screwed
couplers only. Bend in conduits shall be made to the dimension shown in drawing, but a
minimum of 12 times the diameter. Where shown in drawing they shall be treated with
anticorrosive preservative as specified.
Non-metallic conduit for electrical wiring
Non-metallic conduits for electrical use shall conform to IS : 9537 (Part 3) -1983 for
rigid pipes. Fittings shall conform to IS : 3419-1989.
Bends shall be achieved by bending the pipes by inserting suitable solid or inspection
type normal bends, elbows or similar fittings.
Brick works – internal and external
230 mm thick fly ash brick wall with 1:6 Cement- Sand mortar. All non load bearing
Brick work as mentioned in this document shall be with Fly Ash Bricks unless noted
otherwise. Chamber burnt clay bricks shall be used for any non load bearing brickwork
in case of non-availability of Fly ash bricks, subject to the approval of MTPS-I.
Fly Ash Bricks :The Fly Ash Bricks shall conform to IS 12894. The dimensions of the
Flyash bricks shall be 190x90x90mm. Visually the bricks shall be sound, compact and
uniform in shape free from visible cracks, warpage, flaws and organic matter. The bricks
shall be solid and with or without frog on one of its flat side. Fly ash shall confirm to IS
3812.

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Note : Fly ash bricks shall be operated only for non-load bearing walls
Sand : Deleterious materials, such as clay and silt in the sand shall preferably be less
than 5%.
Additives : Any suitable additive considered not detrimental to the durability of bricks
may be used.
01.16 Quality Assurance
The successful bidder shall submit Field Quality Assurance plan for Civil, Structural
and Architectural works for approval of Owner /Owner's consultant.
 The Bidder shall provide a site laboratory with equipment and shall maintain and
engage qualified technical personnel at site to run the laboratory for routine test at his
own cost and to ensure quality of construction and testing of all materials and works
conforming to specifications.
 All defective materials / works which do not conform to the specifications shall be
rejected / dismantled and removed from site by the Bidder at his own cost.
 For those tests which are not possible to be carried out at site laboratory, Bidder shall
arrange to send requisite samples to approved laboratory outside the site and get those
tested as required entirely at his cost.
 Before starting any concreting or erection work at site, the stage passing certificates
have to be obtained from the engineer in the formats prepared after mutual discussion
and agreement.
 Before covering up any work within excavated pits, clearance has to be taken from
engineer in respect of completion of said works as per drawing and specification.
01.17 Safety
The Bidder shall ensure that the safety requirements are met in respect of men,
materials, adjoining structures, equipment etc. and shall be totally responsible in case
any mishap occurs due to negligence or otherwise. In this connection the bidder shall
strictly adhere to the rules norms and regulations as applicable. The successful bidder
shall collect safety rules from the client. The successful bidder shall strictly adhere to
the safety regulations mentioned therein. The penalties for violation of safety norms as
per MTPS-I stipulations are applicable. To ensure effective enforcements of the rules
and requirements relating to safety protection arrangement made by the bidder shall be
open to inspection by MTPS-I.


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In case of complicated work like deep excavation, intricate shuttering and formwork,
excavation in loose soil and below water table, stacking of excavated earth etc., work
plan with necessary drawings and documents have to be prepared by the Contractor and
got approved by the Engineer.
Necessary reference shall be made to the following Indian Standard Codes on safety
requirements for various type of work.
4081 Blasting & Drilling.
5916 Construction with Hot Bituminous Materials.
3764 Excavation Work
5121 Piling & Other Deep Foundations.
4014 - (P-II) Scaffolding, Steel Tubular.
3696 - (P-I & P-II) Scaffolds and Ladders.
6922 Structures Subject to Underground Blasts.
4138 Working in Compressed Air.
8989 Erection of Concrete Framed Structures.
7293 Working with Construction Machinery
Safety requirements for Civil works provided in latest IS Codes shall be referred and
adhered to.
01.18 Design calculations, drawings and documents
01.18.01 Design calculations
The design calculations to be submitted by Bidder prior to submission of construction

drawing shall include but not be limited to the following:
a) Architectural design
The Bidder shall adhere to the norms and basic schemes indicated in the Technical
Specification. The Bidder shall submit all catalogues/specifications for various floors

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and wall finishes, painting, sanitary and plumbing fixtures and fittings, doors and
windows, etc. Architectural drawings shall be prepared based on approved General
Arrangement drawings of relevant system.
b) Building structure and foundation design
 The design calculations for all the buildings and foundations miscellaneous structures,
all equipment foundations etc. shall be furnished. The design calculations shall include
static design calculations dynamic analysis for all important structures and foundation
subjected to impact, vibrations etc. induced by equipment and other external forces.
 Building data sheet showing specifications of materials, design standards followed, load
data assumed including the loading on roof, walkways, different floors, bulk material
density, crane and hoist loading, wind and seismic loading, wind thrusts and vibration
considerations, deflection, rainfall and run-off data assumed and type of framework etc.
shall be furnished. Also, type of flooring, roofing and sheeting and type of construction
are to be indicated. The loading combinations and other design assumptions made in
design are to be furnished.
 Methods to be followed for (a) waterproofing, (b) Corrosion protection (c) thermal
insulation of various areas to be submitted by bidder.
 Measures required for the safety of the buildings and foundations.
 Structural design /drawings shall be prepared based on Approved Architectural and GA
drawings and submitted accordingly for Owner’s approval.
 The following shall be furnished by the Bidder along with design calculations:
- Scheme of loads.
- Result of analysis member forces in design calculation for corrective chosen based on
permissible stresses, deflection, natural frequency etc.
- All documents shall be submitted as per engineering sequence of document submission
(e. g. Foundation design drawings shall be submitted after approval of superstructure
Analysis, design and drawings). Documents with approved input data shall only be
submitted for Owner’s approval by the Contractor.
01.18.02 Drawings
a) Drawings for concrete, reinforced concrete and other civil work
 The Bidder shall prepare general layout drawings giving salient levels and dimensions
of the whole area within the battery limits showing all over ground and underground
services and facilities, buildings, roadways etc. Detailed working drawings shall be
prepared on the basis of the general layout drawings considering overall foundation
layout for the equipment, building services etc., space requirement and clearances as
necessary. The Bidder shall ensure that no further drawing shall be required to be


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prepared by any other agency for successful implementation of the project. The Bidder
shall submit a comprehensive and complete unit wise classified list of drawings.
 The Bidder shall submit for approval or information as the case may be as per
classification given below , general arrangement and detailed working drawings for all
concrete, reinforced concrete and other civil works as follows:
- Architectural drawings for all buildings.

- Loading drawings indicating superstructure loading, equipment loading, floor loadings,
etc.
- Foundation plans and sections for building columns and equipment incorporating
trenches, pipes etc.
- Comprehensive anchor hole plan along with complete details of anchor bolts and
anchor pockets for foundation for building columns and equipment etc. including
schedule for bolts and anchor plates. Design of anchor bolts should be such that it
should be possible for any replacement of the same in case they get damaged.
- Reinforcement details with bar bending schedule for all reinforced concrete works.
- Drawings for all types of bolts, inserts, embedment, miscellaneous steel works, etc.
- All drawings for masonry work, flooring, floor finishes, partitions, false ceiling/floors
etc.
- Necessary sanitary and plumbing drawings.
- Underground faecal sewerage and storm water drainage drawings for areas and
buildings within the battery limit.
- Drawings/catalogues for doors, windows, ventilators, louvers, furniture, miscellaneous
equipment like laboratory etc.
- Drawings for roadways, paved areas and parking areas etc. along with culverts, bridges
etc. as required.
- Detailed bill of materials of all items of work.
- All drawings required for obtaining approval from statutory bodies/local authorities etc.
shall be prepared by the Bidder.
- Bidder shall submit As-built drawings incorporating all site modifications for record
purpose.
01.19 List of Civil Engineering Deliverables for Approval/ Information
Group-1: For Approval
a) Drawing numbering system

b) List of drawings, with document & drawing nos., title along with Schedule submission
dates
c) Basic design criteria and loading for all buildings, structures and foundations.


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d) Types, specification and details of doors, windows, louvers, floor finishes, roof
finishing, partitions, false ceiling, false floor, G.A. of toilet blocks etc.
e) Colour Scheme of all the buildings (For Owner’s approval).
f) Detail of partitions, expansion joints, counters/platforms, stair, balustrade, canopy,
chajja, parapet, gutter, down pipes etc.
g) Design calculations along with load data for buildings, foundation for equipment and
structures, auxiliary facilities etc.
h) Structural drawings for Civil buildings/framed structures, equipment foundations and
other foundations and structures showing dimensions of structural elements like slabs,
beams, columns, foundations etc.
i) Plan and sectional drawings with all dimensions and details for foundation of
equipment and structures, auxiliary facilities etc.
j) Reinforcement drawings with all dimensions and details for foundations of equipments
and structures, auxiliary facilities etc.
k) Design, Layout and sectional details of roads, road crossings, man holes, pits etc.
l) Design, layout and sectional details of drainage network with all invert levels, slopes,
sizes, dimensions, manhole top level etc.
m) Standard General Notes/Specifications.
Group-2: For Information & Comments, if Any
a) Standard drawings
b) Soil Investigation Report
c) Layout and sectional details of sewage network with all invert levels, slopes, sizes,
dimensions, manhole top level etc
d) Bar Bending Schedule. However, Observations, if any, on compliance of
Reinforcement Area in R.C.C. drawings with respect to design calculations shall be
made.
e) Detail of bolts, inserts/embedment’s, coverings, hand railings, ladders etc.
f) Sanitary and plumbing detail drawings.
g) Rain water Harvesting report (approved by Authorised Govt. Agency)
Review category for any other drawings not mentioned in above two categories shall be
decided later considering their importance and utility for the project.
Group-3: As-Built Drawings
Soft Copy in 5 CD’s of all ‘As Built’ drawings shall be submitted.

Hard copy in 5 no. of all ‘As Built’ drawings shall be submitted.


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ANNEXURE - I
GEOTECHNICAL STIPULATION
01 Introduction
The Geotechnical stipulation furnished herein shall be considered by all the

turnkey bidders for Civil foundation design of this package. If any deviation is
found between any clause set out in this document & in any earlier clarification,
the clause set out in this document shall govern.
The stipulation furnished herein shall be followed for bidding, designing,

engineering & execution of all civil foundations for this package.
The bidder shall visit & carefully examine the site & surrounding, before
submission of bid, to acquaint himself about general site condition, terrain, existing
filling, depth of rock layer, accessibility, existing features, existing structures,
existing underground services and all other conditions & matters affecting the work
and build up his rates accordingly. Claims and objections due to ignorance of site
condition shall not be considered after submission of bid.
02 Sub-Surface
The sub-surface generally consists of a top Fill layer, followed by weathered rock
layer at reasonably shallow depth.In some locations, Virgin soil layer may be
observed below Fill layer & above weathered rock layer.The bidder shall consider
the general layout, level of Original Ground and final Terrace Level (TL) of
different structures. Accordingly, choice of foundation shall be made, as per
provision of this geotechnical stipulation. To get indicative idea of sub-surface
stratification, reference can be drawn from the findings in nearby ESP location at
unit-IV of MTPS-1, where, in a Trial Pit location, weathered rock layer has been
reportedat 1.65 m depth, underlying top Fill layer.However, Depth &/or Thickness
&/or Presence &/or Nature of different strata &/or Existing Ground Levels (EGL),
may vary within the battery limit of the package, for which no commercial
implication shall be entertained at any stage of the project. It is the responsibility of
the bidder to assess the rock depth of the subject package location, by suitable
means.
The successful bidder shall conduct geotechnical investigation, at specific locations

as per final plant layout. However, for design purpose, the maximum limit of Net
Allowable Bearing Capacity (NABC) / Pile Capacity, shall be restricted to the
stipulation furnished in this document. As such, for Bearing Capacity & Depth of
Open foundation and for Capacity, Diameter &Length of Pile foundation, the
conservative values among the i) outcome of turnkey contractor’s geotechnical
Vol. – VA GEOTECH Page 1 of 5


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investigation &ii) the stipulation of this document, shall have to be adopted,

without any commercial implication whatsoever.
03 Choice of Foundation
Generally, at this site, structures shall be founded on Open foundation within

weathered rock layer. However, maximum permissible capacities for other
foundation options are also stipulated, in case these are required to be adopted as
per following rationale.
i) Depending on design requirement &/or depth & thickness of different strata &/or
constructability aspect, either Open foundation or Pile foundation shall be adopted.
ii) Open foundation, either in Fill or Virgin Soil layer or in weathered / disintegrated
Rock layer, may be adopted for the proposed structures, conforming to design
requirement, following the recommended maximum limit of NABC stipulated
herein, satisfying the relevant provisions of section 03.A of this document.
iii) In case, the stipulated NABC of Fill or virgin Soil or Rock layer for Open
foundation, is found to be inadequate for particular structure &/or required depth of
Open foundation is found to be too deep from construction aspect &/or Open
foundation is not practically possible due to close proximity of adjacent
structure/slope &/or there is technological / functional / constructability
requirement for pile foundation &/or thickness of Fill below TL is more than 6.0 m
&/or provision/s of Open foundation under clause No. 03.A of this stipulation is
not fulfilled, then Pile foundation shall be adopted.
iv) Higher SPT ‘N’ value in Fill, wherever encountered, shall not be considered as
representative parameter of Fill layer.
v) For Design purpose, Ground Water Table (GWT) shall be considered at respective
TL.
03.A Open Foundation
03.A.01 MinimumDepth of open foundation shall be 1.5 m from TL.
03.A.02 In case, any localized soft / loose spot is encountered at founding level, the same
shall be replaced by PCC (M-10).
03.A.04 Open Foundation in Virgin Soil or Fill


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Only very lightly loaded, unimportant, structures may be placed in Open

foundation on virgin soil or Fill.
The maximum value of Net Allowable Bearing Capacity of Open foundation

placed within Virgin Soil or Fill (wherever applicable), shall be limited to 5 ton/m2
at1.5 m depth from TL without any increase with depth.
Maximum Width (B) of Open foundation shall restricted to 2.0 m.
Design Bulk Density of Virgin soilor Fill shall be considered as 1.70 gm/cc.
Net Allowable Bearing Capacityis furnished considering the maximum permissible

total settlement of 40 mm.
03.A.05 Open Foundation in Rock layer
In weathered Rock layer, encountered at varying depths within this site, Open
foundation shall be placed with an embedment not less than 600mm within such
layer, for which the maximum value of Net Allowable Bearing Capacity, shall be
limited to 30 ton/m2for any size of footing. However, with an embedment of at
least 1500 mm within weathered rock layer, the maximum value of Net Safe
Bearing Capacity shall be limited to 35 ton/m2for any size of footing.
There will not be any increase in Net Safe Bearing Capacity with depth, apart from
the above.
Design Bulk Density of rock shall be considered as 2.1 gm/cc.
Precautionary measures for Safety of Foundation placed on rock layer, shall follow
the relevant clauses of Section 6, 7 & 8 of IS : 13063 - 1991.
03.A.06 Excavation in Rock Layer :
Excavation aspects in Rock layer shall be considered by the bidder from their
Expertise / Experience, Methodology of rock excavation to be adopted, Type of
Equipment to be used, Capacity of Equipment to be used, Site Visit information,
Expert’s observation of rock found in natural & man-made excavation in & around
site, Information gathered from earlier excavations, Study of regional Geology and
any other required considerations for rock excavation. The bidder is solely
responsible for such assessment on excavability of rock layer at any depth. The
geo-engineering description of Rock Core specimen or any test parameter of
individual rock specimen shall not be treated as Rock Mass characteristics for
excavation purpose. No extra claim shall be entertained at any stage of work due to
type of rock encountered during excavation.


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Penetration aspects in rock layer for rock-socketed pile, shall also be solely
considered by the bidder following the similar considerations furnished above for
rock excavation.
3.B Pile Foundation
In case, Pile foundation is adopted, then Bored Cast-in-situ RCC (M-30) Pile shall
be used. The piles shall be bored cast-in-situ cylindrical type RCC piles of 500 mm
&/or 550 mm &/or 600 mm &/or 750 mm &/or 1000 mm diaterminated within
underlying specified weathered rock (& not boulder) layerwith a rock- socket
length not less than 4D (where D is the diameter of the pile) within such weathered
rock layer, to achieve the design capacity. Minimum center to center spacing
between adjacent piles shall be 2.5 D.
With stipulated rock-socket length within such rock layer, to achieve the design
capacity. Minimum center to center spacing between adjacent piles shall be 2.5 D.
The weathered rock for pile socketing shall be recognized by identifiable rock
texture/fabric in the bored material as well as by SPT ‘N’ > 100.
The maximum capacities of such piles shall be limited to the following.
03.B.01 Recommended maximum Vertical Capacities of single Pile ( Ton )
Termination Loading Pile Diameter (mm)

Depth Pattern 450 500 550 600 750 1000
with a socket
length of not
Compressive 70 90 105 130 200 350
less than 4 D
within
weathered
Uplift 27 + w 33 + w 40 + w 48 + w 75 + w 135 + w
rock layer
where, w = Buoyant weight of Pile shaft.
03.B.02 Lateral Pile Capacity
Following stipulations shall be followed for Lateral Capacity of Piles.


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Recommended Lateral Capacities of single Pile ( Ton ) :

(for fully Fixed Head condition)
Maximum value of Lateral Capacity shall be limited to the following.
Pile Diameter (mm)

Parameter
450 500 550 600 750 1000
Lateral
Capacity 2.5 2.9 3.4 3.9 5.5 8.8
(ton)
Zf (m) 5.1 5.6 6.0 6.5 7.7 9.7
For fully Free Head condition, the above capacities shall be reduced to one-third.
Maximum moment due to lateral load shall be evaluated as per Section C-4.3,
Appendix C, of IS : 2911 (Part-1/Sec 2) -2010. ‘Zf’ is the depth of fixity as
defined in the above code.
03.B.03 In case, Pile foundation is adopted, the enclosed Piling TS shall have to be
followed for the same.


(4X210MW)
FOR
TECHNICAL SPECIFICATION FOR

CAST-IN-SITU BORED PILING
MECON LIMITED
RANCHI – 834 002

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01 General
This specification covers the Piling work, required for the Installation of
F.G.D. System at MTPS-1 of Mettur Thermal Power Station of TANGEDCO,
Tamilnadu.
The bidder shall visit & carefully examine the site & surrounding, before
submission of bid, to acquaint himself about general site condition, terrain,
accessibility, existing features,underground utilities, existing structures, and all
other conditions & matters affecting the work and build up his rates
accordingly. Claims and objections due to ignorance of site condition shall not
be considered after submission of bid.
The Termination criteria &maximum Capacity of different diameter piles in

different mode of loading are stipulatedin Geotechnical Specification.
Bored Cast-in-situ cylindrical RCC pile passing through different strata&

terminated at stipulated depth shall be considered. Capacity of different
diameter piles,as furnished in Geotechnical Specification,shall be confirmed
by the turnkey contractor by Load Test on Initial Trial Piles & Routine Load
test on working piles as per IS : 2911 (Part 1, Sec 4), to ascertain that the
tested capacities are not less than the corresponding design capacities. Increase
of stipulated pile capacities &/or decrease in stipulated termination depth, shall
not be acceptable at any stage of the project.
02.01 Codes
Any Standard / Code mentioned in this specification means its latest revision
including amendments, if any.
IS:2911 (Part 1/Section 2) - 2010 : ‘Code of practice for design &

construction of Bored Cast- in- Situ concrete piles’, IS : 2911 (part 4) -1985
‘Load Test on Piles & IS : 14593 : 1998 : ‘Design And Construction of Bored
Cast-in-situ Piles founded on Rocks – Guidelines’ shall be referred to in
conjunction with this specification during the entire design, construction &
Load Testing work. These codes form the integral part of this specification.
If for any material or workmanship, appropriate Indian Standards or Codes are
not available or have not been adequately specified in the Technical
Specification, such materials & workmanship shall conform to other suitable
Standard & Codes, as may be approved by NMDC/MECON.
In case of any conflict between the requirement of this specification & those of
the referred codes / standards, the former shall govern.
Any special requirements as shown or noted on the approved project drawings

shall govern over this specification.
 Vol. – VA  PILE Page 2 of 12

 © 2020 MECON Limited. All rights reserved.

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02.02 Design
The piles shall be bored cast-in-situ cylindrical type RCC (M-30 grade) piles
not shallower than specified depth.
The Capacities of Pile (in Compression, Uplift, Lateral) for different diameter
Piles, terminated at different depths,are stipulated in the Geotechnical
Specification. Such stipulations will be binding to all turnkey bidders for
bidding, designing, engineering & execution of all pile foundations for this
package.
The contractor shall submit the reinforcement design of pile for approval of
TANGEDCO. Such structural design shall be based on pile capacities
specified in the Geotechnical Specification.The contractor need not submit any
calculation for evaluation of geotechnical capacity of pile.
02.03 Materials
All the materials proposed to be used, shall be free from any objectionable
substances, shallconform to the following stipulation & shall be approved by
TANGEDCO. Any testing required to prove the suitability of such materials
shall be carried out by the contractor at his own cost & in presence of
TANGEDCO. Any material rejected by TANGEDCO shall be immediately
removed from the site.
02.03.01 Reinforcement steel shall conform to High yield strength deformed bars of
grade Fe 415 as per IS:1786and for stirrups/links mild steel reinforcement
conforming to IS:432 may be used. For marine / coastal / corrosive
surroundings, corrosion resistant bars shall be used. Test certificate for
reinforcement steel shall be obtained from recognized agency, before using. If
the steel is purchased by the contractor, TANGEDCO may desire to check the
testing of the same and the contractor shall arrange it in an approved
laboratory at his own cost.Reinforcement shall be provided for full depth of
pile as furnished in the approved drawing.
02.03.02 Reinforced Cement Concrete for Piles shall be of Grade M-30 using 20 mm &
downgraded stone aggregates. The slump of concrete shall range between 150
mm to 180 mm. The water-cement ratio shall not exceed 0.5. To achieve the
specified slump using specified water cement ratio without compromising with
strength, suitable plasticiser, if required, may be used at no extra cost, subject
to approval of TANGEDCO. If concentration of Sulphate (measured as SO3)
exceeds 0.5% in soil or 1200 ppm in ground water, sulphate resisting cement
shall be used.


& ITS AUXILIARIES
02.03.03 The cement shall be Ordinary Portland Cement conforming to IS:269 or

Portland Pozzolona Cement conforming to IS :1498 or Blast Furnace Slag
Cement conforming to IS:455. Each batch of cement supply shall be
accompanied by valid manufacturer’s certificate.
02.03.04 The physical properties, mechanical properties & gradation of coarse & fine
aggregate shall follow IS:383. Testing of aggregate properties (if desired by
TANGEDCO) shall follow relevant parts of IS:2386.
02.03.05 Water used for concrete shall be clean & free from injurious amount of
harmful substances in such amounts that may impair the strength & durability
of pile concrete. Generally potable water shall be considered satisfactory. In
case of any doubt felt by TANGEDCO about the quality of water, contractor
has to prove that the concrete prepared with proposed water shall not have a
compressive strength lower than 95% of the strength of similar concrete
prepared with distilled water.
02.03.06 Preliminary mix design shall be done in accordance with IS:10262& SP:23
subject to approval of the customer. Cube tests, slump test & other relevant
tests for preliminary mix design and Routine cube test, slump test for regular
concreting shall be carried out at site / site laboratory at contractor's own cost.
Concrete cube tests shall be done as per IS : 516. The calibration certificate
(not older than one year) of the testing machine shall be available at site. If
TANGEDCO feels any doubt about the calibration, the contractor has to check
the same at an approved laboratory at his own cost. All such tests shall be
conducted in presence of TANGEDCO. At least one set (3 cubes for 7 days &
3 for 28 days strength) of cube shall be tested for every 5 piles or at any
deterioration in concrete quality if felt by TANGEDCO, whichever occurs
earlier.Slump tests (apparatus conforming to IS:IS:7320) shall be carried out at
least once for each pile or more frequently, if desired by TANGEDCO.
02.04 Equipment & Accessories
The equipment & accessories should be compatible with the type of deposit,
method of installation, type of founding strata & required penetration in the
founding strata.
The capacity of rig shall be adequate so as to bore upto required depth

including stipulated rock socketing. Rig shall be equipped with suitable Chisel
&/or Bailer &/or Cutter capable to penetrate through any Local
Obstruction&/orHard stratum.
No excuses, whatsoever, in relation to the inability of equipment shall be

entertained during execution of work.


& ITS AUXILIARIES
Contractor must furnish a detailed list of equipment, accessories& spares (all

in sufficient quantities to complete the job within scheduled time frame & as
per specification) to be deployed by him for this job, indicating quantity, type,
capacity/dimension & model/make of each along with his offer & reconfirm
the same in writing immediately after mobilisation to site.
02.05 Construction
02.05.01 Piles shall be installed as accurately as possible as per approved drawing.

Permissible positional deviation shall be as per clause 7.1. 2, IS: 2911 (part
1/sec 2).
02.05.02 (A) In areas, where heterogeneous Fill & other industrial wastes are encountered,
Boring shall proceed by driving suitable Bailer - Chisel, extracting the bored
material with the boring tools & simultaneously advancing the casing
(temporary or permanent, as the case may be). The hard pieces shall be broken
by Chisel / Hard-face shoe of Bailer & shall be extracted by the Bailer. While
boring in soft material liable to cavitation, boring tools shall not be operated at
a level below the toe of the casing. The Care shall be taken to ensure that the
volume of water added to the bore shall be no more than the minimum
necessary for the operation of the boring tools. The temporary casing shall be
driven down through the soft material to penetrate a hard stratum not subjected
to cavitation and shall be sealed in this material as far as possible. Thereafter
the boring shall be continued by means of boring tools until the approved
bearing layer is reached.
02.05.02 (B) In areas, where piling is to be started right from virgin soil deposit, pile boring
may be done either by Bailer - Chisel method or by rotary boring with mud
circulation process. In rotary boring method, stabilisation of the side of
borehole can be done by the use of bentonite slurry. Either, Direct Mud
Circulation (DMC) or Reverse Mud Circulation (RMC) process shall be
adopted depending on soil condition & pile dimension. In such cases, the
bentonite slurry must be used at least from the level of sub-soil water, & the
hole should then be always kept almost full with the fluid. The density of
bentonite slurry shall be in the range of 1.05 to 1.12. During installation of
Trial piles, the exact density of bentonite to be used, shall be made specific
depending on site-condition. After standardization, the density of bentonite
slurry shall be maintained although the project & checked regularly at an
interval of 5 piles or at any change in its specified quality if felt by the
purchaser, whichever occurs earlier. Pressure of slurry pump shall be sufficient
enough to clear out all cuttings efficiently from the hole.
02.05.02 (C) Hydraulic rotary Piling rig can be used, for any type of areas mentioned above,
subject to its suitability.


& ITS AUXILIARIES
02.05.03 At the last stage of boring or in intermediate hard layers chisel or chopper may
be used. The rate for piling work should be inclusive of any chiseling,
chopping of hard strata, clearing of bottom of pile bore hole etc. complete as
per specifications. The piles shall be installed with due consideration for safety
of adjacent structures by a method which leaves their strength unimpaired and
which develops and retains the required bearing resistance.
Proper precaution shall be taken to prevent any collapse of overlying soil due
to impact / vibration caused by chisel during penetration through hard stratum.
02.05.04 Reinforcement as required shall be made into stiff cages sufficiently welded to
withstand handling without any damage or distortion. Reinforcement shall be
placed immediately after cleaning and inspection of the bottom of bore holes.
The reinforcement should be supported away from the sides of the shaft by
means of suitable space block to ensure concentric alignment in the shaft.
Steps shall be taken to ensure correct positioning during concreting of
reinforcement in the piles without any distortion. The clear cover to main
reinforcement shall not be less than 50 mm.
02.05.05 Immediately before placing of reinforcement and concreting, the bored hole
shall be cleaned of all the loose material, debris and all the water shall be
removed. The pile tip zone shall be thoroughly cleaned by flushing the bore
with fresh Bentonite slurry to completely replace the old Bentonite slurry used
during the previous operations. This shall be carried out for 45 minutes in two
stages. Cleaning for initial 30 minutes shall be done before lowering of
reinforcement cage & final 15 minutes after lowering the reinforcement cage.
02.05.06 Concrete shall be so placed as to fill the entire volume of the tube or bore
without the formation of voids caused by the faulty consolidation or entrapped
air. Proper care shall be taken to ensure that the fluid alluvial soil does not
penetrate between batches of the concrete.
In case of bore holes stabilised by Bentonite slurry, concrete shall be placed by

means of tremie pipe which will be suitably closed at bottom at the start of
concreting. The tremie pipe must extend upto the bottom of the borehole at the
start and may be withdrawn in sections as the level of concrete rises in the
borehole; but its discharge end shall at all times be embedded in the concrete
to a minimum depth of 500 mm. Placing of concrete should be continuous and
the pile holes will be maintained full with the bentonite slurry, wherever used,
throughout the concreting operation. Slurry displaced from the borehole by the
concrete, shall be channeled away or pumped into suitable receptacles for re-
use or disposal to waste.
In case of cased holes, after the required founding level is encountered, the
bottom shall be sealed with concrete and the reinforcement cage shall be
lowered. If the borehole is dry, concrete shall be deposited in such a manner so


& ITS AUXILIARIES
as to avoid any segregation of concrete followed by gradual withdrawal of

casings. If water is present in the borehole, it shall be bailed out by bailer. If
it is difficult to dewater by the bailer, concrete shall be placed under water by
means of a placer. After the head of water has been neutralised by the head of
the concrete, excess water shall be bailed out and concrete shall then be
deposited by direct pouring from the top, as is done, if the borehole is dry.
02.05.07 Concreting of Pile shall continue until the Pile is fully formed upto a level of
not less than 750 mm above cut-off level of piles. Extraction of casing
wherever used, shall be done in such a way, so that, no necking or shearing of
concrete in the shaft takes place. Pile length above cut-off level shall be
trimmed. Trimming of Pile top shall not be permitted before 7 days of
concreting in case of mechanical chipping & not before 3 days concreting in
case of manual chipping.
02.05.08 The concreted length of piles shall be measured from the toe of pile to cutoff
level of pile.
02.05.09 Temporary stoppage of work may be permitted only during boring stage.
Thereafter right from boring or chiseling of final portion of pile length through
subsequent activities of flushing, lowering of reinforcement cage, lowering of
tremie, pre-concrete flushing &upto concreting of full pile length, no halt
whatsoever in the execution of work shall be permitted.
02.05.10 The rate of placing of concrete in the pile shaft shall not be less than 6 m
(length of pile) per hour.
02.05.11 Boring of any pile shall not be carried out within a clear distance of three times
of the pile diameter from the adjacent pile which has been freshly concreted
within past 24 hours.
02.05.12 The contractor shall have to take all necessary actions to prevent side collapse
(if any) of pile bore at his own cost.
02.05.13 The Contractor shall be responsible for the prompt removal from the site of all
spoil due to the boring to places as indicated by TANGEDCO. The cost of
such disposal shall be deemed to have been included in the rate of piling.
02.06 Founding Strata
All the piles shall be socketed in specified rock stratum, with stipulated socket
length, as mentioned in Geotechnical Specification of the package.
It is to be ensured by the contractor that, the piles are not terminated in boulder
deposit, if any.


& ITS AUXILIARIES
For each pile, representative rock samples shall be collected from the top &
bottom level of rock socket portion. Either rock lump samples collected by
Bailer or rock core samples collected by rotary core drilling technique, shall be
used for identification of specified rock stratum for socketing. All such
samples shall be preserved for future reference.
The contractor shall engage a qualified & experienced geologist at site, for
identification of specified rock stratum for pile socketing.
The contractor shall obtain approval from TANGEDCO for finalization of

founding stratum. However such approval does not leave the responsibility of
the contractor for any underperformance of Pile capacity.
02.07 Pile Load Test
02.07.01 Initial Load Test
Immediately on mobilisation to site, the contractor shall arrange to construct

Initial Test Piles (Trial Piles) with a view to establish suitability, installation
criteria, safe load bearing capacity & guidelines for acceptance of routine tests.
Initial tests shall separately be conducted for Vertical Compressive, Vertical
Pull-out & Lateral load in separate non-working piles. Test load to be applied
for such tests, shall be 2.5 times of the corresponding safe design loads.
For this package, One number Initial Pile Load Test shall be conducted, for
each mode of loading (Compressive, Pull-out, Lateral).
Separate Trial piles shall be used for testing in each mode of loading
(Compressive, Pull-out, Lateral).
Initial Load tests in Compressive mode of loading, shall be Cyclic in nature.
The contractor shall obtain necessary approval from TANGEDCO for

selection of location for such Trial piles.
Initial Test piles shall be constructed using the same equipment & technique &
by same piling agency, as for working piles.
While executing the pile bore for Test Piles, a continuous record of borelog
shall be maintained and Standard Penetration Test as per IS:2131at an depth
interval of 1.5 m including one compulsory test at termination level, shall be
conducted at no extra cost.


& ITS AUXILIARIES
02.07.02 Routine Load Test
For vertical mode of loading (Compressive or Pull-out - as per design

requirement), total 2(two) numbers of working piles shall be tested, for
Routine Load Test.
For Routine Load Test in Lateral mode of loading, 2(two) numbersof working
piles shall be tested.
Separate working piles shall be used for testing in each mode of loading.
Exact location of the working pile to be tested for Routine Load Test, shall be
indicated by TANGEDCO at site.
Test load in such tests may be limited to 1.5 times of the corresponding safe
design load.
02.07.03 For all types (Initial / Routine and Compressive / Pull-out / Lateral) of load
tests, testing arrangement, test procedure shall follow relevant criteria set out
in IS:2911(part 4) along with the following stipulations:
i) All the tests shall be carried out in presence of TANGEDCO.
ii) Load test shall be carried out after 28 days from the date of casting.
iii) Test load shall be applied at cut-off level. If the test level is below the ground
water table, suitable arrangement for dewatering shall be made by the
contractor without any extra cost so as to conduct the test at dry condition.
iv) Loading shall be applied by reaction method consisting of a hydraulic jack

placed centrally against a suitable loaded platform / anchorage system.
Reaction system shall be well designed & capable of taking 1.25 times of the
maximum load to be applied. It is the responsibility of the contractor to ensure
the required capacity of the reaction system.
v) Test load shall be applied to pile in a static manner. Stage loading shall be
applied in equal increments of 20% of estimated safe design load. Unloading
may be done in higher decrements with at least 5 stages. For Cyclic Load test,
each stage of loading shall correspond to unloading upto zero load. At each
stage of loading & unloading, deflection of pile top shall be recorded accurate
to 0.02 mm at an interval of 1, 2, 4, 8, 15, 30, 60 & 120 minutes upto a time
when the deflection rate reduces to 0.1mm in 30 minutes or 0.2 mm in one
hour or till two hours whichever occurs earlier.
vi) Increments of loads shall be continued upto Maximum Test Load (2.5 times of
safe design load for Initial Test & 1.5 times of safe design load for Routine


& ITS AUXILIARIES
Test) or failure (soil-pile yielding or structural failure) whichever occurs

earlier.
vii) Where failure does not occur, the final test load shall be maintained for 24
hours and deflection records shall be taken at every 6 hours interval, including
initial 2 hours detailed records, as mentioned earlier.
viii) The contractor shall ensure that all the instrument / apparatus used by him
shall be properly calibrated. The calibration certificates (not older than one
year) of all the dial gauges & pressure gauges proposed to be used for load test
shall be available at site. If TANGEDCO desires to check any calibration, the
contractor has to arrange the same in an approved laboratory at his own cost.
ix) The Contractor shall maintain & submit TANGEDCO immediately after
completion of any load test, the following records / reports:
a. Tabular & Graphical representation of Load vs. Settlement during

loading and unloading.
b. Tabular & Graphical representation of the Time vs. Settlement for each
load.
c. Graphical analysis of initial cyclic load test results (if any) to separate
skin friction & end - bearing. as per Annexure A, IS 2911 (part 4).
d. Remarks concerning any unusual occurrence (if any) during boring,

installation or testing of piles.
02.07.04 In case of failure of piles, in load test, to achieve the specified safe design
load,the contractor shall install extra piles at his own cost as per design
requirement & as instructed by TANGEDCO.
02.08 Standard of Acceptance
The piles shall be accepted as satisfactory only when the work has been
executed in accordance with this specification, IS Codes, and the Standards
stated herein and instructions given by TANGEDCO at site from time to
time:
a) The total volume of concrete shall not be less than actual shaft volume. The
calculated volume for this purpose shall be the cross sectional area inside the
bore multiplied by the length of the shaft. The concrete shall conform to the
specified strength as indicated by the cube test results.
b) The toe of pile shall be at approved bearing level in each case.


& ITS AUXILIARIES
c) Safe Load carrying capacity of pile as obtained from Load test shall not be less
than corresponding Safe Design Load as mentioned.
d) Tolerances specified in clause No. 02.05.01 shall be satisfied.
If an individual pile fails to meet the requirements specified in any of above

clause/s, such pile shall be deemed to be defective.
When any pile is found defective, one or more pile shall be installed as a
replacement of defective pile as necessary without any extra cost to
TANGEDCO. Defective piles shall be left in place or pulled out as directed by
TANGEDCO. Contractor shall not be paid any additional amount on this
account. No payment shall be made for test piles found defective /
unsatisfactory.
02.09 Record
The contractor shall maintain a record for each pile indicating the following
data and shall be signed jointly with TANGEDCO.
a) The date and time of commencement and completion of each stage of piling
operation.
b) The particulars of the equipment and method of boring and concreting.
c) The location and type of pile, Pile number, with a reference to approved
drawings.
d) The diameter of the pile and verticality.
e) Bored depth, concreted depth, empty boring and nature of stratum at founding
Level.
f) The volume of concrete poured, quantity of cement, w/c ratio used and slump
of poured concrete.
g) Details of reinforcement provided.
h) The sequence of installation of pile groups.
i) During boring operation, a separate record for rate of advancement of borehole

in terms of effective time vs. boring depth shall be maintained for each pile.
The effective time implies the time required exclusively for boring operation
barring the time for other activities such as temporary stoppage, cleaning of
hole, in-situ tests, if taken etc.


& ITS AUXILIARIES
j) During chiseling through hard stratum, if encountered, exact record for depth
of penetration against time & number of blows for each 10 cm of chiseling
shall be maintained. Weight & average height of fall of chisel shall also be
recorded.

VOLUME VB
ARCHITECTURAL
WORKS


& ITS AUXILIARIES
01.00 ARCHITECTURAL WORKS
01.01 Planning and space organization
The Control Cum MCC Room Building, Compressor House Buildings will house the
following functional spaces i.e. Cable Cellar, Chiller Plant, A/C & non A/C Switchgear
Room, Clean Agent Room, Control/Equipment Room, Control/ Operator Desk, Cabins,
Offices, AHU Room, PPVS Room, Store & Utility Room, Analyzer room, Operator
room, Pump house etc as per the Technological requirements including other common
spaces. There will be toilets for male and female (as per NBC norms). Sufficient
Staircase (as per NBC norms) will be provided at appropriate location. Waiting,
adequate Circulation area, UPS room, Electrical room, AHU room, A/C plant room etc
will be provided suitably. False ceiling shall also be provided in all the A/C areas.
01.02 Design concept
The design concept for above building will meet the functional, technical and other
requirements for efficient operation, ensuring sufficient lighting and ventilation for
conducive working environment for employees, satisfying the overall modern befitting
building aesthetic requirements. The referenced Publications given below will be
followed for the designing purpose: BIS, NBC, BPE & British codes.
01.03 Space Requirements
01.03.01 Buildings will accommodate spaces to meet the functional requirements as well as
security/safety, maintenance, statutory (stairs/fire exits etc.), utilities & services
(toilets/AC/Electrics/LAN/health etc.)/environmental requirements and incorporated in
design & detail engineering drawings/documents.
01.3.02 Space requirements as indicated in this part of TS is not exhaustive and subjected to
finalization by consultant/Employer during detail engineering stage with modifications
required to meet the building requirements as per technological need.
01.03.03 Sizes of the functional spaces both indicated and not indicated, will be verified against
technological requirements, number of users / furniture layout etc, finalized and
provided.
01.03.04 Functional office spaces in the building will be designed as column free spaces
wherever possible, with provisions for full height cabins, low height cubicles, Open
office area etc. to ensure unobstructed day lighting for the work spaces.
Vol. – VB ARCHITECTURAL WORKS Page 1 of 20


& ITS AUXILIARIES
01.04 Natural lighting & ventilation
The area of windows will be a minimum 15% of the floor area to ensure adequate
natural lighting and ventilation.
01.05 Services
There should be adequate space for all services The main stair case should be
prominent one, visible and easily accessible from entrance. The pipe lines from toilets
and rain water pipes will preferably be enclosed in ducts, but easily accessible for
maintenance purpose and will not spoil the aesthetics of the building.
01.06 Parking
Separate and sufficient Parking will be provided for four wheeler & two wheeler
located near the building and tubular steel structure with coloured metal sheeting &
interlocking pavers blocks (60mm thick) will be provided for the covered shed.
01.07 Plinth level
Finished Floor level (FFL- plinth level) will be 300mm (minimum) above the Road
Level.
01.08 Structural system
The building will be designed as a RCC framed structure.
01.09 Landscaping
Landscaping will include hard-scape, soft-scape including turfing & gardening with
fencing without boundary wall around the building & in vacant spaces. Water tapping
points at convenient locations and micro terracing (if required) by the contractor within
their battery limit. Adequate Trees/plants those can grow in the local soil & climatic
conditions will be planted in proper sequence to provide greenery & Seasonal plants
for gardening will be provided at strategic locations.


& ITS AUXILIARIES
01.10 Stairs
Stairs, having each flight width of minimum 1500mm, will not have normally more
than 15 risers in one flight, with maximum riser of 165mm and a minimum tread width
of 250mm. Proper edge protection has to be ensured. All roofs will be accessed through
the staircases.
01.11 Handrails
Stainless steel ( Grade 304) 1000 mm height of knock down fixing system railing made
of 38 mm dia stainless steel Handrail (Wall Thickness 1.5mm), 40mm x 40mm SS
Square Baluster (Wall Thickness 1.5mm), @ 900mm (maximum) c/c with complete
fixtures, 16mm dia x 3 Nos. SS Horizontal Member shall be provided in staircase,
steps.
Removable M.S. handrail shall be provided wherever required.
01.12 Vertical Headroom
All accessible areas will be provided with a minimum clear headroom as follows,
unless otherwise specified:
a) Floor height - As per Technological requirements

b) Door opening,. - 2100mm (mimum)/ As per technical requirement
Walkways, platform etc.
c) Mumpty - 2500 mm minimum (clear)
d) Canopy - 3600 mm minimum
e) Lintel level of - 2100 mm minimum - From structural floor or up to
window beam bottom matching with the elevation
01.13 Brick masonry and parapet wall
All walls will be non load bearing infill panel walls. External walls of all buildings will
be at least one brick thick. All internal walls will be at least half brick thick excepting
staircase, toilets, AHU etc. with one brick wall.
The thickness of the parapet wall will be one brick thick or 125 thick R.C.C. wall and
height will be 1000 mm minimum for accessible roof & 500 mm for non accessible
roof.


& ITS AUXILIARIES
01.14 Roof drainage
Roof drainage system will be provided for quick and efficient draining of rainwater
from roof to avoid seepage and damage to roof. The roof gradient for the roof will not
be less than 1 in 100. Roof drains will conduct water to storm drains through UPVC
down take pipes. Rainwater pipes (Type -A, conforming to IS :13592) with all
necessary fittings i.e. pipe clips, shoe, inlet mouth, bend of required degree, coupler,
TEE with or without door, etc to be provided as per manufacturers specifications.
01.15 Drainage
Garland drain will be provided after providing plinth protection all around the building
to receive drainage water from roof & floor and lead them to the plant storm water
drainage.
01.16 Statutory requirements
All the applicable statutory rules pertaining to Indian Factories act, factory rules of state
government, Fire safety rules of LPA, Water act of Pollution Control Boards,
Explosives act etc. and stipulations of other relevant statutory authorities will be taken
into consideration at the time of design.
Provisions of safety health and welfare according to factories act will be complied in
design stage. These will include provision of fire escape, locker room for workmen,
toilets rest room etc.
Adequate number of fire escapes will be provided in a building. Fireproof doors,

number of staircases, fire separation walls, For fire safety requirements of buildings IS:
1641 and IS: 1642 will be followed in addition to LPA requirements. All masonry
firewalls will be minimum 1 ½ Brick thick and RCC firewall will be minimum 200mm
thick.
01.17 Design & Other requirements
01.17.01 Entrance to be provided at proper location with canopy/ projection as per design.
01.17.02 600 mm projection to be provided over each window & ventilator and 1000mm
projection over each external door


& ITS AUXILIARIES
01.17.03 Drop Slab (550 clearance) should be considered for toilet block to be filled with jhama
brick bat/ cinder or as directed by Engineer In charge.
01.17.04 Skirting will be of same finish as that of floors. Panel dividers will be provided in
cement concrete/non metallic Heavy Duty flooring
01.17.05 All Air-Conditioned areas will have 12.5 mm thk. MR Gypsum board or approved
equivalent false ceiling.
01.17.06 Painting on Internal masonary walls will be done over White cement putty minimum
1mm thick & primer as per manufacturer specification.
01.17.07 All steel frames, Shutters, Grills etc will be painted with two or more coats of approved
quality Synthetic Enamel Paint of Approved shade over a coat of Approved quality red
oxide /Zinc Chromate Primer.
01.17.08 All paints shall be low VOC paint in nature as per manufacturers specifications. Acrylic
emulsion paints (Internal & external) to be applied minimum two coats on all surfaces,
if required additional coats to be applied to achieve even shade and colour.
01.17.09 False flooring shall be as per item No. 11.54 of DSR and finished with 2mm thick
antistatic PVC tiles will be provided. (As per technical requirement)
01.17.10 General technical specifications (GTS) also to be referred along with this technical
specifications, however if any discrepancy is found, technical specifications shall
prevail over GTS.
01.17.11 If specification for any item is not covered in this TS or GTS then CPWD specification
to be referred for respective item.
01.17.12 1st quality ceramic glazed tiles conforming to IS: 15622 to be used in toilets, janitor of
approved make, shade & complete in all respect
01.17.13 Double charged vitrified tile to be used conforming to IS: 15622 with water absorption
less than 0.08% and of size 600x600 mm


& ITS AUXILIARIES
01.17.14. Internal wall plaster with 12 mm thick cement plaster of mix: 1:6 (1 cement : 6 fine
sand), External wall plaster with 20 mm thick cement plaster of mix: 1:6 (1 cement : 6
fine sand ), ceiling plaster with 6 mm thick cement plaster of mix: 1:3 (1 cement : 3 fine
sand)
01.17.15 Chicken wire mesh to be provided in the plaster on the location of RCC & brick joints.
01.18 Finishes.
01.18.01 Internal Finishes Schedule:
Sl. Location Flooring Skirting/ Walls Ceiling Remarks

No. Dado
1 MCC cum 52 mm thick 150 high cement Acrylic Acrylic -
Switch Gear (including 12 plaster skirting Emulsio Emulsion
Room mm with a floating n Paint Paint
topping)Cement coat of neat
Concrete cement with non
flooring with metallic hardener
non metallic
hardener.
2. Lobby, Min. 20 mm 150 high Min. 20 -Do- -Do-
Corridor & Kota stone slab mm Kota stone
surrounding with good slab with good
area of control finish. finish.
room
Cable Cellar, 52 mm thick 150 high cement Acrylic Acrylic -
3. Store, AHU, (including 12 plaster skirting Distemp Distemper
Pump House, mm topping) with a floating er
Ventilation Cement coat of neat
Room. Chiller Concrete cement with non-
Plant, Clean flooring with metallic hardener
Agent room, non metallic
hardener.
4. Office, Vitrified Tiles 150 high Vitrified Acrylic Acrylic -

Conference (600x600x10m Tiles same as Emulsio Emulsion
room, Cabins, m thick) of floor. n Paint paint over
Control / approved finish 12.5 Thk
Operator & shade MR
Room Gypsum
board false
ceiling

& ITS AUXILIARIES
Sl. Location Flooring Skirting/ Walls Ceiling Remarks

No. Dado
with
underdeck
insulation.
5 Control/ 18mm Thick 150 high granite -Do- -Do-
Equipment granite stone stone same as
Room, flooring. floor.
Electrical
Panel room
5. Staircase & all Min. 20 mm 150 high Min. 20 Acrylic Acrylic -
other rooms. Kota stone slab mm Kota stone Emulsio Emulsion
with good slab with good n Paint Paint
finish. finish.
6. Pantry Min. 20 mm 2100 high glazed -Do- -Do- Pantry
Kota stone slab Ceramic Tiles slab shall
with good have black
finish. granite
7. Toilet, 1st quality 2100 high glazed -Do- -Do- False
Drinking Antiskid Ceramic Tiles ceiling
Water & Ceramic Tiles with
Janitor (300x300x7mm Calcium
min.) of silicate
approved finish, tiles in
shade office
floor
01.18.02 External Finishes Schedule:
Exterior grade Premium Acrylic Smooth exterior paint with Silicone additives over
plaster & Acrylic modified resin based texture (approx. 20% of the external area) of
approved Pattern having anti algae and UV resistance properties to be provided over
plastered wall.
01.19 Doors and Windows
All the floors of electrical building/control rooms, cable cellar/basement will have
minimum two entries/ exits with lobby and two air tight doors. Rolling shutters (if
required) shall be provided in all electrical rooms/ventilation rooms/ AHU rooms in
addition to doors.
Glass for doors, partition and windows to be taken as 6mm thick toughened glass/
frosted glass for toilet.


& ITS AUXILIARIES
Doors & Windows to be provided as per attached schedule and will meet following
specifications:
01.19.01 Doors
01.19.01.01 Pressed steel door frame (Upto 1000mm opening Profile type B, above 1000mm
opening Profile type C as per IS-4351 with 35 mm thick flush door shutter as per IS:
2202 (Part-I) (Teak wood Veneer finished on both side) with 1.5mm thick laminates
pasted on both sides (factory pasted) of approved shade and finish. (Vision panel should
be provided in the shutter).
01.19.01.02 PVC door frame with 30mm thick rigid foam PVC paneled door shutter with paneling
of 5mm thick PVC sheet should be considered in all toilets, janitor room. (DSR -9.119
for Frame), DSR -9.120.2 (Shutter) – Refer DSR -2007.
01.19.01.03 Fire rated Door: Minimum 2 hrs rated fire resistant doors to be provided at all fire exit
points. The door frame shall be as per item No. 9.161 of DSR and door shutter shall be
as per item No. 9.162 of DSR with viewing glass as per item No. 9.164 of DSR. The
door assembly shall be fitted with approved S.S. hardware, panic bar/latch as per item
No. 9.139 of DSR. The door assembly shall be of approved make.
01.19.01.04 Rolling Shutter as required to be provided as per IS code & Steel door with steel frame
with anti corrosive paint as required.
01.19.01.05 Doors and windows of rooms, which are air conditioned, will be air tight and dust –
proof.
01.19.02 Windows
01.19.02.01 All windows shall be sliding / casement/ louvered glazed anodized (AC 25) Aluminium
windows as per standard aluminium section provided including 6mm thick toughened
glass/ frosted glass for toilet, approved quality hardware and all the gaps between frame
and wall to be filled with approved silicone sealant and backer rod (if required). Shop
drawings to be submitted for approval.
01.19.02.02 All windows to be provided with ornamental anodized aluminium grill (anodized
transparent or dyed to required shade according to IS: 1868 with minimum anodic
coating of grade AC 15) of approved design/pattern, with approved standard section
and fixed to the existing window frame with C.P. brass/ stainless steel screws @


& ITS AUXILIARIES
200mm centre to centre, including cutting the grill to proper opening size for fixing and
operation of handles and fixing approved anodized aluminium standard section around
the opening, all complete as per requirement and direction of Engineer-in-charge.
01.19.02.03 Doors and windows of rooms, which are air conditioned, shall be air tight and dust
proof.
01.19.03 Door/Window Schedule:
Sl. Location Doors & Frames Windows Remarks

No.
1 Switchgear Pressed Steel Door frame Glazed coloured
Room and Flushed Steel door anodized
with viewing glass (6mm Aluminium
thick toughened glass) frame & shutters
2 Cable Cellar Pressed Steel Door frame -Do-
and Flush Steel door with
viewing glass (6mm thick
toughened glass)
3 Office Room, Pressed Steel door frame -Do- -
Cabins, & wooden flush doors
Conference viewing glass, door
room, Staff closures, door stoppers,
room, Pantry Al. aldrops mortice locks,
handles etc
4 Staircase 2 hours fire rated door -Do- -
with approved S S
hardwares
6 Toilet, Drinking PVC door frame & PVC -Do- -
Water, Janitor shutter, door closures,
door stoppers, Al.
aldrops, handles etc
7 AC Plant Pressed Steel door frame -Do- -
Room, & Wooden flush doors
Store/Utility with viewing glass, door
Room, closures, door stoppers,
Ventilation Al. aldrops mortice locks,
room, AHU, handles etc
Pump House,
all other rooms
8 Control/ Double door, Air lock -Do-
Equipment arrangement (wherever
Room, required) with coloured


& ITS AUXILIARIES
Electrical Panel Anodized Aluminium

room, Control/ Frame & shutters with
Operator Desk min 6 mm thk toughened
glass, door closures, door
stoppers etc
9 Entrance -Do- - -
01.19.04 Standard Aluminium Section
Sl. Description Section No. Size (In mm.) Weight

No. (Hindalco Kg/mtr.
Alupuram)
I. DOORS
A. Normal Door
1. Door Vertical Plain 9239 85x44.5x2 1.365
2. Door Vertical 9241 -do- 1.412
3. Door Bottom (Shutter 9208 101.1x44.5x3. 2.379
Width<=1 Mt) 1
4. Door Bottom (Shutter Width >1 9212 180x44.5x3.1 3.438
Mt) 8
5. Door Top 9208 101.1x44.5x3. 2.379
1
6. Lock Rail 9232 150x44.45x3. 3.290
2
7. Glazing Clip 4660 19.7x17.8x1.3 0.167
B. Twin Style Door

1. Top / Bottom Rail (for 12mm 9211 90x45x3 3.727
glass thickness)
2. Top / Bottom Rail (more than 9206 90x45x3.0 3.506
12mm glass thickness)
C. Frame 8422 120x80x3 3.143
II WINDOWS
A. Casement– 40mm Series
1. Z Shutter 4132 40x28x2.5 0.585

2. Hollow Z Shutter 9148 41.50x29x1.5 0.636
3. Mullion 9149 63x40x1.5 0.933
4. H Shutter / alternative of Sl. 4133 40x41x2.5 0.638
No. 2
5. Crimping Angle 2081 50x50x4.9 1.177

& ITS AUXILIARIES
6. Double glazing clip 4134 25x8x1.2 0.132

7. Single glazing clip 4135 24x25x1.2 0.166
B. Sliding Window
1. 2 Track Bottom 4095 61.98x29.70 0.875
2. 2 Track Side & Top 4096 61.98x29.70 0.778
3. 3 Track Bottom 4097 92.36x29.70 1.233
4. 3 Track Side & Top 4098 92.36x29.70 1.067
5. 4 Track Bottom 4121 123.02x29.70 1.500
6. 4 Track Side & Top 4120 123.02x29.70 1.293
7. Shutter Vertical 9777 39x20x1.5 0.493
8. Shutter Interlock 9778 39x20x1.5 0.612
9. Shutter Top & Bottom 4148 41x20x1.5 0.472
III. PARTITIONS
A. Partition (Height > 1.5 mtr.)

1. Single Partition (Single 9205 101.5x44.45x3 2.34
Glazing)
2. Double Partition (Single 9204 101.5x44.45x3 2.420
Glazing)
3. Single Partition (Double 9229 101.5x44.45x2.5 2.03
Glazing)
4. Double Partition (Double 9228 101.5x44.45x2.5 2.00
Glazing)
B. Partition (Height <= 1.5

mtr.)
1. Single Partition (Single 9210 63.5x38.1x2.5 1.376
Glzaing)
2. Double Partition (Double 9207 63.5x38.1x2.5 1.443
Glzaing)
3. Glazing Clip 4660 19.7x17.8x1.3 0.167
Note : Similar approved equivalent sections may also be used.
01.20 Sanitary & Plumbing
01.20.01 Toilet alongwith Drinking water, Janitor & Over head water tank to be provided as per
NBC guidelines.
01.20.02 Each toilet block shall have the following minimum facilities. Unless specified all the
fittings shall be of chromium plated brass.


& ITS AUXILIARIES
01.20.03 CPVC pipe of SDR-11 class, conforming to IS:15778 to be used in concealed internal
plumbing network with all required accessories and fixing materials, all complete.
Fixing Chlorinated Polyvinyl Chloride (CPVC) pipes, having thermal stability for hot
& cold water supply, including all CPVC plain & brass threaded fittings, i/c fixing the
pipe with clamps at 1.00 m spacing. This Includes jointing of pipes & fittings with one
step CPVC solvent cement including testing of joints complete as per direction of
Engineer in Charge. Scope also covers connection from water storage tank to concern
toilet in all buildings.
01.20.04 Hubless centrifugally Cast (spun) Iron epoxy coated inside and outside pipes shall be
used as Soil and waste pipe jointed using SS 304 grade shielded coupling with EPDM
gasket along with necessary bends, offsets, traps, fixing materials all complete.
01.20.05 CP brass pressmatic tap with connection pipe and spreader shall be used for Urinals.
01.20.06 Polyethylene water storage tank ISI : 12701 marked, with cover and suitable locking
arrangement and making necessary holes for inlet, outlet and overflow pipes, with all
fittings including valves and the base support for tank (above 1000 mm from roof
level). Above tank shall be provided in all buildings comprising toilet of required
capacity as per NBC norms.
01.20.07 The toilet area shall have finished floor level at 15 mm below the finished floor level of
surrounding area.
01.20.08 Kitchen sink with drain board (size: 510x1040 mm bowl depth 200mm) and without
drain board (610x510 mm bowl depth 200mm) to be provided in all Kitchen/ Pantry
with all fittings, pipes, complete in all respect: Stainless Steel AISi 304 (18/8) kitchen
sink as per IS: 13983. In kitchen & Pantry sink will be provided with drain board & in
Drinking water area, Scrub-up etc areas sink will be without drain board.
01.20.09 Granite stone slab with table rubbed, edges rounded and polished, of size 75x50 cm
deep and 1.8 cm thick of approved shade, to be fixed in urinal partitions by cutting a
chase of appropriate width with chase cutter and embedding the stone in the chase with
epoxy grout or with cement concrete 1:2:4 (1 cement: 2 coarse sand: 4 graded stone
aggregate 6 mm nominal size) as per direction of Engineer-in-charge and finished
smooth.


& ITS AUXILIARIES
01.20.10 Fixing 18 mm thick gang saw cut, mirror polished, pre-moulded and pre-polished,
machine cut for kitchen platforms, office counters, window sills, facias, wash basin
counters, drops of counters and similar locations of required size, approved shade,
colour and texture laid over 20 mm thick base cement mortar 1:4 (1 cement: 4 coarse
sand), joints treated with white cement, mixed with matching pigment, epoxy touch
ups, including rubbing, curing, moulding and polishing to edges to give high gloss
finish etc. complete at all levels. Also making opening for kitchen sink, wash basins etc
including necessary holes for pillar taps etc. including moulding, rubbing and polishing
of cut edges etc. complete.
01.20.11 600x450 mm beveled edge mirror of superior glass (of approved quality) above all
wash basins complete with 6 mm thick hard board ground fixed to wooden cleats with
C.P. brass screws and washers, all complete.
01.20.12 600x120x5mm glass shelf with edges round off, supported on anodised aluminium
angle frame with C.P. brass brackets and guard rail complete fixed with 40 mm long
screws, rawl plugs etc. below all mirrors, all complete.
01.20.13 S.S. toilet paper holder with all the W.C.s, complete in all respect
01.20.14 C.P. brass bib cock of approved quality conforming to IS:8931 to be provided at all
required places.
01.20.15 White Vitreous china Orissa pattern W.C. pan of size 580x440mm with integral type
foot rests with 100mm sand cast Iron P or S trap, 6/3 litre dual flush low level white
P.V.C. flushing cistern, including flush pipe, with manually controlled device (handle
lever) conforming to IS : 7231, connection pipe with brass union, C P brass Quarter
turn angular stop cock, with all fittings and fixtures complete including cutting and
making good the walls and floors, all complete as per instruction of the Engineer in-
charge
01.20.16 White glazed vitreous China pedestal type water closet (EWC) of Hindware
(ECOCat.No.20044) size 38.5 x34.5x50.3 cm,/ nearest size of Parryware or similar
approved equivalent, double trap siphonic pattern, inte-gral with "P" or "S" trap, with or
without vent horn , 3/6 litre flushing low level PVC cistern (Sleek Dual), with all
accessories , PVC flush pipe 32/40 mm dia and 15 mm dia unplasticised PVC inlet
water connection pipe of superior quality with brass union and C P brass Quarter turn
angular stop cock with wall flange of Jaquar (Florentine-Cat. No-FLR- 5053N) / similar

& ITS AUXILIARIES
approved equivalent, white solid plastic seat cover and lid of superior and approved
quality, CP brass bar hinges, screws, bolts, rubber and stainless steel washers, rubber
buffers, fixing EWC to floor with all bye-works cutting and making good the walls and
floors, all complete as per instruction of the Engineer In-charge
01.20.17 White glazed vitreous China flat back, front lipped standing urinal size 59 x 39 x 37.5
cm of Hindware (Cat. No.60002) ,/ nearest size of Parryware or similar approved
equivalent, with concealed CI wall hangers , 32 mm dia PVC waste pipe & C.P dome
shaped perforated waste with union of superior quality with CP brass coupling upto
floor, 95x69x100 size spreader, 80x42x30 size urinal cock with all bye-works cutting
and making good the walls and floors, all complete as per instruction of the Engineer
In-charge.
01.20.18 Under counter wash basins will be provided for toilets at Office floor, in other locations
White Vitreous China flat back Wash basin of size 550x400 mm to be provided. All
wash basins to be provided with connection pipe with brass union, waste pipe, waste
coupling, quarter turn brass Pillar Taps, Brackets, cutting and making good the walls,
all complete.
01.20.19 All W.C., Wash basin, Sink to be provided with CP brass quarter turn angular stop cock
with adjustable wall flange of Jaquar (Cont.-cat. No-FLR-5053N) or approved
equivalent make with all bye-works cutting and making good the walls, complete in all
respect.
01.20.20 S.S. liquid soap container to be provided near all Wash basins with brackets etc with all
bye-works cutting and making good the walls, complete in all respect.
01.20.21 600 mm long single towel rail with brackets of Jaquar (Cont.-cat. No-1111N) / similar
approved equivalent fixed on wooden plugs with CP brass screws to be provided with
all bye-works cutting and making good the walls, complete in all respect.
01.20.22 C P Brass Health faucet with flexible connection pipe for W.C. to be provided in all
toilets all complete.
01.20.23 C.P. Brass long nose bib cock/ long body bib cock of approved quality conforming to
IS standards to be provided for Drinking water area/ sink area (if required), complete in
all respect including all bye-works cutting and making good the walls.


& ITS AUXILIARIES
01.21 Drawings
Drawings are to submitted in the scale mentioned below:
1 Site Plan & Landscape Drawings Suitable Scale (Jointly

agreed)
2 Floors + Roof Plans 1:100 scale
3 Elevations 1:100 scale
4 Sections 1:100 scale
5 Part Sections & Details, Schedule & Detail of 1:50, 1:25,1:10 or any
Doors, Windows & Finishes, Detail of Water other suitable scale
Supply & sanitary fixtures & service lines (jointly agreed)
01.22 List of Approved Makes
In case, the items are not available in the market or in case of a change in trade name,
equivalent makes/ re-designated manufacturer shall be used with prior approval of
MECON. In case of items are not covered in the list, the material shall procured after
approval of MECON as per the standard material available in the market and having
BIS certification mark.
Sl. MATERIALS MANUFACTURERS

A. Masonry works
1 White Cement Birla White, J.K.white or approved equivalent make
B. Flooring
1 Tiles
1a Ceramic / Rectified / Vitrified Tiles Nitco, Johnson, Orient Bell, RAK, Kajaria
1b Terrazzo and Exterior Designer tiles Nitco, Nimco, GK Bansal, Mahul, Ultra tiles,
Stonecrete,Duracrete, Eurocon.
1c Interlock tiles / precast Nitco, Unistone, Hindustan Tiles, Ultra, Duracrete.
1d Joint filler for ceramic/ Vitrified tiles Roff, Pidilite, Bal, Laticrete, BASF.
2. Cement Concrete tiles Nitco, Basant Beton, Tile Italia, Ultra, Stone Crate,
Duracrut, Eurocone
3 Acid Alkali Proof lining / tiles Coromandel Prodorite, Kothari Corrossion
Controllers, Restile, Jhonson
5. Non Metallic Floor Hardener Fosroc, Sika, Pidilite, Cryso or approved equivalent
make

& ITS AUXILIARIES

6. Cavity (False) flooring Unitile, Cani-Microtac, Hyderabad Industries Ltd.
7. Sunken Portion Treatment Choksey, Roffe, Krytone, Sika, Pidilite, HSW
8. PVC Flooring Premier Vinyl Flooring, Responsive Flooring Bhor,
Armstrong, Polyfloor, Wonderfloor.
9. Glass Mosaic Tiles Italica, Bisazza. Palladio or approved equivalent make
10. Antistatic Epoxy Floor Pidilite, Fosroc, Beck, STP, Degussa, Huntsman, Sika,
HSW
11. Epoxy Coating Pidilite, Fosroc, Asian Paints, Huntsman,Degussa,
Sika, HSW
C. Wood Works
1. Pre-Laminated Particle Board/ Novopan, Greenlam, Kitlam, Bhutan Board, Indian
Particle Board / Wooden Doors Plywood Mfg, Co. Ltd., Indian Wood and Wood
Products, Mangalore, Mysore Plywood Limited,
Orchid Ply, Sylvan Ply, Duro
2. Flush Door Shutters Kitply, Navapan, Green Ply, Kutty Flush Doors,
Anchor, Savitri Wood, ALPRO, Indian Plywood,
Mysore Plywood, Northern Doors, Sakthi Flush
Doors., Sylvan Ply
3. Block boards /Ply Board Greenply, Kitply, Indian Plywood Mfg., Nuboard,
Mysore Plywood Ltd., Archidply, Alpro, Savitri
Wood, Eco Board, National, Amul, Century, Kutty
Flush doors, Joinery Manufacturer, Northern Doors, ,
4. Pre-laminated MDF Board Mangalam Timber (Dura Tuff), Century or approved
equivalent make
5. 35mm thick exterior grade panel Mangalam Timber (Dura Tuff) or approved equivalent
door (both side laminated door) make
6. 35mm thick exterior grade flush Century, Savitri Wood, Mangalam Timber (Dura
door Tuff) or approved equivalent make
7. Dry wall partition Saint Gobain, USG or approved equivalent make
8 Adhesive for wood work Dunlop, Fevicol, Vamicol, MRF
D. Steel Works
1. M.S. Pipe Jindal Hisar, Kalinga, TATA
2. Steel Doors, Windows, MS rolling Sen, Harvic; AGEW, Multiwyn, NCL Seccolor Ltd.,

& ITS AUXILIARIES

Shutters, Pressed Steel Door Frames Madhu Industries, Swastic Rolling Shutters &
Engineering Works, Basic Arch Products, Perfect
Industrial Products.
3. Metal Fire Check Doors Godrej, Shakti Hormann or approved equivalent make
4. Stainless Steel Bolts, Screws, Kundan, Puja, Atul or approved equivalent make
Washers, Nuts
5. Stainless Steel Pipes / Flats JINDAL / LLOYDS/ ZENITH/ REMI/ PRAKASH,
SANDVIK CHOKSI, SAIL Salem Steel, or approved
equivalent make
5a STAINLESS STEEL MATERIALS SAIL/ Jindal
FOR RAILING
6. Dash Fasteners / Anchor bolts Hilti, Canon, Fischer, Bosch, WURTH
7 Screws Gkw/ Nattlefold/ Oxidised.
E. Aluminum Works
1. Aluminium Sections Hindalco, Jindal Century Extrusions Ltd., GALCO,
Pennar,
2. Aluminum Cleat arrangement for Deco Indalco, Jindal or approved equivalent make
Glazings
3. Aluminum Composite Panel Alstrong, Alpolic, Alucobond, or approved equivalent
make
4. Door Seal – Woolpile Weather Strip Anand – Reddiplex or approved equivalent make
5. E.P.D.M. Gaskets Anand Reddiplex, Enviro Seals or approved
equivalent make
6. Aluminum fittings Doorex, Glassic, DEEP, Aasra
7 Aluminium Grills Deco/ Alumnigrille
F. Fittings & Fixtures
1. Doors & Windows Fixtures / Everite, Hardwyn, Earl Bihari, Garnish, Crown,
Fittings Jyothi, Godrej & Boyce, Secur Industries, Haffele
2. Stainless Steel Door handles, butt Haffele, Hettich, Dorma or approved equivalent make
hinges (with and without ball
bearings), Floor stoppers, Cabinet
handles, knobs


& ITS AUXILIARIES

3. Stainless Steel Tower bolts, Sliding GARG, Godrej, ARCH or approved equivalent make
Bolts
4. Door Closer / Floor spring Everite, Hardwyn, Dorma, Hafele, ARCH, KICH
5. Door Locks ACME, Godrej, Harrison, PAG, Hafele
5a Hydraulic Door Closures / Floor Godrej, Everite, Hardwyn, Door King, Everest,
Spring & Door Lock Dorma, Ozone, Dorset Arkay.
6. Stainless Steel Friction Stay Securistyle, Hafele, Dorma, Hetich, ARCH, KICH or
approved equivalent make
7. Aluminum Die-cast handles & two Giesse, Securistyle, Alu-alpha or approved equivalent
point locking kit. make
8. Stainless Steel Handrails, Balustrade Ozone, ARCH or approved equivalent make
G. PVC/FRP Doors
1. PVC Doors/FRP Doors ACCUCEL, Thermodeck, Rajashree, Omega Fibres or
approved equivalent make, Sintex, Rajashri Plastic,
Thermodeck, Ambience, Akrosha, Plasopan, Nandini
2 UPVC Doors / windows Duroplast or approved equivalent
H. Painting Works
1. Synthetic Enamel Paints Berger, Asian Paints, Kansai Nerolac, Jenson &
Nicholson, Shalimar, I-Can Nano, Dulux
(AkzoNobel),, British Paints.
2. Acrylic Distemper Asian paints, Berger, Kansai Nerolac, Jenson &
Nicholson, Shalimar.
3. Cement Paint Snowcem Plus, Berger, Nerolac, Jenson & Nicholson,
Shalimar, Dulux (AkzoNobel),
4. Internal acrylic emulsion paint Asian, Berger, Shalimar, Kansai-Nerolac, Jenson &
Nicholson, Super Snowcem, Dulux (AkzoNobel),, I-
Can Nano, MRF, British Paints.
4a Exterior Paints / Water Proof Asian, Berger, Shalimar, Nerolac, Jenson &
Cement Paints Nicholson, Super Snowcem, Dulux (AkzoNobel),, I-
Can Nano, MRF, M/s Terraco (Terraccin & Terracoat)
Ltd.
4b Thermo Plastic Paints Shalimar, AutoMark, Asian, Berger, STP, Kataline
5. Exterior Acrylic Emulsion Paint Dulux (AkzoNobel), Asian, Berger, Johnson &

& ITS AUXILIARIES

Nicholson, Shalimar, Snowcem Plus
6. Epoxy Paint Kansai-Nerolac, Shalimar, Asian Paints, Roto
Polymer and Chemicals, Avcon Technics Pvt. Ltd.,
Huntsman, ICI, Berger, Jenson & Nicholson, BASF.
7. Cement based Wall Putty Birla, JK, Asian,
8. Other Paints / Primers Dulux (AkzoNobel), Asian, Berger, Nerolac
9. Acrylic Copolymer Aggregate finish Heritage of Bakelite Hylam or approved equivalent
make
I. Glass Works / Polycarbonate Sheet Works
1. Glass/ Float Glass / Toughened Modi (GG), Asahi (AIS), Saint Gobain (SG),
Glass
J. False Ceiling / False flooring Works
1. False ceiling – Gypsum Board Lafarge Boral, USG, Gyproc
System
2. False ceiling – Aluminum Hunter Douglas (Luxalon), Armstong or approved
equivalent make
3. Calcium Silicate Board Aerolite, Hilux or Approved equivalent make.
3b False Floors Unitile, NMR Prefabs or approved equivalent
K. Sanitary & Plumbing Works
1. Vitreous China Sanitary ware Hindware, Parryware, Kohler, Geberit, Neycer, Cera
2. White Glazed Fire Clay Sink Sanfire, Cera, Neycer, Hindware
3. Stainless Steel Kitchen Sink Gilma/ Dayana/ Amc/ Parryware/ Prayag/ Frank/
Jayna/ Neelkamal/ Nirali/ Diamond
4. Plastic Seat Cover of E. W.C. Commander, Bestolite, Diplomat, Jaquar, Geberit
5. C.P. Brass Fittings (Plumbing) Jaquar/ Marc/ Ess Essar/ Parryware-Roca/ Kohler/
(General Purpose) Toto, Ebax, Nirali
6. Centrifugally / Sand Cast iron pipes R.I.F., J. NECO, B.C., B.I.C., ISP, SKF, SRIF,
& fittings & fixtures (IS 3989/1729) RIFKO, KFAI, Kapilesh, NEC
7. G.I. Pipes Tata, Jindal ,GST, Swastik, Zenith, Ambica, Bharat,
Surya Prakash Indus tubes.
8. G.I. Fittings Unik, K.S., Zoloto, PEC, MJM, Bimal or approved


& ITS AUXILIARIES

equivalent make
9. Gunmetal Valves Zoloto, Leader, Sant, Kilburn, Neta
10. Ball valve with floats Zoloto, Leader, Sant, Jayco
11. PVC Water Tank Sintex, Polycon, Infra or approved equivalent make
16. Mirror Atul, Modi Guard, Saint Gobain, Triveni, Asahi
17. Hand Drier Kopal, Automat, Euronics or approved equivalent
make
18. PVC flushing cistern Commander, Parryware, Duralite, Hindware
19. UPVC Rain Water Pipes Supreme, Prince, Finolex, Oriplast, Kisan
20. C.I. Pipes Class LA and fittings Keso-spun, supra, Electrosteel or approved equivalent
make
21a C.I. Pipe & Fittings, Conforming to Kesoram, Electro Steel, NECO, TATA, SAIL,
IS – 1729 /3989/15905 RIFKO, Electrotherm, NECO
22 S.C.I. Pipes & Fittings SRIF, RIFKO, KFAI, Kapilesh, NECO
bConforming to IS 1729/3989
23. UPVC / HDPE Pipes & fittings Finolex, Prince, Supreme, Kitec, Oriplast, Polyfab
24a Soil, Waste & Rainwater pipes & Premier, Sudhakar, Finolex, Astral – Flowguard,
fittings, PVC / UPVC / CPVC Pipes Kissan, Supreme, Prince, Reliance, Garware, Geroge
Fisher, Godavari
25. C.P. Flush Valves Jaquar, Roca, MARC
26. C.P. Angle Valves (Ball valve type) ITAP : Italy, Bugatti, Italy
27. Gratings, Strainers, Cleanouts etc. Near Brand (Sage Metals) or approved equivalent
make
28. GI Plaster mesh M/s Arpitha Exports or approved equivalent make
29. CP liquid soap container (tilting OMCO or approved equivalent make
type)
27. PTMT Fittings Prayag/ Watertec/ Shakti.

VOLUME VC
STRUCTURAL WORKS


& ITS AUXILIARIES
01.00 STRUCTURAL WORKS
01.01 General
This specification for Steel structural works furnished herein are intended as guidelines
for execution of the works satisfying the Owner’s requirements as also complying with
all technical norms in totality This specification shall apply to Design, Supply,
fabrication, erection of steel structures including paintings and cladding of structural
buildings in general on turnkey basis and dismantling for installation of Semi Dry Flue
Gas Desulphurization System/ Equipment in Mettur Thermal Power Station (MTPS- I:
4 x 210 MW)
01.01.01 Units
Structural steelwork under the scope of this specification shall consist of the units
broadly described under the clause no. 1.4.
01.01.02 List of Steel Structures
 Columns ( rolled section or built-up ), column bracings , Beams,

 Monorail beams and supports.
 Roof Trusses, Roof Girders, Purlins, Roof panels, Roof hand rails, Sheeting
Posts, Side runners, Louvers, Bracings, Sag angles, Sag rods,
 Wind girders, Platforms, Walk-ways.
 Stairwell, Stairs, Ladders, Hand rails..
 Gutters and Down comers.
 Roof, Gable & Side Cladding with zinc-aluminium/ galvalume high tensile
steel Sheets, Polycarbonate Sheets as translucent sheets.
 Maintenance Platform etc.
01.01.03 General Description of Structures
The following gives only general description of steel structural work. The structural
work shall not be limited to these but shall be guided by Technological / Technical
requirements and aspects for the total scope of work for FGD system.
01.01.04 Description of Unit
General description of structural work for structural buildings, structural shed, structural
platform, walkway, structural support for pipe rack/ trestle, stairs, etc. involved in
installation of Semi Dry Flue Gas Desulphurization System/ Equipment in Mettur
Thermal Power Station (MTPS - 4 x 210 MW). The structural work shall not be limited
to these but shall be guided by technical/technological aspects for the total scope of
work.
Vol. – VC STRUCTURAL WORKS Page 1 of 23


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The above descriptions of steel structural works are indicative only and not limited only
to as mentioned, if any other units are deemed necessary for completion of the Project
those are to be supplied by the Bidder. Successful Bidder shall also ensure the adequacy
of the building parameters to suit equipment layout and technological requirement. If
the Bidder wants any deviation, he shall indicate the same and also the building
parameters unit wise in his offer.
01.01.05 The work to be performed under this specification consists of design, engineering ,
supply, fabrication, erection and cladding, as well as providing all labour, materials,
consumables, equipment, temporary works, temporary labour and staff colony,
constructional plant, fuel supply, transportation and all incidental items not shown or
specified but reasonably implied or necessary for the completion and proper functioning
of all the above units, all in strict accordance with the specifications, including revisions
and amendments thereto as may be required during the execution of the work.
01.01.06 Supply of all materials including structural steel, roof cladding & side-cladding sheets,
fasteners, paints, consumables like gas, electrodes etc. and all other materials as deemed
necessary for proper completion of the work, are included in the scope of the Bidder.
01.01.07 The work shall be carried out according to the design/drawings to be developed by the
Bidder and approved by the Owner/Consultant. For all buildings and structures,
necessary layout and details are to be developed by the Bidder keeping in view the
statutory & functional requirements of the plant and facilities and providing enough
space and access for operation, use and maintenance. Certain minimum requirements
are indicated in this specification for guidance purpose only. However, the Bidder’s
offer shall cover the complete requirements as per the best prevailing practices and to
the complete satisfaction of the Owner .
01.02 Scope of Work
01.02.01 The scope of work shall cover, but shall not be exclusively limited to, the following:
- Collection of all site related data & conducting site investigations,

- Design, preparation of all design drawings, fabrication drawings,
- Providing Estimated quantity of Steel structural work and crane rail in Tons, Roof
sheeting, side sheeting and requirement of translucent sheets in Sqm.
- Obtaining Owner’s/Consultant’s approval on general arrangements and Design of
structures
- Dismantling, retrieval, sorting and storing of any existing structures as directed by the
owner, if dismantling is a part of the total work
- Supply of all materials viz, raw steel, sheeting for side cladding, and paints
- Supply of fasteners like bolts, nuts, washers etc
- Supply of consumables like electrodes for welding, gases for gas cutting etc
- Supply of plant & machinery, tools tackles instruments for fabrication and erection


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- Providing facilities for testing of materials and conducting NDT

- Providing facilities for transport and handling
- Deploying requisite skilled and unskilled manpower
- Making arrangements for all services like approach to site, electricity, water etc
- Fabrication of structures, their transport and proper storing at site
- Erection of structures, claddings, gutters, down pipes etc
- Application of paints at shop after fabrication and at site after erection
- Providing all reasonable facilities for inspection by Owner/Consultant
- Conducting NDT as stipulated by the Owner and making test results available to Owner
/ Consultant for evaluation
- Compliance with primary acceptance tests / inspection, liquidation of defects;
compliance with final acceptance tests / inspection, liquidation of defects;
- Carrying out field-engineering decisions as desired by the Owner
- Preparation of “As Built” drawings for all the structures and hand over to the Owner the
completed structural work to the Owner’s full satisfaction.
- Any other work deemed incidental for the completion of the overall work but not
included in the above detailed scope
01.03 Design of Steel Structures (For Turnkey portion of work)
This specification shall apply to steel work in buildings and general structural steel work.
For technological structures, additional stipulations shall be considered as per technical
requirements.
01.03.01 Design of Structures
01.03.01.01 Design of building & general structures
The Steel Structures shall generally be designed following IS: 800-2007 (Limit State
Design method )
(a) Dead Loads
Dead loads consist of the weights of the complete structure with finishes, fixtures,
partitions, wall panels and all equipment of semi-permanent nature including storage
structures (tanks, silo etc.), partitions, roofing, piping, cable trays, bus ducts etc. The
content of storage structures etc. shall be measured at full capacity for this purpose.
The piping loads, cable tray loads and the contents of the storage structures shall be
listed separately so that they can be excluded from dead load when dead loads are acting
as stabilizing load for uplift.
The following unit weight of material shall be considered for computation of loads.
Loads given in IS: 875 (part-I) shall be made use of for material not listed below.


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Table 1.1
(b) Thermal Loads (during operating condition)
When thermal loads (such as produced by temperature changes in piping, equipment and
structures) results in friction between equipment and supports (exchangers) or piping and
supports, the friction force will be taken as the operating load on the support multiplied
by the applicable friction coefficient given below:
Description Coefficient of friction

Steel to steel 0.30 (longitudinal) and 0.10 (lateral)
01.03.01.02 Description of Design loads
Loads considered in design shall allow fully for all aspects of:
a) Dead weight of structures, wall, floors, equipment, wiring, machinery, pipe-work,

cabling and any item of a permanent nature.
b) Superimposed loads for roofs and floors plus any temporary machinery not allowed
within the general superimposed loads.
c) Crane loading.
d) Temperature loads from process requirements because of the position of the

structure relative to the heat source or from support of mains, pipes etc. subject to
heat.
e) Maximum range of temperature variation for climatic conditions is ± 25C w.r.t

local ambient temperature. i.e temperature variation is limited to 50C.(Max.
Temp=42.8C, min= 15.6C)
f) Dust load of open floor 1 KN/sq.m
g) Dynamic loads from screens and other such reciprocating/ vibrating machinery.
h) Maintenance hoists on Runway beams.
i) Wind Loads as per IS:875 Part-III(Latest).
j) Seismic loads Zone-II as per IS:1893(latest). Zone factor shall be 0.1 & Importance
factor shall be considered as 1.75


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k) Differential settlement load
l) From future extensions.
m) Any special erection requirements.
n) Erection loads on floor and structures
o) Rain fall: Annual rainfall intensity shall be considered as 100mm per hour.
p) Spillage Load
gallery walk way : 1KN/sqm.
Seal plate : 1KN/sqm.
Belt tension for twin conveyor : One belt at start condition and one in running
condition
Impact factor for drive machine= 1.5
01.03.01.03 Design Loads To be considered
i) Besides technological loads, all platforms, walkways, stairs etc. shall be designed for the
following live loads:
a) All Working Floors : 5 KN/m² + 1KN/sqm spillage load

b) Building floors : 10 KN/sqm or equipment load whichever is higher +1 KN/sqm
spillage load (Where equipment is located) for building floor with equipment.
c) Walkways and Platforms : 3 KN/m²
d) Visitor's galleries : 4 KN/m²
e) Maintenance platforms : 4 KN/m²

including crane level walkway.
f) Staircase and treads : 4 KN/m²
g) Monorail walkways : 4 KN/m²
h) Handrails (Horizontal) : 0.75 KN/m run
i) Ladder : 0.9 KN
at middle of rung
j) Dust loads on roof : 0.5 KN/m²


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k) All structures supporting vibrating equipment shall be overloaded by 25% of static load,
unless specified otherwise.
l) For design of monorails, hoists etc, an impact factor of 1.25 for electrically operated
cranes and 1.1 for hand operated cranes, shall be considered. Weight of pulley block and
other accessories shall be considered
m) Structures shall be designed considering an additional load on account of differential

settlement of 1 in 1000 between any two adjacent columns, subject to a maximum
differential settlement of 8 mm.
ii) For all other loads, not specified above, the following codes shall be followed.
a) All live loads shall be considered in accordance with IS: 875(Part-2) -1987.
b) Wind loads shall be in accordance with IS: 875(Part-3) -2015 and any other
consideration specific to the site. For wind load calculation the following data may
be considered
- Basic wind speed ( Vb) = 47m/sec as per IS: 875(Part-3)-2015
- Risk coefficient (K1) = 1.0
- Terrain ht and Structure size factor (K2) shall be calculated with Category 2.
- Topography coefficient (K3) =1.0
- Cyclonic wind factor (K4 ) = 1.15
c) Seismic loads shall be in accordance with IS: 1893-2015 Part 4
d) Crane loading to be considered in design shall be as follows:
I. As per relevant clause of IS: 800-2007
II. IS: 875(Part-2) -1987 for conditions not covered in IS: 800 unless more severe loads
have to be considered for technological/operational conditions.
e) Crane stopper shall be designed in accordance with clause 6.1.4 of IS: 875 (Part-5)
-1987.
f) For design of bins and loading hopper IS: 9178 (Part I to III) shall be followed.
f) In absence of any suitable provision for design loads, any other recognized code of
practice may be followed subject to prior approval of the Purchaser.

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g) Equipment loads shall be considered over and above the imposed loads. Equipment
loads (apart from dead weight) shall be considered as given by equipment supplier.
01.03.01.04 Combination of loads
Various design loads considered shall be combined in accordance with clause 8.0 of IS:
875(Part-5) -1987 and also to give the most severe loading condition for design of
structures.
01.03.01.05 Limiting deflection
Deflections are to be checked for the most adverse but realistic combination of service
loads and their arrangement by elastic analysis using a load factor 1.0
a) The following limitations in deflection shall be followed in design:
Vertical Deflection
i) Monorail track beams , main floor beams, : Span / 400

equipment supporting beams & beams
supporting brick walls
ii) Main roof rafters, roof trusses, roof girders : Span / 400
main floor beams in operating platforms
iii) Secondary floor beams : Span / 325
iv) Crane Girders of cap ≥ 50 T : Span/1000
< 50 T : Span/750
v) Conveyor gallery girders Span/400
v) Floor bracings & Rafter bracings : 10 mm
vi) For Gratings and Chequered plates : Lower of Span/200 but
not to exceed 6 mm
Horizontal Deflection
i) Crane girders due to surge force (from one : Span / 2000

crane only).
ii) Main columns at crane rail level in transverse : H / 2500 but not to
direction due to action of crane surge (for exceed
surge force consider one crane for single bay 10 mm
and one crane each on adjacent aisles for
multi-bay buildings)
iii) Open gantry for condition as in (ii) above : H / 4000 (crane
Where H = Height of Column from bottom of bridge can be
base plate to crane rail level. considered as a

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prop )
iv) Sway of building frame structure at eaves level : H/400
v) End portal of Conveyor gallery girders : Height/325
vi) Sway of 2-legged trestles for supporting : Height/1000
Conveyor gallery girders in transverse
direction
vii) Sway of 4-legged trestles for supporting : Height/1000
Conveyor gallery girders in transverse
direction
viii) Sway of 4-legged trestles for supporting : Height/500
Conveyor gallery girders in longitudinal
direction
ix) Transverse deflection of Junction Houses : Height/500
x) Differential sway deflection between two : Height/1000
floors in Junction Houses where one conveyor
on upper floor feeding another conveyor on
lower floor
b) All deflections shall be calculated without dynamic factor.
c) All other limits of deflection, not specified above, in various elements of structures shall
be in accordance with IS: 800-2007.
01.03.01.06 Camber
Wherever excessive deformation is likely to cause operational problem or is aesthetically

not agreeable, camber shall be provided to neutralize the effect of deformation due to
dead load of structure, equipment plus permanent loads if any.
01.03.01.07 Expansion joints
a) Longitudinal and transverse expansion joints shall be provided in buildings and structures
in accordance with IS: 800-2007.
b) For open gantry structures, pipe line stockades, cable galleries, open conv. galleries
expansion block width shall be limited to 120m.
c) Expansion joints shall be formed by providing double rows of columns, with overhanging
gantry girders, secondary roof and wall framing being detailed to allow the maximum
calculated movement for the specified temperature variation.
01.03.02 Design considerations
01.03.02.01 The contractor shall design as per the technical specifications.


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01.03.02.02 The effective ratio of utility of all sections & welds shall be limited to 0.85.
01.03.02.03 The minimum thickness of structural steel elements shall be in accordance with IS: 800.
Minimum size of beam members, channel members and angle members shall be ISMB
200, ISMC 75 & ISA 50X50X6 respectively. Channels used as floor beams shall not be
smaller than ISMC 150. For column bracings single angles shall not be used. All Plates
of a particular thickness, used in any specific package, shall be of same grade.
01.03.02.04 The diameter of structural bolts shall not be less than 20 mm except for those securing
roof and wall sheets, windows, doors and stitching of thin coverings. For bolted joints, at
least two bolts per joint shall be provided. Minimum diameter of sag rod shall be 16mm.
01.03.02.05 All butt welds shall be full penetration butt welds.
01.03.02.06 The size of fillet welds shall not be less than 6 mm or thickness of the part welded.
01.03.02.07 Structures shall be designed such that they are economical and safe and meet the
functional and service requirement of the technological process for which they are
designed. The architectural planning of the building shall be based on technological
requirements.
01.03.02.08 The structures shall be designed conforming to the relevant safety regulations, Factory
Acts, Electricity Rules and stipulations of statutory bodies as applicable to the project.
01.03.02.09 Natural ventilation shall be provided ensuring that it does not permit rain water entry
into the building. Scope of natural lighting shall be used to the maximum possible
extent. For this purpose, 15% of side sheeting area and 10% of roof sheeting area, unless
otherwise specified, shall be provided with translucent sheets. Protective grating shall be
provided below such sheets to prevent accidents due to damaged sheets.
01.03.02.10 Expanded metal sheet of net size 200 mm X 75 mm and thickness 5 mm as per IS: 412 –
1975 OR standard wire gauge (SWG 10) or 3.251 mm wire mesh of net size 75 mm X
150 mm, shall be provided below the translucent sheets. The mesh shall be firmly fixed
with a frame made of flats of size 50 mm X 6 mm and connected to roof purlins for
safety against possible breakage of sheets due to continuous exposure to sun & heat and
due to live load. The mesh shall not touch the sheet. The mesh thus fixed shall be able to
cater for a load of 75 kg/sq.m or a point load of 75 kg in the middle.
01.03.02.11 Mild steel gutters and down-pipes with gutter outlets having grating cover shall be
provided to carry rain water from roofs of buildings to the drainage system at ground
level. All gutters shall be designed as walkable with 600 mm sole width.
01.03.02.12 Adequate facilities in the form of monorails, hoists, platforms etc. shall be provided to
facilitate repair and maintenance of overhead cranes, equipment, etc. Access to these
platforms shall be provided by stairs / ladders from the nearest accessible floor or
platform.


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01.03.02.13 Access to all floors, gangways and landings shall be by staircases. Access to platforms
and landing of secondary importance or where such access is used only rarely, shall be
by vertical ladders with safety hoops. Roofs with access shall be provided with safety
handrails along the periphery of the roof.
01.03.02.14 Edges of floors, gangways, stairs and landings shall be provided with safety hand
railings. All hand railings shall be of tubular hand railings with vertical post, top rail and
mid rail made up with tubes.
01.03.02.15 At gable ends of buildings, platforms shall be provided connecting the walkways at
crane gantry level.
01.03.02.16 Floors, gangways and landings shall be covered as follows:
a) Gangways and landings shall have chequered plate with a minimum thickness of 6mm o/p
suitably stiffened to meet design load requirements.
b) Floors and operating platforms other than the above shall have chequered plate flooring or
electro-forged gratings, resting on steel structural framework, to suit the technological
requirements. Floor bracings shall be provided in all working floors to take care of the
horizontal loads, due to equipment / due to seismic consideration / owing to nominal skew
forces.
01.03.02.17 All buildings and their foundations shall be designed so that it shall be possible to extend
them in the longitudinal direction at a later date without further strengthening of gable
structures. Provision for transverse extension, if any, shall also be made at the initial
stage.
01.03.02.18 Sheeting on sides and gables shall generally terminate 2.5 m above ground floor level
unless required to be otherwise. Sides below this level shall be generally screened by
brick walls allowing sufficient air inlet to achieve natural ventilation, unless otherwise
required from technological / ventilation requirements.
01.03.02.19 Connection by permanent bolts to structural elements subject to vibration shall be
provided with lock nuts.
01.03.02.20 Monorails shall be designed for local bending both in transverse and longitudinal
direction. Any Mono Rail cantilevered for more than 1500 mm shall have vertical
support.
01.03.02.21 For Analysis of steel structural frame work STAAD PRO soft ware shall be used. And
for design of members EXCEL shall be used. Soft copy of the executable STAAD file
shall be submitted to purchaser / consultant along with the hard copy of the drawing for
its approval. Backup calculations for input loads as well as design of individual elements
carried out separately, shall also be submitted. The design sheets (e.g. editable EXCEL


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files indicating active formulas) shall be submitted for all members. No separate design
criteria shall be proposed except for any clarifications / discrepancies.
01.03.02.22 Chequered plates, Purlins, Side runners, sheeting etc shall not be considered as structural
members for transferring horizontal loads. Except where purlins form part of bracing
system and designed for axial loads also.
01.03.02.23 Design drawings submitted by the vendor shall carry the signatures of the designer and
the approval authority of the vendor. Each drawing shall have a unique drawing number
& a unique description. Drawing shall have enough free space for client’s comments and
stamp of approval.
01.03.02.24 Vendor shall submit readable structural design drawings (including Bill of Material) to
purchaser / consultant for approval, along with the approved technological drawings. All
other supporting documents like the detailed load calculation, design sheets shall be
submitted for reference along with design drawings.
01.03.02.25 If any revised drawing is entirely different from its previous revision, this should be
given a fresh drawing number scrapping the earlier revision.
01.03.02.26 Even if the drawings are approved / Commented by the Purchaser / Consultant, the
Contractor shall not be relieved of the responsibilities for the accuracy of the detailed
dimensions shown in the drawings and the safety of all structural connections.
01.03.02.27 Design drawings shall contain design forces, major load data of equipment considered
and member design forces like moment, shear, axial force values, Section-wise Bill of
Quantity etc .Necessary number of prints of drawings and documents; as per contract
shall be submitted for approval.
01.03.02.28 After approval of the design drawings a scanned soft copy bearing the stamp of approval
shall be submitted to the Purchaser / Consultant for reference.
01.03.02.29 The slopes of bracings, lacings for columns, diagonal members of trusses, bridges,
girders etc shall be kept preferably in the range of 35 to 50 degrees.
01.03.02.30 Structural steel sections & plates shall be so selected that they are readily available in the
market. A list of such sections & plates shall be submitted for Purchaser’s approval
before commencing design works.
01.03.02.31 Purlins and side runners shall be considered as part of cladding unit and shall be
subjected to local wind coefficients as specified in IS 875(Part-3)-2015.
01.03.02.32 Resonance in structures: Structures supporting vibratory/reciprocating equipments shall
be designed so as to obviate occurrence of resonance. The ratio of applied frequency to
natural frequency shall not lie within the range 0.7 to 1.5.


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01.03.02.33 All 2-legged trestles shall be completely braced in vertical plane. All 4-legged trestles
shall be completely braced in all four vertical planes. In addition, specified horizontal
planes shall be completely braced to provide stiffness against torsional sway.
01.03.02.34 All bunkers shall have liner plates as specified by technological sections according to
their requirements.
01.03.02.35 The design drawings shall be submitted in complete for a unit along with design
calculations both in hard copy and soft copy.
01.03.02.36 Structural schematic general arrangement with plans at various levels, elevations along
each row and axes, sections, considered loads and load diagrams with location etc. and
Structural design drawings with BOQ and Table of members containing design forces
along with design calculations shall be submitted for Purchaser’s/Consultant’s approval.
However the approval shall be limited to checking of overall dimensions, general
stability of system, effective load transfer and deflection limits etc. The approval shall
not relieve the contractor of his responsibility of correctness in design, adequacy of
connections, accuracy etc.
01.03.02.37 Submission of Stability certificate for all the steel structures is under the scope of the
contractor.
01.03.02.38 Main structural elements shall be welded continuously. Intermittent welding shall be
used only on secondary members who are not exposed to weather or other corrosive
influence.
01.03.02.39 Field connection and splices shall be made in one of the following ways:
i) By welding after tightening with erection bolts.

ii) By permanent bolts (for secondary members such as purlins, wall runners etc.)
iii) By High Strength bolts
01.03.03 Considerations for Specific Elements of Structures
01.03.03.01 Columns
a) Shear force at the column base shall be resisted either by shear keys shop welded to the
underside of column base plates or by welding base plate to inserts provided in
foundation.
b) The level of underside of column base shall be so chosen such that the base plate/ anchor
table lies above the finished ground level, by at least 500mm.
c) Minimum thickness of base plate for columns at ground level shall be 20 mm (at other
levels 16 mm) and minimum thickness of washer plate at any level shall be 0.5 times of
Base Plate thickness.

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d) All Built-up columns shall be provided with nominal stiffeners to maintain orthogonal &
torsional rigidity, at a spacing not exceeding 1500 mm centre to centre.
e) All laced columns having individual depth more than 600 mm, shall have diaphragm
plates at alternate lacing points.
01.03.03.02 Screen Supporting Structures
i) Screen supporting shall be preferably concrete floor, slab / beam system which will
adequately dampen the vibrations.
ii) Dynamic load imposed by screen is considerable and shall be taken into account while
designing the supporting system.
iii) Concrete supporting system is preferred to structural steel for its larger mass that
imparts better dampening quality.
iv) Supporting beams should have a natural frequency greater than 1.5 times the operational
frequency of the machine.
v) Natural frequency condition is generally fulfilled if the length to depth ratio is less than
12.
vi) Beam span to be kept to a minimum.
01.03.03.03 Roof Structures
a) The main supporting element for roof shall preferably be roof rafters, made of rolled
sections or built-up sections, provided at uniform spacing to suit the Junction House.
b) Roof shall have suitable slope (1:5, i.e. 1 Vertical: 5 Horizontal, unless otherwise
specified) to meet technological as well as rainwater drainage requirements.
c) System of bracings shall be provided in the roof top chord and bottom chord levels along
with longitudinal ties to ensure stability and rigidity of the roof structures.
d) Galvanized wind tie (45x6 mm flat) shall be provided at the free edge of roof sheeting.
Suitable arrangement of anchors shall be provided at the ridge of roof sheeting for holding
lanyards of safety belts.
e) For design of roof and side wall frame work, purlins / side runners shall be treated as part
of cladding unit and shall be subjected to local wind coefficients as given in codes.
01.03.03.04 Wall Structures
a) Wall runners with necessary sag rod arrangements shall be provided to support wall and
gable sheeting, including internal partition wall, wherever required.

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b) Hanging wall posts shall generally terminate at 2.8 m above ground floor level unless
required to be otherwise.
c) Gables of buildings shall have wall post spaced at intervals to suit bay width
d) Walls shall be provided with louvers and translucent sheeting at appropriate levels, to
provide natural ventilation and lighting.
e) Adequate framing arrangement shall be provided both in roof and side wall framing, for
fixing of ventilator fans / exhaust fans as per requirement.
f) Sheeting on sides and gables shall generally terminate 2.5 m above ground floor level
unless required to be otherwise. Sides below this level shall be generally screened by
brick walls allowing sufficient air inlet to achieve natural ventilation, unless otherwise
required from technological / ventilation requirements.
01.03.03.05 Floor Frameworks
a) Floor beams supporting vibrating equipment shall be designed to avoid resonant

frequencies.
b) All floor beams of working floors shall be designed for a limiting deflection of span/500
without impact.
c) Beams along-with framework, shall be provided with both horizontal and vertical bracing
(wherever permissible) to achieve overall rigidity.
01.03.03.06 Vertical bracings
a) Vertical bracings shall be provided on all column rows for each expansion block.
b) Vertical bracings shall extend from ground level to roof level and shall be designed to
transmit longitudinal forces i.e wind forces, seismic forces, etc. to the foundation.
c) Columns with depth 500 mm or less shall have bracings in single plane at the centre line
of the column. For columns of depth more than 500 mm, bracings shall be provided in
both planes with spacing equal to depth of column. Beam column joints shall be detailed
as per seismic resistant joint with adequate ductility.
01.03.03.07 Access staircase, walkways, platforms and ladders
a) Wherever possible, access shall be provided by means of stairs.
b) All walkways and stairs leading to working platforms shall have minimum 1000 mm
width of walkways/flight of stair.

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c) All other walkways and stairs leading to areas for maintenance purpose, or due to
restriction of space, shall have a minimum width of 800 mm of walkway/flight of stair,
unless required otherwise.
d) Stiffeners of suitable size shall be provided for chequered plate walkways.
e) Staircases shall be generally designed with slope of approximate 37.5 with the horizontal
(in no case the slope shall exceed 40  with the horizontal). All flights of a particular
stairwell shall have same slope.
Intermediate landings shall be provided wherever required such that vertical rise of each
flight does not exceed 3000 mm. Risers in one flight shall be equally spaced.
f) Walkway floors shall be designed with Chequered plate (or non-slip type plates).
g) However all stair treads shall be provided with electro forged gratings of suitable loading
capacity and of approved make.
h) Rise of treads in staircases shall not exceed 200 mm. Width of treads shall not be less than
250 mm.
i) Minimum headroom of 2200 mm shall be provided over operating platforms, visitor's

galleries, or other areas with possibility of public gathering. In all other platforms,
walkways and stairs, minimum headroom of 2000 mm shall be provided. Only in special
cases, local headroom of 1800 mm may be allowed (i.e at intersection with structural
members etc.).
j) Cat ladders shall be provided for access, wherever provision of staircase is impractical
due to limitations of space, or the access is required very infrequently.
k) Wherever the height of cat ladder exceeds 4.0 m, safety cage shall be provided.
Intermediate landing shall be provided to cat ladders such that vertical height of single
rise does not exceed 8.0 m.
l) Cat ladders shall be designed with following provisions:
i) Width of rung = 500 mm

ii) Minimum rise of rung = 250 mm
Maximum rise of rung = 300 mm
iii) Minimum clearance from rung of ladder to back of cage (in case of caged ladders)
= 700 mm
iv) Minimum clearance from the centre of cage all round = 350 mm
v) Slope of cat-ladders:


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I. For normal cat-ladders, slope shall be within the range of 75-90 with the
horizontal.
II. For ship-type ladders (i.e. cat-ladders with short side handrails) the slope shall be
within the range of 65-75 with the horizontal.
vi) Cage shall start from 2500 mm above ground level.
m) All walkways, platforms and stairs shall be provided with safety handrails. All handrails
shall be constructed with steel tubes. The vertical posts shall be located at maximum 1000
mm intervals. The vertical post shall be of 40 NB(M), top rail and mid rail shall be of 32
NB(M) tubes. The toe guard shall be made of skelp. In case of stairs, the toe guards need
not be provided.
n) The vertical height of hand-railings on walkways and stairs shall be minimum 1000 mm
above floor level.
01.03.04 Standardization and Uniformity
01.03.04.01 Every endeavor shall be made to achieve standardization and uniformity amongst the steel
structures of different units of the plant.
01.03.04.02 The following items shall be kept in view in design of structures :
a) Uniform layout module shall be adapted to the extent possible consistent with economy. It
is suggested to adapt a basic module of 3 m for building width and 6 m for column spacing
along building length.
b) Uniform slopes of roofs matching with existing buildings unless specifically required
otherwise for any particular unit.
c) Provision of expansion joints by using twin columns.
d) Uniform adoption of clearance between structures and moving parts of equipment.
e) Provision of adequate natural ventilation by using louvres (canopy like structures) at

appropriate location and roof monitors/natural ventilation systems at roof.
01.03.05 Documentation
Bidder shall submit the 6 copies of design drawings along with the design calculation &
soft copy of staad input file for the approval of design drawings.


& ITS AUXILIARIES
a. Submit the list of drawings and their schedule of submission for

Purchaser’s/Consultant’s approval.
b. After approval of the above, Submit Two (2) prints of each design drawing (supported
by design calculation documents) for Purchaser’s/Consultant’s review/reference as per
the approved schedule, till the drawing is finally accepted. Design drawings shall not be
of greater than A1 size.
On completion of approval of all drawings in any unit, one (1) scanned soft copy on CD
of all approved and stamped design drawings shall be submitted along with the list of
these drawings.
a) Drawings for Structural Steel works
 The Bidder shall prepare fabrication drawings, erection drawings, bill of

materials, drawing office despatch lists / shipping documents, schedule of bolts
and nuts and as built drawings.
 The fabrication drawings shall show full length layout with all connecting
members and connections marked thereon. The fabrication drawings shall include
all the necessary blown-up details required for the correct fabrication of the
structures to meet the design requirements. These drawings shall be made in
conformity with the best modern practices and with due regard to speed and
economy in fabrication and erection. Each erection piece shall be clearly
identified by an erection mark in these drawings.
 The preparation / detailing of fabrication drawing shall be complete in all
respects. In the case of bolted connections, the bolt diameter, the hole diameter,
the actual location of holes and the coordinating scheme with connecting/
matching elements shall be clearly indicated. As far as possible, uniformity in the
bolt diameter shall be maintained. Where HSFG bolts are used, method of surface
preparation shall be indicated. In case of welded constructions, the size and length
of welds along the relevant weld lines should be distinctly marked. The length
specified shall be the effective length excluding end crates. For all butt welds,
details of appropriate edge preparation shall be indicated.
 Detailing of structural steel members subjected to dynamic loading shall be so as
to keep the stress concentration to a minimum. Cross welding shall be avoided as
far as practicable.
 For bolted connections subjected to dynamic loading, lock nuts or spring washers
shall be used in addition to plain washers.
 Erection drawings shall consist of line diagrams showing every detailed member
in position with the respective erection mark. Erection marks shall appear on the
left end of the members as detailed. All steel members shall be erected with marks
in the same relative position as shown in plan or elevation. All loose members


& ITS AUXILIARIES
shall either be given part marks or wired on to the main erection mark for
despatch.
 The erection clearances for cleat-connected ends of members connecting steel to
steel shall preferably not be greater than 10 mm. at each end. The erection
clearance at ends of beams shall not be more than 20mm. at each end but where
for particular reasons greater clearance is necessary, suitably designed seats shall
be provided.
 The fabrication drawings shall be prepared in such a manner that structures are
despatched with maximum transportable lengths and work involved at site is
minimum. Steelwork shall be shop-fitted and shop- assembled as far as
practicable.
 All edge preparations for welding shall conform to IS:9595.
 The Bidder shall ensure correctness & completeness of fabrication drawings.
 The Bidder has to submit the drawings in CD form also for every quarter both for
approval & approved categories.
Approved Steel fabrication & erection drawings (to be submitted directly at site based
on approved Structural drawings).
01.04 Fabrication of Steel Structures
01.04.01 Drawings
The Bidder shall prepare fabrication drawings, erection drawings, bill of materials,
drawing office despatch lists / shipping documents, schedule of bolts and nuts and as
built drawings based on the approved design drawings. All drawing work shall be in
metric system and all writing work shall be in English.
01.04.02 Material of Construction
01.04.02.01 All steel and other materials used for steelwork and in association with steelwork shall
conform to appropriate Indian standards. Only tested materials shall be used unless
written authority is obtained for the use of untested materials for certain secondary
structural members.
Unless otherwise specified in the drawings
a) All rolled sections and plates up to & including 20 mm thickness shall conform to
Grade E250 QUALITY "A” as per IS : 2062-2011.
b) Plates of thickness above 20 mm and Plated structures subjected to dynamic loading

shall conform to Grade E250 QUALITY "B” as per IS: 2062-2011.


& ITS AUXILIARIES
01.04.02.02 Steel sheets shall conform to IS : 1079-2009.
01.04.02.03 Steel tubes for structural purpose shall conform to IS : 1161 (of Grade Yst 240)
01.04.02.04 Permanent Colour coated (non-insulated) metal sheets shall be troughed (Minimum
depth of trough= 28 mm & Maximum pitch of trough= 205 mm) zinc-aluminium alloy
(55% Aluminium, 43.4% Zinc and 1.6% Silicon) coated, not less than 200 gm/sq m,
having High Tensile sheet (Fy=550 MPa) of thickness commensurate with purlin
spacing adopted, subject to a minimum Base Metal Thickness of 0.5 mm. The sheets
shall meet the general requirement of IS: 15965 and shall conform to class 4 for the
durability.
01.04.02.05 Polycarbonate sheet shall be 3 mm thick of matching profile with metal cladding profile
confirming to IS:14443-1997. The designation/classification of the sheet shall be
IS:14443*PC1S0*LUTN*2520
01.04.02.06 Gutters shall be of copper bearing steel conforming to Grade E250 QUALITY Grade
"A" as per IS :2062-2011.
01.04.02.07 Crane Rails shall conform to IS : 3443-1980.
01.04.02.08 All black bolts, nuts and locknuts shall conform to IS : 1363 and IS : 1364 (for
precision and semi precision hexagonal bolts) of property class 6.4 unless otherwise
specified. Washers shall conform to IS : 6610
01.04.02.09 All tapered washer shall be as per IS:5372 for channels, and IS:5374 for Joists. Spring
washers shall conform to IS:3063.
01.04.02.10 Covered electrodes for arc welding shall conform to IS: 814-2004.
01.04.02.11 Down commers shall conform to IS:3589-2001.
01.04.02.12 Expanded Metal Nets shall conform to IS:412-1979.
01.04.02.13 Certified mill test reports of materials used in the work shall be made available for
inspection by the Owner / Consultant upon request.
01.04.03 Fabrication
01.04.03.01 Fabrication of all structural steelwork shall be in accordance with IS:800-2007 and in
conformity with various clauses of the Technical Specification.
01.04.03.02 Wherever practicable and wherever perfect matching of parts is required at site,
members shall be shop assembled before despatch to minimise site work. Parts not


& ITS AUXILIARIES
completely assembled in the shop shall be secured, to the extent possible, to prevent
damage during despatch.
01.05 Erection of Steel Structures
01.05.01 Scope
The scope of work under erection includes in addition to provision of erection and
transport equipments, tools and tackles, consumables, materials, labour and
supervision, the following:
a) Storing and stacking at site of erection of all fabricated structural components/

units/assemblies till the time of erection.
b) Transportation of structures at site.
c) Receiving at site of structures including site handling /movement, unloading, storing

and stacking at site of erection of technological structures such as bunkers and the
related structures
d) All minor rectification / modification such as :
i) Removal of bends, kinks, twists, etc. for parts damaged during transportation and
handling;
ii) Cutting chipping, filing, grinding, etc., if required, for preparation and finishing of
site connections;
iii) Reaming for use of next higher size bolt for holes which do not register or which
are damaged.
iv) Welding of connections in place of bolting for which holes are either not drilled at
all or wrongly drilled during fabrication.
e) Other rectification work such as
i) Re-fabrication of parts, damaged beyond repair during transportation and handling

or incorrectly fabricated.
ii) Fabrication of parts omitted during fabrication by oversight or subsequently found
necessary.
iii) Plug-welding and re-drilling of holes which do not register and which cannot be
reamed for use of next higher size bolt.
f) Fabrication of minor items/missing items or such important items as directed by the

Owner / Consultant.
g) Assembly at site of steel structural components wherever required including temporary
supports and staging.

& ITS AUXILIARIES
h) Making arrangements for and providing all facilities for conducting ultrasonic X-ray or
gamma ray tests on welds; getting the tests conducted by reputed testing laboratories,
making available test films/ graphs, reports and interpretation.
i) Rectifying at site, damaged portions of shop primer by cleaning and touch-up paint.
j) Erection of structures including making connections by bolts/high strength friction grip
bolts / welding.
k) Alignment of all structures true to line, level plumb and dimensions within specified
limits of tolerances as per IS :12843 “Tolerance for Erection of Steel Structures”.
l) Application of second coat of primer paint and two coats of finishing paint at site after
erection.
m) Grouting of all column bases after proper alignment of columns and only after obtaining
clearance from Owner / Consultant.
o) Conducting preliminary acceptance and final acceptance tests.
p) Preparation of as built drawings, preparing of sketches/drawings to suit field
engineering decisions, availability of material, convenience of fabrication,
transportation and erection and changes during fabrication and erection.
All such works are subject to approval by the Owner / Consultant.
01.06 Painting of Building Steel Structures
01.06.01 All steel structural work shall be painted as follows unless otherwise stated in the
drawing / Technical Specification.
01.06.02 Surface preparation
The steel surface which is to be painted shall be cleaned of dirt and grease, and the
heavier layers of rust shall be removed by chipping prior to actual surface preparation to
a specified grade.
Following blast cleaning type of surface preparation is to be followed based on the

requirement of a particular painting system or as specified in the design drawings.
Grade Sa-2½: This involves very thorough blast cleaning. Mill scale, rust and foreign
matter shall be removed to the extent that the only traces remain in the form of slight
stains. Finally the surface is cleaned with a vacuum cleaner, clean dry compressed air or
a clean brush. It shall then correspond in appearance to the prints designated as Sa 2½.


& ITS AUXILIARIES
01.06.03 Paint System
Following Epoxy based paint system is to be followed:

i) Surface preparation: Sa 21/2 according to Swedish Standard SIS055900.
ii) Primer paint: -Two coats of epoxy based red oxide or zinc phosphate (DFT =40
microns/coat).
iii) Intermediate paint: - One coat of epoxy based MIO, i.e., micaceous iron oxide (DFT =
75 microns).
iv) Finishing paint: - Two coats of epoxy amine/polyamide cured finish (DFT = 40
microns/coat).
All paints shall be of approved and shade as per Owner / Consultant's requirements.
01.06.04 Paint and Painting
Manufacture of paints, mixing of paints, etc. shall be generally according to the relevant
IS codes of practice.
Generally compatibility between primer intermediate and finishing paint shall be

certified by the paint manufacturer supplying the paints.
Guarantee period shall commerce from the date of completion of finishing coat of paint
on entire structures. The guarantee period shall be indicated depending on the type of
surface preparation and system of painting. To fulfill this obligations, the Bidder may
obtain from the painting manufacturer, guarantee for the performance of paint/painted
surfaces.
Application of paint shall be by spraying or brushing as per IS : 486-1983 and IS :

487-1985 and in uniform layers of 50% overlapping strokes by skilled painters. Painting
shall not be done when the temperature is less than 5 degree C or more than 45 degree C
and relative humidity is more than 85% unless manufacturer's recommendations permit.
Also painting shall not be done in foggy weather. During application, paint agitation
must be provided where such agitation is recommended by the manufacturer.
Painting shall be applied at painting manufacturer's recommended rates. The number of

coats shall be such that minimum dry film thickness specified is achieved. the dry film
thickness (DFT) of painted surfaces shall be checked with ELCOMETER or measuring
gauges to ensure specified DFT.
All structures shall receive one coats of primer paint at shop after fabrication before
despatch after surface preparation has been done as per requirements.


& ITS AUXILIARIES
Unless otherwise specified all structures after erection shall be given one coat of primer
and two coats of finishing paint of approved colour and quality. The under coat shall
have different tint to distinguish the same from the finishing coat.
The proposed make, quality and shade of paint shall have the approval of Owner /
Consultant’
01.07 Quantities of Structural Items
The bidder shall indicate the estimated quantities of structural items of work ie
fabrication/ erection tonnage , sheeting in sq.m etc. Bidder shall not make any
additional claim if structural quantity of any items required for completion of entire
package as per terms of contract exceed the quantity indicated by the bidder.

METTUR THERMAL POWER STATION -I

(4X210MW)
FOR
VOLUME – VI
MANDATORY SPARES AND TOOLS & TACKLES
MECON LIMITED
RANCHI – 834 002

MEETUR THERMAL POWER STATION-I (4X210MW)

& ITS AUXILIARIES
INDEX TO VOLUMES
Volumes Title
Vol. – VI INDEX TO VOLUME Page 2 of 3

MEETUR THERMAL POWER STATION-I (4X210MW)

& ITS AUXILIARIES
Volumes Title
Volume -VA Civil Works
Vol. – VI INDEX TO VOLUME Page 3 of 3


SEMI DRY FLUE GAS DESULPHURIZATION(FGD)
SYSTEM & ITS AUXILIARIES
01.00 LIST OF MANDATORY SPARES
01.01 General
The Bidder shall include in his scope of supply all the necessary Mandatory
spares, as indicated hereunder.
Editable soft copies of lists of mandatory spares preferably in word/excel format

(additionally for compilation purposes), along with the copies of signed non editable
formats.
01.02 Scope
This section covers the general requirements regarding the mandatory spares and tools
and tackles for all the equipment and systems in the power plant.
01.03 Mandatory Spares
The Contractor shall supply in his scope mandatory spares as specified in this Volume.
The supply of mandatory spares shall be started with the consignments of the first unit
and completed before the provisional takeover of the first unit
01.04 Tools and Tackles
The Contractor shall supply the Special Tools & Tackles as listed in this Volume.
The supply of Mandatory spares and tools & tackles shall be delivered with the last
consignment of the respective equipment of first FGD unit. The Mandatory spares and
tools and tackles will be handed over at the Purchaser’s stores after the provisional
takeover of the first FGD unit.
01.05 Prices
The itemized Prices of the mandatory spares and special tools and tackles shall be
indicated and the sum total price of mandatory shall be indicated in the respective price
table in Volume I of the Specification
01.06 Detailed Guidelines for Mandatory Spares and Tools and Tackles
a) The Bidder shall supply the mandatory spares and tools and tackles as listed.
b) The Bidder shall give itemized unit price for the spare parts, tools and tackles while
submitting the bid. The Owner reserves the right to modify or delete the items/quantity of
the spares/tools & tackles. The quoted price for taxes & duties, transport, insurance etc.
shall get reduced proportionately to the extent of the value of ordered spares/tools and
tackles. The list of such spares/tools and tackles to be ordered by the Purchaser shall be
finalised by the Owner before signing of the Contract.
Vol. – VI, MAND. SPARES AND TOOLS & TACKLES Page 1 of 8


c) In case the description / nomenclature of any of the items of spares/tools and tackles is
differing from the description / nomenclature indicated in the list of mandatory
spares/tools and tackles, the bidder shall offer functionally equivalent part in lieu of the
listed item.
d) In case if such items of spares/tools & tackles indicated as “not applicable”, are found
applicable at a later date during execution of the project, such items of spares/tools &
tackles are to be supplied within the ordered cost of the mandatory spares.
e) If any of the items of spares/tools & tackles ordered is found to be not applicable during
detailed engineering stage/execution stage, the contractor shall have to supply alternative
items of spares/tools & tackles. The alternative items of spares/tools & tackles are to be
mutually agreed between the Owner and Supplier.
f) In respect of quantity mentioned as 'Set' means the total quantity of all the
components/items used in particular equipment unless otherwise specified.
Example-1
One set of spare part which is having four different items of which first item is having 2
similar parts, second one is having 3 similar parts and other two are having one part each,
then one set means, combination of 2 similar parts of first item and 3 similar parts of
second and one each of 3rd & 4th items.
Example-2
If the quantity of particular spare part is more than one, set means the total no. of similar
parts.
g) Wherever % is indicated for the mandatory spares, the quantity shall be calculated for %
of supply for total quantity for 2 units, unless otherwise specified. The quantity to be
reckoned for % indicated shall be rounded off to the next higher whole number. For
example if the % arrived is 0.2 the quantity to be supplied shall be 1 and if the % arrived
is 5.1 the quantity to be supplied shall be 6.
h) All relevant drawings to identify of spares/tools & tackles are to be furnished when called
for by the OWNER.
This above details shall be applicable for electrical, C & I and Civil system also.
01.07 List of Mandatory Spares – Mechanical
S. No Description Unit Quantity Remarks

1.0 Booster Fan
1.1 Fan rotor assembly Nos. 2
(excluding servo motor and
blade)
1.2 Booster fan motor complete. Nos. 1
1.3 Booster fan motor bearing Sets 2
1.4 Fan bearings Sets 2
1.5 Spares for blade bearing Assembly
i) Bearings Sets 4



ii) 'O' rings Sets 4
iii) Bushes Sets 4
iv) Metallic rings Sets 4
v) Intermediate piece (if Sets 4
applicable)
1.6 Lube Oil / Hydraulic Oil
system
i) Pump assembly Nos 1 Each type
ii) Motor No 1 Each type & Rating
iii) Pressure regulator Nos 2
iv) Filters Nos 4
v) Coupling between oil pump & Nos 2
motor
vi) Pump Mechanical Seal Nos 2
1.7 Fan Blades Sets 2
1.8 Coupling between Fan & Sets 2
Motor
1.9 Hydraulic servomotor Nos 2
1.10 Booster fan impeller liner Sets 2
1.11 Booster fan casing liner Sets 2
2.0 Gates in Flue Gas System
2.1 Seals sets 2 of each type (Set
means complete
replacement for one
gate)
2.2 Actuator No 1 Each type
2.3 Expansion Joint No 2 Each type
3.0 Air Blower/ Air compressor
3.1 Impeller Assembly Sets 2 each type
3.2 Casing Nos. 2 each type
3.3 Bearings Sets 2 each type
3.4 Motor No. 1 each type
4.0 Agitators
4.1 Impeller Assembly No. 1 each type and size
4.2 Bearing Assembly Nos 2 each type and size
4.3 Motor No. 1 each type and size
4.4 Belt and Pulley (If applicable) Nos 2 each type and size
4.5 Gear Box Assembly (If No. 1 each type and size
Applicable)
4.6 Complete agitator assembly No. 1 each type and size
4.7 Shaft assembly set 1 each type and size
4.8 Shaft seal No. 1 each type and size
5.0 Slurry Pumps
5.1 Impeller Assembly No. 4 each type
5.2 Casing Liners Nos 1 each type
5.3 Seals No. 4 each type
5.4 Bearings Nos 1 each type


5.6 Motor-Pump Coupling No. 1 each type
6.0 Gravimetric Feeders
6.1 Belt sets 4
6.2 Belt drive motor No. 2
6.3 Belt drive reducer Nos 2
6.4 Speed Reducer Assembly set 2
6.5 Weighing Instruments set 2
6.6 Feeder weighing roll No. 2
6.7 Gravimetric feeder gate No. 2
actuator assembly
6.8 Counter assembly of feeder No. 1
complete
6.9 Feeder head pulley assembly No. 1
6.10 Inlet span roller assembly Nos. 6
7.0 Slurry Valves Nos. 4 each type and size
8.0 Slurry Line Bends Nos. 4 each type and size
9.0 Sump Pumps
9.1 Complete Impeller Assembly No. 1 each type
9.2 Casing Liners set 1 each type
9.3 Bearing sets 2 each type
9.5 Pump discharge valve assembly No. 1 each type
10.0 Vent Filter for Silo
10.1 Bag % 20 of Total Population Or
minimum 15 Nos.
10.2 Bag’s Cage % 20 of Total Population Or
minimum 10 Nos.
10.3 Pulse Nozzle % 20 of Total Population Or
minimum 10 Nos.
10.4 Pulse Valve % 20 of Total Population Or
minimum 4 Nos
11.0 SUMP PUMP
11.1 Complete pump assembly with set 1
pump, motor, coupling base etc
11.2 Impeller with key & nut sets 2
11.3 Oil seal Nos. 2 Each type
11.4 Coupling bolt with bushes sets 2 Each type
11.5 Pump shaft sets 2 Each type
11.6 Shaft sleeve sets 2 Each type
11.7 Bearing bush sets 2 Each type
11.8 Set of bearings (pump & motors) sets 2 Each type
12.0 VENTILATION SYSTEM
12.1 V-Belt sets 1 Each type
12.2 Pre-filter element of pressurizing sets 2 Each type
fans
12.3 Foundation Rubber pads sets 1 Each type


12.4 Bearings sets 1 Each type
12.5 Plummer Blocks sets 1 Each type
13.0 Horizontal Centrifugal Pumps
13.1 Complete Impeller Assembly Nos. 1 each type
13.2 Impeller/Casing Liner Nos. 1 each type
13.3 Pump & Motor Bearing Set 1 each type
13.4 Motor Nos. 1 each type
13.5 Pump Discharge Assembly Nos. 1 each type
13.6 Pump motor coupling No. 1 each type
13.7 Gear box No. 1 each type
14.0 Knife Gate Valve
14.1 Slide No 1
14.2 Complete assembly
a) Cylinder operated No 1
b) Manual operated No 1
14.3 Solenoid Valves Nos 1 Each type
15.0 Hoists & Cranes
15.1 Long travel wheel Nos 1
15.2 Cross travel wheel Nos 1
15.3 Bearings for each gear box Set 1
15.4 Bearings for long travel wheels Set 1
15.5 Bearings for cross travel wheels Set 1
15.6 Oil seals for each gear box Set 1
15.7 Pins & rubber bushes for the Set 1
flexible coupling for each motor
15.8 Wire rope for hoist length 1
15.9 Brake linings for all brakes Set 1
15.10 Trustors with cups and seals for Set 1
electro-hydraulic thrustor brakes
15.11 Limit switches for all motions Set 1
15.12 Contact for main and reversing Set 1
contractors
15.13 Carbon brushes and brush Set 1
holders for all slip ring type
motors
15.14 Solenoid coils for all the electro- Set 1
mechanical brakes
15.16 Make & trip coils Set 1
15.17 Fuse links for each motor Set 1
15.18 Push button Set 1 Each type
15.19 Indicating lamp Set 1 Each type
16.0 Fire protection and detection system spares
16.1 Deluge Valve Assemblies 10% or 1 No. of each type, class,
size and model
whichever is more
16.2 Complete deluge valve assembly 10% or 1 No. of each type, class,



along with internals and size and model
accessories whichever is more
16.3 Clapper assembly complete 10% or 1 No. of each type, class,
(consisting of clapper seat size and model
rubber, screws etc.) whichever is more
16.4 Butterfly valve 10% or 1 No. of each type, class,
size and model
whichever is more
16.5 Stem for Butterfly Valve 10% or 1 No. of each type, class,
size and model
whichever is more
16.6 Strainer elements with O-rings 10% or 1 No. of each type, class,
and stiffeners size and model
whichever is more
16.7 Y-Type strainer 10% or 1 No. of each type, class,
size and model
whichever is more
16.8 MVW Spray System
a) Spray Nozzles 10% or 1 No. of each type, class,
size and model
whichever is more
b) QB Detectors 10% or 1 No. of each type, class,
size and model
whichever is more
16.9 HVW Spray System
a) Spray Nozzles 10% or 1 No. of each type, class,
size and model
whichever is more
b) QB Detectors 10% or 1 No. of each type, class,
size and model
whichever is more
17.0 Fire Detectors
17.1 Multi-sensor detectors No. 10% or 1 No. of each type, class,
(Addressable) size and model
whichever is more
17.2 Indicators assembly for smoke No. 10% or 1 No. of each type, class,
detectors provided in false size and model
ceiling (Response indicator) whichever is more
17.3 LHS cable for conveyors No. 10% or 1 No. of each type, class,
size and model
whichever is more
18.0 Fabric filter bag house
18.1 Bag % 20 of Total Population
18.2 Bag’s Cage % 20 of Total Population
18.3 Pulse Nozzle % 20 of Total Population
18.4 Pulse valves % 20 of Total Population



19.0 Absorber -CDS
19.1 Water Injection Nozzles No. 1 Set
19.2 reagent Injection Nozzles No. 1 Set
20.0 Absorber -SDA
20.1 Atomiser assembly No. 1 set
01.08 List of Mandatory Spares – Control & Instrumentation
S. No Description Quantity
1.0 Complete set of CEMS 10% of total quantity or 1 no. whichever is
analyzer more (for each Make, Type/Model)
2.0 PLC Controller, I/O cards 10% of total quantity or 1 no. whichever is
(AI,AO,DI,DO) more (for each Make, Type/Model)
communication Modules,
Interfacing cables etc
3.0 OWS,EWS – Computer CPU 10% of total quantity or 1 no. whichever is
and accessories like Monitor, more (for each Make, Type/Model)
key board, Mouse, SMPS,
Hard disk, etc
4.0 Different field instruments like 10% of total quantity or 1 no. whichever is
Transmitters (press., flow, more (for each Make, Type/Model)
temp, level), switches, Gauges,
indicators, Thermocouples,
RTDs, Vibration pick ups, root
valves etc.
01.09 List of Mandatory Spares – Electrical
S. No Description Quantity
1.0 Floor Mounted VCB (7.2kV, 1 No.
2000A, 40kA) (one to one
interchangeable)
2.0 Bushing CTs, Core balance 1 Set
CTs, Relays, Meters, Surge
absorbers etc.
01.10 List of Tools and Tackles

1 Hydraulic cable crimping tools set 1 of each
2 Set of spanners / tools range/size
a) Box spanners (6-32) set 1

b) Ring spanners (6-32) set 1


3 Electrician tool kit in a bag containing set 1

screw driver, power supply tester
(superior type), set of spanners (6-16),
slide wrench 6”, hex frame, tapes
4 Breaker lifting/handling truck
a) Hydraulic no. 1
b) Manual no. 1
5 Breaker racking handle nos. 2 of each
6 Fuse pullers/handle nos. 4 board
of each type
7 Test plug with coupling cables for nos. 2 for each
testing breaker in withdrawn position board
8 Relay test plug set 1 for each
9 Spring charging handle nos. 10 board
10 PMCC tray racking handle nos. 30

11 Free standing adjustable aluminum no. 1
ladder, adjustable from 5m. to 10m
12 Lux meter No. 1


(4X210MW)
FOR
VOLUME – VII
TENDER DRAWINGS
MECON LIMITED
RANCHI – 834 002


& ITS AUXILIARIES
INDEX TO VOLUMES
Volumes Title
Vol. – VII INDEX TO VOLUME Page 2 of 3


& ITS AUXILIARIES
Volumes Title
Vol. – VII INDEX TO VOLUME Page 3 of 3


TENDER DRAWINGS
The drawings listed below, forming part of the tender specification
Sl. No. Title of Drawings Drawing No. Rev. No.

1. General Layout for Semi Dry based FGD system MEC/11/14/10KP/TS/001 00
2. Flow Diagram for Semi Dry (CDS) based FGD MEC/11/S3/10KP/TS/002 00
System
3. Flow Diagram for Semi Dry (SDA) based FGD MEC/11/S3/10KP/TS/003 00
System
4. Key Single Diagram (Semi Dry Based FGD System) MEC/11/E1/10KP/TS/004 01
5. FGD PLC Configuration Diagram MEC/11/E5/10KP/TS/005 00
Vol. – VII LIST - TENDER DRAWING Page 1 of 1

LEGEND
SPACE FOR FGD SYSTEM
EXISTING UNIT
PROPOSED OUTGOING DUCT
EXISTING ASH SILO
PROPOSED INCOMING DUCT
EXISTING RAILWAY TRACK
FOR TENDER PURPOSE ONLY

NOTE-2
TT
WATER
1
I
(FABRIC FILTER)
GATE GATE GATE
ABSORBER
B B DAMPER DAMPER DAMPER
BY PRODUCT
SILO
4 2
PROCESS
WATER
NOTE-5
TANK
PROCESS WATER
SUPPLY PUMPS
2x100% RECIRCULATION LINE
I
EXISTING NOTE-3
STACK PDT
NOTE-4
B AT
SO2 GATE
DAMPER
1
B I
SILO VENT
DUST FILTER
BY PRODJCT
DISCHARGE
AIR BY PRODUCT
SILO
(PENUMATIC
SILO VENT CONVEYING)
DUST FILTER
3
3
BIPLANE
DAMPER NOTE-2
TC
BIOLER
CONTROL
SILO VENT
DUST FILTER
DISCHARGE TERMINAL POINT
A B A HYDRATED
LIME
BOILER SILO B
FOR EACH
UNIT
SILO VENT B
B B B (7 DAYS) DUST FILTER
STORAGE AIR LIME
BIPLANE BOOSTER BIPLANE CARRYING TRUCK
ID FAN DAMPER DAMPER
COMPRESSED AIR 3
FAN FOR FGD PLANT (BY OTHERS)
3
DUST FILTER
SILO VENT
B
SURGE BIN
SERVICE WATER FROM 1x100%
EXISTING PLANT
COMPRESSER AIR
B FOR FGD PLANT
SERVICE WATER
TANK TO PLANT SERVICE GRAVIMETRIC
WATER RQUIREMENT FEEDER
2x100%
SERVICE WATER
TRANSFER PUMPS
FEEDER
2x100%
3
AIR
MECON LIMITED
PDT
PDT
1
GATE
(FABRIC FILTER)
DAMPER GATE GATE GATE
DAMPER DAMPER DAMPER
SPRAY DRYER
ABSORBER
(PNEUMATIC
CONVEYING)
SILO VENT
STACK DUST FILTER AIR
HYDRATED
LIME
SILO VENT
STORAGE B
SILO DUST FILTER
AT
B SO 2 (7 DAYS)
STORAGE B
1
LIME
B CARRYING TRUCK
GRAVIMETRIC (BY OTHERS)
FEEDER
2x100% 2 SILO VENT
(PNEUMATIC DUST FILTER
AIR CONVEYING)
2
3
SLAKING
BY PRODUCT
WATER
SILO
LIME
SLAKER
2x100%
TC
VIBRATING GRIT TO DISPOSAL

BIPLANE
DAMPER NOTE-2 GRIT SCREEN (VIA PORTABLE
CONTAINER)
DISCHARGE
BIOLER
CONTROL
Ca (OH) SLURRY
2
HOLDING TANK
1x100%
A A
B
BOILER
LIME SLURRY PUMP
B
2x100% B
B B
BIPLANE BOOSTER BIPLANE SERVICE WATER FROM
ID FAN DAMPER DAMPER EXISTING PLANT
FAN B
COMPRESSED AIR
SERVICE WATER
FOR FGD PLANT
TANK TO PLANT SERVICE
WATER RQUIREMENT
SERVICE WATER
PROCESS TRANSFER PUMPS
WATER FROM 2x100%
EXISTING PLANT B
COMPRESSER AIR
FOR FGD PLANT
PROCESS
WATER TANK 3
PROCESS
WATER SUPPLY PUMPS
MECON LIMITED
IS
O ny
90 pa
01 Com
Signature Not Verified

Digitally signed by S SHANTHINI
Date: 2021.02.24 19:29:13 IST
Location: Tamil Nadu-TN

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TAMIL NADU GENERATION AND DISTRIBUTION

CORPORATION LIMITED (TANGEDCO)

METTUR THERMAL POWER STATION - I

DOC. No: MEC/11/S3/10KP/TS/2569/R-0, Rev. 01 November, 2020

TENDER SPECIFICATION FOR

Vol. – IIA INDEX TO VOLUME Page 2 of 3

TENDER SPECIFICATION FOR

Vol. – IIA INDEX TO VOLUME Page 3 of 3

© 2020 MECON Limited. All rights reserved..

TENDER SPECIFICATION FOR

01.02 This Tender Specification shall be read in conjunction with general

Vol. – IIA, Section 01.00 PREAMBLE Page 1 of 2

TENDER SPECIFICATION FOR

01.03 Tender drawings

Vol. – IIA, Section 01.00 PREAMBLE Page 2 of 2

© 2020 MECON Limited. All rights reserved..

TENDER SPECIFICATION FOR

02.00 INTENT OF SPECIFICATION

02.02 This specification is intended to cover design, engineering, manufacture / supply,

a) Basic Engineering of all equipments/ systems;

b) Detailed design of all the equipments/ systems including complete civil,

c) Providing engineering drawings, data, instruction manuals, as built drawings and

d) Compliance with statutory requirements and obtaining clearances from statutory

e) Complete manufacturing including shop testing;

g) Receipt, movement to proper storage, storage, preservation and conservation of

Vol. – IIA, Section 02.00 INTENT OF SPECIFICATION Page 1 of 3

TENDER SPECIFICATION FOR

h) Fabrication, pre-assembly, erection, testing, pre-commissioning and

i) Performance guarantee / acceptance tests after successful completion of Trial

j) Supply of mandatory spares as per specified list

l) Supply of consumables including chemicals, resins, lubricants, lube oils with

m) Training of purchaser’s personnel nominated by the purchaser during erection,

n) Reconciliation with customs authorities, in case of imported equipments;

o) Satisfactory conclusion of the contract;

Vol. – IIA, Section 02.00 INTENT OF SPECIFICATION Page 2 of 3

TENDER SPECIFICATION FOR

Vol. – IIA, Section 02.00 INTENT OF SPECIFICATION Page 3 of 3

© 2017 M © 2020 MECON Limited. All rights reserved..

TENDER SPECIFICATION FOR

03.00 PROJECT INFORMATION

03.02 General & Project Information

03.03 Project & Site Information

i) Owner/Purchaser TANGEDCO Limited, Mettur Thermal

Vol. – IIA, Section 03.00 PROJECT INFORMATION Page 1 of 5

TENDER SPECIFICATION FOR

03.04 FGD Design parameters:

Operating Conditions Design Case

03.05 Primary Fuel Characteristics

Sl. No. Description Symbol Normal Worst Best

Vol. – IIA, Section 03.00 PROJECT INFORMATION Page 2 of 5

TENDER SPECIFICATION FOR

Sl. No. Description Symbol Normal Worst Best

03.06 Lime Chemical and Sieve Analysis

S.No. Name of the Parameter UOM Specifications

Size Distribution 0-10mm Quick lime

Size Distribution 0-80mm

Vol. – IIA, Section 03.00 PROJECT INFORMATION Page 3 of 5

TENDER SPECIFICATION FOR