Ntpc Farakka Specs

NTPC Limited (A Government of India Enterprise)

FARAKKA SUPER THERMAL POWER PROJECT

TECHNICAL SPECIFICATION

FOR

COAL CONVEYING PLANT PACKAGE

BIDDING DOCUMENT NO. :

NTPC Limited (A Government of India Enterprise)



FOR


BIDDING DOCUMENT NO. :

This document is meant for the exclusive purpose of bidding against this specification and shall not be transferred, reproduced

or otherwise used for purposes other than that for which it is specifically issued.

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TABLE OF CONTENTS

PART SECTION NO TITLE

PART-A Sub Section – II : Scope of Supply & Services

IIA-01 Intent of Specification

PART-B Sub Section III : Technical Parameters

IIIA MECHANICAL

IIIA-01 System Parameters and Operation & Control Philosophy

IIIA-02 Brakes & Clamps

IIIA-03 Monorails and Hoists

IIIA-04 Chutes & Hoppers

IIIA-05 Belt Conveyor System

IIIA-06 Drive Equipment

IIIA-07 Belt Scale

IIIA-08 Dust Control & Miscellaneous System

IIIA-09 Ventilation System

IIIA-10 CHP Building

IIIA-11 Inline Magnetic Separator

IIIA-12 Metal Detector

IIIA-13 Coal Sampling Unit

IIIA-14 Vibrating Feeder

III-B ELECTRICAL

IIIB-01 Motors

IIIB-02 LT Switchgear & Bus Duct

IIIB-03 LT Power Cables

IIIB-04 H T Cables

IIIB-05 Control Cables IIIB-06 Instrumentation cables IIIB-07 Illumination System IIIB-08 Cabling, Earthing & Lightning Protection

IIIB-09 Transformers

IIIB-10 H T Switchgear

IIIB-11 PLC Control Cables

PART-B

IIIB-12 Battery

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PART SECTION NO TITLE IIIB-13 Battery Charger

IIIB-14 Measuring Instruments

IIIB-15 CCTV PART-B III-D CIVIL

IIID-01 CHP System - Civil Works PART-B IIID-02 Foundation System and Geotechnical Data

(Turnkey)

PART-B III-E QA & I SECTION

E-01 Coal Conveyors Belt

E-02 Motors

E-03 LT Switchgear

E-04 LT Busduct

E-05 LT Power Cables

E-06 LT Control Cables

E-07 Instrumentation Cables

E-08 Station Lighting

E-09 Cabling, Earthing & Lightning Protection

E-10 H T Cables

E-11 H T Switchgear

E-12 HT Capacitor Bank

E-13 Measuring Instruments

E-14 Power Supply For C&I System

E-15 Transformer

E-16 Battery

E-17 Battery Charger

E-18 Control Panels

E-19 Control System

PART-B

E-20 CHP System - Civil Works

PART-E List of Tender Drawings

CLAUSE NO.

SCOPE OF SUPPLY AND SERVICES



TECHNICAL SPECIFICATION SECTION-VI

PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF

SPECIFICATION

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1.00.00 INTENT OF SPECIFICATION

This specification is intended to cover the following activities and services in respect of all the equipment of Coal Conveying Plant from jetty to plant site to be installed for Farakka Super Thermal Power Project, of the NTPC Limited, located in Murshidabad district,in the state of West Bengal, India.

(a.) (i) Detailed design and engineering of all the equipment and equipment system(s).

(ii) Complete manufacture including shop testing/ type testing.

(iii) Providing engineering data, drawings, Commissioning procedures and O & M manuals, etc.

(iv) Packing and transportation from the manufacturer’s works to site including transit insurance, customs clearance/ port clearance, if required.

(v) Receipt, unloading, storage, preservation, conservation and insurance of equipment at site.

(vi) Fabrication, pre-assembly, (if any), erection, testing and putting into satisfactory operation of all the equipment including successful completion of facilities.

(vii) Associated civil, structural, architectural and electrical works.

(viii) Commissioning and completion of facilities and Performance Guarantee Tests after successful completion of initial operation.

(ix) Furnishing of spares on FOR site basis and handing over to NTPC stores.

(x) Reconciliation with custom authorities, if applicable.

(xi) Satisfactory completion of the contract.

(b.) The Contractor shall be responsible for providing all materials, equipment and services, specified or otherwise (unless specifically excluded) which are required to fulfill the intent of ensuring operability and the reliability of the complete system covered under this specification.

(c.) It is not the intent to specify completely herein, all aspects of design and construction of equipment. Nevertheless, the equipment shall conform in all

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respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation.

(d.) Whenever a material or article is specified or described by the name of a particular brand, manufacturer or trade mark, the specific item shall be understood as establishing type, function and quality desired. Other manufacturer’s products may also be considered provided sufficient information is furnished so as to enable the Employer to determine that the products are equivalent or superior to those named.

(e.) Before submitting his bid, the Bidder should inspect and examine the site and its surroundings and should satisfy himself as to the nature of the ground and subsoil, the quantities and nature of work, materials necessary for completion of the work and their availability, means of access to site and in general shall himself obtain all necessary information as to risks, contingencies and other circumstances which may influence or affect his offer. No consequent extra claims on any misunderstanding or otherwise shall be allowed by the Employer.

(f.) For all the related buildings and facilities in Employer’s scope and not covered under the scope of this package, the contractor shall furnish all the related input data/ details for preparation of Mechanical/ Electrical/ Civil Drawings within 45 days of award of contract.

(g.) The sizes of various buildings/conveyor galleries indicated in the tender drawings and the parameters of equipment indicated in various sections of technical specifications are the minimum requirements of the employer. Any increase in these sizes or the parameters, if required to meet the system/maintenance/operational requirement shall be supplied by the contractor without any extra cost implication to the employer.

(h.) Bidder shall take all necessary precautions to protect all the existing equipment, structures, facilities and buildings etc. from damage. In case any damage occurs due to the activities of the contractor on account of negligence, ignorance, accidental or any other reason whatsoever, the damage shall be immediately made good by the contractor at his own cost to the satisfaction of the Employer. The contractor shall also take all necessary safety measures with specific reference to excavation in rock, at his own cost, to avoid any harm or injury to his workers and staff from the equipment and facilities of the power plant.

(i.) Bidder should note that the existing rail lines within the plant area are operational with rail traffic of coal and liquid fuel rakes. Bidder shall take all precautions to ensure the safety of existing rail tracks and other associated facilities as well as the safety of his men, material and equipment from the

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operating rail traffic. The bidder shall plan and make all arrangements to ensure that disruption to the existing rail traffic is minimum and shall follow the instructions of the Employer in this regard. Further, bidder shall plan and co-ordinate all his activities considering restrictions, if any, on free access to his work areas due to the rail traffic.

(j.) After award of work, before finalising his layout especially the layout / levels of conveyors, cable / pipe routes and other services, the contractor shall carry out a site survey to identify the location & details of existing facilities that may interfere with his proposed facilities. The contractor shall suitably modify his layout / levels to prevent dislocation of existing facilities and any cost / time implication arising out of such modifications will be to his account. Contractor shall also be responsible to determine and obtain the necessary details at site as required for interfacing and interconnection with the existing system / facilities.

If during the execution of works it is found that there is interference with the existing facilities / structures, the contractor shall revise his design / detailed drawings to clear the interference and shall provide all necessary measures for the safety of existing structures. No claim in terms of cost or relaxation in time shall be entertained for any redesign, rework and for safety measures provided. If at any stage of work, any dismantling or modification or relocation of any existing facility is required to be done to complete the work in bidder’s scope and which has been agreed by the Employer, the same shall be done by the bidder at no extra cost or time implication to the Employer. All such changes will be as per drawings and work plan approved by the employer.

1.02.00 Equipment and services covered under COAL CONVEYING PLANT package are described in the following sub-sections :

MECHANICAL

III-A-01 : System parameters and Operation & Control Philosophy

III-A-02 : Brakes and Clamps

III-A-03 : Monorails and Hoists

III-A-04 : Chutes and Hoppers

III-A-05 : Belt Conveyor System

III-A-06 : Drive Equipment

III-A-07 : Belt Scales

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III-A-08 : Dust Control & Miscellaneous Systems

III-A-09 : Ventilation System

III-A-10 : CHP Buildings

III-A-11 : Inline Magnetic Separator

III-A-12 : Metal Detector

III-A-13 : Coal Sampling Unit

IIIA-14: Vibrating Feeder

ELECTRICAL

IIIB-01: Motors

IIIB-02 : LT Switchgear & Bus Duct

IIIB-03 : LT Power Cables

IIIB-04: HT Cables

IIIB-05 : Control Cables

IIIB-06 : Instrumentation cables

IIIB-07 : Illumination System

IIIB-08 : Cabling, Earthing & Lightning Protection

IIIB-09 : Transformers

IIIB-10 : HT Switchgear

IIIB-11 : PLC CONTROL PANEL

IIIB-12 : Battery

IIIB-13 : Battery Charger

IIIIB-14 : MEASURING INSTRUMENTS

IIIB-15: CCTV

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CIVIL

III-D-01 : CHP System – Civil and Structural Works

III-D-02 : Foundation System and Geotechnical Data

QUALITY ASSURANCE

E-01 : Coal Conveyors Belt

E-02 : Motors

E-03 : LT Switchgear

E-04 : LT Busduct

E-05 : LT Power Cables

E-06 : LT Control Cables

E-07 : Instrumentation Cables

E-08 : Station Lighting

E-09 : Cabling, Earthing & Lightning Protection

E-10 : H T Cables

E-11 : H T Switchgear

E-12 : HT Capacitor Bank

E-13 : Measuring Instruments

E-14 : Power Supply For C&I System

E-15 : Transformer

E-16 : Battery

E-17: Battery Charger

E-18 : Control Panels

E-19 : Control System

E-20 : CHP System - Civil Works

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1.03.00 TENDER DRAWINGS

The drawings listed in the specification at Part-E, form part of the specification and shall supplement the requirements specified herein. The scope and terminal points for the equipment to be furnished under this package shall be as identified in these drawings and read in conjunction with the text of these specifications. These drawings are preliminary drawings for bidding purpose only and subject to changes that may be necessary during the detailed engineering.

1.04.00 In case of any conflicts / contradiction among various volumes / sections / annexures / chapters / appendices / tender drawings of bid documents, the same shall be referred to the Employer for clarifications whose decision shall be final and binding. No extra claims shall be allowed on this account.

1.05.00 SCOPE

1.05.01 The scope of Coal Handling Plant to be furnished, erected and commissioned under this specification shall be as detailed hereinafter. The Contractor shall be fully responsible for system and detailed design, engineering, manufacture, shop fabrication, assembly, testing and inspection at manufacturer’s works, packing, dispatch, transportation, transit insurance, custom clearance etc. as applicable, delivery to site, unloading, handling and storage at site, insurance during storage, construction, erection, including erection supervision, testing, inspection, commissioning and handing over to Employer and Guarantee testing including all associated electrical, civil, structural & architectural works as specified, unless specifically excluded as per Section-Terminal Points & Exclusions.

1.05.02 The scope of the contractor shall be deemed to include all such items which although are not specifically mentioned in the bid documents and/or in Contractor’s proposal but are needed to make the system complete in all respects for its safe, reliable, efficient and trouble free operation and the same shall be furnished and erected unless otherwise specifically excluded as per Section Terminal Points & Exclusions. The general description of the proposed system and the broad scope of work under the specification shall include but not be limited to as elaborated below.

2.00.00 DESCRIPTION, SCOPE AND TERMINAL POINTS

2.01.00 BRIEF DESCRIPTION OF PROJECT

Farakka Super Thermal Power Project (STPP) was originally conceived as a pit head coal based power plant of 2100 MW (3x200 MW+3x500 MW + 1x500MW) capacity to be implemented in three stages. Stage-I comprising three units of 200 MW and Stage-II comprising two units of 500 MW of the plant which are under commercial operation. Presently Stage-III comprising one unit of 500 MW is under commissioning and on implementation of the same, the overall plant capacity would thus become 2600MW i.e. the planned ultimate capacity.

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The present proposal of Coal Conveying Plant is for carrying coal as received from Jetty to the plant site and feeding all the stages through various interconnection in the existing Coal handling Plant.

2.01.01 Brief description of proposed Coal Conveying Plant.

This shall be read in conjunction with Coal Flow Diagram and the Coal Conveying Plant layout enclosed else where in the specification.

PHASE-I

(i) Coal as received from barges shall be unloaded by either slewing type grab cranes or mobile type grab cranes to an feed hopper. From feed hopper the coal shall be conveyed through series of Conveyors of 800 TPH capacity (Conveyor A, Conveyor B, Conveyor C) through Junction house JH-1, JH-2 and shall drop coal at existing Stockyard no. 4 & 5 of Stage-I & Stage-II. From Stockyard 4 & 5, coal shall be bull dozed to stockyard for further conveying to bunker of Stage-I, II & III via existing stacker reclaimer and Conveyors.

PHASE-II

(ii) At Junction House JH-2 Conveyor D shall receive coal from conveyor B and shall convey coal through series of conveyors of 800 TPH capacity (Conv. E, Conv. F, Conv. G) through junction houses JH-3,JH-4,JH-5 & JH-6.

2.02.00 DETAILED SCOPE

PHASE-I

2.02.01 Non drive house(NDH), feed hopper with grating, complete with civil, structural, architectural and electrical works including vibro feeder, equipment handling facilities for feeders and other equipment/systems such as DS system, ventilation system, drinking water system, drainage system etc. as specified elsewhere in the specification.

2.02.02 Conveyor A complete with conveyor gallery along with its supporting structures, short supports, stringers, deck-plate, seal-plate, conveyor foundations, drive motors, pulleys, idlers, gravity take ups, take up structure, internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals and accessories. including all civil, structural and architectural works for tunnel, conveyor gallery, gallery supporting trestle and their associated foundation etc.

2.02.03 Belt Conveyors B & Conveyor C complete with conveyor galleries, conveyor supporting structures, short supports, stringers, deck plate, seal plate, conveyor

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foundations, drive motors, drive units, pulleys, idlers, gravity take ups including guides, pits etc., internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals etc. including all civil, structural and architectural works for conveyor gallery, gallery supporting trestles and their associated foundations.

2.02.04 Junction Houses JH-1 & JH-2, complete with all civil, structural, architectural and electrical works including chutes, monorails, hoists/chain pulley blocks, hoist maintenance platforms, external staircases, dust debris chutes etc. All overground junction houses shall have separate debris disposal chute up to the ground floor.

2.02.05 Two (2) nos. Vibro feeders to feed the coal on to Conveyor A complete with drives, all mechanical, electrical accessories and supporting structures etc.

2.02.06 One (1) No. coal sampling unit, for (-) 50 mm size coal in Junction house-1 complete with all accessories, and electrical, civil, structural works, supporting structures, approach/maintenance platforms, hoists etc.

2.02.07 One(1) No. In-line Magnetic Separators on Conveyor A complete with reject chutes, reject trolleys, supporting arrangement, and all mechanical, electrical, civil, structural works and accessories.

2.02.08 One(1) No. Electronic Belt weighers complete with all mechanical, supporting arrangement, electrical, and accessories on conveyors A.

2.02.09 One(1) No Metal Detector complete with all mechanical, electrical, civil, structural works and accessories on Conveyor B.

2.02.10 One (1) No. belt vulcanizing machine of adequate size complete with all mechanical, electrical, accessories and consumables for one year consumption. Further, belt jointing facilities as specified shall be provided.

PHASE-II

2.02.11 Belt Conveyors D, Conveyor E, Conveyor F & Conveyor G complete with conveyor galleries, conveyor supporting structures, short supports, stringers, deck plate, seal plate, conveyor foundations, drive motors, drive units, pulleys, idlers, gravity take ups including guides, pits etc., internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals etc. including all civil, structural and architectural works for conveyor gallery, gallery supporting trestles and their associated foundations.

2.02.12 Junction Houses JH3, JH-4, JH-5 & JH-6, complete with all civil, structural, architectural and electrical works including chutes, monorails, hoists/chain pulley blocks, hoist maintenance platforms, external staircases, dust debris chutes etc. All

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overground junction houses shall have separate debris disposal chute up to the ground floor.

2.02.13 Modification of existing conveyor 24A/B alongwith its gallery in order to retrofit junction house JH-6.

Common for Phase I and II

2.02.14 Complete chute work along with chute block switches and actuator operated flap gates (as applicable) in all Junction Houses between various conveyors.

2.02.15 Pressurized Ventilation system for all Switchgear rooms, MCC rooms complete with all mechanical, electrical, accessories, civil and structural works.

2.02.16 Exhaust fans to be provided in all battery rooms, all toilets complete with electrical, civil & structural works etc. Exhaust fans along with required ducting shall also be provided for all underground Structures/Junction Houses.

Air conditioning of Coal conveying plant control room and office room, RIO room , complete with all electrical, civil & structural works etc.

2.02.17 Complete plain water dust suppression system for control of fugitive dust in underground feed hopper complex, junction houses complete with enclosed pump houses, water tanks, pumps, drives, hoisting arrangements, piping, valves etc. electrical, accessories, civil, structural and architectural works.

2.02.18 Service water, potable water system and cooling water system for complete coal conveying plant.

2.02.19 Cooling water system for scoop couplings, for complete coal conveying plant as specified elsewhere in the specification.

2.02.20 Monorails and electrically operated hoist blocks as well as hand operated chain pulley blocks for servicing/installation/easy replacement of drive machinery, different types of pulleys for all conveyors, GTU and other equipment from ground level to their locations and vice-versa & landing inside the respective Buildings.

2.02.21 All buildings in contractor’s scope shall be complete with all electrical, civil, structural, architectural works, cable trenches, fire safety walls, foundation, earth mat, fencing, earthing for transformers. All cables, duct banks, trenches, cable trestles shall be complete with associated civil/ structural work and necessary civil foundations.

2.02.22 Drainage of all coal conveying buildings, conveyor galleries including all civil & structural works as detailed out elsewhere in the specification.

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2.02.23 All equipment/fittings, supporting structure, along with insert plates, bolts, accessories, MS sleeves, base plates, grouting as may be required and proper alignment etc.

2.02.24 Complete unused set of all special tools and tackles, which are necessary or convenient for erection, commissioning and overhauling of any equipment, covered under the scope.

2.02.25 First fill of all consumables e.g.; oils and lubricants for one year toppings requirements.

2.02.26 Preservative shop coating, final painting of all structures and equipment under the scope.

2.02.27 All inserts, anchor bolts, foundation bolts for Contractor’s equipment, platforms etc. in the entire Coal conveying plant.

2.02.28 All necessary grouting & finishing of the floor after welding at all such pockets & else where is in Contractor’s scope.

2.02.29 (i) All inserts, anchor bolts, foundation bolts for Contractor’s equipment, platforms etc. in the entire Coal conveying plant.

(ii) All necessary grouting & finishing of the floor after welding at all such pockets & else where is in Contractor’s scope.

2.02.30 FIRE DETECTION AND PROTECTION SYSTEM The scope of equipment to be furnished and erected under this specification shall cover all the systems and equipments detailed hereunder. For the basic Fire Detection and Protection System specified, any other items, needed to make the system complete, safe and sound in operation shall be included under the scope of work by the Bidder at no extra cost to the Owner. Fire Water Storage and Pumping System Complete fire water storage and pumping system consisting of MS construction fire water storage tank, spray pumps & drives and Battery Chargers for the diesel engines drives, required instruments, controls, and panels as per detailed specifications. Tapping from nearby water source shall be taken to fill the fire water storage tanks. Further, suitable capacity monorail electic hoist inside fire water pump house shall also be provided by the Contractor.

MVW & Hydrant System Automatic MVW system shall be provided for conveyors & JH/DH protection. Further, hydrant valves (taped from spray header) at strategic location shall be provided as per detailed specifications. Fire Extinguisher To be provided by the bidder at MCC, RIO rooms & Control room.

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Analogue addressable type Fire Alarm System / Annunciation Panels a) LHSC, IRD, cabling, junction boxes, instrumentation, etc. for various

areas/equipments as detailed out elsewhere. For long distance transmission Booster / Repeater station (if applicable) suitable for field shall be provided.

b) PLC based Control Panels complete with all accessories for Fire detection and protection system shall be provided in Fire water pump house. This PLC panel shall also be connected with Fire alarm panel at Control room.

c) Fire alarm panel along with PC & Printer in Control room. Further, due to long distance between fire alarm panel at control room and various field devices, suitable qty. of fire alarm panels shall be required at intermediate locations. These panels shall be located at RIO room envisaged in JHs. All these fire alarm panels shall be interconnected with each other as well as with fire alarm panel at Control room through fibre optic cables.

c) Manual call points, hooters etc., shall be provided as per system requirements.

d) All interconnection cables (instrumentation cables from instruments to panels, control cables to MCC, instrument cables from MCC to control panel, power cables to drives, network cables and fibre optical cables, etc.) shall be provided by the Contractor.

Guarantee tests for PLC with HMI system Set of commissioning spares as may be required during erection and commissioning. One (1) set Special tools and tackles required for maintenance of all the mechanical, electrical and C & I equipments under the scope of Contractor.

Any additional item/ equipment required to make the system complete. All other services described under “Intent of Specifications”.

All civil works related to fire detection and protection system shall be in the scope of works of Contractor. Supply of all consumable materials like initial fill of lubricants, grease, etc. required to complete the erection and commissioning of the total fire protection system. Further, all consumables required for PG test shall also be in Bidder’s scope of supply. Preparation of necessary detailed drawings including schematics, layouts, isometrics, fabrication drgs, erection drgs, etc. as required and also development of “As Built Drawings”.

Conductance of Performance and Guarantee test as per Standard Guaranteed test procedure to be finalized during detailed engineering.

2.02.31 Electrical System / Equipment

2.02.31.01 ELECTRICAL SYSTEM / EQUIPMENT (FOR PHASE-I & PHASE-II) :

Unless specifically excluded in clause no. 2.04.00, contractor’s scope of work shall include all electrical works, as required for putting into successful operation of the

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Coal handling plant covered in this specification. The sizing of various equipments shall be as defined in the specification. Main equipment included in the scope is given below.

2.02.31.02 6.6KV Switchgear :-

6.6KV switchgear as indicated in enclosed single line diagrams. Two (2) spare feeders (one transformer feeder and one motor feeder of highest rating) shall also be provided on 6.6 KV switchgear. In addition to this two (2) nos. 1000A feeder for owner’s use shall also be provided.

2.02.31.03 Motors :-

All HT and LT motors along with lugs and glands.

2.02.31.04 415V MCCs / Switchgear / Distribution boards :-

415V Motor control centers (as indicated in the electrical single line diagram), AC & DC Distribution boards / Fuse boards, Local push button stations for all drives and local motor starters as required for the system and equipment.

In each MCC contractor shall provide 20% spare feeder(minimum One (1) no) for each type and rating of the outgoing feeders provided in that MCC.

Two (2) nos. of 125A Switch fuse feeders (total load 50KVA) shall be provided in each bus of the above indicated MCCs for Owner’s future use.

2.02.31.05 Cables :-

All HT/LT Power cables, LT control cables, instrumentation cables, fiber optic cables, signal cables and any special cables for the completeness of the system.

a) Required for connection between equipment / devices in Contractor’s scope.

b) Required for connection between Contractor’s equipment and Owner’s equipment.

2.02.31.06 Illumination system :-

AC Illumination system for complete internal and external lighting of associated plant and equipment like JH’s, Conveyors, transformer yards, switchgear & control buildings, Drive houses, Pump houses etc. and roads under Contractor’s Scope.

2.02.31.07 Cabling, Earthing and Lightning Protection :-

Cabling viz., cable laying along with cable accessories, cable trays with supporting structure, terminations & jointing kits, trenches, trestle, duct banks etc required for the cables to be supplied by the contractor.

Earthing / Grounding and lightning protection for the plant and equipment under contractor’s scope.

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In addition to this Owner's/ future use feeders shall

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be provided as per Electrical SLD

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2.02.31.08 Transformers :-

6.6KV/0.433KV, ONAN, Outdoor transformers as indicated in the single line diagram.

2.02.31.09 Battery :-

220V DC, 150 AH (min.) Lead acid plante type / 90 AH (min.) Ni-Cd Battery as per electrical single line diagram.

2.02.31.10 Battery Charger :-

One (1) sets of 220V, 40A (min.) float cum boost chargers as per electrical single line diagram. Each set consists of two (2) nos. battery chargers.

2.02.31.11 PLC and Control panels :-

Main control desk with HMI, Large video Screens, PLC panels, Remote I/O stations, UPS, 24V DC battery and battery chargers, for the control of entire Coal handling equipment & HT/ LT Switchgear.

Local control panels for ILMS, Belt weighers, Metal detectors, Coal sampling units sump pumps, DS/DE, ventilation etc. as required for the system. Local control desks with HMIs shall be provided in main control room as per PLC configuration drawing.

2.02.31.12 Closed circuit TV(CCTV) System, Telephone & Public address system :-

CCTV system with 3 nos. of cameras in each JH & 2 nos. in each switchgear room. Public address and telephone system for entire phase-I & phase-II shall also be provided by contractor.

2.02.31.13 Electrical buildings :-

i) Phase-I

i) One(1) no HT/LT Switchgear room shall be provided near Jetty area to accomodate 6.6KV switchgear, 415V MCC, MLDB, WDB, DCFB’s etc. One air conditioned control room shall be provided adjacent to HT/LT switchgear room to accomodate CHP control desk,operator work station, processor panels,I/O panels, EPABX panels UPS, printers, etc. One (1) no. 6.6/0.433KV transformer shall be located adjacent to switchgear building. ii) One(1) no Switchgear room shall be provided near JH-2 to accomodate 415V MCC, MLDB, WDB, DCDB, battery charger panels etc. One air conditioned RI/O room shall be provided near switchgear room. A separate battery room shall also be provided to accomodate 220V dc battery. One(1) nos. 6.6/0.433KV transformer shall be located adjacent to switchgear room. ii) Phase-II

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i) One(1) no Switchgear room shall be provided near JH-5 to accomodate 415V MCC, MLDB, WDB, DCFB’s etc. One air conditioned RI/O room shall be provided near switchgear room.

2.02.32.00 CIVIL

2.02.32.01 The work to be performed under this specification consists of providing all labour, materials, construction equipment, tools and plant, scaffolding, supplies, transportation, all incidental items not shown or specified, but reasonably implied or necessary for successful completion of the work including Contractor’s supervision and in strict accordance with the drawings and specifications. The nature of work shall generally involve earthwork in excavation including controlled blasting & very deep underground excavation, extensive de-watering, shoring and strutting, sheet piling, back filling around completed structures and plinth protection, area paving , disposal of surplus excavated materials, piling, concreting including reinforcement and form work, brick work, fabrication and erection of structural / miscellaneous steel works, inserts, architectural items & finishes such as plastering, painting, flooring, doors, windows & ventilators, glass and glazing, rolling shutters etc., permanently colour coated profiled steel sheeting, anchor bolts, R. C. C. trenches with covers, laying and testing of water pipes, sanitation, water supply, drainage, damp proofing, water proofing and other ancillary items.

2.02.32.02 The work shall have to be carried out both below and above ground level and shall be involving, basements, equipment foundations including grounding, slabs, beams, columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, access roads, culverts, conveyer galleries, trestles, penthouses, underground tunnels, junction house, finishes, complete architectural aspects, drainage, sanitation, water supply (from terminal points to various buildings, conveyor galleries) and all other civil, structural and architectural works associated with the complete Coal Conveying Plant.

2.02.32.03 Scope of the Contractor shall also include supply and laying earthing mat all around the periphery of buildings, structures, and outdoor equipments, as per the approved drawings.

2.02.32.04 The analysis design and detailed drawing for Underground JH, tunnels, culverts, etc. coming directly below the railway track shall be got approved by the Contractor from the Concerned railway authority before taking up construction. All necessary payment for above work shall be made by the contractor to the Railway authority.

2.02.32.05 The work shall also involve arranging construction water from underground sources, storage in underground/ overground tanks and taking the water to construction site through pipelines by pumping or by road tankers etc., including all necessary accessories, tools & tackles etc.

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2.02.32.06 Access roads 4m wide bituminous roads to all buildings/facilities (in Contractor Scope) will be in the Scope of Contractor.

2.03.00 TERMINAL POINTS

Broad terminal points for coal conveying plant have been indicated in the tender drawings. Within these terminal points, all equipment and services, civil, structural and architectural works, electrical distribution, piping network etc. as required for coal handling plant will be furnished and erected by the contractor unless specifically excluded as follows:

2.03.01.01 Wherever Contractor is permitted by Employer to take support from any of the Employer’s Structures, the Contractor shall ensure that no damage is done, to the Employer’s Structures including Painting thereof. In case of any damage to the Employers Structure and/or Painting, then the Contractor shall rectify the same to the complete satisfaction of the Employer.

2.03.01 Water supply connections for dust suppression, service water system, and potable water shall be provided at one location by the employer, details of which are given in the tender drawing. Further network of piping including all pumps, tanks, necessary accessories, supports and fittings etc. for distribution of potable water, water for dust suppression and service water system in all JHs, non drive house, control rooms, MCC rooms, toilets, shall be under the scope of the contractor.

2.03.02 Electrical Terminal Points

(a) Owner’s 6.6 KV switchgear/415V MCC as indicated in electrical single line diagram.

2.04.00 EXCLUSIONS

Nil

3.00.00 SYSTEM DESIGN BASIS

3.01.00 The rated capacity of the Coal conveying plant shall be 800 TPH. The mechanical and structural / civil system shall be designed for 880 TPH capacity and round the clock operation with both the streams operating simultaneously.

3.02.00 Following shall be considered while designing the CHP:

a) The Coal delivered to the power station shall be of size (-)50 mm & below. However occasionally 1-2% coal above (-) 50 mm lump size may also be encountered.

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SPECIFICATION

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b) HGI of the Coal shall be between 44 to 65. Normally moisture content in coal will vary between 12% to 15%. However for design purposes, moisture content of 20% shall be considered.

c) The coal “as received” shall contain varying percentage of fines. Coal with such fines may tend to form adhesive lumps, particularly during monsoon when surface moisture is at its maximum value.

d) The sizing and selection of the vital equipment viz. vibro feeders, etc. covered under the system shall be based on the above characteristic of coal and operating conditions. Contractor shall ensure that equipment/ system efficiency shall not be affected particularly during monsoon when surface moisture is at its maximum value.

3.03.00 For the purpose of volumetric computation, the bulk density of the coal shall be taken as 800 kg/m3. Therefore for calculation of belt conveyor capacity, for their drives & drive motors kW requirement, and sizing (volume calculations) of chute, hoppers etc. the above bulk density shall be considered. For all other purposes viz. for stresses/ load on structures, torque calculations of VF tables, sizing of actuators for flap gates, calculations of plugged chute/ hopper loads etc. the bulk density of the coal shall be taken as 1100 kg/ m3.

CLAUSE NO.

TECHNICAL REQUIREMENTS

FARAKKA SUPER THERMAL POWER

PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI

PART-B

SUB-SECTION-IIIA-01 SYSTEM PARAMETERS

AND OPERTION & CONTROL PHILOSOPHY

PAGE 1 OF 4

A-01 : SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY

1.00.00 The specifications as brought out in various Sub-sections for mechanical equipment shall be applicable to the system of proposed coal handling plant and specifically to all mechanical including their operation & control philosophy. However, some specific parameters of the entire system as a whole and the major equipment are brought out as under.

2.00.00 PARAMETERS

2.01.00 Conveyor System

i. Rated Capacity (Guaranteed) : 800 TPH ii. Design capacity : 880 TPH

iii. Belt width : Minimum 1000 mm iv. Maximum Belt speed : 3.2 M/sec. 2.01.01 Belting and Pulleys

(a.) Belt ratings shall be selected in such a way that there are only three (3) ratings for Nylon/Nylon/polyester/polyamide belting. (Belting shall be completely interchangeable among same rating of belt.) Minimum number of plies for belting shall be four (4). Other details of belting shall be as specified else where in the specification.

(b) For Pulley, following minimum parameters shall be followed:

(1.) Shell thickness : 16 mm (Min.)

(2.) End disc plate thickness : 24 mm(Min.)

(3.) Maximum allowable deflection of shaft at hubs : 5 Minutes

(4.) Diameter :

(i) All drive pulleys : 800 dia (min.)

(ii) All balance pulleys : 630 dia (min)

Further approval from belt manufacturers shall be obtained by the contractor regarding the adequacy of the pulley diameters.

c) Maximum type of pulleys permitted based on pulley diameter and shaft diameter shall be limited to five (5). These shall comprise of two (2) nos. drive pulleys and three (3) nos. for all balance pulleys. Pulleys for SS pulleys are not included in the above categories.

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2.01.02 Vibrating Feeders

(a) Nos. required : Two (2) each (b) Guaranteed (rated) capacity : 400 MTPH

2.01.03 Dust Control System

The capacity of the dust control system specified hereinafter is for Contractor’s guidance only. Contractor shall provide adequately sized and fool proof dust control system, the performance of which should be guaranteed by the Contractor as required in the Technical specifications. The performance guarantee test procedure is to be submitted by the Contractor. However, the capacity of the offered system shall not be less than the specified values below.

a) Dust Suppression System (Dry fog type)

(1) Operation : Water & air sprayed by Fogging

nozzle.

(2) Location of spray : At all coal discharge & receipt point on all transfer point & crusher house (3) Capacity & Pressure : 0.5 Kg/cm2 for water (min.) at inlet of spray head 5.0 Kg/cm2 for air (min.)

2.01.04 Service Water System

Service water connections are to be provided in conveyor galleries & tunnels at 50 meter interval and one (1) no. on each floor of Transfer Points, toilets.

(a.) Flow at each valve : 5 cub.m/hr

(b.) Minimum discharge

Pressure at tap point : 2 kg/sq.cm

(c) No. of valves operated : 6 nos. simultaneously

2.01.05 Potable Water System : As specified elsewhere in the spec. 2.01.06 Ventilation System

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A Mechanical Ventilation System

Battery rooms/ Toilet: Minimum 10 supply air changes per hour. B. Pressurized Ventilation System: Minimum 15 supply air changes per hour C. Air Conditioning System : Adequate number of air changes to Maintain in uniform temp. & humidity as specified elsewhere. 2.01.07 Chutes

Minimum clear cross section of chute : 650 mm x 1000 mm (inside both ways).

2.01.08 Hoists

Suitable hoists as specified elsewhere shall be provided for erection & servicing of all major equipment. The equipment to be covered shall include (but not limit to) all conveyor drive units, all pulleys, along with drive units, in line magnetic separators, sampling units, various DS/service water/potable water pumps, gravity take up units, lifting of belt drum at all transfer houses etc.

2.01.09 All other equipment under the scope shall be suitable to the system capacities parameters as specified above.

3.00.00 OPERATION AND CONTROLS

3.01.00 This section is intended to cover control/instrumentation and operational philosophy as specified hereinafter complete in all respects, required for complete coal handling plant.

3.02.01 Standards / Codes

All construction, installation, workmanship, design & equipment shall conform to acts, rules & regulations of the jurisdiction within which the project is to be located, and to the current edition of the following or equivalent standards or codes, in so far as they apply :

American Iron & Steel Institute (AISI)

American Society for Mech. Engineers (ASME)

American Society for Testing & Materials (ASTM)

American Wire Gauge (AWG)

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Institute of Electrical & Electronic Engrs. (IEEE)

Instrument society of America (ISA)

National Electrical Code (NEC)

National Electrical Manufacturers Association (NEMA)

United States of America standards (USAS)

Bureau of Indian Standards (BIS)

Conveyor Equipment Manufacturers Association (CEMA)

3.02.02 This Sub-section shall be read in conjunction with Electrical Sub-sections.

3.03.00 General Construction and Design

3.03.01 General Construction

Control desks/panels and annunciation system shall be as per the requirement of electrical Section. Annunciations, indications, electrical meters and instrumentation shall be provided as specified.

3.03.02 Design

The complete coal handling plant shall be controlled from PLC system as detailed elsewhere.

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PART-B

SUB-SECTION-IIIA-02 BRAKES AND CLAMPS

PAGE 1 OF 2

A-02: BRAKES AND CLAMPS

1.00.00 GENERAL

Brakes shall be provided for decelerating of driven equipment/conveyors as per requirement. Rail clamps shall be provided for various mobile machines traveling on rails.

2.00.00 STANDARDS

The design, manufacture, inspection and testing of Brakes & Clamps shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Brakes & Clamps shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding.

3.00.00 DESIGN REQUIREMENT 3.01.00 Electro Hydraulic Thruster Brakes/Disc Brakes The necessary Electro Hydraulic Thruster (AC) brakes / disc brakes, totally enclosed

and fail safe, shall be provided as required for various equipment’s. Braking torque shall be adjustable from 0 to 100% of rated braking torque. The thruster brake shall be actuated by compression springs.

3.02.00 Clamps 3.02.01 Electro-hydraulic thruster and manual rail clamp shall be designed for holding the

machine stationary. 3.02.02 Electro-hydraulic thruster and manual rail clamp shall be actuated by compression

springs, the spring shall apply the clamping force directly on the Rail clamp mechanism once power supply is cut-off. The force transmission mechanism from spring to rail clamp faces shall be very simple with minimum linkages.

3.03.00 CONSTRUCTION REQUIREMENT 3.03.01 Thruster Brakes 3.03.01.01 The electro hydraulic thruster shall be fitted with the brake. Limit switches shall be

provided for brake applied/released positions. The windings shall be provided with class-B insulation suitable for 415V ± 10% at 50 Hz ± 5% and combined variation of ± 10%. Brake lining shall be asbestos with inter woven brass wires capable of withstanding 200°C temperature.

DATA SHEET: BRAKES AND CLAMPS

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SUB-SECTION-IIIA-02 BRAKES AND CLAMPS

PAGE 2 OF 2

1.0.0 GENERAL

1.1.0 Brakes (i) For decelerating of conveyors & rotating equipment’s.

(ii) Brakes are mandatory for H.T.

drives involving scoop type coupling except crusher motor.

1.2.0 Rail Clamps For various mobile equipment travelling

on rails.

2.0.0 DESIGN & CONSTRUCTION REQUIREMENT

2.1.0 Brakes

2.1.1 Type Electro Hydraulic Thruster brakes A.C. operated or Disc brakes.

2.1.2 Braking Torque Adjustable from 0 to 100% of rated braking torque.

2.1.3 Brake Shoes Operated directly by spring

2.1.4 Shoe lining Asbestos with interwoven brass wires.

2.1.5 Max. Temperature for shoe lining 200 degree C.

2.1.6 Thrustor Class-B insulation, IP-65 protection.

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PART-B

SUB-SECTION-IIIA-03 MONORAIL AND HOISTS

PAGE 1 OF 6

A-03: MONORAILS AND HOISTS

1.01.00 GENERAL

Suitable handling arrangements shall be provided for all equipment’s included in Contractor’s scope to transfer the equipment to maintenance area within the building and/or to transfer the equipment outside the building upto ground level for further transportation by the Employer. For this purpose Contractor shall provide monorails and hoist blocks with cross travel facility.

1.01.01 CODES AND STANDARDS

The design, manufacture, inspection and testing of Monorails and Hoists shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Monorails & Hoists shall conform to the latest edition of the following standards & codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:3938 : Specification for Electric Wire Rope Hoist IS:3832 : Chain pulley blocks IS:2429 : Round steel short link chain IS:6216 :Short link chain grade 80 IS:8610 :Points hooks with shank for general engineering purposes IS:210 : Cast Iron Castings

1.02.00 DESIGN REQUIREMENTS 1.02.01 For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift, with

the exception of hoists for GTU and bend pulleys motor operated hoist blocks for both long travel and lift shall be provided. Other hoist blocks shall be of hand operated type for both travel and lift. Minimum 3 meter length of Cantilever from edge of building/cladding, shall be provided in monorails coming out of the building to lower the equipment to ground level clearing the building sidewalls / cladding and any other facilities beneath the floor upto ground level.

1.02.02 The exact lift/travel and the number of the hoisting mechanisms and the mode of

lifting equipment’s to various floors of the buildings shall be as decided by the employer at the time of detailed engineering. Clear height shall be maintained when handling one equipment over other, in such case dismantling of any equipment shall not be permitted. The center line of monorail shall not deviate by more than 500 mm from the center of gravity of any equipment that is to be lifted. Contractor shall take clear note of the fact that the number and monorail hoisting systems shall also be

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decided considering the movement of the equipment being lifted over/by the side of other equipment’s without removing the later. The necessary levels of floors in various buildings shall be decided considering the above requirement.

1.02.03 Monorails shall be extended outside the building to handle the equipment to ground

level. For monorail/hoist routed inside the buildings, suitable machinery well and removable handrailing and grating shall be provided on various floors of buildings, as necessary, to handle the equipment.

1.02.04 Electrically operated monogirder type hoists shall consist of following major

components.

(a.) Electrically operated trolley complete with drive motor (Trolley travel speed maximum 15 m/min.).

(b.) Hoist cable, hoisting block and hooks complete with drive motor (Hoisting

speed maximum 6m/min.).

(c.) Limit switch to prevent overhoisting, over lowering and over travel.

(d.) Festoon arrangement of feeding power to trolley assembly.

(e.) Erection hardware.

(f.) Pendent control station suspended from hoist.

(g.) Control panel mounted on wall. 1.02.05 The electric hoist shall be designed and constructed in accordance with the latest

revision of IS:3938 and shall be suitable for duty class 2. 1.02.06 For electric hoists, trolley movement and hoisting shall be effected by using two

separate motors. Motors shall be as per technical requirements discussed elsewhere. However the motors shall be suitable for 150 starts per hour at 40% CDF.

1.02.07 Trolley for motorized / manual cross travel shall be designed to accommodate a

wide range of I beams and shall be capable of travelling on straight as well as curved monorails with the design being such to maintain uniform distribution of pressure on the flanges.

1.02.08 Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which

shall be driven through motor.

1.02.09 Wire rope shall be of pre-formed type, hemp cored, regular lay 6/36 construction with a breaking strength of 160 -175 kgf/ sq. mm. Reverse bend of ropes is not acceptable. Minimum number of falls of rope shall be four (4).

1.02.10 All gears and pinions shall be of hardened and tempered steel with machine cut teeth in metric modules. Surface hardening of steel is not acceptable.

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1.02.11 All running shafts and wheels shall be fitted with ball / roller bearings with a rated life not less than 20 years based on equivalent running time as per IS:3938.

1.02.12 An electromechanical brake shall be provided for hoisting as well as cross travel. Brake lining shall be of asbestos.

1.02.13 Cast iron parts, wherever used, shall be of minimum grade 30, IS:210.

1.02.14 All chain pulley blocks shall be designed to IS:3832, the operating hand chain shall conform to IS:2429 grade 30 pitched and polished and the load chain to IS:6216 grade 80. The chain pulley block shall be suitable for duty class 2. Hooks shall be as per IS: 15560 & with antifriction bearing.

1.02.15 All hoists/chain pulley blocks shall be selected to have minimum headroom and shall be selected to lift heaviest piece of equipment. Further, it shall be possible to handle any equipment without disturbing other equipment.

1.02.16 The hand chain wheels shall be of cast steel, the wheels shall be with flanges and designed to ensure effective operation of hand chain. Further, suitable local brake shall be provided as per IS:3832 to arrest and sustain loads in all working positions.

1.02.17 The velocity rates, effort on chain required to raise the safe working load and travel and speed shall be within the limit specified in IS:3832. Proof load test shall be carried out as per IS:3832. Balance requirements shall be as discussed in earlier clauses pertaining to electric hoists.

1.02.18 Hoist for Gravity Take up arrangement and bend pulley.

For handling bend pulley, take-up pulley and counter weights following hoisting arrangement shall be provided:

(1) For handling bend pulleys, hooks of adequate capacity shall be provided at the top of gallery. Further minimum four (4) nos. manually operated chain pulley blocks of adequate capacity shall also be provided for the entire coal handling plant for handling bend pulleys.

(2) For handling take-up pulleys, manual hoist along with mono rail beam of adequate capacity having cross travel, arrangement shall be provided at bottom of gallery to handle take-up pulley only of conveyors.

(3) For handling take-up weight, a separate manual hoist with mono rail beam of adequate capacity shall be provided to hold complete counter weight (inclusive of all counter weight blocks). This hoist shall be provided for holding the counter weight and shall be located in the zone of counter weight travel.

1.03.00 CONSTRUCTION REQUIREMENT 1.03.01 The hoist mechanism shall consist of a grooved rope drum driven by electric motor

through gears. Each end of the rope shall be anchored to the drum in such a way as the anchorage is readily available for maintenance. Each rope shall have two (2) full turns of the drum when the hook is at its lowest position and one (1) spare groove when the hook is at its highest position. The leading rope taken by the drum should not slope sideways when slack and it should not be caught between the gear wheel.

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1.03.02 Rope drum, gear box, block etc. should be fabricated out of weldable quality steel. 1.03.03 Trolley wheels shall be of single flange type in the taper treads. The wheels shall be

mounted on antifriction bearings and shall be easily removable for repair/ replacement.

1.03.04 The load hook shall be swiveling type forged circular shank section and shall confirm

to IS:15560. 1.03.05 All gears and bearings shall be lubricated by grease. All lubricating points shall be

grouped together in easily accessible position. 1.03.06 The bottom block shall be of enclosed type and shall have guard against rope

jamming in normal use. It shall have standard forged swivel shank hook fitted on antifriction thrust bearing. Lock to prevent hook from rotation and locking arrangement to prevent accidental unlocking shall be provided. Pulley of the bottom block shall be provided with antifriction bearings.

1.03.07 All parts requiring replacement/inspection/lubrication shall be accessible without

need for dismantling of other parts/structures. 1.03.08 All components of hoists of identical capacity and duty shall be interchangeable. 1.03.09 Hoists shall have permanent inscription in English on each side readily recognizable

from floor level stating safe working load. 1.03.10 Pendant shall be provided with flourscent up/down/forward/reverse travel push

buttons and indicating lamps. Its power supply shall be limited to 24V AC. 1.03.11 The control panel shall be wall mounted type & easily approachable from the floor by

a standing man. 1.03.12 For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x

1.5m) with ladder shall be provided for each electrical hoist. 1.03.13 Inline magnetic separator shall have motorised hoist for handling / maintenance

purpose. Each suspended magnet shall be provided with a dedicated motorised trolley.

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DATA SHEET : MONORAILS AND HOISTS

1.0.0 GENERAL

1.1.0 Functional Requirement : To transfer equipment’s to maintenance area or outside the building.


2.1.0 Hoists

2.1.1 Drive

(i) More than 2.0 tonne or more than 10.0 m lift or hoists coming out-side the buildings

Motor driven for both travel & lift.

(ii) Other hoists including the hoists for handling takeup pulley and takeup weight

Manual for both travel & lift.

2.1.2 Maximum trolley travel speed for electric hoists

15m/min

2.1.3 Maximum Hoisting speed for electric hoists

6 m/min

2.1.4 Drive Motors SQIM, Separate for travel & lift

2.1.5 No. of starts for drive motor 150 starts/hr at 40% CDF

2.1.6 Wire Rope

(i) Type/Construction Pre-formed type, hemp cored, regular lay 6/36 construction

(ii) Breaking Strength 160-175 kgf/sq. mm

2.1.7 Bearing

(i) Type Ball/Roller bearing

(ii) Life 20 years

2.1.8 Brake Electro Mechanical type with asbestos lining.

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2.1.9 Load Hook Swiveling type forged circular shank section.

2.1.10 Duty Class –2

2.2.0 Monorail location/layout

2.2.1 Cross section I beam

2.2.2 Distance between C/L of monorail & C.G. of equipment to be lifted

Maximum 500 mm

2.2.3 Power Cables Support Festoon type arrangement 2.3.0 Manual Hoists

2.3.1 Maximum manual effort for operation. 30 Kg

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PART-B

SUB-SECTION-IIIA-04 CHUTES AND HOPPERS

PAGE 1 OF 6

A-04: CHUTES AND HOPPERS 1.00.00 GENERAL

Chutes & Hoppers, flap gates shall be furnished integral with coal handling system being supplied. All necessary accessories, electricals etc. shall be provided to ensure proper flow/storage/bifurcation of coal as per system requirements.


The design, manufacture, inspection and testing of Chutes & Hoppers shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The chutes, hoppers shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding.

IS:4682 :Code of practice for lining of vessels and equipment for chemical processes.

IS:2062 : Structural Steel (Standard Quality)

IS:11592 : Code of practice for selection and design of Belt Conveyors.

1.02.00 DESIGN AND CONSTRUCTION

1.02.01 Chutes, Hoppers

1.02.02 The minimum valley angle of chutes shall be 60 degrees from horizontal.

1.02.03 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal without any accumulation anywhere.

1.02.04 Complete chute work above the drive floor for conveyors provided with ‘In-line belt magnetic separators’ shall be of 10 mm thick SS - 304 in the zone of magnetic field.

1.02.05 Direct impact of material on conveyor belt shall be avoided by providing an inclined surface at 60 degrees valley angle at the feeding point to guide the material in the direction of belt travel. Further, chute construction below flap gate shaft shall be such that there will not be any accumulation of coal dust between chute and flap gate in that zone.

1.02.06 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL / SAILHARD / LSLAS07 or equivalent material. Long chutes guiding flow from considerable height shall be provided with impact plates wherever change in direction of flow takes place. Hinged inspection doors of leak proof construction shall be provided for access/ maintenance purpose, at approachable heights for chutes and flap gates. All

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chutes should have one inspection door at every floor and for the ones in between the floors (more then 1.5 meter above the operating floor level) suitable access for trouble free maintenance shall be provided. For sealing of inspection doors labyrinth type arrangement to be provided. In addition to positive locking arrangement, mounting bolts, to tighten the door further against rubber shall also be provided.

1.02.07 Bottom side of the chutes on which the coal slides shall be welded to the side plates to form a trough. Bottom sides along with its adjacent sides shall be flanged and made from TISCRAL or equivalent material of 20 mm thickness. The non-striking surface i.e. the covers of the trough shall be of 10 mm thick mild steel and bolted to the flange provided on the trough. Inside welding shall be provided in the corners for permanent sealing. Further, the chute boxes not more than 1.5 m in length shall be joined through bolted flange connection to form the chute legs. Adequate care shall be taken to locate the flange joint away from floor level for easy maintenance.

Bolted flange joints shall be of dust tight construction and necessary sealing material shall be provided in all the flange connections for adequate sealing.

Complete chute work in the region of flap gates shall be fabricated from 20 thk TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree) complete chute, work shall be of 20 mm thick TISCRAL or equivalent material. While finalising the chute work inside the building, arrangement for shifting and replacing chute legs, proper handling arrangement/wall openings, trolleys, hoists shall also be provided.

1.02.08 Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum 4 mm M.S. Plates and shall be provided with hinged and gasketed inspection doors with suitable access to them. Further, serrated rubber seal shall also be provided at the very inlet of head chute to minimize dust nuisance.

1.02.09 Separate maintenance sealed door shall be provided for access to belt cleaners in head pulley hood, flap gates for maintenance and inspection doors shall be of hinged with positive locking facility.

1.02.10 (a) There should be sufficient clear space to install, remove and maintain scrappers without cutting structures.

(b) Slope of plates below scrappers to direct coal scrapped by these to the main

stream shall be 60O min.

1.03.00 Skirt Boards

1.03.01 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage. Suitable ‘Skirt Plates’ shall be provided for entire feeding chute and shall be extended minimum 3m ahead of front edge of chute and 500 mm beyond rear edge of chute. The width of the Skirt Boards shall be two-third the conveyor belt width. In the belts where coal of appreciable lump size (250 mm) is being conveyed, the gap between the bottom of the skirt board and the belt shall be made to increase uniformly in the direction of belt travel. The height of the skirt boards shall be

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sufficient to contain the material volume as it is loaded on the belt and shall not be less than 750 mm. The skirt plates shall be fitted with modular segmented and replaceable rubber skirting pads having facility of adjusting the pressure on the belt conveyor and shall have provision of on line removal for the purpose of easy maintenance. Such segmented rubber pads with its holding down adjustment arrangements shall be of proven design. The edges of segmented pads shall be installed at an angle for providing a better seal. All care shall be taken while designing, to combine good sealing with minimum belt wear.

1.04.00 Flap Gates

1.04.01 The motor operated 2 position flap gates shall be provided in transfer chutes as specified and shall be complete with electrically operated actuators. The gates shall be of robust construction and suitable for trouble free operation. The face of the flap gate shall be made out of 20 mm thick TISCRAL or equivalent material.

1.04.02 The equipment shall be capable of being operated for at least 15 switchings per hour at rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at rated load and thrust.

1.04.03 The motor rating for the actuator shall be so selected as to provide sufficient thrust for operation of the flap gates against the moving weight of coal and/or flap gate. The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight.

1.04.04 Lever arm shall be provided between actuator and flap gate shaft for obtaining required thrust.

1.04.05 The actuators shall be capable of preventing any over travel. Suitable travel dependent limit switches controlling the travel of the flap gates on either direction shall be furnished. These shall be placed internal to the drive unit and shall be completely dust-proof. The limit switches shall be capable of adjustments to vary the total length of travel of the gates.

1.04.06 Suitable thrust dependent limit switches shall be provided in the actuator, which shall trip off the actuator motor in case of excessive thrust due to jamming of the gates during its travel in either direction. The same shall also be integral to the drive unit and shall be dust proof.

1.04.07 Provision for alternative manual operation shall also be made using declutchable hand wheel. The diameter of hand wheel shall be selected considering convenient force to be applied by a single operator. However, minimum diameter of hand wheel shall be 500 mm. Limit switch for safety of person operating the hand wheel shall be provided. Manual effort required to operate the flap gate shall not exceed 25 kgs.

1.04.08 All the two way chutes, one way of which is leading towards the future conveyor shall be provided with blind flange.

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1.04.09 All the actuators in the plant should be selected based on heaviest loading, but the rating shall not be less than 2500 kg with a lever arm of 1.0 m in any case.

1.04.10 Suitable stiffening arrangement shall be provided between the two faces of the gate plate. At the end of the travel the total length of edge of the flap gate shall rest on a suitable projected surface from chute to prevent leakage of coal dust through the available clearance between chute and flap gate.

1.04.11 Maximum feasible counterweights shall be provided for better utilisation of system. However, for calculation of thrust required, the benefit of counterweight shall not be taken into considerations.

1.04.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft. Suitable provision for regreasing shall be provided.

1.04.13 For standardization purposes, only one standard type of actuator for flap gates shall be provided. The standard type actuator shall be selected for maximum thrust as calculated for various locations. Flap gate actuator as a whole and individual component wise shall be completely interchangeable for all locations.

1.04.14 The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall be suitable for motor stalled condition and associated twisting.

1.04.15 Approach/maintenance platforms complete with the chequered plate floor, hand rails, ladders etc. shall be provided for all flap gates.

1.04.16 Shaft & flap gate shall be tightly fitted to each other.

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DATA SHEET : CHUTES AND HOPPERS

1.0.0 GENERAL

1.0.1 Coal Parameters As specified elsewhere

2.0.0 DESIGN & CONSTRUCTION

2.1.0 Chutes & Hoppers

2.1.1 Minimum Valley Angle 60 degrees

2.1.2 Material :

(a) Chute work

Sliding zones & adjacent sides 20 mm thk. TISCRAL / equivalent

No striking/ Non sliding zones 10 mm thk MS

Chute with valley angle 80 degree and above

All four sides of 20 mm thk. TISCRAL/equivalent material

In the zone of magnetic field of ILMS (chute above floor over which ILMS is suspended)

SS-304 10 mm thk.

In the zone of flap gates 20 thk TISCRAL/ equivalent material

Discharge Hoods over head pulleys 4 mm thk M.S. with rubber curtain

2.1.4 Inspection Doors Hinged & leak proof construction (min. size 350 x 450 mm)

2.1.5 Chute Construction

(a) Corners One face of removable bolted flange connection

(b) Joints Bolted Flange joints of dust tight construction

(c) Bolt size Min. M-16

(d) Bolts spacing Not more than 125 mm C/C

(e) Fixing Arrangement Bolts with plain spring washers

2.2.0 Skirt Boards

2.2.1 Length Entire feeding chute shall be extended minimum 3mm ahead of front edge of chute & 500 mm beyond rear edge of chute.

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2.2.2 Height Not less than 750 mm

2.2.3 Width 2/3 of belt width

Side plate Min. 10 thk TISCRAL/equivalent

Top cover 6 mm thk M.S.

2.3.0 Flap Gate

2.3.1 Type Linear actuator operated, 2 position

2.3.2 Travel 60 to 70 deg. (with limit switches on both sides).

2.3.3 Automatic operation

(i) Drive Dust tight motor driven with suitable linkages

(ii) Minimum Actuator Rating 2500 kg with 1 m lever arm

(iii) No. of Operation / Hr 15 (with 10 consecutive switchings)

(iv) Protection Travel and Thrust dependent limit Switches.

2.4.4 Manual Operation

(a) Maximum effort Convenient for single operator by declutchable hand wheel regardless of electrical power.

(b) Minimum Handwheel

Diameter

500 mm

2.4.5 Flap gate shaft

(i) Diameter minimum 150 mm

(ii) Material EN-8

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SUB-SECTION-IIIA-05 BELT CONVEYOR

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A-05: BELT CONVEYOR SYSTEM 1.00.00 GENERAL

All Belt Conveyors shall be furnished and erected along with necessary supporting structures, platforms, on ground or overhead galleries, trestle structure with foundation footings, carrying and return idlers, automatic take-ups, pulleys, drive motors with suitable reduction units and couplings, belting, feeder hoppers, transfer chutes, flap gates, hydraulic couplings and other necessary accessories as per scope specified elsewhere.


The design, manufacture, inspection and testing of the Belt Conveyor System shall comply with all the currently applicable statues, regulations and safety codes in the locality where the equipment is to be installed. The belt conveyor system shall confirm to the latest edition of the following standards & codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding.

“Belt Conveyors for Bulk Materials” published by Conveyor Equipment Manufacturers’ Association.

IS:7155 : Codes of Practice for Conveyor Safety.

IS:1891 (Part-I) : General Purpose Belting

IS:8598 : Idlers and Idler Sets for Belt Conveyors

IS:4009 (Part-II) : Conical Head Grease Nipples

IS:8531: Pulleys for Belt Conveyors.

IS:226 : Structural Steel (Standard Quality)

IS:4682 : Codes of Practice for Lining of Vessels and Equipment for Chemical Processes.

IS:11592 :Code of practice for selection and design of Belt Conveyors.

CAN / CASA - M422 M87 : Canadian standard association.

1.02.00 DESIGN REQUIREMENT

1.02.01 Design of belt conveyor system shall be suitable for coal parameters specified elsewhere.

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1.02.02 Slopes of conveyors, wherever applicable, shall not exceed 16 deg. depending on the lump size, and other governing factors.

1.02.03 The guaranteed capacity of all conveyors shall be the rated capacity.

1.02.04 All conveyors shall be designed for 110% of rated capacity. Design capacity of the conveyor system shall be considered for the selection of belt width, belt speed and the continuous motor rating at 50 deg C Ambient.

1.02.05 The drive chain equipment’s for various belt conveyor systems shall consist of drive motors, fluid couplings, gear reduction units, low speed flexible couplings and pulleys. For the ratings of various equipment’s as mentioned above in the drive chain of conveyor systems relevant sections of this specification shall be referred to.

1.02.06 Conveyors shall be provided with electro hydraulic thrustor brakes or fly wheels to adjust the coasting time of conveyors such that there will not be any build up of material in the chutes. Further conveyor shall come to halt as early as possible. All conveyors with HT drives (except bunker conveyors) shall be provided with brakes.

1.02.07 Belt conveyor system shall be designed as per the latest edition of ‘Belt Conveyors for Bulk Materials’ published by Conveyor Equipment Manufacturer’s Association’ or equivalent International Standard. Ai value for idler shall be considered 2.8lb (min.) for the purpose of conveyor design calculation only.

1.03.00 CONSTRUCTION REQUIREMENT

1.04.00 Belting

1.04.01 The belting shall be of either synthetic fabric such as Nylon-Nylon, polyester, polyamide, etc. with rubber covers of adequate flexibility to give a troughing angle of 35 deg. For all the conveyors the number of plies, cover thickness, factor of safety etc. shall be as per the recommendation of belt manufacturer, but not inferior to the figures as tabulated in data sheet.

1.05.00 Idlers

1.05.01 Carrying idlers shall be provided with three equal rolls with troughing angle of 35 deg. and 2 deg. forward tilt (except in case of reversible conveyors).

1.05.02 In no case, shall the diameter of the idler roll be less than 152 mm for both carrying side and return side. However for impact idlers roll the steel diameter shall not be less then 139 mm and rubber thickness shall be minimum 25 mm.

1.05.03 Roller used in idlers shall be made from ERW steel tube. Wall thickness shall be minimum 4.0 mm without any negative tolerance. The rollers shall be mounted on EN-8 or equivalent material spindles by means of ball bearings of either deep groove type or seize resistant type (SKF/Equivalent), of 30 mm size for carrying idlers and 20 mm size for return idlers. The bearings shall be adequately sealed and lubricated for life. The rolls shall be supported from fabricated steel brackets. Fixing

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arrangement of rollers with brackets shall be drop-in type. For adjusting the alignment of the idlers, slotted holes shall be provided in idler supporting base plates. Direction of belt travel shall be clearly marked on the brackets of carrying idlers by embossing / punching.

1.05.04 Idler rollers shall be waterproof, dust proof and weather proof against a high velocity water jet. All idlers shall be provided with minimum double labyrinth dust seal.

1.05.05 Impact idlers used at the loading and transfer point shall be so designed as to avoid direct loading impact, belt damage and excessive punishment to the carrier. The material used in construction of this type of idlers shall be of resilient type.

1.05.06 The return idlers for all conveyors shall be single roll type. For conveyors longer than 400m, two roll return idlers with 10 deg. troughing angle shall be provided.

1.05.07 The self-aligning idlers shall be direct acting type, complete with actuating rollers fitted with the ball bearings and mounted inclined towards the belt. The idler frame shall be suitably cradled about a vertical pivot, supported in bearing over a fixed plate. Adequate sealing arrangement shall be provided to prevent contamination of the lubricant by dirt and moisture.

1.05.08 Transition type troughing idlers shall be used adjacent to all pulleys to permit proper support of the loaded belt near the pulleys without excessive stretch of the belt edges. The transition idlers shall be provided with preferably adjustable concentrator (end) rolls and long center rolls to suit the troughed belt contour between the last regular troughing idler and the adjacent pulleys. The transition length and the number of the transition idlers shall be selected depending upon the tensions, type and size of belt, number of plies and other necessary governing factors.

1.05.09 All the conveyors shall be provided with one self cleaning type rubber disc return idler located near the head pulley for cleaning the return belt.

1.05.10 Proper arrangement shall be provided in the brackets of all types of idlers for preventing the rollers from coming out of the brackets during normal / abnormal conditions.

1.06.00 Belt Cleaners

1.06.01 External Belt Cleaner

Spring loaded scraper type cleaner with modular segmented and replaceable polyurethane scrapers blades complete with main cleaner, pre-cleaner (mounted separately) along with accessories and necessary fines (reject of scrapper) chutes shall be provided for all belt conveyors, tripper head pulley and belt feeders at discharge pulleys. The modular units shall be easily replaceable. The scraper assembly shall be easily maintainable from outside without any interference with the chute arrangement and assembly.

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1.06.02 Internal Belt Cleaner

V-plough type belt cleaner made of mild steel flats and hard rubber strips with automatic wear adjustment and necessary accessories shall be furnished for cleaning internal surface of the conveyor belt.

1.07.00 Belt Take-up Arrangement

1.07.01 Automatic take-up of gravity type shall be generally provided with necessary take-up arrangements complete with bend pulleys, take-up pulley, with its supporting / sliding assembly, wire ropes with turn buckle arrangement (to adjust the level) for suspending the separate take - up weight sliding assembly close to the ground, counter weights and other accessories. Suitable guards marked up scale attached to the frame to monitor belt stretch and access/maintenance platforms with handrails all around etc. shall be provided. Adequate access from conveyor gallery/transfer house/ground etc., as the case may be shall be provided to inspect, repair and maintain the gravity take-up arrangement. Guides of take up pulley/counter weights shall be sufficiently strong so that they do not bend during belt snapping.

1.07.02 The prime consideration should be to locate the automatic take-ups at a place where these will work best, in relation to the drive, to keep belt tension at a minimum. Other considerations such as available space, maintenance considerations and the economics of the location should also be taken into account while designing. Take up shall not be located over buildings unless indicated in tender drawings. Height of take-up guide structure shall be sufficient to allow the take-up weight movement up and down for all operating conditions of conveyor and to allow minimum two (2) vulcanizing lengths margin in the belt or percentage of conveyor length (2.5% for synthetic belting) whichever is larger. Suitable guides shall be provided both for take up pulley and take up weight.

1.07.03 Two (2) meter safety fencing along with suitable gate and locking arrangement shall be provided around gravity take-up at the base level / ground level.

1.07.04 Irrespective of take-up location, the travel zone of take-up weight shall start from a suitable height above ground level.

1.07.05 Suitable buffer arrangement shall be provided to arrest the fall of take-up pulley in order to avoid damage of the pulley assembly in case of belt snapping. Similar buffer arrangement shall be provided for take-up weight also, in case of, take-up weight travel zone terminating above a building floor. Sandpits of 600 mm deep shall be provided at ground below the take-up weights.

1.07.06 In case of double stream conveyors, a partition of 3 mm steel plate shall be provided between the two take-up pulleys along entire travel zone of take-up pulleys. Intermediate platforms shall be provided in the take-up zone for maintenance of take - up pulleys / counter weight.

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1.07.07 Take-up weight shall consist of multi-blocks of RCC/Cast Iron and not of single block to facilitate adjustment in weight if required during operation. Single heaviest piece shall be suitable for easy handling. Take-up weight block shall be provided with edge protection angle to take care of any damage. Take up weights shall be kept inside a take up weight box frame structure and shall be properly anchored / bolted with the main frame, so that the none of the weight shall be loose/free inside the box. The box shall be painted with counter weight and conveyor number and shall have good aesthetic look.

1.08.00 Hold Back Devices

1.08.01 Suitable hold back devices for preventing running back of the conveyor belt in case of conveyor being stopped in loaded conditions due to power failure or during normal operational delays shall be provided to give positive protection. The hold back shall instantaneously engage without shock and be capable of protecting equipment and personnel. It shall be released instantly when ‘power’ resumes or the ‘delay’ is removed. The holdback devices shall be integral with gearbox.

1.09.00 Pulleys

1.09.01 Pulleys shall be provided as required for various conveyors. In determination of pulley diameter, no account shall be taken of the pulley lagging. The nominal diameter and face width of the pulleys shall be as stated in IS: 8531.

1.09.02 The snub pulleys on each conveyor shall be located to provide a belt wrap on the drive pulleys of not less than 210 deg. wrap is envisaged for single snub drive only.

1.09.03 All drive pulley surfaces shall be hot lagged with vulcanised natural rubber lagging grooved in diamond pattern.

1.09.04 All non-drive pulleys shall be vulcanised natural rubber lagged (hot) with plain lagging.

1.09.05 The rubber to be used for lagging of pulleys shall confirm to specifications listed in data sheet of this section.

1.09.06 The rubber lagging of pulleys and method of lagging and testing the same shall conform to IS:4682.

1.09.07 The pulleys shall be made from mild steel conforming to IS:2062 (Tested Quality). However, for conveyors with in line magnetic separators, the head end pulleys shall have shell and end disc made of non-magnetic stainless steel material..

1.09.08 All the pulleys shall be mounted on the forged steel shafts of EN-8 or equivalent material of adequate proportion by taper lock arrangement, running in heavy duty roller bearings with proper greasing arrangement. The plummer blocks for pulleys shall be of horizontally split type construction with minimum (4) nos. bolts holding the two split halves and with min (4) nos. foundation bolts. The plummer blocks shall be dust tight with double labyrinth seals. Conical head shape nipples conforming to IS:4009, suitable drain plug and eye bolt shall be provided. Side covers of plummer blocks shall be heavy duty metallic sheets. No plastic components shall be used.

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1.09.09 Pulleys shall be mounted on machined & ground surfaces. Suitable guards shall be provided for all tail pulleys and bend pulleys for safety of operating personnel.

1.09.10 Suitable stiffening arrangements shall be provided in all pulleys as required. For selection of pulley shaft dia of all the pulleys, a margin of atleast 20% shall be considered on the maximum tension at designed Conveyor capacity. Selection of pulley diameter, shell thickness, stiffening and shaft diameter shall be subject to approval of Employer during detailed engineering.

1.10.00 Belt Protection Equipment

1.10.01 Pull chord Switch

Pull chord type (manually reset type) emergency stop switches shall be located on both sides of belt conveyors along the walkways for the entire length of conveyors for emergency stopping of conveyor. The enclosure shall be of cast aluminum with degree of protection IP-65. It shall have a separate terminal box with a separate hinged cover which shall be totally sealed from main box containing actuating mechanism / limit switch etc. Local pull chord actuation shall be provided by means of mechanical flap. Each switch shall have two NO and two NC contacts, which shall be wired out to the terminal block. The terminal block shall have facilities of cable looping. The Contact rating of the switches shall be rated for atleast 5 Amps, breaking at 240 VAC at 0.3 p.f. lagging. Adequate length of rope and all accessories shall be furnished. Pull chord in stone picking area shall be routed inside G.I. pipe of 1” size.

1.10.02 Belt Sway Switches

Belt sway switches of self resetting type shall be furnished at periodic intervals to limit belt sway to permissible extent. The enclosure shall be of cast aluminum having degree of protection of IP-65. It shall have a separate terminal box with a separate hinged cover totally sealed from the main box containing actuating mechanism/ limit switch etc. Each switch shall have two NO and two NC contacts one for alarm and one for trip, which shall be wired upto terminal block. The terminal block shall have facilities for cable looping. The contacts of the switches shall be rated for atleast 5 Amps. breaking at 240 VAC at 0.3 p.f. lagging. The roller length of the switch shall be at least 150 mm. Belt sway switches shall also be provided at HGTU & VGTU to detect excessive belt away.

1.10.03 Zero Speed Switch

Zero speed switch shall be non-contact (proximity) type electronic switch. Mounting arrangement/ location shall be such that operation, effective sensing distance, sensitivity etc. shall not be effected by accumulation of dust on rotating part or surface of probe. Adequate mechanical protection by means of non-metallic shields shall be provided on top of the switch to prevent any damage due to falling coal / metallic pieces etc. In built initial start up delay and nuisance, tripping delay through timers shall be provided. Each switch shall have two NO and two NC contacts wired out to the terminal blocks. The contact of the switches shall be rated for atleast 5 Amps. breaking at 240 VAC at 0.3 p.f. lagging. The monitoring unit shall have cast aluminum body having IP-65 degree of protection. A separate terminal box with a

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separate cover, which shall be totally sealed from main box, shall be provided. Terminal blocks shall be suitable for terminating 1.5 mm sq. standard copper cable.

1.10.04 Chute Blockage Switches

One no. chute blockage switch of proven type (subject to approval of the employer) shall be provided at a suitable height on each leg of the conveyors discharge chute, vibrating screening feeders by pass chutes, crusher feeding chutes, tripper discharge and feeding chutes nearest to the skirt boards. Chute blockage switch shall trip the feeding conveyor in case of Chute blockage and protect the feeding conveyor equipment. Chute blockage switch shall also be provided at each leg of mobile tripper and shall trip the tripper conveyor.

The switch and its operating arrangement shall be suitable for working in dusty areas. The minimum degree of protection of switch shall be IP-65. Local indication of chute blockage switch actuation shall also be provided. Location of chute block switch shall be such that washing does not affect it.

1.10.05 Sensing arrangement shall be provided in the DDCMIS based control system for detecting the presence of material on the belt which shall in turn be used for operating solenoid valves of dust suppression/extraction system elaborated elsewhere. The arrangement shall detect three events simultaneously as follows:

(a.) Belt loaded

(b.) Belt running at more than preset speed.

(c.) Preset initial start delay.

1.10.06 The terminal boxes of all the belt protection equipments / switches shall be such that all the components / terminals inside are easily accessible for inspection and maintenance without removing the cables / connections / components.

1.10.07 Each pull cord and Belt sway switch shall have necessary chip for using in circuit for the identification of the operated switch in main control room. The scheme for switch identification shall be fail safe and shall have all diagnostic features. The scheme shall have facility to by pass one or more switches, if required.

1.11.00 Drive Motors

1.11.01 Rating of all drive motors of conveyors shall not be less than 120% of the power required at drive motor output shaft at specified design capacity. The motor rating shall be at 50 deg Cent. ambient.

1.11.02 Single LT drive motors shall be used for conveyor drive ratings up to 160 KW. For conveyor drive rating beyond 160 KW, single HT drive shall be used for conveyors. However for boom conveyor drive and intermediate conveyor drive on stacker-reclaimer, single LT motor may be used above 160 KW also.

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1.12.00 Conveyor Bridges

1.12.01 All overground and overhead conveyors shall be located in suitably enclosed bridge structure. Structural steel bridges of adequate width and depth (2700 mm clear head room) shall be provided complete with conveyor bottom deck plates, seal plates, walkways of chequered plates with anti-skid arrangement(s), hand rails (on both sides of each conveyor belt except where equipment (like paddle feeders, stacker/ reclaimer, trippers etc.) traverse over conveyor supports.

1.12.02 The conveyor bridge shall have permanently colour coated steel sheeting covers on roof and both sides, properly screwed or locked to steel structure as required. Adequate provision of windows shall be kept. A continuous slot opening of 500 mm shall be provided on both sides just below the roof sheeting.

1.12.03 The floors of outdoor conveyor galleries shall be designed and constructed as follows:

The side walkways for single conveyors shall be 800 mm on one side and 1100mm on the other side. However, if the centre to centre of conveyors or the width of the gallery is decided by some other criteria, maximum walkway widths consistent with gallery sizes shall be provided. In the complete length of conveyor gallery minimum walkway clearance as indicated above is to be maintained inclusive of all equipments and clearances.

All conveyors shall be provided with 12 G steel seal plates throughout the length of the conveyor gallery in such a way that complete gallery bottom surface area forms a single water proof floor and no water / coal falls down from conveyor gallery incase of cleaning / washing. It is envisaged to clean the conveyor gallery with water periodically. All the water / coal slurry shall be suitably guided to down comers provided at every trestle. Each downcomer shall lead the coal slurry into a 2 cub meter brick wall tank at ground level having 2 Nos. decanting taps at suitable elevations. Decanted water shall be led to the nearest drain in the Contractor’s scope. Necessary arrangement shall be provided to avoid choking of downcomers by bigger coal lumps and for cleaning of choked downcomers.

1.12.04 The conveyors shall be provided with continuous decking plate of minimum 3 mm thickness plain steel sheet.

1.12.05 Structures and floors shall be so designed as to provide suitable space for routing of 200 NB fire fighting pipe with water, cables and conduits.

1.12.06 Steel trestles to support the conveyor bridge shall rest upon concrete foundations to be provided by the Contractor. Complete trestle structures shall also be supplied by the Contractor. Suitable approach/access platforms with hand railings shall be provided to approach the conveyor gallery (like in case of fire) through monkey ladders on the trestles. Suitable wire mesh doors on steel frame construction lockable from outside only shall be provided in the conveyor galleries at these locations. All monkey ladders shall have cage for safety of personnel using them.

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1.12.07 Independent supports for walkways, conveyor structures shall be provided. The width of conveyor galleries shall be decided by the Contractors depending on the equipment’s size and the walkway width as specified. However, in no case the width of gallery shall be less than the width specified in tender drawings.

1.12.08 Provision shall be kept with platforms and ladders for crossing over the conveyors at approximately every 100m intervals of route length and minimum one per conveyor.

1.13.00 Special Cleaning, Protection and Painting

All equipment’s of Coal Handling Plant inclusive of belt conveyor system and technological structures shall be kept clean. Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire brushing. All ferrous surfaces shall be applied with one shop coat of 35 micron and one 35 micron site coat of red oxide zinc chromate and two coats, each of 25 micron, synthetic enamel finishing paints unless specified otherwise. A minimum of 120 microns Dry Film Thickness (DFT) after finished coat of paint shall be ensured. However for deck plate in track hopper and tunnels, painting specifications mentioned at sub section IIID-01 shall be applicable. However idler rolls shall be applied with two coats & each 35 micron of red oxide zinc chromate only.

The painting colour code shall be provided to the Contractor during detailed engineering.

1.15.00 Belt Vulcanizing Machine

1.15.01 Belt Vulcanizing Equipment shall be suitable for hot vulcanizing of belt splice and shall be of easy-to-handle type.

1.15.02 Equipment should be suitable for vulcanizing of entire splice width in single setting.

1.15.03 Equipment should be capable of applying uniform pressure over the splice by pneumatic or hydraulic means.

1.15.04 Heating element should be preferably of flexible type.

1.16.00 Belt Jointing Facilities

For the purpose of jointing the belting or replacement of belting, following belt facilities shall be provided:

1.16.01 5M X 5M paved area near take up to make joints.

1.16.02 Hooks shall be provided on TPs, Conv. Gallery to pull the old belt while replacing the same with new belt.

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DATA SHEET: BELT CONVEYOR

1.0.0 GENERAL

1.1.0 Design Capacity 110% of rated (guaranteed) capacity for all conveyors.

1.2.0 Maximum slope 16 deg

1.3.0 Max. belt Sag between idlers 2%

1.4.0 Minimum Radius

(i) Concave curve 250 m (In case of travelling trippers, the requirement of minimum radius shall be decided based on the space availability)

(ii) Convex Curve 50 m

1.5.0 Coal Parameters As specified elsewhere


2.1.0 Belting

2.1.1 Type Synthetic Fabric of Nylon / Nylon,/ Polyester/polyamide

2.1.2 Cover Grade a) Flame test : Conforming to ISO:340

b) Drum Friction and Electrical Surface

Resistance Test: Conforming to Canadian standard association CAN / CSA M-422- M87 Grade - C.

2.1.3 Cover Thickness (without –ve tolerances).

Synthetic belting

(a) Face 5.0 mm (min.)

(b) Bottom 2.0 mm (min.)

2.1.4 No. of plies Minimum 4

2.1.5 Drive Arrangement

Snub drive

2.1.6 Factor of Safety - 10 (Minimum) for N-N belt.

- 7 (minimum) for Steel Cord Belt.

2.1.7 Normal Working tension at design Less than 80% of max. allowable working

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capacity tension

2.2.0 Idlers

2.2.1 Type

(a) Carrying Three roll, 35 degree troughing, 2 degree forward tilt

(b) Return

Single Roll, For conveyors upto 400 m c/c length. Two roll with 10 degree angle for conveyors more than 400 m c/c length

(c) Loading point Impact type

2.2.2 Spacing

(a) Carrying idlers 1.2 m (0.6 m for convex curves and in the paddle feeder travel range).

(b) Return idlers 3.0 m (for convex curves not more than 1.5 m.)

(c) Loading point Minimum six (6) with 400 mm spacing.

(d) Self-aligning troughing idlers

At 10 m distance from head & Tail pulleys with intermediate spacing 15m

(e) Self - aligning return idlers At 10 m distance from Head & Tail pulleys with intermediate spacing 20m. (Not required for conveyors more than 400m c/c long where 2 roll return idlers are provided).

2.2.3 Bearings

(a) Carrying Ball Bearings of deep groove type or seize resistance type of min. 30 mm size, lubricated for life.

(b) Return Ball Bearings of deep groove type or seize resistance type of min. 20 mm size, lubricated for life.

2.2.4 Material

(a) Roller ERW Steel tube min. wall thickness 4.0 mm

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(b) Spindle E.N. 8 or equivalent.

2.3.0 Belt Cleaners

2.3.1 External Spring loaded scraper type cleaner with modular, segmented and replaceable PU blades with separate main-cleaner & pre-cleaner etc.

2.3.2 Internal V-Plough type, mild steel flats with hard rubber strips.

2.4.0 Belt Take up

2.4.1 Type Automatic Gravity Type.

2.4.2 Location In relation to the drive to keep belt tension at minimum.

2.4.3 Take-up travel To suit all operating conditions or (2.5% for synthetic belt) of conveyor center to center length whichever is larger. Further the initial location of take-up shall be decided in such a way that it is possible to carryout min. two (2) nos. Vulcanizing Joints without adding any external belt.

2.5.0 Hold Back Device

Integral with gear Box

2.6.0 Pulleys

2.6.1 General (for all types of Pulleys)

Pulley shaft diameter Margin of minimum 20% shall be Considered on maximum tension at design capacity for arriving at the shaft dia.

2.6.2 Drive Pulleys

(1) Lagging Hot lagged with vulcanised natural rubber

(2) Lagging thickness 12 mm thick grooved in diamond pattern with grooves 6 mm wide x 6 mm deep

(3) Minimum angle of wrap 210° degrees

(4) Maximum Out of roundness 0.5% of nominal diameter

2.6.3 Other pulleys

(1) Lagging Hot lagged with vulcanised natural rubber

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(2) Lagging thickness 12 mm thick plain

2.6.4 Rubber for lagging

(1) Type Natural rubber blended with styrene Butadiene rubber.

(2) Hardness 55 to 65 durometer (Shore A)

(3) Elongation Over 300%

(4) Strength 160-245 kg/cm2

(5) Abrasion loss 250 mm3 (max.) as per DIN 53516

(6) Specific Gravity Max. 1.5

(7) Adhesion Strength 10 kg/cm (minimum)

2.6.5 Bearings for Pulleys

(1) Type Heavy duty roller type

(2) Casing Horizontal Split Type

(3) Sealing Dust tight with double labyrinth seals.

(4) Lubrication Greasing arrangement with conical head shape nipples.

2.6.6 Pulley Material Mild steel conforming IS:226 / IS : 2062

2.6.7 Shaft Material Forged Steel shaft EN-8 or equivalent material.

2.7.0 Belt Protection Equipment

2.7.1 Emergency Stop Switch System

(1) Type Pull chord type (manually reset)

(2) Location Both sides of conveyor for entire length

(3) Spacing Approx 30 m

2.7.2 Belt Sway Switches

(1) Type Limit switches snap action.

(2) Spacing One pair at 50m interval (Minimum two (2) pairs)

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2.7.3 Zero Speed Switches

(1) Type, Location Proximity switch, mounted on Bend pulley of GTU.

2.8.0 Drive Motors

2.8.1 Type Three Phase Squirrel Cage Induction Motors

2.8.2 Mounting (for conveyors) Base mounted

2.8.3 Continuous motor rating (Name plate rating) at 50OC Ambient

120% of actual power requirement at motor output shaft at design capacity.

2.9.0 Conveyor Bridges

2.9.1 Walkways

(a) Construction Chequered plate with antiskid arrangement. Chequered plate steps shall be provided where conveyor slope exceeds 10 degrees. (Totally sealed so that no water falls down while washing.)

(c) Side walkway width for single conveyors, the width of side walkways shall be 800 mm on one side and 1100 mm on the other)

2.9.2 Side Windows

(a) Spacing (Center to center) 25.0 m on each side (in staggered fashion)

(b) Size 1.2 m x 1.5 m

(c) Window material Refer Civil Section

2.10.0 Trestles

2.10.1 Spacing of monkey ladders on trestles

(a) Where height of conveyor gallery (walkway level) is 10 m or more.

: On every trestle

(b) Where height of conveyor gallery (Walkway level) is

: On alternate trestle

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less than 10m.

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PART-B

SUB-SECTION-IIIA-06 DRIVE EQUIPMENT

PAGE 1 OF 4

A-06: DRIVE EQUIPMENT 1.00.00 GENERAL

Suitable Drive Chain Equipment’s like electric motors, gearboxes (where applicable), fluid couplings (where applicable), flexible couplings and other accessories shall be provided for all the belt conveyor systems, paddle feeders, crushers, mobile trippers, various pumps of dust suppression/extraction system, fans for ventilation system, monorail electrical hoists and other equipment’s specified in this specifications. Various requirements as spelt out in the Technical Specifications for individual equipment’s shall be taken into consideration while designing the associated drive chain equipment’s.


The design, manufacture, inspection and testing of Drive Equipment shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment in to be installed. The Drive Equipment’s shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding.

IS:3688 : Dimensions for shaft ends

IS:3681: General plan for spur & helical gears

IS:7403 : Code of practice for selection of standard worm and helical gear boxes

1.02.00 DESIGN AND CONSTRUCTION REQUIREMENTS

1.02.01 GEAR BOXES

1.02.02 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces.

1.02.03 The gearboxes shall be designed for 24 hours continuous duty. For thermal and mechanical rating of the gearbox the data sheet shall be referred to. Gearboxes with cooling coils are not acceptable.

1.02.04 The gears used shall be helical conforming to IS:3681 (latest revision) or worm reduction units or spiral bevel speed reduction units conforming to suitable Indian Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest revision. Above 40 kW drive rating, all gearboxes shall be helical or bevel helical type only.

1.02.05 Recommended oil grade shall be compatible with gear internals like material of bearing, cages. Further, all gearboxes shall have suitable breather plugs, dipstick, drain plug etc.

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1.02.06 Couplings

1.02.07 Flexible / Rigid Couplings

Couplings shall be used for power transmission depending upon duty requirements. The design of the coupling shall be such that it can take shock and misalignment without sacrificing its efficiency. Flexible couplings shall be used for low speed application only. Geared type flexible coupling shall be used on low speed side for all conveyors and other drive chains where gear box is provided. Other couplings in the drive chains shall be either rigid or flexible type, depending upon the requirement of equipment design.

1.02.08 Fluid Couplings

Fluid couplings shall be provided in all the drive machinery for belt conveyor systems if the actual power requirement at motor output shaft is more than 40 kW. The fluid coupling for LT motors shall be of traction type. Cooling water coils for traction type fluid coupling shall not be accepted. Scoop tube type fluid coupling shall be provided for conveyors with HT motors and ring granulator type coal crushers. Suitable electrically operated actuators shall be provided for scoop tube operation from local as well as remote. Suitable provision for alternate manual operation shall also be kept. Separate pump with motor or integral shaft driven oil pump shall be provided for circulating the fluid coupling oil through oil cooler. Arrangement for forced cooling water supply to oil cooler shall be provided by Contractor. Suitable interlock using flow switches shall be provided in both oil as well as water lines to trip the drive motor in the event of flow in either lines falling below acceptable levels. Suitable pressure indicators and flow indicators shall be provided in the cooling water lines along with all-relevant valves, and accessories. Necessary isolation valves shall be provided in the oil / water line for maintenance of any equipment in the line. Necessary interlock shall also be provided so that the HT motor cannot be started from remote / local unless position of scoop tube permits no load start of the motor. Tripping of downstream equipment while the system is under normal operation shall result in scoop tube re-positioning to permit no load run of the concerned HT motor. Temperature switch shall be provided in the oil circuit and shall trip the system in case of high oil temperature.

Selection of rating & speed of actuator for scoop type fluid coupling shall be made taking into consideration the coasting time of down stream and up stream conveyors and the engagement/disengagement time achievable. The scoop tube operation must be such so to ensure draining of oil from the operating circuit by providing a double speed motor. The speed (for draining) shall be selected to match the coasting time of down stream equipment/conveyor.

DATA SHEET : DRIVE EQUIPMENT

1.0.0 GENERAL

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1.1.0 Continuous Motor Rating (Name Plate Rating) at 50 Degree Centigrade Ambient temp. for Electric Motors

a) For conveyors of belt conveyor systems *120% of actual power at drive motor output shaft at specified design capacity

b) Mono-rail hoists (travel and hoisting), elevators, all the drives in sampling units, various pumps of DS systems, service water systems, cooling water system, potable water system and Ventilation Fans.

*110% of actual power requirement at drive motor output shaft at guaranteed (rated) capacity.

*The actual power at drive motor output shaft shall be calculated after considering all the losses of down the line equipment’s of the drive train.


2.1.0 Gear Box

2.1.1 Type

(a) Below 40 KW Helical, worm, bevel as per requirement without cooling coil

(b) Equal to and Above 40 KW Helical / bevel helical without cooling coil

2.1.2 Service Factor As per accepted engineering practice / manufacturer's recommendations.

2.1.3 Ambient temperature for Thermal rating 50oC Minimum

2.1.4 Mounting On Machined/Ground Surfaces

2.1.5 Output Rating

a) For belt conveyor systems @ Service factor X {1.2 times the actual power requirement at drive pulley shaft at design capacity}

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b) For other equipment

@ Service factor X {1.2 times the actual power requirement of the driven equipment }

@ Service factor shall include all the components considered by the supplier and should be clearly indicated in manufacturer’s gear box selection catalogues.

2.1.6 Duty 24 Hrs. Continuous

2.1.7 Rating Not less than motor name plate rating

2.2.0 Flexible Couplings

2.2.1 Type Geared coupling.

2.2.2 Rating Not less than motor rating.

2.3.0 Fluid Couplings For all motors having rating more than 40 KW.

2.3.1 Type

(a) L.T. Motors Traction type

(b) H.T. motors Scoop tube type.

2.3.2 Rating Not less than motor nameplate rating

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PART-B

SUB-SECTION-IIIA-07 BELT SCALE

PAGE 1 OF 3

A-07: BELT SCALE 1.00.00 GENERAL

Belt weigh scale for measurement of coal flow rate and quantity shall be provided at specified locations. System shall be complete with flow rate indicator, totaliser, control panel etc.

1.01.00 Codes & Standards

The design, manufacture, inspection and testing of Belt Scales shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Belt Scales shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding.

NEMA

NEC For electronic circuit enclosures.

IS:11547 Electronic weighing in motion system.

1.02.00 Design & Construction Requirements

1.02.01 The weigh scale shall be automatic and electronic type. It should be designed for continuous automatic weighing, metering and printing of coal flow.

1.02.02 Each belt weigh scale shall comprise of a belt weigh scale platform with minimum 4 nos. weighing idlers. It shall have unitised construction for ease of installation and shall be fully floating type (without pivot points). Minimum 4 nos. hermetically sealed load cells of precision strain gauge type shall be applied in tension to support the weigh bridge. The load cells shall have 100% overload protection and shall be structurally safe upto to 250% of rated belt scale capacity.

1.02.03 Belt scale shall be electronic microprocessor based with its program stored in non-volatile memory.

1.02.04 It shall be provided with self diagnostic features for trouble shooting of the entire belt scale system.

1.02.05 Fully automatic zero and span calibration facility shall be provided.

1.02.06 The electronic systems offered by the Contractor shall include all signal conditioning, power amplifiers and printed circuits etc. The printed circuits shall be encapsulated against dust and moisture.

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1.02.07 The flow rate indicator shall have minimum 4 digits. The flow totalizer should have 8 digits display scale with reset facility.

1.02.08 Complete belt scale system shall be suitable for 50°C ambient temperature and 100% relative humidity. It shall be suitable for out door installation in a dusty area. The electronic circuit enclosure, sensors housing shall be dust and watertight. The electronic printed circuits shall be encapsulated with epoxy or other suitable material for protection against dust and moisture.

1.02.09 Minimum three years battery back up power failure protection shall be provided.

1.02.10 Belt scale shall be designed for a range of 20% to 120% of rated capacity with an accuracy of atleast (+) 0.25 percent throughout its range.

1.02.11 Per two (2) belt weighers, the contractor shall furnish one (1) necessary test load chain sets required for calibration and periodic testing of the equipment. The test load chain shall be ‘two idler spaces’ longer than the weighing length of the weighers and shall be complete with chain reset equipment with weight adding reels of adequate size. The calibrated weight parameter length of the test chain shall be stamped at a suitable location on the body of the equipment. The test chain shall be installed near belt weigher with suitable arrangement for easy mounting/dismounting of chain onto/from conveyor belt. Alternatively, supply of test weights for calibration of belt scales is also acceptable.

1.02.12 Local panel for belt scale shall be of sheet metal.

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MUZAFFARPUR THERMAL POWER PROJECT STAGE-II (2X195 MW)

COAL HANDLING PLANT PACKAGE BID DOCUMENT NO. : CS-0350-155-2


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DATA SHEET : BELT SCALE

1.0.0 GENERAL

1.1.0 Ambient Temperature 50°C

1.2.0 Relative Humidity

100%


2.1.0 Type Electronic load cell type

2.2.0 Operation Microprocessor based fully automatic

2.3.0 No. of floating idlers Minimum four (4)

2.4.0 Load Cells

2.4.1 Type Strain gauge type hermetically sealed

2.4.2 Minimum Nos. Four (4)

2.4.3 Overload protection 100 % of rated belt scale capacity

2.4.4 Structural capacity 250 % of rated belt scale capacity

2.5.0 Flow Rate Indicator Electronic Digital Display Minimum 4 digits

2.6.0 Flow totalizer 8 digit display with reset facility.

2.7.0 Accuracy For entire range of 20% to 120% of rated capacity : Minimum + 0.25%

2.8.0 Calibration

2.8.1 Automatic

Zero & span calibration

2.8.2 Manual

With test load chain

(a) Test load chain length Two idler spaces more than weighing lengths

(b) Chain reel equipment Complete with weight adding facility.

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PART-B

SUB-SECTION-IIIA-08 DUST CONTROL & MISCELLANEOUS

SYSTEM

PAGE 1 OF 15

A-08: DUST CONTROL AND MISCELLANEOUS SYSTEM

1.00.00 GENERAL


1.01.01 The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete, Dust Control and Miscellaneous Systems as specified hereinafter required for the Coal Handling Plant.

The Contractor shall refer to the other sections and scheme indicated in the tender drawings to appraise himself of the work and scope of supply of the other Contractors/Employer's and shall coordinate his work with the work of other Contractors.

1.01.02 General Information/Description

1.01.03 Dust Control System

The dust control system to be furnished under this specification is required for control of fugitive dust emissions from dust generation points such as transfer points, feeders, crushers etc. Dust control is achieved by dust suppression/extraction system.

Contractor shall guarantee and offer dust control system which shall not allow a dust concentration in the ambient air inside the buildings more than acceptable limits as per Employer approved guidelines or any internationally recognized hygienic Standards/Codes.

The Capacity of dust control system specified elsewhere is for Contractor’s guidance only. Contractor shall provide adequately sized fool proof dust control systems the performance of which should be guaranteed by the Contractor. However, the capacity of the offered system shall not be less than the specified values. Further, for computation of design capacity of the pumps, permanent recirculation lines as shown in tender drawings shall also be considered.

1.01.04 Miscellaneous Systems

Service water system, potable water system, cooling water system & sump pumps shall be provided as specified elsewhere in this specification and as indicated in tender drawings.

1.02.00 Dust Suppression System

1.02.01 (a) Dry Fog Type Dust Suppression System

Complete with water supply system, compressed air system, pressure regulating units, flow activation system, necessary instrumentation for auto & manual operation, drives, pumps, maintenance platforms, alongwith associates civil/structures & electrical works.

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Service water distribution system complete with water supply system, valves, quick couplings, hose pipes with nozzle, piping, pumps, drive motors with canopy, couplings with enclosure, electricals, including supporting structures, handling for equipment’s, civil and structural works and necessary accessories shall be provided throughout the coal handling plant area in Contractor’s scope.

1.02.04 Pipings, Fittings, Valves and Specialities

The material to be supplied for completing the pipe work shall include but not be limited to the following:

(1) Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing unions, couplings, caps, blank flanges, saddles etc. necessary for making reliable piping system.

(2) Gaskets, ring joints, jointing material etc. as required.

(3) Instrument tapping connections, stubs.

(4) Gate / plug, globe and check valves to start/stop, regulate and to prevent back flow.

(5) Duplex Strainers.

(6) Anchors, hangers and supports as required including secondary steel embedment etc.

(7) Bolts, nuts, fasteners as required for interconnection piping, valves and fittings as well as for terminal points.

(8) The entire water piping of DS / SW / PW / CW / DE system shall be routed/supported on concrete pedestal and conveyor galleries. Wherever the layout does not permit the pipes to be routed over ground, the same shall be buried in conformity to the relevant standards & shall be provided with necessary protective coating as per relevant standards and as specified elsewhere in the specification.

(9) Painting, anti-corrosive coatings etc. outside pipes as necessary.

(10) Welding electrodes and welding rods.

(11) The area around storage tanks, strainers, valves etc. (located out side pump house) shall be paved.

1.03.00 Codes and Standards

The design, manufacture, inspection and testing of Dust Control & Miscellaneous Systems shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Dust Control

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& Miscellaneous Systems shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding.

IS:778 : Gun Metal gate, globe & check valves for general purpose.

BS:5150 :Cast Iron Gate Valve for water works purposes

BS:5152 :Cast Iron Globe Valve for water works purposes

BS:5312 :Cast Iron Check Valve for water works purposes

S:1239 : Mild Steel tubes & fittings.

IS:2379 :Colour for the identification of pipe line.

IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm)

IS:5312 : Swing check type reflux (non return) valves.

IS:1520 : Horizontal centrifugal pump for clean, cold fresh water.

IS:5120 :Centrifugal pump for clean, cold & fresh water.

BS: 5169 & BS:1123 : Air Receivers.

ANSI B 31.1:Code for pressure piping.

Hydraulic institute Standards of U.S.A.


Dry Fog Dust Suppression

1.04.01 At specified locations dry fog dust suppression system shall be provided which comprises spray nozzles discharging plain water & air in a fine spray to form dry fog to capture air borne dust particles and direct them into the main coal flow. This dry fog shall be discharged through spray heads at the dust suppression zones.

The dry fog dust suppression system shall consist of the following:

(a) Fogging system & controls consisting of:

(i) Spray bar assemblies.

(ii) Pressure regulating units

(iii) Flow activation system

(iv) Instrumentation for auto spray

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(b) Compressed air system consisting of:

(i) Two (2) nos. (one no. working and one (1) no. standby) air compressors (screw type) for each group of dry fog dust suppression system, alongwith air receivers as specified elsewhere.

(ii) Air receivers

(iii) Various instrumentation & valves.

1.04.02 Each spray head in CHP shall have a provision for installing a pressure gauge whenever required. Further, pressure gauges shall be provided at least at two locations.

1.04.03 Service Water (SW) System

Service water connections are to be provided in conveyor galleries and tunnels at 50 meter intervals. Adequate number of these connections shall be provided in all transfer houses with minimum one no. at each floor and with minimum two (2) nos. at each floor in crusher house. Each connection shall be provided with one (1) no. 32 NB globe valve and quick coupling. One (1) no. hose pipe with nozzle shall be provided in each building.

Service water distribution system shall be designed considering the water scheme and water requirement indicated in tender drawings.

1.04.04 Potable water (PW) system

Potable water connections are to be provided in all transfer points, wagon tippler top, crusher house, all tripper floors, the machinery well at both ends of track hopper, track hopper top at both ends and all control rooms/MCC rooms and toilets etc.

Water shall be drawn from the water storage tank by electric motor driven pumps and discharged via a pipe work system to the overhead drinking water storage PVC tanks of 250 litres capacities. The drinking water storage tanks shall have provision for maintenance & drain.

1.04.05 Hoists with monorail of adequate capacity shall be provided in the service water/dust suppression/potable water pump houses.


1.05.01 Water Supply Pumps

1.05.01.01 Water supply pumps shall be provided as required.

1.05.01.02 The pumps shall be complete with drive motors, baseplate and other accessories. The constructional features of the pump shall be as follows:

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a) Pump casing may be axially or radially split. The casing shall be of robust construction. Casing drain and vent connections shall be provided.

b) Impeller shall be made in one piece and securely keyed to the shaft. Locking device shall be provided to prevent its loosening during all conditions of operation.

c) Wearing rings shall be of renewable type. Opposed wearing surface shall be of hardened material and shall have a hardness difference of at least 50 BHN.

d) Replaceable shaft sleeves shall be provided to protect the shaft where it passes through bearings and stuffing boxes. The end of the shaft sleeve assembly shall extend through the packing gland. Shaft sleeve shall be securely locked or keyed to the shaft to prevent loosening or rotation. Shaft and shaft sleeves shall be machined and assembled for concentric rotation.

e) The design of the shaft shall take into consideration the critical speed, which shall be at least 20% away from operating speed.

f) Pump bearings shall be of antifriction type. Bearings shall be readily accessible without disturbing the alignment of pump.

g) Packed stuffing boxes shall be of sufficient length to prevent leakage along the shaft and shall be complete with all packing and lantern rings required.

h) Pumps shall be furnished complete with an approved type of flexible -coupling.

i) Couplings guards made of expanded metal and bolted to the base plate shall be furnished.

j) The common base plate for pumps and motor shall be in one piece and shall be made of fabricated steel.

k) Pump speed shall be less than 1500 rpm for pumps of capacity more than 10 m3/hr.

1.05.01.03 The power, head and flow characteristics of each pump shall be suitable for parallel operation. The Power characteristics of the pumps shall be of non overloading type.

1.05.01.04 All rotating parts of the pumps shall be statically and dynamically balanced.

1.05.01.05 The motor shall be rated for continuous operation and confirm to companion electrical specification. However, motor rating shall not be less than the max. power demand throughout the entire range of operation of pump.

1.05.01.06 Design duty point of pump shall match with the average value of maximum and minimum flow rates of the pump in the stable operation zone.

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1.05.01.07 Materials of construction of pump components shall be as stated in data-sheet to this section.

1.05.02 Piping, Fittings, Valves and Specialties

1.05.02.01 Piping & Fittings

(a) Material of construction of piping and fittings shall not be inferior to those given in data sheet of this section.

(b) All piping shall be capable of withstanding the maximum pressure in the corresponding line at the relevant temperature.

(c) In general pipe sizes 65 mm NB and larger are to be joined by butt welding and pipe work of size 50 mm NB and below by socket welding/screwed connections. Joints at valves or specialities shall be flanged for sizes 65 mm NB or large and screwed for sizes 50 mm NB and below. All galvanised piping shall be joined by screwed connections. Minimum pipe diameter selected for DS/SW/PW/Cooling Water System (along with branch pipes) shall be 32 NB. However, for dry fog DS system, the minimum pipe size shall be 15 NB.

(d) End preparation for butt welding shall be done by machine/flame cutting. Socket weld and preparation shall be saw/machine cut.

(e) Hangers and supports shall be capable of carrying the sum of all concurrently acting loads. They shall be designed to provide the required supporting effects and allow pipe line movements as necessary. All guides, anchors, braces, dampers, expansion joints and structural steel to be attached to the building/structure, trenches etc. shall be provided.

(f) All piping shall be routed on ground on concrete pedestals and at road crossings, these shall be buried through hume pipes.

1.05.02.02 Valves and Specialities

(a) Valves & Specialities shall be used to start, stop or regulate the flow. All valves/specialities below 50 mm size in service water/dust suppression/ potable water lines should be plug type of proven make.

(b) All valves shall be suitable for most stringent service conditions i.e. flow, temperature and pressure under which they may be required to operate.

(c) Gate/sluice valves shall be used for isolation of flow of pipe lines above 50NB and Globe valves shall be used for regulating the flow.

(d) Valves shall be provided with back seating bush to facilitate gland renewal during full open operation.

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(e) All gate and globe valves of size 65 NB and large shall be bolted bonnet, outside screw, rising type with flanged ends. Valves of size 50 NB and smaller shall be with screwed ends.

(f) Valves shall be provided with the following as necessary :

(1) Hand wheel

(2) Position indicator

(3) Draining arrangement.

(g) Material of construction of valves shall not be inferior to those given in data sheet of this section.

(h) Globe valves shall be provided with contoured plug to have well controllability.

(i) Non-return valves shall be swing check type. These valves will have a permanent ‘arrow’ inscription on its body to indicate direction of motion of the fluid.

(j) All valves shall be provided with hand wheel, chain operated, extension spindle and floor stand wherever required so that they can be easily operated either at a lower or higher elevation as the case may be.

(k) Strainer shall be of duplex type designed with 3 way valves so that one filter can be cleaned while the other is in operation. Suitable vent and drain valves shall also be provided. Screen opening area shall be at least four times the pipe cross sectional area. Pressure drop in clean conditions shall not exceed 1.5 MWC at full flow.

(l) Bib cocks provided for potable water system shall be made of Copper Alloy / Cast Iron.

1.05.03 Special cleaning, protection and painting

1.05.03.01 Piping & Fittings

(a) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire brushing.

(b) For overground exposed steel pipes, one shop and one site coat of red oxide zinc phosphate and two coats of synthetic enamel finishing paints unless specified otherwise shall be applied. A minimum of 120 microns Dry Film Thickness (DFT) after finished coat of paint shall be ensured.

(c) For steel buried pipeline, three (3) coats of heavy duty bitumastic paint shall be applied on the cleaned surface. Finally, it should be wrapped with minimum 3 mm thick bitumen impregnated tar felt. The lap joint of the felt shall be generally touched with heavy duty bitumastic paint.

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1.05.03.02 Pumps for DS/SW/CW/PW/DE systems shall be selected with minimum 10% margin on capacity and 20% margin on computed head.

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DATA SHEET: DUST CONTROL & MISCELLANEOUS SYSTEM

1.0.0 GENERAL

1.1.0 Dust Control Dust suppression/ extraction system

1.2.0 Miscellaneous systems Service water system, Potable water system, Cooling water system.


2.1.0 Dust Suppression

2.1.1 Operation Water sprayed through nozzles.

2.1.2 Pumps 2x100% for water

2.1.3 Spray Head

(i) Minimum No. of nozzles per spray head

4 (Four)

(ii) Pressure at inlet (dry fog)

(iii) Pressure at inlet (Plain water)

Min. 0.5 kg/cm2 for water

Min 5 kg/cm2 for air

Minimum 2.5 kg/sq. cm

2.3.0 Dry Fog Dust Suppression

(i) Compressor Screw Type

(ii) No. of Compressors to be provided One working & one Standby, per group

(iii) Air receivers One no. of min. 2 cu.m capacity located near compressors & 200 litres capacity at various location

(iv) Nozzles Dry fog type


2.6.1 Water connections

(a) Conveyor Galleries and tunnels every 50 m

(b) Transfer points Min. 1 no. at every floor

(c) Crusher House Min. 2 nos. at every floor

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2.6.2 Connection details 32 NB plug valve

2.6.3 Hose pipes with hose reel One in each building of 25 mtr.

Length with nozzle

2.7.0 Potable Water System

2.7.1 Pumps 2 X 100% electric motor driven

2.7.2 Water connections

a) Transfer points Minimum one (1) no. at each floor

(b) Crusher house Minimum two (2) no. at each floor

(c) Tripper floor Minimum one (1) no. at every tripper bay.

(d) Machinery wells Minimum one (1) connection at each machinery well in track hopper

(e) Control room Minimum one (1) no. at each floor

(f) MCC rooms and toilets Minimum one (1) no. each

(g) Track hopper Top Min. one (1) no. at each end.

(h) Wagon tippler top Min. one (1) no.

4.0.0 CONSTRUCTION REQUIREMENTS

3.1.0 Water Supply Pumps for DS/SW/PW/CW

3.1.1 Casing Axial or radially split with drain & vent connection

3.1.2 Impeller One piece, keyed to shaft along with locking device

3.1.3 Shaft Critical speed atleast 20% away from operating speed

3.1.4 Shaft sleeves At bearings & stuffing boxes.

3.1.5 Bearings Antifriction type

3.1.6 Wearing rings Renewable type (preferable)

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3.1.7 Pump speed Below 1500 rpm for capacity more

than 10 cub. m/hr.

3.1.8 Head flow characteristics Suitable for parallel operation.

3.1.9 Materials

(a) Casing Cast Iron to IS:210, FG 260

(b) Impeller Bronze conforming to Gr.I of IS:318

(c) Impeller Wearing ring Bronze conforming to Gr.I of IS:318

(d) Casing Wearing ring Bronze conforming to Gr.I of IS:318

(e) Shaft Medium carbon steel

(f) Shaft sleeve Stainless steel conforming to AISI-416 hardened.

(g) Gland packing Impregnated teflon

3.3.0 Pipings & Fittings 3.3.1 Joints (i) Pipe to pipe

Pipe size < 50 NB Pipe size > 65 NB

Socket welding/screwed Butt welding

(ii) Pipe to valves Pipe size < 50 NB Pipe size > 65 NB

Screwed Flanged

3.3.2 Isolation of flow Plug / Gate / Sluice valves 3.3.3 Regulation of flow Globe Valve

3.3.4 Valves

(i) Size > 65 NB Bolted bonnet outside screw rising type.

(iii) Size < 50 NB

Union bonnet with screwed ends for Globe valve & screwed ends for plug valve

3.3.5 Materials for Pipework

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(a) For sizes 200 NB and Larger ERW carbon steel pipes to API-5L-Gr.B/IS:3589 with minimum thickness 6.35 mm

(b) For sizes 150 NB to 65 NB ERW carbon steel black pipes to IS:1239 (Part-Heavy class).

(c) For sizes below 65 NB

ERW carbon steel galvanized pipes to IS:1239 (Part-I) Heavy class.

3.3.6 Materials for Valves & Specialities

(a) Cast Iron Valves 65 NB and above

(i) Body and bonnet Cast Iron to IS:210, Gr.FG-200

(ii) Disc for non- return Cast Iron to IS:210, Gr.FG-200 valves

(iii) Seating surfaces and rings 13% chromium steel

(iv) Hinge pin for non return valves Stainless steel type AISI-316

(v) Stem for gate and globe valves 13% chromium steel

(vi) Back seat bush 13% chromium steel

(a) Gun metal valves (50 NB & below and upto a working pressure of 10 kg/cm2)

(i) Body Gun metal to IS:318, Gr-2.

(ii) Trim Gun metal to IS:318, Gr-2.

(b) Duplex Strainer

(i) Body MS fabricated

(ii) Strainer Stainless steel type element AISI-316

(c) Pressure Gauge/Switch (to be provided with isolating valves, gauge cock, snubber and syphon)

(i) Dial size 150 mm

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(ii) Accuracy (+/-) 1% of range span

(iii) Bourdon AISI 316 SS

(iv) Block AISI 316 SS

(v) Movement AISI 316 SS

(vi) Case and Bezel Die cast Alum. Weather proof case

stove enameled block with screwed type inner bezel of ABS plastic and glycerin filled.

(vii) No. of contacts 2 NO + 2 NC

(viii) Type of contact Adjustable throughout the range.

(ix) Degree of protection IP. 65

(d) Solenoid valve (to be provided with isolating valve)

(i) Type 2/2 way Diaphragm type pilot operated

(ii) Diaphragm molded synthetic rubber

(iii) Body Forged brass / SS

(iv) Pressure 0.5 to 10 kg/cm2

(v) Protection Class IP 65

(e) Flow Switch (to be provided with isolating valves)

(i) Body Forged steel

(ii) Extension Rod/wire SS-304

(iii) Sleeve and Sleeve pipe SS-304

(iv) Cover Die cast aluminum

(v) Max. working pressure 10 kg/sq.cm

(vi) Repeatability ± 0.5%

(vii) No. of contacts 2 NO + 2 NC

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(viii) Type of contact Adjustable throughout the range.

(ix) Protection class IP – 65

(f) Level Switch

(i) Type Displacer operated magnetic type

(ii) Displacer SS – 316

(iii) Wire rope SS – 316

(iv) Spring Housing Spring and sleeve pipe

SS – 316

(iv) Cover Cast Aluminum

(v) No. of Contacts 2 NO + 2 NC

(vi) Type of Contact Adjustable throughout the range.

(viii) Protection class IP – 65

(g) Level gauges

(i) Type Float type mechanical gauge with arrow scale

(ii) Accuracy (+/-)1% of full scale range

(iii) Material of construction

(aa) Float & Guide wire 316 SS

(bb) Elbows Suitable grade of SS

(cc) Housing Mild Steel

(dd) Cable fastener SS 304

(h) Plain water Dust Suppression Nozzles

(i) Type Fogging, non-clogging type

(ii) Material Stainless Steel

(iii) Nozzle housing To ensure protection of nozzle against damage.

(i) Y Strainer

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(a) Body SS 304

(b) Plug SS 304

(c) Filter Element SS 316, 60 mesh

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MUZAFFARPUR THERMAL POWER PROJECT

STAGE-II (2X195 MW) COAL HANDLING PLANT PACKAGE BID DOCUMENT NO. : CS-0350-155-2


PART-B

SUB-SECTION-IIIA-09 VENTILATION SYSTEM

PAGE 1 OF 11

A-09: VENTILATION SYSTEMS

1.00.00 GENERAL


The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete Ventilation & air conditioning systems as specified hereinafter for the smooth and trouble free operation of CHP.

1.01.01 The Contractor shall refer to the other sections enclosed to appraise himself of the work and scope of supply of the other Contractors and shall coordinate his work with the work of other Contractors.

1.02.00 GENERAL DESCRIPTION

1.02.01 Mechanical Ventilation system

The air quantity for mechanical ventilation system shall be estimated based on equipment and solar heat loads and the temperature rise inside the building. Necessary air filters shall be provided to supply only clean air into building. Exhaust air shall be discharged at a suitable height above building. Exhaust fans shall be provided for tripper floor, Toilets, Battery rooms. All underground structure shall be provided with supply air as well as exhaust air fans.

1.02.02 Pressurised Ventilation System

The pressurised ventilation system having adequate nos. of supply air fans with washable metallic pre filters, HDPE fine filters, and self closing flap (gravity louver shutter), ducting along with 3 phase AC motor drives, electricals, supporting structures, access / maintenance platforms shall be provided in all MCC/switchgear room areas of coal handling plant to be furnished under this specification. The pressurized ventilation system shall be designed considering 15 air changes per hour to maintain these areas pressurised slightly above atmospheric pressure to prevent ingress of dust from outside.

1.02.03 Air Conditioning System

Air conditioning system shall be furnished for control room area of main CHP control building, office room in main CHP control room and in electrical buildings. It shall be designed considering the equipment heat loads, solar heat loads, heat gain into the room, adequate no. of air changes etc. to maintain a uniform temperature and relative humidity within the air conditioned areas.

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1.03.00 VENTILATION AND AIRCONDITIONING SYSTEM

1.03.01 Mechanical Ventilation System

Exhaust fans shall be provided for tripper floor, Toilets, Battery rooms. The exhaust fans for toilets and battery rooms will be propeller type

1.03.02 Pressurised Mechanical Ventilation System

The ventilation system generally consisting of adequate number of supply fans, metallic pre filters, HDPE fine filters, ducting along with 3 phase AC motor drives, electricals, supporting structures, approach / maintenance platforms, necessary shed, civil & structural works and necessary accessories shall be furnished for all MCC/switchgear rooms.

1.03.03 Air Conditioning System

1.03.03.01 2x100% capacity air conditioning packaged units (PAC) with air cooled condensers shall be provided for Main Control Room, office room of Main Control Room & various MCC Rooms as specified elsewhere in spec. complete with supply and return air ducting.

1.03.03.03 Supply and return air distribution ducting complete with insulation, of resin bonded mineral wool equivalent of density at least 24 Kg/m³ and thermal conductivity of max. 0.49 mw/cm°C conforming to IS:8183 including supporting structures, approach/ maintenance platforms, civil and structural works and necessary accessories shall be provided.

1.03.03.04 Area around centrifugal fans, filters, motor foundation shall be paved to have a clear surrounding.

1.04.00 Codes & Standards

The design, manufacture, inspection and testing of Ventilation & A/C System shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Ventilation & A/C System shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding.

IS:3588 : Specification for electrical axial flow fans.

IS:2312 :Propeller type AC Ventilation fans

IS:3963 :Specification for roof-extractor units

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IS:4894 :Centrifugal Fans

IS:655 :Specification for Metal Air Duct

ARI:210 :Standard for Unitary air conditioning equipment.

ARI:270 :Standard for application, installation and servicing of unitary equipment.

IS:8183 :Specification for bonded mineral wool.

IS:661 :Thermal insulation for cold surfaces.

IS:4671:Expanded polystyrene for thermal insulation purpose.

IS:8148 :Packaged Air conditioners.


1.05.01 Axial Fans

1.05.02 Design duty point of the fan shall match with the average value of maximum and minimum flow rates of the fan in the stable operation zone. The speed of the fan shall not preferably exceed 960 rpm for fan with impeller diameter above 450 mm and 1440 rpm for fan with impeller diameter 450 mm and less. The first critical speed of rotating assembly shall be at least 25% above operating speed.

1.05.03 Impellers shall be axial flow type single piece.

1.05.04 Centrifugal Fans

1.05.05 The fan units shall be centrifugal type with radial bladed impeller. For design, purpose out door ambient temperature shall be taken as 50 deg.C.

1.05.06 Fans shall be manufactured vibration free in operation and shall be designed to limit noise level within limits specified in Data Sheet.

1.05.07 The motor shall be rated for continuous operation and conform to companion electrical specification. However, motor rating shall not be less than the max. power demand throughout the entire range of operation of fan.

1.05.08 All fan mountings shall have adequate arrangement for vibration isolation.

1.05.09 The reverse flow through non-working fan shall be prevented by dampers. The dampers shall be made out of 18 SWG MS sheets.

1.05.10 Design duty point of the fans shall match with the average value of maximum and minimum flow rate of the fan in the stable operation zone.

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1.05.11 Filters

1.05.12 Metallic Filters

Metallic cleanable filters shall be provided as required. Max. air velocity considered shall be 2 m/sec.

1.05.13 HDPE Filters

HDPE filters should have an efficiency of 90% down to 5 microns. Velocity across the filter shall be limited to 2.5 m/sec.

1.05.14 High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99% down to 5 microns. Pr. drop across the filter under clean condition shall not be more than 10 mm w.c.

1.05.15 Packaged Air-Conditioning Unit

PAC units shall be provided as required.

1.05.16 PAC units shall be factory tested and assembled self contained units complete with refrigerant compressor, coils, fans, insulation and wiring. Various parts of PAC units wherever required shall be insulated with expanded polyethylene conforming to IS:4671.

1.05.17 The PAC unit shall comprise of an evaporator (indoor air) blower section and an air cooled condenser (outdoor air) section. Heavy gauge steel cabinet finished with paint of approved colour, shall be used to house components of PAC.

1.05.18 The evaporator and condenser coils shall be arranged for direct expansion cooling and shall be formed of aluminum fins mechanically bonded to seamless copper tubes and electrically tinned. The inter-connecting refrigerant circuits shall comprise of hermetically sealed scroll compressor and motor with all necessary isolation valves, with adjustable set point, sight glass, copper tubing and pipeline ancillaries. The condenser coils shall be air cooled by propeller type fans complete with safety guards. The condensing coils shall be suitably arranged to avoid radiant heat pick-up from solar sources.

1.05.19 Condenser capacity control shall be provided by means of fans and ‘head pressure’ sensing.

1.05.20 The evaporator air blower(s) shall be centrifugal forward curved type belt driven by individual motor(s) and suitable for the external static pressure. The fan assembly shall be isolated from the casing by anti-vibration mounts. The fan/motor drive shall be capable of capacity adjustment by pulley changes within +15% of design duty.

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1.05.21 High efficiency filters shall be provided in the main supply air duct and in the fresh air connection to return air duct.

1.06.00 Construction Requirements

1.06.01 General construction details of various equipment under Contractor’s scope shall be as elaborated in subsequent clauses below.

1.06.02 Axial Flow Fans

Axial flow fans shall be provided as required.

1.06.03 Impellers shall be axial flow type and single piece cast aluminum with aerofoil blades construction. It shall be finished all over and balanced dynamically. Impeller shall be mounted directly on the motor shaft.

1.06.04 Casing shall be of heavy gauge construction properly reinforced for rigidity. It shall be provided with suitable supports. Access door shall be provided in the casing for easy access to motor and impeller. Suitable arrangement for mounting of motor shall be provided.

1.06.05 Rain protection cowls will be designed to suit wall exhausters/supply fans for protecting fans/motors from rain. It will be provided with bird screen.

1.06.06 Inlet cone or bell and outlet cone shall be provided as required. It should be made of G.I. or M.S.

1.06.07 Motor shall be of totally enclosed type complying with the companion electrical specification. Suitable rain/sun shade for motors shall also be provided.

1.06.08 Centrifugal Fan

Centrifugal fans shall be provided as required.

1.06.09 The casing shall be of welded construction fabricated with heavy gauge material. It shall be rigidly reinforced and supported by structural angles. The seams shall be permanently sealed airtight. Split casing shall be provided on larger sizes of fans. Casing drain with valves shall be provided wherever required.

1.06.10 The impeller shall have die formed curved blades fabricated out of MS heavy gauge welded to the rim and back plate to have a non overloading characteristics of the fan. Rim shall be spun to have a smooth contour. If required intermediate stiffening rings shall be required. The impeller, pulley and shaft sleeves shall be secured to the shaft by key and/or nuts. The impeller along with driven pulley shall be dynamically balanced. Fan shaft shall be of EN-8 equivalent.

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1.06.11 The bearings shall be self-aligning heavy-duty ball or roller bearings. They shall be adequately supported. They shall be easily accessible and lubricated properly from outside.

1.06.12 Filters

1.06.13 Metallic Filters

Metallic cleanable filters shall consist of V-fold galvanised wire mesh inter spaced with a flat layer of galvanised wire mesh. The density of the filter medium shall increase in the direction of airflow. Wire mesh edges shall be suitably hemmed to eliminate the danger of abrasion during handling. Filter medium shall be supported on either side by galvanised expanded metal casing. Filter frame shall be constructed from galvanised sheet of thickness not less than 18 gauge.

1.06.14 HDPE Filters

HDPE filters shall be provided as required. To facilitage periodic cleaning of filters by water washing, tap of service water connection near the filters shall be provided.

1.06.15 High efficiency filter (for A/C purpose)

The media of the filter shall be made from either special synthetic non-woven bond fiber design or made from micro fiber glass media. It shall be supported with GI wire mesh or aluminum mesh and shall be housed in an aluminum sheet frame. It shall be of washable type several times.

1.06.16 Package A/C Unit

1.06.17 A separate cubicle shall be provided within the overall casing to house the thermostatic controls, which shall be electric/electronic solid state, prewired and tested. The refrigerant system shall be protected by pressure limiting devices, electric and thermal overloads and unloading facilities to provide the required control range tolerances. A low voltage room thermostat or RTD based temperature sensing device shall be provided for wall mounting. The casing shall be fitted with all necessary coil drains and service connections/ entries.

1.06.18 PAC (duty/standby) units shall be selected manually and be ON/OFF switched. The units shall be fully packaged and incorporate integral room air sensing control thermostats and manufacturers work fitted safety interlocks. All controls shall be prewired to unit mounted control/power terminal boxes.

1.06.19 Ventilation and Air Conditioning system ducting

All GI sheet metal ductwork required for ventilation and air conditioning system shall be furnished by the supplier. All ducts and plenums unless otherwise noted shall be constructed out of standard quality galvanised steel sheet. All sheet metal ducts

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shall be fabricated and installed in conformity to the requirements of IS:655. Steel supports for the ductwork shall be furnished as required. The thickness of ducting steel shall be 1 mm min. For ducting with large size exceeding 1300 mm it shall be 1.25 mm. The flexible connection between fan and ducting shall be on teflon impregnated canvas. The zinc coating on GI sheet shall be 275 gm/m2.

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DATA SHEET: VENTILATION SYSTEM

1.0.0 GENERAL

1.1.0 Mech. Ventilation System To provide ventilation using fans for specified areas.

1.1.1 No. of air changes per hour

For overground building Not less than 10 supply air changes

1.1.2 Equipment

(1) Underground tunnel Centrifugal fans/Axial Fans

(2) All other places Axial fans, roof ventilators

1.2.0 Pressurised ventilation system To provide clean air to all MCC / Switchgear buildings

1.2.1 No. of air changes per hour Not less than 15

1.2.2 Equipment Centrifugal fans/Axial Fans

1.3.0 Air-conditioning system

1.3.1 Temperature to be maintained 24 ± 1 deg. C

1.3.2 Humidity to be maintained 60 ± 5% relative humidity

1.3.3 Fresh Air intake Minimum 1.5 air changes per hour.

1.3.4 Equipment 2 x 100 % roof mounted package AC units along with ducting etc.

1.4.0 Outside Ambient Conditions

As per weather data given in project synopsis


2.1.0 Roof Ventilators

2.1.1 Capacity 10% more of actual requirement

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2.1.2 Head 20% more of actual requirement

2.1.3 Speed

(a) Impeller dia above 450 mm Max. 960 rpm

(b) Impeller dia less than or equal to 450 mm Max. 1440 rpm

(c) Critical speed 25% above operating speed.

2.2.0 Axial Fans


2.2.2 Head 20% more of actual requirement

2.2.3 Speed

(a) Impeller dia above 450 mm Max. 960 rpm

(b) Impeller dia less than or equal to 450 mm Max. 1440 rpm

(c) Critical speed 25% above operating speed.

2.3.0 Centrifugal Fans


2.3.2 Head 20% more than actual requirement

2.3.3 Speed Max. 1500 rpm

2.3.4 Outdoor temperature 50 deg. C.

2.3.5 Rating Continuous

2.4.0 Packaged Air-Conditioning Unit

2.4.1 Type Roof top mounting

2.4.2 Service/application Continuous, round the clock.

2.4.3 Capacity

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(i) TR Suitable

(ii) CFM Suitable

2.4.4 Type of compressor Hermetically sealed scroll compressor

2.4.5 Condenser Air cooled type

2.4.6 Fan Forward curved centrifugal fan

2.4.7 Filter High efficiency filter

2.4.8 Cooling Coil

(a) Type Direct Expansion

(b) Material Copper

(c) Fins Aluminum mechanically bonded.

2.4.9 Refrigerant Piping Copper

2.4.10 Insulation for PAC parts Expanded polyethylene of density at least 15 kg/cub.m.

2.5.0 Filters

2.5.1. Metallic Filters

(1) Max. air velocity 2m/sec.

2.5.2 HDPE filters

(1) Efficiency 90% down to 5 microns

(2) Max. velocity 2.5 m/sec.

(3) Testing As per BS 2831 / Sqv.

2.5.3 High Efficiency Filter

(1) Efficiency 99% down to 5 microns.

(2) Pr. drop across 10 mm W.C.

(3) Testing As per BS 2831 / Sqv.

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2.6.0 Insulation for A/C Ducting Resin Bonded Mineral wool as per IS:8183

2.6.1 Density 24 kg/cub.m

2.6.2 Thermal conductivity 0.49 mw/cm deg.C

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PART-B

SUB-SECTION-IIIA-10 CHP BUILDINGS

PAGE 1 OF 5

A 10: CHP BUILDINGS 1.00.00 GENERAL

Various buildings in coal handling plant like transfer houses, crusher house, control rooms, MCC rooms complete with all associated civil foundations and other civil, structural and architectural works shall be provided by the Contractor as per the specification.

Construction/fabrication/erection and designing aspects of various buildings shall be as per the Civil/Structural specifications.


The design and construction of CHP Buildings shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The CHP Buildings shall conform to the latest edition of the Indian standards and codes. Other internationally acceptable standards/ codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standards and this specification, the decision in the Employer shall be final and binding.

1.02.00 Design Requirements

1.02.01 All CHP buildings shall have sufficient space to accommodate the entire equipment like head end, drive unit and tail end of various conveyors, crushers, hoppers, chutes, control equipments, MCCs, batteries, supports for conveyor bridges, tensioning arrangements, approach/maintenance platforms with ladders, external / internal stairs, handrails, RCC floors, foundations etc. Moreover, ample space shall be provided for maintenance purposes. Outside stairs to transfer points and crusher house shall be open type. However, a weather canopy shall be provided at the top.

1.02.02 Mechanical Handling arrangements with adequate monorails etc. shall be furnished for servicing and installation of various housed equipment as described elsewhere.

1.02.03 Building floors shall be washed periodically with water for which necessary slope & drains shall be provided from each floor leading to minimum 4 nos down comers of minimum 273mm OD each building. However for MCC, control buildings and pump houses, minimum 150 mm dia, 4 nos galvanized MS pipes conforming to IS :1239 shall be provided. The system shall be designed considering water mixed with coal. A drain pit shall be provided near each building to collect water/coal mixture. Overflow from this pit shall be connected to nearest drain. 1 mtr x 1 mtr size dust/debris MS chutes from all the floors to ground floor shall be provided at all buildings/transfer houses and crusher house. The plate thickness shall note be less than 6mm.

1.02.04 Various dimensions and relative elevations shown in tender drgs. for various buildings/structures are minimum acceptable to the Employer. However, final dimensions for various buildings/structures and relative elevations shall be decided

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based on actual details/maintenance requirements of contractor’s equipment to meet technical specification requirements without any implication to the Employer. The sizes of these houses shall be approved by the Employer at the stage of detailed employer.

Openings in the floors of CHP buildings (i.e. TPs etc.) shall be provided with curb of 100mm high to avoid water falling down to lower floors.

1.02.05 Vertical bracings in transfer points shall be provided only along four sides. No bracing system projecting outside the building shall be allowed.

1.02.06 Floor at ground shall be provided in all transfer points, ground conveyors etc. Level of floor at ground shall be 500 mm above ground/grade level unless noted otherwise. For enclosed ground conveyor 750mm wide plinth protection along with drainage arrangement shall be provided along the conveyor on both sides. Suitable opening at every 50mtr interval shall be provided on either side in a staggered manner for exit / entry of personals. Necessary drains must be provided all along the floors of ground conveyor.

1.02.07 The accessories for dust control & miscellaneous system like water pumps etc. shall be housed in separate pump houses.

1.02.08 For areas where ground floor is located less than 500 mm above ground level/grade level, outside face of the brickwalls shall be plastered with rich cement-sand mortar (1:4) with neat cement finishing over it for a height of 500 mm above ground level/grade level.

1.02.09 Toilet with potable water facilities shall be provided in all MCC Control Rooms, and potable water shall also be provided at all transfer houses,

1.02.10 Necessary facilities for ventilation of control/MCC rooms, shall be provided as specified elsewhere.

1.02.11 External fire escape stair case alongwith internal staircase(wherever applicable) shall be provided for all MCC/ control rooms & Crusher house.

1.02.12 5 mtr wide paving beyond the surface drains shall be done around all transfer points, Crusher house for movement of trucks. The approach for trucks should be provided around transfer point, crusher house and upto hoist lifting area.

1.02.13 All building shall have the fire protection provisions to meet TAC and IS – 3034 regulations.

1.03.00 Construction Requirements

1.03.01 Junction Houses

1.03.02 All overground buildings shall be of steel frame construction.

1.03.03 All underground & partially underground structures shall be entirely in RCC.

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1.03.04 External staircases shall be provided for all transfer points.

1.03.05 The transfer houses shall have permanently colour coated steel sheet enclosure with steel framed doors and louvered windows.

1.04.00 Control / MCC Rooms

1.05.01 Control rooms, MCC rooms shall be of RCC construction with Brick enclosure. Fire safety wall in/around transformer yards shall be as per detailed engineering.

1.05.02 MCC/Switchgear rooms shall be kept pressurised with dust free air by way of pressurized ventilation. Office room and Control Rooms shall be provided with PAC (Packaged Air Conditioning) units.

1.05.03 Air-conditioned areas of CHP buildings shall have double glass windows. Roofs/sidewalls shall be provided with insulation to minimise the heat load. All frames of doors and windows shall be of extruded aluminum and shall be capable of isolating the conditioned space. All AC Control rooms & MCC rooms shall have double door entry.

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DATA SHEET : CHP BUILDING

1.0.0 GENERAL

1.1.0 Underground/partially underground Transfer Houses

RCC Construction

1.2.0 Overground Transfer Houses, Crusher House

Steel Construction

1.3.0 Control/MCC rooms & S&T room RCC construction


2.1.0 Junction Houses

2.1.1 Space requirement To accommodate all equipments drive units, head/ tail ends of conveyors transfer chutes etc. and to provide adequate space for maintenance.

2.1.2 Floors RCC construction with facility to wash the floors. Min. slope of 1:80 for floors in JHs and 1:100 for floors in crusher house shall be provided towards drain pipes.

2.1.3 Walls/Enclosure Permanently colour coated cladding

2.1.4 Stairs Steel construction with minimum 1000 mm width.

2.1.5 Doors & Windows Steel construction

2.1.6 Monorails Capacity as per equipment installed

2.1.7 Drainage From each floor to drain pit suitable to handle coal slurry.

2.1.9 Vertical bracing Only along four sides.

2.1.10 Maintenance platform with handrails. Chequered plate floors Min.1500 mm wide

2.1.11 Flooring 50 mm thick metallic hardener like ironite floor finish.

2.1.12 Level of ground floor 500 mm above ground level.

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2.2.0 Control/MCC Rooms

2.2.1 Construction RCC construction with Brick Enclosure

2.2.2 MCC Rooms

Pressurised with dust free air

2.2.3 Control Rooms Air conditioned Environment

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PART-B

SUB-SECTION-IIIA-11 IN LINE MAGNETIC

SEPERATOR

PAGE 1 OF 4

A11: IN-LINE MAGNETIC SEPARATOR 1.00.00 GENERAL

Inline Magnetic Separators shall be provided for continuous and automatic extraction and discharge of tramp magnetic pieces from coal being discharged from conveyors as specified. The sets shall be complete in all respects with drives, magnets, inline belts, hoppers, chutes, tramp-iron boxes and all electrical ancillaries like control panels etc.

1.01.00 CODES & STANDARD

The design, manufacture, inspection and testing of In line Magnetic Separators shall comply with all the currently applicable statutes, regulations and safety codes in The Magnetic Separators shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Engineer shall be final and binding.


1.02.01 Inline Magnetic Separator

1.02.02 Magnet core material shall be pure annealed iron or equivalent high permeability magnetic material. The coil shall be of aluminum wire with class ‘H’ insulation, to limit the absolute temperature of the winding to 140 deg. centigrade. The oil used for cooling the ILMS shall be silicon based.

1.02.03 The ‘Force Index’ i.e. the product of flux density in gauss and rate of change of flux density w.r.t. distance, at the bottom of falling material trajectory shall be 100,000 (gauss x gauss/inch) minimum in hot condition for mounting height of 400 mm in the conveyors carrying crushed coal. However, the strength of the magnet shall not be less than 1000 gauss in hot running condition at distance of 400mm in the conveyors carrying coal. The minimum strength of the magnet shall be 1000 gauss at the specified mounting height at the centre of Belt width. Contractor shall select magnet width to suit above.

Mounting height of 400 mm in the conveyors carrying coal shall be taken between top of conveyor belt or bottom of falling material trajectory and the surface of magnetic separator belt. Characteristic curve of magnet with the value of flux density varying between 50 mm to face of conveyor belt shall be provided. The cross section of magnet shall be suitably designed to provide sufficient area for magnetising the coil effectively covering full cross section of the discharge material. The magnetic separator shall be located such that it picks-up tramp iron from coal trajectory after it has been discharged from head pulley.

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1.02.04 The tramp magnetic pieces buried under coal picked up by the magnetic separator shall be discharged suitably to ensure that it falls into the tramp iron chute, which shall be provided upto ground level. All conveyors with magnetic separator at head end shall have non-magnetic SS pulleys. Head pulleys of all conveyors with in line magnetic separator at head end shall be provided with SS shell and end disc. However, hub and shaft shall be of same materials as in other pulleys. (EN-8 or equivalent).

1.02.05 The motor and the gear reduction unit for driving the in-line belt shall be adequately sized with minimum 20% margin to avoid any over loading during operation. Suitable zero speed switch shall be provided. No Chain/belt drives shall be accepted.

1.02.06 The belt shall be designed to withstand high temperature at the bottom of the magnet and any serious damage due to the impact of the sharp edges of the tramp iron. The belt shall be provided with rubber cleats spaced suitably. The belt shall be of fire resistant grade. For other details of belt, refer belt specification as specified else where. Side rollers shall be provided to keep the belt aligned.

1.02.07 The idlers and the pulleys supporting the belt shall be manufactured to the best engineering practices and shall conform to relevant Indian Standards. For details of idlers & pulleys, refer specification as specified else where.


1.03.01 In-line Magnetic separator

1.03.02 The magnetic separator units shall be supported by suitable structural member from the top by taking support from the operating floor beams with turn buckle arrangement to facilitate the necessary adjustments during operation. Further, electric Hoists operated cross travel arrangement shall be provided to move magnetic separator away to facilitate maintenance of the conveyor discharge pulley/Belt.

1.03.03 ON/OFF control push buttons with indicating lamps shall be provided at the local station. The materials of chutes and hoppers associated with magnetic separators above the drive floor shall be SS-304 in the magnetic zone. Other chutes shall be of 1 mtr. sq. dimension and shall be made of MS. chutes shall have poking doors at all floors to clear jammed material.

1.03.04 Suitable arrangements shall be provided in the magnet for keeping the coil of the magnet dry from atmospheric condensation when the magnetic separator is not in use.

1.03.05 Protection against high oil temperature in magnet shall be provided.

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DATA SHEET : ILMS

1.0.0 GENERAL

1.1.0 Type In line type as specified.


2.1.0 In-line Magnetic Separator

2.1.1 Location of ILMS Over discharge pulley.

2.1.2 Force index (As defined earlier) Minimum 100,000

2.1.3 Strength of magnet at the specified mounting height

1000 gauss.

2.1.4 Mounting height Mounting height of In Line Magnetic Separator shall be 400 mm in the conveyors carrying coal (between top of conveyor belt & surface of magnetic separator)

2.1.5 Magnetic Separator Belt

(i) Drive Unit Adequately sized with 20% margin.

(ii) Belting Suitable to withstand high temp. & impact of tramp iron. (FR Grade)

(iii) Discharge Into Tramp iron chute.

2.2.0 Tramp Iron Items

(i) MS cube of 20 mm size

(ii) Brake shoe of Railway Wagon (Cast Iron 15 Kg.)

(iii) MS plate of 250 x 250 x 100 mm size.

(iv) Shovel Teeth and spikes.

Material Carbon Steel

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Size Typical

(v) MS round bar of 50 Kg with L/D ratio not exceeding 5.

2.3.0 Control

Inline Magnetic Separator Local and remote

2.4.0 Electric Supply 415V, 3 phase, 50 Hz input Silicon Rectifier units

2.5.0 Location of silicon rectifier unit Nearby control/MCC room

2.6.0 Handling Arrangement for inline Magnetic separator

(a) Height adjustment With turn buckle arrangement

(b) Cross-travel Electric Hoist operated cross travel facility.

CLAUSE NO.





PART-B

SUB-SECTION-IIIA-12 METAL DETECTOR

PAGE 1 OF 3

A12: METAL DETECTOR 1.00.00 GENERAL

Metal detectors shall be provided at specified location to detect metallic objects in the coal stream.


The design, manufacture, inspection and testing of Metal Detectors shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Metal Detectors shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding.


1.02.01 Metal detectors shall have high reliability with enough sensitivity to detect 25mm aluminum sphere below the burden of coal in case of synthetic belting. However, for steel cord belting the sensitivity shall be 35mm. It shall also detect other metals, like brass, copper, stainless steel, manganese steel, bars, scraps etc.

1.02.02 The equipment shall have provision for automatic static calibration with adjustable sensitivity.

1.02.03 Metal detectors shall be completely solid state using latest state of art technology. It shall be suitable for 50°C ambient and RH of 100%. The search sensor shall be protected from rain and direct sunlight by means of a non metallic covering other than wood. Control unit shall have adjustable controls for sensitivity, ON/OFF push buttons, resettable operation counter, audio-visual alarms local remote selector switch and all other necessary controls for trouble free operation of metal detector. It shall be suitable for mounting on wall, column, structure etc. with IP-65 Degree of protection. It shall be constructed from FRP of thickness not less than 2mm.

1.02.04 The metal detectors shall also have the following features :

(a.) The coils shall be protected against being struck by an oversized material/coal. The coils should have adjustment for magnetite/iron in incoming coal. It should ignore magnetite/iron and shall distinguish between metal pieces and magnetite/iron.

(b.) In order to counteract interference from external sources such as motors, lightning and radio-transmitters, and to nullify the effect of climate changes/aging, dual receiver coils are to be used.

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PART-B


PAGE 2 OF 3

(c.) In order to allow passing of steel cord belt and metal belt fasteners without giving alarm and at the same time detecting tramps, suitable arrangements shall be provided.

(d.) In case a few non-magnetic idlers or non magnetic deck plates are required, the Contractor shall provide these. However, these shall be metallic. Wood is not to be used.

(e.) LED display of COAST COUNT to indicate the number of pieces of tramp iron detected since last reset shall be provided so that the operator is alerted for the pieces of tramps, if any, between tramp marker and coil before restoring conveyor.

(f.) TOTAL COUNT, which is not resettable, shall also be provided on the same LED display on demand.

(g.) The location of tramp metal pieces shall be indicated by sand bag marker.

1.03.00 CONSTRUCTION REQURIEMENT

1.03.01 Fiber glass enclosure (with IP 65 degree of protection) shall be provided for all type of coils.

1.03.02 Sand bag markers shall be provided.

1.03.03 Local control panel shall be provided with IP:65 degree of protection.

CLAUSE NO.





PART-B


PAGE 3 OF 3

DATA SHEET : METAL DETECTOR

1.0.0 GENERAL

1.1.0 Type Coil type


2.1.0 Sensitivity - 25 mm aluminum sphere below coal for synthetic belting.

- 35mm Aluminum sphere

below coal for steel cord belting.

2.2.0 Enclosure Fiber glass

2.3.0 Control Through local control panel.

2.4.0 Calibration Provision for automatic static

calibration with adjustable sensitivity.

CLAUSE NO.





PART-B

SUB-SECTION-IIIA-13 COAL SAMPLING UNIT

PAGE 1 OF 3

A13: COAL SAMPLING UNIT 1.00.00 GENERAL

a) Coal Sampling Unit shall be complete with necessary samplers, crushers, flap valves, chutes, hoppers, belt feeders and sample collectors etc. to give samples from any of the two streams running at guaranteed capacity.

b) Bidder shall source coal sampling system from a manufacturer / supplier who has engineered and supplied two (2) numbers of coal sampling systems for sampling coal / other bulk mineral from conveyor of 1000 MTPH and above and working successfully for two years as on date of bid opening.


The design, manufacture, inspection and testing of Coal Sampling Unit shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Coal Sampling Unit shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding.

ASTM-D-2234 :Standard Methods for collection of a Gross Sample of Coal.

ASTM-D-2013 :Standard Method of Preparing Coal Samples for Analysis.


1.02.01 Coal sampling unit shall be automatic & provided at place specified elsewhere.

1.02.02 The coal sampling units suitable to give “Samples” conforming to ASTM-D-2234 shall be selected by the Contractor for taking samples from any of the two streams running at guaranteed capacity. The different Equipment selected for coal sampling unit shall be such that there shall be no loss of fines and moisture from the samples. The capacity, make and model of all equipments of coal sampling unit shall be subject to approval of Project Manager.

1.02.03 The normal input feed size shall be considered as (-) 50 mm for coal sampling unit. However occasionally (-) 100 mm lumps may also arrive.

1.02.04 Primary samplers (separate for each conveyor) shall be rugged, able to withstand severe shock loads and operate trouble free.

1.02.05 Belt feeders shall be provided for entire sampling path upto sample collector. The feeders shall meter the flow accurately, produce a non-plugging condition and resist sticky and wet coal.

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PART-B


PAGE 2 OF 3

For rejects path also, belt feeders shall be preferred. Screw conveyors for the same shall be accepted only where space constraints do not permit distribution of coal rejects to receiving conveyors below.

1.02.06 Sample crushers (make subject to Employer’s approval) shall be provided for reducing the main input feed coal to 95% minus 8 mesh size and 100% minus 4 mesh size. Single stage crushing shall be provided. There should be no re-circulation of fines in the crushers.

1.02.07 ‘Lot size’ shall be equivalent coal quantity handled in 8 hours operation assuming average conveyor loading at 75% of rated conveyor capacity. However sampling system shall also be suitable for taking one gross sample for each lot of “3500 Te” coal (approx. equal to one rake load).


1.03.01 The traversing mechanism and all electric parts shall have dust tight protection.

1.03.02 Belt feeders shall be positively self cleaning and have dust tight construction. It shall be provided with flanged belt, rubber lagged head pulleys and inspection doors. No chain/belt drives shall be accepted.

1.03.03 The crusher’s base should be built of reinforced concrete and be sufficiently large in mass.

1.03.04 The primary / secondary samplers shall be of dust tight construction and self contained type.

1.03.05 The sample chutes shall have minimum valley angle of 60 degrees to horizontal and shall be of stainless steel plates. The chutes shall be suitable to handle wet sticky coal as specified elsewhere. The welding of chutes shall be done externally only. The inside surface of the material near welds shall be smooth. Radius at corners not less than 1" shall be provided in chutework. All solid connected members shall be by means of bolting flanges with atleast 6 mm thick standard grade neoprene gasket material between the metal flanges. No control gates to regulate the flow of material shall be incorporated in the chute work.

1.03.06 Bias connections shall be provided at suitable locations. The materials rejected from samplers shall be returned to main conveyor stream.

1.03.07 Minimum 4 nos. sample collecting bins shall be provided with auto indexing. The bins shall be provided with air tight connection.

1.03.08 The system shall be suitable for operation through Employer’s DCS/DDCMIS.

CLAUSE NO.





PART-B


PAGE 3 OF 3

DATA SHEET : COAL SAMPLING UNIT

1.0.0 GENERAL

1.1.0 Type Automatic


2.1.0 Codes & Standard ASTM D-2234

2.2.0 feed coal size (-) 50 mm

3.0.0 CHUTES

3.3.1 Min. angle 60 deg

3.3.2 Cross section Square/rectangular with rounded corners.

3.3.3 Joints Bolted flanges with 6 mm thick standard grade neoprene gasket.

4.0.0 CRUSHER

4.4.1 Uncrushed (as received) feed coal size (-) 50 mm

4.4.3 Output size ASTM D-2234

4.4.3 Stages of size reduction Single stage crushing

5.0.0 BELT FEEDER

5.5.1 Belt Flanged type, FR grade

5.5.2 Pulleys Rubber lagged head pulley

5.5.3 Drive Electric Motor

CLAUSE NO.





PART-B

SUB-SECTION-IIIA-14 VIBRATING FEEDER

PAGE 1 OF 1

A:14 – VIBRATING FEEDER

1.00.00 GENERAL

Vibrating feeder shall be provided below each reclaim hopper to feed coal reclaimed by dozers to the conveyor..

1.01.00 CODES & STANDARD

The design, manufacture, inspection and testing of Vibrating Feeder shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Vibrating Feeder shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Project Manager shall be final and binding.

IS:3823 - Dimensions for vibrating conveyors and feeders with rectangular or trapezoidal trough.

1.02.00 DESIGN REQUIREMENTS

1.02.01 The vibrating feeder shall be of mechanical type and shall be provided below each reclaim hopper to feed coal reclaimed by dozers to the conveyor. The drive unit shall be complete with mechanical type of vibrator.

1.02.02 The vibrating feeder shall be suitable for maximum lumps size of 20 mm. The feeder shall be designed to feed coal to the conveyor without material sticking to it. The flow of material shall cease as soon as vibration of the trough or pan ceases.

1.02.03 One (1) sets of Gates each comprising of one rod gate and one actuator operated rack & pinion gate at inlet to each of the vibrating screening feeder shall be provided.

1.03.00 CONSTRUCTION REQUIREMENTS

1.03.01 The vibrating feeders shall be mounted on the floor with the help of helical springs made of alloy steel. No rubber/synthetic material for the support shall be acceptable.

1.03.02 Vibrator bearings shall be grease lubricated, double spherical roller type suitable for vibrating equipment. The bearings shall be sized for minimum 8,000 hours of operation

1.03.03 Vibrating feeders shall be provided with removable abrasion resistant liner plate.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIB-01 MOTORS

PAGE 1 OF 9

MOTORS

1.00.00 GENERAL REQUIREMENTS

1.01.00 For the purpose of design of equipment/systems, an ambient temperature of 50 deg. Centigrade and relative humidity of 95% shall be considered. The equipment shall operate in a highly polluted environment

1.02.00 All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3% & -5%, and 10% combined variation of voltage and frequency unless specifically brought out in the specification.

1.03.00 Contractor shall provide fully compatible electrical system, equipments, accessories and services.

1.04.00 All the equipment, material and systems shall, in general, conform to the latest edition of relevant National and international Codes & Standards, especially the Indian Statutory Regulations.

1.05.00 The auxiliary AC voltage supply arrangement shall have 6.6 KV and 415V systems. It shall be designed to limit voltage variations as given below under worst operating condition :

(a.) 6.6 KV +/- 6%

(b.) 415/240V +/- 10%

1.06.00 The voltage level for motors shall be as follows (other than VFD motors) :-

(a.) Upto 0.2 KW : 240V, Single phase AC / 415V AC Three phase

(b.) Above 0.2KW to 200 KW : 415V, Three phase AC

(c.) Above 200 KW : 6.6 KV, Three phase AC

For CHP, conveyor motors above 160KW rating, 6.6KV supply shall be used.

Voltage rating for special purpose motors viz. screw compressors and those with VFD shall be as per manufacturer standard.

1.07.00 Fault level shall be 40KA RMS for 1 second for 6.6 KV system and 45 KA RMS 1 second for 415V system. 415V system shall be solidly grounded and 220 VDC system shall be isolated type.

1.08.00 Paint shade shall be RAL 5012 (Blue) for indoor and outdoor equipment.

1.09.00 The responsibility of coordination with other agencies and obtaining all necessary clearances shall be of the contractor.

1.10.00 Degree of Protection

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SECTION-VI, PART-B


PAGE 2 OF 9

Degree of protection for various enclosures as per IS:13947 shall be as follows :-

i) Indoor motors – IP 54

ii) Outdoor motors – IP 55

iii) CW motors (in case of Screen prot. Drip proof) – IP 23

iv) Cable box – indoor area – IP 54

v) Cable box – outdoor area – IP 55


1.) Three phase induction motors : IS:325, IEC:60034

2.) Single phase AC motors : IS:996, IEC: 60034

3.) Crane duty motors : IS:3177, IEC: 60034

4.) DC motors/generators : IS:4722

5.) Energy Efficient motors : IS 12615

3.00.00 TYPE

3.01.00 AC Motors:

(a.) Squirrel cage induction motor suitable for direct-on-line starting.

(b.) Continuous duty LT motors upto 160 KW Output rating(at 50 deg.C ambient temperature) ,shall be Energy Efficient motors ,Efficiency class – Eff 1, conforming to IS 12615.

(c.) Crane duty motors shall be slip ring / squirrel cage type induction motor as per the requirement

3.02.00 DC Motors Shunt wound.

4.00.00 RATING

(a.) Continuously rated (S1). However, crane motors shall be rated for S4 duty, 40% cyclic duration factor.

(b.) Whenever the basis for motor ratings are not specified in the corresponding mechanical specification sub-sections, maximum continuous motor ratings shall be at least 10% above the maximum load demand of the driven equipment under entire operating range including voltage and frequency variations.

CLAUSE NO.





SECTION-VI, PART-B


PAGE 3 OF 9

5.00.00 TEMPERATURE RISE

Air cooled motors

70 deg. C by resistance method for both thermal class 130(B) & 155(F) insulation.

Water cooled

80 deg. C over inlet cooling water temperature mentioned elsewhere, by resistance method for both class 130(B) & 155(F) insulation.

6.00.00 OPERATIONAL REQUIREMENTS

6.01.00 Starting Time

6.01.01 For motors with starting time upto 20 seconds at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be at least 2.5 second more than starting time .

6.01.02 For motors with starting time more than 20 second and upto 45 seconds at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be at least 5 second more than starting time.

6.01.03 For motors with starting time more than 45 seconds at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be more than starting time by at least 10% of the starting time.

6.01.04 Speed switches mounted on the motor shaft shall be provided in cases where above requirements are not met.

6.02.00 Torque Requirements

6.02.01 Accelerating torque at any speed with the lowest permissible starting voltage shall be at least 10% motor full load torque.

6.02.02 Pull out torque at rated voltage shall not be less than 205% of full load torque. It shall be 275% for crane duty motors.

6.03.00 Starting voltage requirement

(a) 85% upto 1500KW (b) 80% from 1500KW to 4000KW (c) 75% > 4000KW

7.00.00 DESIGN AND CONSTRUCTIONAL FEATURES

7.01.00 Suitable single phase space heaters shall be provided on motors rated 30KW and above to maintain windings in dry condition when motor is standstill. Separate terminal box for space heaters & RTDs shall be provided.

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SECTION-VI, PART-B


PAGE 4 OF 9

7.02.00 All motors shall be either Totally enclosed fan cooled (TEFC) or Totally enclosed tube ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors rated 3000KW or above can be Closed air circuit water cooled (CACW). CW motors can be screen protected drip proof (SPDP) type. Motors located in hazardous areas shall have flame proof enclosures conforming to IS:2148 as detailed below

(a) Fuel oil area : Group - IIB

(b) Hydrogen generation plant area :

Group – IIC (or Group-I Div-II as per NEC)

7.03.00 Winding and Insulation

(a) Type : Non-hygroscopic, oil resistant, flame resistant

(b) Starting duty : Two hot starts in succession, with motor initially at normal running temperature. However, conveyor motors shall be suitable for 3 consecutive hot starts.

(c) 6.6 KV AC motors

: Thermal class 155(F) insulation with winding temperature rise limited to thermal class 130(B). The winding insulation process shall be total Vacuum Pressure Impregnated i.e. resin poor method. The lightning impulse & interturn insulation surge withstand level shall be as per IEC-60034 Part-15.

(d) 415V AC & 220V DC motors

: Thermal Class 130(B) or better

( e) Short circuit rings of conveyor motors shall be either joint less or welded type. Brazed joint is not acceptable.

7.04.00 Motors rated above 1000KW shall have insulated bearings to prevent flow of shaft currents.

7.05.00 Motors with heat exchangers shall have dial type thermometer with adjustable alarm contacts to indicate inlet and outlet primary air temperature.

7.06.00 Noise level for all motors shall be limited to 85dB (A). Bearing housing vibration shall be limited within the limits prescribed in IEC 60034-14/IS: 12075. Motors shall withstand vibrations produced by driven equipment. HT motor bearing housings shall have flats in both X and Y directions suitable for mounting 80mmX80mm vibration pads.

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SECTION-VI, PART-B


PAGE 5 OF 9

7.07.00 In HT motors, at least four numbers simplex / two numbers duplex platinum resistance type temperature detectors shall be provided for each phase of stator winding. Each bearing shall be provided with dia type thermometer with adjustable alarm contract and minimum one(1) number duplex Platinum resistance type temperature detector.

7.08.00 Motor body shall have two earthing points on opposite sides.

7.09.00 HT motors can be offered with either Elastimold termination or dust tight phase separated double walled (metallic as well as insulated barrier) cable boxes. In case Elastimold terminations are offered, then protective cover and trifurcating sleeves shall also be provided. Removable gland plates of thickness 3 mm (hot/cold rolled sheet steel) or 4 mm (non magnetic material for single core cables) shall be provided in case of cable boxes.

7.10.00 The spacing between gland plate & centre of terminal stud shall be as per Table-I.

7.11.00 All motors shall be so designed that maximum inrush currents and locked rotor and pullout torque developed by them at extreme voltage and frequency variations do not endanger the motor and driven equipment.

7.12.00 The motors shall be suitable for bus transfer schemes provided on the 6.6 KV/415V systems without any injurious effect on its life.

7.13.00 For motors rated 2000 KW & above, neutral current transformers of PS class shall be provided on each phase in a separate neutral terminal box.

7.14.00 6.6 KV Terminal Box shall be suitable for fault level of 500MVA for 0.12 second.

7.15.00 The size and number of cables ( for HT motors) will be intimated to the contractor during detailed engineering and the contractor shall provide the terminal box, cable gland & lugs suitable for the same.

7.16.00 The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the following (without any further tolerance) except for BFP motor.

(a) Upto 110KW 11.0

(b) Above 110KW & upto 1500KW 10.0

(c) Above 1500KW & upto 4000KW 9.0

(d) Above 4000KW 6 to 6.5

CLAUSE NO.





SECTION-VI, PART-B


PAGE 6 OF 9

8.00.00 TYPE TEST

8.01.00 HT MOTORS

8.01.01 The contractor shall carry out the type tests as listed in the “LIST OF TESTS TO BE CONDUCTED” on the equipment mentioned there in. The Bidder shall indicate the charges for each of these type tests separately in the relevant schedule of BPS and the same shall be considered for the evaluation of the Bids. The type test charges shall be paid only for the test(s) actually conducted successfully under this contract and upon certification by the Employer's Engineer.

8.01.02 The type tests shall be carried out in presence of the Employer’s representative, for which minimum 15 days notice shall be given by the Contractor. The Contractor shall obtain the Employer’s approval for the type test procedure before conducting the type test. The type test procedure shall clearly specify the test set-up, instruments to be used, procedure, acceptance norms, recording of different parameters, interval of recording, precautions to be taken etc. for the type test(s) to be carried out.

8.01.03 In case the contractor has conducted such specified type test(s) within last ten years as on the date of bid opening, he may submit during detailed engineering the type test reports to the owner for waivel of conductance of such type test(s). These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. The owner reserves the right to waive conducting of any or all the specified type test(s) under this contract. In case type tests are waived, the type test charges shall not be payable to the contractor.

8.01.04 Further the Contractor shall only submit the reports of the type tests as listed in “LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED” and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at the third party laboratory or in presence of client/owner’s representative and submit the reports for approval.

8.01.05 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.

8.01.06 The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No Design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

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SECTION-VI, PART-B


PAGE 7 OF 9

8.01.07 LIST OF TESTS TO BE CONDUCTED

The following type tests shall be conducted on each type and rating of HT motor

(a) No load saturation and loss curves upto approximately 115% of rated voltage(b) Measurement of noise at no load. (c) Momentary overload test (subject to test bed constraint). (d) Full load test (e) Temperature rise test at rated conditions . During heat run test, bearing temp.,

winding temp., core temp., coolant flow and its temp. shall also be measured. In case the temperature rise test is carried at load other than rated load, specific approval for the test method and procedure is required to be obtained. Wherever ETD's are provided, the temperature shall be measured by ETD's also for the record purpose.

8.01.08 LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED

The following type test reports shall be submitted for each type and rating of HT motor (a) Degree of protection test for the enclosure followed by IR, HV and no load run test. (b)Terminal box-fault level withstand test for each type of terminal box of HT motors

only. (c) Lightning Impulse withstand test on the sample coil shall be as per clause

5.1.3.2, IEC-60034, Part-15. (d) Surge-withstand Voltage test on interturn insulation as per IEC 60034-158

8.02.00 LT MOTORS

8.02.01 All equipment to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owner’s approval the reports of all the type tests as per relevant standards and carried out within last ten years from the date of bid opening. These reports should be for the tests 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.

8.02.02 However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at third part laboratory or in presence of client/owners representative and submit the reports for approval.

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SECTION-VI, PART-B


PAGE 8 OF 9


8.02.04 The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No Design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

9.00.0 Drawing Submission Procedure

Unique manufacturer specific reference drawing nos. shall be allotted by owner to drawings of the equipment or components. Drawing once approved (for any project) shall be treated as reference drawings for subsequent projects. An endorsement sheet shall be submitted by manufacturer confirming similarity and minor changes if any shall be highlighted on the endorsement sheet. However owner reserves right to get the drawings submitted afresh. The reference drawings so approved once along with endorsement sheet shall be used for factory inspection of equipment whenever package/project specific drawings are not submitted afresh/approved.

CLAUSE NO.





SECTION-VI, PART-B


PAGE 9 OF 9

TABLE - I

DIMENSIONS OF TERMINAL BOXES FOR LV MOTORS

Motor MCR in KW Minimum distance between centre of stud and gland plate in mm

UP to 3 KW

As per manufacturer's practice.

Above 3 KW – upto 7 KW 85

Above 7 KW - upto 13 KW 115






Above 125 KW-upto 200 KW 203

For HT motors the distance between gland plate and the terminal studs shall not be less than 500 mm.

NOTE: Minimum inter-phase and phase-earth air clearances for LT motors with lugs installed shall be as follows:

Motor MCR Clearance

Upto 110KW 10.0mm

Above 110KW and Upto 150KW

12.5mm

Above 150KW 19.0mm

CLAUSE NO.




TECHNICAL SPECIFICATION SECTION-VI,

PART-B

PART-B SUB-SECTION-IIIB-02 L.T. SWITCHGEAR &

BUS DUCT

PAGE 1 OF 11

LT SWITCHGEAR & BUSDUCT

1.00.00 CODES AND STANDARDS IEC: 60947, IS : 13947, IEC: 60439,IS:8623,IEC:61850

2.00.00 TYPE

Circuit Breakers Shall be air break, three pole, spring charged, horizontal drawout type, suitable for electrical operation.

Switchgear Fully drawout type single front MCC Fully drawout type single front/Double

front. ACDB/DCDB Fixed type single front

3.00.00 SYSTEM PARAMETERS

415VAC +/- 10 %(SOLIDLY GROUNDED) 50 Hz +3%/-5% 45KA RMS(105 KA PEAK) / 1SEC (FAULT LEVEL) 240V DC ISOLATED TYPE

4.00.00 TEMPERATURE RISE

The temperature rise of the horizontal and vertical busbars and main bus link including all power draw out contacts when carrying 90% of the rated current along the full run shall in no case exceed 55 deg. C with silver plated joints and 40 deg. C with all other types of joints over an ambient of 50 deg C. The temperature rise of the accessible parts/external enclosures expected to be touched in normal operation shall not exceed 20 deg.C. The temperature rise of manual operating means shall not exceed 10 deg. C for metallic & 15 deg. C for insulating material. The above temperature rise limits are applicable for busducts also without any current derating.

5.00.00 OPERATIONAL REQUIREMENTS

5.01.00 Breakers

5.01.01 Breakers shall have anti-pumping feature.

5.01.02 The incomer and bus coupler breakers for switchgear shall be electrically operated with Numerical communicable relays.

5.01.03 Breakers shall have inherent fault making and breaking capacities. They shall have shunt trip coils. All breakers shall have built in interlocks for equipment and personnel safety.

CLAUSE NO.





PART-B


BUS DUCT

PAGE 2 OF 11

5.01.04 Paralleling of two supplies shall be avoided by interlocking except for switchgear where auto-changeover is provided. Breaker contact multiplication, if required, shall be through latch relay.

5.01.05 Mechanical tripping shall be through red ‘Trip’ push button outside the panels for breakers, and through control switches for other circuits.

5.01.06 Provision of mechanical closing of breaker only in ‘Test’ and ‘Withdrawn’ position shall be made. Alternatively, mechanical closing facility should be normally inaccessible, accessibility rendered only after deliberate removal of shrouds. It shall be possible to close the door with breaker in test position.

5.01.07 Clear status indication for each circuit shall be provided through lamps, switch positions or other mechanical means.

5.02.00 Switches, Contactors and Fuses

5.02.01 Incomers for MCCs and DBs rated below 250A could be load break isolators.

5.02.02 Motor starter contactors shall be of air break, electromagnetic type suitable for DOL starting of motor, and shall be of utilisation category AC-3 for ordinary and AC-4 for reversing starters. For conveyor motors, minimum rating of power contactors shall be 200% of the full load current of the motors. For other motors minimum rating of power contactors shall be 160% of full load current of motor. DC contactor shall be of DC-3 utilisation category.

5.02.03 Fuses shall be HRC type with operation indicator. Isolating switches shall be of AC 23A category when used in motor circuit, and AC 22A category for other applications. Fuse switch combination shall be provided wherever possible.

5.02.04 The 250A & above feeders up to 630A shall have MCCB. MCCB shall be provided with Microprocessor based inbuilt front adjustable releases(overload & short circuit) and shall have adjustable earth fault protection unit also . MCCB shall have current limiting feature. ON and OFF position of the operating handle of MCCB shall be displayed and the rotary operating handle shall be mounted on the door of the compartment housing MCCB. The compartment door shall be interlocked mechanically with the MCCB, such that the door can not be opened unless the MCCB is in OFF position. Means shall be provided for defeating this interlock at any time by making use of special tools/tackles. MCCB shall be provided with padlocking facility to enable the operating mechanism to be padlocked.

5.03.00 Panels

5.03.01 All switchgears, MCCs, DBs, panels, modules, local starters and push buttons shall have prominent engraved indentification plates.

5.03.02 Local push button stations shall have metal enclosure of die cast aluminium or rolled sheet steel of 1.6mm thickness & shall be of DOP IP55. The DOP shall be IP-65 in case the same are located in dusty areas. Push buttons shall be of latch type with mushroom knobs.

CLAUSE NO.





PART-B


BUS DUCT

PAGE 3 OF 11

5.03.03 Where breaker/starter module front serves as compartment cover, suitable blanking covers, one for each size of modules per switchboard shall be supplied for use when carriage is withdrawn.

5.03.04 All non-current carrying metal work of boards/panels shall be effectively bonded to earth bus of galavanised steel, extending throughout the switchboard/MCC/DB. Positive earthing shall be maintained for all positions of chassis and breaker frame.

5.03.05 Suitable trolley arrangement shall be provided for breaker/starter modules. Two trolleys per switchgear room shall be provided so that top most breaker module of all types, sizes and rating can be withdrawn on trolley and lowered for maintenance purpose.

5.03.06 The incoming connection to transformer of more than 1000KVA and inter-connecting sections between switchboards shall preferably be of busducts. The busduct enclosure shall be made of minimum 3mm thick aluminium alloy. The section of the busduct should have adequate strength to withstand internal and external forces resulting from the various operating conditions. Aluminium sheet hood shall be provided for outdoor busduct enclosure joints to provide additional protection against water ingress. The busduct top shall be sloped to prevent retention of water.The busduct enclosure shall have DOP of IP55 and paint shade RAL 5012.

5.03.07 It should be possible to carryout maintenance on a feeder with adjacent feeders alive.

5.03.08 DC fuse board shall consist of:

-1 no.63A switch as incomer with meters, lamps and auxiliary contactors. -8 nos.outgoing feeders with 16A HRC fuses.

5.03.09 AC fuse board shall consist of:

-1 no 63A TPN SFU as incomer with lamps and meters. -9 nos.16A SPN SFU & 3 nos.16A TPN SFU as outgoing.

5.03.10 Main lighting distribution board(MLDB) to be located in MCC room shall consist of:-

a) Two(2) nos. x 100% rated, lighting transformers (415V/433V, delta/star, epoxy insulated, air cooled, dry type). Transformer shall be 50KVA/100KVA rating for 10/15 nos. outgoing feeder.

b) TPN SFU on primary and secondary side of the transformer c) 63A TPN SFU as outgoing feeders including 20% spare. d) Voltmeter, ammeter with selector switches, indicating lamps. e) The two incomers (One from Bus-A and One from Bus-B of the MCC) and one

bus-coupler for the power supply to each MLDB shall be provided with castle key networks.

5.03.11 Welding distribution board(WDB) to be located in MCC room shall consist of:-

a) One(1) no welding transformer (415V/433V, delta/star, epoxy insulated, air cooled, dry type). Transformer shall be 50KVA/100KVA.

b) TPN SFU on primary and secondary side of the transformer c) 63A TPN SFU as outgoing feeders including 20% spare. d) Voltmeter, ammeter with selector switches, indicating lamps.

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PART-B


BUS DUCT

PAGE 4 OF 11

5.03.12 MCCs located on the Stacker reclaimer, paddle feeders, travelling trippers shall be fixed type, compartmentalized, single front and suitable for the system fault level.No spare feeders are to be provided on these MCCs. Degree of protection for the MCCs mounted on paddle feeders and travelling trippers shall be IP-65.

5.04.00 Control, Protection & Metering Requirements

5.04.01 Control circuits shall operate at suitable voltage of 110V AC or 240V DC. Necessary control supply transformers having primary and secondary fuses shall be provided for each MCC, 2 x 100% per bus section. However the breakers shall operate on 240V DC The auxiliary bus bars for control supply shall be segregated from main bus bars. The control supplies shall be monitored.

DC operated spring charging motor shall be suitable for voltage variation between 198V to 242V DC. The closing coil of circuit breaker shall operate correctly at all values of voltage between 187V-242V DC. The trip coil of circuit breaker shall operate satisfactorily at all values of voltage between 154V-242V DC.

DC operated contactor coil shall have an economy resistor and shall be suitable for satisfactory continuous operation at 187V-242V DC.

5.04.02 Contractor shall fully co-ordinate overload and short circuit tripping of breaker with upstream and down stream breakers/fuses/MCCBs motor starters. Various equipments shall meet requirement of Type-II class of coordination as per IEC.

5.04.03 The protective relays shall be communicable numerical relays These numerical relays shall be of types as proven for the application and shall be subject to Employer’s approval Numerical relays shall have appropriate setting ranges, accuracy, resetting ratio and other characteristics to provide required sensitivity. All equipments shall have necessary protections as detailed in the standard scheme drawings.

5.04.04 All equipments shall have necessary protections. However, following minimum protections shall be provided:

1)

Contactor controlled motor feeders (Motors up to 200 kW)

a) Instantaneous short circuit protection on all phases through HRC cartridge type fuses rated for 80 kA rms (prospective breaking capacity at 415V).

b) Thermal overload protection c) Single phasing protection for motors protected by fuses 2)

Incomers / buscoupler / outgoing breaker feeders other than motor feeders.

a) Three phase overcurrent protection (50) b) Three phase earthfault protection (50N3) c) Restricted earth fault protection for transformer incomers(64R) d) Sync Check

CLAUSE NO.





PART-B


BUS DUCT

PAGE 5 OF 11

5.05.00 General requirements of Numerical Relays

5.05.01 All relays and timers shall be rated for control supply voltage as mentioned elsewhere under parameters and shall be capable of satisfactory continuous operation between 80-120% of the rated voltage. Making, carrying and breaking current ratings of their contacts shall be adequate for the circuits in which they are used. Interrogation voltage for the binary inputs shall be suitably selected to ensure avoidance of mal operation due to stray voltages.

5.05.02 Numerical relays shall have communications on two ports, local front port for communication to laptop and a second port on IEC 61850 to communicate with owner’s data concentrator through LAN.

5.05.03 All Numerical Relays shall have features for electrical measurement including voltage, current, power (active / reactive) and energy parameters.

5.05.04 All Numerical Relay shall have key pad / keys to allow relay settings from relay front. All hand reset relays shall have reset button on the relay front. Relay to be self or hand reset shall be software selectable. Manual resetting shall be possible from remote.

5.05.05 The protective relays shall have at least 10 Nos. programmable potential free

contacts. Programmable Auxiliary relays shall have contacts as required.

5.05.06 For control from DDCMIS, 24V DC signal shall be provided from DDCMIS to the numerical relays. Preferably, no separate coupling relays shall be provided.

5.05.07 Trip circuit supervision shall be provided for all feeders to monitor the circuit breaker trip circuit both in pre trip and post trip conditions.

5.05.08 Schematics requiring auxiliary relays / timers for protection function shall be a part of Numerical Relay. The number of auxiliary relay and timer function for protection function shall be as required by the scheme. Auxiliary relays for interlocking purpose shall be of self reset type.

5.05.09 The numerical processor shall be capable of measuring and storing values of a wide range of quantities, all events, faults and disturbance recordings with a time stamping using the internal real time clock. Battery back up for real time clock in the event of power supply failure shall be provided.

5.05.10 Sequence of events shall have 1ms resolution at device level.

5.05.11 Ethernet switches shall be “substation hardened” and shall comply to IEC61850-3 for communications and environment requirements. The Ethernet switches shall be of managed type with four(4) no Fibre optic cable ports and sixteen/eight nos. Copper ports to achieve the owners’ LAN configuration. One (1) no. Ethernet switch per switch board shall be provided & these switches shall be mounted inside the switchgear Panels. Ethernet switches shall be suitable for single mode FO Cable connections.

CLAUSE NO.





PART-B


BUS DUCT

PAGE 6 OF 11

5.05.12 In case of remote controlled breaker panels, following shall be ensured. The circuit breaker will normally be controlled from remote control panels (employer’s DDCMIS) through closing and shunt trip coils. The Local control console of the relay flush mounted on the switchgear would normally be used only for testing of circuit breaker in isolated position, and for tripping it in an emergency. Provision for closing & tripping of the circuit breaker locally from laptop through serial port shall be possible to facilitate commissioning activities. The basic control scheme of breaker feeders shall be developed as per the schematic logics in the relay. The schematics shall be developed in soft inside the relay. Numerical relays shall be interfaced with employer’s DDCMIS through 24V DC signal for closing / opening operations.

5.05.13 Hardwired contacts from the relay shall be wired to PLC / DCS system as per requirements. The numerical relay shall be capable of measuring and storing values of a wide range of quantities, events, faults and disturbance recordings.

5.05.14 The alarm / status of each of protection function and trip operation shall be communicated to PLC/DCS. The numerical relays shall have built in feature / hardware interface to provide such inputs to PLC / DCS for analog / digital values..

5.05.15 It shall be possible to carryout open / close operation of breakers from a laptop by interfacing from the relay front port (RS232) during initial commissioning.

5.06.00 Meters / instruments

All meters/ instrument shall be flush mounted on front panel, at least 96 sq.mm. size with 90 degree linear scales and accuracy class of 2.0.

5.06.01 All motors of 30kW and above upto 100 KW shall have an Ammeter & current transducer. Each bus-section shall have bus VT, voltmeter with selector switch, and other relay and timers required for protection. Adequate control and selector switches, push buttons and indicating lamps shall be provided. Thermostatically controlled space heaters with switches shall be provided to prevent condensation.

5.06.02 For all motor feeders related to dust suppression system and for all other motor feeders having 100KW & above rating, contractor shall provide multifunction Digital Energy Meter with communication facility to display the current, voltage, power factor, power, energy related data locally and shall communicate these for remote metering /audit/analysis purposes. The technical specification for Digital indicating energy meter shall be as follow:

a) Input Voltage: 110 V AC/ 240 V DC

b) Input Current:1A

c) Size: 96X96 sq. mm

d) Accuracy:1.0% for power & energy

e) Mounting: Flush mounting

f) Type: True RMS 3-PHASE V, I, KW, PF & KWHr indication

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PART-B


BUS DUCT

PAGE 7 OF 11

g) 4 Digit, seven segment LED display/LCD display, with floating decimal

h) Communication: In built RS 485 serial bus port

i) Operating Frequency: 45 HZ-65HZ

j) Dielectric Test: 2KV RMS for 1 minute

k) Over current: 10 times for 3 sec.

l) Aux. supply: 90V-300V AC/DC

m) Compliance: EMC/EMI

n) Field programmable CT ratio

5.07.00 Control from Remote

Necessary hardware shall be provided in the switchgear panel like coupling relays (if required ) of 24V DC, with max. burden of 2.5VA, auxiliary relays, current/voltage transducers (4-20 mA, dual output) etc. to effect interlocks, exchange information / status and exercise control from remote.

6.00.00 DESIGN AND CONSTRUCTIONAL FEATURES

6.01.00 All 415V switch gear motor control centers (MCCs), AC & DC distribution boards (DB s), etc shall have following features :

1) Shall be of metal enclosed, indoor, floor mounted and free standing type.

2) All frames and load bearing members shall be fabricated

using mild steel structural sections or pressed and shaped cold rolled sheet steel of thickness not less than 2mm.

3) Frame shall be enclosed in cold rolled sheet steel of thickness

not less than 1.6mm.Doors and covers shall also be of cold rolled sheet steel of thickness not less than 1.6 mm. Stiffeners shall be provided wherever necessary. Removable gland plates of thickness 3mm (hot/cold rolled sheet steel) or 4 mm (non-magnetic material) shall be provided for all panels.

4) All switchboards/panels shall be of dust and vermin proof. All

cutouts shall have EPDM/Neoprene gaskets. 5) All switchboards, MCCs and DB s shall have following distinct

vertical sections. a) Completely enclosed bus bar compartment for

horizontal and vertical bus bars.

CLAUSE NO.





PART-B


BUS DUCT

PAGE 8 OF 11

b) Completely enclosed switchgear compartments (one for each circuit housing circuit breakers, motor starter or switch-fuse feeder).

c) A full-height vertical cable alley of minimum 250mm

width shall be provided for power and control cables. Cable alley shall have no exposed live parts and shall have no communication with busbar compartment. Cable terminations located in cable alley shall be designed to meet the Form IVb Type 7 (as per IEC 60439) for safety purpose. The termination for each module shall have its own integral glanding facility. Wherever cable alleys are not provided for distribution boards, segregated cable boxes for individual feeders shall be provided at the rear for direct termination of cables.

d) For cable connection to circuit breaker, a separately

enclosed cable compartment shall also be acceptable. e) Compartment for relays and other control devices

associated with a circuit breaker, wherever necessary. f) The switchboards/MCC/DBs of 1600A & above rating

shall be of DOP IP42 & of IP52 for less than 1600A rating.

g) All 415V switchgears, MCC’s, AC & DC distribution

boards etc. shall be painted by powder coating process. Paint shade for complete panels excluding end covers shall be RAL9002 & RAL5012 for extreme end covers of all boards.

h) All draw out modules shall have distinct service, test

and isolated positions with provision of external pad locking facility in each position. Power contacts shall get disconnected in both test and isolated positions whereas the control contacts shall get disconnected in isolated position only.

6) Busbars shall be of high conductivity aluminium alloy or

copper & entire busbar system shall be insulated with PVC sleeves.

7) The cross section of the horizontal bus bars shall be uniform

through out the length of the switchboard and both horizontal as well as vertical bus bars shall be adequately supported and braced to withstand the stresses due to the specified short circuit currents. Neutral bus bar short circuit strength shall be same as the main bus bars.

8) Minimum air clearance in air between phases and phase-earth shall be 25 mm for busbars and cable terminations. For all other components, the Clearances shall be at least 10mm.

CLAUSE NO.





PART-B


BUS DUCT

PAGE 9 OF 11

Wherever above is not possible except for horizontal and vertical busbars, insulation shall be provided by anti tracking sleeving or barriers. However for horizontal and vertical busbars, clearances specified above shall be maintained even when busbars are insulated/sleeved. In case of DC DBs/ fuse boards, the busbar system shall be insulated or physically segregated with barriers to prevent interpole short circuit.

9) Busbar insulators shall be of track-resistant high strength non-

hygroscopic, non-combustible type and suitable to withstand stresses due to over-voltages and short circuit current. Insulators and barrier of inflammable material such as Hylam shall not be accepted.

10) All types of relays and timer shall be subject to Employer’s

approval. They shall be flush mounted with connections from inside, and shall have transparent & dust tight cover, removable from front, drawout construction for easy replacemernt and testing facility. The auxiliary relays and timer may be provided in fixed cases.

11) Terminal Blocks

Terminal blocks shall be 650V grade, 10Amps rated, made up of unbreakable polyamide 6.6 grade. The terminals shall be either screw type or screw-less (spring loaded) / cage clamp type with lugs. Marking on terminal strips shall correspond to the terminal numbering in wiring diagrams. All metal parts shall be of non-ferrous material. In case of screw type terminals the screw shall be captive, preferably with screw locking design. Maxi terminal / cage clamp type terminal blocks shall be provided for signals to be interfaced with DDCMIS / PLC.

12) The switchgears/MCC shall be designed to offer adequate

level of safety to operating/ maintenance personnel. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear/MCC room describing various safe operating procedure/safety precautions for safe operation and maintenance of switchgear/MCC.

13) All current and voltage transformers as required for metering &

protection specified shall be completely encapsulated castresin insulated type. Incomers from transformers shall have CTs for transformer REF protection. The accuracy shall be asfollows:

CLAUSE NO.





PART-B


BUS DUCT

PAGE 10 OF 11

CTs PTs Protection

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6.02.00 Indicating lamps shall be cluster LED type.All overload relays shall have overload reset push button.

6.03.00 Switchgear/MCC shall have bottom cable entry.

7.00.00 TYPE TESTS

7.01.00 GENERAL

(a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owner’s approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client.

(b.) However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval.

(c.) All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price.

(d.) The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No Design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

7.02.00 BUSDUCTS (as applicable) The following type test certificates on each rating of bus duct shall be submitted. (a.) Heat run test on an assembly of representative sections and fittings (b.) Short circuit test for a duration and current as covered in the specification on

an assembly of representative section. (c.) One minute high potential power frequency voltage withstand test. (d.) Degree of protection test.

CLAUSE NO.





PART-B


BUS DUCT

PAGE 11 OF 11

7.03.00 L. T. SWITCHGEAR

The following type test certificates on each type & rating of L.T. Switchgear and MCC panel shall be submitted.

(a.) Short time withstand test.

(b.) Temperature rise test.

(c.) Type II - Short circuit co-ordination test for any three ratings of MCC module as selected by the Employer.

(d.) Test sequence –1 & combined test sequence shall be carried out on each rating of circuit breaker mounted inside the panel.

(e.) Degree of protection tests

(f.) Type test certificates for numerical relays.

8.00.00 Drawing Submission Procedure

Unique manufacturer specific reference drawing nos. shall be allotted by owner to drawings of the equipment or components. Drawing once approved (for any project) shall be treated as reference drawings for subsequent projects. An endorsement sheet shall be submitted by manufacturer confirming similarity and minor changes if any shall be highlighted on the endorsement sheet. However owner reserves right to get the drawings submitted afresh. The reference drawings so approved once along with endorsement sheet shall be used for factory inspection of equipment whenever package/project specific drawings are not submitted afresh/approved.

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CLAUSE NO.





PART-B SUB-SECTION-IIIB-03 L.T. POWER CABLE

PAGE 1 OF 8

POWER CABLES

1.00.00 CODES & STANDARDS

1.01.00 All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS : codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes:

IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V.

IS : 3961 Recommended current ratings for cables

IS : 3975 Low carbon galvanised steel wires, formed wires and tapes for armouring of cables.

IS : 5831 PVC insulation and sheath of electrical cables.

IS:7098 (Part -I) Cross linked polyethylene insulated PVC sheathed cables for working voltages upto and including 1100V.

IS : 8130 Conductors for insulated electrical cables and flexible cords.

IS : 10418 Specification for drums for electric cables.

IS : 10810 Methods of tests for cables.

ASTM-D -2843 Standard test method for density of smoke from the burning or decomposition of plastics.

ASTM-D-2863 Standard method for measuring the minimum oxygen concentration to support candle like combustion of plastics.

IEC-754 (Part-I) Test on gases evolved during combustion of electric cables.

IEEE-383 Standard for type test of Class IE Electric Cables.

CLAUSE NO.






PAGE 2 OF 8

IEC -332 Tests on Electric cables under fire conditions. Part-3 : Tests on bunched wires or cables (category -B)

2.00.00 TECHNICAL REQUIREMENTS

2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground burried installation with chances of flooding by water.

2.02.00 Cables shall be armoured, flame retardant, low smoke (FRLS), type designed to withstand all mechanical, electrical and thermal stresses develop under steady state and transient operating conditions as specified elsewhere in this specification.

2.03.00 Aluminium conductor used in power cables shall have tensile strength of more than 100 N/ sq.mm. Conductors shall be multi stranded.

2.04.00 XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg. C and short circuit conductor temperature of 250 deg.C. PVC insulation shall be suitable for continuous conductor temperature of 70 deg C and short circuit conductor temperature of 160 deg. C.

2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831.

2.06.00 For single core armoured cables, armouring shall be of aluminium wires. For multicore armoured cables armouring shall be of galvanised steel as follows : -

Calculated nominal dia of cable under armour

Size and Type of armour

i) Upto 13 mm

1.4mm dia GS wire

ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm dia GS wire

iii) Above 25 & upto 40 mm 0.8mm thick GS formed wire / 2.0mm dia GS wire

iv) Above 40 & upto 55mm 1.4 mm thick GS formed wire /2.5mm dia GS wire

v) Above 55 & upto 70 mm 1.4mm thick GS formed wire / 3.15mm dia GS wire

vi) Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire

CLAUSE NO.






PAGE 3 OF 8

2.06.01 The aluminium used for armouring shall be of H4 grade as per IS:8130 with maximum resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of aluminium wires/formed wires for armouring shall be same as indicated above in clause 2.06.00 for galvanised steel.

2.06.02 The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wire / formed wire. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface of G.S. wire/formed wire.

2.07.00 Outer sheath shall be of PVC as per IS:5831 & black in colour. In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables (including trailing cables) shall have the following FRLS properties.

(a.) Oxygen index of min. 29 (As per ASTMD 2863)

(b.) Acid gas emission of max. 20% (As per IEC-754-I).

(c.) Smoke density rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843.

2.08.00 Cores of the cables shall be identified by colouring of insulation. Following colour scheme shall be adopted:

1 core Red, Black, Yellow, Blue

2 core - Red & Black

3 core - Red, Yellow & Blue

4 core - Red, Yellow, Blue and Black

2.09.00 For reduced neutral conductors the core shall be black.

2.10.00 In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath.

(a.) Cable size and voltage grade - To be embossed

(b.) Word 'FRLS' at every 5 metre - To be embossed

(c.) Sequential marking of length of the cable in metres at every one metre-To be embossed / printed

The embossing shall be progressive, automatic, in line and marking shall be legible and indelible. For EPR cables identification shall be printed on outer sheath.

CLAUSE NO.






PAGE 4 OF 8

2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332 Part -3.

2.12.00 Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum over the declared value in the technical data sheets.

2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc.are not acceptable.

2.14.00 Cable selection & sizing

2.14.01 Cables shall be sized based on the following considerations:

(a) Rated current of the equipment

(b) The voltage drop in the cable, during motor starting condition, shall be limited to 10% and during full load running condition, shall be limited to 3% of the rated voltag

(c) Short circuit withstand capability

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

2.14.02 Derating Factors

Derating factors for various conditions of installations including the following shall be considered while selecting the cable sizes:

a) Variation in ambient temperature for cables laid in air

b) Grouping of cables

c) Variation in ground temperature and soil resistivity for buried cables.

2.14.03 Cable lengths shall be considered in such a way that straight through cable joints are avoided.

CLAUSE NO.






PAGE 5 OF 8

2.14.04 All power cables of sizes more than 120 sq.mm. shall be XLPE insulated and preferable sizes are 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm.

3.00.00 CONSTRUCTIONAL FEATURES

(a.) 1.1 KV grade XLPE power cables shall have compacted aluminium conductor, XLPE insulated, PVC inner-sheathed (as applicable), PVC outer-sheathed conforming to IS:7098. (Part-I).

(b.) 1.1KV grade PVC power cables shall have aluminium conductor (compacted type for sizes above 10 sq.mm), PVC Insulated, PVC inner sheathed (as applicable), PVC outer-sheathed conforming to IS:1554 (Part-I).

(c.) Trailing cables shall have tinned copper (class 5) conductor, insulated with heat resistant elastomeric compound based on Ethylene Propyline Rubber (EPR) suitable for withstanding 90 deg.C continuous conductor temperature and 250deg C during short circuit, inner-sheathed with heat resistant elastomeric compound, nylon cord reinforced, outer-sheathed with heat resistant, oil resistant and flame retardant heavy duty elastomeric compound conforming to IS 9968.

4.00.00 CABLE DRUMS

(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS : 10418.

(b.) Each drum shall carry manufacturer's name, purchaser’s name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.

5.00.0 TESTS

(a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owner’s approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests 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.

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(d.) The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No Design Change”. Minor changes if any shall be highlighted on the endorsement sheet

5.01.00 TYPE TESTS

5.01.01 The reports for the following type tests shall be submitted for one size each of XLPE/PVC Power cables:

S.No. Type Test Remarks For Conductor

1. Tensile test For aluminium conductor only.

2. Wrapping test For aluminium conductor only.

3. Resistance test

For Armour Wires/ Formed Wires

5. Measurement of Dimensions

6. Tensile Test

7. Elongation test

8. Torsion test For round wires only

9. Wrapping test For aluminium wires/formed wires only

10. Resistance test

11.(a) Mass of Zinc Coating test For G.S. Formed wires /wires only.

11.(b) Uniformity of zinc coating For G.S. Formed wires /wires only.

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S.No. Type Test Remarks

12. Adhesion test For G.S. Formed wires /wires only.

For PVC/XLPE insulation & PVC Sheath

13. Test for thickness

14. Tensile strength & elongation tests before ageing and after ageing

15. Ageing in air oven

16. Loss of mass test For PVC insulation and sheath only

17. Hot deformation test For PVC insulation and sheath only

18. Heat shock test For PVC insulation and sheath only

19. Shrinkage test

20. Thermal stability test For PVC insulation and sheath only

21. Hot set test For XLPE insulation only

22. Water absorption test For XLPE insulation only

23. Oxygen index test For outer sheath only

24. Smoke density test For outer sheath only

25. Acid gas generation test For outer sheath only

For completed cables

26. Insulation resistance test (Volume resistivity method)

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27. High voltage test

28. Flammability test as per IEC - 332 Part-3 (Category -B)

5.01.02 The reports for all the type tests as per IS 9968 (Along with test reports for FRLS Properties and flammability test) shall be submitted for one size of each voltage grade of trailing cables.

5.02.00 Acceptance Tests and Routine tests

Refer QA table enclosed with specification.

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SUBSECTION IIIB-04 HT CABLES

PAGE 1 OF 8

HT CABLES


1.01.00 All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS : codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes :

IS:7098 (Part -II)

Specification for Cross linked polyethylene insulated PVC sheathed cables. Part-II: For working voltages from 3.3 KV upto and including 33 KV.

IS : 3975 Low Carbon Galvanized steel wires, formed wires and tapes for armouring of cables.

IS : 4905 Methods for random sampling. IS : 5831 PVC insulation and sheath of electrical cables. IS : 8130 Conductors for insulated electrical cables and flexible

cords. IS : 10418 Specification for drums for electric cables. IS : 10810 Methods of tests for cables. ASTM-D -2843

Standard test method for density of smoke from the burning or decomposition of plastics.

IEC-754 (Part-I)

Tests on gases evolved during combustion of electric cables.

IEC-332 Tests on electric cables under fire conditions. Part-3: Tests on bunched wires or cables (Category-B).


2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground (buried) installation with chances of flooding by water.

2.02.00 Cables shall be armoured, flame retardant, low smoke (FRLS) type designed to withstand all mechanical, electrical and thermal stresses developed under steady state and transient operating conditions as specified elsewhere in this specification.

2.03.00 Aluminium conductor used in power cables shall have tensile strength of more than 100 N/ sq.mm. Conductors shall be multi stranded.

2.04.00 XLPE insulation shall be suitable for continuous conductor temperature of 90 deg. C and short circuit conductor temperature of 250 deg C.

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2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS: 5831.

2.06.00 For single core armoured cables, armouring shall be of aluminium wires. For multicore armoured cables armouring shall be of galvanised steel as follows : -

Calculated nominal dia of cable under armour


i) Upto 13 mm 1.4mm dia GS wire

ii) Above 13 & upto 25mm 0.8 mm thick GS formed wire / 1.6 mm dia GS wire

iii) Above 25 & upto 40 mm

0.8mm thick GS formed wire / 2.0mm dia GS wire

iv) Above 40 & upto 55mm 1.4 mm thick GS formed wire/2.5mm dia GS wire

v) Above 55 & upto 70mm 1.4 mm thick GS formed wire/3.15mm dia GS wire

vi)

Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire

2.06.01 The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum resistivity of 0.028264 ohm-sq.mm/mtr at 20 deg.C. The types and sizes of aluminium armouring shall be same as mentioned for galvanised steel at 2.06.00 above.

2.06.02 The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wires / formed wires. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface of GS wires/formed wires.

2.07.00 Distinct extruded PVC inner sheath of black colour as per IS:5831 shall be provided for the cables as follows:

a). For all multicore cables. b). For single core armoured cables , where armouring is not being used as metallic screen.

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2.08.00 Outer sheath shall be of PVC black in colour. In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables shall have the following FRLS properties.

(a.) Oxygen index of min. 29 (Test method as per IS 10810 Part-58)

(b.) Acid gas emission of max. 20% as per IEC-754 (Part-I)


2.09.00 Cores of three core cables shall be identified by colouring of insulation or by providing coloured tapes helically over the cores, with Red, Yellow & Blue colours.

2.10.00 In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath :



(c.) Sequential marking of length of the cable in metres at every one metre

- To be embossed / printed

The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible.

2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC-332 Part-3.


2.13.00 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable.

2.14.00 The cross-sectional area of the metallic screen strip/tape/wires shall be considered in sizing calculations.

Cable selection & sizing

2.15.00 HT cables shall be sized based on the following considerations:

a) Rated current of the equipment

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b) The voltage drop in the cable, during motor starting condition, shall be limited to 10% and during full load running condition, shall be limited to 3% of the rated voltage

c) Short circuit withstand capability

Derating Factors

Derating factors for various conditions of installations including the following shall be considered while selecting the cable sizes: a) Variation in ambient temperature for cables laid in air

b) Grouping of cables

c) Variation in ground temperature and soil resistivity for buried cables.


2.16.01 Cables shall be armoured type if laid in switchyard area, coal handling area or directly buried.

2.17.00 The eccentricity shall be calculated as

tmax -tmin ------------ x 100 t max

and the ovality shall be calculated as

dmax -dmin ------------ x 100 d max

Where t-max/t-min is the maximum/minimum thickness of insulation and d-max/d-min is the maximum / minimum diameter of the core.

The eccentricity of the core shall not exceed 10% and ovality not to exceed 2% .

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3.01.00 3.8/6.6 KV Grade Power Cables:

Cables shall conform to IS-7098 Part-II. These cables shall be multi-stranded, compacted circular aluminium conductor, XLPE-insulated, metallic screened, PVC outer sheathed. The conductor screen and insulation screen shall both be of extruded semiconducting compound and shall be applied along with the XLPE insulation in a single operation of triple extrusion process so as to obtain continuously smooth interfaces. Method of curing shall be “ dry curing / gas curing / steam curing “ . The metallic screen for each core shall be capable of carrying the system earth fault current of 9kA for 1 seconds, shall consist of copper wires or tape with minimum overlap of 20%. However, for single core armoured cables , the armouring shall constitute the metallic part of the screening.

3.02.00 19/33KV Grade Power Cables: Cables shall conform to IS-7098 Part-II. These cables shall be multi-stranded, compacted circular aluminium conductor, XLPE-insulated, metallic screened, PVC outer sheathed. The conductor screen and insulation screen shall both be of extruded semiconducting compound and shall be applied along with the XLPE insulation in a single operation of triple extrusion process so as to obtain continuously smooth interfaces. Method of curing for 19/33 KV cables shall be “dry curing / gas curing “.The metallic screen for each core shall be capable of carrying the system earth fault current of 1kA for 1 second, shall consist of copper wires or tape with minimum overlap of 20%. However, for single core armoured cables , the armouring shall constitute the metallic part of the screening.

4.00.00 CABLE DRUMS

4.01.01 Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof cover. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS: 10418.

4.01.02 Each drum shall carry manufacturer's name, purchaser’s name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.

4.01.03 The standard drum length for power cables shall not be less than 500 meters. The length per drum shall be subjected to a maximum tolerance of +/- 5% of the standard drum length. The Employer shall have the option of rejecting cable drum with shorter

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lengths. For each size, the variance of total quantity, adding all the supplied drum lengths, from the ordered quantity, shall not exceed +/-2%.

5.00.00 TESTS

5.01.00 GENERAL




(d.) The type test reports once approved for any project shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No Design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

5.01.02 Following type tests reports shall be furnished on one size of each type(voltage grade) of cable:

S. No

Type Test Remarks

Conductor 1. Resistance test For Armour Wires / Formed

Wires

2. Measurement of Dimensions 3. Tensile Test 4. Elongation test 5. Torsion test For round wires only 6. Wrapping test 7. Resistance test

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S. No

Type Test Remarks

8(a) Mass & uniformity of Zinc Coating tests

For GS wires/formed wires only.

8(b) Adhesion test For GS wires/formed wires only

For XLPE insulation & PVC Sheath

9. Test for thickness 10. Tensile strength and

elongation test before ageing and after ageing

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

332 Part-3 (Category -B)

For completed cable only

5.01.03 The following type tests shall be submitted for each type(voltage grade) & size of the cable:

S. No.

Type Test For all cables

1. Insulation resistance test (Volume Resistivity method) 2. High voltage test

For cables of 6.6 KV & above Grade only. 3. Partial discharge test 4. Bending test 5. Dielectric power factor test

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a As a function of voltage b

) As a function of temperature

6. Heating cycle test 7. Impulse withstand test

5.02.00 Indicative list of tests/ checks, Routine and Acceptance tests shall be as per Quality Assurance & Inspection table of H.T. Cables enclosed with this chapter.

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SUB-SECTION-IIIB-05 CONTROL CABLES

PAGE 1 OF 6

CONTROL CABLES


1.01.00 All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS: codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes:

IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V.

IS : 3961 Recommended current ratings for cables

IS : 3975 Low carbon galvanised steel wires, formed wire and tapes for armouring of cables.

IS : 4905 Methods for random sampling.

IS : 5831 PVC insulation and sheath of electrical cables.

IS : 8130 Conductors for insulated electrical cables and flexible cords.

IS : 10418 Specification for drums for electric cables.

IS : 10810 Methods of tests for cables.

ASTM-D –2843 Standard test method for density of smoke from the burning or decomposition of plastics.

ASTM-D-2863 Standard method for measuring the minimum oxygen concentration to support candle like combustion of plastics.

IEC-754 (Part-I) Test on gases evolved during combustion of electric cables.

IEEE-383 Standard for type test of Class IE Electric Cables.

IEC –332 Tests on Electric cables under fire conditions. Part-3 : Tests on bunched wires or cables (category -B)

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2.01.00 The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground burried installation with chances of flooding by water.

2.02.00 Cables shall be armoured. flame retardant, low smoke (FRLS), type designed to withstand all mechanical, electrical and thermal stresses develop under steady state and transient operating conditions as specified elsewhere in this specification.

2.03.00 Conductor of control cables shall be made of multi stranded, plain annealed copper.

2.04.00 PVC insulation shall be suitable for continuous conductor temperature of 70 deg C and short circuit conductor temperature of 160 deg. C.

2.05.00 The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831.

2.06.00 For multicore armoured cables, the armouring shall be of galvanised steel as follows: -

Calculated nominal dia. of cable under armour


1) Upto 13 mm

1.4mm dia GS wire

2) Above 13 upto 25 mm

0.8 mm thick GS formed wire / 1.6 mm dia GS wire



4) Above 40 upto 55mm

1.4 mm thick GS formed wire/2.5mm dia GS wire



6) Above 70mm 1.4 mm thick GS formed wire / 4.0 mm dia GS wire

The gap between armour wire / formed wire shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wire / formed wire. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface.

2.07.00 Outer sheath shall be of PVC (grade as applicable) and grey in colour . In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables (including trailing cables) shall have the following FRLS properties.

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(a.) Oxygen index of min. 29 (As per ASTMD 2863)

(b.) Acid gas emission of max. 20% (As per IEC-754-I).


2.08.00 Cores of the cables of upto 5 cores shall be identified by colouring of insulation. Following colour scheme shall be adopted.

1 core - Red, Black, Yellow or Blue

2 core - Red & Black

3 core - Red, Yellow & Blue

4 core - Red, Yellow, Blue and Black

5 core - Red, Yellow, Blue, Black and Grey

2.09.00 For cables having more than 5 cores, core identification shall be done by numbering the insulation of cores sequentially, starting by number 1 in the inner layer (e.g. say for 10 core cable, core numbering shall be from 1 to 10). The number shall be printed in Hindu-Arabic numerals on the outer surfaces of the cores. All the numbers shall be of the same colour, which shall contrast with the colour of insulation. The colour of insulation for all the cores shall be grey only. The numerals shall be legible and indelible. The numbers shall be repeated at regular intervals along the core, consecutive numbers being inverted in relation to each other. When the number is a single numeral, a dash shall be placed underneath it. If the number consists of two numerals, these shall be disposed one below the other and a dash placed below the lower numeral. The spacing between consecutive numbers shall not exceed 50 mm.

2.10.00 In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath:



(c.) Sequential marking of length of the cable in metres at every one metre. - To be embossed / printed.

The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible. For EPR cables identification shall be printed on outer sheath.

2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332 Part -3.

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2.13.00 Inplant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable.

2.14.00 Cable selection & sizing

Control cables shall be sized based on the following considerations: (a) The minimum conductor cross-section shall be 1.5 sq.mm.

(b) The minimum number of spare cores in control cables shall be as follows:

No. of cores in cable Min. No. of spare cores

2C, 3C NIL

5C 1

7C-12C 2

14C & above 3



3.01.00 1.1 KV Grade Control Cables shall have stranded copper conductor multicore PVC insulated, PVC inner-sheathed, PVC outer-sheathed conforming to IS:1554. (Part-I).

3.02.00 1.1KV grade trailing cables shall have tinned copper (class-5) conductor, insulated with heat resistant elastomeric compound based on Ethylene Propyline Rubber (EPR) suitable for withstanding 90 deg C continuous conductor temperature and 250 deg C during short Ckt., inner sheathed with heat resistant, oil resistant and flame retardant heavy duty elastomeric compound conforming to IS 9968. Minimum conductor size shall be 2.5sqmm.

4.00.00 CABLE DRUMS

(a.) Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood

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preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS : 10418.

(b.) Each drum shall carry manufacturer's name, purchaser’s name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both the sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.

5.00.00 TESTS




(d.) The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No Design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

5.01.00 TYPE TESTS

5.01.01 The reports for the following type tests shall be submitted for one size of control cables :

S. No. Type Test Remarks

For Conductor

1. Resistance test

For Armour Wires / Formed Wires

3. Measurement of Dimensions

4. Tensile Test

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5. Elongation test

6. Torsion test For round wire only

7. Wrapping test

8. Resistance test

9(a). Mass of zinc Coating test For GS wires/formed wires only

9(b). Uniformity of zinc coating For GS wires/formed wires only

10. Adhesion test For GS wires/formed wires only

For PVC insulation & PVC Sheath

11. Test for thickness

12. Tensile strength and elongation test

before ageing and after ageing

13. Ageing in air oven

14. Loss of mass test For PVC insulation and sheath only

15. Hot deformation test For PVC insulation and sheath only

16. Heat shock test For PVC insulation and sheath only

17. Shrinkage test

18. Thermal stability test For PVC insulation and sheath only

19. Oxygen index test For outer sheath only

20. Smoke density test For outer sheath only

21. Acid gas generation test For outer sheath only

For completed cables

22. Insulation resistance test(Volume resistivity method)

23. High voltage test

24. Flammability test as per IEC - 332 Part-3 (Category-B)

5.01.02 The reports for all the type tests as per IS 9968 (Along with test reports for FRLS Properties and flammability test) shall be submitted for one size of trailing cables.

5.02.00 Acceptance Tests and Routine tests

Refer QA table enclosed with specification.

.

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SUB-SECTION-IIIB-06 INSTRUMENTATION

CABLES

PAGE 1 OF 11

INSTRUMENTATION CABLES

1.00.00 INSTRUMENTATION CABLES

1.01.00 GENERAL

1.01.01 The Contractor shall supply, erect, terminate and test all instrumentation cables for control and instrumentation equipment/devices/systems included under Contractor's scope.

1.01.02 Any other application where it is felt that instrumentation cables are required due to system/operating condition requirements, are also to be provided by Contractor.

1.01.03 Other type of cables like fiber optic/co-axial cables for system bus, cables for connection of peripherals etc. (under Contractor's scope) are also to be furnished by the Contractor.

1.01.04 Contractor shall supply all cable erection and laying hardware trays, supports, flexible conduits, cable glands, lugs, pull boxes etc. on as required basis for all the systems covered under this specification.

1.02.00 Instrumentation Cable Specifications

1.02.01 All the instrumentation cables shall be Armoured, twisted, shielded multipair, pre fabricated, flame retardant low smoke (FRLS) type. The Cables shall be provided in non-returnable drums. The drum length shall be 1000m (+/-5%) up to & including 12 pairs and 500 m (+/- 5%) above 12 pairs.

1.02.02 Voltage grade of the instrumentation cables shall be 225V (peak value).

1.02.03 All instrumentation cables covered in this specification shall comply with VDE 0815, VDE 0207, Part 4, Part 5, Part 6, VDE 0816,VDE 0472, SEN 4241475, ANSI MC 96.1, IS-8784, IS-10810 (latest editions) and its amendments read along with this specification.

1.02.04 The conductor shall be of minimum 0.5-sq.mm size, high conductivity, multi-stranded copper for all types of instrumentation cables where as the same shall be min. 1.5sqmm when used in the trailing cables.

1.02.05 The insulation of individual conductor shall be extruded PVC meeting the requirements of VDE 0207 Part 4 compound Y I3. The outer sheath of instrumentation cables shall be extruded PVC (compound YM1) as per VDE 0207 Part 5 and shall be of flame-retardant low smoke (FRLS) type. The cable shall be provided with marking including manufacturer's name, insulation material, and conductor sizes, no of pairs, voltage ratings, type of cable etc. at intervals not exceeding 625mm. Progressive sequential marking of the length of the cable at every one meter & progressive markings to read 'FRLS' at every 5 meters shall be provided on the outer sheath of all instrumentation cables. The colour of outer sheath shall be sky blue.

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Fillers in multiple conductor cables shall be flame retardant and moisture resistant. Cable accessories such as harnessing components, markers, bedding, cable jointer, binding tape etc. shall also have flame retardant quality.

1.02.06 All instrumentation cables shall be provided with overall shielding. However, multipair cables carrying analog signals shall be provided with individual pair shielding in addition to overall shielding. Shielding shall be of Aluminium-Mylar tape with 100% coverage and with atleast 20% overlapping. The thickness of individual pair shield shall be 28 micron (minimum) and that of overall shield shall be 55 microns (minimum). Separate drain wires for individual pair shield (wherever applicable) as well as overall shield shall be provided. Drain wire shall be of seven (7) strand 20 AWG (0.51 Sq.mm) tin coated copper conductor. Maximum lay of individual twisted pair shall be 50 mm. Bidder to ensure that individual core diameter shall be suitable for maxi-termi connection. Insulation thickness of individual core shall be between 0.28 and 0.35 mm for 0.5 mm2 cables.

1.02.07 The outer sheath of the instrumentation cables shall meet the following minimum requirements:

(i) An Oxygen index of not less than 29% and a Temperature index of not less

than 250 deg.C as per ASTMD-2863. (ii) Maximum acid gas generation by weight as per IEC-754-I shall not be more

than 20%. (iii) Smoke Density Rating shall not be more than 60% during Smoke Density

Test as per ASTMD-2843. The results of smoke density test shall be plotted on a curve indicating light absorption vs. time as per ASTMD2843. The average area under the curve (smoke density rating) shall not be more than 60%.

(iv) Complete cable assembly shall pass Swedish Chimney test as per SEN-

4241475 and flammability test as per IEEE-383.

The thickness of outer sheath shall be as per the guidelines given in VDE 0816. Thickness of outer sheath shall not be less than 1.8 mm in any case. Allowable tolerance of overall diameter of the cables shall be +/-2 mm max. over the declared value in technical data sheets. The variation in diameter and the ovality at any cross section shall not be more than 1.0 mm.

1.02.08 All instrumentation cables shall be suitable for continuous operation at 70 deg.C, except for high temperature resistant teflon insulated cables which shall be suitable for continuous operation at 205 deg.C. The cables shall be suitable for laying in wet or dry locations in trays, conduits, ducts, trenches and under ground buried installations.

1.02.09 The thermocouple extension cables shall be of single/multi pair, twisted & shielded, PVC insulated, FRLS PVC sheathed and compatible for the type of thermocouples employed. The material of conductor shall be as per ANSI MC-96.1. The material

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and requirements of conductor insulation, shielding and outer sheath shall be as per the above clauses.

1.02.10 Cable parameters such as mutual capacitance between conductors, conductor resistance, insulation resistance, characteristic impedance, cross talk and attenuation figures at 20 deg.C (± 3 deg.C) for various types of cables as applicable shall be as specified under Table A.

1.02.11 Identification of the cores & pairs shall be done with suitable colour coding & band marking as well as by numbering of cores/pairs as per VDE: 0815. The details of colour coding etc. shall be as approved by Employer during detailed stage. Also refer Table B for description of various type of cables.

1.02.12 The Contractor shall furnish all documentary evidence including cross-sectional drgs, test certificates to substantiate the suitability of cables offered for different applications. The contractor shall also clearly bring out the application wise details for each type of cable offered.

1.02.13 All prefabricated cables shall have 10% spare cores which will not be connected to pin connectors.

1.02.14 CABLE PARAMETER

Table – A : CABLE PARAMETER

Conductor Size 0.5 Sq.mm.

Parameter/ Type of Cable

Individual and overall shielded (Type F)

Overall Shielded(Type-G)

Compensating cables (with/without Teflon coating) (Type A,B,C)

Mutual capacitance at 0.8 kHz (max.)

120 nF/Km. 100 nF/Km. 200 nF/Km

Conductor Resistance (max.)

73.4 ohm/km (loop)For Type F

73.4 ohm/km (loop)

Insulation resistance

100 M ohm/ Km 100 M ohm/ Km 100 M ohm/ Km

Cross-Talk figure at 0.8 kHz (min.)

60 dB 60 dB 60 dB

Characteristic impedance (max.)

320 ohm 340 ohm

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Attenuation at 1 kHz (max.)

1.2 dB/Km 1.2 dB/Km

1.02.15 DESCRIPTION OF VARIOUS TYPE OF CABLES

TABLE – B

Type Conductor Size

Description

A 0.5 mm2 Two pair shielded and twisted pair T/C extension cable, ANSI type KX, stranded conductor.

B 0.5 mm2 Two pair shielded & twisted T/C extension cable ANSI type SX, stranded conductor.

C 0.5 mm2 Two pair shielded & twisted heat resistant teflon insulation & Outer sheath T/C extension cable ANSI type KX, stranded conductor.

F 0.5 mm2 Multi pair individual pair & overall shielded twisted pair instrumentation cable (4/8/12/24 pair) for analog signals with stranded copper conductor.

G 0.5 mm2 Multi pair overall shielded & twisted pair instrumentation cable (2/4/8/12/24/48 pair) for binary signals with stranded copper conductor.

I 0.5 mm2 Type F cable/type G cable with heat resistant teflon insulation & outer-sheath for high temperature application.

S As per specific Standard/ Requirement for each application

Multi core/ Multi pair shielded cable for system specific cables. Like conductivity type level switches, Vibration monitoring system cable, System Bus cable, Bus communications cable etc. as applicable.

1.03.00 INSTRUMENTATION CABLE INTERCONNECTION AND TERMINATION PHILOSOPHY

1.03.01 The cable interconnection philosophy to be adopted shall be such that extensive grouping of signals by large scale use of field mounted Group JBs at strategic locations (where large concentration of signals are available, e.g. switchgear) is done and consequently cable with higher number of pairs are extensively used. The details of termination to be followed are mentioned in the given table C.

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TABLE C:- CABLE TERMINATION TO BE FOLLOWED

Application Type Of Termination Type Of Cable

FROM (A) TO (B) END A END B

Valves/dampers drives (Integral Junction box)

Marshalling ubicle/local group JB/Ter- mination/Control Cabinets/System Cabinets

Plug in connector

Post moun ted Maxi termi/cage clamp type.

G

RTD heads Local junction box Plug in connector

Maxitermi/ cage clamp (Rail moun ted) type.

F

Thermocouples CJC box Plug in connector

Screwed/ Cage clamp Type

A,B,C*

RTD thermocouple

Temperature transmitter

Plug in connector

Screwed/ Cage clamp Type

Local Junction box, CJC box, Group JB/ MCC/SWGR

Marshalling Cubicle/local group JB/Termination/ Control Cabinets/System Cabinets



F,G

Local Junction box, MCC/SWGR

Group JB Maxitermi/ cage clamp (Rail moun ted) type.


F,G

Field mounted Instrument

Group JB Maxitermi/ cage clamp (Rail moun ted) type.

Maxitermi/cage clamp (Rail moun ted) type.

F,G

Marshalling cubicle/ Termination Cabinet

Electronic system cabinet

Post mounted Maxi termi/cage clamp type.

Post mounted Maxi termi/cage clamp type.

F,G

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Marshalling / Termination system cabinets

UCP mounted equipments


Plug in connector/Cage clamp type (rail mounted).

F,G (with plug-in connector at one end)

DDCMIS/PLC cabinets

PC, Printers etc. Plug in connector

Plug in connector

Mfr.’s Standard

Notes 1 Normally 10% spare core shall be provided when the number of pairs of cables are more than four pairs.

2 For analog signals individual pair shielding & overall shielding & for Binary signals only overall shielding of instrumentation cables shall be provided.

3 * For high temperature application only.

2.00.00 TERMINAL BLOCKS

2.01.00 All terminal blocks shall be rail mounted/post mounted, cage clamp type/maxi-termi type (MTP) with high quality non-flammable insulating material of melamine suitable for working temperature of 105 deg. C. The terminal blocks in field mounted junction boxes, CJC boxes, etc., shall be suitable for cage clamp/ MTP connections. The terminal blocks in Control Equipment Room logic/termination/marshalling cubicles shall be suitable for post mounted maxi-termi/cage clamp connection at the field input end. The terminal blocks for DDCMIS input/output connections from/to SWGR/MCC, Actuators with Integral Starter (for coupling relays and check back signals of 11 kV and 3.3 kV auxiliaries, LT drives/valves & dampers/solenoids, CT & VT, etc.) shall be provided with built in test and disconnect facilities complete with plug, slide clamp, test socket, etc. The exact type of terminal blocks to be provided by the Contractor and the technical details of the same including width etc. shall be subject to Employer's approval.

2.02.00 All the terminal blocks shall be provided complete with all required accessories including assembly rail, locking pin and section, end brackets, partitions, small partitions, test plug bolts and test plug (as specified above for SWGR connections) transparent covers, support brackets, distance sleeves, warning label, marking, etc.

2.03.00 The marking on terminal strips shall correspond to the terminal numbering on wiring diagrams. At least 20% spare unused terminals shall be provided everywhere including local junction boxes, instrument racks/enclosures, termination/marshalling cabinets, etc. All terminal blocks shall be numbered for identification and grouped according to the function. Engraved labels shall be provided on the terminal blocks.

2.04.00 The terminal blocks shall be arranged with atleast 100 mm clearance between two sets of terminal blocks and between terminal blocks and junction box walls.

2.05.00 For ensuring proper connections, Contractor shall provide suitable accessories, along with insulation sleeves. The exact connecting accessory shall be finalised as

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per application during detail engineering stage subject to Employer's approval without any cost repercussions.

2.06.00 Internal wiring in factory prewired electronic equipment cabinets may be installed according to the Contractor's standard as to wire size and method of termination or internal equipment. Terminal blocks for connection of external circuits into factory prewired electronic equipment cabinets shall meet all the requirements as specified above.

3.00.00 INTERNAL PANELS/CABINETS/SYSTEM CABINETS WIRING

3.01.00 Internal panel/cabinet wiring shall be of multistranded copper conductor with FRLS PVC insulation without shield and outer sheath meeting the requirements of VDE 0815.

3.02.00 Wiring to door mounted devices shall be done by 19 strand copper wire provided with adequate loop lengths of hinge wire so that multiple door opening shall not cause fatigue breaking of the conductor.

3.03.00 All internal wires shall be provided with tag and identification nos. etched on tightly fitted ferules at both ends in Employer's approved format. All wires directly connected to trip devices shall be distinguished by one additional red colour ferrule.

3.04.00 All external connection shall be made with one wire per termination point. Wires shall not be tapped or spliced between terminal points.

3.05.00 All floor slots of desk/panels/cabinets used for cable entrance shall be provided with removable gasketed gland plates and sealing material. Split type grommets shall be used for prefabricated cables.

3.06.00 All the special tools as may be required for solderless connections shall be provided by Bidder.

3.07.00 Wire sizes to be utilised for internal wiring.

(i) Current (4-20 mA), low voltage signals (48V) 0.5 Sq.mm.

(ii) Power supply and internal illumination. 2.5Sq.mm. minimum (shall be as per load requirement.)

4.00.00 CABLE INSTALLATION AND ROUTING

4.01.00 All cables assigned to a particular duct/conduit shall be grouped and pulled in simultaneously using cable grips and suitable lubricants. Cables removed from one duct/conduit shall not be reused without approval of Employer.

Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the higher voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of the tray stack.

4.02.00 Cables shall terminate in the enclosure through cable glands. All cable glands shall be properly gasketed.

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4.03.00 All cables shall be identified by tag. Nos. provided in Employer's approved format at both the ends as well as at an interval of 5 meters.

4.04.00 Line voltage drop due to high resistance splices, terminal contacts, insulation resistance at terminal block, very long transmission line etc. shall be reduced as far as practicable.

4.05.00 The cables emanating from redundant equipment/devices shall be routed through different routes.

5.00.00 CABLE LAYING AND ACCESSORIES

5.01.00 CABLE LAYING

1 Cables shall be laid strictly in line with cable schedule.

2 Identification tags for cables.

Indelible tags to be provided at all terminations, on both sides of wall or floor crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in cable trench/tray.

3 Cable tray numbering and marking.

To be provided at every 10m and at each end of cable way & branch connection.

4 Joints for less than 250 Meters run of cable shall not be permitted.

5 Buried cable protection

With concrete slabs; Route markers at every 20 Meters along the route & at every bend.

6 Road Crossings

Cables to pass through burried high density PE pipes encased in PCC. At least 300 mm clearance shall be provided between

- HT power & LT power cables,

- LT power & LT control/instrumentation cables,

Spacing between cables of same voltage grade shall be in accordance with the derating criteria adopted for cable sizing.

7 Segregation (physical isolation to prevent fire jumping)

a All cable associated with the unit shall be segregated from cables of other Units.

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b Interplant cables of station auxiliaries and unit critical drives shall be segregated in such a way that not more than half of the drives are lost in case of single incident of fire.

8 Cable clamping

All cables laid on trays shall be neatly dressed up & suitably clamped/tied to the tray. For cables in trefoil formation, trefoil clamps shall be provided.

6.00.00 FIELD MOUNTED LOCAL JUNCTION BOXES

(i) No. of ways 12/24/36/48/64/72/96/128 with 20% spare terminals.

(ii) Material and Thickness

4mm thick fiberglass reinforced polyester.

(iii) Type Screwed at all four corners for door. Door handle shall be self locking with common key. Door gasket shall be of synthetic rubber.

(iv) Mounting clamps and accessories

Suitable for mounting on walls, columns, structures etc. The brackets, bolts, nuts, screws, glands and lugs required for erection shall be of corrosion resistant material, included in Bidders scope of supply.

(v) Type of terminal blocks

Rail mounted maxitermi or cage-clamp type suitable for conductor size upto 2.5 mm2. A M6 earthing stud shall be provided.

(vi) Protection Class IP:55 minimum for Indoor & IP-65 Outdoor applications

(vii) Colour To be decided during detailed engineering & subject to Employer’s approval.

7.00.00 CONDUITS

7.01.00 All rigid conduits, couplings and elbows shall be hot dipped galvanised rigid mild steel in accordance with IS:9357 Part-I (1980) and Part-II (1981). The conduit interior and exterior surfaces shall have continuous zinc coating with an overcoat of transparent enamel lacker or zinc chromate. Flexible 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 application.

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8.00.00 TESTS

8.01.00 GENERAL





8.02.00 TYPE TEST

8.02.01 Following type tests reports shall be submitted for one size of each type of instrumentation cables:

8.02.02 For Conductor (including Drain Wire)

Sl.No.

Test Reference Standard Remarks

1. Resistance Test VDE:0815 2. Diameter IS:10810 3. Tin coating test*

(Persulphate Test) As per relevant standard

*Applicable for drain wire only

8.02.03 For PVC Insulation And PVC Sheath

Sl.No. Test Reference Standard

Remarks

1. Test for thickness** IS:10810 2. Tensile strength and elongation test

before and after ageing** VDE:0472

3. Ageing in air ovens** - do- 4. Loss of Mass Test -do-

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5. Hot deformation test -do- 6. Heat shock test - do- 7. Shrinkage test** -do- 8. Cold bend/ cold impact test - do- 9. Colour fastness to water -do- 10. Thermal stability test -do- 11. Bleeding and blooming -do- 12. Oxygen index test (for sheath & fillers) ASTMD-2863 13. Smoke density test (for sheath &

fillers) ASTMD-2843

14. Acid gas generation test (for sheath & fillers)

IEC-754-1

8.02.04 For Al-Mylar Shield

8.03.00 Acceptance tests and routine test

Refer QA table enclosed with the specification.

Sl.No. Test Reference Standard Remarks 1. Continuity test As per relevant standard 2. Shield thickness test -do- 3. Overlap test -do 4. Noise interference

test IEEE-Transaction March'67

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SUB-SECTION-IIIB-07 ILLUMINATION

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ILLUMINATION 1.00.00 GENERAL

1.01.00 This specification covers the general description of design, manufacture and construction features, testing, supply, installation and commissioning of the illumination system equipment required to be provided by the bidder.


1.03.00 All standards and codes of practice referred to herein shall be the latest edition including all applicable official amendments & revisions as on date of bid opening. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards & codes.

1.04.00 Lighting Fixtures and Accessories

IS:1913 General and safety requirements for luminaries.

IS:2148 Flame proof enclosures of electrical apparatus.

IS:418 Tungsten filament general service electric lamps.

IS:1258 Bayonet lamp holders.

IS:1534 Ballast for fluorescent lamps.

IS:1569 Capacitors for use in tubular fluorescent, high pressure mercury vapour and low pressure sodium vapour discharge lamp circuit.

IS:1777 Industrial luminaire with metal reflectors.

IS:2149 Luminaire for Street lighting.

IS:2215 Starters for fluorescent lamps.

IS:2418 Tubular fluorescent lamps for general lighting services.

IS:3323 Bi-pin lamp holders for tubular fluorescent lamps.

IS:3324 Holders for starters for tubular fluorescent lamps.

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IS:4013 Dust-tight electric lighting fittings.

IS:6616 Ballasts for high pressure mercury vapour lamps.

IS:8224 Electric Lighting fittings for Division 2 areas.

IS:9900 High-pressure mercury vapour lamps.

IS:9974 High pressure Sodium vapour lamps.

IS:10276 Edison screw lamp holders.

IS:10322 Luminaires.

IS:13021 AC Supplied Electronic Ballasts for tubular fluorescent lamps.

1.05.00 Lighting Panels, Switch-boxes, Receptacles and Junction Boxes

IS:2147 Degree of protection provided by enclosures for low-voltage switchgear and control gear.

IS:1293 Plugs & socket outlets of rated voltage upto and Including 250volts & rated current upto and including 16 Amps.

IS:2551 Danger notice plates.

IS:13947 Low voltage switchgear and controlgear

IS:3854 Switches for domestic and similar purposes.

IS:6875 Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto and including 1000 V AC and 1200 V DC.

IS:13703 Low voltage fuses for voltages not exceeding 1000V AC or 1500 V DC.

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1.06.00 Conduits, Pipes and Accessories

IS:2667 Fittings for rigid steel conduit for electrical wiring.

IS:3837 Accessories for rigid steel conduits for electrical wiring.

IS:9537 Conduits for electrical installations.

1.07.00 Lighting Wires/Cables

IS:694 PVC insulated cables for working voltages upto and including 1100 V

IS:3961 Recommended current ratings for cables.(PVC Insulated and PVC sheathed heavy duty cables and light duty cables).

IS:8130 Conductors for insulated electric cables and flexible cords.

IS:10810 Methods of tests for cables.

1.08.00 Electrical Installation Practices & Miscellaneous

IS:1944 Code of practice for lighting of public thorough fare

IS:3646 Code of practice for interior illumination.

IS:5572 Classification of Hazardous areas (other than Mines)having flammable gases and Vapours for electrical installation

IS:6665 Code of practice for industrial lighting. . .

National Electrical Code Indian Electricity Rules. Indian Electricity Act

IS:5 Colour for ready mixed paints & enamels.

IS:280 Mild steel wires for general engineering purposes.

IS:374 Electric ceiling type fans & regulators.

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IS:732 Code of practice for electrical wiring installations.

IS:1255 Code of practice for installation and maintenance of power cables Upto and including 33KV rating.

IS:2062 Steel for general structural purposes

IS:2629 Recommended practice for hot-dip galvanizing of iron and steel.

IS:2633 Methods for testing uniformity of coating of zinc coated articles.

IS:2713 Tubular steel poles for overhead power lines.

IS:3043 Code of practice for earthing

IS:5216 Guide for safety procedures and practices in electrical work.

IS:5571 Guide for selection of electrical equipments for hazardous areas.

BS:6121 Mechanical cable glands

2.00.00 LIGHTING SYSTEM DESCRIPTION

2.01.00 Normal AC Lighting System

Normal AC lighting system 415V, 3Phase, 4wire, will be fed from lighting panels (LPs) which will be fed from the lighting distribution boards (LDBs) which in turn will be fed from LT MCCs.

2.02.00 Emergency Lighting System

Self contained emergency lighting fixtures shall be provided, 2 nos. in each control area and in each TP and in each MCC rooms, mounted suitably on wall/columns at strategic points for safe exit of the personnel. Each fixture shall be fed from a dedicated 20A, 240V socket. In the control room these fixtures shall also be provided in the control panel area for emergency operation of the plant. The fixtures shall be switched ‘ON’ automatically in case of failure of AC supply. These shall be switched off automatically after the normal AC supply is restored and the luminaries have attained their full glow. Emergency lighting is to be provided through self contained 4 hour duration fixtures located strategically. Each shall be provided with Ni-Cd battery, battery charger & 2 x 10W fluorescent lamps. These emergency lamps shall be mounted in pilfer proof enclosure having pad locking arrangement.

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In addition to the above, 3 nos. of 100W, 110V DC lighting fixtures shall also be provided in each HT Swichgear room and in each control room

2.03.00 DESIGN PHILOSOPHY

1. A comprehensive illumination system shall be provided.

2. All lighting system shall be automatically controlled by synchronous timer. Provision to bypass the timer shall be provided in the panel for manual control.

3. The system shall include distribution boards, 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 yard 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.

4. 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.

5. Apart from maintenance factor as given below, Temperature correction factor shall be considered in the lighting design for fluorescent fixtures located in non air conditioned area.

(a) Air conditioned area : 0.8

(b.) Non Air conditioned and other indoor area : 0.7

(c.) Dust prone indoor areas and outdoor areas : 0.6

6. All outdoor fixtures shall be weather proof.

7. All lighting fixtures & control gears shall be powder coated.

8. Wires of different phase shall normally run in separate conduit. For areas illuminated by more than one circuit, the adjacent circuits shall be from different phases.

9. Power supply shall be fed from suitable number of conveniently located

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lighting distribution boards (LDB) and lighting panels (LP). AC lighting supply shall be isolated from main supply by isolation transformers (415/433V, delta / star, epoxy insulated, air cooled, dry type) of max. rating of 100KVA and fault level restricted to 3 KA at Lighting Panels. Minimum 2 ways shall be kept as spare feeders in the lighting panels.

10. Lighting panels shall be constructed out of 2 mm thick CRCA sheet steel. The door shall be hinged and the panel shall be gasketted to achieve specified degree of protection. The panel shall be provided with terminal bocks for incoming and outgoing circuits, earthing terminals, removable gland plates at bottom and canopy shall be provided with slope towards the rear side of the panel. Wiring inside the panel shall be carried out with 1100 V grade PVC insulated stranded copper wires of adequate size. Terminal blocks shall be 750 V grade, clip-on stud type, moulded in melamine and shrouded.

All MCBs/ Isolators/ Switches/ Contactors etc. shall be mounted inside the panel and a fibre glass sheet shall be provided inside the main door such that the operating knobs of MCBs etc., shall project out of it for safe operation against accidental contact. MCB’s shall be current limiting type with magnetic and thermal release suitable for manual closing and automatic tripping under fault condition with short circuit interrupting capacity of 9 KA rms. Isolators of AC lighting panels shall be of TPN, continuous duty, load make-break type and fuses shall be of HRC plug in type.

Synchronous timers shall be quartz controlled electronic type, complete with rechargeable nickel cadmium cell, 24 hours range day dial, NO/NC contacts etc. and suitable for operation on 240V AC supply. The exterior side of panel, shall be powder coated with smoke grey, shade RAL9002 and the interior side of panel, shall be white.

Lighting panels shall have IP55 degree of protection in general. However LP located in dusty areas shall have IP65 degree of protection.

Ladder approaches shall be provided for maintaining the fixtures wherever applicable.

12. 20A, 240V AC industrial type receptacles shall be provided in the following areas :

- Two in each switchgear / MCC room, Pump house and on stacker-reclaimer.

- One on each floor of TPs and crusher house building

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- At 30m interval on both sides of the conveyor gallery and track hopper shed. At 50m interval on one side of yard conveyor

- These receptacles shall be energized from lighting panel. Maximum three receptacles shall be connected in one circuit.

10A, 24V AC receptacles with IP55 DOP shall be provided in the following areas.

- One in each switchgear / MCC room, Pump house and on stacker-reclaimer.

- One on each floor of TPs and crusher house building

- It shall not be possible to insert 24V plug into 240V receptacle

- These receptacles shall be energized from lighting panel. Maximum three receptacles shall be connected in one circuit.

13. All fluorescent fixtures shall have energy efficient ‘T5’ type fluorescent lamps except those in div 2 hazardous area. The louvers of these fixtures shall be designed for ‘T5’ type fluorescent lamps. All fluorescent lamps shall have ‘cool day light colour designation. The mirror optics type fluorescent fixtures shall have no iridescence effect.

2.03.00 Ballasts

2.03.01 All HPSV and HPMV lamp fixtures shall be provided with wire-wound ballasts. All fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings (Div-II/Hazardous Area) shall be provided with electronic ballasts.

2.04.00 All luminaires and their accessories and components shall be of type readily replaceable by available Indian makes.

2.05.00 Fans & Regulator

2.05.01 Ceiling Fans, to be provided in non air-conditioned office / control room area shall be suitable for operation on 240 V, 50 Hz, AC supply comprising of class ‘F’ insulated copper wound single phase motor, 1200mm sweep, aerodynamically designed well balanced MS blades (3 Nos.), down rod, die cast aluminium housing, capacitor, suspension hook, canopies etc. finished in stove enameled white. Power factor of fans shall not be less than 0.9. Each fan shall cover approximately 10sq.m. area.

2.06.00 Switch Box

2.06.01 Switch boxes shall be made of 1.6 mm thick, MS sheet with 3 mm. thick decorative, perspex cover. Switchbox shall be hot dip galvanised

2.07.00 Junction boxes

Junction box for lighting fixtures shall be deep drawn or fabricated type made of min. 1.6 mm thick CRCA Sheet. The box shall be hot dip galvanised .

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2.08.00 Conduits, Fittings & Accessories

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.

2.08.01 Rigid Steel Conduits

(a.) 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.

2.08.02 Flexible Steel Conduits

2.08.03 Flexible conduit shall be water proof and rust proof made of heat resistant lead coated steel.

2.08.04 Pull-out Boxes

2.09.00 Pull out boxes shall be provided at approximately 4 (four) metre 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 shall be weather proof type suitable for IP :55 degree of protection. Pull out box & its cover shall be hot dip galvanised.

2.10.00 Lighting Wires

2.10.01 Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed, stranded copper/aluminium wire for fixed wiring installation. colour of the 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. The size of the lighting wires/ cables shall be selected such that the total voltage drop from the LDB to the lighting fixture / receptacle does not exceed 3%.

2.11.00 Lighting Poles

2.11.01 The poles wherever required shall be of ERW tubes of specified lengths, stepped tubular or swaged tubular and joined together. Lighting poles shall be painted with two coats of red Oxide and Zinc chromate in Synthetic compound primer on the exposed outside surface and with Bituminous paint all along the inside of the pole and outside portion which shall be embedded in foundation at manufacturing stage.

2.12.00 Lighting Masts

2.12.01 Each lighting mast shall be provided with minimum 12 nos. of 2x400W HPSV fixtures. Lighting Masts shall be of continuously tapered polygonal cross section hot dip galvanised presenting a pleasing appearance. The Mast shall be of 30M height with lantern carriage to enable raising / lowering for ease of maintenance, including

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the Head Frame, Double Drum Winch, continuous stainless steel wire rope, in built power tool, luminaries, suitable aviation warning light, lightning along with necessary power cables within the mast. The mast shall be delivered only in 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.

2.13.00 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.

2.14.00 Wiring shall run throughout in separate conduits. Wires of different phases shall run in different conduits. Wiring for lighting circuits and receptacle circuits shall be carried out in separate conduits and from separate feeders.

2.15.00 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.

3.00.00 TESTS

3.01.01 All lighting fixtures, lamps and other items shall be subjected to acceptance and routine test, as per relevant specified standards.

3.01.02 Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to physical and dimensional checks.

3.02.00 Galvanizing Tests

3.02.01 The quality of galvanizing shall be smooth, continuous, free from flux stains and shall be inspected visually.

3.03.00 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.

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4.00.00 COMMISSIONING CHECKS

1. On completion of installation work, the Contractor 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 Contractor.

3. The installation shall be then tested and commissioned in presence of the Project manager.

4. The contractor 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 Contractor without any extra cost. The handing over the lighting installation shall be effected only after the receipt of written instruction from the Employer/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.

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.

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ANNEXURE-A

Sl No. Location Average Illumination Level(Lux)

Type of Fixture

(a) Switchgear rooms

200 Industrial trough type fluorescent

(b) Control room, computer room, control equipment room

300 Mirror optics with anti-glare features

(c) Offices, conference rooms,etc.

300 Decorative mirror optics type

(d) Battery rooms

100 Totally enclosed corrosion proof

(e) Transformer yard

10(general) 50(on equipment)

HPSV flood light

(f) Diesel generating room, Compressor room, pump house etc.

150 HPSV medium bay/Industrial trough type fluorescent

(g) Fuel oil pump house

150 Flame proof fluorescent fixtures suitable for division-2 hazardous area

(h) Cable galleries 50 Industrial trough type fluorescent

(i) Street lighting-

primary roads -

secondary roads

20

10

HPSV street lights

Degree of Protection IP54

(j) Outdoor storage handlingand unloading area

20 HPSV flood light

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(k) DM plant,water treatment plant

150 Industrial trough type/corrosion proof fluorescent

(l) Chemical stores 150 Corrosion proof fluorescent

(m) Permanent stores 150 Industrial trough type/HPSV

(n) Workshop.general work bench

150 Industrial trough type fluorescent

(o) Laboratory

General

Analysis area

150

300

Mirror optics fluorescent

Corrosion resistant, fluorescent

(p) Garage/Car Parking 50 Industrial trough type fluorescent

(q) Switchyard and all outdoor areas

20(general

50(on strategic equipment)

HPSV flood light

(r) Stone picking area 300 HPSV dust tight well glass fixture (flood light type)

(s) Transfer points, crusher house, track hopper, track hopper shed, tunnels, bunker house.

100 HPSV dust tight medium bay or well glass fixture.

(t) Conveyor galleries 70 HPSV dust tight well glass fixture.

(u) Stair cases 100 Min. one fixture at every landing.

NOTE:- Any additional fixtures required to take care of the dark patches / shadows shall also be provided.

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M.S. ANGLE 50X50X6

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3 5 X 3 5 X 6 MS ANGLE. ALL STEEL FABRICATION SHALL BE

P A I N E D WITH COATS OF METAL PRIMER FOLLOWED BY THE TWO E A T S OF AL. PAINT.

L2O.DWG I.. -u.

CLAUSE NO.





PART-B

SUB-SECTION-IIIB-08 CABLING EARTHING

& LIGHTNING PROTECTON

PAGE 1 OF 22

CABLING, EARTHING & LIGHTNING PROTECTION


1.01.00 All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standards, etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards/ codes as applicable.

IS:513 Cold rolled low carbon steel sheets and strips.

IS:802 Code of practice for the use of Structural Steel in Overhead

Transmission Line Towers.

IS:1079 Hot Rolled carbon steel sheet & strips

IS:1239 Mild steel tubes, tubular and other wrought steel fittings

IS:1255 Code of practice for installation and maintenance of power cables

upto and including 33 KV rating

IS:1367 Part-

13

Technical supply conditions for threaded Steel fasteners. (Hot dip

galvanized coatings on threaded fasteners).

IS:13947 Degree of protection provided by enclosures for low voltage

switchgear and control gear

IS:2309 Code of Practice for the protection of building and allied structures

against lightning.

IS:2629 Recommended practice for hot dip galvanising of iron & steel

IS:2633 Method for testing uniformity of coating on zinc coated articles.

IS:3043 Code of practice for Earthing

IS:3063 Fasteners single coil rectangular section spring washers.

CLAUSE NO.





PART-B



PAGE 2 OF 22

IS:6745 Methods for determination of mass of zinc coating on zinc coated

iron & steel articles.

IS:8308 Compression type tubular inline connectors for aluminium

conductors of insulated cables

IS:8309 Compression type tubular terminal ends for aluminium conductors

of insulated cables.

IS:9537 Conduits for electrical installation.

IS:9595 Metal – arc welding of carbon and carbon manganese steels -

recommendations.

IS:13573 Joints and terminations for polymeric cables for working voltages

from 6.6kv upto and including 33kv performance requirements and

type tests.

BS:476 Fire tests on building materials and structures

IEEE:80 IEEE guide for safety in AC substation grounding

IEEE:142 Grounding of Industrial & commercial power systems

DIN 46267

(Part-II)

Non tension proof compression joints for Aluminium conductors.

DIN 46329 Cable lugs for compression connections, ring type ,for Aluminium

conductors

VDE 0278 Tests on cable terminations and straight through joints

BS:6121 Specification for mechanical Cable glands for elastomers and

plastic insulated cables.

Indian Electricity Act.

Indian Electricity Rules.

CLAUSE NO.





PART-B



PAGE 3 OF 22

1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, DIN, USA, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison.

2.00.00 DESIGN AND CONSTRUCTIONAL FEATURE 2.01.00 Transformer yard and Switchyard

In transformer yard and switchyard area, cables shall be laid in RCC concrete trenches with RCC covers. Inter-pole cabling in switchyard shall be in GI conduits/shallow trenches. Minimum clear height of trestle shall be 3mtr and for Rail/road crossing it shall be as per rail/road crossing norms.

2.01.01 False floors are not to be provided for cabling purpose. 2.01.02 Cable entry

Cable entry from outdoor underground/cable routes to the buildings, if any, shall be above the finished floor level of the building to avoid water entry in to the room through the trenches.

2.01.03 Trenches

PCC flooring of built up trenches shall be sloped for effective drainage with sump pits and sump pumps.

2.01.04 Interplant cabling for main routes shall be laid along overhead trestles/duct banks. However, from tap-offs, same can be through shallow trenches with approval of Employer. In case of Duct banks, pull-pits shall be filled with sand and provided with a PCC covering. Directly buried cables, if essential, shall not have concentration of more than 4 cables in one route. For overhead trestles, the bottom of the steel supporting structure shall be generally at 3.0M above the grade level except for rail/road crossings where it shall be at 8.0M above grade level.

All overhead cable routes shall be along the route of the conveyor gallery on separate supporting structures and cables shall be laid in vertical trays. The bottom of the steel shall be such that the existing facilities, movement of trucks / human beings etc. does not get affected. The cable trestle shall have a minimum 600mm clear walk way and shall have maintenance platforms as required.

Cables shall not be routed through the conveyor galleries except for the equipment located in the conveyor galleries for a particular conveyor i.e. protection switches, etc.

Cables for PCS and BSS shall be routed along the conveyors through GI conduits.

2.-01.05 Cable trenches shall be provided only in Switchgear/MCC rooms.

CLAUSE NO.





PART-B



PAGE 4 OF 22

3.00.00 EQUIPMENT DESCRIPTION

3.01.00 Cable trays, Fittings & Accessories

3.01.00 Cable trays shall be ladder type for power cables & perforated type for control cables complete with matching fittings (like brackets, elbows, bends, reducers, tees, crosses, etc.) accessories (like side coupler plates, etc. and hardware (like bolts, nuts, washers, G.I. strap, hook etc.) as required.

3.01.01 Cable trays, fittings and accessories shall be fabricated out of rolled mild steel sheets free from flaws such as laminations, rolling marks, pitting etc. These (including hardware) shall be hot dip galvanized as per relevant IS. Cable trays shall be ladder type for power/control cables and shall be perforated type for instrumentation cables.

3.01.02 Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard lengths of 2.5 metre. Minimum thickness of mild steel sheets used for fabrication of cable trays and fittings shall be 2 mm. The thickness of side coupler plates shall be minimum 3 mm. Typical details of cable trays, fittings and accessories are shown in the enclosed drawings

3.01.03 Cable troughs shall be required for branching out few cables from main cable route. These shall be U-shaped, fabricated of mild steel sheets of minimum thickness 2 mm and shall be hot dip galvanised as per relevant IS. Troughs shall be standard width of 50 mm & 75 mm with depth of 25 mm

3.02.00 SUPPORT SYSTEM FOR CABLE TRAYS

3.02.00 Cable tray support system shall be pre-fabricated similar or equivalent to "Unistrut make”.

3.02.01 Support system for cable trays shall essentially comprise of the two components i.e. main support channel and cantilever arms. The main support channel shall be of two types: (i) C1:- having provision of supporting cable trays on one side and (ii) C2:-having provision of supporting cable trays on both sides. The support system shall be the type described hereunder

a.

Cable supporting steel work for cable racks/cables shall comprise of various channel sections, cantilever arms, various brackets, clamps, floor plates, all hardware such as lock washers, hexagon nuts, hexagon head bolt, support hooks, stud nuts, hexagon head screw, channel nut, channel nut with springs, fixing studs, etc.

b. The system shall be designed such that it allows easy assembly at site by using bolting. All cable supporting steel work, hardware fittings and accessories shall be prefabricated factory galvanised.

c. The main support and cantilever arms shall be fixed at site using necessary brackets, clamps, fittings, bolts, nuts and other hardware etc. to form various arrangements required to support the cable trays. Welding

CLAUSE NO.





PART-B



PAGE 5 OF 22

of the components shall not be allowed. However, welding of the bracket (to which the main support channel is bolted) to the overhead beams, structural steel, insert plates or reinforcement bars will be permitted. Any cutting or welding of the galvanised surface shall be brushed and red lead primer, oil primer & aluminium paint shall be applied.

d. All steel components, accessories, fittings and hardware shall be hot dip galvanised after completing welding, cutting, drilling and other machining operation.

e. The typical arrangement of flexible support system is shown in the enclosed drawings and described briefly below:

The main support channel and cantilever arms shall be fabricated out of minimum 2.5 thick rolled steel sheet conforming to IS.

f. Cantilever arms of 300 mm, 600 mm and 750 mm in length are required, and shall be as shown in the enclosed drawing. The arm portion shall be suitable for assembling the complete arm assembly on to component constructed of standard channel section. The back plate shall allow sufficient clearance for fixing bolt to be tightened with tray in position.

3.02.02 The size of structural steel members or thickness of sheet steel of main support channel and cantilever arms and other accessories as indicated above or in the enclosed drawings are indicative only. Main support channels may be supplied in any suitable lengths to minimise the wastage. Nevertheless, the support system shall be designed by the bidder to fully meet the requirements of type tests as specified. In case the system fails in the tests, the components design modification shall be done by the Bidder without any additional cost to the Employer.

3.03.00 Pipes, Fittings & Accessories

3.03.00 Pipes offered shall be complete with fittings and accessories (like tees, elbows, bends, check nuts, bushings, reducers, enlargers, coupling caps, nipples etc.) The size of the pipe shall be selected on the basis of maximum 40% fill criteria

3.03.01 GI Pipes shall be of medium duty as per IS:1239

3.04.00 Junction Boxes

(a) Junction Boxes shall be made of Fire retardant material. Material of JB shall be thermoplastic or thermosetting or FRP type. The box shall be provided with the terminal blocks, mounting bracket and screws etc. the cable entry shall be through galvanized steel conduits of 20 mm diameter. The JB shall have suitable for installing glands of suitable size on the bottom of the box. The JB shall be suitable for surface mounting on ceiling/structures. The JB shall be of grey in color RAL 7035. All the metal parts shall be corrosion protected. Junction boxes surface should be such that it is free from crazing, blistering, wrinkling, color blots/striations. There should not be any mending or repair of surface. JB’s will be provided with captive screws so that screws don’t fall off when cover is opened. JB’s mounting bracket should be of powder coated MS.

CLAUSE NO.





PART-B



PAGE 6 OF 22

3.04.00 Terminal blocks shall be 650 volts grade, 10 Amps rated, made up of unbreakable polyamide 6.6 grade, complete with insulating barriers. Clip on type terminals, washer, nuts and identification strips. Marking on terminal strips shall correspond to the terminal numbering in wiring diagrams. All metal parts shall be non ferrous. WAGO terminal of cage clamp with lugs shall also be acceptable. All terminal blocks shall be suitable for terminating on each side two (2) nos. stranded copper conductors of size up to 2.56 sq mm each.

3.05.00 Terminations & Straight Through Joints

3.05.00 Termination and jointing kits for 6.6 kV grade XLPE insulated cables shall be of proven design and make which have already been extensively used and type tested. Termination kits and jointing kits shall be pre-moulded type, taped type or heat shrinkable type. 6.6 kV grade joints and terminations shall be type tested as per IS-13573. Critical components used in cable accessories shall be of tested and proven quality as per relevant product specification/ESI specification. Kit contents shall be supplied from the same source as were used for type testing. The kit shall be complete with the aluminium solder less crimping type cable lugs & ferrule as per DIN standard.

3.05.01 Straight through joint and termination shall be capable of withstanding the fault level of 40 kA for 0.12 sec with a dynamic peak of 100 kA for 6.6 kV system. Straight through joints shall have provisions for shield connection and earthing wherever required and complete with all accessories and consumables suitable for storage without deterioration at a temperature of 50 deg. C with shelf life of more than five years. 1.1 kV grade straight through joints shall also be of proven design.

3.05.02 1.1 KV grade STJ shall be of proven design.

3.05.04 Motor terminal boxes should of sufficient size to accommodate the selected cables. In case the cable sizes can not be accommodated, power Junction boxes shall be provided with cable interconnection between Junction boxes and motor terminal box.

3.06.00 Cable glands

3.06.00 Cable shall be terminated using double compression type cable glands. Cable glands shall conform to BS:6121 and be of robust construction capable of clamping cable and cable armour firmly without injury to insulation. Cable glands shall be made of heavy duty brass machine finished and nickel chrome plated. Thickness of plating shall not be less than 10 micron. All washers and hardware shall also be made of brass with nickel chrome plating Rubber components shall be of neoprene and of tested quality.

3.06.01 Cable lugs/ferrules

3.06.02 Cable lugs for power cables shall be tinned copper solder less crimping type conforming to IS: 8309 suitable for aluminium compacted conductor cables. Cable lugs and ferrules for control cables shall be tinned copper conforming to IS:8309 . The cable lugs for control cables shall be provided with insulating sleeve and shall suit the type of terminals provided on the equipments.

CLAUSE NO.





PART-B



PAGE 7 OF 22

3.07.00 Trefoil clamps

3.07.00 Trefoil clamps for single core cables shall be pressure die cast aluminum or fiber glass or nylon and shall include necessary fixing accessories like G.I. nuts, bolts, washers, etc. Trefoil clamps shall have adequate mechanical strength to withstand the forces generated by the system short circuit current of 105 KA peak.

3.08.00 Cable Clamps & Straps

3.08.00 The cable clamps required to clamp multicore cables on vertical run shall be made up of Aluminium strip of 25x3 mm size. For clamping the multicore cables, self-locking, de-interlocking type nylon clamps/straps shall be used. The clamps/straps shall have sufficient strength and shall not get affected by direct exposure to sun rays and outdoor environment

3.09.00 Receptacles

3.09.00 Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot dipped gavanised or of die-cast aluminium alloy of thickness not less than 2.5 mm. The boxes shall be provided with two nos. earthing terminals, gasket to achieve IP55 degree of protection, terminal blocks for loop-in loop-out for cable of specified sizes, mounting brackets suitable for surface mounting on wall/column/structure, gland plate etc. The ON-OFF switch shall be rotary type heavy duty double break, AC23 category, suitable for AC supply. Plug and Socket shall be shrouded Die-cast Aluminium. Socket shall be provided with lid safety cover. Robust mechanical interlock shall be provided such that the switch can be put ON only when the plug is fully engaged and plug can be withdrawn only when the switch is in OFF position. Also cover can be opened only when the switch is in OFF position. Wiring shall be carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of adequate size. The Terminal blocks shall be of 750 V grade

3.10.02 For Coal Handling Plant 415V TPN 63A welding sockets with switch having degree of protection of IP-55 shall be provided in the following areas.

1) 1 Number on each floor of TPs and 2 nos. on each floor of the crusher house building.

2) At 50m interval (starting from one end) on both sides of the conveyor galleries. At 50m interval on one side of the yard conveyor.

3) 1 no. in each Switchgear / MCC rooms and Pump house and in stacker / reclaimer machines.

4) Maximum three (3) nos. of receptacles can be connected to one circuit. These receptacles shall be energised through welding distribution board.

CLAUSE NO.





PART-B



PAGE 8 OF 22

3.10.00 Galvanising

3.10.00 Galvanising of steel components and accessories shall conform to IS:2629, IS:2633 & IS 4759. Additionally galvanising shall be uniform, clean smooth, continuous and free from acid spots

3.10.01 The amount of zinc deposit over threaded portion of bolts, nuts, screws and washers shall be as per IS:1367. The removal of extra zinc on threaded portion of components shall be carefully done to ensure that the threads shall have the required zinc coating on them as specified. However nuts and bolts of size lesser than M12 can be electro galvanised / electro plated.

3.11.00 Welding

3.11.00 The welding shall be carried out in accordance with IS: 9595. All welding procedures and welders qualification shall also be followed strictly in line with IS:9595

3.12.00 EXPANSION FASTNER

3.12.00 Expansion Fastener shall be 'HILTI' make HSA-KA type or equivalent. Expansion fastener shall only be used wherever insert plates are not available for supporting the cable structure.

4.00.00 INSTALLATION

4.01.00 Cable tray and Support System Installation

4.01.00 Cables shall run in cable trays mounted horizontally or vertically on cable tray support system which in turn shall be supported from floor, ceiling, overhead structures, trestles, pipe racks, trenches or other building structures. All cable trays shall be in vertical configuration in boiler, CHP & ESP areas.

4.01.01 Horizontally running cable trays shall be clamped by bolting to cantilever arms at an interval of 2000 mm. Vertically running cable trays shall be bolted to main support channel by suitable bracket/clamps on both top and bottom side rails at an interval of 2000 mm. For vertical cable risers/shafts cable trays shall be supported at an interval of 1000mm. Fixing of cable trays to cantilever arms or main support channel by welding shall not be accepted. Cable tray installation shall generally be carried out as per the enclosed drawings.

4.01.02 The cantilever arms shall be positioned on the main support channel with a minimum vertical spacing of 300 mm unless otherwise indicated in the relevant tray layout drawings

4.01.03 All cable way sections shall have identification, designations as per cable way layout drawings and painted/stenciled at each end of cable way and where there is a branch connection to another cable way. Minimum height of letter shall be not less than 75 mm. For long lengths of trays, the identification shall be painted at every 10 meter. Risers shall additionally be painted/ stenciled with identification numbers at every floor.

CLAUSE NO.





PART-B



PAGE 9 OF 22

4.01.04 In certain cases it may be necessary to site fabricate portions of trays, supports and other non standard bends where the normal prefabricated trays, supports and accessories may not be suitable. In such cases the Contractor shall fabricate at site suitable sections of trays, supports and accessories to make the installation complete for the specific purpose after obtaining Project Manager's prior approval, which shall be neat in appearance and shall match with the prefabricated sections in the dimensions. They shall be applied with one coat of red lead primer, one coat of oil primer followed by two finishing coats of aluminium paint.

4.02.00 Conduits/Pipes/Ducts Installation

4.02.00 The Contractor shall be fully responsible for properly embedding conduit pipe sleeves wherever necessary for cabling work. All openings in the floor/roof/wall / cable tunnel/cable trenches made for conduit installation shall be sealed and made water proof by the Contractor.

4.02.01 GI pull wire of adequate size shall be laid in all conduits before installation. Metallic conduit runs at termination shall have two lock nuts wherever required for junction boxes etc.

4.02.02 Conduit runs/sleeves shall be provided with PVC bushings having round edge at each end. All conduits/pipes shall have their ends closed by caps until cables are pulled. After cables are pulled, the ends of conduits/pipes shall be sealed with Glass wool/Cement Mortar/Putty to prevent entrance of moisture and foreign material

4.02.03 Exposed conduit/pipe shall be adequately supported by racks, clamps, straps or by other approved means. Conduits /pipe support shall be installed square and true to line and grade with an average spacing between the supports as given below,

Conduit /pipe size (dia). Spacing

Upto 40 mm 1 M

50 mm 2.0 M

65-85 mm 2.5 M

100 mm 3.0 M

4.02.04 For bending of conduits, bending machine shall be arranged at site by the contractor to facilitate cold bending. The bends formed shall be smooth.

4.03.00 Junction Boxes Installation

4.03.00 Junction boxes shall be mounted at a height of 1200mm above floor level or as specified in the drawings or as decided by Project Manager and shall be adequately supported/mounted on masonry wall by means of anchor fasteners/ expandable bolts

CLAUSE NO.





PART-B



PAGE 10 OF 22

or shall be mounted on an angle, plate or other structural supports fixed to floor, wall, ceiling or equipment

4.03.01 Cable Installation (for cables upto & including 6.6kV grade)

4.03.02 Cable installation shall be carried out as per IS:1255 and other applicable standards. Cable drums shall be unloaded, handled and stored in an approved manner on hard and well drained surface so that they may not sink. In no case shall be drum be stored flat i.e. with flange horizontal. Rolling of drums shall be avoided as far as possible. For short distances, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In absence of any indication, the drums may be rolled in the same direction as it was rolled during taking up the cables. For unreeling the cable, the drum shall be mounted on suitable jacks or on cable wheels and shall be rolled slowly so that cable comes out over the drum and not from below. All possible care shall be taken during unreeling and laying to avoid damage due to twist, kink or sharp bends. Cable ends shall be provided with sealed plastic caps to prevent damage and ingress of moisture.

4.03.03 While laying cable, ground rollers shall be used at every 2 mtr interval to avoid cable touching ground. The cables shall be pushed over the rollers by a gang of people positioned in between the rollers. Cables shall not be pulled from the end without having intermediate pushing arrangements. Pulling tension shall not exceed the values recommended by cable manufacturer. Selection of cable drums for each run shall be so planned so as to avoid using straight through joints. Care should be taken while laying the cables so as to avoid damage to cables. If any particular cable is damaged, the same shall be repaired or changed to the satisfaction of Project Manager.

4.03.04 Cables shall be laid on cable trays strictly in line with cable schedule furnished. Where specific cable layouts are not shown on drawings, Contractor shall route these as directed by the Project Manager

4.03.05 Power and control cables shall be laid on separate tiers. The laying of different voltage grade cables shall be on different tiers according to the voltage grade of the cables. In horizontal tray stacks, H.T. cables shall be laid on topmost tier and cables of subsequent lower voltage grades on lower tiers of trays. Single core cable in trefoil formation shall be laid with a distance of four times the diameter of cable between trefoil center lines and clamped at every 2mtr. All multicore cables shall be laid in touching formation. Power and control cables shall be secured fixed to trays/support with self locking type nylon cable straps with de-interlocking facilities. For horizontal trays arrangements, multicore power cables and control cables shall be secured at every five meter interval. For vertical tray arrangement, individual multicore power cables and control cables shall be secured at every one meter by nylon cable strap. After completion of cable laying work in the particular vertical tray, all the control cables shall be binded to trays/supports by aluminium strips at every five meter interval and at every bend.

4.03.06 Bending radii for cables shall be as per manufacturer’s recommendations and IS:1255.

4.03.07 Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/PVC pipe.

CLAUSE NO.





PART-B



PAGE 11 OF 22

4.03.08 In each cable run some extra length shall be kept at suitable point to enable one LT/two HT straight through joints to made, should the cable develop fault at a later stage. Control cable termination inside equipment enclosure shall have sufficient lengths so that shifting of termination in terminal blocks can be done without requiring any splicing.

4.03.09 Wherever few cables are branching out from main trunk route troughs shall be used.

4.03.10 The installation work shall be carried out in a neat workman like manner & areas of work shall be cleaned of all scraps, water, etc. after the completion of work in each area every day. Contractor shall replace RCC/Steel trench covers after the Installation work in that particular area is completed or when further work is not likely to be taken up for some time.

4.03.11 Separation

In vertically stacked trays, at least 300mm clearance shall be provided between : - HT power & LT power cables,

- LT power & LT control cables

4.03.12 Segregation

1) Segregation means physical isolation to prevent fire jumping. 2) All the cables of one stream shall be segregated from the cables of the other

stream and shall run on either side of the trestle.

4.03.13 All field switches for equipments corresponding to a stream located within a radius of 4-5 mtr. shall be wired out to a field junction box and from field junction box to control panel/Input – Output cabinet by screened instrumentation cables.

4.03.14 Directly Buried Cables

a) Cable trenches shall be constructed for directly buried cables. Construction of cable trench for cables shall include excavation, preparation of sieved sand bedding, riddled soil cover, supply and installation of brick or concrete protective covers, back filling and compacting, supply and installation of route markers and joint markers. Laying of cables and providing protective covering shall be as per IS:1255 and the enclosed drawings showing cabling details.

b) RCC cable route and RCC joint markers shall be provided wherever required. The voltage grade of the higher voltage cables in route shall be engraved on the marker. Location of underground cable joints shall be indicated with cable marker with an additional inscription “Cable Joint”. The marker shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at every change in direction. They shall be located on both sides of road crossings and drain crossings. Top of cable marker/joint marker shall be sloped to avoid accumulation of water/dust on marker.

4.03.15 Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit entry, and at every 20 meters in cable tray/trench runs. Cable tags shall also be

CLAUSE NO.





PART-B



PAGE 12 OF 22

provided inside the switchgear, motor control centers, control and relay panels etc. where a number of cables enter together through a gland plate. Cable tag shall be of rectangular shape for power cables and control cables. Cable tag shall be of 2 mm thick aluminum with number punched on it and securely attached to the cable by not less than two turns of 20 SWG GI wire conforming to IS:280. Alternatively, the Contractor may also provide cable tags made of nylon, cable marking ties of ‘TY-CAB’ or equivalent type with cable number heat stamped on the cable tags

4.03.16 While crossing the floors, unarmoured cables shall be protected in conduits upto a height of 500 mm from floor level if not laid in tray.

4.04.00 Cable Terminations & Connections

4.04.00 The termination and connection of cables shall be done strictly in accordance with cable termination kit manufacturer’’ instructions, drawings and/or as directed by Project Manager. Cable jointer shall be qualified to carryout satisfactory cable jointing/termination. Contractor shall furnish for review documentary evidence/experience reports of the jointers to be deployed at site.

4.04.01 Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumbing, soldering, drilling, cutting, taping, preparation of cable end, crimping of lug, insulated sleeving over control cable lugs, heat shrinking (where applicable), connecting to cable terminal, shorting and grounding as required to complete the job to the satisfaction of the Project Manager.

4.04.02 The equipment will be generally provided with undrilled gland plates for cables/conduit entry. The Contractor shall be responsible for punching of gland plates, painting and touching up. Holes shall not be made by gas cutting. The holes shall be true in shape. All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively sealed by 2mm thick aluminium sheets.

4.04.03 Control cable cores entering control panel/switchgear/MCC/miscellaneous panels shall be neatly bunched, clamped and tied with self locking type nylon cable ties with de interlocking facility to keep them in position.

4.04.04 The panels where a larger number of cables are to be terminated and cable identification may be difficult, each core ferrule shall include the complete cable number as per the drawings. The ferrules shall be indelible interlocking type and shall fit tightly on cores. Spare cores shall have similarly ferrules with a suffix letter ‘S’ alongwith cable numbers and coiled up after end sealing.

4.04.05 All cable terminations shall be appropriately tightened to ensure secure and reliable connections.

4.04.06 It is the responsibility of the Contractor to terminate the cables at motor terminals in correct phase sequence to ensure the proper direction of rotation.

CLAUSE NO.





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PAGE 13 OF 22

5.00.00 EARTHING SYSTEM

5.01.00 Earthing system shall be in strict accordance with IS: 3043 and Indian Electricity

Rules/Acts.

All buildings / structures shall be interconnected together by min. two parallel conductors. Contractor shall furnish the detailed design calculations for the earthing system. Contractor shall obtain all necessary approvals for the system.

5.02.00 The earth conductors shall be free from pitting, laminations, rust, scale and other electrical, mechanical defects

5.03.00 The material of the earthing conductors shall be as follows :

1) Conductors above ground level and in built up trenches.

- Galvanized steel

2) Conductors buried in earth - Mild steel

3) Earth electrodes - Mild steel rod

5.04.00 The sizes of earthing conductors for various electrical equipments shall be as below:

Equipment Earth conductor

buried in earth

Earth conductor above ground

level & in built-up trenches

a) Main earth grid 40 mm dia.MS rod

65x8mm GS flat

b) 33KV/11KV switchgear/equipment 415V switchgear

--- 65x8mm GS flat

c) 6.6 kV switchgear / 415 V MCC/ Distribution boards / Transformers

--- 50x6mm GS flat

d) LT Motors above 125 KW --- 50 x 6mm GS flat

25 KW to 125 KW --- 25 x 6mm GS flat

CLAUSE NO.





PART-B



PAGE 14 OF 22

1KW to 25 KW --- 25 x 3mm GS

flat

Fractional House power motor

--- 8 SWG GS wire

e) Control panel & control desk --- 25 x 3 mm GS

flat

f) Push button station / Junction Box

--- 8 SWG GI wire

g) Columns, structures, cable trays and busduct enclosures

--- 50x6mm GS flat

h) Crane, rails, rail tracks & other non-current carrying metal parts

25x6mm GS flat

5.05.00 Metallic frame of all electrical equipment shall be earthed by two separate and distinct connections to earthing system, each of 100% capacity, Crane rails, tracks, metal pipes and conduits shall also be effectively earthed at two points. Steel RCC columns, metallic stairs, and rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing ensured by bonding the different sections of hand rails and metallic stairs. Metallic sheaths/screens, and armour of multi-core cables shall be earthed at both ends. Metallic Sheaths and armour of single core cables shall be earthed at switchgear end only unless otherwise instructed by the Employer. Every alternate post of the switchyard fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the earthed post. Railway tracks within the plant area shall be bonded across fish plates and connected to earthing grid at several locations. Portable tools, appliances and welding equipment shall be earthed by flexible insulated cable. One separate core in the trailing/flexible cables shall be used for earthing purposes of the moving machines. PLC equipment shall be earthed separately as per the recommendations of the PLC manufacturer.

5.06.00 Each continuous laid lengths of cable tray shall be earthed at minimum two places by G.S. flats to earthing system, the distance between earthing points shall not exceed 30mtr. Wherever earth mat is not available Contractor shall do the necessary connections by driving an earth electrode in the ground.

5.07.00 Neutral points of HT transformer shall be earthed through NG resistors. The Contractor shall connect the NGR earthing point to earth electrodes by suitable earth conductors.

5.08.00 Neutral connections and metallic conduits/pipes shall not be used for the equipment earthing. Lightning protection system down conductors shall not be connected to other earthing conductors above the ground level.

CLAUSE NO.





PART-B



PAGE 15 OF 22

5.09.00 Connections between earth leads and equipment shall normally be of bolted type. Contact surfaces shall be thoroughly cleaned before connections. Equipment bolted connections after being tested and checked shall be painted with anti corrosive paint/compound.

5.10.00 Suitable earth risers as approved by Project Manager shall be provided above finished floor/ground level, if the equipment is not available at the time of laying of main earth conductor.

5.11.00 Connections between equipment earthing leads and between main earthing conductors shall be of welded type. For rust protection the welds should be treated with red lead compound and afterwards thickly coated with bitumen compound. All welded connections shall be made by electric arc welding.

5.12.00 Resistance of the joint shall not be more than the resistance of the equivalent length of conductors.

5.13.00 Earthing conductors buried in ground shall be laid minimum 600 mm below grade level unless otherwise indicated in the drawing. Back filling material to be placed over buried conductors shall be free from stones and harmful mixtures. Back filling shall be placed in layers of 150 mm.

5.14.00 Earthing conductors embedded in the concrete floor of the building shall have approximately 50 mm concrete cover.

5.15.00 A minimum earth coverage of 300 mm shall be provided between earth conductor and the bottom of trench/foundation/underground pipes at crossings. Earthing conductor’s crossings the road can be installed in pipes. Wherever earthing conductor crosses or runs at less than 300 mm distance along metallic structures such as gas, water, steam pipe lines, steel reinforcement in concrete, it shall be bonded to the same.

5.16.00 Earthing conductors along their run on columns, walls, etc. shall be supported by suitable welding / cleating at interval of 1000mm and 750mm respectively.

5.17.00 Earth pit shall be constructed as per IS:3043. Electrodes shall be embedded below permanent moisture level. Minimum spacing between electrodes shall be 600mm. Earth pits shall be treated with salt and charcoal if average resistance of soil is more than 20 ohm metre.

5.18.00 On completion of installation continuity of earth conductors and efficiency of all bonds and joints shall be checked. Earth resistance at earth terminations shall be measured in presence of Employer’s representatives. All equipment required for testing shall be furnished by contractor.

5.19.00 Earthing conductor shall be buried at least 2000mm outside the fence of electrical installations. Every alternate post of the fences and all gates shall be connected to earthing grid by one lead.

6.00.00 LIGHTNING PROTECTION SYSTEM

6.01.00 Lightning protection system shall be in strict accordance with IS:2309

CLAUSE NO.





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6.01.01 Lightning conductor shall be of 25x6mm GS strip when used above ground level and shall be connected through test link with earth electrode/earthing system

6.01.02 Lightning system shall comprise of air terminations, down conductors, test links, earth electrode etc. as per approved drawings

6.02.00 Down Conductors

1. Down conductors shall be as short and straight as practicable and shall follow a direct path to earth electrode.

2. Each down conductor shall be provided with a test link at 1000 mm above ground level for testing but it shall be in accessible to interference. No connections other than the one direct to an earth electrode shall be made below a test point.

3. All joints in the down conductors shall be welded type.

4. Down conductors shall be cleated on outer side of building wall, at 750 mm interval or welded to outside building columns at 1000 mm interval.

5. Lightning conductor on roof shall not be directly cleated on surface of roof. Supporting blocks of PCC/insulating compound shall be used for conductor fixing at an interval of 1500 mm.

6. All metallic structures within a vicinity of two meters of the conductors shall be bonded to conductors of lightning protection system.

7. Lightning conductors shall not pass through or run inside GI Conduits.

8. Testing link shall be made of galvanized steel of size 25x 6mm.

7.00.00 QUALITY ASSURANCE PROGRAMME

7.01.00 Bidder shall furnish detailed Quality Assurance Program and Quality Plans for all materials and accessories to be supplied and installed under the scope of the specification as per General Technical Conditions of technical specification. The Quality Plans shall include all tests/ checks as per relevant National/International Standards and the requirements of this specification including tests listed in this section.

8.00.00 TESTS

GENERAL

(a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owner’s approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client.

CLAUSE NO.





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PAGE 17 OF 22




8.01.00 Type Test reports shall be furnished for the following

8.01.00 Type tests on Cable Trays support system

Test 1: On main support channel type-C2 for cantilever arms fixed on one side only.

a) Test 1A: A 3.5 metre length of main support channel shall be fixed vertically at each end to a rigid structure as per the fixing arrangement as shown in the enclosed drawing. Eight (8) nos. 750 mm cantilever arms shall be fixed to the main channel and each arm shall be loaded over the outboard 600 mm with a uniform working load of 100 kg. Subsequently a point load of 100 kg shall be applied on arm 2. A uniform proof load on all the arms equal to twice the working load shall be then be applied. Deflections shall be measured at the points shown in the enclosed drawings and at the following load intervals:

i) Working load

ii) Working load + point load

iii) Off load

iv) Proof load + point load

v) Off load

The deflection measured at working loads shall not exceed 16mm. The permanent deflection after removing the combination of working load and point load shall not exceed 10 mm at the arm tips and 6 mm on the channel. No collapse of the structure shall occur with a combination of

CLAUSE NO.





PART-B



PAGE 18 OF 22

proof load and point load applied.

b) Test 1B: Test 1A shall be repeated with Eight Cantilever arms uniformly loaded and with the same point load on arm 2.

Test 2: On Main support channel type -C2 for cantilever arms fixed on both sides

a)Test 2A: A 3.5 m length of main support channel C2 for cantilever arms fixing on both sides shall be fixed at each end to rigid structure as per the fixing arrangement as shown in the enclosed drawing. Six (6), 750 mm cantilever arms shall be attached to each sides and each arm uniformly loaded to a working load of 100 kg over the out board 600 mm. A point load of 100 kg shall than be applied to arm 2, followed by a uniform proof load of twice the working load on all the arms; deflection shall be measured at points shown in the enclosed drawings at the following load intervals.

i) Working load

ii) Working load + Point load

iii) Off load

iv) Proof load + Point load

v) Off load

The deflection measured at working loads shall not exceed 16mm. The permanent deflection after removing the combination of working load and point load shall not exceed 10 mm at the arm tips and 6 mm on the channel. No collapse of the structure shall occur with a combination of proof load and point load applied

b) Test 2 B: The test 2 A shall be repeated with the assembly but with an asymmetrical load on the C2 column and point load applied to arm 8. The 100 kg and 200 kg uniformly distributed loads shall be applied to the upper three arms on one side and the lower three arms on the opposite side.

Test 3: Tests on Channel Fixed on Beam/Floor

A length of main support channel section shall be fixed to steel structure/floor and have loads applied as shown in the drawing enclosed and as detailed below

CLAUSE NO.





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PAGE 19 OF 22

a) Test 3A :

A length of steel structure shall be rigidly supported. It should be fitted on a metre length of channel section using beam clamps welded/bolted. A point load of 1200 kg shall be applied to the centre point via two brackets. No distortion or pulling of the components shall take place.

b) Test 3B :

With the components assembled as in Test 3A, two perpendicular point loads of 600 kg shall be simultaneously applied at positions 150 mm either side of the centre line, no distortion or pulling of the components shall take place.

c) Test 3C :

With the components assembled as in Test 3A, a perpendicular point load shall be applied at a point 150 mm on one side of the centre line.

The load shall be gradually increased to the maximum value that can be applied without causing distortion or pulling of the components. This value shall be recorded.

Test 4 : Channel Insert Test

A 2.5 m length of C1 channel fixed to the concrete wall/ steel structure as per actual site installation conditions. 6 nos. of 750 mm cantilever arms shall be attached to C1 channel as shown in enclosed drawing. Each arm uniformly loaded to a working load of 100 kg over the out board 600 mm. A point load of 100 kg shall than be applied to arm 2, followed by a uniform proof load of twice the working load on all the arms; deflection shall be measured at points shown in the enclosed drawings at the following load intervals.

i) Working load

ii) Working load + Point load

iii) Off load

iv) Proof load + Point load

v) Off load

The deflection measured at working loads shall not exceed 16mm. The permanent deflection after removing the combination of working load and point load shall not exceed 10 mm at the arm tips and 6 mm on the channel. No collapse of the structure shall occur with a combination of proof load and point load applied

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PAGE 20 OF 22

Test 5: Channel nut slip characteristics (what ever applicable) Tests 5A1,5A2,5A3 :

A length of channel C1 section 200mm long shall have fitted bracket with the two bolts fixing as shown in drawing enclosed. With loads applied at the position shown in drawing enclosed nut slip shall be determined with bolt torque of 30NM, 50 NM and 65 NM No fewer than three measurements shall be made for each torque setting. A minimum loading of 720 kg shall be obtained before nut slip with bolt torque of 65 NM.

Tests 5B1,5B2,5B3:

The length of channel C1 section 200 mm long shall have fitted bracket with the one bolt fixing as shown in drawing enclosed. With loads applied at the position shown in drawing, nut slip shall be determined with bolt torques of 30 NM, 50 NM and 65 NM. No fewer than three measurements shall be made for each torque setting.

A minimum loading of 350 kg shall be obtained before nut slip with a bolt torque of 65 NM.

Test 6 Weld Integrity Test

After deflection test as per test 1A, 1B, 2, 3, 4 & 5, weld integrity shall be checked by magnetic particle inspection to detect sub-surface cracks developed, if any.

8.01.01 Cable termination kit and straight through joints should have been tested as per IS: 13573 for above 3.3 kV class and as per VDE 0278 for 3.3 kV class.

8.02.00 Routine/ Acceptance Tests

7.03.01 Routine Tests

a) Routine tests as per specification and applicable standards shall be carried out on all equipments/items covered in the specification.

b) Physical & dimensional check on all equipments as per approved drawings/standards.

c) HV/IR as applicable.

d) Check/measurement of thickness of paint/zinc coating/nickel-chrome plating as per specification & applicable standard.

e)

CLAUSE NO.





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PAGE 21 OF 22

7.03.02 Acceptance Test

a) Galvanising Tests as per applicable standards

b) Welding checks

c) Deflection tests on cable trays:

One piece each of 2.5m length of cable tray of 300mm & above shall be taken as sample from each offered lot. It shall be supported at both end & loaded with uniform load of 76 kg/meter along the length of cable tray. The maximum deflection at the mid-span of each size shall not exceed 7mm.

d) Proof load tests on cable tray support system

i) Tests on Main Support Channel shall be done if only C1 Channel are in scope of supply and cantilever arms shall be fitted on one side. This test shall be same as test 4 of type test.

ii) Test on Main Support Channel shall be done with C2 channel and cantilever arms fitted on both sides, if C2 channels are in scope of supply. This test shall be same as test 2A of type test. Then test (i) above shall not be done.

iii) Nut slip characteristic test (it shall support minimum load of 350kg before nut slips with a bolt torque of 65 NM). This test shall be same as test 5B3 of type test.

The procedure for carrying out tests at “d” above shall be as per details given in Type Tests in specification thereafter Die-Penetration test shall be carried out to check weld integrity.

e) The above acceptance tests shall be done only on one sample from each offered lot.

9.00.00 COMMISSIONING

9.01.00 The Contractor shall carry out the following commissioning tests and checks after installation at site. In addition the Contractor shall carry out all other checks and tests as recommended by the Manufacturers.

9.01.01 Cables

a) Check for physical damage

b) Check for insulation resistance before and after termination/jointing.

c) HT cables shall be pressure tested (test voltage as per IS:7098) before commissioning.

d) Check of continuity of all cores of the cables.

CLAUSE NO.





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PAGE 22 OF 22

e) Check for correctness of all connections as per relevant wiring diagrams. Any minor modification to the panel wiring like removing/inserting, shorting, change in terminal connections etc., shall be carried out by the Contractor at no extra cost.

f) Check for correct polarity and phasing of cable connections.

g) Check for proper earth connections for cable glands, cable boxes, cable armour, screens, etc.

h) Check for provision of correct cable tags, core ferrules, and tightness of connections.

9.02.00 Cable trays / supports and accessories

1) Check for proper galvanizing/painting and identification number of the cable trays/supports and accessories.

2) Check for continuity of cable trays over the entire route.

3) Check that all sharp corners, burrs, and waste materials have been removed from the trays supports.

4) Check for earth continuity and earth connection of cable trays.

9.03.00 Earthing and Lightning protection system

1) Earth continuity checks.

2) Earth resistance of the complete system as well as sub-system.

9.04.00 GENERAL COMMISSIONING CHECKS (Application to all electrical equipments)

(a.) Check for name plate details according to specification.

(b.) Check for physical damage, if any.

(c.) Check for tightness of all bolts, clamps & connecting terminals.

(d.) Check for earth connection.

(e.) Check for cleanliness of insulators & bushings.

(f.) Check for lubrication of all moving parts.

(g.) Check for provision of heater.

SECTION A-A

X - FOR 6Klrnrn. TRAY - 20-25 3M)rnrn. TRAY - 10-15

COUPLER PLATE

1. LUTERUL :- M.S. SHEE7 MIN. 2mm. mK.

R TENDER PURPOSE

TRAY3A-211-001.DWG

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NOTE. 1. AU DIMENSK)NS ARE IN mm.

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LADDER TRAY HORIZONTAL TEE A=(2R+W+4)

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TITLE CABLE TRAY DETAILS CROSS

TRAY2A-211-008

6

SIZE A4

SCALE NTS

DRG. NO. 0000-211-PIE-A-008

REV. NO.

RB

TWO LENGTHS OF C1 WELDED BACK TO BACK

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NOTES

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2. MATERIAL HOT DIPGALVANISED

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(X*) NTPC Limited ( A GOVERNMENT OF INDIA ENTERPRISE )

ENGINEERING DMSION

PROJECT STANDARD

TITLE CANTIIEVER ARMS

'IZE

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CAD FILE NAME : STAND-211-016 DWG

\ 0

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DRG. 0000-21 1 -POE-A-()16

REV. NO. RB

C2 CHANNEL C1 CHANNEL

ASSEMBLY- 1 ASSEMBLY-2

ASSEMBLY- 1 UPPER FIXING C2 CHANNEL

ASSEMBLY-2 UPPER FIXING C1 CHANNEL

UPPER FIXING FOR CHANNEL VERTICAL SUPPORTS

C2 CHANNEL

I ASSEMBLY 1 I I I I HEAVY DUTY FLOOR

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C1 CHANNEL

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NOTES - 1) MATERIAL : MILD STEEL.

2) FINISH : HOT DIP GALVANISED.

BRACKET-C2 CHANNEL CLAMP.

BRACKET-C1 CHANNEL CLAMP.

NOTES:

1) MATERIALS -MILD STEEL

2) FINISH-HOT DIP GALV.

1) 600mm TRAY-1 TO 6 TIER-C2

2 ) 3 0 0 m m TRAY-1 TO 3 TIER-C1



ANTILEVER ARM

ARRANGEMENT TYPE-B1

NOTES:

1) IN CASE OF HANGING SUPPORT C2 TO BE USED AS MAIN SUPPORT.

2) ALL DIMENSIONS ARE IN MM.

ANTILEVER ARM ON

BOTH SIDES

ARRANGEMENT TYPE -B2

7 INSERT PCATE

k . 1 CHANNEL

ARRANGEMENT TYPE-C1

NOTES:

1) U P TO 3 TIER C1 CHANNEL

2) ABOVE 3TIER & BOTH SIDE TRAY C2 CHANNEL

3) ALL DIMENSIONS ARE IN MM. ARRANGEMENT TYPE-Dl

BEAM OR RCC FLOOR

ANTILNER ARM

CC FLOOR L N E L

R TENDER PURPOSE

( A GOVERNMENT OF INDIA EWERPRISE ) ENGINEERING DIVISION

1) 600mm TRAY-1 TO 6 TIER-C2 CHANNEL



4) 1 5 0 m m TRAY-1 TO 6 TIER-C1 CHANNEL

MAIN SUPPORT CHANNEL-C1 /CZ

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2 ) ALL DIMENSIONS ARE IN MM. ARRANGEMENT TYPE-S3

DESCRIPTION

MAlN SUPPORT CHANNEL C1/C2

ANTILEVER ARM r4 ARRANGEMENT TYPE-S4

NOTE :

1. ALL DIMENSIONS ARE IN MM (SCALE NTs)

CONDUCTOR GRID OUTSIDE THE BLDG.

INSERT IN RETAINING WALL

EARTH RISER WELDED TO MAIN EARTH CONDUCTOR EMBEDDED

WELDED 7 IN CONCRETE. \ I RCC FLOOR SLAB

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NTPC ~irxiited ( A C O M R N M M OF INDIA ENTERPRISE )

ENGINEERING DMSION I PROJECT

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STANDARD

TITLE I EARTHING D E T W I

SIZE SCALE DRC. NO. REV. NO.

A 4 NTS 0000-211-POE-A-041 RB

CAD FILE N N E : STAND-Zil-C4I.W;

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1 CAO FILE NAUE : STAND-211-MZ.D'*G

GROUND CONDUCTOR ALONG BUILDING WALL

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GROUND CONDUCTOR I! 35x6 G I FLAT l1

q- $ z5 T STEEL COLUMN

5 (I l1 '

l1 OC-

11 -- SEC. 5-5

I' )-

If 1, v" -

GROUND CONDUCTOR ALONG STEEL COLUMN STRUCTURE

NOTES ALL D I M E N S I O N S A R E IN MM (SCALE-NTS)

1 C , 9

t'&/- K~ FA

REV. NO

- - . iwX) NTPC Limited

(AcowwMENTOFlNDNDRD(TOOPR1M) ENCWWlNC DNISK)F(

- PROJECT

STANDARD

TITLE EARTFIWG DETAlLS

CLEARED BY

-

C

TEPBEt fbKPt&

FDR TENDER PURPOSE ONLY

DESCRIPTION

P

SIZE

A4

- FC& m ~ c k 0 s . n

p 47

M ,

- - -

4

SCALE N TS

E

- 4

ORG. NO. 0000-211-POE-A-043

Ul,-

REV. '10.

R 8

r P P D m

&,4y

2

E L

r 2MM Al SHEET

.

BUSHINGS THRO CABLE

i I

i EARTHING DETAILS TRANSFORMER I

j i i

il 1. THE TRANSFORMER NEUTRAL FOR H.T. TRANSFORMER SHALL BE EARTHED THROUGH j FLATS AS SHOWN ABOVE. (SUPPLIED BY TRANSFORMER SUPPLIER) !

j

1 1

b 1

I i

TYP. MFLON. TUBINIC LIGHTNING PROTECTION DOWN-COMER

(TO BE SEALED AFT€ ALVANISED BOX 2MM THK SHEET STEEL INSTALLATION OF CONDUCTOR)

27x8 OPENING

FOR WALL/COL./

60 HOLES FOR FIXING COMR

F R O N T 0

EARTH TERMINAL LIGHTING PROTECTION DOWNCOMER TEST LINK WLDED TO BOX (TO BE

CONNECTED TO EARTHING NOTES: - GRID) 1. THE DOWN COMER ENTRY AND EXIT POINTS IN TO BOX BE MADE

WATER- TIGHT AFTER LAYING OF CONDUCTOR. SADDLE WTH

2. THE TEST LINK SHALL BE OF SAME WIDTH AND THICKNESS AS SPACER

THE DOWNCOMER.THE NUTS BOLTS AND WASHERS TO BE OF G.S SIDE VIEW 3. ALL DIMENSIONS ARE IN MM (SCALE-NTS)

I CAD FILE NAME : STANC-211-O47.DK

33

DESCRIPTION

. .

-

[m*] NTPC ~ i m i t e d ( A C O M R N Y E N ~ O F M D ~ A ~ E )

ENWNEERIW DWSKHJ

PROJECT STANDARD

TITLE ' LIGHTNING PROTCTION DETALIS.

SIZE

A4

SCALE N TS

DRG. NO. R&. NO- 0000-21 1 -FOE-A-047 R B

BLOCK SPACING IOOOMM CENTRE TO CENTRE

TYPICAL DETAILS OF CLEATING HORIZONTAL CONDUCTOR OVER WATER PROOFING

NOTE : ALL DIMENSIONS ARE IN MM

NTPC Lixxxited ( A GOVERNMN OF INDIA ENTERPRISE )

ENGINEERING DMSlON

PROJECT STANDARD

TITLE

SIZE SCALE DRC. NO. REV. NO.

A 4 N TS 0000-21 1-POE-A-048 R e CM) FILE NAME : STAND-211-O&.DHC

I

EARTH BACK FlLLED AND RAMMED

PRECAST CONCRETE C a M K i 50X250X4Mhi

\

SEE 'A'

DETAIL- 'A'

T

1''0

DETAIL

FOR + C (NTPC]

LIGHTING CABLE

j C C

- NOTES: 1. ALL DIMENSIONS ARE IN MM. 2 . ROUTE MARKERS SHALL BE CONSTRUCTED

OF CONCRETE WITH CAST IRON PLATE. WITH THE ROUTE INFORMATION ENGRAVED ON IT. BOLTED ON TOP OF THE CONCRETE BLOCK AS SHOWN.

3. CAST l2ON PLATE SHALL BE OF 6 . 0 MM THICKNESS

,,-6 DIA. HOLES 4 NOS. FIXING

CAST IRON / PU\TE

GESCRl?T!O?4 CLEARED BY

w f f m [NTPC] NTPC L i m i t e d ( A ooMWMENl O f INDU -RISE )

ENClNWlNC D W - .- -. i

I I STANDARD I I TITLE

BURIED CABLE TRENCH DETAILS FOR LIGHTING I R N . NO.

RB SIZE A4

21 1 -049.DWG

SCALE NTS

DRG. NO. 0000-2 1 1 -POE-A-049

I \

DIRECTLY BURIED CABLES DIRECTLY BURIED CABLES IN SINGLE LAYER IN 'TWO LAYER

@-CABLE ROUTE MARKER

@-EARTH BACK FILLED & RAMMED

PROTECTIVE COVERS

o) BRICKS FOR LOW VOLTAGE CABLES

b) RCC FOR HIGH VOLTAGE CABLES WlTH HOLE AT EACH END TO TIE THE TO EACH OTHER WlTH G.S WlRE

&---- ARMOURED POWR CABLE

@- ARMOURED CONTROL CABLE d - OVERALL DIAMETER OF THE BIGGER OF THE TWO CABLES

@- FINE SAND/RIDDLED SOIL COMPACTED x - SPACI~G SHALL BE TAKEN BOTH HORIZONTALLY AND VERTICALLY.

1. SINGLE CORE CABLES SHALL BE RUN IN TREFOIL FORMATION AND SHALL BE BOUND BY SELFLOCKING CABLE n E s A T EMRY 750 MM.

2. CABLE IDENTIFICATION TAG SHALL BE TlED AT BOTH ENDS OF THE CABLE AN0 ALSO AT AN INTERVAL OF 10 METRES.

3. IF THE MINIMUM CLEARENCE AS INDICATED THE ABOM TABLE FOR CABLES OF DIFFERENT CLASSES ARE NOT FEASIBLE,BRICK BARRIERS SHALL BE USED BETWEEN ADJACENT CABLES

4. G.I. PIPE SHALL BE PROVlDED FOR ROAD CROSSING AT A MINIMUM DEPTH

OF 600 FROM THE GRADE LEVEL UNLESS OTHER WSE SPECIFIED. 5. ALL DIMENSIONS ARE IN MM (SCALE NTS)

ENGINEERING DMSlON

DIMENSION l lDOV GRADE FOR 3.3 KV 22KV & 33KV MIN. CABLES TO l l K V

D 1 7 5 0 900 1050

d BETWEEN CABLES OF SAME CLASS

X300MM BETWEEN CABLES OF DEFT CLASS

S X400MM BETWEEN 1/C POWER CABLE AND

COMMUNICATION CABLE.

X300MM BETWEEN MULTlCORE POWER CABLE & COMMUNlCATlON CABLE.

1 CAD RLE NAME : STAND-XK)-W3.CW -

NTPC Limited , . ( A CoMRNMENT OF INDlA ENrmPRlSE )

ENGINEERING DMSION

PROJECT Srmm

TITLE TYPICAL DETAES OF F U C T U R E FOR TESTING

SIZE SCALE ORG' 0000-21 1-POE-A-03'7 REV. NO A4 N TS

1 CAD FILE NAUE : STAND-211-OJ7.DW;

WORKING UDL = 100 KG

y,":::",', PROOF UDL = 200 KG

AS INDICATED POINT LOAD = 100 KG

CANTILEVER ARMS

ADDITIONAL POINT LOAD OF 100 KG

INSTALLATION SECTION

(ASWMETRIC LOADING) OSITlON FOR APPLICATION F 600 K G POINT LOAD FOR TEST 3C

POINT LOAD OF 600 KG AT EACH POSITION FOR TEST 3 B

BEAM CLAMPS AS ACTUAL

TWO BRACKETS LENEHALLY FIXEL

POINT LOAD OF 1200 KG FOR TEST 3 A

TEST 3 A , 3B & 3C

1 FIXING SHALL BE AS PER ACTUAL SITE INSTALLATION CONDITION.

2. ALL DIMENSIONS ARE IN MM

CAO FILE NAME : STAND-211-OJ8.D%

& 3

Clause No. TECHNICAL REQUIREMENTS



TECHNICAL SPECIFICATIONS VOLUME-II, PART-B

SUB-SECTION-IIIB-09 TRANSFORMERS

Page 1of 7

TRANSFORMER 1.00.00 CODES AND STANDARDS 1.01.00 Transformers IEC:60076, IEC 60354, IEC:60726 Bushing CT’s IEC :60044-1 Insulating oil IEC: 60296 2.00.00 TYPE 2.01.00 Out-door Mineral oil filled ONAN type, Three phase unit Transformers 2.02.00 Dry type Epoxy cast resin/resin encapsulated air cooled Transformers type, three phase unit 3.00.00 FEATURES Paint shade RAL 5012 Degree of protection: Dry type transformer IP-23 Cable box, Marshalling box IP-55 4.00.00 TEMPERATURE RISE 4.01.00 Out-door Winding 55oC above ambient 50oC Transformers oil 50oc above ambient 50oC. 4.02.00 Dry type Winding (by resistance method): 90oC or lower Transformers as permissible for class of insulation offered,

above an ambient of 50oC. 5.00.00 OPERATIONAL REQUIRTEMENTS 5.01.00 Tap Changer Off-circuit, +/-5% in steps of 2.5% shall be provided. It shall be hand operated by

an external handle with position markings, pad locking facility in each position and mechanical stops to prevent over cranking beyond extreme positions in case of outdoor type transformers. In case of indoor transformers, it shall be with shrouded bolted links.






Page 2of 7

5.02.00 Loading Capability Continuous operation at rated KVA on any tap with voltage variation of +/-10%

corresponding to the voltage of the tap as well as in accordance with IEC 60354. 5.03.00 Flux Density Not to exceed 1.9 Wb/sq.m. at any tap position with +/-10% voltage variation from

voltage corresponding to the tap. Transformer shall also withstand following overfluxing conditions due to combined voltage and frequency fluctuations:

a) 110% for continuous rating. b) 125% for at least one minute. c) 140% for at least five seconds. 5.04.00 Noise Level :Not to exceed values specified in NEMA TR-1. 6.00.00 DESIGN AND CONSTRUCTIONAL FEATURES All transformers shall be suitable for cable or busduct termination as

contemplated. If cable connection is envisaged, a dust tight cable box shall be provided. Also, a sheet steel, vermin and dust proof marshalling box shall be furnished with each transformer to accommodate temperature indicators, terminal blocks for control cables etc. The transformer shall be provided with all fittings and accessories to be complete in all respects for satisfactory operation.

6.01.00 OUTDOOR TRANSFORMERS 6.01.01 a) Tank Shall be fabricated from tested quality steel and designed to withstand

continuous internal pressure & vacuum as per CBIP guidelines. All steel surfaces in contact with insulating oil shall be painted with two coats of heat resistant oil insoluble insulating paint. Tank shields, if provided, shall not resonate at natural frequency of equipment.

b) Tank mounting Transformer tank shall be mounted on bi-directional rollers. Suitable

locking arrangement shall be provided to prevent accidental movement of transformer. Tank shall also be provided with lifting lugs and minimum four jacking pads.

c) At least two adequately sized inspection openings, one at each end of the

tank for easy access to bushings and earth connections shall be provided.






Page 3of 7

6.01.02 Core shall be High grade non-ageing cold rolled grain oriented silicon steel laminations.

6.01.03 Winding conductor shall be Electrolytic grade copper. Windings of 66kV and

below shall be uniformly insulated. 6.01.04 Conservator tank of adequate capacity for expansion of oil from min. ambient

to100 deg.C. shall be provided. The transformers rated 7.5 MVA and above shall be provided with air bag breathing through silica gel breather. For lower rating transformers, conventional single compartment conservator with dry air filling the space above oil and connected to silica gel breather shall be provided.

6.01.05 Porcelain Bushings shall be used. 6.01.06 Bushing CTs Shall be provided in the LV neutral side of adequate rating for REF

protection, Back up definite time earth fault protection (for HT transformers only), WTI, etc.

6.01.07 Radiators shall be Tank mounted with shut off valves. 6.01.08 Insulating oil No external inhibitors are permitted. 6.01.09 Marshalling box shall be provided with thermostatically controlled space heaters.

6.01.10 The insulation of core to core clamp shall be able to withstand a voltage of 2 KV rms for one (1) minute.

6.01.11 Fittings Transformer shall be provided with following fittings a) Buchholz relay shall be provided with double float type with alarm and trip

contacts, along with suitable gas collecting device. b) At least two numbers of spring operated pressure relief devices with

extension pipe to bring oil to plinth level along with electrically insulated contact for alarm and tripping shall be provided for transformer rating 2MVA and above.

c) Diaphragm type explosion vent shall be provided for all transformers below

2 MVA rating. d) Winding temperature indicator (WTI) and Oil temperature indicator (OTI),

Dial type (150mm) with alarm and trip contacts and max. reading pointer along with resetting device shall be provided.

e) Magnetic oil level gauge with alarm contact shall be provided.






Page 4of 7

f) Oil level gauge Prismatic/toughened glass type.

6.01.12 Neutral grounding resistors (AS APPLICABLE) for neutral point earthing of 6600 volts, 3 phase AC systems shall be of punched stainless steel grid element type. Resistor element shall be insulated from supporting base by mica tubes. NGR shall be housed in a 2.5 mm thick sheet steel enclosure having IP 33 degree of protection. NGR enclosure shall be supported on insulators placed on the mounting structures of minimum height of 2.4 metre above ground level.

i) Resistance Value at 50 deg. C. 12.7 Ohms ii) Rated current 300A for 10 seconds iii) Application Neutral Grounding of Star connected LV

winding of 12.5 MVA transformer iv) Service Outdoor v) Resistor material & connection Punched stainless steel grid element typevi) Maximum allowable temperature

rise over ambient 50 oC 350 deg. C

vii)

Mounting 6.9 KV grade insulators.

viii) Power frequency test level 20 KV (rms)

6.02.00 DRY TYPE TRANSFORMERS 6.02.01 Enclosure Enclosure shall be of a tested quality sheet steel of minimum thickness 2 mm &

shall also accommodate cable terminations. The housing door shall be interlocked such that it should be possible to open the door only when transformer is off. The enclosure shall be provided with lifting lugs and other hardware for floor mounting.

6.02.02 Core Shall be High grade non-ageing cold rolled grain oriented silicon steel laminations. 6.02.03 Winding conductor Shall be electrolytic grade copper or aluminium.

Windings shall be of class F insulation. 6.02.04 Bushings Shall be Solid porcelain / RIP. 6.02.05 Bushing CT’s Shall be provided in the LV neutral side with

adequate rating for REF protection, WTI, etc. 6.02.06 Fittings Winding temperature Shall be Platinum resistance type temperature Indicator (WTI) detector in each limb. Thermistors Shall be embedded in each limb with alarm and trip contacts for remote annunciation.






Page 5of 7

7.00.00 TRANSFORMER SIZING

7.01.01 Size of the transformer shall be decided based on following :

Size shall be greater than or equal to total KVA of continuous load

+ (coincident factor x total kVA of intermittent load other than valves)

+ 0.2 x total valves kVA

+ kVA of largest rated valve or damper motor

+ Employer's requirement, if any.

+ 10% margin on the sum of the above mentioned values.

Coincident factor of intermittent load, such as lifts, cranes, hoists etc shall be taken as 0.5.

7.01.02 Normally 2 x 100% feeding arrangement shall be provided as shown in single line diagram i.e. the total loads to be considered for sizing each transformer shall be the loads working on both the buses. In case of 3 x 50% feeding arrangement, if required, the loads to be considered on each transformer shall be the loads working on any two of the buses.

8.00.00 TYPE TESTS 8.01.00 For each type and rating of transformers rated more than 2 MVA:

8.01.01 The contractor shall carry out the type tests as listed in this specification on the equipment to be supplied under this contract. The Bidder shall indicate the charges for each of these type tests separately in the relevant schedule of BPS and the same shall be considered for the evaluation of the Bids. The type test charges shall be paid only for the test(s) actually conducted successfully under this contract and upon certification by the Owner's Engineer.

8.01.02 The type tests shall be carried out in presence of the Owner’s representative, for which minimum 15 days notice shall be given by the Contractor. The Contractor shall obtain the Owner’s approval for the type test procedure before conducting the type test. The type test procedure shall clearly specify the test set-up, instruments to be used, procedure, acceptance norms, recording of different parameters, interval of recording, precautions to be taken etc. for the type test(s) to be carried out.

8.01.03 In case the Contractor has conducted such specified type test(s) within last five years as on the date of bid opening, he may submit the type test reports to the Employer for waival of conductance of such type test(s). These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. The Employer reserves the right to waive conducting of any or all of the specified type tests






Page 6of 7

under this contract. In case type tests are waived, the type test charges shall not be payable to the Contractor.

8.02.00 For each type and rating of transformers rated up to and including 2 MVA:- 8.02.01 The Contractor shall submit for Owner’s approval the reports of all the type tests

as listed in this specification and carried out within last five years from the date of bid opening. These reports should be for the tests 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. In case the Contractor is not able to submit report of the type test(s) conducted within last five years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract free of cost to the Owner and submit the reports for approval.


8.02.03 The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and “No design change”. Minor changes if any shall be highlighted on the endorsement sheet.

8.03.00 Following is the list of type tests to be conducted (as per IEC) for transformers of rating more than 2 MVA (For transformer of rating upto & including 2MVA, only the valid test reports are to be submitted in line with Cl 8.02.01).

(a) Short circuit test.

(b) Temp. rise test. (c) Lightning impulse (Chopped Wave) voltage test on all three limbs and full

wave LI on neutral if grounded through NGR.

(d) Partial discharge test on dry type transformers only (Max. allowed PD shall be 20 PC).

(e) Noise level test as per NEMA TR-1.

(f) Zero sequence Impedance measurement.

8.04.00 Following type test reports in line with clause no 8.02.01 shall be submitted for each type & rating of transformer:-

(a) Tank pressure test as per CBIP norms (for oil filled transformers). (b) Tank vacuum test as per CBIP norms (for oil filled transformers).






Page 7of 7

(c) Degree of protection test on marshalling box. 8.05.00 The following special tests on all transformers shall be conducted under

this contract as routine tests in addition to all routine tests as per IEC 60076: (a) Oil leakage test for 24 hours (for oil filled transformers).

(b) Repeat no load loss tests after electrical tests. (c) Measurement of capacitance & tan delta to determine capacitance

between winding and earth.




TECHNICAL SPECIFICATIONS

SECTION-VI, PART-B

SUB-SECTION-IIIB-10

HT SWITCHGEAR

Page

1 of 11

HT SWITCHGEAR 1.00.00 CODE AND STANDARDS IEC: 62271, IS: 13118 and IS: 3427 2.00.00 TYPE 2.01.00 Switchgear Free standing, Floor mounted, metal clad, fully compartmentalized draw-out type 2.02.00 Circuit Breaker Vacuum type, restrike free, trip free, stored energy operated and with electrical

anti-pumping features 3.00.00 RATING 3.01.01 HT Voltage: 33 KV+/- 6%, 6.6KV +/-6%

3.01.02 Frequency: 50 Hz, 3%.-5%

3.01.03 Fault Level: 6.6 KV : 40 KA RMS for 1 sec. with short circuit making current of

100KA PEAK

33KV: 21KA RMS for 1 sec with short circuit making current of 52.5KA PEAK

3.01.04 Control Supply: 240 V DC

3.02.00 TEMPERATURE RISE Temperature rise of busbars shall not exceed 55 deg. C for silver plated joints and

40 deg. C for other joints, over an ambient temperature of 50 deg. C under any condition.

4.00.00 OPERATIONAL REQUIREMENT 4.01.00 The circuit breaker shall meet the following requirements a) The breaker shall be remotely controlled. Facilities shall be provided for

mechanical tripping of breaker and manual charging of closing spring to cater to emergency condition.





SECTION-VI, PART-B

SUB-SECTION-IIIB-10

HT SWITCHGEAR

Page

2 of 11

b) Surge arrestor shall be provided for each motor feeder. c) Shall have an Operation duty O-3 min -CO- 3min-CO. d) Closing and tripping coils operating under extreme conditions of control

voltage variation. e) Supervision relays provided for trip coil monitoring. f) Suitable mechanical inter lock shall be provided to prevent inadvertent

earthing of any live part.

g) Suitable interlock shall be provided, which will ensure that breaker is OFF before opening the back doors. For Incomer/Tie panels suitable interlock shall be provided to prevent opening of any compartment doors which has any of the MV (33kV/11kV/6.6kV/3.3kV) equipment, in case the incoming supply is ON.

h) Testing of circuit breaker shall be possible in isolated position by keeping

the control plug connected. i) Only motor wound closing spring charging arrangement is acceptable. j) In a switchgear if there are more than one possible feed (including bus

coupler) then lockout relay (86) contact of incoming breakers shall be connected in series in closing circuit of each of incoming breakers.

k) Automatic change-over shall be provided for bus sections with suitable

synchronizing check facility. The change-over shall be blocked in case of fault on the bus section. Dead Bus change-over after voltage collapse shall also be provided as back-up.

l) Core balance CTs shall be provided for outgoing motor and transformer

feeders having CT ratios greater than 50/1A. m) Each breaker truck shall have Service - Isolated - Withdrawn Position. n) Primary fuse replacement shall be possible with VT in isolated position.

4.02.00 Contactor

(a.) The Bidder shall offer only HRC fuse backed, mechanically latched type contactor for outgoing conveyor motor feeder panels.

(b.) The medium voltage contactors shall be of AC-3 utilization category and shall be vacuum type. The fuse and contactor assembly shall be mounted





SECTION-VI, PART-B

SUB-SECTION-IIIB-10

HT SWITCHGEAR

Page

3 of 11

on a withdraw able truck. Circuits shall be provided with suitable single phasing protection. If required the contactor coil shall have a suitable economy resistor in series and shall be rated for satisfactory operation at 80 to 110% of rated voltage.

(c.) The fuse and overload relay shall be fully coordinated, so that the

contactor operates only for a fault current less than its interrupting capability. The fuses shall be provided with mechanical trip indication.

(d.) The contactors shall close satisfactorily with a control voltage between 85

to 110 per cent and trip satisfactorily with a control voltage between 70 to 100 percent of the rated control supply voltage. Mechanical indication of contactor open / closed shall be provided. An anti-pumping relay shall be provided even if it has mechanical anti-pumping feature. Trip circuit supervision relay shall be provided to monitor the healthiness of trip coil.

(e.) Surge suppressors shall be provided on all contactor controlled motor

feeders. 4.03.00 Surge Arrestor

The surge arrestors shall be provided for all motor feeders and shall be metal oxide, gapless type generally in accordance with IEC 60099-4 and suitable for indoor duty. These shall be mounted within the switchgear cubicle between line and earth, preferably in the cable compartment. Surge arrestor selected shall be suitable for non-effectively earthed system and rating shall be in such a way that the value of steep fronted switching over voltage generated at the switchgear terminals shall be limited to the requirements of switchgear.

5.00.00 Protection, Control and Metering 5.01.00 The switchgears shall have Communicable Numerical relays for Protection,

scheme, Metering and Status monitoring. The Numerical relays shall be networked and integrated to the Coal Handling Plant PLC. Dynamic displays shall be created in the PLC for the 33 KV & 6.6KV SWITCHGEAR for diagnostics and status monitoring. All the feeders shall be remote controlled from PLC and from the local console of the numerical relays.

5.02.00 General requirements of Numerical Relays 5.02.01 All numerical relays, auxiliary relays and devices shall be of types, proven for the

application; satisfying requirements specified elsewhere and shall be subject to Owner's approval. Numerical Relays shall have appropriate setting ranges, accuracy, resetting ratio, transient overreach and other characteristics to provide required sensitivity to the satisfaction of the Owner. All the numerical relays shall have communications on two ports, local front port communication to laptop and a second port on IEC 61850 port.





SECTION-VI, PART-B

SUB-SECTION-IIIB-10

HT SWITCHGEAR

Page

4 of 11

5.02.02 All relays and timers shall be rated for control supply voltage as mentioned elsewhere under parameters and shall be capable of satisfactory continuous operation between 80-120% of the rated voltage. Making, carrying and breaking current ratings of their contacts shall be adequate for the circuits in which they are used. Interrogation voltage for the binary inputs shall be suitably selected to ensure avoidance of mal operation due to stray voltages.

5.02.03 The protective relays shall have at least 10 Nos potential free contacts

(Programmable) Auxiliary relays shall have contacts as required. Relay output contacts shall be suitable for directly wiring in the breaker closing and trip circuit operating from 220 V DC control voltage.

5.02.04 Failure of a control or auxiliary supply and deenergisation of a relay shall not

initiate any circuit breaker /contactor operation. All relays shall withstand a minimum test voltage of 2 KV AC Rms for one minute.

5.02.05 Relays shall be suitable for electrical measurement including voltage, current,

power (active/reactive) and energy parameters. 5.02.06 Relays shall have separate output for individual functionality and the master trip

shall be software configurable in case of multi output relays. Relays shall have event recording feature, recording of abnormalities and operating parameters with time stamping

5.02.07 Preferably comprehensive single numerical relay shall have provision of both

current and voltage inputs. The current operated relay shall have provision for 4 sets of CT inputs, 3 nos. for phase fault & 1 CT input for earth fault. Relay shall be suitable for both residually connected CT input as well as CBCT input. The voltage-operated relay shall have provision for 3 PT inputs. Relays shall be suitable for CT secondary current of 1A/5A selectable at site. Relays used in incomers and bus couplers shall have provision of two sets of voltage signal inputs for the purpose of synchronization.

5.02.08 All CT & PT terminals shall be provided as fixed type terminals on the relay to avoid any hazard due to loose connection leading to CT opening or any other loose connection. In no circumstances Plug In type connectors shall be used for CT / PT connections. Vendor to ensure the same for all protective relay models offered.

5.02.09 All numerical relay shall have key pad / keys to allow relay settings from relay

front. All hand reset relays shall have reset button on the relay front. Relay to be self or hand reset shall be software selectable. Manual resetting shall be possible from remote.

5.02.10 Relays shall have suitable output contact for breaker failure protection. 5.02.11 Relays shall have self diagnostic feature with self check for power failure,

programmable routines, memory and main CPU failures.





SECTION-VI, PART-B

SUB-SECTION-IIIB-10

HT SWITCHGEAR

Page

5 of 11

5.02.12 Relays shall have at least two sets or groups of two different sets of adaptable

settings. Relays shall have multiple IEC/ ANSI programmable characteristics. 5.02.13 Design of the relay must be immune to any kind of electromagnetic interference.

Vendor to submit all related type test reports for the offered model along with the offer.

5.02.14 Protections: Relay Types/ Protections

A. Motor Feeders

a) Thermal Overload Protection (50I) b) Restart Inhibit Protection (49) c) Earth Fault Protection (50N/50N2) d) Negative Phase Sequence Protection (46) e) Reversal Phase Sequence Protection (46 R) f) Locked Rotor Protection (50 L/R) g) Number of starts limitation (66) h) Loss of Load Protection (37) i) Under Voltage protection with timer(27 M) j) Motor Differential protection (87 M) for Motor rating > 2 MW k) Energy Metering l) Monitoring

B. Transformer Feeder Protections

a) Three Phase Over current and Earth Fault protection (50 & 50 N1/50

N2))(The earth fault element should be suitable for both residually connected CT input as well as CBCT input. )

b) Restricted Earth Fault protection (64 R) c) Transformer Differential protection (87 T) for Transformers with rating more

than 5 MW d) Stand by earth fault protection (51 N) e) Transformer buchholz and WTI/OTI high trips f) Energy Metering g) Monitoring

C. Protections for Incomers, Bus couplers and Tie feeders. a) Over current and earth fault protection. b) Synchronizing check relay as a part of fast change over scheme. c) Energy Metering d) Monitoring





SECTION-VI, PART-B

SUB-SECTION-IIIB-10

HT SWITCHGEAR

Page

6 of 11

5.03.00 Other Protections and Control functions in the Relays. 5.03.01 For Breaker control from PLC, hardwired potential free contacts shall be provided

from PLC, to the numerical relays. Preferably no separate coupling relays shall be provided.

5.03.02 Trip circuit supervision shall be provided for all feeders to monitor the circuit

breaker/ contactor trip circuit both in pre trip and post trip conditions. 5.03.03 Schematics requiring auxiliary relays /timers for protection function shall be a part

of numerical relay. The number of auxiliary relay and timer function for protection function shall be as required. Auxiliary relays for interlocking purpose shall be of self reset type.

5.03.04 Bus no volt condition shall be configured to a output contact of the relay of all

incomers 5.03.05 Timer functions shall be programmable for on/off delays. 5.03.06 The numerical relay shall be able to provide supervisory functions such as trip

circuit monitoring, circuit breaker state monitoring, PT and CT supervisions and recording facilities with Post fault analysis.

5.03.07 The numerical processor shall be capable of measuring and storing values of a

wide range of quantities, all events, faults and disturbance recordings with a time stamping using the internal real time clock. Battery back up for real time clock in the event of power supply failure shall be provided.

5.03.08 150 time tagged events /records should be able to store with time stamping Last 5

faults storage including the indication, protection operated , fault location relay and operating time, currents, voltage and time.

5.03.09 Diagnostics Automatic testing, power on diagnostics with continuous monitoring to

ensure high degree of reliability shall be shall be provided. The results of the self reset functions shall be stored in battery back memory. Test features such as examination of input quantities, status of digital inputs and relay outputs shall be shall be available on the user interface

5.03.10 The alarm/status of each individual protection function and trip operation shall be

communicated to PLC The numerical relay system shall have built-in features/hardware interface to provide such inputs to PLC for analog/digital values The provision of receiving the D.C. incoming supplies and its monitoring shall preferably be made in one bus P.T. Panel.

5.03.11 Sequence of events shall have 1 ms resolution at device level. 5.03.12 Measurement accuracy shall be 1 % for RMS Current and voltage.





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5.03.13 It shall be possible to carryout open / close operation of breakers from a laptop by interfacing from the relay front port (RS232) during initial commissioning.

5.04.00 Auxiliary power Supply

Relay shall be suitable to accept both AC & DC supplies with 110V AC or 220V

DC with tolerance of 80% to 120 % of rated voltage

5.05.00 Input / Output Interface, Filters And Optical Isolation

Relay shall be immune to capacitance effect due to long length of connected control cables. Any external hardware, if required for avoiding mal operation of the relay due to cable capacitance shall be included as a standard feature. All IOs shall have optical isolation. Analog inputs shall be protected against switching surges, harmonics etc. No separate earth bus shall be required for the relays. It shall be possible to connect the relay earth to the common earth bus in the switchgear panel which shall be connected to the plant earth mat.

5.06.00 Soft ware Security, License and up gradations

Numerical relays shall have two level pass word protections, one for read only and

other for authorization for modifying the setting etc.

6.00.00 DESIGN AND CONSTRUCTION FEATURES All HT switchgear panels and circuit breakers shall have the following features. a) High conductivity aluminum alloy or copper for the horizontal bus bars,

vertical droppers and connectors to the fixed end of isolating contacts. b) Height of the Switchgear Panel Not to exceed 2600 mm. c) Insulators shall be track-resistant, high strength, non-hygroscopic, non-

combustible type and suitable withstand stresses due to over-voltages and short circuit current. Inter pole barrier of inflammable material like hylam not acceptable

d) Sealing Bushing or other sealing arrangement shall be provided between

breaker and bus bar / cable compartments to avoid air communication around isolating contacts in the safety shutter area with truck in service position.

e) Construction i) The switchgear assembly shall be rodent and vermin proof.





SECTION-VI, PART-B

SUB-SECTION-IIIB-10

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ii) In switchgear design where the breaker front itself serves as a door

suitable blanking covers one for each size of panel per switch board shall be included.

iii) The switchgear enclosure shall be constructed with rolled steel

section of rolled sheet steel of at least 2.0 mm thickness. iv) Pressure relief device shall be provided in each high voltage

compartment to vent out safely the gases produced in case of a fault.

v) Contractor shall furnish calculation during detailed- engineering

stage to establish the adequacy of support insulator and bus bar sizes for the declared continuous & short time current ratings.

vi) Breaker trucks shall have a secure locking in SERVICE position so

that they are not displaced during a short circuit. vii) Current ratings of all switchgears, circuit breakers, CT's etc. Shall

be sufficient for carrying the connected load currents without exceeding the permissible temperature limits or reduction in service life. Use of two breakers in parallel to meet the required rating shall not be acceptable.

viii) HT switchgear shall also have at least two (2) fully equipped spare

feeders (one each for highest size of motor/transformer) for any future requirement.

ix) Suitable trolley arrangement, if required, shall be provided. One

trolley per switchgear room shall be provided suitable for each type of rating of breakers.

f) Earthing Arrangement (i) Internal earth bus shall be provided which has a capacity to

withstand short circuit currents for one second and all enclosures shall be connected to this bus.

(ii) Earthing arrangement through and integral earth switch or through separate Earthing truck shall be provided. Suitable mechanical interlocks shall be provided to prevent the closing of earth switch circuit on live circuit. In case of later arrangement one set of different types of earthing trucks per switch board shall be provided.





SECTION-VI, PART-B

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(iii) Earthing switch/Earthing truck shall be short time (One second) current withstand capability equal to the breaker.

iv) A clearly visible warning label "ISOLATE ELSEWHERE BEFORE

EARTHING" shall be provided on shutters of incoming and other connections which could be energized from other end.

g) Switchgear panel shall be suitable for bottom entry and provided with

removable gland plates.

h) Instrument transformer

CTs and VTs shall be provided for protection and metering and shall be cast-resin encapsulated type. Insulation class 'E' or better. VTs shall have suitable HRC current limiting fuses to both primary and secondary sides, under voltage relays, timers, etc. for motor tripping and remote annunciation on supply failure. Each switchgear section shall have a three phase VT. Single phase VT shall be provided for HT incomers for synchronization. Accuracy class of CTs and VTs shall be as follows

CT Core balance CTS Protection/ 5P 10 PS

Metering 1.0

Differential/REF PS - -

j) Identification plates Each panel to be identified on front as well as back side by large engraved

plate giving detailed feeder description. Identification labels/painted (Not

stickers) plates to be provided inside each panel.

k) Safety Requirements The switchgears shall be designed to offer adequate level of safety to

operating/ maintenance personnel. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate shall be provided for each switch gear room mounting on wall describing various safe operating procedure / safety precautions for safe operation and maintenance of switchgear.





SECTION-VI, PART-B

SUB-SECTION-IIIB-10

HT SWITCHGEAR

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Safety shutters complying with IEC-60298 shall be provided to cover up the fixed high voltage contacts on bus bar and cable sides when the truck is moved to ISOLATED position .The breaker / contactor and the auxiliary compartments provided on the front side shall have strong hinged doors. Bus bar and cabling compartments provided on the rear side shall have separate bolted covers with self retaining bolts for easy maintenance and safety. Breaker / Contactor compartment doors shall have locking facility. Suitable interlock shall be provided, which will ensure that breaker is OFF before opening the back doors. For Incomer/Tie panels suitable interlock shall be provided to prevent opening of any compartment doors which has any of the MV (33kV/11kV/6.6kV/3.3kV) equipment, in case the incoming supply is ON.

7.00.00 Type Tests

GENERAL

(a.) All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owner’s approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client.

(b.) In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost either at third party lab or in presence of client/owners’s representative and submit the reports for approval.

(c.) All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price.

(d.) The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

The contractor shall submit the following type tests reports on the equipments to be supplied under this contract.

a) The following type tests Reports shall be furnished circuit breaker / circuit

breaker panels, of each voltage class and current rating.





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1) Short circuit duty test on circuit breaker, mounted inside the panel

offered along with CTs, bushing and separators.

2) Short time withstand test on circuit breaker, mounted inside panel offered together with CTs, bushings and separators.

3) Power frequency withstand test on breaker mounted in side panel.

4) Lightning impulse withstand test on breaker mounted in side panel.

5) Temperature rise test on breaker and panel together.

6) Test to verify pressure relief devices operation of the panel. This shall be done on one panel of each voltage class.

7) Measurement of resistance of main circuit. 8) Mechanical operation test.

b)

Contactor and Contactor panels of each type and rating.

1) Verification of rated making and breaking capacities of the contactor.

2) Short time withstand test of panel. 3) Power frequency test on the contactor mounted in side panel.

4) Lightning impulse voltage withstand test of the contactor

mounted in side panel.

5) Measurement of resistance of main circuit.

6) Test to confirm coordination between fuse and contactor.

c)

Short circuit withstand test of earthling device (truck / switch). Type Tests Reports for Surge arrestors

Numerical relays

Type test Reports as per IEC 61850

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CLAUSE NO.




TECHNICAL SPECIFICATIONS Section-VI,

Part-B

Sub-Section - IIIB-11 PLC CONTROL PANELS

Page 1 of 11

PLC & CONTROL PANELS


Programmable Logic Controller IEC: 1131

2.00.00 CONTROL TYPE

PLC based

3.00.00 PANEL CONFIGURATION

3.01.00 PLC based Control system

3.01.01 Main control desk

Mosaic based control desk type for mounting push buttons/meters etc. with doors at the rear. The mosaic grid tiles shall be of 24mmx48mm (or 25mmx50mm) size, made of heat and flame retardant, self-extinguishing and non-hygroscopic material with flat-matt finish without glare and non-reflecting type. Industrial PC based OWS (Operator Work Station) of PLC shall be mounted on control desk to house PC/ keyboards/ mouse etc. The profile and dimension shall be decided during detailed engineering and shall be subject to Employer’s approval.

3.01.02 Separate vertical free standing PLC panel with Perspex/glass door for visual access to LEDs.

3.01.03 Power distribution equipment i.e. Control transformers/ UPS/Power Supplies/Backup Batteries/ MCBs etc shall be housed in a separate free standing vertical panels.

3.02.00 Local control panels:

3.02.01 Local control panels for Metal detectors, Sump pumps, ILMS, Belt weigher and Hoists shall be free standing, floor / wall mounting type. They shall be provided with the required Power equipment like Switches, Fuses, Contactors etc. and the required control equipment like selector switches, meters, Push buttons, indications and annunciations etc.

3.02.02 Local control panels shall be provided for CSU, hydraulic scoop coupling and dust suppression system. However control of all these systems shall be through main PLC with starters located in main MCCs only.

3.02.03 Separate control desk shall be provided in the Silo control room with HMI and R I/O panels and their power supply system for the local operation of the silo equipment.

3.02.04 Necessary controls, indications and annunciations for all the above equipment shall also be provided in main control desk as described elsewhere.

4.00.00 SYSTEM CONFIGURATION

a) Control shall be normally effected through OWS/Keyboard. However miniaturised Stop push buttons shall be provided for drives/systems in coal flow path (to be finalised during detailed engineering). These shall be

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sized compatible to mosaic grid.

b) The mimic diagram of the HT & LT switchgear with facilities to operate 6.6KV Breakers and LT MCC incomers shall be provided on the control desk.

c) Indicating instruments

All indicating instruments (i.e. ammeters/ voltmeters) shall be digital type and of accuracy class 1.0.

i)

ii)

iii)

Ammeters shall be provided on control desk for:

All motors in coal flow path and for other motors rated 30 kW and above

6.6KV / LT switchgear. ( KWH display for HT & LT incomers shall also be provided on OWS)

Voltmeters shall be provided on control desk for 6.6KV/LT buses.

Ammeters and Voltmeters shall be suitable for 4-20mA DC signals derived from analog I/O cards in the PLC.

d)

Mimic i) Scrolling Mimic of coal handling system shall be configured on Large Video Screen (LVS) and OWS. It shall be possible to control / monitor / operate from LVS and OWS.

ii) Different colour schemes shall be used in the mimic to indicate status of various equipment i.e. ON/OFF/Ready to start/Trip conditions etc.

e) Large video screen (LVS)

LCD Projection type with rear - screen configuration (other type proven technology eg. that based on digital light processing shall also be acceptable subject to Employer approval) with redundant bulb and shall be complete with screens (1280 x 1024 pixels). Separate workstation/control unit fitted with necessary graphic control card and required software for selecting screens and for other required manipulation. The exact make, model and technical particulars of the LVS shall be approved by the employer during detail engineering stage. Specially designed plant overview mimic, display of important parameters, alarm, annunciation facility etc. shall be provided on the LVS. Size of the LVS shall be 80 – 84 inches diagonal minimum. CCTV system shall be connected to the LVS also.

5.00.00 CONTROL SYSTEM

5.01.00 The control and sequential operation of the all the drives and equipment within the plant shall be done by field proven Programmable Logic Controller (PLC) system.

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5.02.00 The PLC system shall be provided with 2x100% processors in hot standby mode. It shall be possible to keep any of the processors as master and other as hot standby. The hot standby shall be hardware based and there shall be a dedicated link between the two processors for data and program equalization. It shall be possible to keep any of the processors as master and other as hot standby. One processor shall be automatically updated in line with the changes made in software of the other processor. Automatic “Forcing bit” update in the secondary processor/ Controller of PLC when any “Forcing” is applied in the primary processor/controller of PLC shall be provided. Standby processor shall be energised and continuously monitored for healthiness. In case a failure of working processor, the standby processor shall take over the operation automatically and necessary failure alarm shall be provided. The processor along with their accessories shall be housed in a free standing vertical type PLC panel separate from control desk and shall be located in the main control room. I/O system shall be of distributed type. The number and location of I/O panels shall be subject to Employer approval during detailed engineering. The operation and supervisory system for the plant shall consist of Industrial PC (latest model), TFT Monitors with key boards which shall be mounted as an integral part of the control desk.

5.03.00 The processor along with OWS, printer etc. and control panels shall be interlinked through independent dual data highway and independent dual I/O links.

5.04.00 In addition to operation from HMI, it shall also be possible to operate through push buttons (stop command only) & selector switches mounted on control desk. The operation of push button shall send necessary signals through PLC.

5.05.00 Mimic of entire system within the plant along with SLDs of HT/LT switchgear shall be provided on PLC graphic and configured on LVS also. Group annunciation through annunciation window shall be provided for various abnormal conditions through PLC. The list of required annunciations shall be finalised during detail engineering.

5.06.00 In addition to the controls from the control desk/keyboard/local control panels, each motor shall be provided with local stop push button station near the drive and shall be wired to the PLC.

5.07.00 The PLC shall receive 4-20mA signals from belt weighers corresponding to the coal flow rates for integration and indication. Coal flow print out shall also be provided.

5.08.00 PLC system shall provide the outputs for the following:

a) No. of starts per day conveyor wise

b) Number of times the conveyor motor was started 3 times consecutively in a day.

c) Total daily operating hours conveyor wise.

d) Weekly trip reports for each trip condition

e) Total daily coal flow conveyor wise.

5.09.00 The PLC Controller/processor unit shall be capable of executing the following functions:-

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a) Receiving binary and analog signals from the field and operator initiated commands from Operator Station.

b) Implementing all logic functions for control, protection and annunciation of the equipment and systems.

c) Implementing modulating control function for certain applications as specified elsewhere in the specification.

d) Issuing control commands.

e) Providing supervisory information for alarm, various types of displays, status information, trending, historical storage of data etc.

f) The PLC Control system shall have extensive self diagnostic capability which shall include module level diagnostics as well as channel level diagnostics to detect any short circuit/ open circuit at field I/O level.

6.00.00 CONTROL PHILOSOPHY

6.01.00 Normal / local mode of operation shall be selected from the key board.

(a) In normal mode of operation, which shall be the default mode, all drives shall be operated from control desk through keyboard. Whenever required for maintenance, the maintenance mode will be selected from the keyboard of the operation, except trip interlocks is locked using a unique password. After maintenance, the drives shall be started from operator's station through all process interlocks, by re-entering the password. Normal mode of operation can be selected then. Irrespective of any PLC mode of operation, the running equipment can be stopped from keyboard or from desk/panel or from emergency stop push button.

b) Incomers, bus couplers & transformers feeder including spares of HT switchgear and Incomers & bus-coupler feeders of LT switchgear shall be switched ON/OFF from the control desk through key board and also through control switches/push buttons.

c) PLC system shall have facilities to detect the operated pull cord switch and belt sway switch of the conveyor. In addition to the pull cord switch and belt sway switch operation annunciation, conveyor number & operated pull cord / belt sway switch number shall also be displayed in the CRT.

7.00.00 TRAINING

Further to the relevant clause regarding training specified elsewhere, Contractor's experienced personnel/engineers shall also provide training courses on offered PLC system to Employer's engineers in the following areas:

(a.) Operator training

(a.) Hardware Maintenance training

(a.) Software training

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(a.) Any other specalised training as required for system operation and maintenance.

The maintenance training shall include lectures and hands on experience on similar type of equipment / system at manufacturer works and recently commissioned operating plant and / or training simulator. The Employer shall require training of two hardware and two software engineers and the duration of each course shall be minimum two weeks.

The details of hardware and software training shall be finalised during detailed engineering and shall be subject to Employer's approval.

8.00.00 PLC EQUIPMENT AND SYSTEM REQUIREMENTS

8.01.00 PLC system shall consist of redundant processors. redundant Industrial PC with TFT Monitors (latest version with latest application software) & keyboard, I/O modules, UPS/power supply with battery backup, printer etc. The configuration of PLC shall be as per enclosed drawing. Details of various components shall be as given below :

a) Processor Two (2) numbers. one as hot standby

b)

Memory

Non volatile EPROM, Lithium or Ni-Cd battery for 360 hours backFPC

up, 40% spare capacity for future use.

c)

Selection Normal/Test/Programme/Off facility shall be provided. In test mode all outputs shall be blocked.

d)

Monitors & Keyboard

Twenty (20) inches TFT flat monitors with resolution of 1280 x 1024 pixels non interfaced, refresh rate minimum 75 Hz. with flat membrane type keyboard/ mouse. CRT shall have graphic display facility. CRT & keyboard/ mouse shall be used for controlling, monitoring and programming function. Provision for erasing and duplicating the user program and long storage facility, forcing facility for changing the status of inputs and outputs, timers and flags to facilitate fault finding and other testing requirements shall be provided

e)

Processors & I/O racks

Modular design. Possible to change any module without disconnection of any wire. Keying in of individual wire connectors shall be provided to ensure that only the correct card is plugged on the I/O module. Twenty(20) percent spare capacity in input output modules in each rack and forty(40) percent spare capacity in CPU memory modules & in I/O handling capability shall be provided over and above system requirement. One additional Ethernet port shall be made available in each PLC system so that wireless communication modem can be connected by

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the Employer in future.

All Output cards shall be sourcing type and Input cards shall be sinking type.

The Contractor shall provide the following monitoring features:-

a) Power supply monitoring.

b) Contact bounce filtering.

Further, keying-in of individual wire connectors shall be provided to ensure that only the correct card is plugged on the I/O module. It shall be possible to remove the I/O module without disconnecting wiring from field inputs or outputs. Wiring between I/O cards & terminal blocks shall be through pre-fabricated cables.

f)

Isolation between Input, Output and controller

1.5 KV with opto couplers.

g)

Indication Individual signal status of each Input / Output, power supply status.

h)

Fail safe mode

On power supply failure / both PLCs failure / communication failure etc. the output shall be automatically switched over to fail safe mode. In CPU, memory should exist where the sequence was aborted. Further, in case of such failures, operating drives / equipment shall be tripped or kept running as per a pre-determined programmable requirement finalised during detail engineering.

i)

Fusing philosophy

Individual fuses with blown fuse indicator for each output. Individual fuses for each input/ group of inputs, keeping in view of system availability.

j)

Switching capacity

Output modules shall be rated to switch on/off coupling relays of 2.5 VA at 24V DC and solenoid valves at 110 V AC. Coupling relays are provided in HT/LT Switchgears and in local panels.

k)

HMI /CPU and Input output communication links

Hundred percent redundant Communication links through fiber optic cables routed in separate GI conduits

l)

Printer - Type and number of printers shall be as shown in the tender drawing ‘PLC Configuration’.

- Color laser printer shall be suitable for A4 size

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paper, 4 pages per minite, 600 dpi (black) and heavy duty(>_ 30000 pages per month)

- Dot matrix printer shall be Line impact type suitable for 132 column continuous fan fold type paper, 1000 LPM and heavy duty (>_ 50000 pages per month)

m)

Power supply i)

Two(2) nos 415V AC feeders shall be provided for each control panel / desk and remotely located I/O panels.

ii)

Power supply to PCs, printers, OWS, LVS, control desk and CCTV system shall be fed through 2x100% UPS with battery back-up rated for 30 minutes at full load. Main and standby OPS shall have separate battery back ups.The UPS shall be smart type line interactive complete with software & hardware for remote management along with features of surge suppression & AVR facility. The UPS and batteries shall be rated for 20% spare capacity.

iii) All separate UPS systems as indicated shall be provided in each OWS system.

iv)

The batteries for 24V DC system and for UPS shall be sealed maintenance free NI-CD type.

v)

For PLC (processor and I/O) panels, the power supply shall be 24V DC. Necessary redundant transformers and redundant 24V chargers with redundant battery back-up rated for 30 minutes shall be provided for each separately mounted I/O racks/PLC panels. Power supply modules shall be of ample capacity with 20% spare capacity for future use. All voltage supplies shall be monitored.

n)

Command hierarchy

Manual command shall prevail over auto command. Protection command shall have priority over all other commands.

o)

Databus Hundred percent redundant. Necessary interface hardware and software for dual fiber optic connectivity and interconnection with CHP PLC for two way transfer of signals shall also be provided for integration with Employer’s PLC through OPC compliant Ethernet link following TCP/IP standards.

p)

Time Synchronisationsystem.

To be synchronised with other PLC systems of Employer.

q) Date No disturbance due to change of date/year.

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Insensitivity

r)

System reaction time

Less than 100 msec. from input signal to output signal including logic processing.

s)

Display response

Max 1 sec for control related displays. 2 to 3 sec for other displays.

t) Communication speed at I/O level

Min. 5 MBPS

u) Feedback/field interrogation

By 24V DC. Status feedback from MCC/field shall be in the form of one changeover contact. Discrepancy shall be alarmed. All analog signals shall be routed through analog cards.

v)

Programming format

Flow chart/Block logic ladder diagram. Tag based addressing format shall be used for programming in the controller. The same shall be submitted for Employer's review before programming of the system.

w)

Long time storage & retrieval

168 hours latest data on hard disc. Data to be stored:

i) Alarm list.

ii) Five analog points at scan rate.

iii) Fifteen analog points at one secs rate.

iv) Balance analog points at 5 minutes rate.

v) Binary points on status change.

vi) Log reports.

x)

Software All application software with locks and passwords for PLC functioning like input/output scanning, acquisitions, condition processing, control and communication, operator interface of monitors, display trends, curves, bar charts, historical storage/ retrieval and alarm functions. Complete set of documents for modifications / editing / additions/ deletions of features in software. Comprehensive list of all application/system software.

y) Accessories Industrial grade furniture shall be provided along with control desk/OWS/printer.

z) Software license

The contractor shall provide software license for all software being used in PLC based control system including HMI. The software licenses shall be

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provided for the project and shall not be hardware/machine specific. All licenses shall be valid for the continuous service life of the plant.

Software upgrades

As a customer support the contractor shall periodically inform the designated officer of the employer about the software upgrades / new releases that would be taking place after the system is commissioned so that if required, same can be procured and implemented at site.

8.02.00 Annunciation System

i) Facia Translucent glass/plastic window with engraving.

ii) Operation Through PLC.

a)

On occurrence of trouble

Audible horn and flashing of facia lamp.

b) Acknowledge button pressed

Audible horn and flashing of facia lamp shall stop. Facia lamp will become steady.

c) Reset button pressed

If fault is removed then facia lamp will go off.

d) Test button pressed

All lamps will glow.

iii) Monitoring Power supply to annunciator shall be monitored.

9.00.00 DESK/PANEL CONSTRUCTION

a) Type Fabricated from cold rolled sheet steel

Frame thickness 2.0 mm

Enclosure thickness 1.6 mm

Gland plate thickness 3.0 mm

b) Switches AC22 category

c) Fuses HRC cartridge with visual operation indicator.

d) Name Plates & Labels

Each panel shall be identified by a name plate. Panel internal equipment shall be identified by paint marking. Nameplates shall be non rusting metal or 3-ply lamicoid, with engraved lettering and shall be subjected to Employer’s approval.

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e) Grounding 25 x 3 mm copper ground bus to be provided for each panel

f) Space heater 240V AC, single phase, thermostatically controlled space heaters to be provided.

g) Terminal block 650V grade. clip-on type.

h) Type Elmex - CATD type for CTs. Elmex - CSLT for other application.

i) Spare terminals 20 percent.

j) Wiring 650V grade. PVC insulated stranded copper wire.

k) Panel Lighting Each free standing panel shall be provided with a door switch operated fluorescent lamp and a 240V AC plug point.

l) Painting Treatment as per IS:6005. Two coats of lead oxide primer followed by powder painting with final paint shade of RAL 9002. The paint shade of the side end covers shall be RAL 5012.

m) Degree of enclosure protection

For panels located in

i) Air conditioned areas : IP-32

ii) Other areas : IP-52

iii)In dusty areas like : IP-65

Conveyor galleries, Transfer points,

Bunker area etc.

10.00.00 TYPE TESTS


(a.) However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional

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cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval.

(a.) All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price.

(d.) The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No Design Change”. Minor changes if any shall be highlighted on the endorsement sheet

10.02.00 Programmable logic controller

10.02.01 Following test reports shall be submitted for the equipment:

a). Dry heat withstand test

b). Variation of temperature immunity test

c). Variation immunity test

d). Temperature cycle test

e). Noise immunity test

f). Dielectric test.

10.02.02 Following tests shall be conducted under this contract as routine tests:

a). Tests on internal and external wiring.

b). Incoming power supply voltage and frequency variation test.

c). Test for verification of functional characteristics of I/Os.

d). Task transition test (for each task, the contractor will list out the user accessible conditions which shall be used in the simulation of the task).

e). Functional testing of software and hardware in accordance with the approved block logic diagram with simulation of the system with switches, relays and solenoid valves etc. or equivalent loads.

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PART-B

SUB-SECTION-IIIB-12 BATTERY

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BATTERY

1.00.00 BATTERY RATINGS

As per system requirement.

PART-A: NICKEL-CADMIUM BATTERY 2.00.00 CODES AND STANDARDS

2.01.00 All standards, specifications and codes of practice referred to herein, shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid.

In case of conflict between this specification and those (IS codes, Standards etc.) referred to herein, the former shall prevail. All works shall be carried out as per the following standards and codes:

IS : 10918 Specification for vented type Nickel Cadmium Batteries.

IS : 1069 Quality tolerances for water for storage batteries

Indian electricity rules

Indian Electricity Acts.

2.02.00 Equipment complying with other internationally accepted standards such as IEC., BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards along with copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison.

3.00.00 GENERAL TECHNICAL REQUIREMENT

3.01.00 Equipments

(a.) DC Batteries shall be stationary Nickel Cadmium Pocket plate type conforming to IS:10918. For the purpose of design an ambient temperature of 50 degree centigrade and relative humidity of 85% shall be considered.

(b.) DC batteries shall be suitable for standby duty. The batteries shall normally be permanently connected to the load in parallel with a charger and shall supply the load during emergency conditions when AC supplies are lost. Batteries shall be suitable for a long life under continuous float operations and occasional discharges. The batteries shall be boost charged at about 1.54 to 1.7 volts per cell maximum and float charged at about 1.42 V/cell.

(c.) The number of cells for the 110 Volts shall be 84.

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(d.) Batteries should be suitable for continuous operation for the maximum ambient temperature as defined in technical parameters.

3.02.00 Construction Features

3.02.01 Containers

Containers shall be made of polypropylene plastic material. Containers shall be robust, heat resistance, leak proof, non absorbent, alkali resistant, non-bulging type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines shall be marked on container in case of translucent containers.

3.02.02 Vent Plugs

Vent plugs shall be provided in each cells. They shall be anti splash type, having more than one exit hole shall allow the gases to escape freely but shall prevent alkali from coming out. The design shall be such that the water loss due to evaporation is kept to minimum. In addition the ventilator shall be easily removed for topping up the cells and of such dimensions that the syringe type hydrometer can be inserted into the vent to take electrolyte samples.

3.02.03 Plates

The plates shall be designed for maximum durability during all service conditions including high rate of discharge and rapid fluctuations of load. The construction of plates shall conform to latest revisions of IS:10918.

The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. Separators should be suitable for continuous immersion in the electrolyte without distortion.

The positive and negative terminal posts shall be clearly marked.

3.02.04 Sediment Space

Sufficient sediment space shall be provided so that cells will not have to be cleaned during normal life and prevent shorts within the cells.

3.02.05 Cell Insulator

Each cell shall be separately supported on PVC/porcelain/hard rubber insulators fixed on to the racks with adequate clearance between adjacent cells. Minimum distance between the adjacent cells shall be more than the budge allowed for two cells in accordance with IS: 1146.

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3.02.06 Electrolyte

The electrolyte shall be prepared from battery grade potassium hydroxide conforming to BS: 1069.

The cells can be shipped either in charged condition or in dry condition

Necessary electrolyte for make-up shall be supplied separately.

3.02.07 Connectors and Fasteners

Nickel coated copper connectors shall be used for connecting up adjacent cells and rows. Bolts, nuts and washers shall be effectively Nickel coated to prevent corrosion. The thickness of Nickel coating of connectors should be not less than 0.02 mm. All the terminals and cells inter-connectors shall be fully insulated or have insulation shrouds. End take off connections from positive and negative poles of batteries shall be made by single core cables having stranded aluminium conductors and XLPE insulation. Necessary supports and lugs for termination of these cables on batteries shall also be supplied by the contractor. All connectors and lugs shall be capable of continuously carrying the 30 minutes discharge current of the respective batteries and through fault short circuit current which the battery can produce and withstand for the period declared. Contractor shall furnish necessary sizing calculations to prove compliance to the same. Suitable number of Inter-rack connectors shall be supplied by the Bidder to suit the battery room layout during detailed engineering.

3.02.08 Battery racks

Mild steel racks for all the batteries shall be provided. They shall be free standing type mounted on procelain/hard rubber/PVC pads insulators. Batteries shall preferably be located in the single tier arrangement. However, batteries having a complete cell weight of lower than 50 Kg could be located in the double tier arrangement. The batteries racks and supports for cable termination shall be coated with three (3) coats of anti-alkali paint of approved shade. Name plates, resistant to alkali, for each cell shall be attached on to the necessary racks. The bottom tier of the stand shall not be less than 150 mm above the floor.

Wherever racks are transported in dismantled conditions, match markings shall be provided to facilitate easy assembly.

3.02.09 Manufacturer’s Identification System

The following information shall be indelibly marked on outside of each cell.

(a.) Manufacturers’ name and trade marks

(b.) Country and year of manufacture.

(c.) Manufacturer type designation.

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(d.) AH capacity at 5 hour discharge rate.

(e.) Serial number

4.00.00 THE FOLLOWING INFORMATION SHALL BE GIVEN ON THE INSTRUCTION CARDS SUPPLIED WITH THE BATTERY:

(a.) Manufacturer's instructions for filling and initial charging of the battery together with starting and finishing charging rate.

(b.) Maintenance instructions.

(c.) Designation of cell in accordance with IS:10918.

(d.) Storing conditions of electrolyte.

5.00.00 TESTS

5.01.00 GENERAL

(a.) All equipment to be supplied shall be of type test design. During detailed engineering, the contractor shall submit for Owner’s approval the reports of all the type tests as per latest IS-1146 (for all applicable tests for containers) / IS-10918 (for Ni-Cd Batteries) and carried out within last ten years from the date of bid opening. These reports should be for the tests 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. The complete type tests shall be for any rating of battery in a particular group, based on plate dimensions.

(b.) However if the contractor is not able to submit reports of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract at no additional cost to the owner either at third party lab or in presence of client/owners representative and submit the reports for approval.

(c.) All acceptance and routine tests shall be as per Quality assurance and Inspection table of batteries.

(d.) The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

5.02.00 Commissioning checks.

All tests as listed below shall be carried out on sample cell selected at random by the employer at site after completion of installation.

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(a.) Physical Examination

(b.) Dimensions, Mass & layout

(c.) MARKING

(d.) Polarity and absence of short circuit.

(e.) Air pressure test

(f.) Ampere - hour capacity

(g.) Retention of charge

(h.) Insulation resistance

The Contractor shall arrange for all necessary equipment, including the variable resistor, tools, tackles and instruments.

PART-B: LEAD –ACID PLANTE BATTERY 6.00.00 CODES & STANDARDS

6.01.00 All standards, specification and codes of practice, referred to herein, shall be the latest edition including all applicable official amendments and revisions as on date of opening of bid.

In case of conflict between this specification and those (IS Codes Standards etc.) referred to herein, the former shall prevail. All works shall be carried out as per the following standards and codes :

IS : 266 Specification for sulphuric acid

IS : 1069 Specification for water for storage batteries

IS : 1146 Specification for rubber & plastic containers for lead acid storage batteries.

IS : 1652 Specification for stationary cells and batteries, lead acid type (with plant positive plates).

IS : 3116 Specification for sealing compound for lead acid batteries.

IS : 8320 General requirements and methods of tests for lead acid storage batteries.

IS : 6071 Specification for synthetic separators for lead acid batteries.

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Indian Electricity Rules

Indian Electricity Acts

6.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison.

7.00.00 GENERAL TECHNICAL REQUIREMENTS

7.01.00 Equipments

DC Batteries shall be stationary lead acid Plante positive plate type conforming to IS:1652. For the purpose of design an ambient temperature of 50 degree centigrate and relative humidity of 85% shall be considered.

DC Batteries shall be suitable for standby duty. The Batteries shall normally be permanently connected to the load in parallel with a charger and shall supply the load during emergency conditions when AC supplies are lost. Batteries shall be suitable for a long life under continuous float operations and occasional discharges. The batteries shall be boost charged at about 2.7 volts per cell maximum and float charged at about 2.25 V/cell:

The number of cells for the110 Volts shall be 53.

Batteries should be suitable for continuous operation for the maximum ambient temperature as defined in technical parameters.

7.02.00 Construction Features

7.02.01 Containers

Containers shall be made of transparent glass, hard rubber, suitable robust, heat resistance, leak proof, non absorbent, acid resistant, non-bulging type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines shall be marked on container in case of transparent containers. Float type level indicator shall be provided in case of opaque containers. The stem portion of the float should be long enough to prevent falling of the float inside the container even if there is no electrolyte in the container. The marking for the electrolyte level should be for the upper and lower limits. The material of level indicator shall be acid proof and oxidation proof. Container shall be closed/sealed lid type. Lid and sealing compound shall be non-cracking type. The container made of hard rubber and plastics shall be type tested as per IS : 1146. All type tests shall be carried out for sealing compound as per IS:3116.

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The pole sealing arrangement should be such that no acid particle gets entrapped due to acid creep as a result of capillary action and it should be possible to remove and refix the sealing to carry out the maintenance.

7.02.02 Vent Plugs

Vent plugs shall be provided in each cell. They shall be antisplash type, having more than one exit hole shall allow the gases to escape freely but shall prevent acid from coming out. The design shall be such that the water loss due to evaporation is kept to minimum. In addition the ventilator shall be easily removed for topping up the cells and of such dimensions that the syringe type hydrometer can be inserted into the vent to take electrolyte sample.

7.02.03 Plates

The plates shall be designed for maximum durability during all service conditions including high rate of discharge and rapid fluctuations of load. The construction of plates shall conform to latest revisions of IS: 1652 as applicable.

The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. Separators should be suitable for continuous immersion in the electrolyte without distortion. The positive and negative post shall be clearly marked.

7.02.04 Sediment Space

Sufficient sediment space shall be provided so that cells will not have to be cleaned during normal life and prevent shorts within the cells.

7.02.05 Cell Insulator

Each cell shall be separately supported on PVC/porcelain/hard rubber insulators fixed on the racks with adequate clearance between adjacent cells. Minimum distance between adjacent cells shall be more than the buldge allowed for two cells in accordance with IS: 1146.

7.02.06 Electrolyte

The electrolyte shall be prepared from battery grade sulphuric acid conforming to IS:266 and distilled water conforming to IS:1069. The cells shall be shipped dry uncharged. The electrolyte shall be supplied separately.

7.02.07 Connectors and Fasteners

Lead or Lead coated copper connectors shall be used for connecting up adjacent cells and rows. Bolts, nuts and washers shall be effectively lead coated to prevent corrosion. The thickness of lead-coating of connectors should not be less than 0.025 mm. The lead coating thickness shall be measured in accordance with APPENDIX F of IS: 6848 (latest edition). All the terminals and cells inter-connectors shall be fully insulated or have insulation shrouds. End take off connections from positive and negative poles of batteries shall be made by single

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core cables having stranded aluminium conductors and XLPE insulation. Necessary supports and lugs for termination of these cables on batteries shall also be supplied by the contractor. All connectors and lugs shall be capable of continuously carrying the 30 minutes discharge current of the respective Batteries and through fault short circuit current which the battery can produce and withstand for the period declared. Contractor shall furnish necessary sizing calculations to prove compliance to the same.

7.02.08 Battery racks

Wooden racks for all the batteries shall be provided. These racks shall be made of good quality first class seasoned teak wood in line with CPWD specification. They shall be free standing type mounted on porcelain/hard rubber/PVC pads insulators. Batteries shall preferably be located in the single tier arrangement. However, batteries having a complete cell weight of lower than 50 Kg could be located in the double tier arrangement. The batteries rack and wooden support for cable termination shall be coated with three (3) coats of anti-acid paint of approved shade. Numbering tags, resistant to acid, for each cell shall be attached on to the necessary racks. The bottom tier of the stand shall not be less than 150 mm above the floor. Wherever racks are transported in dismantled condition, suitable match markings shall be provided to facilitate easy assembly.

7.02.09 Manufacturer’s Identification Systems

The following information shall be indelibly marked on outside of each cell.

(a.) Manufacturer's name and trade marks

(b.) Country and year of manufacture.

(c.) Manufacturer type designation.

(d.) AH capacity at 10 hour discharge rate.

(e.) Serial number

8.00.00 TESTS

8.01.00 GENERAL

(a) All equipment to be supplied shall be of type test design. During detailed engineering, the contractor shall submit for Owner’s approval the reports of all the type tests as per latest IS-1146 (for rubber & plastic containers for Lead – acid storage batteries) and carried out within last ten years from the date of bid opening. These reports should be for the tests 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

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been witnessed by a client. The complete type tests shall be for any rating of battery in a particular group, based on plate dimensions.

(b) However if the contractor is not able to submit reports of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract at no additional cost to the owner either at third party lab or in presence of client/owners representative and submit the reports for approval.

(c) All acceptance and routine tests shall be as per Quality assurance and Inspection table of batteries.

(d) The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

8.02.00 Commissioning checks

All tests as listed below shall be carried out on sample cell selected at random by the employer at site after completion of installation.

1) Verification of markings.

2) Verification of dimensions.

3) Test for capacities for 10 hrs discharge rate alongwith the test for voltage during discharge.

The Contractor shall arrange for all necessary equipment, including the variable resistor, tools, tackles and instruments. If a battery fails to meet the guaranteed requirements the Employer shall have the option of asking the Contractor to replace the same.

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PART-B

SUB-SECTION-IIIB-13 BATTERY CHARGER

PAGE 1 OF 11

BATTERY CHARGER


1.01.00 All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards and codes.

ANSI-C 37.90a

Guide for surge withstand capability tests

IS:5 Colours for ready mix paints.

IS : 694 PVC Insulated Cable for working voltages upto and including 1100 V.

IS : 1248 Specification for Direct acting indicating analogue electrical measuring instruments.

IS:13947 Part-1

Degree of protection provided by enclosures for low voltage switch gear and control gear.

IS : 13947 Specification for low voltage switch gear and control gear

IS : 3231 Electrical relays for power system protection.

IS : 3842 Application guide for Electrical relays for AC System

IS : 3895 Mono-crystalline semi-conductor Rectifier Cells and Stacks

IS : 4540 Mono crystalline semi-conductor Rectifier assemblies and equipment.

IS:6005 Code of practice for phosphating of Iron and Steel.

IS:6619 Safety Code for Semi-conductor Rectifier Equipment.

IS:6875 Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto 1000 V AC or 1200 V DC.

IS : 9000 Basic environmental testing procedures for electronic and electrical items.

IS:13703 Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC.

EEUA-45D Performance requirements for electrical Alarm Annunciation System

Indian Electricity Rules

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Indian Electricity Act.

1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, VDE. etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison.

2.00.00 EQUIPMENT DESCRIPTION

2.01.00 PART-I BATTERY CHARGER FOR LEAD ACID PLANTE TYPE BATTERY

(a.) The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Trickle mode i.e. Trickle charging the associated DC lead-acid Batteries while supplying the D.C. loads. The Batteries shall be Trickle charged at 2.25 Volts per cell. All chargers shall also be capable of Boost charging the associated D.C. Battery at 2.0 to 2.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, at an ambient air temperature of 50°C.

(b.) Battery Chargers shall have a selector switch for selecting the battery charging mode i.e. whether Trickle or Boost charging.

(c.) All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature which may arise during changeover from Auto to Manual mode or vice-versa under normal operating condition.

(d.) Soft start feature shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall neither damage the Charger nor shall it cause blowing of any of the changer fuses. The Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage shall build up automatically when working in automatic mode.

(e.) When on automatic control mode during Trickle charging, the Charger output voltage shall remain within +/-1% of the set value for AC input voltage variation of +/-10%, frequency variation of +3/-5%, a combined voltage and frequency (absolute sum) variation of 10% and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire Trickle charging output range

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specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Trickle charging mode.

(f.) During Boost charging, the Battery Chargers shall operate on constant current mode (When automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. The charger output voltage shall automatically go on rising, when it is operating on boost mode, as the battery charges up. For limiting the output voltage of the charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage anywhere in the output range specified for boost charging mode. All voltage and current setting potentiometers shall be vernier type.

(g.) Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits as mentioned elsewhere, shall be less than fifteen seconds.

(h.) Momentary output voltage of the Charger, without the Battery connected shall be within 94% to 106% of the voltage setting during sudden load Change from 100% to 20% of full load or vice-versa. Output voltage shall return to, and remain, within the limits specified as mentioned elsewhere in less than 2 seconds after the above mentioned change.

(i.) The Charger manufacturer may offer an arrangement in which the voltage setting device for Trickle charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the trickle charging mode is also used as Boost charging current setting device.

(j.) Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 1% irrespective of the DC load, even when they are not connected to a battery.

(k.) The DC System shall be ungrounded and float with respect to the ground potential when healthy. An earth fault relay shall be provided by the Employer in the DC distribution board for remote annunciation.

2.02.00 PART-II BATTERY CHARGER FOR NICKEL-CADMIUM TYPE BATTERY

(a.) The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Trickle mode i.e. Trickle charging the associated DC Nickel-Cadmium Batteries while supplying the D.C. loads. The Batteries shall be Trickle charged at 1.4 to 1.42 Volts per cell. All chargers shall be capable of Boost charging the associated D.C. Battery at 1.53 to 1.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, at an ambient air temperature of 50°C.

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(b.) Battery Chargers shall have a selector switch for selecting the battery charging mode i.e. whether Trickle or Boost charging.

(c.) All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature which may arise during changeover from Auto to Manual mode or vice-versa under normal operating condition.

(d.) Soft start features shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall not damage the Charger, nor shall it cause blowing of any of the charger fuses. The Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage shall build up automatically when working in automatic mode.

(e.) When on automatic control mode during Trickle charging, the Charger output voltage shall remain within +/-1% of the set value for AC input voltage variation of +/-10%, frequency variation of +3 to -5%, a combined voltage and frequency (absolute sum) variation of 10% and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire Trickle charging output range specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Trickle charging mode.

(f.) During Boost charging, the Battery Chargers shall operate on constant current mode (When automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. The charger output voltage shall automatically go on rising, when it is operating on boost mode, as the battery charges up. For limiting the output voltage of the charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage anywhere in the output range specified for boost charging mode. All voltage and current setting potentiometers shall be vernier type.

(g.) Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits as mentioned elsewhere shall be less than fifteen seconds.

(h.) Momentary output voltage of the Charger, without the Battery connected shall be within 94% to 106% of the voltage setting during sudden load Change from 100% to 20% of full load or vice-versa. Output voltage shall return to,

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and remain, within the limits specified as mentioned elsewhere in less than 2 seconds after the above mentioned change.

(i.) The Charger manufacturer may offer an arrangement in which the voltage setting device for Trickle charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the trickle charging mode is also used as Boost charging current setting device.

(j.) Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 1% irrespective of the DC load, even when they are not connected to a battery.

(k.) The DC System shall be ungrounded and float with respect to the ground potential when healthy. An earth fault relay shall be provided by the Employer in the DC distribution board for remote annunciation.

2.03.00 Printed Circuits Boards (PCB)

PCB shall be made of glass epoxy of 1.6 mm thick, fire resistant, bonded with 99.8% pure copper foil, free of wrinkles, blisters, scratches and pinholes. The contact surface of the edge connectors of the PCBs shall be plated with hard gold to a minimum thickness of 5 microns. Component identification shall be printed on PCB by silk screen method. All PCBs shall be tropicalised and masked.

2.04.00 CONTACTORS

All Battery Chargers shall have an AC contactor on the input side. It shall be of air break type and suitable for continuous duty. The operating coil shall be rated for 415 Volts AC.

2.05.00 Thermal Overload Relay

A thermal overload relay incorporating a distinct single phasing protection (using differential movement of bimetal strips) shall also be provided for the AC input. The relay shall trip the above contactor.

2.06.00 Rectifier-Transformers and Chokes

The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating of the rectifier-transformers and chokes shall correspond to the rating of the associated rectifier assembly. The rectifier-transformers and chokes shall have class-B insulation with temperature rise limited to class-A insulation value.

2.07.00 Rectifier Assembly

The rectifier assembly shall be full wave bridge type and designed to meet the duty as required by the respective Charger. The rectifier cells shall be provided with their own heat dissipation arrangement with natural air cooling. The rectifier shall utilise diodes/thyristors and heat sinks rated to carry 200% of the load current continuously and the temperature of the heat sink shall not be permitted to exceed 85°C absolute duly considering the maximum charger panel inside temperature. The Contractor shall submit calculations to show what maximum junction temperature will be and

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what the heat sink temperature will be when operating at 200% and 100% load current continuously duly considering the maximum surrounding air temperature for these devices inside the charger panel assuming air ambient temperature of 50°C outside the panel. Necessary surge protection devices and rectifier type fast acting fuses shall be provided in each arm of the rectifier connections.

2.08.00 DIGITAL INDICATING INSTRUMENTS

Digital indicating instruments with built in communication port for remote data transfer shall be provided for all chargers. The instruments shall indicate DC current, DC voltage & AC voltage and instrument shall be 96 x 96 sqmm, with display accuracy 0.5%, 4 digit – 7 segment LED/LCD display and RS 485 serial Bus port.

2.09.00 AIR BREAK SWITCHES

All Chargers shall have AC input and DC output switches of air break, single throw, load break and fault make type. The contacts of the switches shall open and close with a snap action. Switches shall be rated for 120% of the maximum continuous load. ‘ON’ & ‘OFF’ position of the switch shall be clearly indicated.

2.10.00 CONTROL AND SELECTOR SWITCHES

Control and selector switches shall be of rotory stayput type with escutcheon plates showing the functions and positions. The switches shall be of sturdy construction and suitable for mounting on panel front. Switches with shrouding of live parts and sealing of contacts against dust ingress shall be preferred. The contact ratings shall be atleast the following :

(a.) Make and carry continuously – 10 Amps.

(b.) Breaking current at 220 V DC – 0.5 Amp. (inductive)

(c.) Breaking current at 240 V AC – 5 Amp. At 0.3 p.f.

2.11.00 FUSES

Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse carriers which are mounted on fuse bases. Wherever it is not possible to mount fuses on fuse carriers, fuses shall be directly mounted on plug in type bases. In such cases one insulated fuse pulling handle shall be supplied for each charger. Kick-off fuses (trip fuses) with alarm contacts shall be provided for all D.C. fuses.

2.12.00 Indicating Lamps

Three (3) indicating lamps shall be provided to indicate A.C. supply availability. The indicating lamp shall be of panel mounting, filament type low wattage or LEDs and capable of clear status indication under the normal room illumination. The lamps shall be provided with series resistors (non-hygroscopic) preferably built in the lamp assembly and replaceable from front. The lamp covers shall be preferably screwed type, unbreakable and moulded from heat resistant material.

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2.13.00 Blocking Diode

Blocking diode shall be provided in the output circuit of each Charger to prevent current flow from the D.C. Battery into the Charger.

2.14.00 Annunciation System

Visual indications through indicating lamps/LEDs or annunciation facia as per EEUA-45D shall be provided in all Chargers for the following:

(a.) A.C. supply failure

(b.) Rectifier fuse failure

(c.) Surge circuit fuse failure

(d.) Filter fuse failure

(e.) Load limiter operated

(f.) Charger trip

(g.) Battery on Boost

Potential free NO contacts of all above conditions shall be provided for following remote alarms in the Employer’s Unit Control Board:

(h.) Battery on Boost

(i.) Charger trouble (this being a group alarm initiated by any of the faults other than ‘Battery on Boost’)

2.15.00 Name Plates and Marking

The name plates shall be made of non-rusting metal/3 ply Lamicoid and shall have black back-ground with white engraved letters and secured by screws. These shall be provided near top edge on the front as well as on rear side of Charger. Name plates with full and clear inscriptions shall also be provided on and inside the panels for identification of the various equipments.

3.00.00 CONSTRUCTION

3.01.00 The Chargers shall be indoor, floor mounted, self supporting sheet metal enclosed cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and hardware. The Charger shall be fabricated using cold rolled sheet steel shall not less than 1.6 mm and shall have folded type of construction. The panel frame shall be fabricated using cold rolled sheet steel of thickness not less than 2.0 mm. Removable undrilled gland plates of at least 3.0 mm sheet steel and lugs for all cables shall be supplied by the Contractor. The lugs for cables shall be made of electrolytic copper with tin coat. Cable sizes shall be advised to the Contractor at a later date for provision of suitable lugs and gland plates. The Charger shall be tropicalised and vermin proof. Ventilation louvers shall be backed with fine brass wire

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mesh. All doors and covers shall be fitted with synthetic rubber gaskets. The Chargers shall have hinged double leaf doors provided on front and/or backside for adequate access to the Charger internals. All the Charger cubicle doors shall be properly earthed. The degree of protection of Charger enclosure shall be atleast IP-42.

3.02.00 All indicating instruments, control & selector switches and indicating lamps shall be mounted on the front side of the Charger. Design of panels shall be based on the following dimensions.

1) Overall height - Maximum 2350 mm 2) Operating handles - Maximum 1800 mm

(highest and lowest Minimum 350 mm positions reached by operator’s hands), protective mechanical

indicators 3) Doors and panel - Maximum 1800 mm handles and locks Minimum 300 mm

3.03.00 Electronic equipments shall be of modular design consisting of plug in modules in standard 19 inches metallic racks with metallic card guides. The cards should be provided with proper handles. Card to card wiring should be preferably through a mother board. Unplanned jumpering and track modifications are not permitted. Mechanical interlocks to prevent wrong insertion of cards should be provided. Each card shall have its junction and test points identified. Maintenance aids such as extension printed wiring boards and jumper leads shall be provided.

3.04.00 The layout of Charger components shall be such that their heat losses do not give rise to excessive temperature within the Charger panel surface. Location of the electronic modules will be such that temperature rise of the location, in no case, will exceed 10°C over ambient air temperature outside the Charger.

3.05.00 Each Charger panel shall be provided with an illuminating lamp and one 5 Amp. Socket. Switches and fuses shall be provided separately for each of the above.

3.06.00 Locking facilities shall be provided as following:

(a.) For locking Trickle/Boost selector switch in the trickle position only. This would be used for having key mechanical interlock between Trickle/Boost selector switch and isolator in D.C. distribution board which is being procured separately by the employer.

(b.) The Charger enclosure door locking requirements shall be met by the application of padlocks. Padlocking arrangement shall allow ready insertion of the padlock shackle but shall not permit excessive movement of the locked parts with the padlock in position.

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3.07.00 Wiring

3.07.01 Each Charger shall be furnished completely wired upto power cable lugs and terminal blocks ready for external connection. The power wiring shall be carried out with 1.1 KV grade PVC insulated cables conforming to IS:1554 (Part-I). The control wiring shall be of 1.1KV grade PVC insulated stranded copper conductors of 2.5 sq.mm. conforming to IS:694. Control wiring terminating at electronic cards shall not be less than 1.0 sq. mm. Control terminal shall be suitable for connecting two wires with 2.5 sq.mm. stranded copper conductors. All terminals shall be numbered for ease of connections and identification. At least 20% spare terminals shall be provided for circuits.

3.07.02 Power and control wiring within panels shall be kept separate. Any terminal or metal work which remains alive at greater than 415 V, when panel door is opened, shall be fully protected by shrouding.

3.07.03 An air clearance of at least ten (10) mm shall be maintained throughout all circuits, except low voltage electronic circuits, right upto the terminal lugs. Whenever this clearance is not available, the live parts should be insulated or shrouded.

3.08.00 PAINTING

Treatment as per IS:6005. Two coats of lead oxide primer followed by powder painting with final shade of RAL9002 for complete panel except end covers & RAL 5012 for end covers.

4.00.00 TESTS

4.01.00 GENERAL 1. All equipment to be supplied shall be of type test design. During detailed

engineering, the contractor shall submit for Owner’s approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests 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.

a) Complete physical examination b) Temperature rise test at full load. c) Temperature rise test of rectifier assembly at 200% of full load. d) Insulation resistance test. e) High voltage (power frequency) test on power and control circuits

except low voltage electronic circuits. f) Ripple content test at

i) No load

ii) Half load

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iii) Full load g) Automatic voltage regulator operation test at specified A.C. supply

variations at

i) No load

ii) Half load

iii) Full load h) Load limiter operation test i) Efficiency and power factor measurement. j) Input and output surge withstand capability test. Surge Voltage as per

ANSI-C37.90a shall be applied for period not less than 2 sec. At the following points of the Charger operating at 50 deg. C at full load :

i) Across each A.C. input phase

ii) Across AC input line to ground.

iii) Across D.C. output terminals.

iv) Across each D.C. output terminal to ground

The Charger shall not exhibit any component damage and there shall be no change in performance as per (g) and (h).

k) Environmental Tests

Steady state performance tests (g) and (h))shall be carried out before and after each of the following tests.

i) Soak Test

The electronic modules shall be subjected to continuous operation for a minimum period of 72 hours. During last 48 hours, the ambient temperature shall be maintained at 50 deg. C. The 48 hour test period shall be divided into four equal 12 hour segments. The input voltage during each 12 hours shall be nominal voltage for 11 hours followed by 110% of nominal voltage for 30 minutes, followed by 90% of nominal voltage for 30 minutes.

ii) Degree of protection test. 2. However if the Contractor is not able to submit report of the type test(s)

conducted within last ten years from the date of bid opening, or in case the

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type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval.

3. All routine tests as per QA table and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price.

4. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and “No design Change”. Minor changes if any shall be highlighted on the endorsement sheet.

5.00.00 COMMISSIONING

5.01.00 The contractor shall carryout the following commissioning tests and checks after installation of the equipment at site:

(a.) Complete physical examination.

(b.) Checking of proper operation of annunciation system.

(c.) Temperature rise test at full load.

(d.) Insulation resistance test.

(e.) Automatic voltage regulator operation.

(f.) Load limiter operation.

(g.) Dynamic response test.

Overshoot/Undershoot in output voltage of the Charger as a result of sudden change in load from 100% to 20% and 20% to 100% shall be measured with the Batteries connected/disconnected. Output voltage of the Charger connected with Battery shall be within 94% to 106% of the voltage setting in above conditions and shall return to, and remain, within the limits specified as mentioned elsewhere, in less than 2 seconds (as applicable).

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PART-B

SUB-SECTION-IIIB-14 MEASURING

INSTRUMENTS

PAGE 1 OF 10

MEASURING INSTRUMENTS

1.00.00 MEASURING INSTRUMENTS

1.01.00 Measuring instruments/equipment and subsystems offered by the Bidder shall be from reputed experienced manufacturers of specified type and range of equipment, whose guaranteed and trouble free operation has been proven. Further, all instruments shall be of proven reliability, accuracy, and repeatability requiring a minimum of maintenance. They shall comply with the acceptable international standards and shall be subject to Employer's approval. All instrumentation equipment and accessories under this specification shall be furnished as per technical specifications, ranges, makes/numbers as approved by the Employer during detailed engineering.

1.02.00 Every panel-mounted instrument requiring power supply shall be provided with a pair of easily replaceable glass cartridge fuses of suitable rating. Every instrument shall be provided with a grounding terminal and shall be suitably connected to the panel grounding bus.

1.03.00 All local gauges as well as transmitters, sensors, and switches for parameters like pressure, temperature, level, flow etc. as required for the safe and efficient operation and maintenance as well as for operator and management information (including all computation) of equipment under the scope of specification shall be provided on as required basis within the quoted lump sum price.

1.04.00 The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve manifolds and all the other accessories required for mounting/erection of these local instruments shall be furnished, even if not specifically asked for, on as required basis. The contacts of equipment mounted instruments, sensors, switches etc. for external connection including spare contacts shall be wired out in flexible/rigid conduits, independently to suitably located common junction boxes. The proposal shall include the necessary cables, flexible conduits, junction boxes and accessories for the above purpose. Double root valves shall be provided for all pressure tapping where the pressure exceeds 40 Kg./sq.cm.

2.00.00 SPECIFICATION FOR ELECTRONIC TRANSMITTER FOR PRESSURE AND D.P. 2.01.00 ELECTRONIC TRANSMITTERS

Sr. No.

Features Essential/Minimum Requirements

1. Type of Transmitter Microprocessor based 2 wire type, HART protocol compatible.

2. Accuracy ± 0.1% of calibrated span ( minimum)

3. Output signal range 4-20 Ma DC (Analog) along with superimposed digital signal (based on HART protocol)

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10:1 for vacuum/very low pressure applications. 4. Turn down ratio

30:1 for other applications.

5. ± 0.1% of calibrated span for six months for Ranges up to and including70 Kg/cm².

Stability

± 0.25% of calibrated span for six months for Ranges more than 70 Kg/cm² (g).

+/- 0.015% per deg.C at max span. 6. Zero and span drift

+/-0.11% per deg.C at min. span.

7. Load impedance 500 ohm (min.)

8. Housing Weather proof as per IP-55 with durable corrosion resistant coating.

9. Over Pressure 150% of max. Operating pr.

10. Connection (Electrical) Plug and socket type

11. Process connection 1/2 inch NPT (F)

12. Span and Zero Continuous, tamper proof, Remote as well as adjustability manual from instrument with zero suppression and elevation facility.

-Diaphragm seal, pulsation dampeners, siphon etc. as required by service and operating condition.

-2 valve manifold for absolute pressure transmitters (3-valve manifold for gauge/ vacuum pressure transmitters) and 5 valve manifold for DP/level/flow transmitters.

13. Accessories

-For hazardous area, explosions proof enclosure as described in NEC article 500.

14. Diagnostics Self Indicating feature

15. Power supply 24V DC ± 10%.

16. Adjustment/calibration/maintenance

Total two (2) no. of hand- held type universal calibrators compatible with HART protocol , shall be provided (for all three units).

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Note.

In case it becomes necessary to use a DP transmitter for pressure measurement, then a 3-valve manifold should be used in place of 2-valve manifold.

LVDT type is not acceptable.

Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm seals shall be provided. Parts below the diaphragm shall be removable for cleaning. The entire volume above the diaphragm shall be completely filled with an inert liquid suitable for the application.

2.02.00 ULTRASONIC LEVEL TRANSMITTERS

Sl. no Features Essential/Minimum requirements 1. Type of Transmitter Non contact Microprocessor based 2 wire

type, HART protocol compatible Ultrasonic transmitter.

2. Output signal Galvanic ally isolated 4-20mA DC (Analog) along with superimposed digital signal (based on HART protocol).

3. Sensor Accuracy +/- 0.5% of calibrated span.

4. Sensor Repeatability 3 mm or better.

5. Power supply 24 V DC +/- 10%

6. Temperature compensation

To be provided within transducer.

7. Configuration Sensor unit and Electronic units are to be separate. It shall be possible to mount the Electronic unit at a remote accessible location from the transducer. All cables and weather proof fittings to interconnect transducer to electronic unit shall be provided by Bidder.

8. Housing Weather proof as per IP-55 with durable corrosion resistant coating.

9. Calibration Through HART Communicator.

10. Zero and Span adjustment

Continuous, tamper proof, remote as well as manual adjustability from instrument. It shall be possible to calibrate the instrument without any level in the tank/sump etc

11. Sensor Material Corrosion resistant material to suit individual application requirement.

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12. False signal tolerance Transmitter shall be capable of ignoring false echoes from internal tank/sumps obstructions such as pipes, heating coils or agitator blades. Also transmitter shall have adjustable damping circuitry

13. Range Range of transmitter shall be capable of covering the complete level span of tank taking care of blocking distance, frequency attenuation due to surface, obstructions, vapors etc

14. Display Minimum 4 character display with integral keypad, access protected by user code.

15. Diagnostics Loss of echo alarm etc

16. Load Impedance 500 ohms minimum

17. Electrical Connection Plug and socket

18. Accessories • All weather canopy for protection from direct sunlight and direct rain.

• All mounting hardware and accessories required for erection and commissioning mounting fittings material shall be SS 316.

• For hazardous areas, explosion proof enclosure as described in NEC article 500.

Note:-

Contractor can also provide Radar type transmitter in place of ultrasonic transmitters subject to approval by Employer during detailed Engineering.

3.00.00 TEMPERATURE ELEMENTS

3.01.00 RESISTANCE TEMPERATURE DETECTOR ( RTD )

Sr. No.

Features Essential/Minimum Requirements

1 Type of RTD. : Pt-100 (100 Ohms resistance at zero degree centigrade)

2 No. of element : Duplex 3 Housing/Head : IP-55/Diecast Aluminium. Plug in

connectors are to be provided for external signal cable connection.

4 Sheathing of RTD : Metal sheathed, ceramic packed 5 Calibration and accuracy : As per DIN-43760 Class-A

6 Characteristic : Linear with respect to temp, within ±1/2

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percent of top range value. 7 Accessories : Thermo well (as specified below) and

shall be spring loaded for positive contacts with the well.

8 Standard : DIN-43760 for RTD and ASME PTC-19.3 for Thermo-well.

3.02.00 THERMO WELL

Thermo well shall be one piece solid bored type of 316SS of Step-less tapered design (as per ASME PTC 19.3, 1974).

TEMPERATURE TRANSMITTER

Following type of 2-wire temperature transmitter (directly powered from 4-20mA input cards of DDCMIS) shall be provided. The temperature transmitter shall be fully compatible with thermocouples and RTDs being provided by the contractor. Temperature compensation of the thermocouples shall be performed in the temperature transmitter itself. Single Input DIN-rail mounted Temperature Transmitter These shall be suitable for mounting on DIN-rails in JBs. The specifications of the JBs shall be same as indicated in Subsection INST CABLE with additional DIN-rails and IP 65 Protection class. This temperature transmitter shall be the ones which are especially designed for DIN-rail mounting with IP 20 protection class. These shall have terminals for input/output provided on front side when mounted on DIN-rail. Head mounted temperature transmitter with clamps to make it suitable for DIN-rail mounting shall not be acceptable under this category. Requirements for each of the above type of temperature transmitters Output : 2-wire (power supply from input card of

Control System) with 4-20mA output with superimposed HART protocol signal.

Input : Same transmitter shall be capable to handle Pt-100 RTD , Thermocouples –K&R types (input type to be selectable at site through HART terminal)

Isolation : min. 500 V AC

EMC compatibility : as per EN 61326

0 to 85 deg C (without indicator)

Operating ambient temperature

:

0 to 70 deg C (with indicator)

Power supply compatible with input module of Control System

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Accessories Mounting arrangements including clamps etc.

Composite Accuracy

(Refer note 2) RTD =<0.4% of 0-250 deg C span

T/C-K type =<0.4% of 0-600 deg C span

T/C-R type =<0.4% of 0-1000 deg C span

CJC accuracy (for thermocouples) shall be =< 1 deg C

Notes:- 1. In case of failure (open or burn-out) of RTD/thermocouple, temp. Transmitter

shall provide low temperature output. 2. Composite Accuracy is to be calculated as summation of all applicable

accuracies of temp transmitter, for converting sensor input to output in 4-20 mA (e.g., basic accuracy, digital accuracy, D/A accuracy, etc.) and temperature effect on these accuracies at ambient temperature of 50 deg C, based on the figure/ formula given in the standard product catalogue for span as specified above for various types of Temperature Elements specified. All such accuracy/ temp effect figures in catalogue shall be first converted to deg C, and then percentage of this converted accuracy in specified span shall be calculated to compare with the specified composite accuracy figures.

3.04.00 Hand held calibrator

Hand held calibrators (2 nos) shall be provided for adjustment/calibration/ maintenance of the HART compatible temperature transmitters.

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4.00.00 SPECIFICATIONS FOR PR. GAUGE, D.P. GAUGE, TEMP. GAUGE AND LEVEL GAUGE.

Sl.No

FEATURES ESSENTIAL/MINIMUM REQUIREMENTS

Pr. Gauge/ DP Gauge/ Draught gauges

Temperature Gauge

Level Gauge

1 Sensing Element and material

Bourdon for high pressure, Diaphragm/Bellow for low pr. Of 316 SS

Mercury in steel for below 450°C and inert gas actuated for above 450°C of SS bulb and capillary.

Tempered * toughened Borosilicate gauge glass steel armoured reflex or transparent type.

2 Body material

Die-cast aluminium

Die-cast aluminium

Forged carbon steel/304 SS

3 Dial size 150mm 150 mm Tubular covering entire range

4 End connection

1/2 inch NPT (M)

3/4" NPT (M) Process connection as per ASME PTC and drain/vent 15 NB

5 Accuracy ±1% of span ± 1% of span ± 2%

6 Scale Linear, 270° arc graduated in metric units

Linear, 270° arc graduated in °C

Linear vertical

7 Range selection

Cover 125% of max. of scale



8 Over range test

Test pr. for the assembly shall be1.5 to the max. Design pr. at 38°C.

9 Housing Weather and dust proof as per IP-55

Weather and dust proof as per IP-55

CS/304 SS leak proof

10 Zero/span adjustment

Provided Provided --

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11 Identification Engraved with service legend or laminated Phenolic name plate

12 Accessories Blow out disc, siphon, snubber, pulsation dampener, chemical seal (if required by process) gauge isolation valve

SS Thermo well Gasket for all KEL-F shields for transparent type vent and drain valves of Steel/SS as per CS/Alloy process Requirement.

13 Material of Bourdon/ movement

316 SS / 304 SS

316 SS / 304 SS

Notes:-

*Bicolor type level gauges will be provided for applications involving steam and water except for condensate and feed water services.

Length of gauge glass shall not be more than 1400 mm. If the vessel is higher, multiple gauge glasses with 50 mm overlapping shall be provided.


5.00.00 ROTAMETERS

Sr. No.

Features Essential / minimum requirements

1. Type Variable Area Metal Tube

2. Fluid media Water/oil

3. Tube body SS316

4. Material of float 316 SS

5. Indicator Linear scale

6. Accessories Flange orifice in case of bypass rotameter (for line size above 100 mm)

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7. Housing protection class

IP-55

8. Accuracy + 2% of measured value.

6.00.00 PROCESS ACTUATED SWITCHES

FEATURES ESSENTIAL / MINIMUM REQUIREMENTS

Pressure/ Draft Switches/ DP Switches

Temperature switches

Level switches

Capacitance types for oil and dirty medium, water, condensate application.

Float type switches for applications as decided by Employer during detailed engineering.

Capacitance/ Conductivity/ Ultrasonic type for acid and alkali application.

Sensing Element

Piston actuated for high pressure and diaphragm or bellows for low pr./ vacuum

Vapor pressure sensing, liquid filled bellow type with SS bulb and capillary (10 m minimum)

Material 316 SS Bulb 316 SS/ capillary 304 SS

316 SS

End connection

½ inch NPT (F)

½ inch NPT (F) Manufacturer standard

Over range proof pressure

150% of max. design pr.

- 150% of max. design pressure

Repeat-ability + 0.5% of full range

No. of contacts

2 No.+2NC. SPDT snap action dry contact

Rating of contacts

60 V DC, 6 VA (or more if required by DDCMIS or PLC)*

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Elect. Connection

Plug in socket

Set point/ dead band adjustment

Provided over full range

Enclosure Weather and dust proof as per IP-55

Accessories Siphon, snubber, chemical seal, pulsation dampeners as required by process

Thermo well of 316 SS and packing glands

All mounting accessories

Mounting Suitable for enclosure/ rack mounting or direct mounting

Suitable for rack mounting or direct mounting

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Part-B

Sub-Section - IIIB-15 CCTV

Page 1 of 8

CLOSE CIRCUIT TELEVISION SYSTEM (CCTV)


1.01.01 The intent of the specification is to define the functional & design requirements for the CCTV System meant for gathering video information from the various operational areas of the Coal Handling Plant. The Contractor shall be responsible for selection, design, engineering, manufacture, testing at manufacturer’s works/site, installation and commissioning of the system to the satisfaction of Employer. All the cables, cable trays, power packs, erection hardwares etc. are also included in contractor’s scope.

1.01.02 The Contractor’s scope shall also include successful demonstration of performance testing specified herein complete in all respects alongwith cables, cable trays, junction boxes, earth wire and accessories like standard brackets, nut-bolts, glands, lugs, conduit sleeves, etc., as required, to complete the proper installation conforming to IS:1881, IS:1882 of all the equipments supplied as covered in this specification. All equipment, accessories and facilities required for completeness of this system are included in Contractor's scope, whether these are specifically mentioned herein or not.

1.01.03 The CCTV System offered by the Contractor shall be from reputed manufacturer who should have designed, manufactured, tested and commissioned a distributed type CCTV systems as specified in any coal handling plants or any large industrial installation as on the date of bid opening. All major equipment such as Cameras, Video Switcher/Control System, Key Boards, Receiver Drivers, Pan Tilt Units, Post equalisation Video amplifiers, Digital Video Recorder, (DVR) Archiving System etc. shall be of the same make. Dome type cameras are also acceptable.

1.01.04 The system and all the equipment shall conform to the latest edition of Indian / International and CCITT standards as applicable.

1.01.05 The Contractor shall guarantee satisfactory performance of the equipment under stipulated variations of voltage and frequency. The design and manufacture shall be such that equipments/components of same type and rating shall be interchangeable.

1.01.06 All the cameras shall be connected to a central redundant microprocessor based video switcher/control system to be located in CHP control room.

1.01.07 Any other equipment, module required for the safe and satisfactory operation, control, protection, monitoring, testing and maintenance of the system are also included in Contractor's scope.

2.00.00 POWER SUPPLY ARRANGEMENT

2.01.00 The Contractor shall provide power to the CCTV System from UPS system for microprocessor based switching / control unit, monitor, digital video recorder, etc. in the control room.

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3.00.00 DESIGN AND TECHNICAL REQUIREMENTS

3.01.00 The CCTV system shall be able to provide surveillance of different locations of the plant.

3.02.00 The system shall comprise of Redundant Microprocessor based Video Switcher/Control System capable of controlling

- 32 nos. of Cameras for Zoom, Pan/Tilt, Multiple pre positionsand auxiliaries

- 1 no. of digital video recorder.

- Multiplexor

- Required no. of 21” colour monitors with key board for controlling both manually and automatically and all other accessories required to provide best quality video with controls for making the system complete. It shall be possible to view the CCTV out put on the large video screen also.

3.03.00 The system operation would be of covering the complete view of the areas with pan / tilt, zoom, propositioning of the cameras and with programmability to monitor any camera or number of cameras at a time on any monitor either manually or automatically in a defined switching. The system shall be suitable for installation and shall be able to work successfully in Coal dusty environment.

3.04.00 The system shall have the following facilities:

a) Zooming

b) Pan control

c) Tilt control

d) Computer interface

e) Logging printer part

f) Multiple prepositions

g) SALVO switching

h) Programmability

i) Alarm interface

3.05.00 The system supplied shall be complete in all respects for reliable performance. The Contractor shall submit the details block schematic, video, signal & power wiring diagram, describing the connections between the Microprocessor based Video Switcher/Control System and various cameras, pan tilt, receiver driver units, monitors, DVR and keyboard. Programming required shall be done by the Contractor for satisfactory operation.

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3.06.00 The system should be completely compatible to be integrated to Fire Alarm System. When the fire is detected by a particular detector the camera assigned should automatically focus the site of the fire.

3.07.00 The video switcher/control system shall permit the design of a distributed matrix video switching system with control at one central location and individual control at the local sites. The main control site could view/control local cameras plus cameras located at any of the remotely distributed sites.

4.00.00 DETAILED DESCRIPTION OF THE SYSTEM COMPONENTS :

4.01.00 Microprocessor based Video Switcher/Control System

4.01.01 The Video Switcher/Control System shall be Redundant, Microprocessor based and modular in construction. It should offer full matrix switching capability, i.e., the system should be programmable to display the video from any camera or number of cameras at a time on any monitor, either manually or via independent automatic switching sequences.

4.01.02 The Video switcher/Control System should have provision for minimum 32 camera inputs 2 monitor outputs, keyboards, Digital video recorders, 32 direct connect alarm input points, an integral signal distribution unit, a computer interface port, and a logging printer port including all other hardware / software.

4.01.03 The Video Switcher/Control System should be programmable with up to 30 sequences, which can run independently of each other in either forward or reverse direction. Any of the sequences should utilise the Salvo Switching capability where any number of system monitors may be selected to switch as a group.

4.01.04 The video switcher/control system should have easy provision for integral signal distribution ports, connections to on-site receiver/drivers. It should have built-in alarm interface capability, any monitor or group of monitors could be set to display cameras under alarm conditions. In addition, 16-character alarm title could be selected to appear instead of the camera title during alarm conditions.

4.01.05 The video switcher/control system should include on screen display for time-date, camera number, camera Id, and monitor or status information. The system should have provision for logging printer output port to provide permanent record of system status showing time and date of changes such as : incoming alarms, acknowledgement of alarms, loading of sequences, user log-on to keyboard, transfer of system tables and sequence, video loss messages, and a power up reset message, so that a hard copy of the system’s configuration tables and sequences can be obtained.

4.01.06 The system shall also have the following provisions.

- User friendly spreadsheet format providing the ability to enter camera titles, operator names, timely events, change system parameters, program camera sequences and install lockouts.

- It should provide high performance programming, control and monitoring of all the system functions by using on-screen icons to reflect real time status of the devices being controlled by the system.

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- Software should also provide the ability to monitor system status events. System alarms, switching functions, sequence events, keyboard actions, and video loss information.

4.01.07 All the video switcher/control system shall be connected to a 10/100 Base Fiber Optic full Duplex Ethernet network, to be provided by the Contractor. In case it is the standard practice of the Contractor to provide PC based video switcher / control system to achieve all the above functions, the same is also acceptable.

4.01.08 The CCTV system shall be connected to LVS also.

4.02.00 Keyboard :

4.02.01 Keyboard should have full function used for system control and programming and should be ergonomically designed. It should include integral pan/tilt joystick and zoom lens controls. This would be connected to the video switcher/control system for signal and power.

4.02.02 Keyboard shall have full function used for system control and programming for selection of various video switcher/ DVR / camera functions including pan/tilt and zoom lens controls and shall be ergonomically designed. The Key board shall be able to access DVR and video switcher. Incase it is the standard practice of the contractor to offer PC based integrated keyboard and monitor, then the same is also acceptable, subject to Employer’s approval.

4.03.00 Cameras :

4.03.01 The cameras shall be rugged, 1/4 inch image format, full performance color CCD cameras. These cameras should provide high resolution and high sensitivity suitable for operation in a coal handling plant, both in natural and artificial lighted areas.

4.03.02 The cameras should have features as mentioned below :

- Suitable for night-time surveillance

- Manual or Automatic colour/infra red switching

- Automatic picture enhancement to give a balanced picture where there is too little/too much light

- Remote camera setup, with on screen menu display.

- Character generator giving up to 24 character text-in-picture.

- Backlight composition

- Automatic white balance, with mode selection options

- Contour correction and contrast compression control.

- Synchronisation selection for Gen lock, external V-lock, mains lock and internal free-running.

- All cameras shall be network compatible.

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4.03.03 Detailed technical specifications are as under :

Imager : Interline transfer CCD, 1/4 inch image format

Horizontal resolution : 480TVL in PAL B mode

Sensitivity (at f1/4, 6dB), scene illumination 0.7 lux ( at 50 IRE color)

Light Range

Signal-to-noise : > 50dB.

AGC : Upto 18 dB

Shutter Speed : 1/50-1/1,00,000 LUX. Auto select

Lens Mount : Video Iris

Gamma Correction : 0.45/1.0

Auto-black contour correction : Colour

Contrast compensation : 2.5x

Power Supply : 230V AC

4.04.00 Lens :

4.04.01 The lens should be Auto-iris lens of 1/4 inch to be mounted on the above camera. It should be zoom lens with CS-Mount. The details are as under:

Focal Length : 6 – 90 mm zoom lens (approx.)

Iris range : 1.2 to 360

4.05.00 Camera Housing

4.05.01 All the cameras and accessories are to be housed in Weather Proof (IP-65) environmental housing made of aluminum. The housing with heater and blower installed should provide protection for camera/lens assemblies in the ambient temperature range of - 0 deg. C to 60 deg. C.

4.05.02 The housing should also have thermostatically controlled heater kit, continuous duty blower kit, purge air arrangement and Window wipers available within the housing. Complete assembly including camera shall be suitable for hot and highly polluted environment of Coal Handling Plant.

4.06.00 Pan & Tilt Unit :

4.06.01 The Pan & Tilt unit should be weather proof (IP-65) with pan/tilts designed to meet the rigorous requirement and should be constructed with corrosion resistant hardware.

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4.06.02 They should be capable of handling loads up to 10 kg and should be having 100% duty cycle motors to permit continuous operation.

4.06.03 The pan & tilt should comply with the following :

- Electrical – 230V AC, 50 Hz

- Pan range : 120 deg movement in horizontal plane.

- Pan speed : 6 deg./sec.

- Tilt : +3 deg to –90 deg movement in vertical plane

- Tilt speed : 3 deg./sec.

- Construction : Cast aluminum base and yoke, corrosion resistant cover.

4.07.00 On-site Receiver/Driver Unit :

4.07.01 The on-site receiver/drive unit should be able to control the motor drives for pan/tilt and cameras for zoom and aux control. These would be used in conjunction with the Microprocessor based video switcher/controller systems.

4.07.02 The on-site receiver/driver unit should have features like focus/zoom/iris controls, 99 prepositions lockable enclosure latches, an integral local test function and IP 65 rated environmental enclosure.

4.07.03 The On-site receiver/driver unit should be operated from 230V AC, 50 Hz and provision to be within hazardous are in the vicinity of the camera and pan tilt unit. The cable from the receiver drive unit to the pan/tilt unit and the camera is to be provided with the receiver driver unit.

4.08.00 Monitor & Key board:

4.08.01 The monitors should be colour video monitors that the versatile and attractive units to be mounted on the wall/desk. It should have built in audio. Monitors are to be operable at 230V AC, 50 Hz. They should comply to the following specifications.

General : Automatic degaussing, Fast warm up time

Display tube : 51 cm diagonal, 90 deg deflection, integral implosion protection.

Resolution : 450 TVL minimum

Controls : Colour system select, volume, colour, brightness, contrast, power, video input select and Y/C termination.

4.09.00 Digital Video Recorder:

Parameter Specification

Horizontal Resolution 720x570 lines

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Color system PAL/ NSTC, compatible with the CCTV system being proposed by the contractor.

Recording system Applied JPEG, MPEG, Wavelet or better with Motion detection-Hi performance system.

Recording speed 1-50 frames per second ( fps) , programmable

Inputs 16 channel with Inbuilt Multiplexer and storage for minimum eight days on HDD for all the connected camera signals.

Characters generation Date, hours, minutes and seconds.

Record time by alarm Minimum range from 5 sec. To 3 min, to be finalised during detailed engineering stage.

Input signal Compatible with the finally selected cameras/ network

View Multiple, 2x2, 4x4, single to be finalised during detailed engineering stage.

Power supply Manufacturer’s standard

Search By date, time or cameras

Alarm Inputs Minimum 8.

Video I/P 1V p-p 75 Ohm to be finalised during detailed engineering stage.

Video O/P 1 V p-p 75 Ohm to be finalised during detailed engineering stage.

Zones Minimum 5 User Customizable Zones per camera

Archiving The recorder shall be fully compatible with any standard 10/100 Base FO full Duplex Ethernet port for networking to a central DVD or AIT or Hard Disk Arrays after seven days of recording is over on the HDD. All or selected portions of the recorder material shall be shifted on to AIT or DVD and archived. The Archiving unit shall be common for the stations.

4.09.01 In case the contractor’s standard practice is to provide Digital video recorder which integrates the function of video switcher / controller, then the same is also acceptable. In that case, the DVR shall record multiple camera signals while simultaneously providing live multiscreen viewing and playback.

4.09.02 The images per second rate and image quality shall be selectable for each connected camera. The digital recorders shall allow selectable frames per second (fps) record rates from zero fps to minimum twenty five fps.

4.09.03 DVR shall also have features: on screen display which records time, date, number of alarms etc

4.10.00 Post Equalisation Video Amplifier :

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4.10.01 The post equalisation video amplifier should provide of controls of adjustable overall gain and frequency boost while maintaining full video amplitude, contrast and detail. It should work on 230V AC, 50Hz.

4.10.02 The post equalisation video amplifier should comply to the following :

Gain : adjustable from 1 dB to +8 dB

Frequency response : Adjustable from flat (+/- 1 dB) at 12 Mhz to greater than +18 dB at 12 Mhz.

Controls : Gain, HF boost, LF boost and indication of red LED when power is on.

5.00.00 OPERATIONAL REQUIREMENTS :

The CCTV system should comply to the following operational requirement.

1. From the master control panel(keyboard) it shall be possible to select any camera and display the picture on any of the monitors.

2. Commands from the video switcher/control unit is sent via a onsite receiver/drive unit to the camera which in turn controls the pan/tilt zoom etc., functions.

3. Operator shall be able to control all the cameras, pan / tilt and zoom functions manually.

4. The video recorder shall record the activities of all the places where alarm have been alerted. The time-lapse video recorder shall be able to record up to 720 hrs without reloading.

6.00.00 CABLES :

6.01.00 Power, control and instrumentation cables shall conform to the relevant section of this specification. Any special cables for use in CCTV shall conform to the relevant Indian/International standards. The signal / Video transfer from Cameras to the main control room equipment shall be through fibre optic cable. However all cables shall be FRLS type as specified elsewhere.

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TECHNICAL SPECIFICATIONS SECTION VI, PART-B

BID DOC. NO.:CS- - -

Sub-Section - IIID-01 CHP CIVIL WORKS

Page 1 of 46

CONTENTS

CLAUSE

NO. DESCRIPTION

1.00.00 GENERAL

2.00.00 LAYOUT & LEVELS

3.00.00 DRAWINGS/DOCUMENTS

4.00.00 WORK DESCRIPTION

4.01.00 - Overhead / Ground Conveyor Galleries and Trestles

4.02.00 – Transfer Houses

4.03.00 – Control Buildings, MCC Buildings

4.04.00 – Staircases

4.05.00 – Trenches

5.00.00 Drainage & Water Supply Works

5.01.00 – Drainage System

5.02.00 – Internal and external water supply, drainage

6.00.00 COLOUR COATED AND OTHER SHEETING WORK

7.00.00 ROOF DETAILS

8.00.00 FLOOR AND GRADE DETAILS

9.00.00 BRICKWORK & ALLIED MASONRY WORKS

10.00.00 EARTHING MAT

11.00.00 FENCING

12.00.00 LOADING

13.00.00 DESIGN CRITERIA

14.00.00 CONCRETE

15.00.00 EXCAVATION DETAILS

15.01.00 – Excavation in soil

15.02.00 – Excavation in rock

15.03.00 – Dewatering of deep foundations

15.04.00 – Backfilling, disposal & stacking of materials

16.00.00 Galvanising

17.00.00 Architectural Features

17.01.00 – Glazing

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17.02.00 – False ceiling

17.03.00 – Acid/Alkali Resistant Lining

17.04.00 – Finishing Schedule

17.04.01 – Flooring

17.04.02 – Interior wall/ ceiling finish

17.04.03 – Exterior finish

17.05.00 – Door, windows & rolling shutters

17.05.01 – Doors & Windows

17.05.02 – Rolling Shutters

18.00.00 Painting

19.00.00 Miscellaneous

20.00.00 Packaging & Transportation

21.00.00 Plant Life

22.00.00 PTFE Bearing

23.00.00 Tests for Materials/Workmanship

24.00.00 Materials


Annexure A Criteria for Earthquake Resistant Design of structures & Equipment

Annexure B Criteria for Wind Resistant Design of structures & Equipment

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1.00.00 GENERAL

1.01.00 This section of the bidding document deals mainly with the technical specification needed for the design and preparation of detailed drawings, getting the design and drawings approved by the Engineering, fabrication, erection and construction of the necessary civil, structural and architectural works associated with the coal handling plant to be installed at FARAKKA SUPER THERMAL POWER PROJECT. The work shall have to be carried out both below and above ground level and shall be involving, basements, equipment foundations, slabs, beams, columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, finishes, complete architectural aspects, drainage, sanitation, water supply (from terminal points to various buildings, conveyor galleries), Bituminous access roads (3.75m wide) to all structures and all other civil and structural works associated with the Coal Handling Plant.

1.02.00 The specifications are intended for the general description of the work, quality and workmanship. The specifications are not, however, intended to cover minutest details and the work shall be executed according to the relevant latest Indian Standard Codes / I. R. S. / I. R. C. specifications. In absence of the above, the work shall be executed according to the best prevailing local Public Works Department practices or to the recommendations of relevant American and British Standards or to the instructions of the Engineer. List of I. S. Codes to be followed is mentioned in the Technical Specifications. The Contractor is expected to get clarified on any doubts about the specifications, etc. before bidding, in writing with the Employer in respect of interpretation of any portions of this document.

1.00.00 LAYOUT AND LEVELS

2.01.00 The layout and levels of all structures, etc. shall be made by the Contractor at his own cost from the general grid of the plot and bench mark given by the Engineer. He shall provide all instrument, materials and men to the Engineer for checking the layout and levels. However, the Contractor shall be fully responsible for correctness of layout and levels.

2.00.00 DRAWINGS / DOCUMENTS

3.01.00 The drawings included in the Bidding Document provide a general idea about the work to be performed under the scope of this contract. These are preliminary drawings for bidding purposes only and are by no means the final drawings or show the full range of the work under the scope. Work has to be executed according to drawings prepared by the contractor and approved by the Engineering.

3.02.00 Conceptual arrangement of civil works supported by calculations shall be submitted along with tender bids. Later on, detailed construction drawings and design calculations for all civil works for static as well as dynamic analysis (wherever essential) shall be submitted for approval prior to undertaking construction work.

3.03.00 Design calculations shall be done in STRAPP / M.S. Office (latest version) and Drawings shall be prepared in Auto Cad (latest version). The analysis shall be done by using STADD PRO / ANSYS / STRAPP (latest version). However design may be carried out by manually, using computer work sheets or by using suitable software programmes, as mutually agreed by Employer. Final calculations and drawings shall be submitted in Compact Disc (CD) (2 Sets)

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3.04.00 Civil Task drawings indicating various equipment loading and supporting arrangement and floor loads shall be submitted along with design calculations. Soft copies of all STAAD input files shall be submitted along with the design calculations for all revisions.

3.05.00 Consolidated B.O.Q. for major items of all Architectural, Civil and Structural works shall be submitted structure wise and area wise for N.T.P.C. record. However each drawing shall indicate approximate quantity of structure (Sectionwise) Concrete (Grade wise) and reinforcement (Diameterwise.)

3.06.00 Structural steel fabrication drawings to be prepared by the contractor will not be approved by the Employer. However, the Contractor for Employer’s reference shall submit all fabrication drawings. Copy of detailed bar bending schedule as prepared by contractor shall also be submitted to the Engineering and also to Engineer in charge for the reference.

3.07.00 Approval of construction drawings prepared by the contractor shall not relieve the Contractor of his responsibility regarding the adequacy of design and correctness of the drawing.

4.00.00 WORK DESCRIPTION

It includes the Civil, Structural and Architectural works related mainly to the following areas (but not limited to):

4.01.0 Overhead / Ground Conveyor Galleries and Trestles

Overhead conveyors shall be located in a suitably enclosed gallery of structural steel. The overhead gallery shall consist of two vertical latticed girders having rigid jointed portal frame at both ends. Cross beams at floor level supporting conveyor stringer beams shall be made of single rolled steel beam or single channel section (ISMB or ISMC) or plate girder. Horizontal bracings are to be provided at top & bottom plan of the gallery (latticed girders shall be braced together in plan at the top and bottom). Common end portal frame shall not be used for adjacent conveyor spans. Roof truss shall be provided at upper node points of latticed girders to form an enclosure. The maximum span of overhead gallery shall be limited to 25 meters unless higher span is required due to site conditions, which shall be subject to approval of the Engineer. The gallery should as far as possible be erected as a box section keeping all the vertical and horizontal bracing tied in proper position. The gallery should be checked for all erection stresses that are likely to develop during handling and erection and if required, temporary strengthening of gallery members during erection shall be made.

Seal plates under the conveyor galleries shall be provided in such a way that complete gallery bottom shall form a leak proof floor.

The ground conveyors shall be located in suitably enclosed gallery of structural steel consisting of rigid portal frames spaced at regular intervals and suitably braced. Plinth protection along with drains shall be routed along the ground conveyors.

For double stream conveyor gallery, two side and one central walkway of width 800 mm and 1100 mm respectively shall be provided. The width of two side walkways for single stream conveyor gallery shall be 800 mm and 1100 mm respectively. Both sides of central and side walkways shall be provided with pipe handrails all along the

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conveyor gallery. Hand railing should not be supported on conveyor supporting stringers. The walkways shall be chequered plate construction with anti - skid arrangement. The anti - skid arrangement will consist of welding of 10 mm square steel bars at a maximum spacing of 500 mm along the length of the gallery. Where the slope of walkway is more than 10o, chequered plate steps with nosing and toe guard shall be provided. The floor of conveyor gallery all along the gallery length, shall be provided with minimum 12 gauge thick seal plates and other drainage arrangements as specified elsewhere

Conveyor gallery shall have permanently colour coated steel sheet covers on roof and both sides. However in roof, a panel of minimum 1.5 m x 1.5 m area at about 6.0 m center shall be provided with translucent sheets of polycarbonate material for natural lighting. A continuous slit opening of 500 mm shall be provided on both sides just below the roof sheeting. Adequate provision of windows shall be kept on both sides of conveyor gallery as appended in Mechanical Section (Belt conveyor system). Windows shall be provided with wire mesh as specified elsewhere in this specification.

Cross - over with chequered plate platform and ladder for crossing over the conveyors shall be provided at approximately every 100 M intervals of conveyor. Crossover shall preferably be located over four-legged rigid trestle location.

For railway tracks passing below overhead conveyor gallery and along conveyors, the railway clearances both underground as well as over ground shall have to be adhered to for design, execution and erection of foundations, trestles, galleries etc., so that movement of locomotives and wagons is not hampered in any way during execution and afterwards. However at the location where the overhead conveyor gallery crosses road / rail line, minimum clearance of 8.0m above the road crest / rail top shall be provided.

For calculation of coal load on moving conveyor, a multiplication factor 1.6 shall be used to take care of inertia force, casual over burden and impact factor etc.

Thus coal load per unit length of each moving conveyor shall be

Rated Capacity of Conveyor system 1100

------------------------------------------------ ---------

1.6

X

Conveyor Belt Speed

X

800

It should be noted that for structural design, unit weight of coal shall be assumed as 1100 Kgs. / Cu. M. instead of 800 Kgs. / Cu. M. considered for system sizing purpose.

Conveyor Gallery structure shall be designed considering both conveyors operating simultaneously.

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Conveyor gallery and supporting trestles located between transfer houses / buildings shall be arranged in any one of the following ways.

a) All gallery supporting trestles shall be four legged type only. One end of each gallery span shall be hinged to the supporting trestle and the other end shall be slide type. Slide type support shall be with P. T. F. E. bearings to allow both rotation & longitudinal movements.

b) In between transfer houses / buildings, four legged trestles shall be placed at a maximum interval of 90 metres. The arrangement shall be such so as to ensure that force in the longitudinal direction (i. e. along the conveyor length) of conveyor gallery of length not more than 90 m is transferred to any four legged trestle. In the space between each successive four legged trestles, two legged trestles shall be provided at regular intervals. The end supports resting on the four-legged trestle can have either ends hinged or one hinge and the other on slide type depending on the arrangements. Slide type support shall be with P. T. F. E. bearings to allow both rotation & longitudinal movements.

End of conveyor gallery which will be supported over transfer house, shall be so detailed that only vertical reaction is transferred from conveyor gallery and no horizontal force in longitudinal direction is transferred from conveyor gallery to transfer house structure and vice - versa.

For trestles and trestle foundations for conveyor galleries located adjacent to existing structures, over ground and under ground facilities, location and details of these trestles and foundations shall have to be decided such that there is no interference both underground as well as over ground with existing structures and facilities. Trestle columns / ground conveyor portal column base shall be kept 300 mm higher than the existing ground level.

4.02.00 Transfer Houses

The over ground portion of the transfer house shall be framed structure of structural steel work with permanently colour coated profiled steel sheet side cladding and R. C. C. floors over structural beams. However the lower portion of side cladding for a minimum height of 0.9 m above the finished floor level at ground shall be one brick thick wall plastered on both side. In some areas like MCC floors etc., one brick thick wall cladding shall be provided. Brick wall cladding shall be supported on encased wall beams and suitably anchored to adjoining columns and beams.

Adequate steel doors and windows for proper natural lighting and ventilation shall be provided. In addition to steel windows, panels of suitable size to suit the architectural treatment and made of translucent sheets of polycarbonate material shall also be provided on the side cladding for natural lighting.

Roof shall be provided with troughed profile permanently colour coated sheet on outside and plain permanently colour coated sheet on inside with 50mm thick mineral wool insulation in between the two sheets. A slope of 1 in 5 shall be provided for quick drainage of rain water.

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4.03.00 Control building, M. C. C. Buildings

These shall be R. C. C. framed structures with columns, beams, slabs and foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof shall be provided with roof water proofing treatment, as specified elsewhere in the Technical specification.

In case of control building suitable permanent interconnection shall be provided at appropriate level with the existing respective buildings.

All air - conditioned areas, shall be provided with the suspended permanently colour coated aluminium false ceiling system (details specified elsewhere).

Adequate aluminium doors and windows shall be provided for natural lighting, ventilation and view.

4.04.00 Pump Houses

These shall be of R.C.C. or steel framed structure with columns, beams, slab and foundations etc. cladding shall be of brick work with plastering on both sides. Roof shall be provided with roof water proofing treatment as specified elsewhere. Underground sump and water tanks shall be of R.C.C. Adequate number of doors, Windows and Rolling Shutters shall be provided.

Galvanized steel ladder / rung ladder shall be provided for access to the roof level of the pump house and water tanks.

4.05.00 Staircases

All floors of transfer houses shall be accessible through staircase. However, for the pump houses, access to the roof will be provided by cage ladder

All stairs other than those of M. C. C. rooms and control rooms shall be of steel (minimum 1000 mm wide)and maximum rise should not be more than 180 mm and minimum tread width 250 mm. Stringers shall be of rolled steel channel( minimum ISMC 250 )and tread shall be of steel gratings. Stairs shall be provided with 32 mm dia nominal bore medium duty M. S. pipe hand rail.

Handrails (for staircases, around openings, in walkways etc.) shall be of standard weight steel pipe of flush welded constructions, ground smooth using 32 mm nominal bore medium class pipe provided with double rail, top rail about 1.0 metre above platform level and pipe posts spaced not more than 1.5 metres apart. Angle handrail post may be provided when specifically called for in drawings approved by Engineering. Handrails around openings should have toe plates.

Smooth uniform curves and bends shall be provided at stair returns and also where so ever required. Posts connected to curb plates shall have a neat closure at the bottom and a 6 mm thick plate neatly welded to posts for attachment to curb plate. All necessary fittings including inner dowels at splices, brackets, belts, bends, flanges and chains, where required shall be plugged and welded. A minimum radius of 3 times the pipe diameter shall be provided at all points of direction changes in the handrail.

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Treads and landing shall be suitable for the prescribed loading. The maximum width of openings in gratings shall not exceed 40 mm. The minimum thickness of main bars shall be 6 mm. The usual span of grating will not generally exceed 1.5 meters. Stair case gratings shall be galvanized to grade 610g/m2.

Out side stairs to transfer points shall be open type. However sheeting shall be provided at the top.

All floors and roof of MCC/Control rooms shall be accessible through staircase. Stairs of control room and M. C. C. room shall be of R. C. C. construction, and minimum 1200 mm wide, maximum rise should not be more than 180 mm and minimum tread with 250 mm.

Numbers and arrangement (including enclosures etc.) of stair cases shall be such as to meet the fire safety requirement as per guide lines of statutory regulatory bodies.

4.06.00 Trenches

All trenches for cables or any other underground facility as detailed out elsewhere shall be of R. C. C. Cable trenches shall be provided with pre - cast R. C. C. covers / chequered plate cover. Cable trenches as well as pre - cast covers shall be provided with edge protection angles and lifting hooks. All embedments / block outs as required and specified elsewhere in these specifications shall be provided. Proper drainage arrangement shall be provided. Trench pre - cast cover weight shall not be more than 65 Kgs. Trench covers near entry or at road crossings shall be designed for 10 T wheel load at centre. Pre - cast covers shall be designed for central point load of 75 Kgs. R. C. C. cable trenches shall be filled with sand after erection of cables, up to top level and covered with pre - cast R. C. C. covers. For cable trenches outside buildings, top level shall be 200 mm above G. L.

Minimum 50 x 50 x 6 mm size angles with lugs shall be provided as edge protection all around cut outs / openings in floor slabs, edges of drains supporting grating/precast RCC covers, edges of R. C. C. trenches supporting pre - cast covers, supported edges of pre - cast cover, treads of RCC stairs.

5.00.00 Drainage & Water Supply Works

5.01.00 Drainage System:-

The drainage arrangements shall be so planned so as to ensure quick disposal of drainage water without stagnation and / or overflow. It is envisaged to clean the conveyor galleries, transfer points, crusher building, penthouse etc. with water periodically.

Minimum 4 nos. down comers shall be provided in each transfer house / crusher house. In case of enclosed conveyor galleries, the down comer shall be provided at every trestle location.

For enclosed conveyor galleries each down comer shall lead the water / coal slurry to pit (of 2 Cu.M capacity) to allow settling of coal. The water from the pit shall overflow into contractor’s R.C.C drain, which will lead the discharge finally into existing drain/water body.

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For Non-Drive House/Transfer House each down comer shall lead the water / coal slurry into the peripheral drains (Brick drains with steel gratings provided around the building) which will lead the water / coal slurry to contractor’s RCC drain and finally to the existing drain/water body. In case of Control rooms and M. C. C. buildings Pump houses, etc, water / coal slurry coming from down comers shall discharge into peripheral drains (Brick drains with steel gratings provided around the building) which will lead the water / coal slurry into contractor’s R.C.C drain, which will lead the discharge finally into existing drain/water body. Suitable kick plates/Curb beams shall be provided around the floor openings, stair case landings, in the transfer points, and other buildings. Contractor’s scope shall also include construction of necessary culverts under the rail lines / roads as per railway / I. R. C. standards and approval of Railway culverts from concern Railway authorities.

5.02.00 Internal and external water supply, drainage etc.:-

The scope for potable water supply includes all distribution systems, tanks, pipes, fittings etc. as required and as described here or elsewhere in these specifications.

The scope for service water supply and dust control water supply shall be as described elsewhere in these specifications.

For water supply, medium class galvanized mild steel pipes conforming to IS: 1239 shall be used.

The scope for drainage of surface water shall include design, layout and construction of drains for and from buildings. Drainage system shall be designed for maximum intensity of rainfall as 75 mm/hr and 60 % runoff coefficient. All buildings (including transfer houses/drive house) shall be provided with open surface brick drains of minimum size of 300 mm width and 300 mm depth all around the periphery. All drains excepting the peripheral drains around the transfer points, crusher house, control / M. C. C. buildings, pumps house etc., shall be of R. C. C. construction. All open drains shall have removable steel grating designed for loads as specified under loading clause. Minimum thickness of grating (Galvanised to 610 gm/m2) shall be 12 mm. However at entry or road crossing point’s minimum thickness shall be 40 mm. The opening size of grating shall not be more than 90 mm x 35 mm. All drains as well as pre - cast covers shall be provided with edge protection angles and lifting hooks.

For rain water down comer and those to be used for conveying water / coal slurry generated from cleaning of conveyor gallery and buildings floors, Galvanised MS pipes conforming to IS: 1239 (for 150 mm NB Medium grade pipes) with welded joints shall be used for MCC buildings, pump houses, penthouse, control rooms. Galvanised steel ERW pipes (273mm OD, 4mm thk) of steel grade Fe330 conforming to IS: 3589 with welded joints shall be used for all TP’s, Crusher house, and Conveyor galleries. Galvanising shall be as per IS: 4736. The minimum mass of zinc coating shall not be less than 400 gms/sq.m. as per IS:6745. The zinc coating shall be smooth and shall

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be subjected to testing as per IS: 2633, for uniformity of coating. The zinc coating shall be free from all defects as per IS: 2629. All rain water down comers shall be provided with roof drain heads and complete with shoes bends, junctions, sockets, adapters, brackets and finished with anti corrosive painting over a coat or primer. For design of building drainage system IS: 1742 shall be followed.

For sanitary / sewerage pipes above ground, sand cast iron pipes conforming to IS : 1729 with leak proof lead joints.

For underground drain pipes, minimum class NP - 2 pipes conforming to IS: 458. At road crossings, concrete pipes of class NP 3 conforming to IS: 458 and at rail crossing R.C.C. box culvert to be provided.

For sewerage below ground stoneware pipes conforming to IS: 651 with concrete bedding and haunch.

6.00.00 COLOUR COATED AND OTHER SHEETING WORK

6.01.00 For floor/roof decking, troughed permanently colour coated metal decking sheet, shall conform to any one of the following – (i) of steel with zinc coated to class Z275 with minimum bare metal thickness (

i.e. excluding the thickness of coating and painting) of 0.8mm of grade G250 as per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per EN 10326.

(ii) of steel with zinc coated to class Z275 with minimum bare metal thickness (

i.e. excluding the thickness of coating and painting) of 0.6mm of grade G350 as per AS1397 / grade SS340 class 4 as per ASTM A653M / grade S350GD as per EN 10326 / grade G550 as per AS1397 / grade SS550 as per ASTM A653M / grade S550GD as per EN 10326.

6.02.00 For roofing & side cladding, troughed permanently colour coated sheets (internal or

external) shall conform to any one of the following – (i) of steel with zinc coated to class Z275 with minimum bare metal thickness

(i.e. excluding the thickness of coating and painting) of 0.6mm of grade G250 as per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per EN 10326.

(ii) of steel with aluminium-zinc alloy coated to class AZ150 with minimum bare

metal thickness (i.e. excluding the thickness of coating and painting) of 0.5mm of grade G350 as per AS1397 / grade SS340 class 4 as per ASTM A792M / grade S350GD as per EN 10326.

(iii) of steel with aluminium-zinc alloy coated to class AZ150 with minimum bare

metal thickness (i.e. excluding the thickness of coating and painting) of 0.4mm of grade G550 as per AS1397 / grade SS550 as per ASTM A792M / grade S550GD as per EN 10326.

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6.03.00 Steel shall be colour coated with total coating thickness of 35 microns (nominal) dry film thickness (DFT) comprising of Silicon Modified Polyester paint (SMP with silicon content of 30% to 50%) or Polyester paint, of 20 microns (nominal) SMP or polyester paint on one side (exposed side) over 5 micron (nominal) primer coat and 5 micron (nominal) SMP or Polyester paint over 5 micron (nominal) primer coat on other side,(SMP and Polyester paint shall conform to Product type 4 of AS/ANZ 2728. Coated surface shall be provided with a protected guard film (polyethylene) of about 40 microns to avoid any damage to the coating during handling.

6.04.00 Sheet shall be of approved profile, sectional properties, colour and shade. 6.05.00 Chemical composition of troughed permanently colour coated metal decking sheets

and metal sheet for roofing and side cladding, shall conform to the provisions of the same reference code to which the mechanical properties conform to. Mechanical properties shall be confirmed by relevant tests.

6.06.00 Tolerance on minimum BMT (bare metal thickness) shall be (-)0.00mm and

(+)0.06mm. 6.07.00 Plain permanently colour coated steel metal sheets for ridge and hips, flashings,

trimmings, closure for vertical and horizontal joints, capping etc shall confirm to the same requirements as those of troughed permanently colour coated metal sheet for roofing and side cladding.

6.08.00 For metal decking the sectional modulus and moment of inertia of troughed profile

per meter width shall be so as to limit the deflection of sheets to span/250 for two span condition. The sectional modulus and moment of inertia of troughed profile shall be computed as per the provisions of IS:801 for satisfying the deflection and strength requirements.

6.09.00 For metal roofing and side cladding, the sectional modulus and moment of inertia of

troughed profile per metre width shall be such that the deflection of sheets is limited to span/250 for two span condition. The sectional modulus and moment of inertia of troughed profile shall be computed as per the provisions of IS: 801 for satisfying the deflection and strength requirements. No increase in allowable stress is permissible under wind load condition.

6.10.00 Maximum spacing of the fasteners shall be 390 mm c/c along the length of

beams/purlins / runners. However exact spacing shall be as per the design done by the bidder for the fasteners considering the wind load, self load and other associated loads. Minimum diameter of the fastener shall be 5.5 mm and at least 3 nos. of fasteners shall be used per sheet.

6.11.00 Sealant used for cladding shall be butyl based, two parts poly sulphide or equivalent

approved, non-staining material and shall be flexible enough not to interface with fit of the sheets.

6.12.00 Filler blocks as a trough filler shall be used to seal cavities formed between the

profiled sheet and the support or flashing. The filler blocks shall be manufactured from black synthetic rubber or any other material approved by the Engineer.

6.13.00 For insulation of cladding, mineral wool conforming to IS: 8183 shall be used. The

density shall be 32 or 48 kg. /Cu.M. for glass or rock wool respectively. The nominal thickness of insulation shall be 50mm.

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6.14.00 Special coated fasteners shall be used conforming to corrosion resistant class 3 as

per AS3566 and shall be tested to 1000 hours salt spray test. 6.15.00 The dimensional tolerances of profiled sheets for sheet length, sheet cover width,

straightness, squareness, depth of profile, radius and angle of curved sheets, ripple of side lap, etc. shall be as per “Manufacturing tolerances for profiled metal roof and wall cladding & roofing” by The Metal Cladding & Roofing Manufacturers Association Limited, UK.

6.16.00 Sheets shall be laid with a minimum overlap of 15 cm at the ends and side laps shall

be of one trough length subject to a minimum of 50 mm, having a proper water tight arrangement. The minimum lap of sheets with ridges, hips and valleys shall be 15 cm measured at right angles to the line of the ridge, hip and valley respectively.

6.17.00 Metal decking sheets shall be laid over the supporting beams/purlins with a minimum

bearing of 50 mm and end projection of 75 mm at lap joints. 6.18.00 Flashings, cappings, trimming, closure for vertical/horizontal joints, ridge and hips etc.

shall be provided with a minimum lap of 15 cm. The lapping of sheets shall provide the dust free, airtight enclosure. If required, this may be achieved by using 2-parts polysulphide sealing compound or butyl tape.

6.19.00 Distorted, blemished or water stained sheets shall not be used. 6.20.00 Side and end laps of the sheets shall be made weather proof by securing them with

the fasteners not less than 4.8mm dia with 2.0 mm thick neoprene washer. Maximum spacing of the fasteners should not exceed 500 mm.

6.21.00 Precautions shall be taken during the erection of the sheets to ensure that partially

erected sheets are protected from damage at all times and particularly during inclement weather. Sheets shall be laid over the supporting purlins/runners with a minimum bearing of 50 mm and end projection of 75 mm at lap joints.

6.22.00 Side cladding for Transfer points & conveyor galleries(including roof) shall have

single skin troughed profile permanently colour coated sheets. However, roof of transfer points shall be provided with troughed profile permanently colour coated sheet on outside and plain permanently coated sheet on inside with 50mm thick mineral wool insulation in between the two sheets.

6.23.00 The polycarbonate sheet to be used for cladding and glazing purpose in conveyor

galleries shall have toughed profile to match with the metal cladding profile. Minimum 2.0mm thick fire retardant and UV resistant polycarbonate clean sheet of GE plastic or equivalent approved make shall be used. The polycarbonate sheet shall be installed along with the metal cladding so as to have a watertight lapping arrangement. Suitable detailing shall be made to cater for the thermal expansion. IS:14434 to be referred for other details.

6.24.00 Polycarbonate sheet minimum 6mm thick multi (twin) wall fire retardant (Continuous use under temperature 100oC), impact resistant and ultraviolet resistant sheet shall be provided (as glazing) in transfer houses etc.

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7.00.00 Roof Details

Roof slab shall be minimum 150 mm thick and shall have minimum 10 dia HYSD reinforcement bars placed at 200 mm center both ways at top and bottom.

For efficient disposal of rain water, the run off gradient for the roof shall not be less than 1: 100. This gradient can be provided either in structure or subsequently by screed concrete M-15 (using 12.5 mm coarse aggregate) and / or cement mortar (1: 4). However, minimum 25 mm thick cement mortar (1: 4) shall be provided on top to achieve smooth surface.

900 mm high and minimum 100 mm thick R. C. C. parapet wall shall be provided over roofs of all buildings. Parapet wall shall have suitable coping. External face of parapet wall of the buildings provided with metal cladding shall also be finished with metal cladding of design and colour as per approved architectural drawings.

Junction of roof and parapet shall be provided with 150 x 150 mm size concrete fillet.

Drain level shall be provided with 45 x 45 cm size khurras having minimum thickness of 30 mm of M-15 concrete over PVC sheet of 1 m x 1m x 400 micron and finished with 12 mm 1 : 3 cement : sand plaster.

Roofs of all transfer houses, crusher houses, control rooms, M. C. C. rooms, penthouse etc., shall have roof water proofing treatment. Roof water proofing treatment shall be as follows:

1) Application of polymerised mastic over the RCC roof to achieve smooth surface as primer coat.

2) Application of high solid content liquid applied urethane based elastomeric water proofing membrane, over the primer coat, to give uniform joint less dry film thickness of minimum 1.5 mm (as per ASTM C 836 and C 898).

3) For efficient disposal of rain water, the run off gradient for the roof shall not be less than 1: 100. This gradient shall be provided by screed concrete M-15 (using 12.5 mm coarse aggregate) and / or cement mortar (1: 4) over the elastomeric water proofing membrane with 25mm thick cement mortar (1:4) topping.

4) Wearing course at top, shall consist of 25 mm thick P. C. C. (M-15) cast in panels of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized chicken wire mesh and sealing of joints using sealing compound / elastomeric water proofing membrane. Pathways for handling of materials and movement of personnel shall be provided with 22 mm thick chequered cement concrete tiles as per IS : 13801 for a width of 1000 mm in place of P. C. C.

8.00.00 Floors and Grade level details

The floor slabs shall be minimum 150 mm thick and shall have minimum 10 dia HYSD reinforcement bars placed at 200 mm center both ways at top and bottom Floors of transfer points/drive house shall have cross slope of not flatter than 1: 80, towards the floor washing drainage outlets, for efficient drainage. For ground conveyor & crusher house slope shall be 1:100.

Chequered plates (used for floors, walkways etc.) shall be minimum 6 mm thick o/p or as indicated on drawings. The chequered plate pattern shall be approved by

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Employer / Engineer. Mild steel flats/angles of suitable size shall be welded to the bottom portion of chequered plates at a designed spacing to stiffen chequered plates suitably. Chequered plates shall be fixed by staggered welding of suitable size. Floors of trenches shall have integral finish to concrete base.

Toe guard of size 100 x 6 mm shall be provided at various openings provided in floors e.g. around stair case openings, chute openings and other similar cutouts. For conveyor walkways, angle runner to act as toe guard shall be provided.

All along the periphery of R. C. C. floors (where no brick masonry walls are provided) shall be provided with one brick thick 300 mm high brick wall and 700 mm high steel hand rails all around over this brick work.

The grade slab shall consists of 230 mm thick rubble soling (63 mm downgraded hard stone aggregate as per IRC specification, watering and compaction to minimum of 90% Standard Proctor density, including filling the interstices of stone aggregates with sand), over well compacted earth, overlaid by 75 mm thick P. C. C. M-7.5 and 100 mm thick R. C. C. of grade M-20 with minimum 8 mm dia bars placed at 200 mm C / C in either direction respectively. There will be minimum 50 mm thick metallic hardener finish over the R. C. C. slab.

All buildings (including transfer houses/drive house) and ground conveyors shall be provided with 750 mm wide plinth protection all around. It consists of 50 mm thick P.C.C. M-20 grade with 12 mm maximum size aggregate over 200 mm thick stone soling using 40 mm nominal size rammed, consolidated and grouted with fine sand.

An area of 5 m width all round the transfer houses /drive house shall be paved. This paving will be in addition to plinth protection. The paving construction shall be as per specifications for the grade slab at ground level. However, 50 mm thick metallic hardener finish is not required to be provided in paved area.

Plinth level of all buildings shall be kept at least 500 mm above the finished grade / formation level.

9.00.00 Brickwork and allied masonry works

All brick walls shall be non - load bearing in-filled panel walls.

All brickwork shall be designed as per Indian Standards and shall be plastered on both faces. All external walls shall be minimum one brick thick in 1: 6 cement: sand mortar. Brick walls shall be provided with 12 mm and 18 mm thick 1: 6 cement: sand plaster on smooth and rough face of the brick work respectively.

Bricks to be used in brickwork shall be of minimum Class designation 50.

Brickwork cladding for various structures shall be so provided that there is a clear gap of 40 mm between inside face of external brick wall and outside face of column flange. Structural steel wall beams supporting brickwork shall be suitably encased with plaster or 1: 2: 4 concrete as the case may be. In case of box type steel beam, encasement shall be done with cement sand plaster in specified thickness and proportions over G. I. wire netting of 0.9 mm thickness.

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Parapets, chajjas, windows and door heads, architectural faces, fins etc. shall be provided with drip course in 1 : 4 cement sand mortar.

50 mm thick Damp proof course shall be provided at plinth level for all brick wall.

All R. C. C. ceilings shall be rendered smooth and finished with whitewash unless otherwise specified. Ceiling of control rooms, M. C. C. rooms (except areas provided with false ceiling) shall be provided with 6 mm thick plaster.

10.00.00 Earthing Mat

40 mm Dia MS Rods as earthing mat, placed at a distance of 1.0M away and at depths between 0.60M and 1.00M shall be supplied and laid all around the periphery of buildings, structures, and outdoor equipment, as per the approved drawings. Risers of 40 mm Dia MS Rods and connecting to the above Earthing mat shall also be supplied and laid in position by the Contractor, as per the approved drawings. Risers shall be laid up to a height of 300 mm above the local Ground level, at each of the columns of the buildings on outside of the buildings, and minimum 2 (Two) numbers for structures and outdoor equipment. The contractor also supply and lay necessary number of 3.0 M deep vertical 40 mm Dia MS Rods Earthing electrodes and connecting them to the Earthing mat, as per the approved drawings and the supplying and laying of 40 mm Dia MS Rods for connecting the Contractor's earthing mat with the Employer's earthing mat separately at two locations.

11.00.00 Fencing

Fencing with toe wall and steel gates shall be provided around the transformers. Fencing shall comprise of PVC coated GI chain link fencing of minimum 8G (including PVC coating) of mesh size 75 mm and of height 2.4 m above the toe wall. The diameter of the steel wire for chain link fence (excluding PVC coating) shall not be less than 12G. Fence posts shall be of pre – cast R. C. C. of minimum M20 grade. All corner posts will have two stay posts and every tenth post will have transverse stay post. Suitable R. C. C. foundation for the post and stays shall be provided based on prevailing soil conditions. Gates shall be sturdy with locking provisions.

Toe walls of brick masonry shall be provided between fence posts all along the run of the fence with suitable foundation. Toe wall shall be minimum 200 mm above the formation level with 50 mm thick P. C. C. coping (1: 1. 5: 3) and shall extend minimum 300 mm below the formation level. Toe wall shall be plastered on both sides and painted with two coats of cement paint of approved colour and shade. Toe wall shall be provided with weep holes at suitable spacing.

12.00.00 LOADING

For consideration of loads on structures IS : 875 - ‘Code of practice for structural safety of buildings’ shall be followed. In addition to the dead load, live load, equipment load (including impact / vibration). Temperature loads etc. various loading conditions arising due to operation and maintenance of equipment shall be considered in the design. The structure and equipment shall also be designed for seismic loads as per the “Criteria for Earthquake Resistant Design of Structures and equipment" and the “Criteria for Wind Resistant Design of Structures and equipment" specified in the Annexure A and B respectively in Civil Section, whichever is governing. Wind and seismic forces shall not be considered to act simultaneously.

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The following minimum live loads shall be adopted for the design of various structures. If actual expected load is more than the specified load, then actual load is to be considered.

a ) Roofs 150 Kgs. / Sq. M. for accessible roofs

and 75 Kgs. / Sq. M. for non - accessible roofs. In addition to this coal dust load (Dead load) of 150 Kgs. / sq. m. on flat roofs & 75 Kgs. / sq. m. on inclined roofs shall also be considered.

b ) R. C. C. floors

500 Kgs. / Sq. M.

c ) Stair and balconies

500 Kgs. / Sq. M.

d ) Toilet rooms

200 Kgs. / Sq. M.

e ) Chequered plate floors

400 Kgs. / Sq. M.

f ) Walkways ( including walkways in conveyor galleries )

300 Kgs. / Sq. M.

g ) Conveyor galleries In addition to the live loads, loads due to cable trays, fire fighting / service water pipes shall also be considered @ 125 Kgs. / m ( minimum ) on each of the longitudinal girder. Roof-truss members are to be checked for supporting fire fighting pipes/ Service water pipes. Tentative locations and diameter for pipes are shown in Tender Drawing.

h ) Road Culverts and its allied structures including R. C. C. pipe crossing & road crossing of trenches.

For class 'AA' loading and checked for class A loading as per IRC standard.

i ) Channels / trenches In addition to earth pressure and water pressure, etc. additional earth pressure due to surcharge of 2T / Sq. M. shall also be considered for design.

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

k ) Sumps and tanks and other underground basement type structures

In addition to earth pressure with a surcharge of 2T / Sq. M. (or surcharge due to Railway loading whichever is critical for Railway load bearing

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structures etc.) and sub - soil water pressure etc. These are also to be designed for the following conditions : i ) Water / liquid inside and no earth outside (applicable only to such structures which are liable to be filled up with water or any liquid ). ii ) Earth with surcharge outside and no water / liquid inside iii ) For underground (basement) structures protection against buoyancy during execution and after execution shall be ensured without superimposed loadings with minimum factor of safety of 1.2 against buoyancy.

l ) Unit weight of coal shall be taken as 1100 Kgs. / cum. for design purposes.

If the erection load is higher than the specified live loads on any floor or part thereof,

then the erection loads are to be considered for the design.

Permissible increase in stresses of materials and bearing pressure of soil due to wind load or seismic load shall be as per relevant I. R. S. and I. S. code.

13.00.00 DESIGN CRITERIA

The design of all R. C. C. structures shall be carried out as per ‘code of practice for plain and reinforced concrete for general building construction’, IS : 456 ( latest ).

The steel structures shall be designed and fabricated as per ‘code of practice for use of structural steel in general building construction’, IS : 800 ( latest ) and other relevant IS Standards. Minimum size of the angle section to be used as structural members shall be 50 X 50 X 6. Minimum weld size shall be 6 mm. Connections shall be designed for 70 % of shear capacity of the member or the actual shear force, whichever is higher.

The building shall conform to local bye - laws, rules and regulations for industrial buildings and also B. I. S. publications, SP 32 and 41.

Slotted holes shall not be assumed to act as expansion joint for relieving of stresses and suitable bearings shall be provided at the supports.

All gallery supporting trestles shall be so proportioned that the transverse deflection of gallery due to wind / seismic load should not exceed trestle height / 1000 as stipulated in IS: 11592. This deflection condition shall be strictly followed. Peak wind speed method shall be considered for checking the transverse deflection.

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The transfer house structures shall be so designed that transverse deflection at places where conveyor galleries meet, should be equal to the respective transverse deflection of conveyor supporting trestles.

Stresses for all CHP structures shall be checked for the higher of the forces obtained from gust factor method and the peak wind speed method.

The permissible vertical deflection for beams supporting drive machinery shall be restricted to span / 500 and for other beams it shall be within span / 325.

Horizontal bracing system shall be provided at floor levels around the openings.

Shear force in steel columns shall be transferred to the pedestals / foundations exclusively either through foundation bolts or the shear key arrangement.

For design of liquid retaining structures, IS : 3370 ( Part - I to IV ) ( latest ) shall be followed. Face of the structure in contact with liquid shall be designed as un - cracked section. For design of R. C. C. pipes for culverts, latest editions of IS : 458, IS : 783 should be followed.

For design of all underground structures / foundations, ground water table shall be assumed at the formation level ( i. e. the adjoining ground level ).

Design of masonry walls shall be made as per IS : 1905.

Civil task drawing indicating various equipment loading and supporting arrangement and floor loads to be submitted along with the design calculation.

For metal roofing and side cladding, the spacing of purlins/runners shall be such that the deflection of metal sheet used is limited to span/250 under adverse loading condition.

Minimum reinforcement shall be provided at the top face of the footing, even if, no reinforcements are required as per design.

14.00.00 CONCRETE

All R. C. C. works to the done under this specification, unless specified otherwise shall be design mix concrete. Minimum grade of concrete for various structures shall be as follows:

a ) M30 - For underground / sub structural R. C. C. work (other than railway load bearing structures).

b ) M25 - For R. C. C. superstructure works including ground floor slabs, trenches & drains.

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Minimum 75 mm thick P.C.C M-7.5 shall be provided as mud mat below all foundations.

For concreting of underground structures requiring water tightness, plasticizer cum water proofing admixture shall be added to the concrete mix.

Both coarse and fine aggregates shall conform to IS: 383 for concrete, shotcreting etc. unless otherwise mentioned.

15.00.00 Excavation Details

15.01.00 Excavation in soil

Excavation for foundation shall be to the bottom of lean concrete and as shown on drawing or as directed by the Engineer. The bottom of all excavations shall be trimmed to required levels and when excavation is carried below such levels by error, it shall be brought back to the specified level by filling with concrete of nominal mix 1 : 3 : 6 (cement: coarse sand: 40 mm down aggregates ), as directed by the Engineer.

The Contractor shall ascertain for himself the nature of materials to be excavated and the difficulties, if any, likely to be encountered in executing this work. Cofferdams, sheet piling, shoring, bracing to maintain suitable slopes, draining etc. shall be provided and installed by the contractor, to the satisfaction of the Engineer.

Surplus excavated materials shall be disposed off by the contractor at locations up to a lead of 5 kms from the plant boundary wall as directed by the engineer.

The Contractor shall have to constantly pump out any water collected in excavated pits and other areas due to rain water, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, concreting, Backfilling is completed. The Contractor shall remove all slush/muck from the excavated areas to keep the work area dry. The Contractor, if required, shall employ sludge pumps, for this purpose.

For other details, excavation clauses as given in Sub-Section III-D-02 are to be referred.

15.02.00 Excavation in rock

For the work of excavation in rock, Contractor shall engage specialised agency having experience of excavation in rock involving wedging and blasting. The agency shall be subject to approval of Engineer and the Contractor shall furnish details of relevant experience in support while seeking approval for the agency.

Blasting shall be resorted to only with the written permission of the Engineer. All the statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc. pertaining to the acquisition, transport, storage, handling and use of explosives etc. shall be strictly followed.

The contractor shall obtain Licenses from Competent Authorities for undertaking blasting work as well as for procuring, transporting to site and storing the explosives

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as per Explosives Act. The Contractor shall be responsible for the safe transport, use, custody and proper accounting of the explosive materials.

Surplus excavated materials shall be disposed off by the contractor at locations up to a lead of 5 kms from the plant boundary wall as directed by the engineer.

The Contractor shall have to constantly pump out any water collected in excavated pits and other areas due to rain water, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, concreting, backfilling is completed.

15.03.00 De-watering of Deep Excavations

For deep underground structures like track hopper, machinery hatches, tunnels and underground transfer houses, requiring open excavation with extensive de - watering, completely dry working conditions during excavation, shuttering, placement of reinforcement, concreting, water proofing of structures, backfilling and any other operation shall be maintained by suitable de - watering method of suitable capacity.

15.04.00 Backfilling, Disposal and Stacking of materials

Backfilled earth shall be compacted to minimum 90 % of the standard proctor density at OMC. Sand filling shall be compacted to minimum 80 % of the relative density. Also refer Sub-section III D-02 for more details.

However, the backfill under the rail lines and roads shall be compacted to minimum 95 % of the standard proctor density at OMC unless otherwise stated by rail Authorities.

The contractor is required to excavate upto any depth as shown on the drawings or as directed by the Engineer. Lifting of excavated materials shall be done either by manual or mechanical or both means if called for by the Engineer.

The disposal / stacking areas for excavated materials shall be indicated by the Engineer. The carriage of excavated materials shall be done by the methods mentioned below:

The excavated materials shall be carried beyond the initial lead of 50 m but upto 500 m by manual / animal labour or by mechanical means. If directed by the Engineer this material shall be used directly for filling purposes.

For leads exceeding 500 m the Contractor shall transport the excavated materials by mechanical means only and as directed by the Engineer. The Contractor may be allowed to carry materials through Kuccha roads. Providing and maintaining of the Kuccha roads shall be the responsibility of the Contractor. The transported material shall be neatly stacked as directed by the Engineer.

Some excavated materials required for filling purposes, may have to be carried upto a lead of 500 m and stacked as per instructions of the Engineer. Excavated materials carried beyond 500 m shall normally be for disposal purpose only. Double handling of materials shall be avoided as far as possible. However, depending on site condition

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excavated materials carried beyond a lead of 500 m may also be required to be brought back for filling purpose.

Materials to be used for filling purpose shall be stone, sand or other inorganic materials and they shall be clean and free from shingle, salts, organic matter, large roots and excessive amount of sod, lumps, concrete or any other foreign substances which could harm or impair the strength of the substances in any manner. All clods shall be suitably broken to small pieces. When the materials are mostly rock boulders, these shall be broken into pieces not larger then 150 mm size. Sand used for filling shall be clean, medium grained and free from impurities. Fines less than 75 microns shall not be more than 20%. In any case, the materials to be used for filling purposes shall have the prior written approval of the Engineer.

In case the materials have to be brought from pits / quarries, then it shall be the Contractor’s responsibility for identification of such quarry areas, obtaining approval from their use from concerned authorities, excavation / quarrying loading and carriage of such material, unloading and filling at specified locations. The Contractor shall pay any fees, royalties etc. that may have to be pain for utilisation of borrow areas.

16.00.00 GALVANISING

All burrs and irregular edges of the structural steel members to be galvanised shall be ground smooth before galvanising.

Purity of Zinc to be used for galvanising shall be 99.5 % as per IS : 209 ( latest edition ).

The weight of the zinc coating shall be at least 610 Gms. / m2 unless noted otherwise.

18.00.00 Architectural Features

All architectural features of buildings like control rooms, crusher houses, M. C. C. rooms, transfer houses and conveyor galleries etc. shall be detailed by contractor’s qualified architect. Necessary projections, fins etc. in addition to the minimum specified elsewhere in this specification shall be provided as required. The Contractor for Employer’s approval shall submit detailed architectural drawings along with colour schemes. Nothing extra shall be payable for any changes required while getting the drawings / schemes approved and for executing the same.

In case structural column base plates are proposed below the floor level, the same shall be encased with adequate cover up to the finished floor level with minimum M - 20 grade concrete. Dowels shall be left from the pedestals to be lapped to the skin reinforcement of the encasing.

18.01.00 Glazing

Window glazing for various locations shall be as below:

(i) In transfer houses, crusher house and pump houses etc:

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6mm. thick toughened float glass & Polycarbonate sheet (Details described elsewhere).

(ii) In Switchgear / M. C. C. buildings

(a) In air conditioned (A / C) areas:

Composite double glazing with clear float glass of 6 mm thick on one side and 6mm thick tinted glass on the other side hermetically sealed and separated by 12 mm thick gap for thermal insulation at partition of A / C and non A / C areas.

Composite double glazing with clear float glass of 6 mm thick on inside and 6mm thick toughened reflective glass hermetically sealed and separated by 12 mm thick gap for exterior windows.

(b) In toilets:

Frosted glass of minimum thickness 6 mm.

(c) In other areas:

Toughened glass of minimum thickness 6 mm

The above mentioned glass thickness are bare minimum only and actual thickness will depend on the panel size of the glazing to be provided.

18.02.00 False Ceiling

All air - conditioned areas, shall be provided with the suspended permanently colour coated aluminium false ceiling system with corrosion resistance aluminium alloy panels of minimum thickness 0.5 mm. The suspension system for false ceiling shall be as per manufacturers guidelines.

Additional hangers and height adjustment clips shall be provided for returns air grills, light fixtures, A. C. ducts etc.

Under deck insulation shall be provided on the ceiling (underside of roof slab) and underside of floor slab of air - conditioned areas depending upon the functional requirements. This under deck insulation shall consist of 50 mm thick mineral wool insulation mat conforming to IS: 8183 having a density of 32 kg/cum for glass wool or 48 kg/cum for rock wool, backed with 0.05mm thick aluminium foil and 24G x 25 mm mesh wire netting and shall be fixed to the ceiling with 14G wire ties.

18.03.00 Acid / Alkali Resistant Lining

Battery Room

Acid, alkali and oil resistant high build self smoothing, seamless epoxy resin floor finish, on horizontal and vertical surfaces, at all levels, for all types of works, including all labour, material, equipment, scaffolding, handling, transportation, preparation of surface, application of epoxy based primer coat, of approved colour,

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quality and make to give minimum thickness of 300 micron (in two coats) and dado upto 1200 mm, etc., all complete, shall be provided.

18.04.00 FINISHING SCHEDULE

The contractor's scope also includes all doors, windows, glazing, rolling shutters, finishes, damp proofing, inserts, anchor bolts, embedments, stairs, nosing, railings, toe - guards, ladders, edge protection angles, etc.

The Contractor shall adhere to the finishing schedule as given.

18.04.01 Flooring

I. P. S. (cement concrete flooring) with metallic hardener topping shall be provided for all floors in track hopper, wagon tipplers, reclaim hopper, transfer houses, including ground floors of transfer houses, ground conveyors, operating floor of pump houses, M. C. C. rooms, cable vault / cable spreader rooms, maintenance and unloading areas, general storage areas and all other areas in plant buildings where heavy duty flooring is required.

Heavy Duty Ceramic Tiles (matt finish), 300mm x 300mm x 7mm of approved colour shade & finish, shall be provided for floors of toilets, pantry, etc with 300 x 200mm designer wall ceramic tiles for dado in toilets & pantries.

Vitrified ceramic tile (mirror polished) 600 x 600 x 10mm thick shall be provided for floors of office rooms, conference room, laboratories, control room & control equipment room and for dado upto false ceiling.

Well polished marble stone (20mm thick) shall be provided for staircases, passages, lobbies and general circulation areas.

The nominal total thickness of floor finish shall be 50 mm i.e. under bed and topping. The floor shall be laid on an already laid and matured concrete base.

Sunken R. C. C. slab shall be provided in false flooring area and toilet area so as to keep the finished floor level of these areas same as that of the surrounding area.

Wherever specified metallic hardener topping shall be 12 mm with ordinary grey cement.

Paving details shall be similar to grade slab excluding metallic hardener.

Skirting in general shall be 150 mm high. Dado in toilets and pantries shall be up to 2.1 m height from finished floor level. Skirting and dado shall match with the floor finish.

18.04.02 Interior Wall / Ceiling Finish

For all air conditioned control room, 600 x 600 x 10mm th. Vitrified ceramic tile dado shall be provided upto false ceiling and for other air - conditioned areas acrylic emulsion paint of approved make and shade over 2 mm thick plaster of paris punning shall be provided.

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For toilets and pantries minimum 300 x 200 mm thick decorative coloured ceramic tiles of approved make and shade with approved pattern up to 2.10 m. height from finished floor level shall be provided. Oil bound distemper over plaster of paris punning above 2.10 m height shall be provided.

For all other areas oil bound distemper ( IS : 428 ) of approved shade over 2 mm thick plaster of paris punning shall be provided.

For battery room and other areas coming in contact with acid / alkali fumes, chemical resistant chlorinated rubber paint shall be provided above 2.1 m height. Up to 2.1 m height from finished floor level acid alkali resistant epoxy resin finish shall be provided as specified elsewhere.

All R. C. C. ceilings shall be finished with acrylic distemper.

18.04.03 Exterior Finish

Permanently colour coated M. S. / High tensile steel metal cladding ( non - insulated ) of approved colour combination shall be provided for transfer points, conveyor galleries, elevator shafts, and parapet walls of buildings where metal cladding is specified. The cladding sheets shall be coated with silicon modified paint as specified elsewhere.

Solvent based acrylic exterior paint in combination with textured paint with 2.5mm stone chips in the ratio of 3 : 1 shall be provided for the under mentioned areas :

(a.) All buildings with R. C. C. framework unless specified otherwise in this specification.

(b.) Brick work in the lower portion of metal cladding.

(c.) Fire walls

(d.) Projections and facia : R. C. C. parapets ( excepting parapets of buildings where metal cladding is specified )

(e.) Exterior brick walls.

18.05.00 DOORS, WINDOWS AND ROLLING SHUTTERS.

18.05.01 Doors and Windows

All doors, windows and ventilators of control room building, S and T control room and M. C. C. buildings shall have Electro colour coated (anodised) aluminium frame work with glazing. All doors of office and toilet areas shall be of factory made pre-laminated particle board (M D F exterior grade). All other buildings shall have steel doors, windows and ventilators.

Single glazed panels with aluminium framework shall be provided as partition between two air - conditioned areas wherever clear view is necessary.

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Coal conveyor galleries shall have steel windows of openable type. The window shutters shall be provided with M. S. louvers.

All steel doors shall consist of double plate flush door shutters. The door shutter shall be 45 mm thick with two outer sheets of 18 G rigidly connected with continuous vertical 20 G stiffeners at the rate 150 mm centre to centre. Side, top and bottom edges of shutters shall be reinforced by continuous pressed steel channel with minimum 18G. The door shall be sound deadened by filling the inside void with mineral wool. Doors shall be complete with all hardware and fixtures like door closer, tower bolts, handles, stoppers aldrops, etc.

Windows of coal galleries shall be provided with welded wire fabric of 1.6 mm thick wire as per IS: 4948 and 12 mm x 30 mm mesh size.

Wherever functionally required rolling shutters shall be provided and these shall be either electrically operated or manually operated or with geared arrangement.

In transfer points, windows near floors shall be steel and openable types. The window shutters shall be provided with MS louvers. Windows / ventilators at higher level can be of steel with fixed glazing. All openable windows shall be provided with suitable stays.

All windows and ventilators on ground floor of all switchgear and M. C. C. buildings shall be provided with suitable anodized aluminium grill.

Fire - Proof doors with panic devices and all necessary fixtures shall be provided at all fire exit points as per the recommendations of statutory regulatory bodies These doors shall generally be as per IS : 3614 ( Part I and Part II ) meeting TAC requirements. Fire rating of the doors shall be as per requirements of statutory regulatory bodies. However minimum rating shall be 2 hours. These doors shall be double cover-plated types with mineral wool insulation.

Hollow extruded section of minimum 2 mm wall thickness as manufactured by INDAL or equivalent shall be used for all aluminium doors, windows, and ventilators.

All doors should have opening as indicated in the drawings. Doors and windows on external walls of the buildings having brick enclosures i.e. enclosure other than with permanently colour coated steel sheet cladding, shall be provided with sunshade over the openings with width 600 mm more than the opening width. Projections from the wall for the sunshade shall be 500 mm over window openings and 500 mm over door openings. Minimum size of door provided should be 2.1 m high and 1.2 m wide, except for toiler rooms, where door may be 0.75 m wide. All doors ( other than those in W/C and urinal area ) shall be double plate flush door shutters. For W/C and urinals area, wooden panel doors shall be provided. Area of windows shall be at least 10 % of the floor area of the respective building. The area of translucent polycarbonate sheet panels shall also be at least 10 % of the floor area of the respective building.

Monorail doors shall be provided with steel stays / chains etc for convenient operation of the shutters.

The louvre blade shall be ‘Z’ shaped and made out of 18G sheets in EZ7 steel frames. The frames shall be of ISMC 100.

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18.05.02 Rolling Shutters

Rolling Shutters/ grills shall be with motor drives, gear arrangement including all accessories and shall conform to IS: 6248. All electrical work shall be in strict accordance with the relevant Indian Electricity Rules.

After installing the shutters, the Contractor shall test the performance of the shutter in presence of the Engineer. The shutters shall be smoothly operable under all ambient conditions. All control and locking devices shall give fault free performance.

19.00.00 PAINTING

Painting of all steel structures, including seal plates, hand rails, steel doors & windows, ventilators, louvers, Rolling Shutters Stair Cases (except gratings), etc. shall be with paints as per following:

19.01.00 Materials

Zinc silicate primer (minimum 75 micron Dry Film Thickness - DFT) shall be inorganic (Ethyl) self curing high built (Solid by volume minimum 60%) formulation as per BS : 5493 (Inorganic Zinc rich systems).

Intermediate (Under) coat (minimum 75 micron DFT) shall be of polyamide cured titanium di-oxide / micaceous iron oxide pigmented high performance (solid by volume minimum 60%) epoxy coating as per BS : 5493 ( two pack chemical resistant under coats).

Finish coat (minimum 75 micron DFT) shall be of polyamide cured colored pigmented high performance (solid by volume minimum 60%) epoxy coating as per BS: 5493 (two pack chemical resistant finishes).

Final finish coat (minimum 25 Micron DFT) shall be of polyurethane colour pigmented (solid by volume minimum 40%) as per BS: 5493 (two pack chemical resistant finishes).

All paints including primer shall be of reputed brand / manufacturer and as approved by the engineer.

19.02.00 Preparation of Surface

The surfaces shall be blast cleaned to near white metal surface (Sa 2 ½) i.e. 2nd quality (requiring at least 95% of the surface completely cleaned) as given in BS : 4232 . For blast cleaning shot blasting shall be used.

Approved type of abrasives shall only be used for blast cleaning of steel surfaces by shot blasting. Suitable enclosure shall be provided to carry out the blast cleaning operation. If required prior approval from the factory inspector / pollution control board etc. shall be obtained regarding the method of blast cleaning and abrasives used therein.

Immediately after blast cleaning of the steel surfaces, primer coat shall be applied onto the surfaces.

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19.03.00 Application of paint

The contractor shall submit the total painting scheme and works shall be started after the approval of the scheme, from the engineer.

Painting works shall be carried out on structural as per the approved scheme. The total painting scheme to be submitted to the engineer shall include the following:

i) Method of blast cleaning giving the details and sizing of various equipment required, abrasive used, enclosure provided to avoid contamination of the adjoining area, expected productivity on an eight (08) hour shift working etc.

ii) Arrangement of airless spray with the equipment rating.

iii) Drying time to be allowed before the application of subsequent coat.

iv) Recommended paint for primer, intermediate (under) coat, finish coat and final finish coat with their brand name and designation, considering the requirements of BS : 5493 for long range (typical time to first maintenance 10 to 20 years), life for exterior exposed non polluted inland atmosphere.

v) Number of coat and the thickness of each coat to be applied to achieve the specified thickness of each coat i.e. primer, intermediate (under), finish and final finish coats.

vi) Environmental conditions i.e. ambient temperature and humidity at the time of application of the paint.

vii) Quality control setup for painting i.e. checking of surface preparation, thickness of each coat, quality of applied paints vis-à-vis the approved sample etc.

viii) Method of touch up painting for surfaces damaged during handling, transit, erection, welding, subsequent to painting, removal of the temporary supports etc.

ix) Reference of relevant Indian / International standards for the testing and acceptance.

Before application of inorganic zinc silicate primer, the steel surfaces shall be blast cleaned to near white metal surface (Sa 2 ½).

Primer paint and intermediate (Under) coat shall be done by airless spray. However finish coat and final finish coat can be applied either by spray and or brush.

All subsequent coats shall be applied only after acceptance of the previous applied coat. Inaccessible surfaces shall be primer painted before shop assembly.

For final touch up painting of surfaces, which are damaged during handling, transit, erection, etc. surfaces shall be well prepared, by rubbing the entire damaged area using wire brush, emery paper etc. and shall be provided with minimum 100 micron (DFT) of self priming high build epoxy based primer followed by intermediate, finish and final finish coats as described elsewhere in this document. Touch up painting of

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areas welded subsequent to painting and areas exposed after removal of temporary supports shall also be carried out in same way.

Rectification of the damaged painted surfaces on account of welding / handling etc. of each coat shall be done by touch up painting, before the application of next coat, using minimum 100 micron (DFT) self priming high build epoxy based primer followed by various coats in sequence of thickness as specified elsewhere.

19.04.00 Acceptance Criteria

All painted surfaces shall be uniform and pleasing in appearance.

Dry film thickness of each coat shall be checked and measured by using elcho-meter. The thickness as measured shall not be less than the minimum thickness specified for the coat of paint under relevant clauses of the technical specification.

Measurement of paint thickness shall be as per “SSPC : The society for Protective Coatings Paint Application Standard no. 2” titled “Measurement of Dry Coating thickness with magnetic gages”.

Colour, texture shall match exactly with the approved sample.

20.00.00 Miscellaneous

20.01.00 Ordinary form work shall be used in roofs and floor slabs in transfer houses, footings, pedestals, cable trenches, pits etc., Plywood form work shall be used for all over ground exposed work like columns, beams, floors and ceilings in control room and M. C. C. buildings.

20.02.00 Monorail girders and fixtures shall be provided for monorails at the locations as required and as described elsewhere in these specifications or drawings. Monorail openings in the walls shall be provided with steel frame doors preferably sliding type or otherwise open able inside, access platforms and ladders.

20.03.00 Steel frame around openings in roof and on external walls for mounting of exhaust fans shall be provided.

20.04.00 Ready mix non - shrink cementitious grout of reputed manufacturer as approved by the Employer shall be used for grouting of block outs and foundation bolts, underpinning of base plates and machine bases. Crushing strength of grout shall be one grade higher than the foundation concrete. Minimum crushing strength shall be 30 N / mm2 unless higher strength requirement is specified by the equipment supplier or the grout manufacturers.

20.05.00 The bottom of steel in case of cable / pipe galleries and trestles shall be generally 3m above the ground except for rail / road crossing where it shall be 8m above the rail top / road crest/ground. Further in bunker areas it shall be 8 m above the ground.

20.06.00 Polysulphide Sealing Compound shall be two-part polysulphide sealant and shall be from approved manufacturer, conforming to IS : 12118. Materials shall consist of polysulphide polymer and a curing agent. Gun grade material shall be used unless

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otherwise specified. The application of the sealant shall be strictly followed as per manufacturer’s guidelines.

24.00.00 Packaging and Transportation.

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

25.00.00 Plant Life

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

26.00.00 PTFE (Poly Tetra Fluoroethylene) Bearing

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

27.00.00 TESTS FOR MATERIAL / WORKMANSHIP

All tests required for all materials, quality of workmanship or any other tests as desired by the Engineer shall be at contractor’s cost.

28.00.00 MATERIALS

28.01.00 For Civil, Structural and Architectural works

Employer will not supply any material. All materials including cement, reinforcement steel and structural steel, whatsoever required for execution and completion of the entire scope of work covered under this specification shall be arranged by the contractor at his own cost. All materials procured by the contractor shall meet the quality requirements specified in this specification.

The contractor shall keep sufficient stock of cement and steel at site at any point of time when the work is in progress excluding what has been already incorporated in the works, so that any disruption / delay in availability of these materials during procurement will not affect the progress of work at site. The minimum quantity of such materials in stock at site shall not be less then the Requirement of one ( 1 )

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month in case of Cement and Requirement of two ( 2 ) Consecutive months in case of Steel.

28.02.00 Structural steel

28.02.01 Mild Steel

(a.) Rolled sections shall conform to E250A of IS 2062:2006 in as rolled and semi killed condition.

(b.) Plates up to 20mm thickness shall conform to E250A of IS 2062:2006 in as rolled and semi killed condition.

(c.) Plates beyond 20mm and up to 40 mm shall conform to E250B of IS 2062:2006 as rolled in killed condition.

(d.) Plates beyond 40mm shall conform to E250B of IS 2062:2006 in normalized and ultrasonically tested quality.

(e.) Pipes for handrail shall conform to medium grade of IS : 1161.

(f.) Chequered plates shall conform to IS : 3502. Tensile properties shall conform to E250A of IS 2062:2006.

(g.) Seal plates shall conform to IS : 1079 ( semi - skilled quality )

28.02.02 Medium & High Tensile Steel

(a.) Rolled section shall conform to Grade E350 of IS 2062:2006, Semi Killed.

(b.) Plates up to 20 mm thickness shall conform to Grade E350 of IS 2062:2006, Semi Killed.

(c.) Plates beyond 20 mm and 40mm shall be as per Grade E350 of IS 2062:2006, Killed type.

(d.) Beyond 40mm shall conform to Grade E350 of IS 2062:2006, in normalized condition and ultrasonically tested quality.

28.02.03 All plates up to and including 40mm thickness shall be ultrasonically tested on audit basis to check the laminations.

28.03.00 Fly ash based Portland pozzolona cement conforming to IS: 1489 Part - I shall preferably be used. However, the contractor may use other types of cements conforming to IS: 269, IS: 8112, IS: 12269, & IS: 455. However Ordinary Portland cement conforming to IS: 269 or IS: 8112 shall necessarily be used for Crusher Deck.

28.04.00 Reinforcement steel shall conform to:

a) Mild steel grade I of IS: 432 Part – I and grade A of IS: 2062.

b) High yield strength deformed bar of Gr. Fe 415/ Fe 500 produced by thermo-mechanical treatment process, having elongation more than 14.5 percent and

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conforming to other requirements of IS 1786 shall be used for the reinforcement.

28.00.00 BITUMINOUS ROADS

28.01.00 Contents

This section deals with specifications for construction of flexible road pavements. The details of work shall consist of :

a) Construction of sub grade

b) Construction of Water Bound Macadam base and sub – base

c) Bituminous surfacing


28.02.01 The Contractor shall mobilise at site all equipment, including paver, roller, water tanker, etc.

28.02.02 The Contractor shall carry out the survey and setting out works, including alignment, layout, grading, curves etc.

28.02.03 The contractor shall also hire the services of a specialized agency, wherever required.

28.03.00 Construction of Sub-grade

28.03.01 The sub–grade shall be either in embankment, cutting or on the existing leveled ground. The cutting and embankment works, wherever involved shall be carried out, as per relevant specification of excavation and filling.

The excavation for laying of base and sub-base courses shall be carried out in the required profile using box cutting. The lower 500 mm of the sub-–grade shall be compacted to 95% of the Proctor Density at Optimum Moisture Content, if not done earlier; otherwise the top surface of the sub-grade shall be compacted using 8 to 10 Tonne roller with 6 passes. All undulations in the surface that develop due to rolling shall be made good with material or quarry spoils, as the case may be and the sub grade shall be re-rolled.

The finished surface shall be uniform, and conform to the lines, grades and typical cross-section shown in the drawings, when tested with the template and straight edge. The permissible variation shall be 25 mm in the longitudinal profile and 15 mm in the cross profile.

The shoulders area shall also be compacted in the same way maintaining the required profile on the top surface.

28.04.00 WATER BOUND MACADAM

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Water bound macadam using crushed stone aggregate shall be used for construction of sub- base and base material.

28.04.01 Materials

Coarse aggregates shall be of crushed or broken stone meeting the requirements of IRC specification with respect to physical properties and grading. Grade – I material having size range of 90 to 45 mm shall only be used for sub–base. Grade – II and III having size range of 63 to 45 mm and 53 to 22.4 mm respectively shall be used for base construction.

Moorum (Non Plastic Material) shall be used in the screenings as the filling material to fill the voids in the coarse aggregate. The moorum shall be obtained from pits of weathered disintegrated rocks. It should preferably contain silicious material and natural mixture of clay of calcareous origin. The size of moorum shall not be more than 20 mm.

28.05.00 Binding Materials

No separate binding material is required and the same moorum used as screening material shall also serve the purpose.

28.06.00 Construction Operations

The construction operation shall involve preparation of base, spreading of coarse aggregates followed by rolling, application of binding material, setting and drying. The details of construction activities quantity and the quality of various materials to be used shall be as per the stipulations of IRC specification.

The spreading shall be done from stockpile along the side of the roadway or directly from the vehicle. The segregation of large and fine aggregates shall be avoided.

It may be ensured that the thickness of each compacted layer is not more than 100 mm for grading 1 material and 75 mm for grading 2 and 3 materials, for sub-base and base respectively. The number of layers and actual thickness of the base and sub-base shall depend upon the CBR value of the sub-grade. The surface evenness and finishes of the Water Bound Macadam shall be checked and defects, if any, shall be rectified. In no case shall depressions be filled up with screenings and binding materials.

28.07.00 Bituminous Macadam

28.07.01 The work shall consist of construction, in a single course of 75 mm thickness of compacted crushed aggregates, premixed with a bituminous binder, to serve as base / binder course, laid immediately after mixing, on a base prepared previously in accordance with the requirements of these specifications and in conformity with the line, grades and cross sections shown on the drawings or as directed by the Engineer.

28.08.00 Materials

28.08.01 Bitumen

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The bitumen shall be paving bitumen of suitable penetration grade within the range S 35 to S 90 or A 35 to A 90 (30 / 40 to 80 / 100), as per Indian standards specifications for “Paving Bitumen” IS : 73. The actual grade of bitumen to be used shall be decided by the Engineer appropriate to the region, traffic, rainfall and other environmental conditions.

28.08.02 Aggregates

The aggregates shall consist of crushed stone. They shall be clean, strong, durable of fairly cubical shape and free from disintegrated pieces, organic or other deleterious matters and adherent coating. The aggregates shall satisfy the physical requirements set forth in IRC standards.

28.08.03 Proportioning of Materials

The bitumen content for premixing shall be 4 percent by weight of the total mix except when otherwise directed by the Engineer.

The quantities of aggregates to be used shall be sufficient to yield the specified thickness after compaction.

28.08.04 Construction Operations

The construction operation shall be carried out as per the stipulations of IRC standards. This shall involve preparation of base, application of tach coat, preparation and transportation of mix, spreading of mix, rolling, surface finish and quality control. The mix shall be prepared in a hot mix plant of adequate capacity and capable to yield a mix of proper and uniform quality works thoroughly coated aggregates. The mix transferred from the tipper at site to the paver shall be spread immediately by mixer, if self propelled. Mechanical road paver with suitable screeds capable of spreading temping and finishing the mix trial to the specified lines, grades and cross sections shall be used.

28.09.00 BITUMINOUS SURFACING

28.09.01 This shall involve laying and compacting of an open graded premix carpet of 25 mm thickness in a single course composed of suitable small sized aggregates premixed with a bituminous binder on a previously prepared base to serve as a wearing course. This surface finish shall be provided directly on WBM or on Bituminous Macadam depending on the type / category of road.

28.09.02 Materials

28.09.03 Binder

Bitumen of suitable grade conforming to IS: 73 shall be used as a binder.

28.09.04 Aggregates

Stone chips size, grading, physical properties shall be as specified in IRC standards.

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28.09.05 Proportioning of different types of materials shall be as given in IRC specifications. However, due to higher thickness of 25 mm, the quantity of material shall be proportionately increased.

28.10.00 Construction operations

28.10.01 The construction operations shall involve the preparation of base, application of tack coat, preparation of premix, spreading and rolling followed by a seal coat. The details of construction activities and the quantity of various materials to be used shall be as per the stipulations of IRC specifications. A mechanical road paver finisher shall be used for laying of premix carpet.

28.11.00 Seal coat

28.11.01 A premixed seal coat (type-B) for sealing the voids in the bituminous surface comprising of a thin application of fine aggregate (Stone dust / grit) premixed with bituminous binder shall be provided, as per the stipulations of IRC specifications.

28.11.02 Tack Coat

Tack coat of low viscosity conforming to IRC shall be applied, as mentioned in Schedule of Items.

28.12.00 SHOULDERS

28.12.01 Content

This section deals with specifications for construction of shoulder (hard) on either side of the pavement, in accordance with the requirements of these specifications and in conformity with the lines, grades and cross sections shown on the drawings or as directed by the Engineer.

28.12.02 Materials

Shoulder on either side of the road shall be of WBM using stone aggregate.

28.12.03 Size of shoulder

Shoulder (hard) dimensions shall be minimum 10m wide.

28.12.04 Construction operations

Except in the case of bituminous constructions, shoulders shall be constructed in advance of the laying of pavement courses. The compacted thickness of each layer of shoulder shall correspond to the compacted layer of the pavement course to be laid adjacent to it. After compaction, the inside edges of shoulders shall be trimmed vertical and included area cleaned of all spilled material before proceeding with the construction of the pavement layer.

In the case of bituminous courses, work on shoulder (hard) shall start only after the pavement course has been laid and compacted.

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During all stages of shoulder (earthen/hard) construction, the required cross-fall shall be maintained to drain off surface water.

Regardless of the method of laying, all shoulder construction material shall be placed directly on the shoulder. Any spilled material dragged on to the pavement surface shall be immediately removed, without damage to the pavement and the area so affected thoroughly cleaned.

28.12.05 Surface finish and quality control of works

The surface finish of construction shall conform to the requirements of IRC. Control on the quality of materials and works shall be exercised by the Engineer in accordance with IRC.

28.12.06 Brick edging

Brick edging shall be provided on both sides of the road all along the length. Fly ash based bricks having strength not less than 7.5 MPa shall be used for this purpose, unless otherwise specified. The edging shall be of one brick width and half brick depth. In the case of hard shoulder, the brick edging shall not be provided. Trenches shall be excavated after construction of the road and the bed of trenches shall be compacted to a firm and even surface. The bricks shall be abutting to the wearing course, true to line, gradient and in camber with the finished road surface at the edges.

28.13.00 INSPECTION AND TESTING

The surfaces finish, alignment, profile, gradient, tolerance, quality control during construction and characteristics of different materials shall be checked, as per the requirements of IRC specifications, for road and bridge works.


All standards, specifications, acts and code of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. Other Indian, foreign Codes and Standards not listed here but referred to elsewhere within this specification shall also be deemed to be part of this list.

In case of conflict between this specification and those (IS standards, codes etc.) referred to herein, the former shall prevail.

Some of the relevant Indian standards, Acts and Codes applicable to this section of the specification are listed below

IS : 383 Specification for coarse and fine aggregates from

natural sources for Concrete.

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IS : 432 Specification for mild steel and medium tensile steel bars and hard drawn steel wire for concrete reinforcement.

IS : 456 Code of practice for plain and reinforced concrete.

IS : 458 Specification for concrete pipes.

IS : 516 Method of test for strength of concrete.

IS : 800 Code of practice for use of structural steel in general building construction.

IS : 814 Specification for covered electrodes for metal arc welding for weld steel.

IS : 816 Code of practice for use of metal arc welding for general construction.

IS : 817 Code of practice for training and testing of metal arc welders.

IS : 875 (Pt. I to V) Code of practice for design loads other than earthquake) for buildings and structures.

IS : 1038 Steel doors, windows and ventilators.

IS : 1172 Basic requirements for water supply, drainage and sanitation.

IS : 1361 Steel windows for industrial buildings.

IS : 1786 Specification for high strength deformed steel bars and wires for concrete reinforcement.

IS : 1892 Code of practice for subsurface investigation for foundation.

IS : 1893 Criteria for earthquake resistant design of structures.

IS : 1904 Code of practice for design and construction of foundations in soils; general requirements.

IS : 1905 Code of practice for structural safety of buildings - Masonry walls.

IS : 1948 Specification for aluminium doors, windows and ventilators.

IS : 2062 Steel for general structural purposes.

IS : 2131 Method of standard penetration test for soils.

IS : 2212 Code of practice for brickwork.

IS : 2645 Specification for Integral cement water proofing compounds.

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

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IV TO VIII, XIV, XXI, XXIII, XXIV, XXVII TO XXIX, XL)

content etc code of practice for earth work on canals.

IS : 2911 Code of practice for design and construction of pile foundations.

(Part-1/Sec.1) Driven cast in situ concrete piles.

(Part-1/Sec.2) Bored cast-in-situ concrete piles.

(Part-IV) Load test on piles.

IS : 2974 (Part - I TO V)

Code of practice for design and construction of machine foundations.

IS : 3370 (Part I to IV)

Code of practice for concrete structures for the storage of liquids.

IS : 3658 Code of practice for liquid penetrant flaw detection.

IS : 3664 Code of practice for ultra sonic testing by pulse echo method.

IS : 4326 Code of practice for earthquake resistant design and construction of buildings.

IS : 4990 Specification for plywood for concrete shuttering work.

IS : 5624 Specification for foundation bolts.

IS : 7215 Tolerances for fabrication steel structures.

IS : 8112 Specification for 43 grade Ordinary Portland Cement.

IS : 9103 Specification for admixtures for concrete.

IS : 9595 Code of procedure of manual metal arc welding of mild steel.

IS : 10262 Recommended guidelines for concrete mix design.

IS : 13311 Method of non - destructive testing of concrete.

IS : 13755 Dust pressed ceramic tiles with water absorption of 3%, E6% (Group B11a)

ASTM 898 -89 Standard guide for use of high solid content, cold liquid-applied elastomeric water proofing membrane for use with separate wearing course.

AS/NZS 2728 Pre finished / pre painted sheet metal product for interior / exterior building applications – Performance requirements.

AS : 1365 Standards for steel manufacturing.

AS : 1397 A steel sheet & strip – hot – dipped-zinc-coated or

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Aluminium-Zinc coated.

AS : 3566 Self drilling screws for building and construction industry.

IRC : 37 Guidelines for the design of flexible pavements.

- Manual on sewerage and sewage treatment (Published by CPH & EEO) As updated.

Indian Explosives Act. 1940 as updated.

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ANNEXURE-A

CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND

EQUIPMENT

All structures and equipment shall be designed for seismic forces adopting the site specific seismic information provided in this document and using the other provisions in accordance with IS:1893 (Part 1):2002 and IS:1893 (Part 4):2005. Pending finalisation of Parts 2, 3 and 5 of IS:1893, provisions of part 1 shall be read along with the relevant clauses of IS:1893:1984, for structures other than the buildings and industrial structures including stack-like structures. A site specific seismic study has been conducted for the project site. The peak ground horizontal acceleration for the project site, the site specific acceleration spectral coefficients (in units of gravity acceleration ‘g’) in the horizontal direction for the various damping values and the multiplying factor (to be used over the spectral coefficients) for evaluating the design acceleration spectra are as given at Annexure-I. Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding horizontal values. The site specific design acceleration spectra shall be used in place of the response acceleration spectra, given at figure-2 in IS:1893 (Part 1) and Annex B of IS:1893 (Part 4). The site specific acceleration spectra along with multiplying factors specified in Annexure-I includes the effect of the seismic environment of the site, the importance factor related to the structures and the response reduction factor. Hence, the design spectra do not require any further consideration of the zone factor (Z), the importance factor (I) and response reduction factor (R) as used in the IS:1893 (Part 1 and Part 4).

Damping in Structures The damping factor (as a percentage of critical damping) to be adopted shall not be more than as indicated below for:

a) Steel structures : 2%

b) Reinforced Concrete structures : 5%

c) Reinforced Concrete Stacks : 3%

d) ND Cooling Towers : 2%

e)

Steel stacks : 2%

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Method of Analysis Since most structures in a power plant are irregular in shape and have irregular distribution of mass and stiffness, dynamic analysis for obtaining the design seismic forces shall be carried out using the response spectrum method. The number of vibration modes used in the analysis should be such that the sum total of modal masses of all modes considered is at least 90 percent of the total seismic mass and shall also meet requirements of IS:1893 (Part 1). Modal combination of the peak response quantities shall be performed as per Complete Quadratic Combination (CQC) method or by an acceptable alternative as per IS:1893 (Part 1). In general, seismic analysis shall be performed for the three orthogonal (two principal horizontal and one vertical) components of earthquake motion. The seismic response from the three components shall be combined as specified in IS:1893 (Part 1). For buildings, if the design base shear (VB) obtained from modal combination is less than the base shear (⎯VB) computed using the approximate fundamental period (Ta) given in IS:1893:Part 1 and using site specific acceleration spectra with appropriate multiplying factor, the response quantities (e.g. member forces, displacements, storey forces, storey shears and base reactions) shall be enhanced in the ratio of ⎯VB/ VB. However, no reduction is permitted if ⎯VB is less than VB. For regular buildings less than 12m in height, design seismic base shear and its distribution to different floor levels along the height of the building may be carried out as specified under clause 7.5, 7.6 & 7.7 of IS:1893 (Part 1) and using site specific design acceleration spectra. The design horizontal acceleration spectrum value (Ah) shall be computed for the fundamental natural period as per clause 7.6 of IS:1893 (Part 1) using site specific spectral acceleration coefficients with appropriate multiplying factor given in Annexure-I. Further, the spectral acceleration coefficient shall get restricted to the peak spectral value if the fundamental natural period of the structure falls to the left of the peak in the spectral acceleration curve. Design/Detailing for Ductility for Structures The site specific design acceleration spectra is a reduced spectra and has an in-built allowance for ductility. Structures shall be engineered and detailed in accordance with relevant Indian/International standards to achieve ductility.

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Page 41 of 46

ANNEXURE – I

SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES AND EQUIPMENT

The various site specific seismic parameters for the project site shall be as follows:

1) Peak ground horizontal acceleration

: 0.24g

2) Multiplying factor to be applied to the site specific horizontal acceleration spectral coefficients (in units of gravity acceleration ‘g’) to obtain the design acceleration spectra

a) for moment resisting steel frames designed and

detailed as per IS:800 and moment resisting RC frames designed and detailed as per IS:456

: 0.08

b) for braced steel frames designed and detailed as per IS:800

: 0.06

c) for moment resisting RC frames designed and detailed as per IS:456 and IS:13920

: 0.048

d) For steel chimney : 0.12 e) for design of structures not covered under 2 (a) to 2 (d)

above and under 3 below

: 0.08

3) Multiplying factor to be applied to the site specific horizontal acceleration spectral coefficients (in units of gravity acceleration ‘g’) for design of equipment and structures where inelastic action is not relevant or not permitted

: 0.16

Note: g = Acceleration due to gravity The horizontal seismic acceleration spectral coefficients are furnished in subsequent pages.

CLAUSE NO.







Page 42 of 46

ANNEXURE – I

HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTSIn units of ‘g’

Time Period Damping Factor (as a percentage of critical damping)

(Sec) 5% 2% 0.000 1.000 1.000 0.030 1.000 1.000 0.050 1.353 1.479 0.100 2.040 2.515 0.150 2.593 3.431 0.162 2.714 3.639 0.170 2.714 3.774 0.200 2.714 3.774 0.250 2.714 3.774 0.300 2.714 3.774 0.350 2.714 3.774 0.400 2.714 3.774 0.450 2.714 3.774 0.500 2.714 3.774 0.525 2.714 3.774 0.550 2.714 3.774 0.600 2.714 3.774 0.650 2.714 3.774 0.670 2.714 3.774 0.700 2.714 3.774 0.750 2.714 3.774 0.809 2.714 3.774 0.849 2.587 3.774 0.900 2.440 3.559 0.950 2.312 3.372 1.000 2.196 3.203 1.050 2.091 3.050 1.100 1.996 2.912 1.150 1.910 2.785 1.200 1.830 2.669 1.250 1.757 2.562 1.300 1.689 2.464 1.350 1.627 2.373 1.400 1.569 2.288 1.450 1.514 2.209 1.500 1.464 2.135 1.550 1.417 2.066 1.600 1.373 2.002

CLAUSE NO.







Page 43 of 46

ANNEXURE – I



(Sec) 5% 2% 1.650 1.331 1.941 1.700 1.292 1.884 1.750 1.255 1.830 1.800 1.220 1.779 1.850 1.187 1.731 1.900 1.156 1.686 1.950 1.126 1.643 2.000 1.098 1.602 2.050 1.071 1.562 2.100 1.046 1.525 2.150 1.021 1.490 2.200 0.998 1.456 2.250 0.976 1.424 2.300 0.955 1.393 2.350 0.934 1.363 2.400 0.915 1.335 2.450 0.896 1.307 2.500 0.878 1.281 2.550 0.861 1.256 2.600 0.845 1.232 2.650 0.829 1.209 2.700 0.813 1.186 2.750 0.799 1.165 2.800 0.784 1.144 2.850 0.771 1.124 2.900 0.757 1.104 2.950 0.744 1.086 3.000 0.732 1.068 3.050 0.720 1.050 3.100 0.708 1.033 3.150 0.697 1.017 3.200 0.686 1.001 3.250 0.676 0.986 3.300 0.665 0.971 3.350 0.656 0.956 3.400 0.646 0.942 3.450 0.637 0.928 3.500 0.627 0.915

CLAUSE NO.







Page 44 of 46

ANNEXURE – I



(Sec) 5% 2% 3.550 0.619 0.902 3.600 0.610 0.890 3.650 0.602 0.878 3.700 0.594 0.866 3.750 0.586 0.854 3.800 0.578 0.843 3.825 0.574 0.837 3.850 0.570 0.832 3.900 0.563 0.821 3.950 0.556 0.811 4.000 0.549 0.801

CLAUSE NO.







Page 45 of 46

ANNEXURE-B

CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT

All structures shall be designed for wind forces in accordance with IS: 875 (Part-3) and as specified in this document. See Annexure – B for site specific information. Along wind forces shall generally be computed by the Peak (i.e. 3 second gust) Wind Speed method as defined in the standard. Along wind forces on slender and wind sensitive structures and structural elements shall also be computed, for dynamic effects, using the Gust Factor or Gust Effectiveness Factor Method as defined in the standard. The structures shall be designed for the higher of the forces obtained from Gust Factor method and the Peak Wind Speed method. Analysis for dynamic effects of wind must be undertaken for any structure which has a height to minimum lateral dimension ratio greater than “5” and/or if the fundamental frequency of the structure is less than 1 Hz. Susceptibility of structures to across-wind forces, galloping, flutter, ovalling etc. should be examined and designed/detailed accordingly following the recommendations of IS:875(Part-3) and other relevant Indian standards. It should be estimated if size and relative position of other structures are likely to enhance the wind loading on the structure under consideration. Enhancement factor, if necessary, shall suitably be estimated and applied to the wind loading to account for the interference effects. Damping in Structures The damping factor (as a percentage of critical damping) to be adopted shall not be more than as indicated below for: a) Welded steel structures : 1.0% b) Bolted steel structures : 2.0% c) Reinforced concrete structures : 1.6% d) Steel stacks : As per IS:6533 & CICIND Model Code whichever is more critical.

CLAUSE NO.







Page 46 of 46

SITE SPECIFIC DESIGN PARAMETERS The various design parameters, as defined in IS: 875 (Part-3), to be adopted for the project site shall be as follows: a) The basic wind speed “Vb” at ten metres above the mean ground level : 47 metres/second b) The risk coefficient “K1” : 1.07 c) Category of terrain : Category-2 Note: Notwithstanding the values of the above mentioned parameters, the design wind pressure so computed at any point shall not be taken less than 1500 N/Sq. meter for all classes of structures, i.e. A, B & C, as defined in IS: 875 (Part-3).

CLAUSE NO.






Sub-Section - IIID-02 GEOTECHNICAL

INVESTIGATION & FDN. SYSTEM

Page 1 of 6

1.00.00 GEOTECHNICAL INVESTIGATION & FOUNDATION SYSTEM

1.01.00 Geotechnical investigation for the scope of work shall be done by the bidder. Owner has carried out geotechnical investigation within plant. The details of few borelogs are enclosed at Annexure-I. These are solely for the purpose of guidance of the Bidder. The onus of correct assessment/interpretation and understanding of the existing sub soil conditions/data is on the Bidder.

1.01.01 The geotechnical investigation shall be carried out in all work areas for establishing

the sub-soil conditions & to decide type of foundations for the structures envisaged, construction methods, any special requirements/ treatment called for/ remedial measures for sub-soil/ foundations etc. for soft sub-soils, aggressive sub-soils & water, expansive/ swelling soils etc.

1.02.0 Scheme of Soil Investigation 1.02.01 The diameter of borehole shall be minimum 150 mm in soil and 76 mm in rock. The

diameter of UDS sampler shall be 90 mm minimum. Drilling in rock shall be done by means of hydraulic feed equipment using double tube core barrel with diamond bid attachment.

1.02.02 Field test shall include but not be limited to the following:- Boreholes, Standard Penetration Test (SPT), collection of disturbed and undisturbed

soil samples (UDS), Trial Pits (TP), Electrical Resistivity Test (ERT), collection of water samples, etc.

1.02.03 The minimum tests are indicated in Annexure A. Adequate number of tests shall be

conducted upto sufficient depth for complete determination of subsoil conditions. The depth of boreholes shall be as specified in Annexure A. SPT shall be carried out in all types of soil deposits and in all rock formations with core recovery upto 20%, met within a borehole. This test shall be conducted at every 3.0 m interval or at change of strata, upto the final depth. Number of blows shall be recorded for every 15 cm of penetration upto 45 cm or 100 blows whichever occurs earlier. SPT ‘N’ of 100 and above shall be referred as refusal. UDS shall be collected at every 3.0 m interval or at change of strata upto depth of borehole. UDS may be replaced by additional SPT, if SPT’N’ value in the strata is above 50.

1.02.04 Laboratory tests shall be done as per relevant IS codes. The laboratory tests, not be

limited to the following shall be conducted on disturbed and undisturbed soil / rock samples & water samples collected during field investigations in sufficient numbers.

Laboratory tests shall be carried out on disturbed and undisturbed soil samples for Grain Size Analysis, Hydrometer Analysis, Atterberg Limits, Trixial Shear Tests (UU), Natural Moisture Content, Specific Gravity and Bulk Unit Weight, Consolidation Tests, Unconfined Compression Test, Free swell Index, Shrinkage Limit, Swell Pressure Test, Chemical Analysis test on soil and water samples to determine the carbonates, sulphates, chlorides, nitrates, pH, organic matter and any other chemicals harmful to concrete and reinforcement/ steel.

1.02.05 Geotechnical investigation shall be carried out in accordance with the provisions of

relevant Indian Standards.

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Page 2 of 6

1.02.06 On completion of all field & laboratory work, geotechnical investigation report shall be submitted for Owner’s information/review. The Geotechnical investigation report shall contain geological information of the region, procedure adopted for investigation, field & laboratory observations/ data/ records, analysis of results & recommendations on type of foundation for different type of structures envisaged for all areas of work with supporting calculations. Recommendations on treatment for soil, foundation, based on subsoil characteristics, soft soils, aggressive chemicals, expansive soils, etc.

1.03.00 Foundation System 1.03.01 General Requirements:

a) Contractor can either provide open foundations (isolated footing/ raft) or pile foundations depending upon the results of the geotechnical investigations to be carried out by him along with any special requirements/ remedial measurement/ treatment called for subsoil/ foundations as approved by the Owner.

b) All foundations shall be designed in accordance with provisions of the relevant parts

of the latest revisions of Indian Standards. For design purpose, ground water table shall be considered at Finished Ground Level (FGL)

c) Roads, ground floor slabs, trenches, channels/ drains and other lightly loaded

structures (such as staircase foundation, pipe pedestals with foundation loading intensity less than 5 T/ M2) may be supported on open/ shallow foundations resting on virgin/ controlled compacted filled up soil. Minimum depth of foundation shall be 1.0 m below Finished Ground Level (FGL) for pipe pedestals and stair case foundation. No other foundation shall rest on the filled up ground/ soil.

d) Foundation shall be designed for worst combination of loads as described elsewhere

in the specification.

1.03.02 Open Foundations

In case open foundations are adopted following shall be adhered to:

a) Minimum width of foundation shall be 1.0 m

b) Minimum depth of foundation shall be 1.0 m below NGL.

c) Permissible settlement of foundations.

The total permissible settlement and differential settlement shall be governed by IS:1904 and IS: 13063 and from functional requirements, whichever is more stringent. However, total settlement shall be restricted to the following:

i) All foundations including pipe supports, isolated/ strip/ continuous) for widths

upto 6.0 m - 40 mm

ii) Footings width greater than 6.0 m (raft) - 75 mm

Incase pile foundations are to be adopted the requirements under para "pile foundations" shall be adhered to.

1.03.03 Pile Foundations

CLAUSE NO.








Page 3 of 6

The pile foundation shall be cast-in-situ bored piles as per IS: 2911 (relevant part). Piles shall be installed by using self erecting / supporting rotary hydraulic rig or conventional tripod rigs. Two stage flushing of pile bore shall be ensured by air lift technique or any other international method duly approved by Owner. The construction methodology to be adopted shall be suitable to ensure proper termination of pile in the strata as specified elsewhere to ensure pile bore free from spoils.

a) Only RCC piles shall be provided.

b) Minimum diameter, vertical (compression) capacity and pile termination criteria of reservoir side piles for the approach walk way / bridge shall be as mentioned below.

Diameter Vertical Capacity

600 140 T

760 250 T

The uplift and lateral load capacities shall be restricted to 35% and 5% respectively of the allowable load capacity in vertical compression. However, the pile capacities to be adopted shall be the least of the estimated design values and that obtained from the pile load tests.

c) Only Straight piles shall be used.

d) The piling work shall be carried out in accordance with the provisions of IS: 2911.

e) The Contractor shall furnish the design of piles (in terms of rated capacity,

length, diameter, termination strata and criterion to locate the founding level for construction of pile, reinforcement for job as well as test piles etc.), construction methodology/ specifications for construction of piles and scheme of initial pile load tests in vertical, lateral and uplift, and the details of equipment for Owner’s approval. The Contractor shall submit the proposed locations of initial test piles for Owner’s information prior to their installation.

f) Testing of piles and interpretation of pile load test results shall be carried out

as per IS:2911 (Part-4). Contractor shall ensure that all the measuring equipment and instruments are properly calibrated at a reputed laboratory / institute prior to their use. Settlement / movement of the pile top shall be made by Linear Variable Differential Transducers (LVDT) having a least count of 0.01mm.

g) The test load on initial test piles shall be applied by means of reaction from

anchor piles / rock anchors alone or combination of anchor piles / rock anchors and kentledge.

h) Low Strain Pile Integrity test shall be conducted on all test piles and job piles.

This test shall be used to identify the routine load test and not intended to replace the use of static load test. This test is limited to assess the imperfection of the pile shaft and shall be undertaken by an independent specialist agency. The test equipment shall be of TNO or PDI make or

CLAUSE NO.








Page 4 of 6

equivalent. The process shall confirm to ASTM D 5882 and method of testing shall be Pulse Echo Method (PEM).

i) Regular QA checks for density of circulation mud, contaminated mud and samples from pile bore bottom, slump of concrete, pile integrity test on all piles etc. shall be done by the Contractor.

1.03.04 Pile Load Tests

Contractor shall install the piles for initial load test. Number of initial load tests to be performed for each diameter and rated capacity of pile shall be as under:

i) Vertical (Compression) - 2

ii) Lateral (Horizontal) - 2

iii) Uplift (Tension) - 2

The initial pile load test shall be conducted with test load upto three times the estimated pile capacity. In case of vertical load test, the method of loading shall by cyclic as per IS:2911 (relevant part).

Safe load interpretation from pile load test shall be as per IS:2911 (Part-IV).

Number or routine pile load tests to be performed for each diameter/ allowable capacity of pile shall be as under.

i) Vertical - 0.5% of the total number of piles provided subject to a minimum of one.

ii) Lateral - 0.5% of the total number of piles

provided subject to a minimum of one.

The routine test on piles shall be conducted upto test load of one and half times the allowable pile capacity by direct loading method. Piles for routine load test shall be approved by the Owner.

1.03.05 A report on the pile load tests shall be submitted for Owner’s approval. In case,

routine pile load test shows that the pile has not achieved the desired capacity or pile (s) have been rejected due to any other reason, then Contractor shall install additional pile (s) as required and accordingly, pile cap design should be reviewed and modified if required at no extra cost to the Owner.

1.03.06 Low strain integrity test shall be conducted on all the test and job piles through an

approved agency and as directed by the Engineer. The system shall have the computer read out facility and report on the findings of this shall be furnished to the Owner. This test shall be used to identify the piles for routine load test.

1.04.00 Other Requirements

i) Cement type - As approved by the Owner based on soil water chemical environment.

Concrete grade - Minimum grade of concrete for piles shall be M-25 unless specified otherwise elsewhere. Concrete shall be dense & durable.

Cement content - Min 400 kg/cum in case of piles. Admixtures are not permitted in concrete used for piling.

CLAUSE NO.








Page 5 of 6

Reinforcement steel type - TMT bars Fe 500 grade Cover to reinforcement - As per IS:456, subject to minimum of 50

mm. (ii) For excavation works, comprehensive dewatering with well point or deep

wells arrangement wherever required shall be adopted. Scheme for dewatering and design with all computations and back data for dewatering shall be submitted for the owner’s information. The water table shall be maintained at 0.5m below the founding depth.

(iii) The founding level for trenches/ channels shall be decided as per functional

requirement. The bottom of excavation shall be properly compacted prior to casting of bottom slab of trenches/ channels.

(iv) Excavation for open foundations shall be covered with PCC immediately after

reaching the founding level. In case of any local loosening of soil at founding level during excavation, the same shall be removed and compensated by PCC.

(v) Backfilling, around foundations and bottom of pipes, thrust blocks, etc. shall

be compacted to 90% standard proctor density for cohesive soil and to 75% of relative density for non-cohesive soils.

CLAUSE NO.








Page 6 of 6

ANNEXURE - A

S.No Structure Tests

1 Junction House One borehole at each identified Junction House

Depth of borehole shall be

i) 35 m below ground level.

ii) 5 m into rock with RQD ≥ 50% continuously

Whichever above occurs earlier.

2 Conveyors One borehole at 100 m c/c along the identified conveyor.

Depth of borehole shall be

i) 25 m below ground level

ii) 5 m into rock with RQD ≥ 50% continuously

Whichever above occurs earlier.

3 MCC room, Pump house

One borehole at each structure.

Depth of borehole shall be 20m

Two Electrical Resistivity Test (ERT) at each structure.

NOTE: Investigation in any other new building / structure / facilities / and associated works / items in the scope of the package, which are not listed above shall also be carried out.

KND Engineering Technologies Ltd

BORELOG DATASHEET

Projects NTPC-FSTPP, Stage-Ill Barehaie diameter. 1 SOmm Location: Transformer Yard Borehole No . Q3 Commenced on:23.07.2006 at: l.Wm BEGL Completed on: 27.07.2006 Cosrdinafe: - - S-1147 / E-250 - - -- - - - - - --

Depth Description of soil Details of samples

Ref. No. Type ~apth(m)

grey siRy clay, mixed with

- - - - - - .- - - 1 50 soh light brwnleh grey,

3 00 ~ o d e r a g y stiff, li&j -

brownish grey Sllty Clay small pockets of rust bro

12.00 stiff dark grey 8iG Cly. Small pockets of rust b m sills are also observed in the strata occas~iona!ly. Cotour of the strata changes to Muiah grey belovv 21 .Elm

nodubs are observed in the 4.75 strara below 26.50m depth.

. - -- - - - - -- -- - - - - - - - 27 25 Very Dense to compact,

light reddish brown Sandy

P Panelmmeler Tesl UD undtslurtted Tube Sample

o r I3wulaad aacnprs CMleMma rroril petlslmfiieter DC Dlslurtted Sanlples Callecled From lubes Culttm Shoe D Daunma Sample

KND Engineerin( Technologies Ltc

BORELOG DATA-SHEET

Projects: NTPCFSTPP, Stage-Ill Borehole diameter. 150mm I

Location: TG Hall R.L. of ground: 26.50m Borehole No.: 12 Soil boring termination depth: 26.15m BEGL Commenced on:21.08.2006 Ground water struck at: 1.90 m BEGL Completed on: 23.08.2006 Standing water level. 1.80 m BEGL Co-ordinate: S-1108 I E-219 ----

Thickness . Details of sampbs , I Penetration

I - - . Ref. ~ o - ~ ~ p e ~epth(m) Blows11 5cm I

-- -- . - - - - 0711 0 - - I

I

- - oALap~- - - I--/-----&- 7--1 i I I - I

i - . . - -. - - - - .

0715 P 1.35-1.80 2 0716 u 2.95-3.40 ti717 D 3.50 0718 P 4.45-4.90 2 5719 U 6.154,6Q

8 1

(3720 D 6.70 0721 P 7.55-8.00

11 14.25 0722 U 9.05-9.50 ' 1

0723 D 9.60 0724 P 10.50-10.95 2 3

. . 0725 P 12.00-12.45 2 0726 U 73.80-14.05 0727 D 14.15 0728 P 15.00-95.45 2 3 6 1

F - - ---- - - i 0731 U '16.50-16.95

- - I Q730 D 17.05*-'1

. 0 3 P 18 00-18.45 3 8 1 3 ' 0733 U 79.50-19.B 0734 D 20.05 I

! depth. Colour of the strata W P 21.00-21.45 fi. 6 i 8 W changes to brownish grey 0736 U 22.55-23.00 below 22.00m depth. 0737' D 23.10

-- -- - - - - - I

60/12cm sleo 0740 D

2.40

I -- -

BEGL, as boring could not be progressed more than 15cm from 16.60m J

KND Engineering I Technologies Ltd I

BORELOG DATA-SHEET

Projects: NTPC-FSTPP, Stage-Ill Borehole diameter: 150mm . Location: Boiler And mills R.L. of ground:26.50m Borehole No.:28 Soil boring termination depth. 28.50m BEGL Commenced on:04.09.2006 Ground water struck at. 1 40m BEGL Completed on: 05.09.2006 Standing water level: 1 25 m BEGL Co-ordinate: S-I 065 1 €-I 84

. - . -- Method of bor~ng; Shell &Auger

Details of samples

Blows/l5cm

Fill consisting of dark grey 0.60 silty clay, mixed with fine

grained sand, stone pieces,

075 D 1.00 076 P 1.45-l.9tli

kankars and nodules. 077 U 3.15.3.60 Pockets of rust brown silts 078 D 3.70 are found occassionally 079 P 4.55-5.00

16.60 Colour of the strata changes OBO U 8.124.57 to dark bluish grey below 081 D 6.67

082 P 7.*-7.95 083 U 9.10-9.55

"U 12.70-12.55 O M D 12.85

089 D 45.70 090 P 1&10-16.55 3

093 bl 20.05-20.50

OM P 21.50-2-

088 P 21.5027.95 20 28 31 59 1 099 P 28.10-28.33 40 i 6518crn 1 : >lo0 I

100 D 28.50 I

I I I I I

ote: BH-28 is minated at 28.50m BEGL, as boring wutd not be progressed more than 15cm from 28.35m by &Wling of 2 houw

P Penemmeter Test UD undlslurbed Tube Sample

DP: Disturbed tarnpie Collected From penelmmeter DC, Disturbed Samples Collected From lubes Cutllng Shoe b No. CS-3236- b: D l t t u W Sample WS Water sampte

(1IlOIl5 L

-

KND Engineering Technologies Ltc

BORELOG DATA-SHEET

Projects. NTPC-FSTPP, Stage-Ill Borehole diameter. 150mm Location:Air Compressor House. Boiler And Mills R.L. of ground: 26.75m Borehole No.: 33 Soil boring termination depth: 28.10 m BEGL Commenced on:08.09.2006 Ground water struck at. 1.45 m BEGL Completed on: 10.09.2006 Standing water level: 1 .OO m BEGL Co-ordinate S-1040 1 E-216 . -- - Method of boring; Shell &Auger

- - I - - - - -.-

Depth Description of soil in metre1

of layer Details of samples penetration test N' value! Remarks I

Blows 1 15cm 1

. . -- - - - - - - - - C EGL

45 8 >-- - 050 I

Fill consisting of coal, ash, I

stone pieces followed by 2 2 4 brownish grey silty clay, 2.75 2 2 * I A I mixed with coal pieces, brick I

2 75 I bats, stone chips etc. I

__ -1._.___ 2 75 ,Moderately Stiff, brownisg i --- 11.9 U

- - -- ' -A

'grey Silty Clay, wirh 1 1110 D 3.65 1 occassional pockets of rust / 1111 P I 4.60-5.05 1 2 2 P 5

I 1 brown silt Colour of the 11112 U 612-6.57 strata changes to Bluish 1 4.75 / 11 13 D 6.67 , lgrey below 7.00m depth. 1

strata changes to reddish brown with bluish patchec below 17.00 m depth.

I 1

1148 P 20.00-20.45

- -- 1149 P 21.50-21.95- 16 1150 P 23.00-23.45

by chiselling of 2 hours.

P: PeRemn~W T a l UD undlsiulbstd Tube Sample

DP: D18Wed sample Ce&@w Fmm prnrelrompter DC. Dlslufbed Samples Collecled From tubes Cult~ng Shoa D: QbkBnd S@@e wS Water sample

KND Engineering Technologies Ltd I

BORELOG DATA-SHET

Borehole diameter: 150mm R.L. of ground: 26.2511 Soil boring termination depth: 27.25m BEGL Ground water struck at: 3.25m BEGL Standing water level: 3.20 m BEGL

Projects: NTPC-FSTPP, Stage-Ill Location: ESP Borehole No.: 41 Commenced on:23.07.2006 Completed on: 26.07.200@- Co-or din at^: 5-962 1 E-178 Method of boring; Shell &A

I --- -

Thickness Depth Description of soil of laym Details of s m p l m

in.fm@ Penehtion test ! N' value - i n metre !

I - - - - . .. - -- . -- - - - ----- EGL f Fill consisting of light 0930 D 1.00

/brownish grey Silty Clay 1 .5a 1 50 mixed with brick bats etc.

I - t a - I - - - - L ---- L

1.50 ,Moderately Stiff, light #031 P 1.50-1.95 ' tB32 U 3.05-3.50 browniosh grey Silty Clay

with pockets of rust b row W 3 D 3.60 SR P 4.50-4.95 4

MI35 U 6.25-6.5Q 1 9 . 0 h a 1 6.60

7 P 7.50-7.95 1 m 8 U 9.05-9.S

10.50 lx239 D 9.60

10.50 - % f f z e y kitty Claywith p;ockets of rust brown Silts. 0041 U 12.15-12.50 jColour of the strata changes I 0042 D 12.60 1

I

/to yellowish brown below 0043 P 13.50-13.95; 5 5 7 1 2 ' 18.00m depth. 0044 U 1505-15.50 I I 9'00 0045 D 15.60

10046 P 16.50-16.951 8 / ' 0047 U 18.17-18.67

1950 ! 0048 D 18.67

. - - - -- - - - . -- - 19.50

' ~ed ium dense brownish 0049 P 19.50119.9%'- grey Sandy Silt with very 0860 U 21.14-21.m

22.50 fine grained mica pieces. 0851 D 21.49 3'00

, . - -- .- - - - . -- -- -- - - . -- . -.

22.50 Very dense light yellowish 0182 P 22.57-23.02 17 38 - 64 brown, very fine r--'ned

3.00 8783 P 24.00-24.45 16 Silty sand

25.50 -- - 25.50 ' ~ a r d yellowish- b&-- 0184 P 25.35-2538' 9

Clayey Silt mixed & v&y 0185 P 26.25-26.70 fine grained sand partilck, 0186 P 27.25-27.35 100/10m I

27.25 Fragmented rock pieces are ' ?-74 observed below 26.25111 I

depth. I I I

I I

Note: BH-43 is terminated at 27.25rn BEGL, $s baring could not be progressed more than 10cm

by chisellin$ qf 2 bowa - .

P: Psnamter Tea DP: D i a M m p l e Colleoled Fmrn penekimler

0: Dlsbrbed Sample

UD: undislwhsd Tube Sam*

Dislwbed Samples Collected Fmm tubes CutUng Srtoa WS: Water smnple nrl r) ri f;

t KND Engineering Technologies Ltd

BORELOG DATA-SHEET I Projects: NTPC-FSTPP, Stage-Ill Location: ID ducts Borehole No.: 51 Commenced on: 10.08.2006 Completed on: 14.08.2006

Borehole diameter: 150mm R.L. of ground: 26.75m Soil boring termination depth: 26.50m BEGL Ground water struck at: 1.75m BEGL Standing water level: 1.65 m BEGL

Co-ordinate 5-870 1 E-344 - - Method - - - - - of boring; Shell &Auger . . . - . - -

Depth ' Description of so11 Details of samples I Penetrat~on test I

N' value; Remarks In metre1 m metre ----- -- -.

Ref. No. Type Depth(m) 1. - - - ~ iowsl l5cm - . - -- , 30 45 - - -

EGL 04427 D 0.53 F~ll consisting of coal, waste 0428 D 1.00 1 materials, stone chips, brick I 1

1 50 /bats etc. 'followed by, 1 brownosh grey silty clay,

1.50 I ,mixed with stone pieces, Icoal, brick bats etc. ,- - - - - . -- , moderately stiff brownish 1 grey Silty Clay mixed with very small pockets of black

1 silt nodulss.

I

light brownish grey Silty Clay. Colour of the strata changes to bluish grey

i below 10.25m depth. i Dense dark grey, coarse grained Clayey Sand

1 - --- 1 1 I

I Very. stiiclslrk grey Silty -

Clay. Colour orthe strata changes to brownish grey /below 19.50m depth. Calcareous nodules of various sizes are also observed in We strata.

Very dense to compact, y e l M ~ h brow, Rw pained Silty wnd. Fragmented rock pieces mix& with eYaygy silt A observed below 26.60rn '

depth.

BH-51 is terminated at 26.50m I I 1

I I BEGL, as 5.00m in refusal strata with SPT-'N' value >I00

5 "Sample Slipped

. P: Penelpmeter Test UD: ufl@~turbed Tube emple

DP M.lrrrhn0 r.~qD(e @~@$*d Fmm pnralmtn@(ar DG DtsiluTbed SarnpIn~~ C01bet.d Fmm lubrss CuW@ %O.

0. Proiwbea Sunpla W5: WaMC samph

--<------ - . - - 7 -

b KND Engineerin( Technologies Ltc

BORELOG DATA-SHEET

Projects: NTPC-FSTPP, Stage-Ill Borehole diameter: 150mm Location: Chimney R.L. of ground: 26.75 Borehole No.: 55 Soil boring termination depth: 26.15m BEGL Commenced on:22.08.2006 Ground water struck at:1.15m BEGL Completed on: 24.08.2006 Standing water level: 0.80m BEGL Co-ordinate: , S-847 1 E-216 -- -- -, -- .---- Method of -. boring; . . Shell - . . &Auger - .. .~ - . -

i Thickness ! Depth ~esc r i ~ t i on of soil N ' value! Remarks

in metre, , -.

i I . . 30 ' 45

EGL I ! 0628 1 0.50 : {Fill consisting of brownish ( I 0629 1

I ! 1.00 1

grey silty day mixed with 2,75 i 0630 / P ; 1.50-1.95 2 2 2 4 ' 2.75 I brick bats, boulders, stone /

chips, coal etc. 1 1 I I

I . . . - . . .. i I I 1 i. ! . . . .

[TI P 2.85-3.30 i 2 2.75 i ~ o d e r i e l ~ stiff, brownish 3 4 7 I igrey Silty Clay. Coal pieces : *U 1 4.05-4.50 'Samle 'and stone chips are I 0 6 3 5 ) D 4.50 Slipped 1 observed at upper depth : ; 0633 1 P 4.75-5.20 2 4 8

i 0634 ' U I 5.90-6.35 ,

1 9.00 ' 0635 D 6.45 , I I

1 7.40-7.85 2 1 3 ' 3 . 6 ':

i 1 9.10-9.55 1 11.75 ; 1 0638 D 9.65 1 I

I

j , 10.50-10.95 1 2 i 3 5 8 I I ' . -- - . -. - 4. - - ~ . . -. - .. - 1~~ I

1 1 .75 'very stiff to hard, bluish grey 1 ;Silty Clay. Colour of the , 0 6 4 1 I D , 12.70 1 strata changes to bluish ; 1 0642 1 P 13.45-13.90 4 lgreyl yellowush brown I i 0643 I U 15.10-15.55 ;below 15.00m depth. 10644 D m 15.65 1 - / kankars and nodules are ' 9.00 I 0645 P / 16.56-17.01 i 10 14 18 32

I 1 0646 U 18.20-18.65 1 ~occassionally observed in 1 20.75 jthe strata between 15.00m i ' 0647 , D 18.75 ! 1

;to 17.00m depth. ; 0648 / P 19.40-19.85 13 : 18 ' 22 40 I

I I . --

20 75 Very dense to compact, 0649 P 20 85-21.07 36 60t7cm ' >I& yellowish brown, fine 1650 P 22 70-22.93 42 &/8crn >I00 grained Silty Sand. 5.61 0486 I P 24 30-24 53 49 66/8crn >I00

26 36 , 0487 i P 26 15-26 36 50 1 BSBcm .I00 I

I 1 ' ,

I Note: BH-55 is terminated at 26.15m BEGL. in 5.00m refusal strata, with SPT-'N' >I00 .

P Penelmmeter Twl UD umslumed Tube Sample

DP Dlslurb~d mnpla ColIecIed Fmrn penelmmeler DC Dlslurbed Samples Collected From lubes Cullvlg Shoe D DlSIurtMd Sample WS Waler sample

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-01 Coal Conveyors Belt

PAGE 1 OF 7

1.01.00 Brakes and Clamps 1.01.01 Final testing of brakes shall include load, HV/IR & heat run tests. 1.02.00 Monorails and Hoists 1.02.01 All electric hoist shall be tested as per IS 3938 and chain pulley block shall be tested

as per IS 3832. 1.03.00 Hoppers & Liners 1.03.01 Rack & Pinion Gates/Flap Gates/Rod Gates a) MPI/DP test shall be conducted on rack and pinion / rod / weld joint

b) Functional checks on the gates shall be carried out alongwith respective actuator, if applicable.

1.04.00 Belt Conveyor System

The details of the checks to be carried out in the various equipments are to be submitted by the Contractor for Owner’s approval. However, some indicative checks on different items are given below which should necessarily form a part of the Quality Assurance Plan to be agreed with the Owner.

1.04.01 Idlers

a) Check for run out and free movement shall be carried out on idlers. Run out shall be restricted as per IS:8598

b) Test for dust proofness, water proofness and dynamic friction factor of the

Idlers shall be conducted at shop. The detailed procedures for the same shall be submitted for review and approval.

1.04.02 Belting

(a) Rubber cover of finished belt shall be checked for tensile strength and elongation at break before and after ageing. Rubber cover shall also be checked for abrasion, tear strength and hardness.

(b) For finished belts, checks for elongation at 10% nominal tensile strength, tensile and

elongation at break in longitudinal (warp) direction and tensile in transverse (weft) direction shall be carried out.

(c) Adhesion test between ply to ply and cover to ply shall be carried out.

(d) Troughability test and Test for fire resistance shall be carried out.

(e) Test for procedure qualification for belt vulcanizing joint (at site) shall be done.

Procedure for belt vulcanizing joint shall be discussed and finalized during FQP finalization.

CLAUSE NO.





SECTION-VI, PART-B


PAGE 2 OF 7

(f) There will be a limitation on the no. of repairs allowed on the belts. Following will be the acceptance norm for the cover repairs.

i) The maximum size of a repair shall be limited to a size equivalent to one fifth

the belt width. No single dimension shall exceed one fifth(1/5) of belt width.

ii) Small local repair by dough filling of size 25mm x 25mm to a limited extent shall not be counted of repairs. However, in case of cluster of repairs, same shall be counted as a patch repair.

iii) The maximum number of patch repair shall not exceed 5 per 100 mts. However, the total number of patch and dough filling repairs shall not exceed 10 per 100 meters.

(g) In addition to above, Steel Cord belt shall also be tested for following.

i. Cord dia and breaking strength ii. Finished belt shall be tested for cord pull-out strength before and after

aeging, peeling resistance. iii. Dynamic cord pull out test iv. Cord dia, pitch and number of cords

(h) In no case shall the cover thickness or the width of belt be less than that given in specification.

(i) For testing purpose,belt sample shall be taken from anywhere of the belt roll length offered

1.04.03 Belt Vulcanizing Machine

a) Check for tensile strength shall be carried out on a sample vulcanized belt joint for each type of belt in shop.However if such test has been done earlier, the report for same shall be submitted for verification.

b) Complete assembly shall be tested at shop for temp. and pressure developed

1.04.04 Pulleys

a) In addition to chemical,mechanical,hardness,microstructure as per applicable material specification, pulleys shaft forgings shall be subjected to ultrasonic testing.

b) 100% MPI/DPT on all welds shall be conducted and 10% RT/UT on butt welds shall be conducted.

c) Static balancing of pulleys shall be carried out after rubber lagging.

CLAUSE NO.





SECTION-VI, PART-B


PAGE 3 OF 7

d) Checks on rubber lagging to include abrasion loss, shore hardness test, peel-off strength test and physical properties. Peel-off strength shall be 10 Kg/Cm, Abrasion loss shall be less than 250 cubic mm when tested as per DIN 53516.

1.04.05 Pull Chord & Belt Sway Switches

a. Acceptance tests

i) Over all dimension and functional test.

ii) HV & IR test

iii) Degree of protection test report. 1.04.06 Zero Speed Switch, Under Belt Switch and Chute Blockage Switch

a Acceptance test

i) Burn in test at 50 degree C for 48 hours shall be done for electronic switches. ii) Over all dimension and functional test shall be carried out. iii) HV & IR

iv) Degree of protection test

1.05.00 Drive Equipments 1.05.01 Gear Boxes :

(a) In addition to checks for physical, chemical, hardness, microstructure as per relevant standard, the shaft and gear/pinion forgings shall be subjected to ultrasonic testing .

(b) MPI to be carried out on Gears/Pinions after machining. Case depth, hardness and MPI after hardfacing shall be checked to ensure freedom from defects.

(c) Gear reducer shall be checked for reduction ratio, backlash and contact pattern. No load shop trial run to be conducted on gear boxes to check for oil leakage, temperature rise, noise level and vibration.

1.05.02 Flexible Coupling

(a) Ultrasonic testing shall be conducted on forgings for gear sleeve and gear hub, if gear coupling is provided.

(b) MPI shall be carried out after machining to ensure freedom from cracks.

CLAUSE NO.





SECTION-VI, PART-B


PAGE 4 OF 7

1.05.03 Fluid Coupling

(a) Dynamic balancing shall be carried out for the rotating parts.

(b) Check for leak tightness of the coupling shall be carried out.

(c) Functional test on fusible plug for each type of coupling shall be conducted at shop.

(d) All couplings to be run tested at shop on no load

(e) Check for temperature rise, torque-speed, torque-slip characteristics and over speed test shall be included during performance test of one coupling of each type preferably at full load.

1.06.00 Belt Scales

The details of the checks to be carried out in the various equipments are to be submitted by the Contractor for Employer’s approval. However, some indicative checks are given below which should necessarily form a part of the quality assurance plan to be agreed with the Employer.

1.06.01 Mounting arrangement/Overall dimensional check shall be carried out on the Belt

Scales. 1.06.02 Belt scale shall be calibrated with test weight/test chain in static at works and with

test weight for dynamic condition at site. 1.06.03 All electronic modules shall be subjected to burn in test at 50 Degree C for 48

hours. 1.06.03.1.1 General check for load cell shall be carried out. 1.06.04 Test report for degree of protection on enclosure shall be furnished. 1.06.04.1.1 Accuracy/performance check shall be demonstrated at site. 1.07.00 Dust Control & Miscellaneous Systems (Dust Suppression System)

The details of the checks to be carried out on the various equipments are to be submitted by the Contractor for Owners approval. However some indicative checks on different items are given below which should necessarily form a part of the Quality Assurance Plan to be agreed with by the Owner.

1.07.01 Pumps

(a) All materials should be of tested quality and test certificates to be provided.

(b) DPT of machined shaft and impeller shall be done.

(c) Shaft forgings to be also subjected to ultrasonic testing.

CLAUSE NO.





SECTION-VI, PART-B


PAGE 5 OF 7

(d) Impellers to be dynamically balanced to ISO 1940 Gr.6.3

(e) All pressure parts shall be hydraulically tested at 150% of the shut-off head or

200% of rated head, whichever is higher for 30 minutes. No leakage is allowed.

(f) All pumps to be performance tested as per Hydraulic Institute Standard/Indian Standard. Performance test to include check for noise, vibration level and temperature rise.

1.07.02 Valves & Specialties

(a) Valves and Specialties shall be tested as per relevant standards / codes.

(b) Seat Leakage and hydraulic test to be carried out as per relevant standards / codes.

1.07.03 Pipes and Fittings

Pipes and fittings shall be tested as per relevant standards/ codes. 1.07.04 Air Compressor

a) All pressure parts shall be hydraulically tested at not less than 150% of design

pressure for a duration of 30 minutes prior to painting.

b) All other parts including inter-connecting piping shall be hydraulically tested wherever possible, as per relevant codes.

c) Ultrasonic testing shall be carried out on all forgings and rotor for dia 50mm and

above. MPI/DPT shall be done on machined area of the components.

d) During assembly all clearances and alignments shall also be checked and recorded

e) Rotor shall be statically and dynamically balanced

f) Performance Test(Shop Test)

i. Performance test on the compressor shall be carried out in accordance with ISO:1217/Eq. The test shall also include demonstration of loading and unloading mechanism(Capacity control) and operation of safety valve

ii. Vibration and Noise level measurement shall be done during shop performance test.

CLAUSE NO.





SECTION-VI, PART-B


PAGE 6 OF 7

1.07.05 Air Receiver

a) Each finished vessel shall be hydraulically tested at 150% of the design pressure for a duration of 30 minutes

b) NDT on weld joints shall be as per respective code requirements or the minimum

as specified below

i. 100% DPT on root run of butt welds ii. 100% DPT on all finished butt welds and fillet welds iii. 10% RT on butt welds which shall include all T-Joints

1.08.00 Dust Extraction, Ventilation Systems 1.08.01 Fan

(a) All materials should be of tested quality and test certificates should be provided.

(b) Dynamic balancing of the fan impellers to be carried out.

(c) Shop run test shall be conducted on all centrifugal fans including check for noise and vibration level.

(d) Performance test shall be conducted on one fan of each type at shop for capacity, pressure, efficiency and power consumption.

1.08.02 Valves and Specialties Refer 1.08.02 above 1.08.03 Pipes and Fittings

Refer 1.08.03 above 1.09.00 Vibrating Feeders

(a) Shaft forgings to be checked for ultrasonic testing in addition to check for chemical, mechanical, hardness, microstructure etc. as per applicable material specification

(b) Following minimum NDT requirements to be ensured for welds: i) Butt welds - 10% UT/RT and 100% MPI/DPT. ii) Fillet Welds - 10% MPI/DPT.

(c) Shop trial run test shall be conducted to checks for speed(RPM), amplitude(stroke), temperature rise and noise level.

CLAUSE NO.





SECTION-VI, PART-B


PAGE 7 OF 7

1.10.00 In-Line Magnetic Separators

i) Overall Dimensional, Visual check alongwith control panel. ii) HV & IR. iii) Operation, temperature rise, lifting capacity, force index and gauss strength.

1.11.00 Metal Detectors

i) Functional test including sensitivity, Burn in test, operation of liquid spray marker, detection of smallest piece of different materials as specified.

ii) Test report for Degree of protection test to be furnished.

1.12.00 Coal Sampling Units

(a) Free carriage and cutter movement, speed of cutter and dust door closing and sealing shall be tested for samplers.

(b) “No load test” shall be carried out for crushers.





SECTION-VI, PART-B

SUB-SECTION-IIIE-02 INDUCTION MOTOR &

SYNCHRONOUS MACHINE

PAGE 1 OF 2

INDUCTION MOTOR & SYNCHRONOUS MACHINE SQE_7 TESTS/CHECKS

TEMS/COMPONENTS Vi

sual

Dim

ensi

onal

Mak

e/Ty

pe/R

atin

g/TC

/Gen

eral

Ph

ysic

al In

spec

tion

Mec

h/C

hem

. Pro

perti

es

ND

T /D

P/M

PI/U

T

Met

allo

grap

hy

Elec

trica

l Cha

ract

eris

tics

Wel

ding

/Bra

zing

(WP

S/P

QR

)

Hea

t Tre

atm

ent

Mag

netic

Cha

ract

eris

tics

Hyd

rual

ic/L

eak/

Pre

ssur

e Te

st

Ther

mal

Cha

ract

eris

tics

Run

out

Dyn

amic

Bal

anci

ng

All R

outin

e te

sts

as p

er IS

-325

/IS-

4722

/ 9

283

Vibr

atio

n

Ove

r spe

ed

Tan

delta

, sh

aft

volta

ge

&

pola

risat

ion

inde

x te

st

Plates for stator frame,end shield, spider etc.

Y Y Y Y Y

Shaft Y Y Y Y Y Y Y Magnetic Material Y Y Y Y Y Y Y Y Rotor Copper/Aluminium Y Y Y Y Y Y Y Stator copper Y Y Y Y Y Y Y SC Ring Y Y Y Y Y Y Y Y Y Insulating Material Y Y Y Y Y Tubes for Cooler Y Y Y Y Y Y Y Sleeve Bearing Y Y Y Y Y Y Y Stator/Rotor, Exciter Coils Y Y Y Y Y





SECTION-VI, PART-B

SUB-SECTION-IIIE-02 INDUCTION MOTOR &

SYNCHRONOUS MACHINE

PAGE 2 OF 2

Castings, stator frame,terminal box and bearing housing etc.

Y Y Y Y Y Y

Fabrication & machining of stator, rotor, terminal box

Y Y Y Y

Wound stator Y Y Y Y Wound Exciter Y Y Y Y Rotor complete Y Y Y Y Y Exciter, Stator, Rotor, Terminal Box assembly

Y Y Y

Accessories, RTD, BTD,CT, Brushes, Diodes,Space heater, antifriction bearing, cable glands, lugs, gaskets etc.

Y Y Y

Motor ( IS 325 / 4722/ 9283) Y Y Y Y Y Y Y1

Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality Plan indicating the practices & Procedure followed along with relevant supporting documents during QP finalization. However, No QP for LT motor up to 50KW. 2. Makes of all major bought out items will be subject to NTPC approval. Y1 = for HT Motor / Machines only.

CLAUSE NO.





PART-B

SUB-SECTION-IIIE-03 LT SWITCHGEAR

PAGE 1 OF 2

SQE _10

LT SWITCHGEAR ( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL MOTOR STARTERS) ATTRIBUTES / CHARACTERIS-TICS

ITEMS/ COMPONENTS/ SUB SYSTEM ASSEMBLIY M

ake,

Mod

el, T

ype,

Rat

ing

& T

C

Dim

ensi

ons

& F

inis

h

Ele

ctric

al p

rope

rties

Mec

hani

cal P

rope

rties

Che

mic

al p

rope

rties

Func

tiona

l &

Ope

ratio

nal

Feat

ures

as

per N

TPC

Spe

c.

Item

to c

onfo

rm to

rele

vant

Sta

ndar

ds

Pre

treat

men

t as

per I

S 60

05

Pai

nt

Sha

de,

Adhe

sion

, Th

ickn

ess

&Fi

ih

Func

tiona

l Che

cks

Mill

i-vol

t dro

p Te

st

IR –

HV

– IR

Tes

t D

egre

e of

Pro

tect

ion

Rou

tine

test

as

per N

TPC

spe

c (B

y ph

ysic

al v

erifi

catio

nof

gas

ketti

ng a

rran

gem

ent a

nd b

y pa

per

inse

rtion

met

hod)

All

Rou

tine

test

s as

per

NTP

C s

pec.

&IS

Sheet Steel (IS : 513) Y Y Y Y Y

Aluminum Bus bar Material (IS : 5082)

Y Y Y Y Y Y

Copper Bus bar Material (IS : 613)

Y Y Y Y Y Y

Support Insulator Y Y Y Y Y Air Circuit Breaker ( IS: 13947)

Y Y Y Y Y Y Y

Energy Meters ( IS : 13010, 13779 )

Y Y Y Y Y Y

Power & Aux. Contactors (IS : 13947 )

Y Y Y Y Y

Protection & Aux. Relays (IS : 3231)

Y Y Y Y Y Y

Control & Selector Switches ( IS : 13947)

Y Y Y Y Y

CT’s & PT’s ( IS 2705 / 3156)

Y Y Y Y

MCCB ( IS : 13947 ) Y Y Y Y Indicating Meters ( IS : 1248 )

Y Y Y Y Y Y

Indicating Lamps ( IS : 13947 )

Y Y Y Y Y

Air Break Switches ( IS : 13947 )

Y Y Y Y Y

Control Terminal Blocks

Y Y Y Y

CLAUSE NO.





PART-B

SUB-SECTION-IIIE-03 LT SWITCHGEAR

PAGE 2 OF 2

LT SWITCHGEAR ( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL MOTOR STARTERS) ATTRIBUTES / CHARACTERIS-TICS

ITEMS/ COMPONENTS/ SUB SYSTEM ASSEMBLIY

Mak

e, M

odel

, Typ

e, R

atin

g &

TC

Dim

ensi

ons

& Fi

nish

Ele

ctric

al p

rope

rties

M

echa

nica

l Pro

perti

es

Che

mic

al p

rope

rties

Fu

nctio

nal

& O

pera

tiona

l Fe

atur

es a

s pe

rN

TPC

Spe

c.

Item

to c

onfo

rm to

rele

vant

Sta

ndar

ds

Pre

treat

men

t as

per I

S 6

005

Pai

nt S

hade

, Adh

esio

n, T

hick

ness

& F

inis

h

Func

tiona

l Che

cks

Mill

i-vol

t dro

p Te

st

IR –

HV

– IR

Tes

t D

egre

e of

Pro

tect

ion

Rou

tine

test

as

per

NTP

C s

pec

All

Rou

tine

test

s as

per

NTP

C s

pec.

& IS

Fuse ( IS 13703) Y Y Y Y

Control Transformer ( IS : 12021)

Y Y Y Y Y Y

Push Buttons ( IS : 4794 ) Y Y Y Y Y

Transducer (IEC : 60688) Y Y Y Y Y Y

MCB ( IS : 8828) Y Y Y Y Y

Breaker Handling Trolley Y Y Y Y Y Y

Synthetic Rubber Gasket (IS : 11149 )

Y Y Y Y Y

LT SWITCHGEAR ( IS : 8623 )

Y Y Y Y Y Y Y Y Y Y Y

Notes: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. Makes of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-04 LT BUSDUCT

PAGE 1 OF 1

LT BUSDUCT ATTRIBUTES ,

CHARACTERISTICS ITEM, COMPONENTS, SUB SYSTEM ASSEMBLY D

imen

sion

& S

urfa

ce F

inis

h M

ake,

Typ

e, R

atin

g &

TC

E

lect

rical

Pro

perti

es

Mec

hani

cal P

rope

rties

C

hem

ical

Pro

perti

es

Item

to c

onfo

rm to

rele

vant

IS

WP

S A

ppro

val,

Wel

der Q

ualif

icat

ion

Wel

d Q

ualit

y C

heck

( D

P te

st

&

x-ra

y P

aint

Sha

de,

Thic

knes

s, A

dhes

ion

&

Tigh

tnes

s by

Tor

que

mea

sure

men

t E

lect

rical

Cle

aran

ces

G

alva

nizi

ng T

est a

s pe

r IS

262

9/ 2

633/

47

59IR

– H

V –

IR T

est

Pha

se S

eque

nce

Che

ck

Deg

ree

of P

rote

ctio

n ro

utin

e te

st a

s pe

r N

TPC

spe

c.

Aluminum Sheets / Plates / Strips / Flexibles / tubes ( IS : 5082 / 737 )

Y Y Y Y Y Y Y

CRCA Flats / ISMC ( IS 2062 ) Y Y Y Y Y Neoprene / Synthetic Rubber Gaskets ( IS 11149 / 3400 )

Y Y Y Y

Rubber Bellows (IS : 3400) Y Y Y Y Support Insulator ( BS : 2782, IEC : 660, IS : 10912 )

Y Y Y Y

Galvanized Structure & GI Earthing Flat (IS : 2629 / 2633 / 4749 )

Y Y Y Y

Space Heater & Thermostat Y Y Y LT Busduct (IS : 8623 PART 2) Y Y Y Y Y Y Y Y Y Y Y Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality

Plan indicating the practice and procedure along with relevant supporting documents.

2. Makes of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-05 L.T POWER CABLES

PAGE 1 OF 3

Attributes / Characteristics Item / Components / Sub System Assembly

Mak

e, R

atin

g, T

ype

& TC

Dim

ensi

on/s

urfa

ce fi

nish

Mec

hani

cal P

rope

rties

Che

mic

al C

ompo

sitio

n

Elec

trica

l Pro

perti

es

Spar

k Te

st

Hot

set

test

(XLP

E)

Lay

leng

th /

Sequ

ence

Arm

our

cove

rage

, C

ross

ove

r, lo

osen

ess,

Gap

be

twee

n tw

o ar

mou

r wire

/stri

p

Sequ

entia

l mar

king

/sur

face

fini

sh /c

able

leng

th

Tens

ile s

treng

th,

elon

gatio

n be

fore

&

afte

r ag

eing

of i

nsul

atio

n &

out

er s

heat

h

Ther

mal

Sta

bilit

y of

insu

latio

n an

d ou

ter s

heat

h *

Anti

tern

ite tr

eatm

ent o

n w

oode

n dr

ums

Con

stru

ctio

nal /

requ

irem

ent a

s pe

r NTP

C S

pec.

Rou

tine

and

acce

ptan

ce te

st a

s pe

r R

elev

ant S

tand

ard

and

NTP

C s

peci

ficat

ion

FRLS

Tes

t

Aluminum (IS-8130) Y Y Y Y Y PVC Compound (IS-5831) Y Y Y Y XLPE Compound(IS-7098 Part-I) Y Y Y Y Y FRLS PVC Compound(IS-5831 ) ASTM-D-2843/ ASTM-D-2863 IEC-754 Part-I

Y Y Y

Armour wire/strip (IS-3975) Y Y Y Insulated Core Y Y Y Y Laid up core Y Y PVC Inner sheath Y Armouring Y Y Outer sheath Y Y Y Y YFinish cable (IS-1554 & 7098 – Part-1) ASTM-D-2843/ IS 10810 ( Part- - 58 ) IEC-754 Part-I Swedish Chimney SS 4241475 for (F3 category) Flammability test IEC-332 Part –3 Cat-B

Y Y Y Y Y Y Y

Y Y

Wooden drum (IS-10418) / Steel drum Y Y

Note: 1.This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the practice and procedure along with relevant supporting documents. All major BoIs to be of makes approved from owner.

∗ 2. Not applicable for XLPE insulation

CLAUSE NO.





SECTION-VI, PART-B


PAGE 2 OF 3

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

1) Conductor Resistance test

2) High voltage test at room temperature

ACCEPTANCE TESTS

Following Acceptance tests shall be carried out for each type and

size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 1554 Part 1 & IS 7098 Part-I

A) For Conductor 1) Annealing test For copper conductor only 2) Tensile test For aluminium conductor only 3) Wrapping test For aluminium conductor only 4) Resistance test B) For Armour Wires / Formed Wires ( If applicable ) 1) Measurement of Dimensions 2) Tensile Tests 3) Elongation Test 4) Torsion Test For Round wires only 5) Wrapping Test 6) Resistance Test 7) Mass of Zinc coating test For G S wires / Formed wires

only 8) Uniformity of Zinc coating For G S wires / Formed wires

only 9) Adhesion test For G S wires / Formed wires

only 10) Freedom from defects C) For PVC / XLPE insulation & PVC Sheath 1) Test for thickness 2) Hot set test For XLPE insulation only 3) Tensile strength & Elongation before ageing

CLAUSE NO.





SECTION-VI, PART-B


PAGE 3 OF 3

D) For completed cables 1) Insulation resistance test ( Volume resistivity method ) 2) High voltage test at room temperature E) Following tests shall be carried out and only one sample shall be

taken from each offered lot of all sizes for these tests:- 1) Tensile strength & elongation after ageing on PVC / XLPE insulation and

PVC outer sheath

2) Thermal stability test on PVC insulation and outer sheath

3) Oxygen index test on outer sheath

4) Smoke density rating test on outer sheath as per ASTM –D 2843

5) Acid gas generation test on outer sheath as per IEC – 754 (Part 1)

6) Flammability test as per IEC-332 - Part- 3 ( Category- B ) on completed cable

7) Fire resistance test as per SS 4241475 (F3 Category ) on completed cable

F) Following tests shall be carried on one length of each size of

offered lot:

1) Surface finish, length measurement, sequence of cores, armour coverage, Gap between two consecutive armour wires / formed wires

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-06 CONTROL CABLE

PAGE 1 OF 3

Attributes / Characteristics Item / Components / Sub System Assembly M

ake,

Typ

e, R

atin

g, T

.C

Dim

ensi

on/s

urfa

ce fi

nish

Mec

hani

cal P

rope

rties

Che

mic

al C

ompo

sitio

n

Ele

ctric

al P

rope

rties

Spa

rk T

est

Lay

leng

th/S

eque

nce

Arm

our

cove

rage

, cr

oss

over

, lo

osen

ess

gap

betw

een

two

arm

our

Seq

uent

ial

mar

king

/sur

face

fin

ish/

cabl

ele

ngth

Tens

ile

stre

ngth

, el

onga

tion

befo

re

&af

ter

agei

ngof

insu

latio

n&

oute

rTh

erm

al

stab

ility

of

insu

latio

n an

d ou

ters

heat

hA

ntit

erm

itetre

atm

ent

onw

oode

ndr

ums

Con

stru

ctio

nal

feat

ure

as p

er N

TPC

S R

outin

e &

A

ccep

tanc

e te

st a

s pe

r re

leva

ntst

anda

rd&

page

2&

3of

FRLS

Tes

t

Copper Conductor (IS-8130) Y Y Y Y Y PVC Compound (IS-5831) Y Y Y Y FRLS PVC Compound IS-5831 ASTM-D-2843/ IS 10810 (Part-58 ) IEC-754 Part-1

Y Y Y Y

Armour wire/strip (IS-3975) Y Y Y Insulated Core Y Y Y Y Laid up core Y Y PVC Inner sheath Y Armouring Y Y Outer sheath Y Y Y Y YFinish cable (IS-1554- 1 ) ASTM-D-2843/ IS 10810 (Part-58 ) IEC-754 Part-1 Swedish Chimney: SEN SS 424-1475( F3 category) Flammability test IEC-332 Part-3 Cat-B

Y Y Y Y Y Y Y Y Y

Wooden drum( IS : 10418) / Steel drum

Y Y

• 1.Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the Practice and procedure along with relevant supporting documents.

CLAUSE NO.





SECTION-VI, PART-B


PAGE 2 OF 3

CONTROL CABLE ROUTINE TESTS

Routine tests shall be carried out on each drum of finished cables for all types & sizes. Following shall constitute routine tests:


2) High voltage test at room temperature

ACCEPTANCE TESTS


size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 1554 Part 1

A) For Conductor 1) Annealing test For copper conductor only 2) Resistance test B) For Armour Wires / Formed Wires ( If applicable ) 1) Measurement of Dimensions 2) Tensile Tests 3) Elongation Test 4) Torsion Test For Round wires only 5) Wrapping Test 6) Resistance Test 7) Mass of Zinc coating test For G S wires / Formed wires



only 10) Freedom from defects C) For PVC insulation & PVC Sheath 1) Test for thickness 2) Tensile strength & Elongation before ageing D) For completed cables 1) Insulation resistance test ( Volume resistivity method ) 2) High voltage test at room temperature

CLAUSE NO.





SECTION-VI, PART-B


PAGE 3 OF 3

E) Following tests shall be carried out and only one sample shall be taken from each offered lot of all sizes for these tests:-

1) Tensile strength & elongation after ageing on PVC insulation and PVC outer sheath

2) Thermal stability test on PVC insulation and outer sheath





7) Fire resistance test as per SS 4241475 (F3 Category ) on completed cable


offered lot:


CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-07 INSTRUMENTATION

CABLE

PAGE 1 OF 1

INSTRUMENTATION CABLE TESTS ITEMS

Con

duct

or R

esis

tanc

e ®

& (A

) H

igh

Vol

tage

® &

(A)

Insu

latio

n R

esis

tanc

e ®

& (

A)

Con

stru

ctio

nal d

etai

l, di

men

sion

s (A

) O

uter

-She

athe

/cor

e m

arki

ng, e

nd s

ealin

g (A

)

Ther

mal

Sta

bilit

y (A

) +

Visu

al, S

urfa

ce fi

nish

(A) +

Elec

trica

l Par

amet

ers

**

(A) +

Pers

ulph

ate

Test

(A) +

Ove

rall/

Cov

erag

e/C

ontin

uity

(A)

Swid

esh

chim

ney

Tes

t (S

S-4

2414

75) (

A) +

+

FRLS

Tes

t * (A

) ++

Tens

ile &

Elo

ngat

ion

befo

re &

afte

r agi

ng (A

) ++

Vol.

Res

istiv

ity. a

t roo

m &

Ele

vate

d Te

mp.

(A) +

+

Spar

k te

st re

port

revi

ew ®

1. Instrument cable twisted and shielded

Conductor(IS-8130) Y Y Y Insulation(VDE-207) Y Y Y Y Y Y Pairing/Twisting Y Y Y Shielding Y Y Y Drain wire Y Y Y Y Y Inner Sheath Y Y Y Y Y Y Outer Sheath Y Y Y Y Y Y Over all cable Y Y Y Y Y Y Y Y Y CableDrums(IS-10418) Y Y Note : High Temp. cables shall be subjected to tests as per VDE-207(Part-6) Compensating cables shall be checked for Thermal EMF/Endurance test as per IS 8784. Note : This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality Plan indicating his practice & Procedure along with relevant supporting documents during QP finalization for all item. Note : ® - Routine Test A - Acceptance Test Y - Test Applicable Note : Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable) • * FRLS Tests: Oxygen / Temp Index ( ASTM D-2863), Smoke Density Rating (

ASTM – D 2843), HCL Emission ( IEC-754-1) • ** Characterisitic Impedence, Attenuation, Mutual Capacitance, Cross Talk ( As

applicable) + Sample size will be One No. of each size/type per lot. ++ Sample size will be One No. sample for complete lot offered irrespective of size/type.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-08 STATION LIGHTING

PAGE 1 OF 1

STATION LIGHTING Item Components Sub System Assembly Attributes Characteristics M

ake,

Typ

e , R

atin

g/ T

C

Dim

ensi

on

Pre

-Tre

atm

ent o

f she

et

Pai

nt

Shad

e Th

ickn

ess

Adh

esio

n &

Fi

nish

Gal

vani

zatio

n Te

st

IP T

est

Bou

ght O

ut It

ems/

Bill

of M

ater

ial

HV

& IR

Func

tiona

l Che

ck a

s pe

r spe

c.

Con

stru

ctio

nal

Feat

ure

as p

er N

TPC

sp

ec.

Rou

tine

Test

as

per

rele

vant

std

and

sp

ec

Acc

epta

nce

Tes

t as

per

rel

evan

t st

d an

d sp

ec

Item

to c

onfo

rm to

rele

vant

sta

ndar

d

Luminaries (IS-10322 Part-5 Sec.1)

Y Y Y Y

Y

Electronic Ballast Y Y Y Y Lighting Wire (IS-694) Y Y Fans (IS-374) Y Y Pole (IS-2713) Y Y Y Y Y

Lamps (IS-9800, IS-9974) Y Y Y Lighting Mast Y Y Y Y Y Y Wall Mounted Lighting Panel (IS-513, IS-5)

Y Y Y Y Y Y Y Y Y Y Y Y

Switch Box/ Junction Box/Receptacles/ Local Push Button Station,Lighting Panel (IS-513, 2629, 2633, 4759, 6745)


Cable Gland (BS-6121) Y Y Y

Cable Lug (IS-8309) Y Y Y

Flexible Conduit Y Y

Lighting Transformer (IS-1117)

Y Y Y

Epoxy & Galvanised Conduit (IS-9537, 2629, 2633, 4759, 6745)

Y Y Y Y

Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan

indicating the practice and procedure along with relevant supporting documents. 2. Make of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-09 CABLING, EARTHING,

LIGHTNING PROTECTION

PAGE 1 OF 2

QUALITY ASSURANCE & INSPECTION MODULE NO. SQE16 Page 1 of 1

CABLING, EARTHING, LIGHTNING PROTECTION ATTRIBUTES / CHARACTERISTICS

ITEMS/COMPONENTS /

SUB SYSTEMS D

imen

sion

Pai

nt s

hade

, pai

nt th

ickn

ess,

adh

esio

n

Pre

-trea

tmen

t of s

heet

IP

prot

ectio

n (B

y ph

ysic

al

verif

icat

ion

of

gask

ettin

g ar

rang

emen

t an

d by

pap

er i

nser

tion

Pro

of lo

ad*

Sur

face

fini

sh

Def

lect

ion

test

*

HV

& IR

Gal

vani

se T

est (

If A

pplic

able

)

Func

tiona

l

Bou

ght o

ut it

ems/

Bill

of m

ater

ial

Rou

tine

test

s as

pe

r

rele

vant

st

anda

rd

& sp

ecifi

catio

n

Acc

epta

nce

test

s as

per

rel

evan

t st

anda

rd &

sp

ecifi

catio

nC

onst

ruct

iona

l fe

atur

e as

pe

r N

TPC

Wall Mounted-Lighting Panel (IS-513, IS:5, IS:2629, 2633, 6745)


Switch box/junction box/ Receptacles Panel (IS-513, IS:5, IS:2629, 2633, 6745)


Cable glands(BS-6121) Y Y Cable lug(IS-8309) Y Y Lighting wire(IS-694) Y Y Flexible conduits Y Y YConduits(Galvanise & Epoxy) IS-9537 & IS-2629,2633 ,6745

Y Y Y Y Y

RCC Hume Pipe (IS-458) Y Cable termination & straight through joint (VDE-0278)

Y Y Y

Cable Trays, Flexible supports system & accessories IS-513, 2629,2633,6745


Trefoil clamp Y Y

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-09 CABLING, EARTHING,

LIGHTNING PROTECTION

PAGE 2 OF 2

GI flats for earthing & lighting protection (IS 2062, 2629, 6745,2633)

Y Y Y Y Y

GI wire (IS-280) Y Y Fire Sealing System ( BS –476)

Y Y Y

.Note:1.This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2.* Deflection Test on cable trays and Proof Load test on cable trays support system will be as per details given in the NTPC technical specification & approved MQP. The above acceptance tests shall be done only on one sample from each size of offered lot. 3. Make of all items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-10 H.T CABLES

PAGE 1 OF 3

Attributes/ Characteristics Item / Components / Sub System Assembly M

ake,

Typ

e, R

atin

g &

T.C

D

imen

sion

/sur

face

fini

sh

Mec

hani

alpr

oper

ties

Che

mic

al C

ompo

sitio

n S

park

Tes

t(as

appl

icab

le)

Cur

ing

Pro

perti

es

Ele

ctric

al p

rope

rties

H

ot S

et T

est/

Ecc

entri

city

& O

valit

y La

y le

ngth

& S

eque

nce

Arm

our

cove

rage

, cr

oss

over

, lo

osen

ess,

ga

p be

twee

n tw

o w

ire

Seq

uent

ial

mar

king

/sur

face

fin

ish/

ca

ble

leng

th

T.S

& el

onga

tion

befo

re &

afte

r ag

eing

on

ou

ter s

heat

h &

insu

latio

n

The

rmal

sea

bilit

y on

out

er s

heat

h M

etal

lic (

Cu

) Scr

eeni

ng (

If a

pplic

able

) A

nti t

erm

ite c

oatin

g on

woo

den

drum

s C

onst

ruct

iona

l req

uire

men

ts fe

atur

e as

pe

r N

TPC

spe

cific

atio

n R

outin

e &

Acc

epta

nce

Test

as

per

rele

vant

t

dd

&N

TPC

ifiti

FRLS

Tes

t

Aluminium (IS-8130) Y Y Y Y Y Semiconducting Compound

Y Y Y Y

XLPE Compound (IS-7098 Part-II)

Y Y Y Y Y

FRLS PVC Compound (IS-5831, ASTM-D2843, IS10810( Part 58) ,IEC-60754 Part-1)

Y Y Y Y Y

Triple Extrusion & curing /Manufacturing of Core

Y Y Y Y

Copper Tape Y Y Y Y Polyster tape Y Y Armour wire/strip Y Y Y Copper tapping Y Y Y Inner sheath Y Y Armouring Y Y Outer Sheathing Y Y Y Y Y YPower Cable (Finished) (IS : 7098 Part II, IEC : 60332 (Part 3 Cat. B), IS-5831, ASTM-D2843, IS10810(Part 58) , IEC-60754 Part-1)

Y Y Y Y Y Y Y Y Y

Wooden drum(IS-10418) /Steel Drum

Y Y

CLAUSE NO.





SECTION-VI, PART-B


PAGE 2 OF 3

Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish

a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents.

2. Make of all major Bought Out Items will be subject to NTPC approval. ROUTINE TESTS Routine tests shall be carried out on each drum of finished cables for all types & sizes. Following shall constitute routine tests:


2) High voltage test

3) Partial discharge test ( for Screened cables only )

ACCEPTANCE TESTS


size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 7098 Part 1I

A) For Conductor 1) Tensile Test 2) Wrapping Test 3) Resistance test B) For Armour Wires / Formed Wires ( If applicable ) 1) Measurement of Dimensions 2) Tensile Tests 3) Elongation Test 4) Torsion Test For Round wires only 5) Wrapping Test 6) Resistance Test 7) Mass of Zinc coating test For G S wires / Formed wires



only 10) Freedom from defects C) For XLPE insulation & PVC Sheath 1) Test for thickness

CLAUSE NO.





SECTION-VI, PART-B


PAGE 3 OF 3

2) Tensile strength & Elongation before ageing 3) Hot set test (For XLPE insulation) D) For completed cables 1) Insulation resistance test ( Volume resistivity method ) 2) High voltage test 3 Partial discharge test ( for Screened cables only ) E) Following tests shall be carried out and only one sample shall be

taken from each offered lot of all sizes for these tests:- 1) Tensile strength & elongation after ageing on XLPE insulation and PVC

outer sheath

2) Thermal stability test on outer sheath






offered lot:


2) Measurement of Eccentricity & Ovality

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-11 HT SWITCHGEAR

PAGE 1 OF 2

HT SWITCHGEAR SQE_5 ATTRIBUTES / CHARACTERISTICS

ITEMS, COMPONENTS, SUB-SYSTEM ASSEMBLY M

ake,

Typ

e, M

odel

, R

atin

g &

TC

Ele

ctric

al P

rope

rties

M

echa

nica

l pro

perti

es

Che

mic

al P

rope

rties

D

imen

sion

s &

Fin

ish

Func

tiona

l & O

pera

tiona

l Fea

ture

s as

pe

r NTP

C S

pec.

Item

to c

onfo

rm to

rele

vant

Sta

ndar

ds

Pre

treat

men

t as

per I

S 6

005

Pai

nt s

hade

, th

ickn

ess,

adh

esio

n &

Fu

nctio

nal C

heck

s H

V &

IR T

est

Deg

ree

of P

rote

ctio

n R

outin

e te

st a

s pe

r N

TPC

sp

ec.

(By

phys

ical

ve

rific

atio

n of

gas

ketti

ng a

rran

gem

ent

and

by p

aper

inse

rtion

met

hod)

CB

Ope

ratio

n tim

ing

che

ck

All

Rou

tine

Test

s as

per

re

leva

nt

stan

dard

Aluminum Bus bar material ( IS : 5082 )

Y Y Y Y Y Y

Copper Bus bar material ( IS : 613 )

Y Y Y Y Y Y

Bus bar Support Insulator (IS : 9431 )

Y Y Y Y Y Y

HT Circuit Breaker (IEC : 56 ) Y Y Y Y Y Y Y HT Contactors ( IS : 9046 ) Y Y Y Y Y Y Protection & Auxilliary Relays ( IS : 3231 / 8686 )

Y Y Y Y Y Y

HT CT’s & PT’s ( IS : 2705 / 3156 )

Y Y Y Y

HT Fuses ( IS : 9385 ) Y Y Y Y Surge Arrester ( IEC : 99 –4 ) Y Y Y Y LT Contactors ( IS : 13947) Y Y Y Y Y Control & Selector Switches ( IS : 6875 )

Y Y Y Y Y

Indicating Meters ( IS : 1248) Y Y Y Y Y Y Indicating Lamps ( IS : 13947) Y Y Y Y Y Push Buttons ( IS : 4794) Y Y Y Y Y Control Transformer ( IS : 12021 )

Y Y Y Y Y Y

LT Fuses ( IS : 13703) Y Y Y Y Energy Meters ( IS : 722 ) Y Y Y Y Y Y Transducers ( IEC : 60688) Y Y Y Y Y Y Diodes Y Y Y Y Y Terminal Blocks Y Y Y Y Synthetic Rubber Gasket ( IS : 11149 / 3400 )

Y Y Y Y

Breaker Handling Trolley Y Y Y Y Y HT Switchgear Panel ( IS : 3427)


CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-11 HT SWITCHGEAR

PAGE 2 OF 2

Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality

Plan indicating the practice and procedure along with relevant supporting documents. 2. Make of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-12 HT Capacitor Bank

PAGE 1 OF 1

HT Capacitor Bank

ATTRIBUTES / CHARACTERISTICS ITEMS, COMPONENTS, SUB-SYSTEM ASSEMBLY M

ake,

Typ

e, M

odel

, R

atin

g &

TC

Ele

ctric

al P

rope

rties

Mec

hani

cal p

rope

rties

Che

mic

al P

rope

rties

Dim

ensi

ons

& F

inis

h

Func

tiona

l &

Ope

ratio

nal

Feat

ures

as

per N

TPC

Spe

c.

All

Rou

tine

Test

s as

pe

r

rele

vant

st

anda

rd

Enclosure Y Y Y

Oil / Paper Y Y Y Y

Insulator Y Y Y Y

Accessories Y Y Y Y Y Y

Supporting Structure (Galvanized)

Y Y Y

Complete Capacitor Y Y Y Y

Notes: 1. This is an indicative list of tests / checks. The manufacturer is

to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents.

2. Make of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-13 MEASURING

INSTRUMENTS

PAGE 1 OF 2

MEASURING INSTRUMENTS (PRIMARY AND SECONDARY) TESTS ITEMS D

imen

sion

s (R

)

Mak

e , M

odel

, Typ

e, R

atin

g (R

) P

roce

ss /

Ele

ctric

al c

onne

ctio

n (R

)

Cal

ibra

tion

(R)

Test

as

per s

tand

ard(

R)

Insu

latio

n R

esis

tanc

e (R

)

IBR

Cer

tific

atio

n (if

app

licab

le )(

R)

Hyd

ro T

est(R

)

Mat

eria

l Tes

t cer

tific

ate

®

1. PR Gauge (IS-3624) Y Y Y Y Y 2. Temp. Gauge (BS-5235) Y Y Y Y Y 3. Pr./D.P.Switch(BS-6134) Y Y Y Y Y Y 4. Electronic Transmitter(BS-6447 / IEC-60770)

Y Y Y Y Y Y

5. Temp. Switch Y Y Y Y Y Y 6. Recorder(IS-9319/ANSI C-39.4)

Y Y Y Y Y Y

7. Vertical indicators Y Y Y Y Y 8. Digital Indicators Y Y Y Y Y 9. Integrators Y Y Y Y 10. Electrical Metering Instrument (IS-1248)

Y Y Y Y Y Y

11. Transducer (IEC-688) Y Y Y Y Y Y 12. Thermocouples (ANSI-MC-96.1)

Y Y Y Y Y Y

13. RTD(IEC-751) Y Y Y Y Y Y 14. Thermowell Y Y Y Y Y R-Routine Test A- Acceptance Test Y – Test applicable : Note: 1) Detailed procedure of Environmental Stress Screening

Test shall be as per Quality Assurance Programme in General Technical Conditions

2) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed quality plan indicating the Practices and Procedure adopted alongwith relevant supporting documents.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-13 MEASURING

INSTRUMENTS

PAGE 2 OF 2

TESTS ITEMS D

imen

sion

s (R

)

Mak

e, M

odel

, Typ

e, R

atin

g (R

)

Pro

cess

/ E

lect

rical

con

nect

ion

(R)

Cal

ibra

tion

(R)

Req

uire

men

t as

per s

tand

ard

(R)

WP

S a

ppro

val (

A)

Non

-des

truct

ive

test

ing

(R)

Cal

cula

tion

for a

ccur

acy

(R)

Insu

latio

n R

esis

tanc

e (R

)

IBR

Cer

tific

atio

n as

app

licab

le (R

)

Hyd

ro te

st (R

)

Mat

eria

l tes

t cer

tific

ate

(A)

15. Cold junction compensation box

Y Y Y Y Y

16. Orifice plate(BS-1042) Y Y Y Y*

Y Y**

Y**

Y Y**

Y

17. Flow nozzle(BS-1042) Y Y Y Y*

Y Y Y Y Y Y

18. Impact head type element Y Y Y Y Y 19. Level transmitter/float type switch

Y Y Y Y Y Y Y Y

20. Flue Gas analyser Y Y Y Y 21. Dust emission monitors Y Y Y Y *Calibration to be carried out on one flow element of each type and size if calibration carried out as type test same shall not be repeated.

** If applicable R-Routine Test A- Acceptance Test Y – Test applicable Note: 1) Detailed procedure of Environmental Stress Screening test shall be as

per Quality Assurance Programme in General Technical Conditions 2) This is an indicative list of tests/checks. The manufacturer is to furnish a

detailed quality plan indicating the Practices and Procedure adopted alongwith relevant supporting documents.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-14 POWER SUPPLY FOR

C&I SYSTEMS

PAGE 1 OF 1

POWER SUPPLY FOR C&I SYSTEMS (UPS/BATTERY/BATTERY

CHARGER/ACDB/DCDB) TESTS

ITEMS V

isua

l/dim

ensi

on/ra

ting/

P

aint

A

dhes

ion/

Th

ickn

ess

(R)

Gen

eral

ar

rang

emen

t/BO

M/m

ake

of

com

pone

nts

/Mim

ic ®

E

ffici

ency

,reg

ulat

ion(

R)

Inpu

t vol

tage

var

iatio

n (A

)

Out

put

vol

tage

and

freq

uenc

y ad

j.ran

ge(A

)

Pre

milin

ary

light

load

test

(R)

Load

tran

sfer

retra

nsfe

r tes

t (R

) *

AC

inpu

t fal

iure

and

retu

rn te

st (R

)

Par

rale

l ope

ratio

n an

d cu

rren

t div

ison

(R)

Rel

ativ

e ha

rmon

ic c

onte

nt(R

)

Res

tart

with

PR

I A.C

and

bat

tery

(sep

arat

ely)

(R)

Sys

tem

tran

sfer

and

retra

nsfe

r (R

)*

Asy

nchr

onou

s tra

nsfe

r(R

)

Rip

ple

cont

ent(R

)

Load

lim

iter o

pera

tion

(R)

IR/H

V(R

)

Test

s as

per

sta

ndar

d &

spec

ifica

tion

(R)&

(A)

UPS/CONVERTER (IEC-146 PT-4) Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y

VOLTAGE STABILISER Y Y Y Y Y Y Y Y LEAD ACID BATTERY(TUBLAR)-IS-1651

Y

LEAD ACID BATTERY (PLANTE)-IS-1652 Y

NICKEL CADMIUM BATTERY(IS-10918/IEC-623)

Y

SMF BATTERY YACDB/DCDB Y Y Y YBATTERY CHARGER Y Y Y Y Y Y Y Y Y YR-Routine Test A- Acceptance Test Y – Test applicable * Transfer time and Over shoot /under shoot during load & system transfer shall be recorded .

Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality Assurance Programme in General Technical Conditions

2) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed quality plan indicating the Practices and Procedure adopted alongwith relevant supporting documents.

CLAUSE NO.

Quality Assurance




Sub-Section - IIIE-15 Aux. Transformer

Page 1 of 1

AUX. TRANSFORMER Attributes / Characteristics Items/Components Sub Systems

Visu

al &

Dim

ensi

onal

Che

cks

Mec

hani

cal p

rope

rties

Elec

trica

l stre

ngth

Ther

mal

pro

perti

es

Che

mic

al C

ompo

sitio

n

Com

patib

ility

with

oil

Cor

e Lo

ss*,

Hot

Spo

t

ND

T / D

PT /

MPI

/ U

T

Agei

ng T

est.

Volta

ge

Rat

io,

Vec

tor

Gro

up

& Po

larit

y, M

agne

tic B

alan

ce T

est

Mak

e / T

ype

/ Rat

ing

/ Mod

el /

TC

/ G

ener

al P

hysi

cal I

nspe

ctio

n.

WP

S &

PQR

Rou

tine

Test

as

per r

elev

ant t

est

Rou

tine

Test

Tank, H.V. & L.V. Cable Box / Flange throat Y Y Y

Conservator / Radiator / Cooler / Pipes Y Y Y

Copper Conductor (IS:191) Y Y Y Y Insulating Material Y Y Y Y Y Y CRGO Lamination & Built Core Y Y Y Y Y Y Bushing / Insulator ( IS:2544 / 5621) Y Y Y Y

Gasket Y Y Y Y Y Transformer Oil ( IS:335) Y Off-Circuit Tap Changer Y Y Core Coil Assembly & Pre-tanking Y Y Marshalling Box Y Y Y Y

Attributes / Characteristics Items/Components Sub Systems

Visu

al &

Dim

ensi

onal

Che

cks

Mec

hani

cal p

rope

rties

Elec

trica

l stre

ngth

Ther

mal

pro

perti

es

Che

mic

al C

ompo

sitio

n

Com

patib

ility

with

oil

Cor

e Lo

ss*,

Hot

Spo

t

ND

T / D

PT /

MPI

/ U

T

Agei

ng T

est.

Volta

ge

Rat

io,

Vec

tor

Gro

up

& Po

larit

y,

Mag

netic

Bal

ance

Tes

t

Mak

e /

Type

/ R

atin

g /

Mod

el /

TC

/

Gen

eral

Ph

ysic

al In

spec

tion.

WP

S &

PQR

Rou

tine

Test

as

per r

elev

ant t

est

Vacu

um &

Pre

ssur

e Te

st

Rou

tine

Test

WTI, OTI, MOG, PRD, Breather, Terminal Connector, Bucholz Relay, Globe & Gate Valve,

Y Y

Welding (ASME Sect-IX) Y Y

Complete Transformer (IS:2026)

Y Y

* Core Loss on first Job Note: 1) This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2) All major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-16 BATTERY

PAGE 1 OF 2

LEAD ACID BATTERY ATTRIBUTES / CHARACTERISTICS ITEMS, COMPONENTS, SUB SYSTEM ASSEMBLY

Dim

ensi

ons

& F

inis

h

Con

form

ance

to

rele

vant

par

t dr

g. &

M

anuf

actu

rer’s

stan

dard

sC

hem

ical

com

posi

tion

Lead

C

oatin

g Th

ickn

ess

(min

. 25

m

icro

ns,

IS:

6848

App

.F)

& A

dhes

ion

Con

form

ance

to C

PW

D S

pec.

for

Teak

P

aint

P

roce

ss

chec

ks,

Pai

nt

Sha

de,

Thic

knes

s, A

dhes

ion

& F

inis

h

Con

stru

ctio

nal

requ

irem

ents

as

pe

r N

TPC

SIn

sula

tion

Res

ista

nce

M

arki

ng (

Rou

tine

& A

ccep

tanc

e Te

st)

Che

ckin

g of

Pol

arity

& a

bsen

ce o

f sho

rt ci

rcui

t (R

outin

e &

Acc

epta

nce

Test

)

Test

fo

r C

apac

ities

fo

r 10

hr

s.

disc

harg

e ra

te a

long

with

the

tes

t fo

r vo

ltage

dur

ing

disc

harg

e (

Acc

epta

nce

Test

)

Container & Lids ( IS : 1146)

Y Y

Vent Plugs Y Y Sealing Compound ( IS : 3116 )

Y Y

Positive & Negative Plates

Y Y

Separators ( IS : 6071 ) Y Y Electrolyte ( Water / Sulphuric Acid ) ( IS : 1069 / 266 )

Y Y

Inter-cell Connectors & Fasteners

Y Y Y

Battery Stand Y Y Y Y Cell Insulators Y Y Y Stack Assembly Y Y Lead Acid Battery ( IS : 1652 )

Y Y Y Y Y

Note: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-16 BATTERY

PAGE 2 OF 2

Ni- Cd BATTERY ATTRIBUTES / CHARACTERISTICS

ITEMS, COMPONENTS, SUB SYSTEM ASSEMBLY

Dim

ensi

ons

& F

inis

h Im

pact

Stre

ngth

C

onfo

rman

ce

to

rele

vant

pa

rt dr

g.

& M

anuf

actu

rer’s

sta

ndar

ds

Res

ista

nce

to A

lkal

i C

hem

ical

com

posi

tion

Nic

kel P

latin

g th

ickn

ess

Pai

nt S

hade

, Thi

ckne

ss, A

dhes

ion

& F

inis

h A

ir Pr

essu

re T

est a

fter h

eat s

ealin

g M

arki

n g &

Mas

s (R

outin

e &

Acc

epta

nce

Test

) A

ir P

ress

ure

Test

(Acc

epta

nce

Test

) R

eten

tion

of C

harg

e Te

st (

Acc

epta

nce

Test

) A

H T

est (

Acc

epta

nce

Test

) In

sula

tion

Res

ista

nce

(A

ccep

tanc

e Te

st)

Pol

arity

& a

bsen

ce o

f sh

ort

circ

uit

(Rou

tine

&

Acc

epta

nce

Test

)

Container & Lids Y Y Y Y Vent Plugs Y Y Y Perforated Steel Strips Y Y Y Y Active Material for Positive & Negative Plates

Y Y

Separators Y Y Y Electrolyte Y Y Inter-cell Connectors & Fasteners

Y Y Y Y

Battery Stand Y Y Y Cell Insulators Y Y Y Stack Assembly Y Y Y Y Y Y Ni-Cd Battery ( IS : 10918)

Y Y Y Y Y Y Y

Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a

detailed Quality Plan indicating the practice and procedure along with relevant supporting documents.

2. Makes of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-17 BATTERY CHARGER

PAGE 1 OF 1

BATTERY CHARGER (220 / 110 V) Attributes / Characteristics Items / Components / Sub- assembly

Mak

e, M

odel

, Typ

e, R

atin

g &

Fin

ish

Ver

ifica

tion

of R

outin

e te

st r

epor

ts

as p

er

rele

vant

ISS

heet

St

eel

Pret

reat

men

t &

Pai

ntin

g h

kC

onfo

rm to

rele

vant

Sta

ndar

d &

NTP

C s

pec

Dim

ensi

onal

ch

eck

and

Pai

nt

shad

e,

thic

knes

s, a

dhes

ion

& F

inis

h ch

ecks

Com

plet

e ph

ysic

al

exam

inat

ion

for

cons

truct

iona

l fe

atur

es

as

per

NTP

C

Tem

pera

ture

Ris

e Te

st o

n on

e un

it of

eac

h ra

ting

ifTy

pete

stin

gis

wai

ved

off

Rip

ple

Con

tent

Tes

t, Lo

ad L

imite

r &

AV

R

Ope

ratio

n Te

st

Dyn

amic

Res

pons

e Te

st

Ope

ratio

nal &

Fun

ctio

nal C

heck

s H

V &

IR T

est

Bur

n-In

Test

at50

^Cfo

r48

hrs

inen

ergi

sed

Alte

rnat

ing

curr

ent m

easu

rem

ent t

est

Deg

ree

of P

rote

ctio

n Te

st a

s pe

r N

TCP

S

pec.

(By

phys

ical

ver

ifica

tion

of g

aske

tting

t

db

iti

Rectifier Transformer and Reactors IS : 4540, 2026)

Y Y Y Y Y

Electronic Components including Potentiometer ( Vernier Type)

Y Y Y

Electronic Cards Y Y Y PCB & racks for electroniccards

Y Y

Control & Selector Switches ( IS : 6875)

Y Y Y

Indicating Meters (IS: 1248 ) Y Y Y Indicating Lamps (IS: 13947) Y Y Y Air Break Switches / Fuses ( IS : 13947 / 13703 )

Y Y Y

Control Terminal Blocks (IS : 13947)

Y Y

Control Transformer ( IS : 12021)

Y Y Y

Push Buttons ( IS : 4794 ) Y Y Y MCB ( IS : 8828) Y Y Y PVC insulated Copper control wires (IS : 694 )

Y Y

Sheet Steel ( IS : 513 ) Y Y Y Synthetic Rubber Gaskets Y Y Annunciator Y Y Y Battery Charger Y Y Y Y Y Y Y Y Y Y Y Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan

indicating the practice and procedure along with relevant supporting documents. 2. Makes of all major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-18 CONTROL PANEL

( AHP & CHP)

PAGE 1 OF 2

CONTROL PANEL ( AHP & CHP) SQE_25 Attributes Characteristics Item Components Sub System Assembly

Ele

ctric

al P

rope

rties

Mec

hani

cal P

rope

rties

C

hem

ical

Pro

perti

es

Dim

ensi

ons

/ Fin

ish

T ype

/ Rat

ing/

Func

tiona

l che

ck

H

V/IR

R

outin

e te

st a

s pe

r rel

evan

t s

td.

Con

stru

ctio

nal F

eatu

res

IS:6

005

,Sev

en ta

nk p

roce

ss

Pai

nt

finis

h/

shad

e/th

ickn

ess

M

ount

ings

/

BO

M/

M

ake,

Com

plet

enes

s

Inte

rlock

Fun

ctio

nal

& O

pera

tion

Test

ing

/ Sim

ulat

ion

chec

k

Deg

ree

of

Pro

tect

ion

Test

(B

y ph

ysic

al v

erifi

catio

n of

gas

ketti

ng

arra

ngem

ent

and

bypa

per

Spe

cific

atio

n re

quire

men

t

Sheet Steel (IS-513) Y Y

Y

Aluminum / Copper Bus-bar(IS-5082/IS-613/IS-1987)

Y Y Y Y

Support Insulator (BS-2782/IEC-660/IS-10912)

Y Y Y Y

Control / Selector Switch(IS-6875)

Y Y Y

Contractor/ MCB(IS-13947)

Y Y Y

O/L Protection relays(IS-3231)

Y Y

C.T /V.T/ Indicating Meter(IS-2705/3156/1248)

Y Y Y

Fuse/ Fuse carrier(IS-13703)

Y Y Y

Terminals/lugs/pvc wires(IS-13947//IS-694)

Y Y Y Y Y

Timers(IS-3231) Y Y Y LVS, Mosaics Y Push Button/ Lamp/ (IS-6875)

Y Y Y

Control Transformer (IS-12021)

Y Y Y

Mimic, Annunciater Y Y GASKET(IS-11149) Y Y Y Y Y Fabrication Y Pretreatment & Painting

Y Y

Control panel Y Y Y Y Y

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-18 CONTROL PANEL

( AHP & CHP)

PAGE 2 OF 2

NOTE: 1. This is an indicative list of Test/ Checks. The manufacturer to furnish a detailed Quality Plan indicating

the practice and procedure along with relevant supporting documents. 2. All major Bought Out Items will be subject to NTPC approval.

CLAUSE NO.





SECTION-VI, PART-B

SUB-SECTION-IIIE-19 CONTROL SYSTEM

PAGE 1 OF 1

CONTROL DESK, PLC PANEL, SMOKE DETECTOR, FIRE ALARM & CONTROL SYSTEM

TESTS

ITEMS V

isua

l ®

GA

, BO

M ,L

ay O

ut o

f com

pone

nts

®

Dim

ensi

ons

®

Pai

nt S

hade

/Thi

ckne

ss/A

dhes

ion

®

Alig

nmen

t of S

ectio

n ®

Com

pone

nt R

atin

g/ M

ake

/ Typ

e ®

Wiri

ng ®

IR &

HV

®

Rev

iew

of

TC f

or in

stru

men

ts/

Dev

ices

/ R

ecor

ders

, In

dica

tors

/ osa

ic It

ems/

Tra

nsdu

cers

®

Acc

essi

bilit

y of

TB

S/ D

evic

es ®

Illum

inat

ion

®

Func

tiona

l C

heck

fo

r C

ontro

l E

lem

ent

,

Mim

ic ®

Test

as

per I

EC

113

1 ®

*

Test

as

per S

td ®

& (

A)

1. Control Desk Y Y Y Y Y Y Y Y Y Y Y Y Y

2. Annunciation/ Control/ PLC Panel


3.Smoke Detectors ( UL-268,EN-54 PT-7), Heat Detectors( UL-521/EN 54 PT-5 ) Annunciation/ Control Panel ( UL -864, EN-54, PT-2)

Y

Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality Assurance Programme in General Technical Conditions

2) This is an indicative list of test/ checks. The manufacturer is to furnish a detailed quality plan indicating the Practice and Procedure alongwith relevant supporting documents.

• *Applicable for PLC • Y - Test Applicable , ® - Routine Test (A) - Acceptance Test

CLAUSE NO.

QUALITY ASSURANCE




BID DOC. NO.: CS-2140-157-2

Sub-Section - IIIE-20 CHP System

Page 1 of 17

CHP System - Civil Works

1.00.00 SAMPLING, TESTING AND QUALITY ASSURANCE

1.01.00 GENERAL REQUIREMENT

1.01.01 This part of the specification covers the sampling, testing and quality assurance requirement ( including construction tolerances and acceptance criteria for all works and structures covered in this specification i.e. excavation and filling, cast in situ concrete and allied works, fabrication and erection of structural steel works, masonry / sheeting and allied works, finishing items, water supply and sanitation, modular aerated concrete panel, pre-engineered building, special items of works, and piling.

1.01.02 This part of the technical specification shall be read in conjunction with other Parts of the technical specification.

1.01.03 All tests required for all materials ( bought by Contractor ) and workmanship shall be done / got done by the contractor at his own cost. The unit rate for respective items of the schedule of items shall include the cost for all works, activities, equipment, instrument, personnel, material etc. whatsoever associated to comply with sampling, testing and quality assurance requirement including construction tolerances and acceptance criteria and as specified in subsequent clauses of this part.

1.01.04 The Contractor shall provide the facilities whatsoever required and also bear all cost for all sampling, testing and quality assurance in the field and in the laboratory. The Contractor shall carry out all sampling and testing in accordance with the relevant Indian standards and / or international standards and this technical specification. Where no specific testing procedure is mentioned, the tests shall be carried out as per the best prevalent engineering practices and to the directions of the Engineer. All sampling shall be done in the presence of the Engineer or his authorised representative. The Contractor shall establish the Field Quality Assurance ( F. Q. A. ) laboratory and field tests shall be done in the presence of the Engineer and / or his authorised representative. The tests which cannot be carried out in the field laboratory shall be done at a laboratory of repute ( CSMRS, NCBM, IITs, Shriram Test House, New Delhi / National Test House, New Delhi etc. ), as agreed by the Engineer, If the Engineer desires to witness such tests at laboratory, Contractor shall arrange to conduct the test in his presence.

1.01.05 The recommendations and suitability of material including petrographic examination of fine and coarse aggregates shall be sought from the testing agency. The Contractor shall submit the test results to the Engineer in triplicate, within three (03) days after completion of any test.

1.01.06 The Contractor shall maintain Records of all Inspection and Testing, which shall be made available to the Engineer.

1.01.07 All records shall be submitted, unless specified otherwise, as per the format developed by the Contractor and approved by the Engineer.

1.01.08 Work found unsuitable for acceptance shall be removed and replaced by the Contractor, as per Technical Specification requirements and to the satisfaction of the Engineer.

1.01.09 Representative samples shall be procured by the Contractor (from approved vendors) and submitted to the Engineer for his approval before bulk procurement. Approval of material / sample by the Engineer shall not relieve the Contractor of his

CLAUSE NO.

QUALITY ASSURANCE




BID DOC. NO.: CS-2140-157-2


Page 2 of 17

responsibility, for their conformance to the specification, the requisite quality and performance of material.

1.01.10 All Equipment and Instruments shall be calibrated before the commencement of Tests and then at regular intervals, as directed by the Engineer. If the Engineer so desires, the Contractor shall arrange for having the Instruments / Equipment get Tested for their calibration, at an Approved Laboratory and the Test report shall be submitted to the Engineer.

1.01.11 The F. Q. A. laboratory shall have all necessary equipment and instruments and shall be managed by a qualified / experienced person. F. Q. A. laboratory shall be equipped with minimum equipment, as appended at Appendix – I to these technical Specifications.

1.01.12 The F. Q. A laboratory shall be managed by personnel specially trained for such job and approved by the Engineer. The personnel who have been trained for carrying out the relevant tests shall do all testing. The Contractor shall engage all such personnel for the duration of the Contract.

1.01.13 The F. Q. A laboratory building shall be constructed by the Contractor at his own cost. The laboratory building shall be constructed and installed with the appropriate facilities. Temperature and humidity controls shall be available wherever necessary during testing of samples.

1.01.14 Indicative (not exhaustive) list of typical F. Q. A. laboratory equipment shall be as specified elsewhere in this specification. The contractor at his owns cost shall provide all these equipment. The contractor shall maintain the equipment in good working condition for the duration of the contract. Any other equipment though required for testing but not listed in the equipment list shall be provided / arranged by the contractor at his own cost.

1.01.15 If any facility for testing or the trained personnel for conducting test is not available with the Contractor then the Contractor may get the test done from reputed / approved laboratory or out source the personnel as approved by the Engineer.

1.01.16 An indicative (not exhaustive) Field Quality Assurance organisational set up is placed at Appendix - II. The set up shall be suitably augmented as and when directed by the Engineer to cope with the work demand. Based on the schedule of work and the approved Field Quality Plan (F. Q. P.). The Contractor shall prepare a schedule of F. Q. A. tests and shall submit to the owner and shall organise the tests as scheduled.

1.01.17 The contractor shall prepare and obtain the approval of the Owner of the F. Q. P. before the award of the work. This F. Q. P. shall cover for all the items / activities covered in the schedule of items and required for the completion of the work.

1.01.18 Owner at their discretion shall also carry out quality audit and quality surveillance of systems and procedures of contractor’s quality control activities. However generally the field quality audit shall take place at an interval of three months all through the construction stage.

1.01.19 The contractor shall store and handle the materials as per the requirements of the relevant standards at his own cost.

2.00.00 CONSTRUCTION TOLERANCE AND ACCEPTANCE CRITERIA 2.01.00 EXCAVATION AND FILLING

2.01.01 Tolerance

Finished surface level shall be within 20 mm of the level shown in the drawing.

CLAUSE NO.

QUALITY ASSURANCE




BID DOC. NO.: CS-2140-157-2


Page 3 of 17


Following Acceptance Criteria shall be followed.

(a.) When only one set of sample is tested, then all individual samples collected and tested should pass without any deviation

(b.) For retest of any sample two additional samples shall be collected and tested, and both should pass without any deviation.

(c.) Where a large number of samples are tested for a particular test than 9 samples out of every 10 consecutive samples tested shall meet the specification Requirement.

(d.) Tolerance on finished levels for important filling areas at approved interval shall be + 20 mm. However, for an unimportant area, tolerance upto +75 mm shall be acceptable at the discretion of the Engineer. However, these tolerances shall be applicable for localised areas only.

2.02.00 CAST-IN-SITU CONCRETE AND ALLIED WORKS

2.02.01 Tolerances

(a.) CAST-IN-SITU CONCRETE Unless otherwise specified, the dimensions of concrete as cast when compared with those on the drawings i. e. the tolerance in construction shall be as given hereunder :

DESCRIPTION OF ITEM / STRUCTURAL ELEMENT

PERMISSIBLE DEVIATION IN MM (MAX)

Faces of concrete in foundations and structural members against which backfill is placed

+ 25 - 10

Location of footing (for RCC framed structures only)

+25 - 25

Eccentricity of footing 2% of footing width in direction of misplace - ment but limiting to 50mm

Top surfaces of slabs and of concrete to receive base plates to be grouted

+5 - 5

Alignment of beams, lintels, columns, walls, slabs and similar structural elements

+5 - 5

Cross sectional dimensions of walls, slabs and similar structural elements

+5 - 5

Deviation from specified dimensions of cross - section of columns and beams.

+12 - 6

Alignment of holding down bolts without sleeves

+1.5 - 1.5

Alignment of holding down bolts with sleeves. +5 - 5 Level of holding down bolt assemblies. +10 - 10 Embedded parts (in any direction) +5 - 5 Centres of pockets or holes with greatest lateral dimension not exceeding 150mm

+10 - 10

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Variation in steps : Riser +1.5 - 1.5 Tread +3.0 - 3.0 Plumb 3mm for every meter

subject to a maximum of 10mm.

(b.) Reinforcement Tolerance on placing of reinforcement and for cover shall be as per clause number 12.3 of IS : 456.

Reinforcement shall be placed within the following tolerances:

Sl.

No.

Description Tolerance limits

a ) For effective depth 200 mm or less ± 10 mm

b ) For effective depth more than 200 mm ± 15 mm

(c.) Cover Actual concrete cover should not deviate from the required nominal cover by + 10 mm

(d.) Pre cast concrete Tolerance on dimensions of pre-cast units shall be as follows:

(1.) Length : +/- 0.1 percent subject to minimum of +/- 5 mm and maximum of + 10 mm.

(2.) Cross-sectional dimensions : +/- 3 mm or +/- 0.1 percent whichever is greater.

(3.) Straightness or Bow : 1/750 of the length subject to minimum of +/- 5 mm and maximum of +/- 10 mm.

(4.) Squareness : When considering the squareness of the corner the length of the two adjacent sides being checked shall be taken as the base line. The shorter side shall not vary in length from the perpendicular by more than 5 mm.

(5.) Flatness : The maximum deviation from a 1.5m straight edge placed in any position on a nominal plant surface shall not exceed 5 mm.

(e.) FORMWORK AND STAGING (1.) Staging shall be checked for its soundness as a whole and for adequacy

of the joints and its foundations. Formwork joints shall be inspected for soundness of connections. All joints shall be either vertical or horizontal and shall be such as to avoid loss of liquid through the FormWork.

(2.) Dimensional tolerance for formwork shall be as per Clause 9.6 of IS : 14687 and 11.1 of IS : 456 and as given below :

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Description Tolerances

Levels and heights +6mm

Plumb 3mm for every meter subject to a maximum of 10mm.

Unevenness of any surfaces +3mm

Length or breadth +12mm

Diagonals +15mm

In case of inclined surfaces like folded plates etc., the deviation in the alignment of inclined surfaces, shall not exceed 3mm with reference to the theoretical alignment, for a length of 1000 mm measured vertically, subject to a maximum of 10mm.

Deviation from specified dimensions of cross section of columns and beams

+12 mm / - 6 mm

Deviation from dimensions of footings

1 ) Dimensions in plan + 50 / - 12 mm

2 ) Eccentricity 0.02 times the width of the footing in the direction of deviation but not more than 50 mm

3 ) Thickness ± 0.05 times the specified thickness

The above tolerances apply to concrete dimensions only, and not to positioning of vertical reinforcing steel or dowels

(3.) Checklist for formwork shall be as per Clause 9.9 of IS : 14687. Format as per Annexure - C of IS : 14687 shall necessarily be made for all important structures including all machine foundations.


(a.) The acceptance criteria of concrete shall be in accordance with clause no. 16 of IS : 456. However in exceptional circumstances, and that too in non-critical areas, the Engineer may accept concrete work which is marginally unacceptable as per the criteria laid down in IS : 456. For such accepted work, payment shall be made at a reduced rate pro rate to the concrete cube strength obtained, against that stipulated.

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(b.) Unacceptable Concrete Work shall be dismantled by the Contractor and replaced by fresh Work, meeting the specification Requirements. In the course of dismantling, if any damage is done to the Embedded items or adjacent structures, the same shall be made good, by the Contractor, to the satisfaction of the Engineer, at no extra cost to the Owner.

(c.) Test shall be conducted for the Water tightness of the liquid retaining structures as per IS : 3370 and IS : 6494.

2.03.00 FABRICATION AND ERECTION OF STRUCTURAL STEEL WORK

2.03.01 Fillet Welds

(a.) Check for size and visual examination.

(b.) Macroetch examination on production test coupons for main fillet welds with minimum one joint per built up beams, columns and crane girder etc.

(c.) 25% weld length of tension member of crane girder shall be subjected to Dye Penetration Test ( D. P. T. )

(d.) On all other fillet welds, D. P. T. on 5% of weld length with minimum 300 mm at each location shall be carried out.

2.03.02 Butt Welds

(a.) 100% visual examination

(b.) D. P. T. on all butt welds after back gouging

(c.) Mechanical testing of production test coupons with minimum one joint per built up beam, column and crane girder.

(d.) 100% radiography test on butt welds of tension flange ( bottom flange ) of crane girder. All other butt welds shall be subjected to Radiography Test ( R. T. ) on 10% weld length of each welder. Wherever R. T. is not feasible, U. T. shall be carried out.

(e.) Full penetration welds ( other than butt welds ) shall be subjected to Ultrasonic Testing in following quantum :

(1.) 100% U. T. on web to flange joint of crane girder.

(2.) 10% U. T. on other full penetration joints.

(f.) In case of failure of any welds in 10% R. T. / U. T., the %age for retesting shall be doubled at that particular location. Acceptance criteria of Non Destructive Tests ( N. D. T. ) on welds shall be as per AWS D1.1.

2.03.03 All structure components / members shall be checked for following dimensional tolerances during fabrication and erection.

(a.) Fabrication tolerances

(1.) maximum permissible gap in built up members.

(2.) maximum permissible deviation in depth and / or width of girder at the joints.

(3.) maximum permissible out-of-square of flanges in built-up girders.

(4.) length of beams and girders and their components.

(5.) permissible deviation in column heights.

All tolerances for above shall be as per drawings / IS : 7215.

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(b.) Erection tolerances

(1.) permissible tolerances in erected steel columns.

(2.) permissible tolerances in erected steel trusses.

(3.) permissible tolerances in crane girder and rails.

All tolerances for above shall be as per approved drawings / IS : 12843.

(c.) Requirement of pre-heating

Thickness of thickest part at the

point of welding electrodes

Welding using

other than low

hydrogen welding

electrodes IS :

2062

Welding using low

hydrogen welding

electrodes or

submerged arc

welding IS:2062

Upto 20 mm ( including ) None None

Over 20 mm to 40 mm ( including ) 66o C 20o C

Over 20 mm to 63 mm (including) Not allowed 66o C

Over 63 mm Not allowed 110o C


(a.) The acceptance criteria of Non Destructive Testing ( N. D. T. ) on welds shall be as per AWS D1.1 ( Dynamically Loaded Structures - tension welds ). In case of failure of any of the tests, the Contractor at his own cost shall also carry out rectification of such defective welds. The Contractor, at his own cost shall also carry out re-testing of the rectified joint.

(b.) Every 1st and further every 10th set of identical structure shall be checked for control assembly in shop before erection.

2.04.00 Embedded Parts

2.04.01 Tolerances

Tolerances shall be as specified under concrete works.

2.05.00 Masonry, Sheeting, and Allied works

2.05.01 Tolerances

(a.) All masonry shall be built true and plumb within the tolerances prescribed as below. Care shall be taken to keep perpends properly aligned. Unless specified otherwise the tolerances in construction of masonry shall be as below :

(1.) Deviation in verticality in total height of any wall of a building more than one storey in height shall not exceed ( 12.5 mm.

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(2.) Deviation from vertical within a storey shall not exceed ( 6 mm per 3m height.

(3.) Deviation from the position shown on the plan of any brickwork more than one storey in height shall not exceed 12.5 mm.

(4.) Relative displacement between load bearing walls in adjacent storey intended to be in vertical alignment shall not exceed 6 mm.

(5.) Deviation of bed joint from horizontal in any length upto 12m shall not exceed 6 mm, and in any length over 12m it shall not exceed 12.5 mm total.

(6.) Deviation from the specified thickness of bed-joints, cross-joints or perpends shall not exceed ( 3 mm.

(b.) The plastered surface shall be checked for

(1.) Blistering, bond failure or loss of adhesion, cracking, crazing, efflorescence, grinning, irregularity of surface texture, popping or blowing, recurrent surface dampness, softness or chalkiness defects and the remedial measures for the same shall be adopted as per IS: 1661.

(2.) The finished plastered surface shall not show any deviation more than 4 mm when checked with a straight edge of 2 metre length placed against the surface.

(3.) The thickness of the plaster shall be measured exclusive of the thickness of key i.e., grooves or open joints in brickwork. The average thickness of plaster shall not be less than the specified thickness. The minimum thickness over any portion of the surface shall not be less than the specified thickness by more than 3 mm for plaster thickness above 12 mm and 1 mm for ceiling plaster. Extra thickness required in dubbing, behind rounding of the corners, at junctions of wall or in plastering of masonry cornices etc. shall be ignored.

(c.) Sheeting works shall be checked for the following

(1.) Material Test Certificate ( M. T. C. ) for structural steel submitted by the contractor shall be checked for compliance with the applicable IS code.

(2.) Material test certificate for coated sheet ( issued by an approved laboratory ) submitted by the contractor for each supply of batch.

(3.) At least three random samples of sheet, from three different batches of supply, shall be selected by the Engineer, which shall be got tested by the Contractor, for salt spray test for 1000 hrs, type of coating, physical properties, thickness of coating at an approved laboratory.

(4.) Constructional tolerances for sheeting works shall be similar to those allowed for masonry works


Following acceptance criteria shall be followed:

(a.) General workmanship is being good and as recommended by the manufacturer and approved by the Engineer.

(b.) Tolerances are within the specified limits.

(c.) Material test certificate is in compliance with the applicable codes/standards.

(d.) Bought out material is from the approved manufacturer / vendor.

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(e.) Bought out material is matching with the approved sample.

2.06.00 FINISHING AND ALLIED WORKS

2.06.01 Floor Finish

The tolerances shall be checked specially for the following :

(a.) Level, slope, plumb as the case may be

(b.) Pattern and symmetry

(c.) Alignment of joints, dividing strips etc.

(d.) Colour, texture

(e.) Surface finish

(f.) Thickness of joints

(g.) Details of edges, junction etc.

(h.) PERFORMANCE

(i.) Precautions specified for durability

Local depressions on account of faulty workmanship shall not be acceptable. Tiles / natural stones with cracked or broken / chipped edges shall not be acceptable.

2.06.02 Door, Window, Ventilator, Partitions

(a.) Before fitting and fixing in position following shall be checked :

(1.) Overall dimensions shall be within + 1.5 mm of the size shown on drawing.

(2.) Mullions, transoms etc. shall be in one length and permissible deviations from straightness shall be limited to + 1.5 mm from the axis of the member.

iii ). Door leaves shall be undercut where shown on drawings.

(3.) Doors, windows, ventilators, partition frames, etc., shall be on a true plane, free from warp or buckle.

(4.) All welds shall be dressed flush on exposed and contact surfaces.

(5.) Correctness of location and smoothness of operation of all shop installed hardware and fixtures.

(6.) Provision for hardware and fixtures to be installed at site and compliance with relevant IS codes.

(7.) Glazing beads shall be cut with mitered corners.

(8.) Glazing clips, fixing devices etc. shall be supplied in adequate numbers.

(9.) Shop coats shall be properly applied.

(10.) Exposed aluminium surface shall be free from scratches, stains and discoloration. Anodised surfaces shall present a uniform and pleasant look.

(11.) Correlating the material with the test certificate ( M. T. C. )

(12.) Matching the material supplied with the approved sample

(13.) Thickness of paint / anodized coating

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(14.) All welds shall be dressed flush on exposed and contact surfaces.

(b.) During and after fitting and fixing in position following shall be checked.

(1.) Installation shall be at correct locations, elevations and in general on a true vertical plane.

(2.) Fixing details shall be strictly as shown on drawings.

(3.) Assembly of composite units shall be strictly as per drawing, with mastic caulking at transoms and mullions, gaskets, weather strips etc. complete.

(4.) All frames on external wall shall be mastic caulked to prevent leakage through joint between frames and masonry.

(5.) All openable sections shall operate smoothly without jamming. Lock, fasteners, etc, shall engage positively. Keys shall be non-interchangeable.

(6.) Cutting to concrete or masonry shall be made good and all abrasions to shop paint shall be touched up with paint or same quality as shop paint.

(7.) Aluminium doors, windows, ventilators, partitions etc., shall be free from scratches, stains or discoloration.

(8.) Door and window shutters shall operate without jamming. The clearance at head and jamb for door shutters shall not exceed 1.5 mm. For double leaf doors, the gap at the meeting stiles shall not be more than 2.5 mm.

2.06.03 Fire Proof Doors

(a.) Fire Proof doors shall be tested for the requirements mentioned in IS-3614 Part-II. The doors shall have minimum 2 hours fire rating.

(b.) D. F. T. and fire retardancy of paint of fireproof doors shall be checked.

2.06.04 Rolling Shutters / Grills / Sliding doors

(a.) After installing the shutters, the contractor shall test the performance of the shutter in the presence of the engineer. The shutter shall be smoothly operable under all ambient conditions. All controls and locking devices shall give fault free performance.

(b.) Sliding doors : The sliding mechanism shall provide for smoothly operable by gentle push / pull of a single person.

2.06.05 GLASS AND GLAZING

Following shall be checked for :

(a.) All Glazing is free from cracked, broken or damaged glass.

(b.) Edges of large panes of glass shall be inspected carefully for chipped, cracked or ungrounded edges.

(c.) At completion, the panes shall be free from dirt, stains, excess putty, etc., to the complete satisfaction of the Engineer.

(d.) All glasses shall be embedded in martie or fixed by neoprene gaskets to give a leak proof installation.

2.06.06 False Ceiling System

(a.) Following shall be checked for :

(1.) as installed shall be true to shape, level.

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Page 11 of 17

(2.) correctness for the opening for the fixtures, colour and shade.

(3.) All joints shall be in the same line and cross-joints shall be securely fixed to walls.

(4.) There shall not be any sagging and / or unevenness in the surface

(b.) Acceptance Criteria Ceiling panels shall be best quality material in thickness and properties called for in the schedule of items. Material Test Certificate to be submitted before bulk supply.

Finished ceiling shall be at the correct plane and prevent an aesthetically pleasing and uniform appearance, free from sags and warps. Joints and exposed grids shall be in true lines and symmetrically placed in manner as shown in drawings. Cut outs for light fixtures, diffusers and other relevant services shall be of exact dimensions and in exact locations.

2.06.07 Water proofing

Water proofing shall be tested for water tightness by creating a pond of water minimum 25 mm height on area of 6 m x 6 m, for the period of 48 hrs on fully dried elastomeric membrane surfaces. Minimum 5% area of the roof shall be subjected to water tightness test. Such test necessarily be conducted on vulnerable areas like drain channel/ drain head. No dampness shall be visible on the underneath side of roof ( i.e. ceiling ), parapet and well junctions etc. which have been subjected for testing. The above testing shall be carried out prior to application of wearing course.

2.07.00 PAINTING AND ALLIED WORKS

2.07.01 Various materials used shall conform and tested for the requirements of Indian/International Codes specified in the technical specification.

2.07.02 Surface to receive paint shall be made smooth.

2.07.03 Painting shall be checked for thickness and or number of different coats as specified in schedule of items/drawing.




(b.) Tolerances are within the specified limit.

(c.) Material test certificate is in compliance with the applicable codes/standards.



2.08.00 WATER SUPPLY, DRAINAGE AND SANITATION

2.08.01 Tolerances

(a.) All soil pipes, waste pipes, ventilating pipes and all other pipes, when above ground, shall be gas tight. All sewers and drain laid below ground shall be watertight.

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(b.) Obstruction / Straightness Test The obstructions shall be checked by inserting a smooth ball, of diameter 13 mm less than the pipe bore at the high end of the sewer or drain. If absence of any obstructions, such as yarn or mortar projecting through the joints, ball shall roll down the invert of the pipe and emerge at the lower end. The straightness shall be checked by means of a mirror at one end of the line and lamp at the other. If the pipeline is straight, the full circle of the light may be observed. The mirror will also indicate obstruction in the barrel, if the pipeline is not straight.

(c.) Service Pipes Testing with Water The service Pipes shall be slowly and carefully charged with Water, allowing all air to escape avoiding all shock or Water hammer. The service Pipe shall then be inspected under Working condition of Pressure and flow, when all draw off Taps are closed. The service Pipes shall be checked for satisfactorily support and protection from damage corrosion and frost.

(d.) Fixtures etc.

Watertight joints shall connect all fixtures and fittings. No dripping of water shall be acceptable.



(a.) General workmanship is being good and is recommend by the manufacturer and approved by the engineer.


(c.) Material test certificate is in compliance with the applicable IS Codes.



2.09.00 Bored Cast - in - Situ Piles

2.09.01 Tolerances

(a.) Founding level of the piles shall be checked as per the criteria given elsewhere in the Technical specifications and Standard Penetration Test ( S. P. T. ), core recovery of rock, as applicable.

(b.) The permissible limits for deviation with respect to position and ( inclination ) alignment shall conform to IS : 2911 Part - I and as given below.

(1.) The maximum deviation of vertical piles shall not exceed 1.5 per cent in alignment.

(2.) Piles shall not deviate more than 75 mm or D / 10 whichever is higher from their designed position at cut-off-level.

(c.) Limits for Bentonite for piling work shall satisfy the following requirements

(1.) Liquid limit of bentonite when tested in accordance with IS : 2720 ( Part - V ) shall be more than 300 percent and less than 450 percent.

(2.) Sand content of the bentonite powder shall not be greater than 7 percent.

(3.) Bentonite solution should be made by mixing it with fresh water using pump for circulation. The density of the freshly prepared bentonite suspension shall be between 1.034 and 1.10 gm/ml depending upon the

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pile dimensions and type of soil in which the pile is to be installed. However, the density of bentonite suspension after getting mixed with deleterious materials in the pile bore may be upto 1.25 gm / ml.

(4.) The Marsh viscosity when tested by a Marsh cone shall be between 30 to 60 seconds.

(5.) The differential free swell shall be more than 540 percent.

(6.) The pH value of the bentonite suspension shall be between 9 and 11.5.

(d.) Check for pile bore: on completion of boring and cleaning, the bottom of each pile bore shall be checked from the samples of the contaminated drilling mud collected from near the bottom of pile bore.

(e.) Slump of concrete shall be 150 - 180 mm

(f.) Cover to reinforcement shall be as per technical specifications.

(g.) Concrete above Cut-off-Level ( C. O. L. ) shall be 1.0 m.


(a.) The founding level shall be as per technical specification.

(b.) Density of drilling mud from pile bore bottom shall not be more than 1.25 T / m3 before concreting.

(c.) Tolerances are in the specified limits.

2.10.00 SPECIAL ITEMS

2.10.01 Vibration Isolation System ( V. I. S. )

Stiffness values shall be checked. The permissible deviations shall be as per DIN 2096.

For accepting, following acceptance criteria shall be followed:



(c.) Material test certificate ( M. T. C. ) is in compliance with the applicable codes / standards.



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QUALITY ASSURANCE





Page 14 of 17

ANNEXURE – I TYPICAL FIELD QUALITY LAB EQUIPMENT

Sl. No.

Equipment Minimum Nos.

1 Vicat Apparatus with deskpot 2

2 Le chatelier flask 2

3 Le chatelier Mould 2

4 Cube Moulds for cement testing 6

5 Vibration Machine 1

6 Laboratory cement autoclave 2

7 Length comparator 2

8 Shrinkage Bar mould 2

9 Sieve shaker 1

10 Sieves for sand, coarse and fine aggregate 1 set for each

11 Sieves for coarse aggregate for Road 1 set

12 Proctor testing equipment 1 sets + 9 cores

13 Slump testing equipment 3 sets

14 Oven 1

15 Physical balance 1

16 Rapid moisture meter 2

17 Thermometer 2

18 Burret 1

19 Measuring cylinders 5

20 Measuring flasks 2

21 Compression testing machine 1 sets of 200 kN capacity each

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22 Cube moulds 15

23 Electronic balance 1 (12 kg capacity ), 2 (200 mg capacity)

24 pH balance 1

25 Radiographic facilities Party should deploy BARC approved agency for carrying out R. T.

26 Mechanical weighing machine 1 (100 kg capacity)

27 Ultrasonic testing machine As per requirement

28 D. P. Test kit 5

29 Vernier 300 mm, 600 mm 2

30 Micrometer ( 0.25 mm ) out side ( 25.00 ) 2

31 Radiography film viewer 1

32 Inside Micrometer 25-750 dia 2

33 Digital elcometer for paint thickness 2

34 Baking oven for electrode 2

35 Portable ovens As per requirement

Note : The list of equipment above is only indicative and shall be suitably modified depending upon the size and capacity of package and project.

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ANNEXURE - II Notes :

(i.) All test reports / inspection reports have to be computerized and maintained

on LAN with an access to the owner.

(ii.) Computers - 2 Nos shall be deployed with Windows operating system and connected to the NTPC server.

(iii.) Based on the schedule (L2 Network), Quality control and Quality Assurance

work plan including the schedule of tests shall be generated on the computer which shall be accessed by the owner for database and day to day monitoring.

(iv.) The above organisation setup is indicative only. The contractor shall mobilize

required number of skilled and supporting staff and additional resources, if any to meet the work schedule.

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APPENDIX – II

FQA ORGANISATION SET UP

Project Manager

Manager (Quality)

CIVIL ENGINEER FOR ENGINEER (NDT) CONCRETING WORK CUM STRUCTURE EARTH WORK & LAB INCHARGE Lab Assistance & Qualified Manpower Sufficient skilled manpower RT Level II UT Level II NOTE :

1. All test reports/inspection reports have to be computerized and maintained on LAN with an access to the Employer.

2. Computers – 2 Nos. shall be deployed with Windows operating system and

connected to the NTPC server.

3. Based on the schedule (L2 Network), Quality Control & Assurance work plan shall be generated on the computer to be accessed by the Employer for database and day to day monitoring.

4. The above organisation setup is indicative only. The contractor shall mobilise

required number of skilled & supporting staff and additional resources, if any to meet the work schedule.

CLAUSE NO.

LIST OF TENDER DRAWINGS




PART - E

LIST OF TENDER DRAWINGS

PAGE 1 OF 1

---------------------------------------------------------------------------------------------------------------- S.NO. DRG. NO. TITLE ----------------------------------------------------------------------------------------------------------------

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1. 4140-999-POE-A-001 Coal Conveyors Plant Single Line Diagram (Two sheets)

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