Wagon Tippler

Annexure I-Technical Specification
NATIONAL ALUMINIUM COMPANY LIMITED
BID DOCUMENT No. :OT/05/2012-13/WT/RITES-BBSR/NALCO

BBSR/NALCO-ANGUL
TENDER DOCUMENT FORDESIGN, MANUFACTURE, SUPPLY, ERECTION,

TESTING AND COMMISSIONING OF WAGON TIPPLER AND CONVEYOR
SYSTEM FOR M/S. NALCO AT ANGUL.
CONTENTS
1. GENERAL
2. INTENT OF SPECIFICATIONS
3. SPECIAL STIPULATIONS TO BIDDERS
4. SYSTEM PARAMETERS, OPERATION AND CONTROL PHILOSOPHY
5. GENERAL TECHNICAL REQUIREMENTS
6. ELECTRICAL
7. CIVIL
8. CONDITION OF CONTRACT FOR FIELD SERVICES
9. MISCELLANEOUS
(A GOVERNMENT OF INDIAENTERPRISE)
PROJECT OFFICE
ST
BHAGWANTOWER, 1 FLOOR
CUTTACK ROAD,
BHUBANESWAR 751006
1
INDEX
DESCRIPTION
SECTION
PAGE NO
GENERAL
1-5
INTENT OF SPECIFICATIONS
1-17
SPECIAL STIPULATIONS TO BIDDERS
1-11
1-64
SYSTEM PARAMETERS, OPERATION AND

CONTROL PHILOSOPHY
GENERAL TECHNICAL REQUIREMENTS
1-27
ELECTRICAL
1-97
CIVIL
1-21
CONDITIONS OF CONTRACT FOR FIELD SERVICES
1-23
MISCELLANEOUS
1-55
SECTION 1
1.0
GENERAL
M/S. National Aluminium Company Ltd. (NALCO), Angul have undergone 2nd phase
expansion of their Captive Power Plant (CPP).The 9th & 10th units are added in 2nd phase
expansion of the Existing Captive Power Plant (CPP) by increasing the station capacity to
1200MW. Facility for Storage and Handling of about 90,000 t additional uncrushed Coal has
been envisaged to be added in 2nd phase expansion of Captive Power Plant. The new
uncrushed coal storage yard shall be equipped with stacker and reclaimer machines and
shall have uncrushed coal supply connectivity to old and new coal bunkers
bu
through
respective Crusherhouse.
2.0
3.0
Basic Data
Material to be handled
Feed size
Specific gravity of coal
Moisture (%)
No of working days / yr
No of working shift / day
Uncrushed coal (Grade E / F / G)

(-) 300 mm
0.8 t/m3 for volume calculation
1.1 t/m3 for strength calculation
6% to 10%
330
3 shift of 8 hrs per day
DESCRIPTION OF EXISTING SYSTEM

The salient features of existing coal handling facilities consist of following:
3.1
mm size is brought from coalfields in Bottom Discharge Captive Railway

ROM Coal of (-) 300mm
Wagons.
3.2
Coal from coalfield is received through a Merry Go-round

Go round (MGR) system between the CHP
and coalfield.
3.3
There are two (2) nos. of existing Track Hopper Buildings with underground
undergrou RCC hopper.
3.4
Each TrackHopperBuilding has four (4) nos. of paddle feeders of travelling type at its bottom
to scoop coal from the track hopper. Two paddle feeders are mounted on individual
conveyor.
3.5
There are two (2) underground conveyors at bottom of each track hopper. Both conveyors
are running parallel at the bottom of the track hopper1.
hopper 1. The parallel conveyor installed at
the bottom of track hopper2
hopper run in opposite direction.
3.6
There are two (2) Bunker Bays. The old BunkerBay meets the crushed coal requirement for
Unit 1 6 whereas the new BunkerBay meets the crushed coal requirement for unit 7 to 10.
Thus, there are two separate conveyor paths. Each path has two conveyor streams running
in parallel.
Technical Specification:Sec-1 General
Page 1 of 5
3.7
Rated & designed capacity of each conveyor stream is 800 TPH & 960 TPH respectively.
3.8
Two parallel conveyors with moving tripper are installed on the top of each BunkerBay. One
moving tripper is provided on each conveyor installed on the top of BunkerBay.
Bun
Moving
trippers feed the crushed coal in desired bunkers as per requirement.
3.9
house is provided on conveyor path

The CHP has two (2) Crusher Houses. The old Crusherhouse
that is feeding crushed coal to Units 11 6. The new Crusherhouse
house is provided on conveyor
con
path that is conveying crushed coal to Unit 7 to 10.
3.10
& associated equipment installed on parallel

Each Crusher house has two (2) Crusher&
conveyor series. Thus, each Crusherseries
series has been provided with dedicated Crusher and
associated equipment.
3.11
There are three uncrushed coal storage yards with stacker cum reclaimer machine (SCR) in
present CHP. One SCR machine is provided on each storage yard.
3.12
Storage yard 1 & 2 receive uncrushed coal from track hopper 1 & 2. Storage yard 3 receives
uncrushed coal
oal from track hopper 2 only.
3.13
Scooped uncrushed coal from track hopper 1 is conveyed to old Crusher house and then to
coal bunker bay of Units 1-6
1 6 through conveyor path that is conveying crushed coal to coal
bunkers Bay of Units 1-6.
6.
OR,
Uncrushed coall is conveyed to storage yard 1 & 2. Preparation of coal Stock Pile is carried
out by installed Stacker--cum-Reclaimer
Reclaimer (SCR) machine. Uncrushed coal is reclaimed by SCR
machine and conveyed to either of boiler bunkers through dedicated conveyor paths which
is operating for these two boiler bunker bays.
OR,
It is conveyed to boiler bunker Bay of Units 7 to 10 through new Crusherhouse
Crusher
by conveyor
path that is feeding crushed coal in boiler bunkers of Unit 7 & 8. SCR machine is positioned
in by-pass mode whilee conveying coal from track hopper 1.
3.14
Scooped coal from track hopper 2 is conveyed to Crusher house and then to coal bunker bay
of Units 7 to 10 through conveyor path that is conveying crushed coal to coal bunkers Bay of
Units 7 to 10.
OR,
It is conveyed to boiler bunker Bay of Units 11 6 through conveyor path linked with track
hopper 1. OR, It is conveyed to storage yard 3. Preparation of stockpile is made with the help
of SCR machine. Coal from the Stock Pile is reclaimed by SCR machine and is fed on to yard
conveyor. The yard conveyor discharges the coal on to the conveyor path linked with boiler
bunker bay of Units 7 to 10.
Page 2 of 5
OR,
It is conveyed to the storage Yard 1&2 through the conveyor paths linked with track hopper
1.
4.0
Additions to existing system currently under development:
Presently an additional coal storage and handling system is being implemented

under a separate contract to augment the coal handling system. The salient features
of the new scheme are:
4.1
The terminal points for Additional

Additional Coal Storage & Handling System of CHP in 2nd Phase
Expansion commences from and consist of:
4.2
Modification and shifting of discharge end of existing belt conveyor BC-115

BC
in Junction
House JH-7
7 with a provision of two way chute and flap gate to feed uncrushed
uncr
coal received
from Track Hopper No. 2 to either the existing conveyor BC-116
BC 116 or to new conveyor BC-118A
BC
under implementation.
4.3
Modification of existing Junction House JH-7

JH 7 to accommodate tail end of new conveyor BCBC
118A for receiving & conveying uncrushed
uncrushed coal to the proposed Additional Coal Storage
Yard.
4.4
Provision of new Junction House JH-7A

JH 7A adjacent to existing Junction House JH-7
JH to
accommodate discharge / head end of new belt conveyor BC-122
BC 122 from the proposed
Additional Coal Storage Yard and extended
ex
tail end of conveyor BC-116
116 to receive uncrushed
coal from new conveyor BC-122.
BC
4.5
Extension of tail end of existing conveyor BC-116

BC 116 from existing Junction House JH-7
JH to new
Junction House JH-7A
7A to receive reclaimed uncrushed coal from the Additional Coal Storage
Yard through a new conveyor BC-122.
BC 122. Uncrushed coal received on conveyor BC-116
BC
will be
conveyed to the new Crusher house through existing belt conveyor system for supplying the
crushed coal to bunkers of unit 7-10.
7
Extension of tail end of existing
e
conveyor BC - 104 from existing Junction House JH-2
JH to new
Junction House JH-13
13 to receive reclaimed uncrushed coal from the Additional Coal Storage
Yard through a new conveyor BC-120
BC
and BC-121.Uncrushed
121.Uncrushed coal received on the extended
conveyor BC-104
04 shall be Conveyed to the old Crusherhouse
house through the existing belt
conveyor system for supplying crushed coal to the bunkers of unit # 1-6.
1 6.
4.6
4.7
For Receipt of uncrushed coal for the proposed Additional Coal Storage and Handling
System, uncrushed coal conveyed
con
to JH-7 by existing conveyor BC-115
115 from Track Hopper
No.2 can be diverted either to existing conveyor BC-116
BC 116 or to new conveyor BC-118A
BC
at
Junction House JH-7.
7. The new conveyor BC-118A
BC 118A will convey material to the proposed
Additional Coal Storage Yard
Yard through a new conveyor system under development. For this,
the existing Junction House JH-7,
JH 7, shall be modified to accommodate the tail end of new
conveyor BC-118A.
118A. The discharge chute of the existing conveyor BC-115
BC 115 shall be replaced
Page 3 of 5
with new chute arrangement

gement having a two way chute with a flap gate. Two-way
Two
chute with
flap gate will divert the material discharged from conveyor BC - 115 either to existing
conveyor BC-116
116 or to the new conveyor BC-118A
BC 118A depending on position of the gate.
The discharge pulley of existing conveyor BC-115
BC 115 will be relocated suitably to ensure the
flow of uncrushed coal, either to conveyor BC-116
BC 116 or to the new conveyor BC-118A
BC
is
smooth through the new flap gate and chute arrangement. The rated capacity of conveying
conv
system is 800 t/hr.
4.8
For storage of uncrushed coal in the Additional Coal Storage Yard under development, the
coal received through conveyor BC-118A
BC 118A will be conveyed to the Yard through conveyors BCBC
119 & BC-120
120 and new Junction Houses JH-10
JH
& JH-11.
1. The conveyor BC-120
BC
will be
equipped with a Slew Stacker Machine. The Slew Stacker Machine will be capable of forming
two identical stock piles of uncrushed coal on either side of its track. The length of each
stock pile will be 275 m. The storage capacity
capacity of each Stock Pile will be 45,000 t of uncrushed
coal. The rated capacity of stacking system is 800 t/hr
4.9
For Reclaiming the uncrushed coal from Additional Coal Storage Yard, a Bucket Wheel
Reclaimer will be provided. The Bucket Wheel Reclaimer will be installed on conveyor BC 120 such that its discharge is collected on the yard conveyor BC-120.
BC 120. The BWR will be
operating on the same track as that of the Slew Stacker Machine. Simultaneous operation of
stacking and reclaiming is also proposed on the yard conveyor BC-120.
120. Uncrushed coal
reclaimed on conveyor BC-120
BC 120 will be conveyed to new Junction House JH-12.
JH
The rated
capacity of the reclaiming system shall be 800 t/hr.
4.10
120 will convey reclaimed material to new Junction House JH-12.

JH
Head/
Conveyor BC-120
discharge
scharge end of conveyor BC-120
BC 120 will be provided with two way chute with flap gate
arrangement. Depending on position of flap gate in the discharge chute, uncrushed coal
reclaimed from the Additional Coal Storage Yard will be diverted either to conveyor BC-121
BC
or to conveyor BC-122
122 at new Junction House JH-12.
JH
Conveyor BC-121
121 will transport the
material to new JH-13
13 and transfer material to the tail end of existing and extended
conveyor BC-104,
104, Conveyor BC-122
BC 122 will convey the material to new Junction House JH-7A
J
and transfer the material to tail end of existing and extended conveyor BC-116.
BC
The rated
capacity of conveying system is 800 t/hr.
4.11
Conveying of uncrushed coal to new Crusherhouse.. Uncrushed coal received on conveyor

BC-122
122 will be conveyed to new Junction House JH-7A,
JH 7A, located adjacent to existing JH-7.
JH At
Junction House JH-7A,
7A, conveyor BC-122
BC 122 shall discharge the uncrushed coal at the extended
tail end of existing conveyor BC-116.
BC
Uncrushed coal received on conveyor BC-116
BC
will be
conveyed to the new Crusherhouse
Crusherhouse through the existing coal flow path. The rated capacity
of conveying system is 800 t/hr.
4.12
For Conveying the uncrushed coal to the old Crusher house, uncrushed coal received on
conveyor BC-121
121 shall be conveyed to new Junction House JH-13.
JH 13. At this new Junction
House JH-13,
13, conveyor BC-121
BC 121 will discharge the material to the extended tail end of the
Page 4 of 5
existing conveyor BC-104.

104. Coal received on conveyor BC-104
BC 104 will be conveyed to the old
Crusherhouse
house through existing coal flow path.
The tail end of existing conveyor BC-104
BC
at JH-2
2 will be extended up to the new Junction
House JH-13
13 and a new conveyor gallery between existing Junction House JH-2
JH and the new
Junction House JH-13
13 will
will be provided to house the extended length of existing conveyor BCBC
104. The system rated capacity is 800 t/hr.
4.13
Dust Suppression System will be provided at all transfer points at various Junction Houses
and uncrushed coal storage yard.
4.14
on and air conditioning facilities will be provided in Switch gear cum MCC
Suitable ventilation
room, Battery room, Transformer rooms.
4.15
PLC based operation & control system is being provided for additional coal storage &
handling system. Controls are being suitably interfaced with existing conveyor system
through limit switches.
Page 5 of 5
SECTION 2
1.0
1.1
INTENT OF SPECIFICATIONS
This specification is intended to cover the following activities and services in respect of
all the equipment of Wagon Tippler and Conveyor System Package to be installed for
National Aluminium Company Limited (NALCO), Captive Power Project located in Angul
Angu
of Orissa State in India.
(a.) The broad scope of work covers the following:
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. for the Owner/RITESs
Owner
s review, approval and records.
iv. Packing and transportation from the manufacturers works to site.
v. Receipt, unloading, storage, preservation and conservation of equipment at
site.
tion, pre-assembly,
pre assembly, (if any), erection, testing and satisfactory operation
vi. Fabrication,
of all the equipment including successful completion of facilities.
vii. All associated civil, structural,electrical
structural
and C&I works.
viii. Commissioning and completion of facilities and Performance Guarantee Tests.
ix. Furnishing of mandatory spares and handing over to NALCO stores.
x. Supply of commissioning spares
xi. Reconciliation (if any) with custom authorities.
authorities
xii. Satisfactory conclusion of the contract.
(b.) The equipment and services to be furnished and installed as required in this Technical
Specification shall also meet all the requirements as stated in other sections of bid
documents which shall be considered as a part of this technical specification as bound
herewith.
(c.) The Contractor
or 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.
(d.) It is not the intent to specify completely herein, all aspects of design and construction of
equipment. Nevertheless, the equipment shall conform in all respects to high standards
of engineering, design and workmanship and shall be capable of performing in
continuous commercial operation.
(e.) 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
d quality desired. Other manufacturers products may also be considered
Technical Specification Sec-2,:Intent
:Intent of Specifications
Page 1 of 17
provided sufficient information is furnished so as to enable the Owner/consultant

Owner
to
determine that the products are equivalent or superior to those named.
to carefully examine and understand the specifications and seek
(f.) Bidder is requested to
clarifications, if required, to ensure that they have understood the specifications. Such
clarifications should reach Owner/consultant
Owner
at least 15 days before the scheduled date of
the opening of the bids. The Bidders offer should not carry any sections like clarifications,
interpretations and/or assumptions.
(g.) If the Bidder feels that, in his opinion, certain features brought out in his offer are superior
to what has been specified, those may be highlighted separately. The Bidder may also
make alternative offers provided such offers are superior in his opinion. In which case,
adequate technical information, operating feedback,, etc. shall be enclosed with the offer,
to enable the Owner/cons
/consultant to assess the superiority and reliability of the alternatives
offered. In case of each alternative offer, its implications on the performance, guaranteed
efficiency, auxiliary power consumption etc. shall be clearly brought out for the
Owner/consultant to make an overall assessment. In any case, the base offer shall
necessarily be in line with the bidding documents/ specifications. Under no circumstances
the equipment / system specification in Technical Specification shall be brought out as
alternative offer.
(h.) Any deviation or variation from the scope, requirement and/or intent of this specification
shall be clearly defined by the Bidder in Deviation to NIT Document irrespective of the
fact that such deviations/ variations may be standard practice or a possible interpretation
of the specification by the Bidder. Except for those deviations/ variations covered under
Deviation Schedules, which are accepted by the Owner before the award of the Contract, it
will be the responsibility of the Bidder to fully meet the intent and the requirements of the
specification within the quoted price. No other deviation whatsoever from this
specification, except for the declared deviations
deviations submitted by the Bidder with his proposal
under Deviations to NIT Document
Document shall be considered. Bids not complying with this
requirement shall be treated as non-responsive
non responsive and hence liable for rejection. The
interpretation of the Owner/consultant
Owner
in respect of the scope, details and services to be
performed by the Bidder shall be binding unless specifically clarified otherwise by the
Owner/RITES in writing before the Award of the Contract.
and examine the site and its
(i.) Before submitting his bid, the Bidder should inspect and
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 Owner. The contractor shall, prior to commencement of design work, carry
out the Geo-technical
technical investigation in the area proposed for development of wagon tippler
and conveyor system package. The number of bore holes shall be decided by the
contractor to ensure adequate data to carry out the design and guaranteeing the
Page 2 of 17
installation. The cost of such Geo-technical

Geo technical investigation is deemed to be included in the
bid submitted by the contractor.
(j.) 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 Owner. Any increase in these sizes or the parameters, if
required to meet the system/maintenance/operational requirement shall be supplied
supplie by
the contractor without any extra cost implication to the Owner.
(k.) The works under the scope of this contract are to be executed in an operating power
station. The contractor shall take all necessary precautions to protect all the existing
equipment,
nt, 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
ntractor at his own cost to the satisfaction of the Owner. The contractor shall also
take all necessary safety measures, at his own cost, to avoid any harm or injury to his
workers and staff from the equipment and facilities of the power plant.
(l.) Contractor should note that the existing rail lines within the plant area are operational with
rail traffic of coal and liquid fuel rakes. Contractor shall take all precautions to ensure the
safety of existing rail tracks and other associated facilities as well as the safety of his men,
material and equipment from the operating rail traffic. The contractor shall plan and make
all arrangements to ensure that disruption to the existing rail traffic is minimum and shall
follow the instructions of the Owner in this regard. Further, contractor shall plan and
coordinate all his activities considering restrictions, if any, on free access to his work areas
due to the rail traffic.
l
of
(m.) After award of work and, before finalising his layout especially the layout / levels
conveyors, cable / pipe routes/transmission
routes
lines 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
suitably modify his layout / levels
to prevent dislocation of existing facilities and any cost / time implication arising out of
such modifications shall be to his account. Contractor shall also be responsible to
determine and obtain the necessary details at site
site as required for interfacing and
interconnection with the existing system / facilities.
(n) 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
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
any stage of work, any dismantling or modification
or relocation of any existing facility is required to be done to complete the work in
contractors scope and which has been agreed by the Owner, the same shall be done by
the contractor at no extra cost or time
time implication to the Owner. All such changes will be as
per drawings and work plan approved by the Owner.
Page 3 of 17
Equipment and services covered under WAGON TIPPLER AND CONVEYOR SYSTEM PACKAGE
are described in the subsequent sections:
1.2
cifications of equipment / system indicated in various sections as above

In addition to the specifications
and General Technical Requirement and Erection Conditions of Contract attached of the
Specification shall also form part of this Technical specification.
1.3
TENDER DRAWINGS
1.3.1
The drawings listed elsewhere, 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
co
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.
In case of any conflicts / contradiction among various volumes
volumes / sections / annexures /
chapters / appendices / tender drawings of bid documents, the same shall be referred to the
Owner for clarifications whose decision shall be final and binding. No extra claims shall be
allowed on this account.
1.3.2
2.0
IPTION OF PROJECT
BRIEF DESCRIPTION
NALCO intends to augment the coal handling facilities at its Captive Power Plant by an
additional annual volume of 2.0 Million tonnes.
For this purpose, it intends to install a wagon tippler and connecting conveyor System to
receive the above quantum of coal through rail mode. The wagon tippler system shall be
suitable for handling all prevailing wagons in coal circuits such as BOX / BOX-N
BOX / BOXNHA /
BOX N.MKDII.
The facility provided shall be suitable to accommodate locomotives of maximum
maxi
140 T
weight passing through the platform at a maximum speed of 8kmph.
The Wagon Tippler System shall have an in built weighing mechanism (load cell type) below
the platform for weighment of wagons prior to and after each tippling cycle to record the
exact quantity of coal unloaded from each wagon.
Coal received at the tippler hopper would be transported by belt conveyors and integrated
to existing system for feeding the existing and the new stockpiles under development.
2.1
BRIEF DESCRIPTION OF PROPOSED

PROPOSED WAGON TIPPLER AND CONVEYOR PACKAGE
(i) Indian Railway rakes consisting of Box-N
Box N wagons shall transport coal to the power plant.
These Box-N
N wagons are proposed to be unloaded in underground RCC hopper by means of
a Rota side Wagon Tippler/Rotary
Tippler
Wagon Tippler.. Wagon tippler hopper shall have a holding
capacity of minimum 2 wagons loads of coal.
coal One Rota side wagon tippler/Rotary
tippler

Page 4 of 17
WagonTippler(WT-1)
1) is to be utilised for unloading of IR coal rake. A Side arm charger is
envisaged for placement of loaded wagon on the tippler table & retrieval of empty wagon
from the tippler table after tippling. Clear access shall be provided for movement of pay
loaders on the hopper side of Wagon tippler. Wagon tippler hopper grating is to be
positioned and designed
d accordingly.
(ii) Apron feeder is proposed under the Wagon tippler for extracting coal from the Wagon
tippler hopper and feed into the apron feeder which in turn discharges crushed coal on to
the proposed receiving conveyor RC-1.
RC Conveyor RC-1 will transfer
sfer the coal to conveyor RC-2
RC
at the new transfer tower TP-1.
TP Conveyor RC-2
2 shall feed coal on to existing Conveyor BCBC
103/BC-115
115 at the existing junction house (JH-1).
(JH 1). The rated capacity of all the conveyors in
this package shall be 1200 TPH.
(iii) The existing CHP control and monitoring system is PLC based. It is proposed to provide
an independent PLC based control for smooth, efficient & trouble free operations of Wagon
Tippler and conveyor system package. The control and monitoring system for belt conveyors
con
covered under this Package shall be integrated with the existing control system such that the
operation of existing CHP is not hampered. Necessary interlocks and software changes in the
existing PLC logic are also envisaged in this package.
3.0
SCOPE OF WORK
3.1.1
The scope of Wagon Tippler and Conveyor System Package 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,
engineering, manufacture, shop
fabrication, assembly, testing and inspection at manufacturers works, packing, dispatch,
transportation, transit insurance, custom clearance etc. as applicable, delivery to site,
unloading, handling and storage at site, insurance during
during storage, construction, erection,
including erection supervision, testing, inspection, commissioning and handing over to
Owner and Guarantee testing including all associated electrical, civil & structural works as
specified, unless specifically excluded
exclude as per Section-Terminal
Terminal Points & Exclusions.
3.1.2
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 Contractors proposal but are
needed to make the system complete in all respects for its safe, reliable, efficient and
trouble free operation and the same shall be furnished and erected unless otherwise
specifically excluded in this document. The general description of the proposed system and
the broad scope off work under the specification shall include but not be limited to as
detailed below.
3.1.3
An underground RCC Wagon Tippler Hopper, machinery hatches with wagon tippler hopper,
associated underground tunnel, transfer point and pent house complete with civil,
ci structural
and electrical works for Wagon Tippler hopper and machinery hatches, steel grating over
hopper portion, removable chequered plate covers over openings in machinery hatches for
handling underground equipment, equipment handling facilities for
for apron feederinside
feeder

Page 5 of 17
below wagon tippler hopper including the structural steel shed with E.O.T crane over the
WT-1
1 and other equipment/systems such as Dust Suppression system, ventilation system,
drainage system etc. as specified elsewhere in the specification.
specification. However, the track work is
excluded from Contractors scope however rails over tippler table and the track for Side Arm
Charger are included in Contractors scope.
3.1.4
One (1) no. Rotaside Wagon Tippler/Rotary

Tippler
Wagon Tippler complete with clamping
arrangements, all structural members, tippler platform, tippling mechanism, tippler drive
along with necessary controls, associated electricals, civil / structural works and accessories.
3.1.5
Side arm charger associated with the Wagon Tippler complete with travel rails, drive
equipment along with necessary controls, associated electricals, civil/structural works &
accessories.
3.1.6
One (1) no. Apron feeder complete with drives, all mechanical, electrical accessories &
supportingg structure etc.
3.1.7
Receiving Belt Conveyors RC-1

RC 1 complete with conveyor supporting structures, short
supports, stringers, deck plate, seal plate, conveyor foundations, drive motors, drive units,
pulleys, idlers, gravity take ups, take up structure upto
upto ground level, take-up
take
platforms at
intermediate level, internal and external belt cleaners, pull chord switches, belt sway and
zero speed switches, electro-hydraulic
electro hydraulic thruster brakes, all electricals etc. including RCC
tunnel for receiving Conveyor RC-1
RC and
nd underground tunnel portion upto pent house of
Conveyor RC-1
1 with all civil, structural and architectural works for conveyor gallery, gallery
supporting trestles and their associated foundations.
3.1.8
A new pent house along with over ground structures,

structures for conveyor Rc--1 complete with all
civil structural, architectural and electrical works including chutes, monorails, hoists/chain
pulley blocks, hoist maintenance platforms, RCC/steel floors, external staircases, hand rails
etc.
3.1.9
1 complete with civil, structural and electrical works and associated

A transfer point TP-1
foundations for transfer of coal from conveyor RC-1
RC to conveyor RC-2.
3.1.10 Complete chute work along with chute plug switches and actuator operated flap gates in all
Transfer points,
nts, maintenance platforms along with suitable approach.
3.1.11 Adequate number of ventilation equipment for ventilating the wagon tippler hopper,
underground conv. RC-1
1 upto Pent House, complete with all mechanical, electrical, civil and
structural works.
3.1.12 Pressurised Ventilation system for all Switchgear rooms, MCC rooms complete with all
mechanical, electrical, accessories, civil and structural works.

Page 6 of 17
3.1.13 Air conditioning of Wagon Tippler control room,

room PLC room and battery room,
room complete with
all electrical, civil & structural works etc.
3.1.14 Exhaust fans for all toilets complete with electrical, civil & structural works etc. Exhaust fans
along with required ducting shall also be provided for all underground structures/Transfer
Points.
3.1.15 Minimum of four (4) Nos. sump pumps in Wagon Tippler house complete with motors, local
control panel, level switches, individual discharge piping with fittings and valves to nearest
plant drain etc.
control of fugitive dust at Wagon tippler, apron
3.1.16 A complete dust suppression system for control
feeder, transfer points, complete with enclosed pump houses, water tanks, pumps, drives,
hoisting arrangements, piping, valves etc. electrical, accessories, civil and structural works as
briefly specified below:
a) Plain water dust suppression through fogging nozzles for control of dust during Wagon
Tippler operation.
b) Dry fog type dust suppression system at all Transfer Points both at discharge and
loading points including all electrical and accessories.
c) Compressor units, Pump houses & water tanks for dust suppression, service water and
cooling water system.
3.1.17 Cooling water system for scoop coupling, Service water system for Wagon Tippler Package
System shall be taken from nearest header located at new track hopper
hopper area.
3.1.18 An E.O.T crane for installation & maintenance of equipment in wagon tippler complex
complete with all electrical and control including the covered structural steel shed.
as hand operated chain pulley blocks
3.1.19 Monorails and electrically operated hoist blocks as well as
for servicing/installation/easy replacement of drive machinery, different types of pulleys for
all conveyors, GTU and other equipment.
3.1.20All
All buildings in contractors scope shall be complete with all electrical, civil,
civ structural,
architectural works, cable trenches, fire safety walls, foundation / fencing / earthingfor
earthing
all
equipments, structures, transformers etc.. All cables / duct banks, trenches, cable trestles
shall be complete with associated civil/ structural work
work and necessary civil foundations.
3.1.21 Drainage of Wagon Tippler hoppers, tunnels, conveyor galleries, TPs, upto nearest existing
CHP drain including all civil & structural works.
insert plates, bolts, accessories, MS
3.1.22 All equipment/fittings, supporting structure, along with insert
sleeves, base plates, grouting as may be required and proper alignment etc.
3.1.23 A complete set of all special tools and tackles, which are necessary or convenient for
erection, commissioning and overhauling of any equipment, covered under the scope.

Page 7 of 17
3.1.24 First fill of all consumables e.g.; oils and lubricants for one year toppings requirements.
r
3.1.25 Preservative shop coating, final painting of all structures and equipment under the scope.
unction houses, Wagon
3.1.26 (a) Adequate fire alarm & detection of coal conveyor gallery area, Junction
tippler area, Electrical switch gear rooms, Control
Control rooms, Battery rooms, Transformer
rooms, cable spreader rooms etc. consisting of heat detectors(both
detectors(both ceiling mounted &
Canopy mounted type), smoke detectors, LHS cables, manual call points, fire alarm panels at
main control room of Wagon Tippler, repeater
repeater panel at CISF Fire control room near CPP
main gate etc shall be considered. Fire alarm & detection
de ction system shall be of Intelligent
Addressable type of Notifire/Siemens make.
(b)
b) The successful bidder is to obtain necessary approval from TAC for the complete Fire
protection System of Wagon Tippler Package.
(c)
c) Underground pipes will be M.S heavy duty with coating wrapping by 4mm thick coal tat
tape conforming to IS15337 (latest version). Over ground pipes shall be of heavy
he
duty GI
pipes with fittings etc. Suitable number of water actuated deluge valves shall be provided
for the hydrant system. Hydrant line will be tapped suitably from the existing hydrant net
work.
d) The coal conveyors shall also be provided with MVW (Medium Velocity Water) Spray
(d)
System which
h will be operating automatically for protection of conveyors.
3.2
Electrical System / Equipment
3.2.1
Unless specifically excluded, contractors scope of work shall include all electrical works
wor as
required for putting into successful operation of the Wagon Tipplers & Associated Conveyors
covered under this specification.
3.2.2
LT SWITCHGEAR
415V Switchgear/motor control centers distribution boards, AC & DC fuse boards, local
emergency stop push button stations for all drives and local motor starters as required for
plant and equipment.
3.2.3
MOTORS
Motors along with couplings and coupling guards for all rotating auxiliaries are covered
under this package. All motors shall be with cable glands & lugs.
3.2.4
CABLES
HT & LT Power cables, control cables, Instrumentation cables and any special cables required
for connection between equipment / devices in Contractors scope and also cables between
Owners equipment and Contractor's equipment.
3.2.5
CABLING, EARTHING AND LIGHTNING PROTECTION

Page 8 of 17
(a) All cabling with cable accessories, cable trays with supporting structure, terminations and
jointing kits, trenches, overhead trestle, duct banks etc. as required for the cables to be
supplied by the Contractor.
(b) Grounding and lightning protection for the plant and equipment under Contractors
scope along with its interconnection to the nearest Owners earth grid at two points.
3.2.6
ILLUMINATION SYSTEM
Complete illumination system as required for complete internal and external lighting of
associated plant, equipment and buildings covered under Contractors scope including 2
Nos. of Lighting Masts for area lighting in W.T. area.
3.2.7
CONTROL SYSTEM
An independent Control desk, PLC panels, I/O
I/O racks, UPS, battery & battery chargers etc. for
the control of Wagon Tipplers and other equipment.
One (1) No. control building to be located near WT-1
WT 1 . This building shall have two floors i.e.
ground & first floors. The first floor of control room shall house PLC panels, control desks for
operation of WT-1.
1. One office room (5m x 5m) at the first floor. There shall be a projected
viewing balcony at a suitable location to have clear view of the Wagon Tipplers
Tipp
during
operation. The ground floor shall house the MCC, DBS, Battery DBS etc.
3.3
CIVIL WORKS
3.3.1
The work to be performed under this specification consists of providing all labor, 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 Contractors supervision and in strict accordance with the drawings
and specifications. The nature of work shall generally involve earthwork in excavation
including very deep underground excavation, de-watering,
de watering, shoring and strutting, sheet
piling, back filling around completed structures and plinth protection, area paving, disposal
of surplus excavated materials,
aterials, 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,, Aluminum industrial troughed sheets,
sheets anchor bolts, R. C. C. trenches with covers,
drainage, damp proofing, water proofing and other ancillary items. Supply of cement,
reinforcement steel, structural steel sections ,MS rounds, chequered plates, flats etc will be
within the scope of the bidder.
bidder
3.3.2
The work shall have to be carried out both below and above ground level and shall be
involving, basements, equipment
equipment foundations, grounding, slabs, beams, columns, footings,
rafts, walls, steel frames, brick walls, stairs, trenches, pits, access roads, culverts, conveyer

Page 9 of 17
galleries, trestles, penthouses, Wagon tippler hopper, underground tunnels, transfer points,
finishes,
hes, complete architectural aspects, drainage and all other civil, architectural and
structural works associated with the complete Wagon Tippler and conveyor system
Package.
3.3.3
Scope of work shall also include dismantling and modifications of the existing
exi
structures/facilities, which may be required to facilitate, inter connection between the
existing and the new structures or facilities and making good the dismantled/modified
structures.
4.0
TERMINAL POINTS
Terminal point for Wagon Tippler and conveyor system commences from wagon tippler
complex upto feeding points at conveyors BC-103
BC
& BC-115,
115, in Junction House (JH-1)
(JH
including the modification necessary to the Junction Houseand
and interconnection with the
existing system. Within these terminal points, all equipment and services, civil, structural
and architectural works, electrical distribution, piping network etc. as required for wagon
tippler and conveyor system package will be furnished and erected by the contractor
co
unless
specifically excluded.
4.1
Contractor's Scope responsibilities shall include but not be limited to the following:
4.1.1
Wherever Contractor is permitted by Owner to take support from any of the Owners
Structures, the Contractor shall ensure that no damage is done, to the Owners Structures
including Painting thereof. In case of any damage to the Owners Structure and/or Painting,
then the Contractor shall rectify the same to the complete satisfaction of the Owner.
4.1.2
JH 1 and shall ensure that the proposed

The contractor shall carry out the redesign of JH-1
modifications are adequate to support the discharge point of the conveyor RC-2
RC as well.
4.1.3
Regarding erection of transfer point on existing junction house-1,

house 1, contractor shall ensure
ensur
that opening on existing building and erection of conveyor chutes/skirts & platform are done
in a manner to minimize shut down of existing conv. BC-103
BC
& BC-115.
115. As work is to be
executed in operating project, extra care must be taken by the Contractor.
4.1.4
Water supply connections for dust suppression, service water system & cooling water shall
be provided by the Owner, details of which are given elsewhere in the specification. Further
network of piping including all compressors, pumps, tanks, necessary
necessary accessories, supports
and fittings etc. for distribution of water for dust suppression and service water system in all
transfer points, control rooms, MCC rooms, toilets, Machinery hatches of the Wagon tippler
etc. shall be under the scope of the contractor.
contra
4.1.5
Road lighting in wagon tippler area, for the roads, is included in the scope of Contractor.
4.2
EXCLUSIONS

Page 10 of 17
4.2.1
Supply, laying and fixing of rail track for the inhaul and out haul siding is excluded from
fr
the
scope of this Contract. However, supply, laying and fixing of rail over Wagon Tippler table
and for side arm charger is included in the scope of this Contract.The
Contract.The approaches of wagon
tippler where track is to be laid on concrete base( to the extent required)
equired) and aligning with
the inhaul/outhaul
haul/outhaul track junctions is also included in the scope of this contract the cost of
which is deemed to be included in the quoted rate of relevant items.
items
5.0
SYSTEM DESIGN BASIS
5.1
The rated capacity of the Conveyors shall be 1200 TPH.. The design capacity of the conveyors
shall be 1320 TPH.. The mechanical and structural / civil system shall be designed for 1320
TPH capacity and round the clock operation with both the streams operating
operatin simultaneously.
5.2
Following shall be considered while designing the Conveyors :

a. The Coal delivered to the power station shall be of size 300 mm & below. However
occasionally coal of higher lump size may also be encountered.
b. HGI of the Coal shall be between 44 to 65. Normally moisture content in coal will vary
between 6% to 10%. However for design purposes, moisture content of 10% shall be
considered.
c. The coal as received shall contain varying percentage of fines. Coal with such fines may
tend to form
orm adhesive lumps, particularly during monsoon when surface moisture is at its
maximum value.
d. The sizing and selection of the vital equipment viz. apron feeder covered under the system
shall be based on the above characteristic of coal and operating conditions.
conditions. Contractor shall
ensure that equipment/ system efficiency shall not be effected particularly during monsoon
when surface moisture is at its maximum value.
5.3
For the purpose of volumetric computation, the bulk density of the coal shall be taken as
a
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,
loading on Apron Feeder 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.
5.4
Coal Flow paths
5.4.1
For the purpose of conducting guarantee test coal, the following flow path would be
assessed.

Page 11 of 17
Apron feeder will feed coal unloaded at WT-1

WT to Conveyor RC-1.
1. Coal on RC-1
RC will be
transferred to RC-2
2 through Transfer point feeding on to existing Conveyors (either BC-103
BC
or BC-115) in JH-1.
5.4.2
Contractor shall also demonstrate that all intermediate equipments can perform as per
specification and design requirement during PG Test.
5.4.3
Performance and Guarantee tests have been elaborated elsewhere in the specification.
6.0
ENGINEERING
NG SCHEDULES
6.1
Within one month of acceptance of Award Letter, Contractor shall submit, for review and
approval, detailed engineering schedules, based on Master Network (as per requirement of
bid documents), to the Owner / Consultant, showing the logic & duration of activities in the
following areas :
a) Detailed engineering, including submission and approval of quality plans and PG test
procedure.
b) Inputs required from Owner for smooth and timely execution of contract.
6.2
The Contractor shall submit within 30 days of letter of award a master list of drawings
incorporating the scheduled dates of submissions. The schedule date of submissions should
match with the manufacturing and erection programme submitted in the detailed Master
Network Schedule. The list shall be updated every month reflecting the additions / deletions
during the period.
6.3
The network schedule shall be updated at a frequency mutually agreed upon for the
purposes of progress monitoring. However, for the purpose of identification of Contractor's
Contractual Liability the agreed Master Network shall only be applicable.
7.0
GUARANTEE AND LIQUIDATED DAMAGES
7.1
Guarantee
The Bidder shall guarantee that equipment offered shall meet the rating, performance and
functional requirement stipulated
stipulated for various equipment covered in this specification. The
Bidder shall also furnish a declaration in the manner prescribed and included in the Bid
Proposal Sheets and other Schedules for certain guaranteed parameters which shall attract
levy of liquidated
uidated damages for shortfall in performance.
7.2
Performance Requirement
Guaranteed parameters of the major equipments shall be as follows:
7.2.1
Flow Path Capacity

Flow path capacity including the intermediate equipment for conveyor streams to be tested
teste
for 1200 TPH

Page 12 of 17
7.2.2
Equipment Capacity
Capacity of individual equipment shall be tested separately:
(i) Each Wagon Tippler : 20 tips/hour (Guaranteed)
(ii) Each Apron feeder : 1200 TPH (Guaranteed)
7.2.3
Contractor shall also demonstrate that all intermediate equipments viz. Gates, Dust
suppression, Ventilation System etc. can perform as per specification and design
requirement.
7.2.4
Performance and guarantee requirement of various other equipments have been elaborated
elsewhere.
8.0
PERFORMANCE & GUARANTEE TEST PROCEDURE

In accordance with GTR the plant shall be subjected to performance and Guarantee Tests on
successful completion of trial operations. Further, the performance and Guarantee Tests
shall be conducted as per the guideline procedure indicated elsewhere. However, detailed
procedure shall be submitted by vendor as per the guidelines for Owner/RITES's
Owner
approval.
The P&G Test procedure shall be submitted by the bidder.
8.1
Liquidated Damages for Shortfall in Performance

Should the resultss of the performance and guarantee tests show that the equipments /
system have failed to meet the guaranteed parameters, the Contractor shall carry out
modifications, if considered necessary, within 90 days of the notification by Owner.
If the equipment fails
ails to meet the guarantee parameters at the end of the above specified
period of 90 days, Owner may at his discretion, reject the equipment or accept it after
assessing the liquidated damages at rates specified herein, to be payable by the Contractor.
8.2
The following equipments/streams shall be subjected to performance and guarantee test in

line with the specification to prove the performance guarantee for all intermediate
equipment.
Liquidated Damages towards shortfall in guaranteed performance shall be imposed as % of
the order value limiting to 5% against following parameters.
Sl.
No.
1
Equipment
Wagon Tippler
Guaranteed
parameter
20 Tips /Hour
Apron Feeder
1200TPH
Conveyors (R1 & R2)
1200TPH

Short fall
By One tip per hour
By two tips per Hour
Beyond two tips per hour
By 0.5%
By 1.0%
Beyond 1.0%
By 0.5%
By 1.0%
Beyond 1.0%
LD amount to be
imposed
1% of order value
2% of order value
Rejected
1% of order value
1.5 of order value
1.5%
Rejected
1% of order value
15 of order value
15%
Rejected
Page 13 of 17
The LD shall be assessed on the basis of conveyor equipment having the poorest
performance.
9.0
COMMISSIONING (SYSTEM TRIAL OPERATION)

Duration of the trial operation of the
he complete equipment shall be 30 continuous days with
available no of loaded rakes during the period or as to be mutually agreed.
agreed
10.0
TYPE TESTS AND TYPE TEST CHARGES
10.1
All equipment / systems to be supplied shall conform to type tests as per relevant
re
standards
and proven type.
10.2
The Bidder / Contractor shall furnish the reports of all the type tests carried out within five
years of the date of bid opening as per specification and relevant standards for all
components / equipments / systems. These reports should be for the tests conducted on
identical / similar components / equipments / systems to those offered / proposed to be
supplied under this contract.
10.3
In case contractor is not able to submit report of type test(s) conducted in last five years, or
in case type test report(s) are not found to be meeting the specification / relevant standard
requirements, then all such tests shall be conducted under this contract by the Contractor
free of cost to Owner, and reports shall be submitted for
f approval.
10.4
All acceptance and routine tests as per relevant standard and specification shall be carried
out. Charges for these shall be deemed to be included in the bid price.
11.0
11.1
SPARES
GENERAL
The Contractor shall include in his scope of supply all the necessary Mandatory spares, start
up and commissioning spares and recommended spares and indicates these in the relevant
schedules of the Bid Form and Price Schedules. The general requirements pertaining to the
supply of these spares have been
b
described in the following paras.
11.2
MANDATORY SPARES
Owner/RITES is included in this

11.2.1 The list of mandatory spares considered essential by the Owner/RITES
specification. The Bidder shall indicate the prices for each and every item (except for items
not applicable to the Bidders design) in the
the Schedule of mandatory Spares . If the Bidder
fails to comply with the above or fails to quote the price of any spare item, the cost of such
spares shall be deemed to be included in the bid price unless the bidder specifies "not
applicable" for the type of equipment/system offered by him.
him. However during execution if
such spares are found to be applicable, the Contractor shall supply them without extra cost
to the Owner. The Bidder shall furnish the population per unit of each item in the relevant
Page 14 of 17
Schedules. Whenever the quantity is mentioned

mentioned in sets the Bidder has to give the item
details and prices of each item.
11.2.2 Whenever the quantity is indicated as a percentage, it shall mean percentage of total
population of that item in the Package, unless specified otherwise, and the fraction will be
rounded off to the next higher whole number. Wherever the requirement has been specified
as a set it will include the total requirement of the item for a unit, module or the station or
as specified. Where it is not specified a set it will include the
the total requirement of the item
for a unit, module or the station or as specified. Where it is not specified a set would mean
the requirement for the single equipment/system as the case may be. Also one set for the
particular equipment. e.g. set of bearings
bearings for a pump would include the total number of
bearings in a pump. Also the set would include all components required to replace the
item; for example, a set of bearings shall include all hardware normally required while
replacing the bearings.
11.2.3 The Owner reserves the right to buy any or all the mandatory spare parts.
11.2.4 The prices of mandatory spares indicated by the Bidder in the Price Schedules shall be used
for bid evaluation purposes.
11.2.5 All mandatory spares shall be delivered at site at least two months
months before scheduled date of
initial operation. However, spares shall not be dispatched before dispatch of corresponding
main equipments.
11.2.6 Wherever quantity is specified both as a percentage and a value, the Contractor has to
supply the higher quantity until
u
and unless specified otherwise.
12.0
RECOMMENDED SPARES
12.1
In addition to the spare parts mentioned above, the contractor shall also provide a list of
recommended spares for 1 year of normal operation of the plant and indicate the list and
total prices in relevant schedule of the Bid Form and Price Schedules. This list shall take into
consideration the mandatory spares specified in this Volume, and should be independent of
the list of the mandatory spares. The Owner reserves the right to buy any or all of the
recommended spares. The recommended spares shall be delivered at project site at least
two months before the scheduled date of initial operation. However, the spares shall not be
dispatched before the dispatch of the main equipment.
12.2
Price of recommended spares will not be used for evaluation of the bids. The price of these
spares will remain valid upto 6 months after placement of Notification of Award for the main
equipment during which the Contractor shall provide necessary justification for the quoted
prices for these spares. However, if the Contractor fails to provide the aforesaid justification
of the quoted prices, the prices of recommended spare shall remain valid for 2 months from
the last date of providing such justification to the satisfaction
satisfaction of the Owner.

Page 15 of 17
13.0
START-UP
UP & COMMISSIONING SPARES
up and commissioning spares are those spares which may be required during the startstart
Start-up
up and commissioning of the equipment/system. All spares used till the plant is handed over
to the Owner shall come under this category. The Contractor shall provide for an adequate
stock of such start up and commissioning spares to be brought by him to the site for the
plant erection and commissioning. They must be available at site before the equipments are
energized. The unused spares, if any, should be removed from there only after the issue of
Taking Over certificate. All start up spares which remain unused at the time shall remain the
property of the Purchaser.
Purchase
14.0
14.1
COMMON REQUIREMENTS
The Contractor shall include in his scope of supply all the necessary Mandatory
Man
spares, start
up and commissioning spares and recommended spares and indicate these in the relevant
schedules of the Bid Form and Price Schedules. The general requirements pertaining to the
supply of these spares is given below.
14.2
The Contractor shall indicate the service expectancy period for the spares parts (both
mandatory and recommended) under normal operating conditions before replacement is
necessary.
14.3
All spares supplied under this contract shall be strictly inter changeable with the parts for
which they are intended for replacements. The spares shall be treated and packed for long
storage under the climatic conditions prevailing at the site e.g. small items shall be packed in
sealed transparent plastic with desecrator packs as necessary.
necess
14.4
All the spares (both recommended and mandatory) shall be manufactured along with the
main equipment components as a continuous operation as per same specification and
quality plan.
14.5
The contractor will provide Owner with cross-sectional

cross
drawings,
wings, catalogues, assembly
drawings and other relevant documents so as to enable the Owner to identify and finalise
order for recommended spares.
14.6
Each spare part shall be clearly marked or labeled on the outside of the packing with its
description. When more than one spares part is packed in a single case, a general
description of the content shall be shown on the outside of such case and a detailed list
enclosed. All cases, containers and other packages must be suitably marked and numbered
for the purposes
urposes of identification.
14.7
All cases, containers or other packages are to be opened for such examination as may be
considered necessary by the Owner.
14.8
The contractor will provide the Owner with all the addresses and particulars of his sub
suppliers
ers while placing the order on vendors for items/components/equipments covered

Page 16 of 17
under the contract and will further ensure with his vendors that the Owner, if so desires, will
have the right to place order for spares directly on them on mutually agreed terms
term based on
offers of such Contractors.
14.9
The Contractor shall warrant that all spares supplied will be new and in accordance with the
contract Documents and will be free from defects in design, material and workmanship.
recommended spares listed by the contractor, if the Owner further

14.10 In addition to the recommended
identifies certain particular items of spares, the contractor shall submit the prices and
delivery quotation for such spares within 30 days of receipt of such request with a validity
period of 6 months
onths for consideration by the Owner and placement of order for additional
spares if the Owner so desires.
14.11 The Contractor shall guarantee the long term availability of spares to the Owner for the full
life of the equipment covered under the contract. The Contractor shall guarantee that
before going out of production of spares parts of the equipment covered under
unde the
Contract, he shall give the Owner at least 2 years advance notice so that the latter may order
his bulk requirement of spares, if he so desires. The same provision will also be applicable to
sub-contractors.
contractors. Further, in case of discontinuance of manufacture
manufacture of any spares by the
Contractor and/or his sub contractors, Contractor will provide the Owner, two years in
advance, with full manufacturing drawings, material specifications and technical information
including information on alternative equivalent makes required by the Owner for the
purpose of manufacture/procurement of such items.
14.12 In case of equipment supplied with grease/lubricants from imported origin, the supplier shall
clearly indicate the indigenous equivalent of the grease/lubricant and
and source of supply so as
to enable the Owner to procure these items from indigenous sources.

Page 17 of 17
SECTION 3
(SPECIAL STIPULATIONS TO BIDDERS)
1.1.
GENERAL
1.1.1
This Technical Specification shall be read in conjunction with Commercial, General Condition
of Contract and other project requirement mentioned in this specification.
1.1.2
The Bidder shall quote for complete scope of work as covered in this specification.
1.1.3
This Technical Specification is for turnkey supply of the plant & equipment and related
structures including execution of structural steel works and civil works as specified in
subsequent chapters, along with necessary modification, as detailed in the Scope of Work
and Technical Specification.
1.1.4
idders / Special Instruction specified in other chapters shall be read in

Instructions to Bidders
conjunction with stipulation stated in this chapter.
1.1.5
The Bidder shall submit the drawings / documents, technical data / information as
mentioned in various sections and annexure without which the Bid shall be considered as
incomplete and may not be considered further.
1.1.6
The Bidder shall submit along with the bid a work schedule in the form of a bar chart
indicating the commencement and completion dates of each activity
activity such as preparation of
design, approval of design & drawings, preparation & approval of fabrication drawings,
procurement of steel and other material, ordering of bought out items, their delivery to
shop, major shop activities like fabrication of structures/
structures/ manufacture of equipment,
assembly, shop testing, inspection, shop painting &dispatch
&
to the site, schedule of erection,
final painting after erection at site, testing and commissioning of Plant and Equipment,
without which the bid may not be considered.
consi
1.1.7
The Bidder shall clearly indicate the clause wise compliance to the specification. Non
compliance with this and generalized statements like. "The equipment shall be
manufactured as per IS standard / our specification etc" may result in rejection
reje
of the Bid.
The deviation, if any, shall be clearly specified clause-wise
clause wise in the format enclosed with this
technical specification. In absence of deviation indicated, it will be presumed that the Bidder
has no deviations.
1.1.8
er document and drawings shall be duly signed by the Bidder as a

One copy of the Tender
token of acceptance of all clauses / parameters / data mentioned therein and returned along
with the Bid without which the Bid is liable to be rejected. In case the Bidder intends to
change any
ny data / parameter given in Technical Specifications the same shall be clearly
mentioned in the deviation list, with reasons thereof.
Technical Specification: Sec-3,Special

3,Special Stipulation To The Bidders
Page 1 of 11
1.1.9
If the Bidder feels that any information/ data described in the technical specification needs
to be modified, he shall indicate the same specifically and submit an alternative proposal, on
the basis of the design data, that he considers suitable and capable of meeting the
requirement of this specification.
shall be new and the best of their kind and

1.1.10 All the materials used and equipment supplied shall
shall comply with the statutory requirements of the Govt. of Orissa, Govt. of India and the
latest revision of the Indian Standards/ Indian Electricity Rules. Where the equipment/
material supplied is not according to
to Indian Standards or regulations to which the equipment
/ material conform, the Bidder shall submit relevant document along with the Bid.
1.1.11 The Bidder shall visit the plant / site, and satisfy himself fully about the existing plant /site
conditionss etc. The successful Bidder shall bear full responsibility for inferences and
conclusions as to the nature and conditions under which the work is to be executed,
including effect of climate, rainfall etc. Failure to do so shall not absolve the Bidder of his
h
responsibilities about the proper execution of the job. No claim for extra payments due to
any special site conditions and ignorance about the site conditions shall be considered after
acceptance of his Bid. For the site visit, the Bidder shall contact the Purchaser and take prior
appointment from them.
1.1.12 The drawings of the existing coal handling plant, available with the Purchaser, can be made
available to the successful Bidder for reference. However, for the areas of the plant for
which drawingss are not available, the Bidder shall make site measurements and work
accordingly.
1.1.13 The Bidder as far as practicable ensure that major equipments are brought to site in pre
assembled condition to minimize site work and to achieve an early commissioning
commissi
of the
equipment after delivery. Site welding shall be avoided as far as possible. The Successful
Bidder before proceeding with design details shall satisfy himself about the site condition so
as to avoid any difficulty in erection arising out of design.
des
1.1.14 The equipment shall be inspected during different stages of its manufacture (starting from
raw material till the completion of manufacture) by the Purchaser / his authorized
representative at the Bidder's or his sub Successful Bidder's works as per the inspection
procedure mutually agreed between the Purchaser or his authorized representative and the
successful Bidder. Inspection shall be regarded as a check up and shall be in no way binding
on the Purchaser. However, general terms and conditions
conditions of inspection and testing is
indicated in the subsequent chapter of this specification.
1.1.15 Documents of all electrical and mechanical equipment supplied with equipment shall be put
up for inspection along with the equipment. After inspection, an
an endorsement would be
made in the inspection certificate about the availability of the documents.

Page 2 of 11
1.1.16 The offer shall be complete in all respects and any additional equipment, accessories,
auxiliaries, services, work etc. which are not specifically mentioned in the specification but
are required for smooth and trouble free operation and to achieve performance required to
be guaranteed in terms of the Bid Document, shall be included by the Bidder in the offer.
1.1.17 The make of all bought out items shall be as per List of preferred makes of supplies and
equipment mentioned in tender document.
1.1.18 Metric systems & English language shall only be used throughout the Bid and in the
drawings.
1.1.19 The Bidder shall satisfy himself about his ability for completing the work as per the time
schedule before submitting his offer. In case the Bidder is unable to adhere to the schedule
indicated in this specification, the Bidder need not submit their offer against this Bid.
Bid
1.1.20 A complete list of exclusions from Bidder's scope of work shall be clearly indicated in the Bid.
1.1.21 In case of any contradiction between Instructions to Bidder and Technical Specifications,
stipulation in the Technical Specification shall prevail.
1.1.22 The Bidder has to carry out the work is such a manner that it does not affect the plant
operations. If other Contractors are also engaged at the same work site for other jobs, the
Bidder shall work in co-ordination
ordination with them such that the
the work of other Contractor is not
affected. For integration of new facilities & the existing one, shutdowns period in phases, as
per the schedule mutually agreed between Purchaser and successful Bidder would be
provided. Hence, Bidder shall indicate in their offer, the stages at which the shut downs are
required and their respective duration.
1.1.23 All parts of equipment requiring replacement or inspection or lubrication shall be so
arranged/ assembled that they are easily accessible without the need of dismantling of other
equipment or structures. All electrical cables shall be so laid that they are not liable to be
damaged and can be easily inspected and maintained and when necessary any damaged
cable can be accessed & replaced individually.
1.1.24 All equipment shall be complete with adequate safety devices wherever a potential hazard
to personnel exists. Provision for safe access of personnel working to and around equipment
for operation and maintenance, shall be provided.
1.1.25 The Bidder shall train the Purchasers personnel in all disciplines of the operation &
maintenance of the plant & equipment being provided by them under the contract.
maximu possible
1.1.26 Standardization of components and assemblies shall be carried out to the maximum
extent to ensure interchangeability/as well as to minimize inventory levels.

Page 3 of 11
1.1.27 Bidders shall furnish drive ratings of all equipments including conveyors along with the offer.
Conveyor profiles enclosed with this specification are indicative
indicat only.
1.1.28 The Bidder shall include in his scope of supply, a complete set of new and unused special
tools and tackles required for operation and maintenance of the plant and equipment. The
list of tools & tackles considered in the bid shall also be submitted.
1.1.29 The Bidder shall include in his scope, the requirement of initial fill of oils, lubricants, grease,
and all other consumables required for startstart up, testing, commissioning and performance
guarantee
uarantee tests of the unit/equipment. A list of such consumables shall also be furnished by
the successful Bidder for Purchasers use.
1.1.30 The Bidder shall include in his scope the supply of spares required for successful
commissioning of plant & equipment.
equipment. The list of commissioning spares considered in the bid
shall also be furnished along with the bid.
1.1.31 The Bidder shall quote separately for the spares required for the normal operation and
maintenance of the plant and equipment for a period of 24 months to be reckoned from the
date of taking over of the plant and equipment. A list of the spare parts shall also be
furnished along with item wise price.
subcont
1.1.32 The successful Bidder shall not offload the contract or part thereof to any subcontractor
without written permission of the purchaser. In the event of subletting of any part of the
work with due permission by the purchaser, the fact that such permission has been
accorded shall not absolve the successful Bidder from any of his obligations and liabilities
under the contract.
1.1.33 Subject to availability and at the request of the successful Bidder, water for construction
purpose will be made available by the Purchaser at one mutually agreed point at site. The
successful Bidder shall make
make his own arrangement for any further distribution at his own
cost. Water supply shall be free of cost and shall be provided as specified under clause no.
54.13 b) of the GCC.
1.1.34 Power Supply
Subject to availability and at the request of the successful
successful Bidder, Electric Power will be
made available at one point only at a distance not more than 500 meters away from the
Contractors premises. The power will be supplied at 400/440 Volt and shall be metered and
charged at the rate as specified in the GCC.
GCC. The successful Bidder should have sufficient
number & capacity of DG sets to meet the emergency power requirements in the event of
failure in power supply.
1.1.35 Civil and structural steel works

Page 4 of 11
The supply of conveyor galleries, trestles, Junction towers,

towers, buildings & civil work are in the
scope of this tender including the Design of Civil & Structural works , shall be within the
scope of successful bidder.
1.1.36 Fire hydrant system
The Bidder shall include in his scope the extension & rerouting of fire hydrant system to the
wagon tippler & conveyor system. The hydrant line should be laid as per IS specification.
1.1.37
Exclusions:: Following items are excluded from the scope of work

1.
Railway track system.
1.2
ERECTION
1.2.1
The successfull Bidder shall be responsible and perform the following with respect to the
erection of the Plant and supplies.
1.2.2
The scope of work of the successful Bidder shall be complete erection of the Plant and
Equipment etc. as specified in the Technical Specification.
Specification. The Bidder shall make all
arrangements to deliver the equipment at their site stores by wagons / truck / trailers, build
his own stores (covered, uncovered and air-conditioned,
air conditioned, if necessary) for the proper storage
of equipment, maintain the stores
stores and all related documents and records, transport the
equipment to site for erection purpose and take an ErectionErection cum- Storage insurance policy
covering all the risks including third party liability for all supplies as well as human life. All
security arrangements also shall be made by the successful Bidder. Space only for stores and
site office shall be made available to the Bidder by the Purchaser.
1.2.3
The successful Bidder shall take the equipment from their site stores and transport the same
to erection site.
1.2.4
The successful Bidder shall unpack and do visual checking against physical damages to the
equipment / cases, cleaning of equipment before start of erection. Damage / shortage if any,
will be reported to the Purchaser / consultant and shall be rectified / replaced expeditiously,
free of charge to Purchaser so as not to upset the erection and commissioning schedule.
Delay on account of settlement of insurance claims by the successful Bidder shall not be
considered an excuse for delay in completion.
The successful Bidder shall lay and maintain properly all the temporary supply lines in the
erection site for temporary power and water required for storage and erection purposes
from a single point to be provided by the Purchaser. Drinking water shall also be made
available at one central point at site. The successful Bidder shall make his own arrangement
for any further distribution.
1.2.5
1.2.6
The successful Bidder shall arrange all necessary construction

construction machinery/ equipment, tools
& tackles, instruments, compressors, small hand tools, welding equipment, all
commissioning instruments, erection & service bolts, nuts, jigs and fixtures, winches,

Page 5 of 11
alignment tools, precision levels etc., Crane/ hoists and other

other equipment which may be
required for carrying out the erection work efficiently within the time schedule provided
herein the specification. Unless otherwise specified, the above construction materials shall
be the property of the successful Bidder. However
However Purchaser's prior permission shall be
required for removal of these construction materials from the site. Successful Bidder shall
ensure that proper documentation is maintained for such items, which are required to be
carried back by successful Bidder after the completion of work.
1.2.7
The successful Bidder shall provide all temporary ladders, scaffolding materials, platforms,
supports and other necessary facilities required for handling, erection, testing and visual
inspection of supplies at the point
point of installation and shall also provide necessary packing
plates, wedges, shims, levelling screws etc. required for erection of equipment and
technological structures.
1.2.8
The successful Bidder shall provide erection consumables like oxygen and acetylene gas,
welding rods, solder lugs, oil, grease, kerosene, cotton waste, etc. required for erection of
equipment and technological structures.
1.2.9
The successful Bidder shall

shall erect and maintain his own site offices, main stores and site
temporary stores as required for the work and arrange for maintaining in neat manner of
the area placed at the Successful Bidder's disposal.
sufficient fencing, notice boards and lights to protect and

1.2.10 The successful Bidder shall provide sufficient
warn others as may be considered necessary by the purchaser / consultant. All materials
used for providing these facilities shall be properties of the successful Bidder.
echnological structures will be erected as per the instructions of the
1.2.11 The equipment and technological
suppliers & under the supervision of the supervisory staffs to be deployed by the successful
Bidder at site and only with the approval of Purchaser / Consultant. The successful Bidder
shall use pre-assembly
assembly and mechanisation to the maximum extent in order to fulfill erection
& construction targets.
1.2.12 The Successful Bidder shall align, level, couple and securely fix all equipment, appurtenances
and accessories in accordance with drawings
drawings and / or instructions of Purchaser/ Consultant.
1.2.13 Laying and termination of cables, bus bars, bus ducts, lightening protection and earthing
shall be done by the Successful Bidder.
1.2.14 The successful Bidder shall be responsible for protection
protection and / or diversion of all existing
underground and over ground services, wherever required. The terms and conditions for
protection / diversion of services not shown on drawing / indicated in the specifications shall
be mutually agreed.

Page 6 of 11
1.2.15 Installation
stallation and connection of all piping and fittings within the scope of work shall be
responsibility of the successful Bidder.
1.2.16 The successful Bidder shall be responsible for checking the correctness of erection of
mechanical equipment, technological
technological structures and auxiliary systems, electrical equipment
etc. as per the specification.
1.2.17 The successful bidder has to carry out the work in such a manner that it does not affect the
operation of other plant/ shop. If other Contractors are also engaged
engaged in the same work site
for other jobs the bidder shall work with them in a co-ordinated
co ordinated manner.
1.2.18 The successful Bidder shall be responsible for the management of erection work with proper
and adequate supervision for ensuring progress of erection
erection work and quality of
workmanship.
1.2.19 The successful Bidder shall deploy required number of supervisory, skilled, unskilled and
auxiliary labour as required for the erection work: as per detail mobilisation schedule (to be
furnished with Bid by successful Bidder) and comply with such reasonable
reasonabl instructions of the
Purchaser / Consultant in the interest of satisfactory progress and completion of the work
according to the schedule. The successful Bidder shall work in 3 shifts per day basis for
meeting the completion target, if required within the contract price.
1.2.20 The successful Bidder shall organise the work in a manner that other work at site is not
impeded and the workmen therein not endangered and shall arrange temporary access at
site, if required for the erection work.
essful Bidder shall return to the Purchaser all crates, packing cases and packing
1.2.21 Successful
materials excess commissioning spares, oil and lubricants at a place designated by the
Purchaser.
during erection.
1.2.22 The successful Bidder shall conduct all necessary tests / checks during
1.2.23 The successful Bidder shall attend to the rectification of erection defects, if any,
expeditiously. The successful Bidder shall arrange all testing instruments for such testing at
site.
1.2.24 The successful Bidder shall carry out final painting of the Plant & Equipment and
technological Structures etc. erected as per the instructions stipulated in the Technical
Specification.
1.2.25 The successful Bidder shall be responsible for total commissioning of the Plant and
equipment including cold trial run and demonstration of Performance Guarantee Test. The
Purchaser's supervisory and skilled operating personnel shall, however, be available to work
under the guidance and supervision of the Bidder. Necessary raw materials, auxiliaries,
auxiliari

Page 7 of 11
utilities, electricity and operating personnel shall be made available by the Purchaser
covering 3 shifts operation as per the programme agreed to in advance.
reliabl and
1.2.26 The Successful Bidder shall supervise running of the Plant for satisfactory, reliable
regular operation and performance after its successful commissioning for establishing
performance guarantees.
1.2.27 Electrical energy and construction water shall be supplied by Purchaser to the successful
Bidder during erection, at one point.
1.2.28 All safety measures required to be adopted as per the Statutory Regulations & the Safety
Rules of the Plant shall be strictly followed by the successful Bidder during the execution of
the Contract. The successful Bidder shall depute safety engineers
engineers for strictly compliance of
safety rules & regulations.
1.2.29 The successful Bidder shall intimate the Plant authorities in writing well in advance about
the requirement of shut down of any of the existing units / facilities for inter connection /
incorporation
orporation of additional facilities. The shut down period shall be mutually discussed and
finalised. The work to be undertaken during the shutdown period shall be planned
meticulously to reduce the shut down period to the minimum.
1.2.30 The successful Bidder shall comply with all statutory Rules, Regulations with respect to the
employment of labour at site.
1.2.31 The successful Bidder shall carry out any and all such works, as may be required, to build a
Plant complete in all respect as per the Technical Specification and achieve the Performance
Guarantees and other parameters as given in the subsequent chapter of this specification.
1.2.32 Any loss of plant and equipment due to imprudence, negligence and / or inequitable
treatment and handling shall be replaced by the Successful Bidder / his sub-contractor
sub
at his
own cost.
1.3
PAINTING
All parts of the equipment
ipment shall be thoroughly cleaned of loose mill scales, rust or foreign
matters.
All parts excepting motors, resistors, gears etc. shall be painted at shop and at site with two
coats of epoxy zinc based on zinc dust.
Interior of all gear housing shall be painted with oil resistant paint. All machine pads,
bearings surface or structures or housing shall be painted with white lead. All parts,
inaccessible after assembly, shall be painted and assembled while the paint is wet.

Page 8 of 11
After erection, the damaged portion of the painted surface shall be retouched and an
intermediate coat / final coat of PVC copolymer alkyd resin with micaceaus iron oxide (MIO)
shall be applied. The colour shall be as per the choice of the Purchaser.
The subsequent one final coat of paint of PVC copolymer alkyd with weather resistant
pigment (approved by the Purchaser) and glossy finish shall be applied.
The details of the dry film thickness (DFT) of the different coats shall be as follows:
a)
b)
c)
Primary coat
Intermediate coat
Final coat
:
:
:
30 40 micron per coat

The painting scheme & colour code shall be approved by the Purchaser. The successful
Bidder shall refer to Section 8 for further detail off painting scheme & colour codes.
1.4
OPERATING / PERFORMANCE PARAMETERS

All the equipment covered in this specification shall fulfill the operating and performance
requirement covered under this Technical Specification and indicated in the approved
drawings.
The successful Bidder shall study the specification and satisfy himself thoroughly regarding
the workability and suitability of the equipment offered by him. He shall take full
responsibility for the guaranteed and satisfactory operation of the equipment
equipment as regards to
its performance and smooth and reliable working.
1.5
PRELIMINARY ACCEPTANCE
1.6
After completing the erection of a unit or agreed portion thereof, the successful Bidder shall
give a notice in writing stating that the job is complete in all respects and ready for
preliminary acceptance. The job shall be visually inspected by representatives
representa
of the
Successful Bidder and Purchaser / Consultant to ascertain whether supply, fabrication and
erection are as per contract drawings and Technical Specification. All observed defects,
deficiencies and omissions shall be noted down. If the defects, deficiencies and omissions
are not major in the opinion of the Purchaser / Consultant, the successful Bidder shall be
issued a preliminary acceptance certificate mentioning the defects, deficiencies and
omissions. The noted defects, deficiencies and omissions
omissions shall be made good by the
successful Bidder within a period of 3 to 4 weeks.
FINAL ACCEPTANCE
Before commencement of final acceptance test of the building or unit, the successful Bidder
shall make available required numbers of complete sets of ordinary prints of drawings,
required numbers of set of DOD list for the drawings and one set of reproducible film of all

Page 9 of 11
drawings, all representing As-Built

As Built condition (i.e. all additions and alterations done during
fabrication and erection shall be incorporated
incorp
in the drawings).
The successful Bidder shall attend to all defects, deficiencies and omissions noted down
during preliminary acceptance and after rectifying or making good the above in all respects,
shall inform 10 days in advance the Purchaser / Consultant for conducting final acceptance.
During Final Acceptance all defects, deficiencies and omissions noted earlier shall be
checked. The successful Bidder shall also make good any defect, deficiency or omission not
notified during earlier preliminary
preliminary acceptance, but pointed out during final acceptance. Final
Acceptance certificate shall be issued by the Purchaser after all defects, deficiencies and
omissions noted under preliminary or final acceptance have been rectified.
1.7
SCOPE OF WORK
1.7.1
The broad turnkey scope of work shall be as per the following:
Design, manufacture, inspection, shop & primary coat of paint & supply of complete
plant & equipment, fabrication (shop & site) of building structures & technological
structures, civil construction materials, power distribution, electrics, instrumentation &
automation, illumination, all utilities & services, in-plant
in plant road networks, drainage
systems, landscaping, fire detection & alarm system, fire fighting pump house, as
required, for complete
mplete & trouble free operation of Coal Handling System in an
integrated manner.
Basic engineering, detail engineering and reference category of drawings, operating

software and documents, in requisite copies, for approval of NALCO/ RITES. Further, the
Tenderer
nderer will furnish final basic & detail engineering drawings, manufacturing drawings
of fast wearing items and non-standard
non standard items, as built drawings, erection
drawings/documents, operating software, operation and maintenance manuals in soft
editable format.
Receipt of material, loading / unloading, storage, civil construction, complete erection,

testing, commissioning, handing over of Wagon Tippler Complex to Purchaser,
demonstration of performance guarantee and post commissioning services . Preparation
and
nd approval of erection survey / alignment schemes, grouting clearances, painting
clearances, testing of welds, pressure testing protocols and other related site protocols.
Deputation of representatives of equipment suppliers and technology suppliers to site

for supervision of erection, testing and commissioning.
Applying final finish coat of paint as per approved procedure & shades before handing
over, first fill of lubricant & oil, special tools & tackles, mobile equipment, handling &
hoisting equipmentt etc.

Page 10 of 11
Supply of all commissioning spares. A list of such commissioning spares shall be

indicated separately.
separately Tenderer shall quote separately for one year recommended spares
with the main offer.
Progress reporting as per agreed formats, providing documentary

documentary evidence of purchase
orders on sub vendors with addresses of contact persons, attending all site progress
review / engineering review meetings at NALCO, Angul or at RITES, Gurgaon /
Bhubaneswar, opening an equipped site office with coordinator overseeing
oversee all activities.
Arrangement of all erection equipment viz. cranes, hoists, winches, etc, and safety
appliances as required for erection of plant & equipment. Appointment of safety officer
by the contractor shall be included.
Specialized training of Purchasers personnel for operation, maintenance, for smooth

handing over the plant.
Testing and cold trial run of systems/ sub - systems and integrated testing shall be
carried out by the successful Tenderer on continuous basis for complete Coal Handling
System along with associated facilities followed by commissioning. On successful
commissioning of the various sub-systems
sub systems of the Wagon Tippler complex, PG test of the
entire Tippler House shall be carried out as elaborated in the relevant chapter.
Receivingg delivery of items at site, their proper storage, and handling at site, watch and
ward services, removal of debris to a location specified by the Purchaser etc. Site shall
be handed over to the Purchaser in clean and orderly manner to the satisfaction of the
site engineers after commissioning of the project.
Getting Purchasers/ consultants approval for the drawings prepared by the successful
Tenderer, obtaining required approval from statutory authorities, providing adequate
personnel, equipment, tools & tackles for timely completion of the project.
For detailed scope of work and design parameters on various subsystems & facilities, the
Tender Specification shall be referred to.
This is a turnkey project for Installation of Wagon Tippler and conveyor
conveyor system and all the
facilities required for proper functioning of the wagon tippler and achieving the rated
capacity shall be deemed to be covered in the tender specification, unless specifically
excluded from the Tenderers scope.
1.7.2

Page 11 of 11
SECTION 4
1.0
SYSTEM PARAMETERS, OPERATION & CONTROL PHILOSOPHY
1.1
The specifications as brought out in various Sub-sections

Sub sections for mechanical equipment shall be
applicable for the proposed wagon tippler and conveyor system 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.
2.0
PARAMETERS
2. 1
Conveyor System
i. Rated Capacity (Guaranteed) : 1200 TPH
ii. Design capacity : 1320 TPH
iii. Belt width : 1200 MM
iv. Belt speed : 3.5 m/sec. (approx.)
2.1.1
Belting and Pulleys

Belts of conveyors shall be provided with latest belt weighing system to measure/record the
quantum of coal falling on the belt and being carried by the conveyor
conveyor system. The weighing system
shall have adequate no of load cell., digitizer and intelligent terminal with printer facility for
computerized
zed print out of the weight.
(a) Belt ratings with appropriate ratings shall be selected.
(b) Minimum number of plies for belting shall be four (4) if possible, can be standardized
with the type of belting available with NALCO.
(c) For Pulley, following minimum parameters shall be adopted:
(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 for all drive pulleys shall be minimum 800 mm. Diameter
Di
of all other
pulleys shall be minimum 630 mm
The contractor shall obtain confirmation from belt manufacturers regarding the adequacy of
the pulley diameters.
2.1.2
Wagon Tipplers
(a) No. required: 1 (One)
(b) Guaranteed tips per hour per tippler: 20
2.1.3
Side Arm charger

(a) Nos. required :1 (one)
(b) Guaranteed haulage : 60 fully loaded coal wagons (Box N)
2.1.4
Apron Feeder
(a) No. required : One (1)
Technical Specification:Sec-4,System
System Parameters, Operation & Control Philosophy
Page 1 of 64
2.1.5
2.1.7
(b) Guaranteed (rated) capacity: 1200 TPH Apron Feeder

E.O.T Crane
(a) No. of unit : One (1)
(b) Guaranteed (rated) capacity (Main/Aux.)
: 25 T/5T
Dust Control System
The parameters for the dust control system specified hereinafter are intended for
Contractors guidance only. Contractor shall provide adequately sized and effective dust
control system, the performance of which shall 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
system shall not be less
than that specified below.
(a.) Area Dust Suppression System at Wagon Tippler
(1) Location
: Wagon Tippler Top
(2) Capacity of each nozzle
: 2.0 lpm at 2.5 kg/ cm2
(3) Nozzle spacing.
: 500 mm
All nozzles to operate simultaneously in each wagon tippler area.
(b) Dust Suppression System for other areas
(1) Operation
: Water sprayed with fogging nozzle
(2) Location of spray
: All coal loading and discharge point on the
conveyor
(3) Capacity / Pressure
: 2.0 lpm / 2.5 kg/cm2 inlet of spray head
2.1.8
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 Point.
(a.) Flow at each valve
: 5 cub . m/hr
(b.) Minimum discharge Pressure at tap point : 2 kg/sq.cm
(c.) No of pumps
: 2 nos.
(d) No. of valves operated
: 6 nos. simultaneously
2.1.9
Ventilation System
A Mechanical Ventilation System
For Underground Areas a Minimum of 15 supply air changes and minimum 7 exhaust
air changes per hour.
For other Areas a Minimum of 10 supply air changes per hour.
B. Pressurized Ventilation System:
System: Minimum 15 supply air changes per hour
C. Air Conditioning System :
Adequate number of air changes to Maintain
Maintain uniform temp. & humidity.
2.1.10 Chutes
Page 2 of 64
Minimum clear cross section of chute shall be 1200 mm x 1000 mm (inside both ways).
2.1.11 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, Apron feeder, sump pumps, various DS/service water/potable water pumps,
gravity take up units, removal of equipment from tunnels, lifting of belt drum at all transfer
tr
houses.
2.1.12 All other equipment under the scope shall be suitable to the system capacities parameters
as specified above.
3.0
OPERATION AND CONTROLS
3.1
This section is intended to cover design, engineering manufacture, supply, erection, testing
tes
and commissioning of the complete control and instrument panel/desk with annunciation
panel, etc. as specified hereinafter complete in all respects, required for the system.
3.2
General Requirements
The instruments and controls to be furnished and erected
erected under this specification are as
required for safe and satisfactory operation of the plant & equipment under Wagon Tippler
and Conveyor System Package, as outlined under mechanical section and as specified
elsewhere in the specification. For the equipment
equipment and materials procured by the Contractor
from his sub-vendors,
vendors, the Contractor shall study the specification, safety requirements,
interface drawings for such equipment and material in detail and shall coordinate his work
with his subvendors and supply instrumentation and control to ensure suitability of the
system.
3.2.1
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)
Institute of Electrical & Electronic Engineers (IEEE)
Instrument society of America (ISA)
National Electrical Code (NEC)
National Electrical Manufacturers Association (NEMA)
Bureau of Indian Standards (BIS)
Conveyor Equipment Manufacturers Association
Ass
(CEMA)
Page 3 of 64
Guideline for wagon tipplers issued by RDSO G33 (Rev. 1) of May 2010 with latest
amendments if any.
3.2.2
section shall be read in conjunction with Electrical Sub-sections.

Sub sections.
This Sub-section
3.3
Construction and Design
3.3.1
Construction
Control desks/panels and annunciation system shall be provided as per the requirement of
electrical Section. Annunciations, indications, electrical meters and instrumentation shall be
provided as specified. Ammeters shall be provided on control desk for all
a motors rated 30
kW and above and for all equipment.
3.3.2
Design
The Contractor shall provide a comprehensive control indication and annunciation scheme
for the plant & equipment under wagon tippler and conveyor system package and integrate
the same with the existing control & monitoring scheme of the CHP. Contractor shall furnish
a block diagram and write-up
write up on the scheme proposed. The final scheme will be approved by
the Owner/RITES and the Contractor shall be required to execute the approved scheme.
scheme In
general, interlocking shall be achieved through feed-back
feed back signals from field equipment. A
comprehensive Annunciation and Indication scheme shall be provided such that, it will be
possible for the operator to locate and identify the fault from the display
disp
ace of Control
desk. The scheme shall include the basic remote control instrumentation, indication and
annunciation requirements as per various technical specification requirements. However,
the Contractor may offer any alternative proposal which he considers
considers to be equal, superior
to the scheme as described in subsequent clauses below for achieving reliable and trouble
free operation of the plant, for consideration of the Owner.
4.0
4.1
OPERATION AND CONTROL PHILOSOPHY

The Wagon Tippler control room shall
shall be located by the side of Wagon Tippler to
accommodate control & monitoring equipment of wagon tipplers. It shall also have a battery
room.
4.2
The existing coal handling system is being controlled from the following control points. The
existing control
ol philosophy of the coal handling plant is being described below for the
contractor to understand the existing system and suitably plan integration of the controls
and interlocks of the proposed control system of the wagon tippler package with the existing
existin
system.
4.2.1
Owners Existing Coal Handling Plant Control Room

Operation of the CHP equipment is being controlled from the Owners CHP control room.
(a.) Conveyors, feeders, flap gates, hydraulic couplings etc.
(b.) Complete Dust Suppression system & service
s
water system.
(c.) Ventilation system (group/individual control as required).
(d.) In line Magnetic separators and Suspended Magnet (ON/OFF control with indication).
Page 4 of 64
(e.) Metal Detectors (ON/OFF control with indication).

(f.) Belt weigher (ON/OFF control
co
with indication)
4.2.2
Local Control Panels

Local control stations for following equipment shall be provided for
(a) All conveyors
(b) All gates
(c) Electric hoist - wall mounted control box with pendent push button controls.
(d) Wagon Tippler
(e) Apron feeder
(f) Sump Pump
(g)) Dust suppression system for wagon unloading
(h)) Hydraulic scoop coupling, if any.
All the above local control panels shall be accessible and located near their respective
equipment and shall be complete with all the required controls, interlocks, annunciations
etc. Necessary controls, indications and annunciations for all the above equipment shall also
be provided at main CHP Control Room.
4.2.3
In addition to the remote control of various equipments, local stop push button
butto stations
shall be provided for all equipment.
4.3
SYSTEM OPERATION
4.3.1
Typical Operation philosophy of the plant, in general, as elaborated below is for the
information of the contractor to facilitate development of the control & monitoring scheme
of wagon tippler and conveyor system package and integration with the existing control &
monitoring system of existing CHP.
(a.) Coal flow path selection shall be done from Owners existing control desk to select
conveying paths.
(b.) The coal handling system operator
operator will select any one of the paths from the main control
desk. The flow stream path is then selected by positioning different flap gates at desired
positions. Once the system is in the operation, the gates can not be moved from their
positions and path. Flap gates which do not form
f rm the stream in which coal flow is taking
place, can be operated at any time.
(c.) The Control system will be designed for both Auto & Manual operation of the
conveyors in the selected path. Auto/Manual Selection shall be done from
from Owners existing
control desk.
Auto Mode : In the Auto mode, the conveyors and related equipment will start
sequentially when the System Start is activated. During stopping, when the System Stop
Page 5 of 64
is activated, all conveyors will also stop sequentially

sequentially (in the reverse sequence) allowing time
delays for clearing the belts.
Manual Mode : In Manual Mode, the operator will start the conveyor system, in the same
sequence as in Auto mode from control desk. The operator will also stop the conveyor
system,, by pressing "System stop" or individual Stop push buttons/command from control
desk in the reverse sequence. System Start and System Stop PBs and located on the
Owners Control Desk.
4.3.2
Conveyor System
(a) Normally the operation of the apron feeder and the reclaim conveyor shall be controlled
from main control room for evacuating coal from tippler hopper.
(b) The approach of a Railway wagon rake to the plant shall be signaled (visual and audible) in
the wagon tippler Control room as well as to the main coal handling plant control room, as
soon as the rake come within 100 meters distances from the wagon tippler.
(c) Each conveyor shall be protected against damage to the edge of the belt due to excessive
sideways movement by providing adequate number of belt sway switches. In addition, each
conveyor shall be provided with one (1) No. speed detection device (zero speed switch). The
zero speed switches shall be designed to sense belt speed.
failur by providing
(d) All the conveyors shall be protected from roll back due to power failure
mechanical / or electrical locking system.
(e) The starting sequence of the conveyors shall follow a direction opposite to that of flow of
material. The details of Coal flow diagram of the existing stage-I
stage I CHP shall be furnished to
the successful bidder.
(f) Any individual equipment (belt conveyor etc.) should not be allowed to start unless the
equipment immediately following the same in the direction of flow of material is already in
operation.
(g) Pull-cord
cord switches shall be provided along the length of each belt conveyor, which shall
enable the respective conveyor to be stopped immediately. Each pull operated chord switch
and belt sway switch shall be tagged and shall be identifiable in the main control room.
fore
personnel
sonnel working nearby when starting any conveyor.
(h) Siren shall be provided to fore-warn
(i) Interlocking of various conveyors shall be achieved with Flap Gate, limit switches and zero
speed switches.
if provided, is in open condition. This
(j) Motors shall start only when the brake/rail clamp if-provided,
signal
al shall be obtained from limit switch provided for that purpose.
Page 6 of 64
(k) Once a conveyor trips, flap gate directing coal from this conveyor shall change over its
position with a time delay and shall come back to the original position again, to prevent
jamming of gate.
(l) Where ever scoop type coupling provided for HT motors, the coasting time of respective
conveyor, thruster brake, actuator selection and the chute size shall be so selected such that
there is no spillage of coal from any downstream conveyors.
4.3.3
Interlocking
a) The following conveyors / equipment are considered under interlock scheme ::
(1.) All conveyors
(2.) All gates
(3.) Wagon tippler
(4.) Apron Feeder
b) The following equipment will not come under interlock of the conveyor scheme.
(1.) All dust suppression systems & service water system.
(2.) Ventilation systems
c) All conveyors and equipment have local push button stations each consist of :
(1.) Pos - I, Pos - II & stop button for flap gate
(2.) Emergency stop push button (Red) for other equipment
d) Belt scale is started when relevant conveyors are started.
e) The dust suppression systems will be energized as soon as the conveyors are energized.
f) Coal Handling plant shall be tripped in case of detection of fire. Necessary input contact
shall be made available
lable to the Contractor in the Owners main control room.
g) Interlock for H.T. Motor : H.T. motors used will continue to run on no load by
disengaging the fluid coupling in case of failure of any process interlock. The H.T.
motors will however be tripped in case of any motor fault like O/L, high motor winding
temperature etc. In addition, in case of normal stop command, after running of the
system, motors will stop.
h) The following are the various safety interlocks for the conveyors and other equipment.
This list
st is indicative only and the Contractor shall develop a comprehensive interlocking
scheme.
Conveyors
a). Pull - Chord switch - not operated
b). Belt sway switch - not operated
c). Underspeed switch - closed at 90% speed of the conveyor within designed
accelerating time.
d). Motor protection - not tripped
e). Local stop PB reset
f). Chute Block switch - not operated.
g). Brakes for conveyor not operated.
h). Trip circuits healthy.
i). Temp. of fluid coupling oil - not high
Page 7 of 64
Wagon Tippler
a). Motor O/L - not tripped
b). Local E-Stop PB - reset
c). Stop PB in main CHP control room - reset
d). All Limit Switches reset
e). All limit switches not tripped
Apron Feeder
a). Motor O/L - not tripped.
b). Local stop PB - reset.
Flap Gates
vel limit switches - reset.
a). End of travel
b). Torque limit switches - reset.
c). Local stop - reset.
4.3.4
The lists of indications and audio-visual

audio visual annunciation given in subsequent clauses are
indicative only and the same shall be finalised during detail engineering.
4.3.5
Status indications in Mimic.

Following individual status indications shall be provided in mimic with individual ON/ OFF
/TRIP indications on HMI of PLC.
(a.) Conveyor 'ON'
(b.) Flap Gate/Rack and Pinion position.
(c.) Belt scale flow rate indication
indicati and totalizer.
(d.) Belt sway switch operated for each conveyor (individual switch indication on CRT).
(e.) Pull cord switch operated for each conveyor (Individual switches indication on CRT).
(f.) Zero speed switch operated for each conveyor
(g.) Wagon Tippler ON'
(h.) Apron Feeder ON'
.) DS/ SW/ VentON (System wise)
(i.)
Further Mimic lamps and Controls for HT and LT Breakers shall be provided on the control
desk.
4.3.6
Annunication System:
The Control desk shall be provided with adequate number of facia type annunciation
windows for the following audio-visual
audio visual fault annunciation purposes. Wherever group
annunciation is provided, alarm status of individual equipment shall be provided on mimic.
Page 8 of 64
All audio visual annunciation of following parameters should be incorporated in the HMI of
PLC.
(a) 33 kV Breaker Trip (Group wise for each board)
(b) 415 V MCC Breaker Trip (MCC wise)
(c) Bus under voltage for each LT MCC
(d) Following group wise annunciation
annunciation shall be provided for transformers :
(i) Buchholz alarm
(ii) Winding/oil temperature high alarm
(iii) Oil level low alarm
(iv) Buchholz trip
(v) Winding/oil temperature high trip
(e) A.C Control Supply failure.
(f) D.C. Control Supply failure.
(g) Annunciation supply failure.
(h) Both CPU fail
(i) Stand by CPU in service
(j) LT motor overload tripped (Group).
(k)) Belt sway switch operated (Group)
(l)) Pull cord switch operated (Group)
(m)) Zero speed switch operated. (Group)
(n)) Chute plugged (Group)
(o) Wagon rake arrival.
(p)) Wagon Tippler tripped (group)
(q) Apron feeder.
Dust suppression/service water system faults and trips (system wise)
(r)Dust
(s)) Water level low in tanks (group)
(t)) Oil temperature of fluid coupling high
(u) 20% spare windows
For identification of the fault for a particular conveyor or equipment, status indication
against that conveyor / equipment in the mimic will start fast flickering and the annunciation
window will be blinking against that particular fault. In addition, a buzzer (alarm) will also
start
tart sounding. After acknowledgement of the fault, the buzzer will stop, but the fast
flickering on the mimic and the steady glow on the annunciation window will continue until
the fault is cleared and the Reset push button is pressed. When the fault is cleared
cl
and the
Reset push button is pressed, the status indication of that conveyor / equipment on the
mimic will start slow blinking if it is on selected path otherwise it will go off and the steady
glow in the annunciation window will go off. However, pressing
pressing of the Reset push button
before clearance of the fault, will have no effect on the lamps.
At the time of a fault, the faulty conveyor / equipment, as well as the preceding conveyors /
equipment in the interlock sequence, will stop except H.T. motors for which only scoop
coupling will be disengaged and motor will continue to run for process fault. In case of
motor fault, H.T. motor will trip but the succeeding conveyors / equipment will continue to
run. The status indication against the preceding conveyors
conveyors / equipment will start slow
Page 9 of 64
blinking while the faulty conveyor / equipment will be fast blinking. Start command shall not
be initiated unless reset button in pressed after clearance offault.
The sequence of operation of the annunciation system shall be as follows:follows:
Ann. Window
Status indication
Buzzer
Ann. Window
Status indication
Buzzer
Status
: Off.
: Steady glow
: Off.
: Blinking.
: Fast blinking
: Sounding.
Press Accept PB.

Ann. Window
Status indication
Buzzer
: Steady glow.
: Fast blinking
: Off.
Condition
Normal :
Fault :
4.3.7
Press Reset PB (When fault is cleared):

Ann. Window
: Off.
Status indication
: i) Steady blinking (if on selected path)
ii) Off (if not on selected path)
Buzzer.
: Off.
Dust Suppression System
(a.)
Conveyors / Equipment
1. It shall be possible to spray the water on to coal stream only when corresponding
conveyors/equipments are running with material at spray application points.
2. If a running pump trips stand-by
stand
pump shall start automatically.
lly. It shall be possible to select
any of the pumps as auto standby from main CHP control room.
3. Pump/pumps shall trip with a time delay, if discharge valves fail to open. Suitable
pressure/flow switch shall be provided to sense this condition.
4. Pumps shall trip in case of low level of water in tank.
5. All feeding pumps to tank shall trip in case of high-high
high
level in tank.
6. All the controls shall be through control desk.
(b.) Wagon unloading

1. System shall be operated from local control panel.
2. Dust suppression system shall be provided to cover the WT Hopper.
3. Pumps shall be started manually or from control panel.. If any of the pump/pumps trips,
stand-by
by pump/pumps shall start automatically. It shall be possible to select any of the
pumps as auto stand - by.
4. Pumps shall trip in case of low level of water in tank.
5. Following annunciations shall be provided at local control panel.
Page 10 of 64
(i) Motor electrical protection operated (Group)

(ii) Discharge water pressure low (Group)
(iii) Water level low in tank (Individual)
6. Following individual indications shall be provided at local control panel.
(i.) Motor ON/OFF/TRIP
(ii.) Discharge pressure healthy
(iii.) Water level high in tank.
4.3.8
Sump Pumps
(a) Sump Pumps shall start and stop by the level switches in the sump automatically.
Further manual override start / stop push button shall be provided locally on ground
level.
auto
(b) Any of the pumps can be selected as auto-standby.
(c) If the sump level continues to be high even after the first pump is under operation
second pump shallll start automatically.
(d) The following indications for sump pumps shall be provided on local Control Panel.
(1.) Water level high
(2.) Motor ON/OFF/TRIP.
4.3.9
Wagon Tippler
Wagon Tippler shall be controlled from the local control panel suitably placed. Requirement
Require
of operation as described elsewhere in the specification shall be complied with. Following
indications shall also be provided on the local control panel:
(a.) Motor ON/OFF
(b.) Motor O/L protection operated
(c.) Brakes applied (if provided)
(d.) Hydraulic power pack indications as applicable.
4.3.10 Flap Gates

All flap gates shall be motorised and remote controlled from the main control desk. Their
position shall be indicated on the mimic of main control room.
4.3.11 Service water and Cooling Water
Wa
(a) These pumps shall be started from main CHP control room
(b) Pump shall trip in case of low water level in tank.
(c) Following individual inputs shall also be provided to PLC system for alarms/indications :
(1.) Motor ON/OFF/TRIP
(2.) Discharge water
er pressure low
(3.) Water level low in tank
(4.) Water level high in tank
5.0
WAGON TIPPLER
GENERAL
Rotaside / Rotary wagon tippler shall be furnished complete with all structural members,
tippler platform, tipping mechanism, tippler drive motors, brakes, couplings, shafting and all
Page 11 of 64
automatic controls for positioning, tipping and discharging the entire contents
contents of the wagons
into the hopper.
5.1
Wagon Unloading System
5.1.1
The rake comprising of specified maximum60number

maximum number of wagons shall be pushed into the
reach of in-haul
haul equipment by a locomotive. Further placing of wagons over tippler
platforms and carrying away
away the empty wagons shall be accomplished with the help of a side
arm charger under scope of bidder.
5.1.2
Wagon unloading equipment shall be suitable to handle any type of wagons being used by
Indian Railways for transportation of coal. Thus side arm charger and
and wagon tippler shall be
suitable to handle all standard broad gauge (1676 mm) wagons of RDSO design used by
Indian Railways conforming to latest revision of IS: 10095.
5.1.3
Maximum moving dimensions of locomotive & wagon as per Indian Railway norms shall be
adopted for providing clearances with respect to structures, equipment and tippler
arrangement.
5.1.4
Complete wagon tippler and accessories shall have the approval of concerned Indian Railway
Authorities and RDSO. Further, the contractor shall submit to the Owner detailed drawings
of wagon tippler and accessories including civil and structural drawing only after getting the
same approved from the concerned Railway authorities.
5.1.5
The bidder shall obtain all statutory approvals from the relevant Railway authorities,
authorit
before
the wagon tippler complex is put into operation. Any statutory payment charges, to be made
to the concerned authorities shall be to Bidders account. It is the responsibility of the
Contractor to carry out any modifications as required by the Railway
Railway authorities, at no extra
cost to the Owner.
5.2
Wagon Tippler Hopper
5.2.1
The wagon tippler hopper shall be of RCC construction and adequately sized to
accommodate the coal load for atleast two (2) nos. 8 wheeled wagons of RDSO design used
by Indian
ian Railways. For effective volumetric capacity computation of the hopper, the angle
of repose of coal shall be considered as 37. The minimum valley angle of the hopper shall
be considered as 60. The hopper shall have opening below which apron feeders shall
sh be
provided to evacuate coal from the hopper and feed onto associated belt conveyors below.
Complete inside surfaces of the hopper shall be provided with 50 mm thick guniting. Further
it shall be possible to empty out all the coal, without any dead stock
stock from the hopper.
5.2.2
Steel gratings of mesh size 300

30 mm x 300 mm over wagon tippler hopper shall be provided.
The gratings shall be built of minimum 200 mm x 36 mm thick flats. The hopper and gratings
shall be designed for movement of front
f
end loader/bulldozer over them. Bull-dozer
Bull
weight
shall be considered as about 35 T.
Page 12 of 64
5.3
CODES AND STANDRDS

The design, manufacture, inspection and testing of Wagon Tippler shall comply with all the
currently applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed. The Wagon Tippler shall conform to the latest edition of the
standards and codes. Other internationally acceptable standards/codes, which ensure equal
or higher performance than those specified, shall
shall also be accepted. Nothing in this
specification shall be constructed to relieve the contractor of the required statutory
responsibility. In case of any conflict in the standard and this specification, the decision so
the Engineer shall be final and binding.
bindi
5.4
DESIGN REQUIREMENT
Keeping in view Technical guideline issued by RDSO (Research & design services organization
)G 33 Rev.01 issued on May10 & effective from Dec10, the specification of wagon tippler
along with apron feeder to be designed as under:
a) Wagon tippler capacity
: 25 Tips per Hour
b) Load handling capacity of wagon tippler
: 140 Ton
5.4.1
The wagon tippler shall be suitable to unload

unloa a coal wagon.
5.4.2
During each cycle of operation, the tippler shall be capable of holding, completely unloading
and replacing the wagon to its original position without damage to the tippler or the wagon
or the track.
5.4.3
The tippler shall be suitable for continuous operation, 24 hours a day, round the clock.
5.4.4
The wagon tippler structure shall be designed to conform to the requirements of Indian
Railways Research, Design and Standards Organisation, (RDSO) - G 33 Rev.1 with regard
to the nature of loading, impact factor and allowable stresses. It shall be the sole
responsibility of the contractor to ensure that each and every component of the wagon
tippler is adequate in rigidity, strength and of heavy duty construction of first class quality to
guarantee against failure or major damage, assuming proper maintenance and usage. The
tippler shall be designed to allow passage of all standard broad gauge (1676 mm) Indian
Railways diesel locomotives over tippler table at restricted speed.
5.4.5
The wagon tippler shall be suitably counter balanced at each stage of operation so as to
require minimum driving power.
5.5
WAGON TIPPLER WEIGHING SYSTEM
5.5.1
This specification calls for an electronic static weighing system to measure / record the
quantum of coal, wagon wise on the wagon tippler table before & after tippling. The
weighbridge with adequate no. of load cells shall be provided beneath the wagon tippler
ti
Page 13 of 64
platform with a minimum accuracy of 1% of the gross weight of the wagon. The platform
shall be freely supported on the weigh bridge before and after tipping for accurate weighing.
The wagon tippler weighbridge shall be designed to statically weigh the
th wagons in an
uncoupled condition. The system shall comprise of a weighbridge, a tippler table, load cells,
weight digitizer and an intelligent terminal with printer with the facility for computerized
printed output of data gross weight, tare weight, wagon
wagon no., time, date etc. the weighbridge
shall be chosen to accommodate all types of wagons as per RDSO guidelines to move coal.
The weighbridge shall be supported on minimum 4 nos. compression type load cells
mounted on free motion structural unit assembly.
motion weigh scales in both in-haul
in
and out-haul
haul tracks shall be provided
Alternatively, in-motion
for the purpose. The load cells shall be suitable for dusty environmental conditions. The
calibration of the weigh bridge shall be the scope of the bidder. The bidder
bidder shall co-ordinate
co
with statutory authority to get the necessary stamping & other requirements.
6.0
CONSTRUCTION REQUIREMENT
6.1
6.1.1
Cradle
The cradle shall consist of a pair of heavy welded steel plate sections reinforced with
stiffeners and connected
cted by side bearer beams pivotally attached, each section being fitted
with a massive trunion shaft carried in bronze bushed cast steel bearings on each side,
bolted to steel pedestal carried on concrete pedestals. Circumferential driving rack shall be
rigidly
gidly bolted to the peripheries of the sectors. The sectors shall be made of cast steel.
Necessary features of safety against coming down of wagon tippler in the event of failure of
one of the drive pinions and / or gear racks shall be provided and the same
sam shall be clearly
indicated in the bid.
6.2
6.2.1
Rail Table
The rail table shall be constructed of rolled steel joints with standard steel rails (52
kg/metre) mounted on it. The table shall be pivoted from arms extended from the sectors.
The table shall be covered with chequered plates between the rails.
6.3
Feeders and Clamps
6.3.1
The wagon shall be clamped automatically by hydraulic system and firmly on the cradle
during the tipping without any damage or undue pressure on any part of the wagon and no
hand adjustment of any sort shall be necessary. Sliding side stop pads shall be of resilient
material to prevent damage to either the wagon or the stops.
6.4
Spill Plate
6.4.1
Fixed to the cradle of the tippler shall be a plain steel spill plate for deflecting material into
the tippler hopper.
6.5
Driving Gear
Page 14 of 64
6.5.1
Multiple pinions meshing with cast steel racks bolted to the end sectors shall impart drive
through hydraulic drive with each pinion drive through slow speed high torque hydraulic
hydr
motors using gear boxes as applicable. Suitable oil coolers shall be provided for hydraulic
power pack. Suitable dust protective cover shall be provided.
6.6
Brake
6.6.1
An automatic electro hydraulic brake shall be furnished to hold the tippler in any position
with the load and against any movement except that provided by drive.
6.7
Limit Switches
6.7.1
Limit switches of suitable type which can be readily adjusted to give the desired tippling
angle shall be provided. An emergency over tip limit
limit switch operated by a striker on the
tippler trunnion shaft shall be furnished.
6.8
Ballast
6.8.1
Ballast necessary for counter weight and balancing the tippler shall be provided as per the
requirement.
6.9
Lubrication
6.9.1
All bearings shall be properly lubricated. Grease nipples and reservoirs shall be furnished
where necessary.
6.10
Guards
6.10.1 All gears inside machinery pits and other moving parts shall be securely guarded.
6.10.2 All necessary base plates, guide plates, chequered plate covering for drive pit and any other
pits, all required fixing materials, inserts and sleeves shall be furnished.
7.0
7.1
DATA SHEET
GENERAL
Wagon Type
Moving Profile
No. of tips (guaranteed)
Designed
Rail Gauge
Weigh bridge
Duty
7.2
: All types of wagons in coal transport used by Indian

Railways to move coal (as per latest
test RDSO guidelines)
: As per IR norms.
: 20 per hour.
: 25 Tips per Hour
: 1676 mm.
: Load cell type
: Continuous 24 hrs.
DESIGN & CONSTRUCTION

Page 15 of 64
A.
Wagon Tippler Hopper

Construction
Size
No. of openings
: RCC Construction.
: To accommodate atleast 2 nos. 8 wheeled wagons.
wagons
: One (1)
Angle of repose of coal for

wagon tippler hopper sizing
Lining
Steel Grating
(i) Mesh size
(ii) Grating Section
B
Wagon Tippler
Type
Tipping angle
Duty Requirement
Counter balancing
Cradle
Driving Gear
(i) Racks
(ii) Pinion
Rail Table
Drive
Brake
Clamping
Top & side stops
: 37
: 50 mm thick guniting.
: 300 mm x 300 mm
: 200 mm x 36 mm thick flats.
: Rotaside / Rotary type (As per latest RDSO guidelines)

: The Wagon Tippler shall be suitable to unload Coal
Coa wagons.
The angle of tippling shall conform to RDSO G-33
G
(Rev 1)
Technical pamphlet for requirement of tippler installation
for approval by RDSO.
: Continuous operation
: Suitable to keep power requirement at minimum.
: Heavy welded steel plate construction trunion mounted.
: Cast steel rack sections bolted to end sectors.
: Multiple pinions meshing with rack.
: Rolled steel joists with
ith steel rails mounted on it.
: Hydraulic motors.
: Electro hydraulic thruster operated.
: Hydraulically operated
: Self aligning type made of resilient material.
8.0
SIDE ARM CHARGER
8.1
GENERAL
8.1.1
Side Arm Charger shall be furnished complete with travel rails, drive equipments and
associated accessories.
8.1.2
The rake comprising of specified maximum number of wagons shall be pushed into the
reach of inhaul equipment by a locomotive. Further placing of wagons over tippler platform
and moving out the empty wagons shall be accomplished with the help of side arm charger.
c
Page 16 of 64
8.2
CODES & STANDARDS

The design, manufacture, inspection and testing of Side Arm Charger shall comply with all
the currently applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed and all norms
nor
stipulated by RDSO- G 33 Rev.1. The Side Arm
Charger shall conform to the latest edition of the 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.
8.3
DESIGN REQUIREMENT
8.3.1
A single module of side arm charger shall be used for inhaul and outhaul operations. Thus,
side arm charger shall be used for indexing forward the rake of 60 nos loaded wagons,
placing decoupled wagons on the tippler table and out hauling
hauling the empty wagons.
8.3.2
The rake of 60 loaded wagons will be brought by locomotive and placed on the retipping
line such that the leading wagon will be within the reach of the side arm charger. Now the
side arm charger will be coupled to the leading wagon,
wagon, pull the rake of 60 nos. loaded
wagons towards tippler table. The first wagon will be decoupled manually from the rake and
signal will be given to the side arm charger operator that the wagon is de-coupled.
de
Now the
leading wagon will be placed centrally
centrally onto the tippler table by side arm charger,
(simultaneously ejecting the empty wagon from the tippler table). After the loaded wagon is
placed on the tippler table, the arm is de-coupled
de coupled from the loaded wagon. Adequate
clearance between tippler table and
and empty wagon shall be ensured. The side arm charger
will stop at the end of its strokes, the arm will be swung vertically-up
vertically up and the machine will
move towards in-haul
haul direction and occupies the initial position. In the meantime, the
tippler will tip the loaded wagon placed on the tippler table and return to its original
position. Before tippling operation of wagon tippler is completed, the arm of the side arm
charger will be swung to horizontal position and will be coupled to the rake of remaining
loaded wagons at waiting position just before the tippler table and is now ready for the next
cycle to start. After the tippling operation of wagon tippler is completed the cycle will be
repeated.
8.4
TECHNICAL REQUIREMENTS
8.4.0
8.4.1
The Side Arm Charger shall be suitable to handle60
handle number of loaded wagons.
wagons The pusher
arm shall be vertically rotatable arm mounted on a carriage running back and forth parallel
to the train track.
8.4.2
The arm shall be raised to clear the movement of wagons

wagons and locomotives during reversing
back of positioner carriage and shall be lowered for engaging the head of the arm with the
wagon coupler for index strokes.
Page 17 of 64
8.4.3
The arm shall be raised and lowered by means of hydraulic cylinder mounted on the
carriage.
iage. Suitable means shall be provided to prevent damage to the arms should the arm be
accidentally lowered into the side of wagon.
8.4.4
The arm shall be of robust construction either of cast steel or of heavy duty fabricated steel
for the required duty.
8.4.5
The construction of the head assembly of the push arm shall be such that no damage is
suffered by the couplers of wagons and engagement of arm over the coupling assembly as
well as transmittance of indexing forces to accelerate, run and decelerate the train during
the positioning cycle shall be very smooth.
8.4.6
The carriage frame shall be a suitable fabrication assembly of large proportions massive
enough in strength and rigidity for the required duty.
8.5
Travel Carriage Drive System
8.5.1
The travel carriage with push arm shall be propelled to and fro, parallel to train track
through hydraulic motor driving through a gear box and EHT brake.
8.5.2
The rating of the drive equipment and its characteristics shall match with indexing forces
required
quired to be exerted in varying amounts depending upon train dynamics and to suit
haulage of 60 wagon loaded rake.
8.5.3
The travel carriage shall ride on vertical bearing wheels and will be guided by horizontal
bearing wheels by suitably transmitting the thrust load from the positioned arm to the
foundation. The wheels/rollers shall be of forged steel and shall run on the rails supported
over the RCC pedestal.
8.5.4
Cushioned emergency bumpers (buffers) shall be provided at the forward and return end of
carriage travel run for protection. These shall be designed to arrest the machine without
undue shock in case the machine exceeds its extremities because of any mal-operation.
mal
9.0
9.1
DATA SHEETS
GENERAL
: 1 (One) no
Quantity
No. of wagons to be handled By
each side arm charger at a time
: 60
No. of tips by wagon tippler
: 20 (min.) per hour (guaranteed)
: 25 per Hour (designed)
DESIGN & CONSTRUCTION REQUIREMENTS
9.2
Arm
Arm Drive
: Robust construction either of cast steel or heavy duty fabricated

steel.
: Hydraulic cylinder
Page 18 of 64
Carriage Frame
Travel Carriage drive
Motor
Travel brake
Bearings for sheaves
10.0
10.1
: Single fabrication assembly.

: Hydraulic
: Integral part of hydraulic motor
: Anti friction bearings.
APRON FEEDER
GENERAL
Apron feeders complete with all accessories shall be furnished for wagon tippler hoppers as
specified.
10.2
CODES & STANDARDS

The design, manufacture, inspection and testing of apron feeders shall comply with all the
equipment is to be installed. The apron feeders shall conform to the latest edition of the
standards and codes. Other internationally acceptable standards/codes, which ensure equal
or higher performancee than those specified, shall also be accepted. Nothing in this
specification shall be constructed 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
eer shall be final and binding.
10.3
DESIGN REQUIRMENTS
Apron feeders shall be of robust construction & designed for handling ROM coal as specified
and without any choking particularly during rainy season when coal is sticking. A drible
conveyor shall be provided for proper clean up. The pan and chain shall be of proven design
and shall be with adequate factor of safety.
10.4
The frame shall be manufactured from rolled steel section welded and bolted together to
form a rigid structure.
cture. The roller shall be life time lubricated and shall be manufactured from
alloy steel.
The chain Link shall be forged steel. Pins and rollers shall be of hardened steel. The chain link
shall be bolted to the pans. Apron/pan shall be of suitable thickness
thickn
which shall be
constructed out of fabricated MS with wear resistant liner plate or special alloy steel without
any liner plate for the duty requirement. The pan would be fitted directly to the chain
attachment. The head and tail end shall be of sturdy steel construction suitably stiffened.
The sprocket shall be made of cast alloy steel with case hardened teeth or forged steel. The
traction wheel shall be made of cast steel with case hardened surface. Tensioning
arrangement with sufficient travel shall be
be provided for the tensioning of the chain.
chain
Complete dribble belt system consisting of head pulley, tail pulley, drive, motor, stringers,
deck plates etc. shall be provided.
Page 19 of 64
10.5
DATA SHEET
Capacity (TPH)
Angle of Installation
Chain Link
Apron pan
Traction wheel
Rollers
11.0
12.0
: 1500 MTPH ( Design)

1200 MTPH ( Rated )
: Horizontal
: Forged alloy Steel
: MS fabricated with wear resistant plate or special alloy steel .
: Cast Steel
: Forged Alloy Steel
No sizer or crusher is required.

DRIVE EQUIPMENT
GENERAL
Suitable Drive Chain Equipments like electric motors, gearboxes (where applicable), fluid
couplings (where applicable), flexible couplings and other accessories shall be provided for
all the belt conveyor systems, wagon tippler,
tippler, side arm charger, apron feeders, various
pumps of dust suppression system, fans for ventilation system, monorail electrical hoists and
other equipments specified in this specifications. Various requirements as spelt out in the
Technical Specifications for
for individual equipments shall be taken into consideration while
designing the associated drive chain equipments.
12.1
CODES AND STANDARDS

The design, manufacture, inspection and testing of Drive Equipment shall comply with all the
equipment in to be installed. The Drive Equipments shall conform to the latest edition of
the following standards and codes. Other internationally acceptable standards/codes, which
whic
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,
specification, the decision of
the Owner 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
12.2 DESIGN AND CONSTRUCTION REQUIREMENTS

12.2.1 GEAR BOXES
12.2.2 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces.
12.2.3 The gearboxes shall be designed for 24 hours continuous duty and gear boxes shall have
appropriate thermal rating.
Page 20 of 64
12.2.4 Thee 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
Ab
40 kW drive
rating, all gearboxes shall be helical or bevel helical type only.
12.2.5 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.
12.3
COUPLINGS
12.3.1 Flexible / Rigid Couplings
Approved type of 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. Geared type flexible coupling shall be used on
low speed side
ide 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 and shall be finalized during detailed engineering.
12.3.2 Fluid Couplings
Fluid couplings shall be provided in all the drive machinery for wagon tipplers & associated
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
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. 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 shall necessarily
be provided for circulating the fluid coupling oil through oil cooler. Independent
arrangement for forced cooling water
water supply using 2X100% capacity pumps 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
eptable levels. Suitable pressure indicators and flow indicators shall be
provided in the cooling water lines along with all-relevant
all relevant valves, strainers 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
n
operation
shall result in scoop tube re-positioning
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
actuator for scoop type fluid coupling
shall be made taking into consideration the coasting time of downstream and upstream
conveyors and the engagement/disengagement time achievable. The scoop tube operation
must be such so to ensure quick draining out of oil
oil from the operating circuit, by providing a
double speed motor.
Page 21 of 64
12.4
DATA SHEET: DRIVE EQUIPMENT

GENERAL
12.4.1
Continuous Motor Rating (Name Plate Rating) at 50 Degree Centigrade Ambient temp. for
Electric Motors
For conveyors of belt conveyor systems and belt for In line magnetic separator:
a)
*120%
120% of actual power at drive motor output shaft at specified design capacity
b)
WT, SAC, apron feeders: *110%
110% of actual power requirement at drive motor output
shaft at guaranteed (rated) capacity.
c)
Mono-rail
rail hoists (travel and hoisting), various pumps of DS systems, service water
systems, cooling water system, potable water system and sump pumps: *110% of
actual power requirement at drive motor output shaft at guaranteed (rated)
capacity.
Ventilation Fans: *110%
110% of actual power requirement at drive motor output shaft at
d)
guaranteed (rated) capacity. In case of belt drive, the efficiency of transmission shall
be considered as 95%.
*The
The actual power at drive motor output shaft
shaft shall be calculated after considering all the
losses of down the line equipments of the drive train.
1.0
Drive Equipment Rating
a) For Conveyors : 120% of actual design requirement
b) Other Equipment 1 x 100 % duty: 120% of actual design requirement
c)) Other Equipment 2 x 50 % duty: 110 % of actual design requirement
2.0 DESIGN & CONSTRUCTION REQUIREMENT
2.1.0 Gear Box
2.1.1 Type
(a) Below 40 KW: Helical, worm, bevel as per requirement without cooling coil
(b) Above 40 KW: Helical / bevel helical without
w
cooling coil
2.1.2
Service Factor:
As per accepted engineering practice / manufacturer's
recommendations
2.1.3 Ambient temperature for Thermal rating: 50o C 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}
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 manufacturers gear box selection catalogues.
2.1.6 Duty: 24 Hrs. Continuous
2.2.0 Flexible Couplings:
2.2.1 Type: Geared capacity.
2.2.2 Rating: Not less than
han motor rating.
Page 22 of 64
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 rating
13.0
13.1
EOT CRANE
GENERAL
An E. O. T. crane complete with all accessories shall be furnished for maintenance at wagon
tippler house.
The design, manufacture, supply erection and commissioning of EOT crane complying with
all the currently applicable statutes, regulations and safety codes in the locality
loca
where the
equipment is to be installed. The EOT crane shall conform to the latest edition of the
standards and codes. Other internationally acceptable standards/codes, which insure equal
or higher performance than those specified, shall also be accepted.
accepted. Nothing in this
specification shall be construed to relieve the contractor of the required statutory
the Engineer shall be final and binding.
13.2
EQUIREMENTS AND CONSTRUCTION REQUIREMENTS

DESIGN REQUIREMENTS
The crane shall be generally of box type double girder construction and shall designed for
appropriate class of duty in accordance with BSS: 466/1960 and or IS:3177 to meet the
installation and maintenance of wagon
wagon tippler and the associated equipment.
The bridge should comprise of two main girders with two out riggers and the end carriage
built up from mild steel channel with adequate diaphragms or stiffing plates. Each bridge
girder shall be fabricated and dispatched
dis
without any spliced joints.
Box Girder & End carriage joints shall preferably have fit bolts. For all bolted joints the holes
are to be drilled and reamed and bolts are to be force fitted.
Hand railing shall be fitted on both sides of the end carriages and throughout the length of
the platform (height of 1.1m) parallel to girder. Size of the hand rail shall be not less than 25
mm bore heavy gauge steel pipe. The vertical pipes shall have flanges at the bottom for
proper support. Suitable hand railing
railing should be provided on Cross Travel Trolley also.
All Rotating parts & Overhang parts shall be provided with suitable guard.
The end carriages shall be of approved design, with L type Brackets of substantial
construction and ample stiffness built up of mild steel sections securely welded.
The end carriages of the crane are to be mounted on double flanged wheels of approved
diameter in accordance with IS: 3177. Number of wheels on each side of the crane shall be 2
Page 23 of 64
Nos (Total 4 Nos in the Crane for

for Long Travel motion) The Wheel shall be of forged steel
having composition as Cr 55 Mn 75 (EN 9) hardened to 300-350
300 350 BHN with minimum depth
10mm confirming SAE 1055 / IS 1570 & shall be fitted with roller bearings with dust proof
seals. For lubrication, Grease nipples shall be provided at convenient points.
Twin drive system to be adopted for Long Travel of E. O. T. in the bay.
One wheel in each carriage is to be driven by forged steel gears through a motor mounted
on or adjacent to the carriage.
Long travel mechanism shall be provided with, a thruster brake on each individual drive of
the track wheels. These brakes shall be such that it can be operated from both the control
desk as well as remote control. The brakes shall be of post type with hinged
hing shoes, lined
with good quality reinforced bonded brake lining and suitable for easy of adjustment of the
wear on lining.
13.3
An independent additional mech. / electrical operating brake are to be provided with LT

motion to stop the crane immediately in case
ca of power failure.
DATA SHEET
13.3.0
13.3.1
13.3.2
13.3.3
13.3.4
CAPACITY AND LEADING DIMENSION

Safe Working Load: Main Hoist - 25T
Safe Working Load: Aux. Hoist - 5T
Duty as per I.S.3177 (Latest Amendment)
SPEED OF MECHANISMS:
(a) Main hoist
Hoisting / Lowering
(b) Aux. Hoist
Hoisting / Lowering
(c) Cross Traverse (CT) Forward/ reverse
(d) Long Travel (LT)
Left / Right
- 6 M/Min
- 8 M/Min
- 10 M/Min
- 30 M/Min
13.3.5 (a) Normal Span: Actual span & other dimensions as required as per structural steel
shed of wagon tippler shall be evaluated by the bidder and confirmed in the bid.
13.3.6 (b) RailCenter to Center: Bidder to confirm
13.3.7 Gantry Rail heights above floor level: Bidder to confirm
13.3.8 Hook lift above floor
floor level to be provided: Bidder to confirm depending upon actual
site condition
13.3.9 Type of Hook - Shank type
13.3.10 Available head height above rail top: to be confirmed by Bidder
13.3.11 Available side clearance from gantry rail center: Bidder to confirm
13.3.12 Location
Wagon tippler shed, Bay Length & Width: Bidder to confirm
13.3.13 Electric power supply - 415 Volt, 3 Phase, 50 HZ A.C. Supply
13.3.14 Gantry rail size - Bidder to confirm.
Page 24 of 64
14.0
14.1
MONORAILS AND HOISTS

GENERAL
Suitable handling arrangements shall be provided for all equipments included in
Contractors 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 Owner. For this purpose Contractor shall provide monorails and hoist
blocks with cross travel facility.
14.1.1 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
al 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
the Owner/RITES shall be final and binding.
14.2
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
general engineering purposes
IS:210 : Cast Iron Castings
DESIGN REQUIREMENTS
14.2.1 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. For hoists for GTUs and bend pulleys clause no. 1.02.18 shall be referred to.
All monorails coming out of the buildings shall be provided
provided with electric hoist blocks,
irrespective of load and lift. Minimum 3 meter length of Cantilever shall be provided in
monorails coming out of the building to lower the equipment to ground level clearing the
building sidewalls and any other facilities beneath
beneath the floor upto ground level.
14.2.2 The exact lift/travel and the number of the hoisting mechanisms and the mode of lifting
equipments to various floors of the buildings shall be as decided by the Owner/RITES
Owner
at the
time of detailed engineering. Use
Use of single hoist shall be avoided for handling more than one
equipment. 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 deviatee 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 decided considering the movement of the equipment being
Page 25 of 64
lifted over/by the side of other equipments without removing the later. The necessary
levels of floors in various buildings shall be decided considering the above requirement.
g
level.
14.2.3 Monorails shall be extended outside the building to handle the equipment to ground
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.
14.2.4 Electrically operated monogirder type
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.
designed and constructed in accordance with the latest revision of
14.2.5 The electric hoist shall be designed
IS:3938 and shall be suitable for duty class 2.
14.2.6 For electric hoists, trolley movement and hoisting shall be effected by using two separate
motors. Motors shall be as per technical requirements
requirements discussed elsewhere. However the
motors shall be suitable for 150 starts per hour at 40% CDF.
14.2.7 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.
14.2.8 Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which shall be
driven through motor.
14.2.9 Wire rope shall be of pre-formed
pre formed type, hemp cored, regular lay 6/36 construction with a
breaking strength of 160 -175
175 kgf/ sq. mm. Reverse bend of ropes is not acceptable.
Minimum number of falls of rope shall be four (4).
14.2.10 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.
14.2.11 All running shafts and wheels shall be fitted with roller bearings with a rated life not less
than 20 years based on equivalent
eq
running time as per IS:3938.
14.2.12 An electromechanical brake shall provided for hoisting as well as cross travel. Brake lining
shall be of asbestos.
Page 26 of 64
14.2.13 Cast iron parts, wherever used, shall be of minimum grade 30, IS:210.
n pulley blocks shall be designed to IS:3832, the operating hand chain shall conform to
14.2.14All chain
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: 8610 & with
antifriction bearing for bottom look.
14.2.15 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
disturb other equipment.
14.2.16 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
load in all working positions.
14.2.17 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.
14.2.18 Hoist for Gravity Take up arrangement and bend pulley.
For handling bend pulley, take-up
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
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
take
pulley only of conveyors.
(3) For handling take-up
up weight, a separate manual
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.
14.3
14.3.1 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.
maintenance. Each rope shall have not more than 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
nd it should not be caught between the gear wheel.
14.3.2 Rope drum, gear box, block etc. should be fabricated out of weldable quality steel.
Page 27 of 64
14.3.3 Trolley wheels shall be of single flange type in the taper treads. The wheels shall be mounted
on antifriction
iction bearings and shall be easily removable for repair/replacement.
14.3.4 The load hook shall be swiveling type forged circular shank section and shall confirm to
IS:8610.
points shall be grouped
14.3.5 All gears and bearings shall be lubricated by grease. All lubricating points
together in easily accessible position.
14.3.6 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.
14.3.7 All parts requiring replacement/inspection/lubrication shall be accessible without need for
dismantling of other parts/structures.
14.3.8 All components of hoists of identical capacity and duty shall be interchangeable.
14.3.9 Hoists shall have permanent inscription in English on each side readily recognizable from
floor level stating safe working load.
14.3.10 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.
14.3.11 The control panel shall be wall mounted type & easily approachable from the floor by a
standing man.
14.3.12 For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x 1.5m) with
ladder shall be provided for each hoist.
independent motorised hoist for its handling /
14.3.13 Each inline magnetic separator shall have independent
maintenance purpose. Each suspended magnet shall also be provided with a dedicated
electric hoist.
14.4 DATA SHEET : MONORAILS AND HOISTS
1.0
GENERAL
Functional Requirement : To transfer equipments to maintenance area
a
or outside
1.1
the building.
2.0
2.1.0
2.1.1
2.1.2
DESIGN & CONSTRUCTION REQUIREMENT

Hoists
Drive
More than 2.0 tonne or more than 10.0 m lift or hoists coming out-side
out
the
(i)
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.
Maximum trolley travel speed for electric hoists: 15m/min
Page 28 of 64
2.1.3
2.1.4
2.1.5
2.1.6
Maximum Hoisting speed for electric hoists: 6 m/min

Drive Motors: SQIM, Separate for travel & lift
No. of starts for drive motor: 150 starts/hr at 40% CDF
Wire Rope
(i) Type/Construction: Pre-formed
Pre formed type, hemp cored, regular lay 6/36 construction
(ii) Breaking Strength: 160-175
160
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.
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
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
15.0
15.1
CHUTES AND HOPPERS

GENERAL
Chutes & Hoppers, flap gates and 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.
15.1.1 CODES AND STANDARDS

The design,
gn, 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
editio 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
the required statutory
the Owner/RITES shall be final and binding.
IS:4682 :Code of practice for lining of vessels and equipment for chemical
processes.
IS:226 : Structural Steel (Standard Quality)
IS:11592 : Code of practice for selection and design of Belt Conveyors.

15.2 DESIGN AND CONSTRUCTION
15.2.1 Chutes, Hoppers
15.2.2 The minimum valley angle of chutes shall be 60 degrees from horizontal.
Page 29 of 64
15.2.3 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal without
any accumulation anywhere.
15.2.4 Complete chute work above the drive floor for conveyors provided with In-line
In
belt
magnetic separators shall be of 10 mm thick SS - 304 in the zone of magnetic field.
15.2.5 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
ute 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.
15.2.6 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL or equivalent material.
However, Contractor
ntractor to submit test certificates stating composition of material and
mechanical properties of these wear resistant steel to the Owner during detail engineering.
Long chutes guiding flow from considerable height shall be provided with impact plates
wherever
ever change in direction of flow takes place. Hinged inspection doors (generously sized)
of leak proof construction shall be provided for access/ maintenance purpose, at
approachable heights for chutes and flap gates. All 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.
Maximum distance between two inspection doors in a chute shall be 2 mtrs. For sealing
s
of
inspection doors labyrinth type arrangement (with rubber inserted in grooves) to be
provided. In addition to positive locking arrangement, mounting bolts, to tighten the door
further against rubber shall also be provided.
15.2.7 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
non striking surface i.e. the covers of
o 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
fl
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
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. While
fabricating the chute, the constituent
constituent plates used shall be in one piece. No welds in between
shall be allowed. In the zones of direct impact due to Coal trajectory, wear resistant backing
plate with stiffners shall be provided in coal flow chutes. Similar backing plates & stiffening
arrangement
ement shall also be provided on the chute surfaces having direct coal fall.
Page 30 of 64
15.2.8 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
suit
access to them. Further, serrated rubber seal shall also be provided at the very inlet of head
chute to minimise dust nuisance.
15.2.9 Separate maintenance sealed door shall be provided for access to belt cleaners in head
pulley hood impact plates, flap gates for maintenance and inspection doors shall be of
hinged with positive locking facility.
15.3.
Skirt Boards
15.3.1 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage. Suitable
Skirt Plates of minimum 3.0 meters length shall be provided at each feeding point of
conveyor. The width of the Skirt Boards shall be two-third
two third the conveyor belt width.
width In the
beltswhere coal of appreciable lump size (250 mm) is being conveyed,
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 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
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.
15.4
Flap Gates
15.4.1 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.
15.4.2 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
r
load
and thrust. The equipment shall be shop tested to prove this requirement.
15.4.3 The motor rating for the actuator shall be so selected as to provide sufficient thrust for
operation of the flop gates against the moving weight of coal and/or flap
flap gate. The flap gate
travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight.
15.4.4 Lever arm shall be provided between actuator and flap gate shaft for obtaining required
thrust. The linkage mechanism proposed shall be indicated in the Bid.
15.4.5 The actuators shall be capable of preventing any over travel. Suitable travel dependent limit
switches controlling the travel of the flop gates on either direction shall be furnished. These
Page 31 of 64
shall be placed internal to the drive unit and shall be completely dust-proof.
dust
The limit
switches shall be capable of adjustments to vary the total length of travel of the gates.
15.4.6 Suitable thrust dependent limit switches shall be provided in the actuator, which shall trip
off thee 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.
15.4.7 Provision for alternative manual operation shall also be made
made using declutchable
handwheel. The diameter of handwheel 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.
15.4.8 All the two way chutes, one way of which is leading towards the future conveyor, shall be
provided with blind flange and flap gate with a provision to mount an actuator in future.
15.4.9 The Contractor shall furnish calculations for selection of actuator for each location for
approval of Owner/RITES
/RITES.
15.4.10 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
shall rest on a suitable
projected surface from chute to prevent leakage of coal dust through the available clearance
between chute and flap gate.
15.4.11 Maximum feasible counterweights shall be provided for better utilisation of system.
However, for calculation
lation of thrust required, the benefit of counterweight shall not be taken
into considerations.
15.4.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft.
Suitable provision for re--greasing shall be provided.
15.4.13 For standardisation 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
component wise shall be
completely interchangeable for all locations.
15.4.14 The material of shaft shall be EN-8
EN 8 or equivalent. The diameter of the shaft shall be suitable
for motor stalled condition and associated twisting.
15.4.15 Approach/maintenance platforms complete with the chequered plate floor, hand rails,
ladders etc. shall be provided for all flap gates.
15.4.16 Shaft & flap gate shall be tightly fitted to each other.
Page 32 of 64
15.4.17 On both faces of flap gate main plate, 20mm thick TISCRAL liner plate
plate or equivalent material
shall be provided.
15.5 DATA SHEET : CHUTES AND HOPPERS
1.0
GENERAL
1.1 Coal Parameters As specified elsewhere
2.0 DESIGN & CONSTRUCTION
2.1.0 Chutes & Hoppers
MinimumValley Angle: 60 degrees
2.1.1
2.1.2
Material :
(a) Chute work
Sliding zones & adjacent sides
No striking/ Non sliding zones
Chute with valley angle 80 degree and above
: 20 mm thk. TISCRAL / equivalent

: 10 mm thk MS
: All four sides of 20 mm thk.
TISCRAL/equivalent material
In the zone of magnetic field of ILMS (chute above floor level) : SS-304
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
2.1.3 Size of Chutes
: Minimum 1200mm X 1000mm (inside both ways)
way
2.1.4 Inspection Doors
:Hinged & leak proof construction (min. size 35 x 45 cm)
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
M
(d) Bolts spacing: Not more than 125 mm C/C
(e) Fixing Arrangement: Bolts with plain spring washers
2.2.0 Skirt Boards
: Min. 3 m for each feeding point
2.2.1 Length
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
wit 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.
Page 33 of 64
2.3.4 Manual Operation

(a)
Maximum effort
: Convenient for single
operator by declutchable hand wheel regardless
of electrical power.
Minimum Handwheel : Diameter 500 mm
(b)
2.3.5 Flap gate shaft
(i) Diameter: minimum 130 mm
(ii) Material: EN-8
16.0
16.1
DUST CONTROL AND MISCELLANEOUS SYSTEM

GENERAL
INTENT OF SPECIFICATION
16.1.1 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 Wagon Tippler Package. 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/Owner's and shall coordinate his work
with the work of other Contractors.
16. 1.2 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 etc. Dust
control is achieved by dust suppression system.
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 Owner/RITES
Owner
approved guidelines or any
internationally recognized hygienic Standards/Codes.
Standards/Codes. The Capacity of dust control system
specified elsewhere is for Contractors guidance only. Contractor shall provide adequately
sized fool proof dust control systems the performance of which should be guaranteed by the
Contractor. However, the
he 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. Water scheme dust suppression
shall be provided as indicated in tender drawings. Clarified water shall be used for Service
water system, Plain water dust suppression system shall be used for all receipt and discharge
points in Transfer.
16.1.3 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.
16.2 Scope
16.2.1 Plain Water Dust Suppression System
Complete with water supply system, piping, spray
spray heads, pumps, drive motors with canopy
(wherever required), couplings with enclosure, electricals, supporting structures,
Page 34 of 64
approach/maintenance platforms, handling for equipment, civil and structural works and
necessary accessories shall be provided for WT hopper top & all transfer points, etc.
16.2.2 Sump Pump
4x100% sump pumps alongwith level switches and piping up to nearest Owner's drain (max.
up to 50.0 meters from outside the building) shall be provided at all locations wherever
natural drainage is not possible. Sump pumps along with drain pits shall be provided at other
locations also, if required, during detailed engineering stage. Sealing pumps with valves,
piping fittings and other accessories for sealing of sump pumps shall be provided.
16.2.3 Service Water System
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 equipments, civil and
structural works and necessary accessories shall be provided throughout the coal handling
plant area in Contractors scope.
16.2.4 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,
ints, jointing material etc. as required.
(3) Instrument tapping connections, stubs.
(4) Gate, 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 embedments 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 shall be routed/supported on concrete
pedestal and conveyor galleries. Whereever 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.
(9) Painting, anti-corrosive
corrosive coatings etc. inside and outside pipes
pipes as necessary.
(10) Welding electrodes and welding rods.
(11) The area around storage tanks strainers, two valves etc. (located out side pump house)
shall be paved with drains.
16.3
Terminal Points
Owner shall provide supply of water for dust suppression system, service water, potable
water at one terminal point as elaborated elsewhere. Beyond the terminal point, the
complete pipe work along with associated valves, specialities, instruments, fittings and
Page 35 of 64
supports, pumps, tanks, etc. as required for the satisfactory operation of dust control,
service water & potable water systems shall be furnished by the Contractor.
16.4
Codes and Standards
16.5
The design, manufacture, inspection and testing of Dust Control

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 & 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
required statutory responsibility. In case of any conflict in the
standard and this specification, the decision of the Owner/RITES
Owner
shall be final and binding.
IS:778 : Gun Metal gate, globe & check valves for general purpose.
IS:780 :Sluice valves for water works
work purposes (50 to 300 mm)
IS:1239 : Mild Steel tubes & fittings.
IS:2379 :Colour for the identification of pipe line.
IS:2906 :Sluice valves for water work purposes.
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.
ANSI B 31.1:Code for pressure piping.
Hydraulic institute Standards of U.S.A.
DESIGN REQUIREMENT
Plain Water Dust Suppression
16.5.1 At specified locations dust suppression system shall be provided which comprises spray
nozzles discharging plain water in a fine spray to capture air borne dust particles and direct
them into the main
in coal flow. Water shall be discharged via a pipe work system through
spray heads at the dust suppression zones.
16.5.2 Water shall be drawn from the water storage tank by 2x100% electric motor driven pumps
and discharged into tank from where 2x100% duty
duty electric motor driven pumps shall
discharge the water via a pipe network system through spray heads at the dust suppression
zones. Solenoid valves shall be provided for open/close control of water line to each spray
head. Each spray head shall consist of minimum 4 nos. nozzles. Spray heads shall be
provided at coal loading and receipt zone. Pressure at inlet to spray head shall not be less
than 2.5 Kg/sq.cm(g).
16.5.3 The dust suppression system over the WT hopper shall have a canopy on which fogging
nozzles
zzles are fixed at specified distance. Each nozzle header shall be provided with adequate
number of spray nozzles spaced at 500 mm interval so that the entire length & width of the
wagon tippler hopper are covered by a grid of nozzles. Further, the water spray
s
shall be of
Page 36 of 64
fogging type with a minimum pressure of 2.5 kg/sq.cm(g) at spray nozzle inlet. It should be
possible to operate any number of zones simultaneously. The operation of wagon tippler
dust suppression system shall be automatic so that the fogging
fogging water spray shall get
activated only when the tippling is in operation.
16.5.4 Each spray head shall have a provision for installing a pressure gauge whenever required.
Further, pressure gauges shall be provided at least at two locations.
16.5.5 Sump Pumps
Sump pumps shall be vertical centrifugal type with separate discharge pipe and shall be
capable of developing required head at rated capacity for continuous operation. Sump
pumps shall be suitable for handling coal slurry & sludge. Head capacity
capacity curve of the pump
shall be rising type up to the shut off condition. Sump pumps alongwith level switches &
piping upto nearest Owner's drain (max upto 50.0 mtrs. from outside the building) shall be
provided at all locations wherever natural drainage is not
not possible. Further sump pumps
alongwith drain pits shall be provided at other locations also, if required, during detailed
engineering stage. The capacity of each pump shall not be less than 50 cub. M/hr.
Continuous motor rating (name plate rating) at 50 deg. C. for sump pump shall have at least
10% margin above the maximum load demand of the equipment in the entire operating
range (including run out condition of pumps in case of parallel operation). The maximum
load demand shall include the drive losses in the transmission system. Size of the sump pit
shall not be less than 2.0 meters x 2.0 meters x 2.5 meters. One no. of settling pit, of
adequate size, before the sump pit shall also be provided so that water without heavy coal
particles goes into sump pump
pump pit. High and low level switches shall be provided in the sump
pump pit.
16.5.6 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. 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
distribution system shall be designed considering the water
scheme and water requirement indicated in tender drawings.
16.6
16.6.1 Water Supply Pumps

16.6.1.1 Water supply pumps shall be provided as required.
16.6.1.2
The pumps shall be complete with drive motors, baseplate and other accessories. The
constructional features of the pump shall be as follows:
Page 37 of 64
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
h
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
acking 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
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.
cum
k. Pump speed shall be less than 1500 rpm for pumps of capacity more than 10 cum/hr.
16.6.1.3
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.
16.6.1.4
All rotating parts of the pumps shall be statically and dynamically balanced.
16.6.1.5
The motor shall be rated for continuous

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.
16.6.1.6
Design duty point of pump shall match with the average value of
of maximum and minimum
flow rates of the pump in the stable operation zone.
Page 38 of 64
16.6.1.7
Materials of construction of pump components shall be as stated in data-sheet

data
to this
section.
16.6.2
Sump Pumps
16.6.2.1
The column pipe shall serve as a housing for the line shaft and bearing and support for
bowl (casing). The line shaft bearing shall be supported from the pump column pipe.
Individual sections of column pipe shall be coupled by flanged joints. The flange outside
diameter shall not exceed the bowl outside diameter.
16.6.2.2
Casing shall house the impeller and shall be hydraulically designed to minimize radial
thrust. Further suitable sealing arrangement shall be provided to prevent the leakage of
pumped liquid into the column pipe.
16.6.2.3
The impeller shall be semi open or open (non clogging) as per standard design of the
Manufacturer. All rotating parts including the impeller shall be statically and dynamically
balanced. Impeller shall be securely fastened to the impeller shaft with keys taper
bushings or locknuts and shall be specifically designed to pass large solids or unscreened
liquids. The clearances between stationary and moving part shall be such as to allow
sustained performance without excessive maintenance.
16.6.2.4
ipe should be terminated above the base plate or mounting channel.

The discharge pipe
Type of end connection shall be as specified in data sheets. No support shall be provided
for the bottom elbow (near pump bowl) to facilitate easy removal of line pump from top
without the necessary to go down to the sump for removal of bottom support, if
provided.
The design of the bunt shaft shall also take into consideration the critical speed of the
shall which shall be minimum 20% higher than any operating or run away speed.
Individual sections of the shaft shall be interchangeable.
16.6.2.5
16.6.2.6
16.6.2.7
The type of couplings for the line shaft shall be such to prevent loosening during reserve
rotation.
16.6.2.8
Line shaft bearings shall be water lubricated. Line shaft bearings

bearings shall be spaced not more
than 1.5 meters apart. For lubrication purpose clarified water shall be used.
16.6.2.9
For meeting the sealing/lubricating water requirement, Contractor to provide seal water
pumps (2x100% capacity).
aft sleeves shall be furnished. The shaft sleeve shall be securely locked to
16.6.2.10 Replaceable shaft
shaft to prevent loosening while in operation.
16.6.2.11 Replaceable type wear rings shall be provided for casing and/or impellers wherever
applicable.
16.6.2.12 For the following accessories shall be provided for sump pumps
Page 39 of 64
(i) Base plates together with foundation bolts and nuts. The base plate shall
accommodate the discharge pipe, which is to be terminated above the floor level.
(ii) Motor stool.
return valves and gate valves
valves on pump discharge lines (unless otherwise
(iii) Non-return
specifically excluded).
(iv) Lifting lugs, eye bolts etc.
(v) Pre-lubricating
lubricating tank with accessories (if necessary).
(vi) Sleeves and inserts to be embedded in concrete.
(vii) Coupling guard, if necessary
16.6.2.13 The pump shaft shall be connected to motor shaft by a heavy duty rigid/flexible coupling
or the pump shall be V-belt
V
driven.
16.6.3 PIPING, FITTINGS, VALVES AND SPECIALTIES
16.6.3.1 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 galvanized piping shall be joined by screwed connections.
connections. Minimum pipe
diameter selected for DS/SW/PW/Cooling Water System (along with branch pipes) shall
be 32 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
ports 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.
The type of hangers and components for all piping shall be selected and approval
obtained from the Owner/RITES.
Owner
(f) All piping shall be routed on ground on concrete pedestals and at road crossings, these
shall be laid through hume pipes.
16.6.3.2 Valves and Specialties
(a) Valves & Specialties shall be used to start, stop or regulate the flow. All valves/specialities
below 50 mm size (for isolation purpose) 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.
Page 40 of 64
(c) Gate/sluice valves shall be used for isolation of flow of pipe lines above 50 NB 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.
(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:

i. Hand wheel
ii. Position indicator
pass valve and spur gear reduction
reductio unit for larger valves.
iii. By-pass
iv. 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)
(j)
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.
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 stainless steel
16.6.4 Special cleaning, protection and painting

16.6.4.1 Piping & Fittings
(a) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire
brushing.
p
(b) For over ground 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.
duty bitumastic paint shall be applied on
(c) For steel buried pipeline, three (3) coats of heavy duty
the cleaned surface. Finally, it should be wrapped with minimum 3 mm thick bitumen
Page 41 of 64
impregnated tar felt. The lap joint of the felt shall be generally touched with heavy duty
bitumastic paint.
16.7
DATA SHEET : DUST CONTROL & MISCELLANEOUS SYSTEM

1.0 GENERAL
1.1
1.2
Dust Control: Plain water dust suppression

Miscellaneous systems: Service water system, Potable water system, Cooling water
system & Sump pumps.
2.0
DESIGN REQUIREMENT
2.1
2.1.1
2.1.2
2.1.3
Dust Suppression
ration: Water sprayed through nozzles.
Operation:
Pumps: 2x100% for water
Spray Head
(i) Minimum No. of nozzles per spray head: 4 (Four)
(ii) Pressure at inlet: Minimum 2.5 kg/sq. cm
2.2.0
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
Plain Water Dust Suppression

Pumps: 2x100% electric motor driven
Minimum Pressure at inlet of spray nozzles: 2.5 kg/sq. cm
Nozzle spacing on WT Top: 500 mm
Nozzles: Fogging type
Flow from each nozzle: 2.0 Lpm
2.3.0
Sumps Pumps
(i) Type: 2x100% electric motor driven
(ii) Capacity: 50 cub.m/hr minimum with 10% margin
(iii) Head: 20% margin on computed head
2.3.1
Drain Pits: Minimum 2x2x2.5 mts. and 1 No. settling pit for slurry & high/low level
switches in drain pit.
2.3.2
Piping: To nearest plant drain
2.4.0
2.4.1
ice Water System

Service
Water connections
(a) Conveyor Galleries and tunnels: every 50 m
(b) Transfer points: Min. 1 no. at every floor
2.4.2
Connection details: 1 No. 32 NB globe valve & quick coupling
2.4.3
Hose pipes with hose reel: One in each building of 25 mtr. Length with nozzle
Page 42 of 64
3.0
CONSTRUCTION REQUIREMENTS
3.1
Water Supply Pumps for DS/SW/PW/CW
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
Casing Axial or radially split with drain & vent connection

Impeller One piece, keyed to shaft along with locking device
Shaft Critical speed atleast 20% away from operating speed
Shaft sleeves at bearings & stuffing boxes.
Bearings Antifriction type
Wearing rings Renewable type (preferable)
Pump speed Below 1500 rpm for capacity more than 10 cub. m/hr.
Head flow characteristics Suitable for parallel operation.
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
AISI
hardened.
(g) Gland packing: Impregnated Teflon
3.2.0
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
Sump Pumps
Type: Vertical, centrifugal, single stage,
stage, semi open or open (non clogging) type impeller.
Duty: Intermittent. However, to be designed for contineous operation.
Fluid to be Pumped: Sludge/Coal slurry
Suction Condition: Submerged
Pump speed (maximum): 1000 RPM
Type of coupling between pump and motor: Directly driven through flexible or rigid
coupling/V-Belt
3.2.7 Location of pump thrust bearing: In motor stool
3.2.8 Materials
(a) Casing: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.)
(b) Impeller: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.)
(c) Impeller: Shaft Stainless steel
(d) Line Shaft: EN-8
8 to BS; 970
(e) Column pipe and discharge pipe: Fabricated steel to IS: 226 (min. 6mm thick).
(f) Shaft sleeve: Hardened stainless steel to 400 BHN
(g) Base Plate: Steel to IS: 226 up to 20mm thickness and IS: 2062 over 20mm thickness.
3.2.9 Accessories Provided with the Pump
i. Lubrication and sealing water system: Yes
ii. Common base plate for Pumps and Motor and Motor stool: Yes
iii. Anchor Bolts, nuts, sleeves and inserts (which will be embedded in concrete): Yes
iv. Coupling, guards lifting lug, eye bolt, positioning Dove: Yes
Page 43 of 64
3.3.0 Pipings & Fittings

3.3.1 Joints
(i) Pipe to pipe
Pipe size < 50 NB: Socket welding/screwed Butt
Pipe size > 65 NB: welding
(ii) Pipe to valves
0 NB: Screwed
Pipe size 50
Pipe size 65 NB: Flanged
3.3.2
3.3.3
Isolation of flow: Plug / Gate / Sluice valves

Regulation of flow: Globe Valve
3.3.4 Valves
Size > 65 NB: Bolted bonnet outside screw rising type.
i.
ii.
Size < 50 NB: Union bonnet with screwed ends for Globe valves & screwed
ends for plug valves.
3.3.5 Materials for Pipework
For sizes 200 NB and Larger: ERW carbon steel pipes to API-5LGr.B
API
minimum
thick 6.35 mm or plate fabricated and welded pipes to IS:3589, Class-2.
Class
(b) For sizes 150 NB to 65 NB: ERW carbon steel black pipes to IS:1239 (Part-I,
(Part Heavy
Class).
(Part Heavy
(c) For sizes upto 50 NB: ERW carbon steel galvanized pipes to IS:1239 (Part-I)
class.
(a)
3.3.6
(a)
(b)
(c)
(d)
Materials for Valves & Specialities

Cast Iron Valves: (65 NB & above)
i.
Body and bonnet: Cast Iron to IS:210, Gr.FG-200
ii.
Disc for nonnon return: Cast Iron to IS:210, Gr.FG-200
200 valves
iii.
Seating surfaces and rings: 13% chromium steel
iv.
Hinge pin for non return valves: Stainless steel type AISIAISI-316
v.
Stem for gate and globe valves: 13% chromium steel
vi.
Back seat bush: 13% chromium steel
Gun metal valves (50 NB & below and upto a working pressure of 10 kg/cm2)
(i) Body: Gun metal to IS:318, Gr-2.
Gr
(ii) Trim: Gun metal to IS:318, Gr-2.
Gr
Duplex Strainer
(i) Body: MS fabricated
(ii) Strainer: Stainless steel type element AISI-316
Pressure Gauge/Switch (to be provided with isolating valves, gauge cock, snubber and
syphon)
(i)
Dial size
: 150 mm
(ii)
Accuracy
: (+/-) 1% of range span
Page 44 of 64
(iii)
(iv)
(v)
(vi)
(e)
(f)
Bourdon
Block
Movement
: AISI 316 SS
: AISI 316 SS
: AISI 316 SS
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
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 20 kg/cm2
(v) Protection : Class IP 65
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
SS
(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
(viii)Type of contact : Adjustable throughout the range.
(ix) Protection
: class IP 65
(g)
Level Switch
(i) Type : Displacer operated magnetic type
(ii) Displacer: SS 316
(iii) Wire rope: SS 316
(iii) 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
(h) Level gauges
(i) Type: Float type mechanical gauge with
wit arrow scale
(ii) Accuracy: (+/--) 1% of full scale range
(iii) Material of construction
(a) Float & Guide wire: 316 SS
(b) Elbows: Suitable grade of SS
(c) Housing: Mild Steel
(d) Cable fastener: SS 304
(i) Nozzles
Page 45 of 64
(i) Type: Fogging, non-clogging

non
type
(ii) Material: Stainless Steel
(iii) Nozzle housing : To ensure protection of nozzle against damage.
(j) Y Strainer
(a) Body: SS 304
(b) Plug: SS 304
(c) Filter Element: SS 316, 60 mesh
17.0
VENTILATION SYSTEMS
17.1 GENERAL
17.1.1 INTENT OF SPECIFICATION
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 plant & equipment of
Wagon tippler package.
17.1.1.1 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.
17.2
GENERAL DESCRIPTION
17.2.1 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
ided to supply only clean air into building. Exhaust air shall be discharged at a
suitable height above building. Exhaust fans shall be provided for Toilets, Battery rooms. All
underground structure shall be provided with supply air as well as exhaust air fans.
17.2.2 Pressurised Ventilation System
The pressurised ventilation system having adequate nos. of supply and exhaust air fans with
washable metallic pre filters, HDPE fine filters, and exhaust fans with self closing flaps,
ducting along with 3 phase
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
onsidering 20 air changes per hour to maintain these areas pressurized slightly
above atmospheric pressure to prevent ingress of dust from outside.
17.2.3 Air Conditioning System
Air conditioning system shall be furnished for control room area of Wagon tippler control
building, it shall be designed considering the equipment heat loads, solar heat loads, heat
Page 46 of 64
gain into the room, adequate no. of air changes etc. to maintain a uniform temperature and
relative humidity within the air conditioned areas.
17.3
SCOPE
17.3.1 Mechanical Ventilation System

The ventilation system generally consisting of adequate number of supply and exhaust air
fans, air filters, ducting along with 3 phase AC motor drives, electricals, supporting
structures, approach/maintenance platforms, civil and structural works and necessary
accessories shall be furnished for ventilating the WT hopper, underground portion of
transfer points, underground conveyor tunnels
tunnels and pent houses. Exhaust fans shall be
provided for Toilets & Battery rooms.
17.3.2 Pressurised Mechanical Ventilation System
The ventilation system generally consisting of adequate number of supply and exhaust fans,
metallic pre filters, HDPE fine filters,
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.
17.3.3 Air Conditioning
ioning System
17.3.4 2x100% capacity air conditioning units shall be provided for Wagon Tippler Control Room.
17.3.5 Supply and return air distribution ducting complete with insulation, of resin bonded mineral
wool equivalent of density at least 24 Kg/m
Kg/m and thermal conductivity of max. 0.49
mw/cmC conforming to IS:8183 including supporting structures, approach/ maintenance
platforms, civil and structural works and necessary accessories shall be provided.
provided
17.3.6 Air cooled PAC shall be provided.
17.3.7 Area around centrifugal fans, filters, motor foundation shall be paved to have a clear
surrounding.
17.4
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
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,
ion, the decision of the Owner/RITES
Owner
shall be final and binding.
IS:3588 : Specification for electrical axial flow fans.
Page 47 of 64
IS:2312 :Propeller type AC Ventilation fans

IS:3963 :Specification for roof-extractor
roof
units
IS:4894 :Centrifugal Fans
IS:655 :Specification
ation 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.
surfa
IS:4671:Expanded polystyrene for thermal insulation purpose.
IS:8148 :Packaged Air conditioners.
17.5 DESIGN REQUIREMENT

17.5.1 Roof Ventilators & Accessories
17.5.2 Roof ventilators & accessories shall be provided as required. Impeller shall be axial flow
type.
17.5.3 Design duty point of the fan shall match with the average value of maximum and minimum
flow rates of the fan in stable operation zone.
17.5.4 The speed of the roof ventilators shall not exceed 960 rpm for ventilators with impeller
diameter above 450 mm & 1440 rpm for ventilators with impeller diameter 450 mm and
less. The first critical speed of rotating assembly shall be at least 25% above operating speed.
17.5.5 Motor shall be totally enclosed type suitable for vertical mounting.
mounting. Motors shall comply with
the companion electrical specifications.
17.5.6 Axial Fans
17.5.7 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 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.
low type single piece.
17.5.8 Impellers shall be axial flow
17.5.9 Centrifugal Fans
17.5.10 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.
17.5.11 Fans shall be manufactured vibration free in operation and shall be designed to limit noise
level within limits specified in Data Sheet.
17.5.12 The motor shall be rated for continuous operation and conform to companion electrical
specification. However, motor rating shall not be less than the max.
m
power demand
throughout the entire range of operation of fan.
Page 48 of 64
17.5.13 All fan mountings shall have adequate arrangement for vibration isolation.
non working fan shall be prevented by dampers. The dampers
17.5.14 The reverse flow through non-working
shall be made out of 18 SWG MS sheets.
17.5.15 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
oper
zone.
17.5.16 Filters
17.5.16.1 Metallic Filters
Metallic cleanable filters shall be provided as required. Max. air velocity considered shall be
2 m/sec.
17.5.16.2 HDPE Filters
HDPE filters should have an efficiency of 90% down to 5 microns. Velocity
Velocity across the filter
shall be limited to 2.5 m/sec.
17.5.17 High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99.9% down
to 5 microns. Pr. drop across the filter under clean condition shall not be more than 10 mm
w.c.
Conditioning Unit
17.5.18 Packaged Air-Conditioning
PAC units shall be provided as required.
17.5.19 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.
17.5.20 The PAC unit shall comprise of an evaporator (indoor air) blower section and an air cooled
condenser (outdoor air) section. Heavy gauge steel cabinet factory finished with two coats of
epoxy paint of approved colour, shall be used to house components of PAC.
17.5.21 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
connecting refrigerant circuits shall comprise of multiple cylinder hermetic
compressor(s) and motor(s) with all necessary isolation valves, suction gas controlled
thermal expansion 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
pick
from solar sources.
Page 49 of 64
17.5.22 Condenser capacity control shall be provided by means of variable speed fans and head
pressure sensing.
17.5.23 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
anti vibration mounts. The fan/motor drive shall be capable of
capacity adjustment by pulley changes within +15% of design duty.
17.5.24 High efficiency filters shall be provided
provided in the main supply air duct and in the fresh air
connection to return air duct.
17.6
Construction Requirements
17.6.1 General construction details of various equipment under Contractors scope shall be as
elaborated in subsequent clauses below.
17.6.2 Roof Ventilators and accessories
Roof ventilators and accessories shall be provided as required.
17.6.3 Impeller shall be axial flow type, cast in one piece finished all over and carefully dynamically
balanced after final assembly. All impellers shall consist of high efficiency aerofoil blades.
Impellers shall be mounted directly on the motor shaft.
17.6.4 Casing shall be of heavy gauge construction and shall be properly reinforced for rigidity.
Access door with suitable locking arrangement
arrang
shall be provided.
17.6.5 Hood shall be of hinged type providing easy access to motor and impeller. It will also protect
them from rain and any other contingencies. Weather-proof
Weather proof lockable type disconnect switch
shall be provided such that the hoods can be opened only when the disconnect switch is in
OFF positions. On larger sizes of roof ventilators, hoods shall be of split construction. 15
mm mesh galvanised bird screen shall be provided. The hoods will have low pressure drop
across it.
17.6.6 Suitable
uitable arrangement shall be provided for mounting the roof ventilators such that ingress
of rainwater into the building will be avoided completely.
17.6.7 Axial Flow Fans
Axial flow fans shall be provided as required.
17.6.8 Impellers shall be axial flow
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.
17.6.9
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.
Page 50 of 64
17.6.10 Rain protection cowls will be designed

designed to suit wall exhausters/supply fans for protecting
fans/motors from rain. It will be provided with bird screen.
17.6.11 Inlet cone or bell and outlet cone shall be provided as required. It should be made of G.I. or
M.S.
otally enclosed type complying with the companion electrical
17.6.12 Motor shall be of totally
specification. Suitable rain/sun shade for motors shall also be provided.
17.6.13 Centrifugal Fan
Centrifugal fans shall be provided as required.
17.6.14 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.
17.6.15 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
ve 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.
17.6.16 The bearings shall be self-aligning
self
heavy-duty
duty ball or roller bearings. They shall be
adequately supported. They shall be easily accessible and lubricated properly from outside.
17.6.17 Filters
17.6.18 Metallic Filters
allic cleanable filters shall consist of V-fold
V fold galvanised wire mesh inter spaced with a flat
Metallic
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.
17.6.19 HDPE Filters
all be provided as required. This shall be constructed of HDPE fabric with
HDPE filters shall
continuous water spraying on it from a header for keeping it clean.
17.6.20 High efficiency filter (for A/C purpose)
Page 51 of 64
The media of the filter shall be made from either special synthetic non-woven
non
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.
17.6.21 Package A/C Unit
.22 A separate cubicle shall be provided within the overall casing to house the thermostatic
17.6.22
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 shall be provided for wall mounting. The casing shall be fitted with all necessary
coil drains and service connections/
entries.
17.. 6.23 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
prewir to unit mounted
control/power terminal boxes.
17.6.24 Ventilation and Air Conditioning system ducting
17.6.25 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 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/cm2.
17.7
DATA SHEET : VENTILATION SYSTEM

1.0
GENERAL
1.1.0
1.1.1
Mech. Ventilation System: To provide ventilation using fans for specified areas.
No. of air changes per hour
(a) For overground building: Not less than 10 supply air changes & 7 Exhaust air
changes
(b) For underground areas: Not less than 15 supply air changes & 7 Exhaust 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
ventilation system: To provide clean air to all MCC / Switchgear buildings
1.2.1 No. of air changes per hour: Not less than 20
Page 52 of 64
1.2.2 Equipment: Centrifugal fans/Axial Fans and exhaust air fan

conditioning system As specified
1.3.0 Air-conditioning
1.3.1 Temperature to be maintained
: 24 1 deg. C
1.3.2 Humidity to be maintained
: 50 5% relative humidity
1.3.3 Fresh Air intake
: More than 1.5 air changes per hour.
1.3.4 Equipment: 2 x 100 % roof mounted package AC units along with ducting etc.
and window AC
1.4.0 Outside Ambient Conditions
(i) Summer: As per weather data given in project synopsis.
(ii) Monsoon: - Do
(iii) Winter: - Do
2.0.0 DESIGN & CONSTRUCTION
2.1.0 Roof Ventilators
2.1.1 Capacity: 10% more of actual requirement
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
2.2.1 Capacity: 10% more of actual requirement
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
2.3.1 Capacity: 10% more of actual
actu requirement
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
Conditioning Unit
2.4.0 Packaged Air-Conditioning
2.4.1 Type: Roof top mounting
2.4.2 Service/application: Continuous, round the clock.
2.4.3 Capacity
(i) TR: Suitable
(ii) CFM: Suitable
2.4.4 Type of compressor: Multiple cylinder hermetic compressor.
Page 53 of 64
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: 99.9% down to 5 microns.
(2) Pr. drop across: 10 mm W.C.
(3) Testing: As per BS 2831 / Sqv.
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
18.0 DESIGN OF CONVEYOR GALLERIES AND JUNCTION HOUSES
18.1 Design Considerations
11592
a) The general parameters for conveyor galleries shall conform to the provision of IS : 115921985 unless specified otherwise in Technical Specifications. The structures shall be designed
so as to meet functional requirements
requirements and shall provide space for operation, maintenance
and removal of machinery and give the workers good and safe environment.
b) Gallery floors shall be of chequered plates supported on steel beams.
mm along the walkways if the gallery
c) Steps shall be provided with (rise not exceeding 130 mm
slope exceeds 12.. In case the slope of gallery is between 6
6 to 12,, suitable ribs (without any
sharp edges) shall be provided on floor at 250 to 300 mm intervals.
d) Roof and side walls of conveyor galleries shall be covered with Aluminium industrial
troughed sheets.. with a provision of gap of 300 mm below roof and 150 mm from top of
floor level on the side wall for ventilation.
inside conveyor gallery shall be made through side walls
e) Adequate provision for natural light inside
by providing translucent sheets (FRP sheets as per IS: 12866-1989).
12866 1989). Every sixth sheet on side
wall shall be FRP sheet and shall be staggered on opposite wall.
Page 54 of 64
b 1:5 (1 vertical, 5 Horizontal).

f) Roof slopes of conveyor galleries shall be
g) The level of underside of the base plate of gallery supporting trestles shall be 300 mm above
the average ground level of the surrounding area.
platf
stairways,
h) Protective hand railing shall be provided along gallery walkways, open platform,
landings, edges of walkways when the gallery is not enclosed, and around erection openings,
if any, to ensure safety of operating personnel.
i) Conveyor galleries longer than 150 m shall be provided with expansion joints with twin
trestles/supports.
pports. Each expansion block shall have fixed support/rigid trestle with adequate
arrangement (provision of top chord and bottom chord bracing to gallery girder etc.) for
transferring the transverse and longitudinal forces to the foundation.
rs near junction house shall be preferably supported on trestle located as close
j) Gallery girders
to the junction house as possible, with part of gallery girder between junction house and
trestle cantilevered from the trestle. Supporting gallery girders on junction house shall
s
be
generally avoided.
k) The underside of the belt conveyor shall be fully covered with 3 mm sheet in case of
conveyors located within the boundaries of the plant area. including the gallery crossing the
roads / railway lines / areas of public gatherings.
gathering
l) When conveyor gallery crosses above or below H.T cables, a minimum clear distance of 1.0
m between the structural elements/cladding and HT cables shall be maintained.
m) When the conveyor bridge passes over plant roads, clearance between the road surface and
the lowest points of the bridges shall not be less than 8.0 m or the height needed for the
passage of the largest individual components of the plant equipment, whichever is the
larger.
n) The junction house shall be designed to suit the functional requirement. Number of floors,
height of building etc. shall be decided accordingly.
o) In general the junction house shall be designed as framed structures on shorter span side
and vertically braced on longer side to achieve stability.
ouses shall be of RCC slab / Chequered plate supported on steel beams,
p) Floor of junction houses
unless required otherwise from technological suitable lugs.
q) Roof and side covering of junction houses shall be with Aluminium industrial troughed
sheets as specified. Roof slope shall be 1: 5 ( 1 Vertical : 5 Horizontal).
Page 55 of 64
r) Suitable access staircase with safety hand railing shall be provided to all floors of junction
houses.
s) Wall sheeting shall generally start from the lowest working floor and extend up to roof level
with louvers at each
h floor level to ensure adequate natural ventilation.
t) Monorails for maintenance hoists shall be provided for maintenance and repair of various
equipments located on the floors.
18.2 Components of structures
a) Gallery Trusses and Roof
Gallery truss shall be of latticed type construction. The trusses shall be adequately braced at
top and bottom chord level to transfer the horizontal wind forces to end portals.
b) Stringer Beam
These beams shall be suitably spaced to support the conveyor stringer supports and shall
transfer load to gallery. Walkways on either side of the conveyor shall also be supported on
these stringer beams.
c) Supporting Trestles
Intermediate trestles shall be two legged and shall deliver loads from gallery trusses to the
foundations. In addition, four legged trestles shall be provided which will act as fixed support
to transmit all longitudinal forces between expansion block, in addition to other forces.
d) Junction Houses
layout as well as equipment
i) Floors - Floor beam layout shall be arranged to suit equipment layout
anchoring system.
ii) Columns - In addition to loads from floor and roof, columns shall be designed to transmit
horizontal load due to belt tension/snapping of belts to the foundation.
e) Belt Tensioning Device
belt tensioning device which may be
Suitable structures shall be provided to accommodate belt-tensioning
located either under the conveyor gallery or in the junction house itself.
f)
(i)
(ii)
Wall Structures
Wall runners with necessary sag rods shall be provided to support wall sheeting in
conveyor galleries and junction houses.
Walls shall be provided with louvers and translucent sheeting at appropriate levels,
to provide natural ventilation and lighting.
g) Access stairs, walkways, platforms, ladders, hand railing etc.

Page 56 of 64
(i) Wherever possible, access shall be provided by means of stairs.

(ii) All walkways and stairs leading to working platforms shall have minimum 800 mm width
of walkways/flight of stair.
(iii) All other walkways and stairs leading to areas for maintenance purpose, or due to
restriction
iction of space, shall have a minimum width of 800 mm of walkway/flight of stair,
unless required otherwise.
(iv) Staircases shall be generally designed with slope of approximate 37.5
37.5 with the
horizontal. (In no case the slope shall exceed 40 with the horizontal).
horizo
Intermediate
landings shall be provided wherever required such that vertical rise of each flight does
not exceed 3000mm. Risers in one flight shall be equally spaced.
(v) Walkway floors and stair treads shall be designed with chequered plate (or non-slip
non
type plates). Ribbed floor/treads may be provided wherever the possibility of
accumulation of dust exists, taking care that such provisions do not crate a nuisance to
the operating personnel on the shop floor.
(vi) Rise of treads in staircases shall not exceed
excee 200 mm.
(vii) A minimum headroom of 2200 mm shall be provided over operating platforms, visitor's
galleries, or other areas with possibility of public gathering. In all other platforms,
walkways and stairs, minimum headroom of 2000 mm shall be provided. Only in
i special
cases, local headroom of 1800 mm may be allowed (i.e. at intersection with structural
members etc.).
(viii) Cat ladders shall be provided for access, wherever provision of staircase is impractical
due to limitations of space, or the access is required very
very infrequently.
(ix) Wherever the height of cat ladder exceeds 4.0 m, safety cage shall be provided.
Intermediate landing shall be provided to cat ladders such that vertical height of single
rise does not exceed 8.0 m.
(x) Cat ladders shall be designed with following
follo
provisions:
i.
Width of rung = 500 mm
ii.
Minimum rise of rung = 250 mm; Maximum rise of rung = 300 mm
iii.
Minimum clearance from rung of ladder to back of cage (in case of caged
ladders) = 700 mm
iv.
Minimum clearance from the centre of cage all round = 350 mm
v.
Slope of cat--ladders:
I. For normal cat-ladders,
cat ladders, slope shall be within the range of 75-90
75
with the
horizontal.
type ladders (i.e cat-ladders
cat ladders with short side handrails) the slope shall be
II. For ship-type
within the range of 65-75
65
with the horizontal.
(xi) All walkways, platforms and stairs shall be provided with safety handrails. All handrails
shall be constructed with steel tubes / angles for posts, top and middle rail and
plates/sheets for toe plates. In case of stairs, the toe guards need not be provided.
(xii) The
he vertical height of hand-railings
hand railings on walkways and stairs shall be minimum 1000 mm
above floor level.
railing along edge of roof and gutters shall have a minimum height of 600 mm
(xiii) Hand-railing
over top edge of gutters/sheets. In such hand railings toe guards need not be provided.
(Only top handrail and midrail shall be provided).
Page 57 of 64
18.3
ADDITIONAL DESIGN CRITERIA

a)
Design of steel structures shall be done in accordance with IS:800-1984.

IS:800 1984.
b)
In absence of specified dynamic factor to be considered for the load from the belt
conveyor, a dynamic factor of not less than 1.3 shall be considered for the design of
floor beams and gallery girders.
Gallery trusses and stringers as well as floor beams
beams of junction house shall be checked
for obviating occurrence of resonance and shall be designed such that the ratio of
applied frequency to natural frequency shall not lie within the range 0.7 to 1.5.
c)
d)
As far as possible gallery structure shall be made

made independent of junction houses. A
trestle shall be planned close to the junction house to avoid gallery span resting on the
junction house.
e)
The contractor after the award of work shall submit design criteria to owner /
consultant for approval before
befo submission of design drawings.
f)
The design drawings shall be submitted in complete for a unit along with design
calculations both in hard copy and soft copy. Design shall be done using STAAD.
g) The effective ratio of utility of all main sections shall be limited to 0.85
h) Structural schematic general arrangement with plans at various levels, elevations along
each row and axes, sections, considered loads and load diagrams with location etc. and
Structural design drawings with BOQ and Table of members
members containing design forces shall
be submitted for Owners/Consultants approval. However the approval shall be limited
to checking of overall dimensions, general stability of system, effective load transfer and
deflection limits etc. The approval shall not relieve the contractor of his responsibility of
correctness in design, adequacy of connections, accuracy etc.
i) Submission of Stability certificate for all the steel structures is under the scope of the
contractor.
18.4
Description of loads and loading codes

a)
b)
c)
d)
e)
Unless specified otherwise hereinafter, all the live loads shall be considered in
accordance with IS: 875 (Part-2)
(Part -1987.
Wind loads shall be considered in accordance with IS: 875 (Part-3)-1987.
(Part 1987.
Seismic loads shall be considered in accordance
accordance with IS:1893(part1)-2002
IS:1893(part1)
and
1893(part 4)-2005
Live loads from conveyor on the gallery floor shall be as per conveyor suppliers load
data.
While designing the fixed support/rigid trestles in an expansion block of conveyor
gallery the following loads (in addition to wind load) shall be considered.
Page 58 of 64
(i) Forces due to difference in frictional resistance of top and return idle rollers of
conveyor.
(ii) Forces due to inertia of rollers at the time of starting of conveyor belt.
(iii) Break down load caused by snapping of belt
belt (in case of multiple conveyors,
snapping of one belt at a time) shall be considered.
(iv) Special loads if any
f)
Gallery girders and floor shall be designed for the following live loads,inclusive of
spillage loads on floors.
i) Walkway/Supporting beams for floor - 4.0 KN/m
ii Under the conveyor belt - 0.75 KN/m
iii) Gallery girder, for floor load of - 3.0 KN/m
g)
Dust load on roof of junction house and conveyor galleries shall be considered as
follows:
i. For building and structures located at a distance of 300m from the dust
producing units - 0.5 KN/m
ii. At a distance of 300 m to 800 m from the dust producing unit - 0.25 KN/m
As per technological requirements, provision of supporting the following, and load
arising thereof shall be considered in the design of conveyor gallery.
i) Ventilation duct.
ii) Electrical cables/cable racks.
iii) Fire Fighting equipment.
Junction house floors shall be designed for the following loads:
i) Live load on floor - 5.0 KN/m
ii) Tension from conveyor belt
ii) Load duee to equipment located on floor.
iv) Load due to jamming of chutes.
v) Erection loads anywhere on the floor.
h)
i)
18.5
j)
Combination of loads
The various loads specified shall be combined in accordance with clause 8.0 of IS: 875
(Part-5)-1987
1987 to give the most severe loading condition for design of structures.
k)
Stress enhancements
Permissible limits of stress may be increased, wherever permissible, in accordance with
IS:800-1984.
Limiting deflection
a.
b.
The deflection shall be limited in various elements of structures in accordance with

clause 3.13 IS: 800-1984.
1984.
In addition following limitation in deflection shall be observed in design:
Page 59 of 64
i)
ii)
iii)
18.6
Gallery Trusses
Top of End portal of gallery truss
Traverse deflection of top of Trestle
Span / 400
H / 325 where H =Height of portal above beams
H/1000 where H = Height of trestle above foundation
FABRICATION OF STEEL STRUCTURES
18.6.1 Drawings
The Contractor shall prepare fabrication drawings, erection drawings, bill of materials,
drawing office despatch lists / shipping documents, schedule of bolts and nuts and as built
drawings. All drawing work shall be in metric system and all writing work shall be in English.
The work shall be carried out as described in General Technical Specifications for structural
s
works.
18.6.2 Material of Construction
18.6.2.1All steel and other materials used for steelwork and in association with steelwork shall
conform to appropriate Indian standards. Only tested materials shall be used unless written
authority is obtained for the use of untested materials for certain secondary structural
members.
Unless otherwise specified in the drawings
i.
All rolled sections and plates upto 20 mm thk. Shall conform to Grade-E250
Grade
& quality
A of IS: 2062-2006
2006 and shall generally be of tested quality.
ii.
Plates above 20 mm thk. and plated structures subjected to dynamic loading shall
conform to Grade-E
Grade 250 & quality B as per IS: 2062-2006.
iii.
For High Tensile steel requirements, material conforming to IS: 8500 or SAILSAIL MA
(HYA or HYB) shall be used.
18.6.2.2
Steel sheets shall conform to IS: 1079.
18.6.2.3
18.6.2.4
18.6.2.7
18.6.2.8
Steel tubes for structural purpose shall conform to IS: 1161 (of Grade Yst 240)
Corrugated Galvanised Sheets shall conform to IS: 277 with appropriate Zinc coating for
the selected thickness of sheet on roof and sides. (1.0mm thk for roof and 0.8mm thk for
sides)
Aluminium industrial troughed sheets conforming to IS: 1254 shall be used as follows:
i) On roof - 0.91mm thick ii) On side walls - 0.71mm thick
Translucent sheets shall be fibre glass reinforced polyester sheets of matching profile as
per IS: 12866.
Colour coated sheets shall be as per appropriate standard.
Gutters shall be of copper bearing steel conforming to Grade "A" as per IS:2062.
18.6.2.9
Rails shall conform to IS: 3443.
18.6.2.5
18.6.2.6
18.6.2.10 All black bolts, nuts and locknuts shall conform to IS: 1363 and IS: 1364 (for precision and
semi precision hexagonal bolts) of property class 6.4unless otherwise specified. Washers
shall conform to IS: 6610
Page 60 of 64
18.6.2.11 All tapered washer shall be as per IS: 5372

5372 for channels, and IS: 5374 for Joists. Spring
washers shall conform to IS: 3063.
18.6.2.12 All HSFG bolts shall conform to IS: 3757. Assembly of joints using HSFG bolts shall
conform to IS: 4000. Nuts and washers for HSFG bolts shall be as per IS: 6623
66 & IS:6649
respectively.
IS:814 2004. Electrode to be used
18.6.2.13 Covered electrodes for arc welding shall conform to IS:8142004.
for submerged arc welding shall conform specification IS: 7280-1974. Alternatively
Covered electrodes for arc welding shall confirm to AWS Specifications and shall be as
follows.
- E 6013 for all fillet welds of IS 2062 steel dr E250 , quality A & B
- E 7018 for all fillet welds of SAIL-MA
SAIL
350 HYA steel
- E 7018 for all but welds including site welds irrespective of the quality of steel.Viz.
ste
IS
2062 gr E250 , quality A , B or SAILMA-350
SAILMA
HYA steel.
18.6.2.14 Certified mill test reports of materials used in the work shall be made available for
inspection by the Owner / Consultant upon request.
18.6.3 Fabrication
18.6.3.1 Fabrication of all structural steelwork shall be in accordance with IS:800 or their equivalent
foreign national standard of the country of origin of supply unless otherwise specified, and
in conformity with various clauses of the Technical Specification.
herever practicable and wherever perfect matching of parts is required at site, members
18.6.3.2 Wherever
shall be shop assembled before despatch to minimise site work. Parts not completely
assembled in the shop shall be secured, to the extent possible, to prevent damage during
du
despatch.
18.6.3.3 ERECTION OF STEEL STRUCTURES
18.6.3.3.1 Scope
The scope of work under erection includes in addition to provision of erection and transport
equipments, tools and tackles, consumables, materials, labour and supervision, the
following:
a) Storing and stacking at site of erection of all fabricated structural components/
units/assemblies till the time of erection.
b) Transportation of structures at site.
c) Receiving at site of structures including site handling /movement, unloading, storing and
stacking at site of erection of technological structures such as bunkers and the related
structures
d) All minor rectification / modification such as :
Page 61 of 64
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
i) Removal of bends, kinks, twists, etc. for parts damaged during transportation and
handling;
ii) Cutting chipping, filing, grinding, etc., if required, for preparation and finishing of site
connections;
iii) Reaming for use of next higher size bolt for holes which do not register or which are
damaged.
iv) Welding of connections in place of bolting
bolting for which holes are either not drilled at all or
wrongly drilled during fabrication.
Other rectification work such as
i) Re-fabrication
fabrication of parts, damaged beyond repair during transportation and handling or
incorrectly fabricated.
ii) Fabrication of partss omitted during fabrication by oversight or subsequently found
necessary.
drilling of holes which do not register and which cannot be reamed
iii) Plug-welding and re-drilling
for use of next higher size bolt.
Fabrication of minor items/missing items or such important
important items as directed by the Owner /
Consultant.
Assembly at site of steel structural components wherever required including temporary
supports and staging.
Making arrangements for and providing all facilities for conducting ultrasonic X-ray
X
or
gamma ray tests on welds; getting the tests conducted by reputed testing laboratories,
making available test films/ graphs,reports and interpretation.
Rectifying at site, damaged portions of shop primer by cleaning and touchup paint.
Erection of structures including making connections by bolts/high strength friction grip bolts
/ welding.
Alignment of all structures true to line, level plumb and dimensions within specified limits of
tolerances as per IS :12843 Tolerance for Erection of Steel Structures.
Application of second coat of primer paint and two coats of finishing paint at site after
erection.
Grouting of all column bases after proper alignment of columns and only after obtaining
clearance from Owner / Consultant.
Conducting preliminary acceptance and final acceptance
a
tests.
Preparation of as built drawings, preparing of sketches/drawings to suit
field engineering decisions, availability of material, convenience of fabrication,
transportation and erection and changes during fabrication and erection.
All such works are subject to approval by the Owner / Consultant.
18.6.4 PAINTING OF BUILDING STEEL STRUCTURES

18.6.4.1All steel structural work shall be painted as follows unless otherwise stated in the drawing /
Technical Specification.
Page 62 of 64
18.6.4.2 Surface preparation

The steel surface which is to be painted shall be cleaned of dirt and grease, and the heavier
layers of rust shall be removed by chipping prior to actual surface preparation to a specified
grade.
Following are the type and standards of surface preparation to be followed based on the
requirement of a particular painting system or as specified in the design drawings.
Manual/Power tool cleaning :: Manual/Power tool cleaning shall be done as per Grade St-2
St or
St-3
3 of Swedish Standard Institution
Institution SIS 05 5900 or cl.6.2.1.1 & 6.2.1.2 of IS : 1477 - 1987 (Part
- 1).
Grade St-2 :- Thorough scraping and wire brushing, machine brushing, grinding etc. This grade
of preparation shall remove loose mill scale, rust cleaner or with clean compressed air or clean
brush. After preparation, the surface should have a faint metallic sheen. The appearance shall
correspond to the prints designated St-2.
St 2. If no grade of surface preparation is specified, St-2
St
grade of preparation as per Swedish Standard shall be followed.
18.6.4.3 Paint System
(i) Surface preparation :: St-2
(ii) Primer paint:- Two coats of zinc phosphate in phenolic alkyd medium
(35microns/coat).
(iii) Finishing paint:- Two coats of synthetic enamel (25 microns/coat) conforming to IS :
2932 - 1974.
All paints shall be of approved and shade as per Purchaser / Consultant's requirements.
18.6.4.4 Paint and Painting
Manufacture of paints, mixing of paints, etc. shall be generally according to the relevant IS
codes of practice.
Generally compatibility between primer intermediate and finishing paint shall be certified by
the paint manufacturer supplying the paints.
Guarantee period shall commerce from the date of completion of finishing coat of paint on
entire structures. The guarantee period shall be indicated depending on the type of surface
preparation and system of painting. To fulfill this obligations, the Contractor may obtain
from the painting manufacturer, guarantee for the performance of paint/painted surfaces.
Application of paint shall be by spraying or brushing as per IS : 486-1983
1983 and IS : 487-1985
487
and in uniform layers of 50% overlapping strokes by skilled painters. Painting shall not be
done when the temperature is less than 5 degree C or more than 45 degree C and relative
humidity is more than 85%
85% unless manufacturer's recommendations permit. Also painting
Page 63 of 64
shall not be done in foggy weather. During application, paint agitation must be provided
where such agitation is recommended by the manufacturer.
Painting shall be applied at painting manufacturer's
manufacturer's recommended rates. The number of
coats shall be such that minimum dry film thickness specified is achieved. The dry film
thickness (DFT) of painted surfaces shall be checked with ELCOMETER or measuring gauges
to ensure specified DFT.
All structures shall receive one coats of primer paint at shop after fabrication before
despatch after surface preparation has been done as per requirements.
Unless otherwise specified all structures after erection shall be given one coat of primer and
two coats of finishing
shing paint of approved colour and quality. The under coat shall have
different tint to distinguish the same from the finishing coat.
The proposed make, quality and shade of paint shall have the approval of Purchaser /
Consultant.
Page 64 of 64
SECTION 5
1.0
INTRODUCTION
This part covers technical requirements which will form an integral part of the Contract. The
following provisions shall supplement all the detailed technical requirements brought out in
the Technical Specifications and the Technical Data Sheets.
2.0
BRAND NAME
Whenever a material or article is specified or described by the name of a particular brand,
b
manufacturer or vendor, the specific item mentioned shall be understood to be indicative of
the function and quality desired, and not restrictive; other manufacturer's products may be
considered provided sufficient information is furnished to enable the Employer to determine
that the products proposed are equivalent to those named.
3.0
COMPLETENESS OF FACILITIES
3.1
Contractors may note that this is a contract inclusive of the scope as indicated elsewhere in
the specification. Each of the plant shall
shall be engineered and designed in accordance with the
specification requirement. All engineering and associated services are required to ensure
that a completely engineered plant is provided.
3.2
All equipments furnished by the Contractor shall be complete in every respect, with all
mountings, fittings, fixtures and standard accessories normally provided with such
equipment and/or those needed for erection, completion and safe operation & maintenance
maintenan
of the equipment and for the safety of the operating personnel, as required by applicable
codes, though they may not have been specifically detailed in the respective specifications,
unless included in the list of exclusions. All similar standard components/
components/ parts of similar
standard equipment provided, shall be interchangeable with one another.
4.0
CODES & STANDARDS
4.1
In addition to the codes and standards specifically mentioned in the relevant technical
specifications for the equipment / plant / system,
system, all equipment parts, systems and works
covered under this specification shall comply with all currently applicable statutory
regulations and safety codes, including the following:
a. Bureau of Indian Standards (BIS)
b. Indian electricity act
c. Indian electricity
city rules
d. Indian Explosives Act
e. Indian Factories Act and State Factories Act
f. Indian Boiler Regulations (IBR)
g. Regulations of the Central Pollution Control Board, India
h. Regulations of the Ministry of Environment & Forest (MoEF), Government of India
Technical Specifications: Sec-5,General Techn

chnical Requirements
Page 1 of 27
i. Pollution
n Control Regulations of Department of Environment, Government of India
j. State Pollution Control Board.
k. Rules for Electrical installation by Tariff Advisory Committee (TAC).
l. Guideline for wagon tippler G33 Rev.01 of May 2010.
m. Any other statutory codes / standards / regulations, as may be applicable.
4.2
Unless covered otherwise by Indian codes & standards and in case nothing to the contrary is
specifically mentioned elsewhere in the specifications, the latest editions (as applicable as
on date of bid opening),
pening), of the codes and standards given below shall also apply:
(a.) Japanese Industrial Standards (JIS)
(b.) American National Standards Institute (ANSI)
(c.) American Society of Testing and Materials (ASTM)
(d.) American Society of Mechanical Engineers (ASME)
(e.) American Petroleum Institute (API)
(f.) Standards of the Hydraulic Institute, U.S.A.
(g.) International Organisation for Standardization (ISO)
(h.) Tubular Exchanger Manufacturer's Association (TEMA)
(i.) American Welding Society (AWS)
(j.) National Electrical Manufacturers Association (NEMA)
(k.) National Fire Protection Association (NFPA)
(l.) International Electro-Technical
Electro
Commission (IEC)
(m.) Expansion Joint Manufacturers Association (EJMA)
(n.) Heat Exchange Institute (HEI)
4.3
In thee event of any conflict between the codes and standards referred to in the above
clauses and the requirement of this specification, the requirement of Technical Specification
shall govern.
4.4
In case of any change in codes, standards & regulations between

between the date of bid opening and
the date when vendors proceed with fabrication, the Employer shall have the option to
incorporate the changed requirements or to retain the original standard. It shall be the
responsibility of the Contractor to bring to the notice
notice of the Employer such changes and
advise Employer of the resulting effect.
4.5
EQUIPMENT FUNCTIONAL GUARANTEE

The functional guarantees of the equipment and the system under the scope of the Contract
is given elsewhere in the technical specification. These guarantees shall supplement the
general provisions covered under General Conditions of Contract.
4.6
DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY CONSIDERATIONS
4.6.1
Design of Facilities
All thee design procedures, systems and components proposed shall have already been
adequately developed and shall have demonstrated good reliability under similar conditions
elsewhere. The Contractor shall be responsible for the selection and design of appropriate
appropria

Page 2 of 27
equipments to provide the best co-ordinated

co ordinated performance of the entire system. The basic
requirements are detailed out in various clauses of the Technical Specifications. The design
of various components, assemblies and subassemblies shall be done so that
tha it facilitates easy
field assembly and dismantling. All the rotating components shall be so selected that the
natural frequency of the complete unit is not critical or close to the operating range of the
unit.
4.7
DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED

FURNISHED BY CONTRACTOR
4.7.1
Contractors may note that this is a contract inclusive of the scope as indicated elsewhere in
the specification. Each of the plant and equipment shall be fully integrated, engineered and
designed to perform in accordance with the technical specification. All engineering and
technical services required ensuring a completely engineered plant shall be provided in
respect of mechanical, electrical, control & instrumentation, civil & structural works as per
the scope. The Contractor shall
shall furnish engineering data/drgs. in accordance with the
schedule of information as specified in Technical Specification and data sheet.
4.7.2
The number of copies/prints/CD-ROMs/manuals

copies/prints/CD ROMs/manuals to be furnished for various types of
documents is given in Section 5.. Distribution schedule shall be informed to successful
Contractor.
4.7.3
The documentation that shall be provided by the Contractor is indicated in the various
sections of specification. This documentation shall include but not be limited to the
following :
4.8
INSTRUCTION MANUALS
The Contractor shall submit to the Employer, Instruction Manuals for all the equipments
covered under the Contract. The Instruction manuals shall contain full details required for
erection, commissioning, operation and maintenance of each equipment. The manual
ma
shall
be specifically compiled for this project. The Instruction Manuals shall comprise of the
following.
4.8.1
Erection Manuals
The erection manuals shall be submitted prior to the commencement of erection activities
of particular equipment/system.
equipment/system. The erection manual should contain the following as a
minimum.
a) Erection strategy.
b) Sequence of erection.
c) Erection instructions.
d) Critical checks and permissible deviation/tolerances.
e) List of tool, tackles, heavy equipments like cranes, dozers, etc.
f) Bill of Materials
g) Procedure for erection.
h) General safety procedures to followed during erection/installation.

Page 3 of 27
i) Procedure for initial checking after erection.

j) Procedure for testing and acceptance norms.
k) Procedure / Check list for
f pre-commissioning activities.
l) Procedure / Check list for commissioning of the system.
m) Safety precautions to be followed in electrical supply distribution during erection
4.8.2
Operation & Maintenance Manuals

i. The operating and maintenance instructions
instructions together with drawings (other than shop
drawings) of the equipment, as completed, shall be in sufficient detail to enable the
Employer to operate, maintain, dismantle, reassemble and adjust all parts of the
equipment. They shall give a step by step
step procedure for all operations likely to be carried
out during the life of the plant / equipment including, operation, maintenance,
dismantling and repair including periodical activities wherever required. Each manual
shall also include a complete set of drawings of the equipment.
ii. If after the commissioning and initial operation of the plant, the manuals require any
modification / additions / changes, the same shall be incorporated and the updated final
instruction manuals shall be submitted to the Employer
Emp
for records.
iii. A separate section of the manual shall be for each size/ type of equipment and shall
contain a detailed description of construction and operation, together with all relevant
pamphlets and drawings.
iv. The manuals shall include the following:
a) List of spare parts along with their drawing and catalogues and procedure for
ordering spares.
b) Lubrication Schedule including charts showing lubrication checking, testing and
replacement procedure to be carried daily, weekly, monthly & at longer intervals to
ensure trouble free operation.
c) Where applicable, fault location charts shall be included to facilitate finding the
cause of mal-operation
operation or break down.
v. Detailed specifications for all the consumables including lubricant oils, greases, chemicals
che
etc. system/equipment/assembly/subassembly - wise required for the complete plant.
vi. On completion of erection, a complete list of bearings / equipment giving their location,
and identification marks etc. shall also be furnished to the Employer indicating lubrication
method for each type/category of bearing.
4.8.3
Project Completion Report

The Contractor shall submit a Project Completion Report at the time of handing over the
plant.
4.8.4
DRAWINGS
(a.) All documents submitted by the Contractor for Employer's review shall be in electronic
form (soft copies) along with the number of hard copies. The soft copies to be supplied
shall be either in CDs, or through direct transfer via E-mail,
E mail, etc. depending upon the
nature/volume/size of the document. The drawings submitted for approval could be in
the Image form.

Page 4 of 27
(b.) Final copies of the approved drawings shall be submitted in vector form on CDROM
along with the requisite number of hard copies.
(c.) All documents/text information shall be in latest version of MS Office.
(d.) All drawings submitted by the Contractor including those submitted at the time of bid
shall be in sufficient detail indicating the type, size, arrangement, weight of each
component for packing and shipment, the external connection, fixing arrangement
arrangeme
required, the dimensions required for installation and interconnections with other
equipments and materials, clearance and spaces required between various portions of
equipment and any other information specifically requested in the drawing schedules.
(e.) Each
ach drawing submitted by the Contractor (including those of sub-vendors)
sub vendors) shall bear a
title block at the right hand bottom corner with clear mention of the name of the
Employer, the system designation, the specifications title, the specification number, the
th
name of the Project, drawing number and revisions. If standard catalogue pages are
submitted the applicable items shall be indicated therein. All titles, notings, markings
and writings on the drawing shall be in English. All the dimensions should be in metric
m
units.
sub vendors) shall bear Employers
(f.) The drawings submitted by the Contractor (or their sub-vendors)
drawing number in addition to contractors (their sub-vendors)
sub vendors) own drawing number.
Employers drawing numbering system shall be made available to the successful
succe
Contractor so as to enable him to assign Employers drawing numbers to the drawings
to be submitted by him during the course of execution of the Contract.
(g.) The Contractor shall also furnish a Master Drawing List which shall be a
comprehensive list of all drawings/ documents/ calculations envisaged to be furnished
by him during the detailed engineering to the Employer in line with engineering
information flow schedule (to be tied up with successful Contractor). Such list should
clearly indicate the purpose
purpose of submission of these drawings i.e. FOR APPROVAL or
FOR INFORMATION ONLY.
(h.) Similarly, all the drawings/ documents submitted by the Contractor during detailed
engineering stage shall be stamped FOR APPROVAL or FOR INFORMATION prior to
submission.
(i.) The furnishing of detailed engineering data and drawings by the Contractor shall be in
accordance with the time schedule for the project. The review of these documents/
data/ drawings by the Employer will cover only general conformance of the data/
drawings/
awings/ documents to the specifications and contract, interfaces with the
equipments provided by others and external connections & dimensions which might
affect plant layout. The review by the Employer should not be construed to be a
thorough review of all dimensions, quantities and details of the equipments, materials,
any devices or items indicated or the accuracy of the information submitted. The
review and/ or approval by the Employer / Project Manager shall not relieve the
Contractor of any of his responsibilities
responsibilities and liabilities under this contract.
(j.) After the approval of the drawings, further work by the Contractor shall be in strict
accordance with these approved drawings and no deviation shall be permitted without
the written approval of the Employer.
Employe

Page 5 of 27
(k.) All manufacturing, fabrication and execution of work in connection with the equipment
/ system, prior to the approval of the drawings, shall be at the Contractors risk. The
Contractor is expected not to make any changes in the design of the equipment
/system,
system, once they are approved by the Employer. However, if some changes are
necessitated in the design of the equipment/ system at a later date, the Contractor may
do so, but such changes shall promptly be brought to the notice of the Employer
indicating the reasons for the change and get the revised drawing approved again in
strict conformance to the provisions of the Technical Specification.
(l.) Drawings shall include all installations and detailed piping and wiring drawings.
(m.) Assessing & anticipating the requirement
requirement and supply of all piping and equipment shall
be done by the contractor well in advance so as not to hinder the progress of piping &
equipment erection, subsequent system charging and its effective draining & venting
arrangement as per site suitability.
suita
(n.) Any software used by the contractor shall be given to the project manager and
concerned engineer of employer. The contractor shall make the engineer of the
employer aware of the programme. Any computer aided programme shall be approved
subject to giving entire detail to the project manager.
(o.) Drawings must be checked by the Contractor in terms of its completeness, data
adequacy and relevance with respect to Engineering schedule prior to submission to
the Employer. In case drawings are found to be submitted
submitted without proper endorsement
for checking by the Contractor, the same shall not be reviewed and returned to the
Contractor for re-submission.
submission. The contractor shall make a visit to site to see the existing
facilities and understand the layout completely
completely and collect all necessary data /
drawings at site which are needed as an input to the engineering. The contractor shall
do the complete engineering including interfacing and integration of all his equipment,
systems & facilities within his scope of work as well as interface engineering &
integration of systems, facilities, equipment & works under Employers scope and
submit all necessary drawings/ documents for the same.
(p.) All drawings shall be reviewed and approved by Engineering coordinator, including the
following drawings / data which require specific approval.
1. Data sheets for various equipments / systems.
2. Field testing procedures for various equipment and piping system.
3. Pre commissioning / commissioning procedures including flushing, Chemical
cleaning,
g, steam blowing and hydro test etc. (Wherever applicable) O&M manual
shall also be reviewed and approved by Employer. The content of O&M manual
shall be as specified elsewhere in the specification.
4. Guarantee test procedures.
5. Any other drawings that may be required by the Engineer from time to time.)
6. Data furnished in the bid shall be binding on the contractor even if superior to
the technical specification requirement and any revision shall be done with the
owner/RITES
/RITESs agreement.

Page 6 of 27
(q.) The Contractor shall submit adequate prints of drawing / data / document for
Employers review and approval. The Employer shall review the drawings and return
one (1) copy to the Contractor authorizing either to proceed with manufacture or
fabrication, or marked to show changes
changes desired. When changes are required, drawings
shall be re-submitted
submitted promptly, with revisions clearly marked, for final review. Any
delays arising out of the failure of the Contractor to submit/rectify and resubmit in time
shall not be accepted as a reason for delay in the contract schedule
(r.) Upon review of each drawing, depending on the correctness and completeness of the
drawing, the same will be categorised and approval accorded in one of the following
categories :
CATEGORY I Approved
CATEGORY II Approved subject to incorporation of comments/ modification as
noted. Resubmit revised drawing incorporating the Comments
CATEGORY III Not approved. Resubmit revised drawings for approval after
incorporating comments/modification as noted.
CATEGORY IV For information
informat
and records.
(s.) Vendor shall resubmit the drawings approved under Category II and III within three (3)
weeks of receipt of comments on the drawings, incorporating all comments. Every
revision of the drawing shall bear a revision index wherein such revisions
revisio shall be
highlighted in the form of description or marked up in the drawing identifying the same
with relevant revision Number enclosed in a triangle (eg. 1, 2, 3 etc).
In case Vendor does not agree with any specific comment, he shall furnish the
explanation for the same to owner / consultant for consideration. In all such cases
vendor shall necessarily enclose explanations along with the revised drawing (taking
care of balance comments) to avoid any delay and/or duplication in review work.
It is responsibility of the Vendor to get all the drawings approved in the Category I
& IV (as the case may be) and complete engineering activities within the agreed
schedule. Any delay arising out of submission and modification of drawings shall
not alter the contract
ontract completion schedule. Vendor shall not make any changes in
the portions of the drawing other than those commented upon. If changes are
required to be made in the portions already approved, the vendor shall resubmit
the drawing identifying the changes
change for owner/RITESs
s review and approval.
(t.) If Vendor fails to resubmit the drawings as per the schedule, construction work at site
will not be held up and work will be carried out on the basis of comments furnished on
previous issues of the drawing. These comments
comments will be taken care by the contractor
while submitting the revised drawing.
(u.) All engineering data submitted by the Contractor after final process including review
and approval by the Project Manager/ Employer shall form part of the contract
documentss and the entire works covered under these specification shall be performed
in strict conformity with technical specifications unless otherwise expressly requested
by the Project Manager in writing.

Page 7 of 27
(v.) After final acceptance of individual equipment / system by

by the Employer, the
Contractor will update all original drawings and documents for the equipment / system
to as built conditions.
4.8.5
ENGINEERING INFORMATION SUBMISSION SCHEDULE

Prior to the award of Contract, a Detailed Engineering Information Submission
Submi
Schedule shall
be tied up with the Employer. For this, the Contractor shall furnish a detailed list of
engineering information along with the proposed submission schedule. This list would be a
comprehensive one including all engineering data / drawings
drawings / information for all bought out
items and manufactured items. The information shall be categorised into the following
parts.
Information that shall be submitted for the approval of the Employer before proceeding
further, and Information that would be submitted for Employers information only. The
Engineering Information Schedule shall be updated month wise. The schedule should allow
adequate time for proper review and incorporation of changes/ modifications, if any, to
meet the contract without affecting
affecting the equipment delivery schedule and overall project
schedule. The early submission of drawings and data is as important as the manufacture and
delivery of equipment and hardware and this shall be duly considered while determining the
overall performancee and progress.
4.9
ENGINEERING COORDINATION PROCEDURE
4.9.1
Identification of Principal Engineering Coordinators

The following principal coordinators will be identified by respective organisations at time of
award of contract
RITES COORDINATORS
RITES- Engineering Coordinators
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
EMPLOYERS COORDINATORS
NALCO- Engineering Coordinators (NALCO EC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :

Page 8 of 27
FAX : TELEPHONE :
ORDINATOR (NALCO SC)
NALCO- SITE CO-ORDINATOR
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
4.9.2
VENDOR ENGINEERING CO-ORDINATOR

CO
(VENDOR EC)
Name :
Designation :
Address :
a) Postal :
b) Telegraphic :
TELEX :
FAX : TELEPHONE :
All engineering correspondence shall be in the name of above coordinators on behalf of the
respective organisations.
4.9.3 Vendors Drawings

(a) The contractor shall furnish, discuss and finalise with the Employer, the engineering
information
ion flow schedule at the time of award of the contract. The dates for submission of
drawings as finalised in the above engineering schedule, shall be strictly adhered to. This is
essential for the timely completion of the project.
(b) A detailed drive list shall
shall be furnished along with the tender. Further drive list shall be
submitted to the RITESs Engineering coordinator within 60 days from the date of award of
the contract.
s
(c) In any case, in order to achieve the project completion dates, the contractor must strictly
comply with engineering schedules.
(d) Final distribution copies of all approved drgs. (in Cat. I & IV) shall be submitted by the
contractor to the Engineer within two (2) weeks of the approval.
(e) Copies of all approved drgs. (in cat. I & IV) shall be submitted incorporating all site
modifications, if any, during construction, erection, commission stages and performance and
guarantee testing (till its continuous operation) as As Built Drgs.
(f) The contractor shall use a single transmittal for drgs. Submission. This shall include
transmittal numbers and date, number of copies being sent, names of the agencies to whom
are all the copies being sent drg. numbers and titles, remarks or special notes if any etc.
(g) All manufacturing and fabrication work in connection with the equipments prior to the
approval of the drg. shall be at contractors risks. (h) Approval of contractors drgs. or work

Page 9 of 27
by the Engineer shall not relieve the contractor of any of his responsibilities or liabilities
under the contract.
4.9.4
Erection Drawings
(a) Contractor shall furnish erection drawings for the guidance of his/ RITESs site staff at
least 4 weeks before scheduled commencement of erection or the first shipment,
whicheverr is earlier. These shall generally comprise of fabrication/assembly drawings,
various component/part details drawings, assembly, clearance, data requirements etc.
The drawings shall contain details of components/ equipment with identification
numbers, match
ch marks, bills of materials, assembly procedures etc.
(b) For all major equipment apart from above details, assembly sequence and instructions
with check lists shall be furnished in the form of erection manuals CLAUSE NO.
4.9.5
ENGINEERING PROGRESS AND EXCEPTION REPORT

R
A report giving the status of each engineering information including the list of
drawings/engineering information which remains unapproved for more than one (1)
weeks after the date of first submission Drawings which were not submitted as per
agreed schedule.
4.9.6
TECHNICAL CO-ORDINATION
ORDINATION MEETING
(a) The Contractor shall be called upon to organise and attend monthly Design/ Technical
Co-ordination
ordination Meetings (TCMs) with the owner/owners representatives and other
Contractors of the Employer during the period of contract. The Contractor shall attend
such meetings at his own cost as and when required and fully co-operate
co
with such
persons and agencies involved during the discussions.
(b) The Contractor should note that Time is the essence of the contract. In order to expedite
the early completion of engineering activities, the Contractor shall submit all drawings as
per the agreed Engineering Information Submission Schedule. The drawings submitted
by the Contractor will be reviewed by the Employer as far as practicable
practica within three (3)
weeks from the date of receipt of the drawing .The comments of the Employer shall
then be discussed across the table during the above Technical Co-ordination
Co ordination Meeting (s)
wherein best efforts shall be made by both sides to ensure the approval
approval of the drawing.
(c) The Contractor shall ensure availability of the concerned experts / consultants/
personnel who are empowered to take necessary decisions during these meetings.
(d) Should any drawing remain unapproved for more than one (1)) weeks after its first
submission, this shall be brought out in the monthly Engineering Progress and Exception
Report with reasons thereof.
(e) Any delays arising out of failure by the Contractor to incorporate Employers comments
and resubmit the same during the TCM shall
shall be considered as a default and in no case
shall entitle the Contractor to alter the Contract completion date.

Page 10 of 27
4.9.7 DESIGN IMPROVEMENTS

The Employer/RITES or the Contractor may propose changes in the specification of the
equipment or quality thereof and if the parties agree upon any such changes the
specification shall be modified accordingly. If any such agreed upon change is such that it
affects the price and schedule of completion, the parties shall agree in writing as to the
extent of any changingg the price and/or schedule of completion before the Contractor
proceeds with the change. Following such agreement, the provision thereof, shall be
deemed to have been amended accordingly.
4.9.8
EQUIPMENT BASES
A cast iron or welded steel base plate shall be provided for all rotating equipment which is to
be installed on a concrete base, unless otherwise specifically agreed to by the Employer.
Each base plate which support the unit and its drive assembly, shall be
be of a neat design with
pads for anchoring the units.
4.9.9
PROTECTIVE GUARDS
Suitable guards shall be provided for protection of personnel on all exposed rotating and/or
moving machine parts. All such guards shall be designed for easy installation and removal for
maintenance purpose.
4.9.10 LUBRICANTS, SERVO FLUIDS AND CHEMICALS

(a) The Contractors scope includes all the first fill of consumables such as oils, lubricants
including grease, servo fluids, gases and essential chemicals etc. Consumption of all these
thes
consumables during the initial operation and final filling after the initial operation shall also
be included in the scope of the Contractor.
(b) The variety of lubricants shall be kept to a minimum possible. Detailed specifications for the
lubricating oil, grease, gases, servo fluids, control fluids, chemicals etc. required for the
complete plant covered herein shall be furnished. On completion of erection, a complete list
of bearings/ equipment giving their location and identification marks shall be furnished
furnis
to
the Employer along with lubrication requirements.
4.9.11 Lubrication
Equipment shall be lubricated by systems designed for continuous operation. Lubricant level
indicators shall be furnished and marked to indicate proper levels under both standstill
standsti and
operating conditions.
4.9.12 Material of Construction
All materials used for the construction of the equipment shall be new and shall be in
accordance with the requirements of this specification. Materials utilised for various
components shall be those which have established themselves for use in such applications.
4.9.13 RATING PLATES, NAME PLATES & LABELS
Page 11 of 27
Each main and auxiliary item of plant including instruments shall have permanently attached
to it in a conspicuous position, a rating plate of
o non-corrosive
corrosive material upon which shall be
engraved manufacturers name, equipment, type or serial number together with details of
the ratings, service conditions under which the item of plant in question has been designed
to operate.
Each item of plantt shall be provided with nameplate or label designating the service of the
particular equipment.
Such nameplates or labels shall be of white non hygroscopic material with engraved black
lettering or alternately, in the case of indoor circuit breakers, starters,
starters, etc. of transparent
plastic material with suitably coloured lettering engraved on the back. The name plates shall
be suitably fixed on both front and rear sides.
Items of plant such as valves, which are subject to handling, shall be provided with an
engraved chromium plated nameplate or label with engraving filled with enamel..
All segregated phases of conductors or bus ducts, indoor or outdoor, shall be provided with
coloured phase plates to clearly identify the phase of the system
4.9.14 TOOLS AND TACKLES
The Contractor shall supply with the equipment one complete set of all special tools and
tackles and other instruments required for the erection, assembly, disassembly
disassembly and proper
maintenance of the plant and equipment and systems (including software). These special
tools will also include special material handling equipment, jigs and fixtures for maintenance
and calibration / readjustment, checking and measurement
measurement aids etc. A list of such tools and
tackles shall be submitted by the Contractor alongwith the offer. The price of each tool /
tackle shall be deemed to have been included in the total bid price. These tools and tackles
shall be separately packed and sent
sent to site. The Contractor shall also ensure that these tools
and tackles are not used by him during erection, commissioning and initial operation. For
this period the Contractor should bring his own tools and tackles. All the tools and tackles
shall be off reputed make acceptable to the Employer.
4.9.15 Welding
If the manufacturer has special requirements relating to the welding procedures for welds at
the terminals of the equipments to be per formed by others the requirements shall be
submitted to the Employer in advance of commencement of erection work.
4.9.16 COLOUR CODE FOR ALL EQUIPMENTS/ SERVICES
All equipment/ services are to be painted by the Contractor in accordance with Employers
standard colour coding scheme, which will be furnished to the Contractor during detailed
engineering stage.
4.10
PROTECTION AND PRESERVATIVE SHOP COATING

Page 12 of 27
4.10.1 PROTECTION
All coated surfaces shall be protected against abrasion, impact, discoloration and any other
damages. All exposed threaded portions shall be suitably protected with either metallic or a
nonmetallic protection device. All ends of all valves and pipings and conduit equipment
connections shall be properly sealed with suitable devices to protect them from damage.
The parts which are likely to get rusted, due to exposure to weather, should also be properly
treated and protected in a suitable manner. All primers/paints/coatings shall take into
account the hot humid, corrosive & alkaline, subsoil or over ground environment as the case
may be.
4.10.2 Preservative Shop Coating
All exposed metallic surfaces subject to corrosion shall be protected by shop application of
suitable coatings. All surfaces which will not be easily accessible after the shop assembly,
shall be treated beforehand and protected for
for the life of the equipment. All surfaces shall be
thoroughly cleaned of all mill scales, oxides and other coatings and prepared in the shop.
The surfaces that are to be finish-painted
finish painted after installation or require corrosion protection
until installation, shall be shop painted with atleast two coats of primer. Transformers and
other electrical equipments if included shall be shop finished with one or more coats of
primer and two coats of high grade resistance enamel. The finished colors shall be as per
manufacturers
ufacturers standards, to be selected and specified by the Employer at a later date.
Shop primer for all steel surfaces which will be exposed to operating temperature below 95
degrees Celsius shall be selected by the Contractor after obtaining specific approval
ap
of the
Employer regarding the quality of primer proposed to be applied. Special high temperature
primer shall be used on surfaces exposed to temperature higher than 95 degrees Celsius and
such primer shall also be subject to the approval of the Employer.
Empl
All other steel surfaces which are not to be painted shall be coated with suitable rust
preventive compound subject to the approval of the Employer.
All piping shall be cleaned after shop assembly.
Painting for Civil structures shall be done as per relevant part of technical specification
4.11
QUALITY ASSURANCE PROGRAMME

The Contractor shall adopt suitable quality assurance programme to ensure that the
equipment and services under the scope of contract
contract whether manufactured or performed
within the Contractors works or at his sub-contractors
sub contractors premises or at the Employers site or
at any other place of work are in accordance with the specifications. Such programmes shall
be outlined by the Contractor
Contractor and shall be finally accepted by the Employer/authorised
representative after discussions before the award of the contract. The QA programme shall
be generally in line with IS/ISOIS/ISO 9001.A quality assurance programme of the contractor shall
generally coverr the following:

Page 13 of 27
(a) His organisation structure for the management and implementation of the proposed
quality assurance programme
(b) Quality System Manual
(c) Design Control System
(d) Documentation and Data Control System
(e) Qualification data for Contractors key personnel.
(f) The procedure for purchase of materials, parts, components and selection of subsub
contractors services including vendor analysis, source inspection, incoming raw-material
raw
inspection, verification of materials purchased etc.
(g) System for shop manufacturing
manufacturing and site erection controls including process, fabrication
and assembly.
conforming items and system for corrective actions and resolution of
(h) Control of non-conforming
deviations.
(i) Inspection and test procedure both for manufacture and field activities.
(j) Control of calibration and testing of measuring testing equipment.
(k) System for Quality Audits.
(l) System for identification and appraisal of inspection status.
(m) System for authorising release of manufactured product to the Employer.
(n) System for handling, storage and delivery.
(o) System for maintenance of records, and
(p) Quality plans for manufacturing and field activities detailing out the specific quality
control procedure adopted for controlling the quality characteristics relevant to each
item of equipment/component.
4.12
GENERAL REQUIREMENTS - QUALITY ASSURANCE
4.12.1 All materials, components and equipment covered under this specification shall be
procured, manufactured, erected, commissioned and tested at all the stages, as per a
comprehensive Quality Assurance Programme.
Programme. An indicative programme of inspection/tests
to be carried out by the contractor for some of the major items is given in the respective
technical specification. This is, however, not intended to form a comprehensive programme
as it is the contractors responsibility to draw up and implement such programme duly
approved by the Employer. The detailed Quality Plans for manufacturing and field activities
shall be drawn up by the Contractor and will be submitted to Employer for approval.
Schedule of finalisation
ation of such quality plans will be finalised before award. Monthly
progress reports on MQP/FQP submission/approval shall be furnished on enclosed format
No. QS-01-QAI-P-02/F1.
e
various
4.12.2 Manufacturing Quality Plan will detail out for all the components and equipment,
tests/inspection, to be carried out as per the requirements of this specification and
standards mentioned therein and quality practices and procedures followed by Contractors/
Sub-contractors/ sub-supplier's
supplier's Quality Control Organisation,
Organisation, the relevant reference
documents and standards, acceptance norms, inspection documents raised etc., during all
stages of materials procurement, manufacture, assembly and final testing/performance
testing. The Quality Plan shall be submitted on electronic media e.g. floppy or E-mail
E
in
addition to hard copy, for review and approval. After approval the same shall be submitted
in compiled form on CD--ROM.
Page 14 of 27
4.12.3 Field Quality Plans will detail out for all the equipment, the quality practices and procedures
etc.
tc. to be followed by the Contractors "Site Quality Control Organisation", during various
stages of site activities starting from receipt of materials/equipment at site.
4.12.4 The Contractor shall also furnish copies of the reference documents/plant
standards/acceptance
ndards/acceptance norms/tests and inspection procedure etc., as referred in Quality
Plans along with Quality Plans. These Quality Plans and reference documents/standards etc.
will be subject to Employers approval without which manufacturer shall not proceed.
proce
These
approved documents shall form a part of the contract. In these approved Quality Plans,
Employer shall identify customer hold points (CHP), i.e. test/checks which shall be carried
out in presence of the Employers Project Manager or his authorised representative and
beyond which the work will not proceed without consent of Employer in writing. All
deviations to this specification, approved quality plans and applicable standards must be
documented and referred to Employer along with technical justification
justification for approval and
dispositioning.
4.12.5 No material shall be despatched from the manufacturers works before the same is
accepted, subsequent to predespatch final inspection including verification of records of all
previous tests/inspections by Employers
Employers Project Manager/Authorised representative and
duly authorised for despatch by issuance of Material Despatch Clearance Certificate (MDCC).
4.12.6 All material used for equipment manufacture including casting and forging etc. shall be of
tested quality
lity as per relevant codes/standards. Details of results of the tests conducted to
determine the mechanical properties; chemical analysis and details of heat treatment
procedure recommended and actually followed shall be recorded on certificates and time
temperature
emperature chart. Tests shall be carried out as per applicable material standards and/or
agreed details.
4.12.7 The contractor shall submit to the Employer Field Welding Schedule for field welding
activities in the enclosed format No.: QS-01-QAI-P-02/F3.
QS
The field welding schedule shall be
submitted to the Employer along with all supporting documents, like welding procedures,
heat treatment procedures, NDT procedures etc. at least ninety days before schedule start
of erection work at site.
4.12.8 All welding and brazing shall be carried out as per procedure drawn and qualified in
accordance with requirements of ASME Section IX/BS-4870
IX/BS 4870 or other International equivalent
standard acceptable to the Employer. All welding/brazing procedures shall be submitted
submitte to
the Employer or its authorized representative for approval prior to carrying out the
welding/brazing.
4.12.9 All brazers, welders and welding operators employed on any part of the contract either in
Contractors/sub-contractors
contractors works or at site or elsewhere
elsewhere shall be qualified as per ASME
Section-IX or BS-4871
4871 or other equivalent International Standards acceptable to the
Employer.

Page 15 of 27
4.12.10 Welding procedure qualification & Welder qualification test results shall be furnished to the
Employer for approval.
al. However, where required by the Employer, tests shall be conducted
in presence of Employer/authorised representative.
4.12.11 Unless otherwise proven and specifically agreed with the Employer, welding of dissimilar
materials and high alloy materials shall
sh be carried out at shop only.
4.12.12No welding shall be carried out on cast iron components for repair.
4.12.13 All the heat treatment results shall be recorded on time temperature charts and verified
with recommended regimes.
tive examination shall be performed in accordance with written procedures
4.12.14 All non-destructive
as per International Standards, The NDT operator shall be qualified as per SNT-TC-IA
SNT
(of the
American Society of non-destructive
non destructive examination). NDT shall be recorded in a report, which
whic
includes details of methods and equipment used, result/evaluation, job data and
identification of personnel employed and details of correlation of the test report with the
job. All Bar stock / forgings of diameter equal to or greater than 50mm shall be ultrasonically
u
tested. In general all plates of thickness equal to or greater than 40mm and for pressure
parts, pates of thickness equal to or greater than 25mm shall be ultrasonically tested unless
as specified otherwise in respective equipment specification.
specificati
4.12.15The Contractor shall list out all major items/ equipment/ components to be manufactured in
house as well as procured from sub-contractors.
sub
All the subcontractor proposed by the
Contractor for procurement of major bought out items including castings, forging, semisemi
finished and finished components/equipment etc., list of which shall be drawn up by the
Contractor and finalised with the Employer, shall be subject to Employer's approval. The
contractors proposal shall include vendors facilities established at the respective works, the
process capability, process stabilization, QC systems followed, experience list, etc. along with
his own technical evaluation
ation for identified sub-contractors
sub contractors enclosed and shall be submitted
to the Employer for approval within the period agreed at the time of pre-awards
pre
discussion
and identified in "DR" category prior to any procurement. Monthly progress reports on subsub
contractor
ctor detail submission / approval shall be furnished. Such vendor approval shall not
relieve the contractor from any obligation, duty or responsibility under the contract.
4.12.16For components/equipment procured by the contractors for the purpose of the contract,
after obtaining the written approval of the Employer, the contractors purchase
specifications and inquiries shall call for quality plans to be submitted by the suppliers. The
quality plans called for from the sub-contractor
sub
shall set out, during the various stages of
manufacture and installation, the quality practices and procedures followed by the vendors
quality control organisation, the relevant reference documents/standards used, acceptance
level, inspection of documentation raised, etc. Such
Such quality plans of the successful vendors
shall be finalised with the Employer and such approved Quality Plans shall form a part of the
purchase order/contract between the Contractor and sub-contractor.
sub contractor. Within three weeks of
the release of the purchase orders
orders /contracts for such bought out items /components, a
copy of the same without price details but together with the detailed purchase
specifications, quality plans and delivery conditions shall be furnished to the Employer on

Page 16 of 27
the monthly basis by the Contractor

Contractor along with a report of the Purchase Order placed so far
for the contract. **
4.12.17Employer reserves the right to carry out quality audit and quality surveillance of the systems
and procedures of the Contractors or their sub-contractors
sub contractors quality management and
control activities. The contractor shall provide all necessary assistance to enable the
Employer carry out such audit and surveillance.
4.12.18The contractor shall carry out an inspection and testing programme during manufacture in
his work and that of his sub-contractors
sub contractors and at site to ensure the mechanical accuracy of
components, compliance with drawings, conformance to functional and performance
requirements, identity and acceptability of all materials parts and equipment. Contractor
shallll carry out all tests/inspection required to establish that the items/equipment conform
to requirements of the specification and the relevant codes/standards specified in the
specification, in addition to carrying out tests as per the approved quality plan.
pla
4.12.19Quality audit/surveillance/approval of the results of the tests and inspection will not,
however, prejudice the right of the Employer to reject the equipment if it does not comply
with the specification when erected or does not give complete satisfaction
satisfaction in service and the
above shall in no way limit the liabilities and responsibilities of the Contractor in ensuring
complete conformance of the materials/equipment supplied to relevant specification,
standard, data sheets, drawings, etc.
or all spares and replacement items, the quality requirements as agreed for the main
4.12.20 For
equipment supply shall be applicable.
4.12.21 Repair/rectification procedures to be adopted to make the job acceptable shall be subject to
the approval of the Employer/ authorised representative.
4.13
QA DOCUMENTATION PACKAGE
The Contractor shall be required to submit the QA Documentation in two hard copies and
two CD ROMs.
4.13.1 Each QA Documentation shall have a project specific Cover Sheet bearing name &
identification
ation number of equipment and including an index of its contents with page control
on each document. The QA Documentation file shall be progressively completed by the
Suppliers sub-supplier
supplier to allow regular reviews by all parties during the manufacturing. The
final quality document will be compiled and issued at the final assembly place of equipment
before despatch. However CD-Rom
CD Rom may be issued not later than three weeks.
below:
4.13.2 Typical contents of QA Documentation is as below:(a) Quality Plan
(b) Material mill test reports on components as specified by the specification and approved
Quality Plans.

Page 17 of 27
(c) Manufacturer / works test reports/results for testing required as per applicable codes
and standard referred in the specification and approved Quality Plans.
(d) Non-destructive
ructive examination results /reports including radiography interpretation
reports. Sketches/drawings used for indicating the method of traceability of the
radiographs to the location on the equipment.
(e) Heat Treatment Certificate/Record (Time(Time temperature Chart)
(f) All the accepted Non-conformance
Non conformance Reports (Major/Minor) / deviation, including
complete technical details / repair procedure).
(g) Inspection reports duly signed by the Inspector of the Employer and Contractor for the
agreed Customer Hold Points.
(h) Certificate
te of Conformance (COC) wherever applicable.
(i) MDCC
4.13.3 Similarly, the contractor shall be required to submit two sets (two hard copies and two CD
ROMs), containing QA Documentation pertaining to field activities as per Approved Field
Quality Plans and other agreed manuals/ procedures, prior to commissioning of individual
system.
4.13.4 Before despatch / commissioning of any equipment, the Supplier shall make sure that the
corresponding quality document or in the case of protracted phased deliveries, the
t
applicable section of the quality document file is completed. The supplier will then notify the
Inspector regarding the readiness of the quality document (or applicable section) for review.
If the result of the review carried out by the Inspector is satisfactory,
satisfactory, the Inspector shall
stamp the quality document (or applicable section) for release. If the quality document is
unsatisfactory, the Supplier shall endeavor to correct the incompleteness, thus allowing to
finalize the quality document (or applicable
applicable section) by time compatible with the
requirements as per contract documents. When it is done, the quality document (or
applicable section) is stamped by the Inspector. If a decision is made despatch, whereas all
outstanding actions cannot be readily cleared
cleared for the release of the quality document by
that time. The supplier shall immediately, upon shipment of the equipment, send a copy of
the quality document Review Status signed by the Supplier Representative to the Inspector
and notify of the committed date for the completion of all outstanding actions & submission.
The Inspector shall stamp the quality document for applicable section when it is effectively
completed. The submission of QA documentation package shall not be later than 3 weeks
after the despatch
spatch of equipment.
4.13.5 TRANSMISSION OF QA DOCUMENTATION
On release of QA Documentation by Inspector, one set of quality document shall be
forwarded to Corporate Quality Assurance Department and other set to respective Project
Site of Employer. For the
the particular case of phased deliveries, the complete quality
document to the Employer shall be issued not later than 3 weeks after the date of the last
delivery of equipment.
4.14
Project Managers Supervision

Page 18 of 27
4.14.1 To eliminate delays and avoid disputes

disputes and litigation, it is agreed between the parties to the
Contract that all matters and questions shall be referred to the Project Manager and without
prejudice to the provisions of Arbitration clause in GCC, the Contractor shall proceed to
comply with the Project Manager's decision.
4.14.2 The work shall be performed under the supervision of the Project Manager. The scope of the
duties of the Project Manager pursuant to the Contract, will include but not be limited to the
following:
(a) Interpretation of all the terms and conditions of these documents and specifications:
(b) Review and interpretation of all the Contractors drawing, engineering data, etc:
(c) Witness or his authorised representative to witness tests and trials either at the
manufacturers works or at site, or at any place where work is performed under the
contract :
(d) Inspect, accept or reject any equipment, material and work under the contract:
(e) Issue certificate of acceptance and/or progressive payment and final payment
certificates
(f) Review and suggest modifications and improvement in completion schedules from time
to time, and
(g) Supervise Quality Assurance Programme implementation at all stages of the works.
4.15
INSPECTION, TESTING AND INSPECTION CERTIFICATES
Project Manager and/or his authorized representative

(a) The word Inspector shall mean the Project
and/or an outside inspection agency acting on behalf of the Employer to inspect and
examine the materials and workmanship of the works during its manufacture or erection.
authorised representative and/or an outside inspection
(b) The Project Manager or his duly authorised
agency acting on behalf of the Employer shall have access at all reasonable times to inspect
and examine the materials and workmanship of the works during its manufacture or
erection and if part of the works
works is being manufactured or assembled on other premises or
works, the Contractor shall obtain for the Project Manager and for his duly authorised
representative permission to inspect as if the works were manufactured or assembled on
the Contractors own premises
remises or works.
(c) The Contractor shall give the Project Manager/Inspector fifteen (15) days written notice of
any material being ready for testing. Such tests shall be to the Contractors account except
for the expenses of the Inspectors. The Project Manager/Inspector,
Manager/Inspector, unless the witnessing of
the tests is virtually waived and confirmed in writing, will attend such tests within fifteen
(15) days of the date on which the equipment is noticed as being ready for test/inspection
failing which the contractor may
may proceed with test which shall be deemed to have been
made in the inspectors presence and he shall forthwith forward to the inspector duly
certified copies of test reports in two (2) copies.
(d) The Project Manager or Inspector shall within fifteen (15) days
days from the date of inspection
as defined herein give notice in writing to the Contractor, or any objection to any drawings
and all or any equipment and workmanship which is in his opinion not in accordance with
the contract. The Contractor shall give due consideration to such objections and shall either
Page 19 of 27
make modifications that may be necessary to meet the said objections or shall inform in
writing to the Project Manager/Inspector giving reasons therein, that no modifications are
necessary to comply with the
th contract.
(e) When the factory tests have been completed at the Contractors or sub-contractors
sub
works,
the Project Manager /Inspector shall issue a certificate to this effect fifteen (15) days after
completion of tests but if the tests are not witnessed by the Project Manager /Inspectors,
the certificate shall be issued within fifteen (15) days of the receipt of the Contractors test
certificate by the Project Manager /Inspector. Project Manager /Inspector to issue such a
certificate shall not prevent the Contractor
Contractor from proceeding with the works. The completion
of these tests or the issue of the certificates shall not bind the Employer to accept the
equipment should it, on further tests after erection be found not to comply with the
contract.
here the contract provides for tests whether at the premises or works of the
(f) In all cases where
Contractor or any sub-contractor,
contractor, the Contractor, except where otherwise specified shall
provide free of charge such items as labour, material, electricity, fuel, water, stores,
apparatus
pparatus and instruments as may be reasonably demanded by the Project Manager
/Inspector or his authorised representatives to carry out effectively such tests on the
equipment in accordance with the Contractor and shall give facilities to the Project
Manager/Inspector
er/Inspector or to his authorised representative to accomplish testing.
(g) The inspection by Project Manager / Inspector and issue of Inspection Certificate thereon
shall in no way limit the liabilities and responsibilities of the Contractor in respect of the
th
agreed Quality Assurance Programme forming a part of the contract.
(h) To facilitate advance planning of inspection, the Contractor shall furnish quarterly inspection
programme indicating schedule dates of inspection at Customer Hold Point and final
inspection
ion stages. Updated quarterly inspection plans will be made for each three
consecutive months and shall be furnished before beginning of each calendar month.
(i) All inspection, measuring and test equipment used by contractor shall be calibrated
periodically depending on its use and criticality of the test/measurement to be done. The
Contractor shall maintain all the relevant records of periodic calibration and instrument
identification, and shall produce the same for inspection by NALCO. Wherever asked
specifically,
ically, the contractor shall re-calibrate
re calibrate the measuring/test equipment in the presence
of Project Manager / Inspector.
4.16
COMMISSIONING AND COMMISSIONING FACILITIES

PRE-COMMISSIONING
(a) As soon as the facilities or part thereof has been completed operationally and
structurally
cturally and before start-up,
start up, each item of the equipment and systems forming part
of facilities shall be thoroughly cleaned and then inspected jointly by the Employer and
the Contractor for correctness of and completeness of facility or part thereof and
acceptability
ceptability for initial pre-commissioning
pre commissioning tests, commissioning and start-up
start
at Site. The
list of pre-commissioning
commissioning tests to be performed shall be as mutually agreed and

Page 20 of 27
included in the Contractors quality assurance programme as well as those included

elsewhere
where in the Technical Specifications.
pre
commissioning/start-up
up engineers, specially
(b) The Contractors pre-commissioning/
identified as far as possible, shall be responsible for carrying out all the prepre
commissioning tests at Site. On completion of inspection,
inspection, checking and after the prepre
commissioning tests are satisfactorily over, the commissioning of the complete facilities
shall be commenced during which period the complete facilities, equipments shall be
operated integral with sub-systems
sub
and supporting equipment
uipment as a complete plant.
(c) The time consumed in the inspection and checking of the units shall be considered as a
part of the erection and installation period.
(d) The check outs during the pre - commissioning period should be programmed to follow
the construction
truction completion schedule. Each equipment/system, as it is completed in
construction and turned over to RITES/Employer's
Employer's commissioning (startup) Engineer(s),
should be checked out and cleaned. The checking and inspection of individual systems
should then follow a prescribed commissioning documentation [SLs (Standard Check
List) / TS (Testing Schedule) / CS (Commissioning Schedule)] approved by the
Employer/RITES.
(e) On completion of all pre-commissioning
pre commissioning activities / tests and as a part of commissioning
the complete facilities shall be put on 'Trial Operation' during which period all necessary
adjustments shall be made while operating over the full load range enabling the
facilities to be made ready for the Guarantee Tests
(f)
The duration of 'Trial Operation'

Operation' of the complete facility as an integral unit shall be 30
continuous days with available wagon loads or as to be mutually agreed.
agreed The Trial
Operation shall be considered successful, provided that each item/part of the facility
can operate continuously at the specified operating characteristics, for the period of
Trial Operation with all operating parameters within the specified limits and at or near
the predicted performance of facility/equipment.
operation with any load shall be counted.

(g) For the period of 'Trial Operation', the time of operation
(h) A Trial Operation report comprising of observations and recordings of various
parameters to be measured in respect of the above Trial Operation shall be prepared by
the Contractor. This report, besides recording the details
details of the various observations
during trial operation shall also include the dates of start and finish of the Trial
Operation and shall be signed by the representatives of both the parties. The report
shall have sheets, recording all the details of interruptions
interruptions occurred, adjustments made
and any minor repairs done during the Trial Operation. Based on the observations,
necessary modifications/repairs to the plant shall be carried out by the Contractor to
the full satisfaction of the Project Manager to enable
enable the latter to accord permission to
carry out the Guarantee tests on the facilities. However, minor defects which do not

Page 21 of 27
endanger the safe operation of the equipment, shall not be considered as reasons for
with- holding the aforesaid permission
ctor shall furnish the commissioning organization chart for review & acceptance
Contractor
of employer at least eighteen months prior to the schedule date of synchronization of
1st unit. The chart should contain:
a) Experience of the Commissioning Engineers.
b) Role and responsibilities
sponsibilities of the Commissioning Organisation members.
c) Expected duration of posting of the above Commissioning Engineers at site.
GUARANTEE TESTS
(i)
4.17
(a) The final tests as to the guarantees shall be conducted at Site, by the Contractor. The
Contractor's Commissioning and start-up
start up Engineers shall make the unit ready for such
tests. Such test will be commenced, within a period of three (3) months after the
successful completion of Trial Operation. Any extension of time beyond the above three
months shall be subject to Employer's approval.
(b) These tests shall be binding on both the parties of the Contract to determine
compliance of the equipment with the performance guarantee.
(c) Any special equipment, tools and tackles required for the successful completion of the
Guarantee Tests shall be provided by the Contractor, free of cost.
cost The bidder should
particularly note that suitable and necessary method and arrangement for the PG test
for 1200TPH of the new conveyor integrating into 800 TPH of existing conveyor system
has to be made by him/them acceptable to owner/RITES at no extra cost.
(d) The guarantee figures and design/performance parameters of the equipment shall be
proved by the Contractor during these Guarantee Tests/ and or during the 'Trial
operation' as detailed
detailed out elsewhere. Should the results of these tests show any
deterioration from the guaranteed values, the Contractor shall modify the equipment as
required to enable it to meet the guarantees. In such case, the Guarantee Tests shall be
repeated and all cost
cost for modifications including labour, materials and the cost of
additional testing to prove that the equipment meets the guarantees, shall be borne by
the Contractor.
(e) The specific tests to be conducted on equipment have been brought out in the technical
specification.
4.18
Test Codes
The provisions outlined in the ASME Performance Test Codes shall be used as a guide for all
the above test procedures unless otherwise specified in the technical specifications.
4.19
TAKING OVER
Upon successful completion
completion of Initial Operations and all the tests conducted to the
Employer's satisfaction, the Employer shall issue to the Contractor a Taking over Certificate

Page 22 of 27
as a proof of the final acceptance of the equipment. Such certificate shall not unreasonably
be with held
ld nor will the Employer delay the issuance thereof, on account of minor
omissions or defects which do not affect the commercial operation and/or cause any serious
risk to the equipment. Such certificate shall not relieve the Contractor of any of his
obligations
ations which otherwise survive, by the terms and conditions of the Contract after
issuance of such certificate.
4.20
TRAINING OF EMPLOYER'S PERSONNEL

The scope of service under training of Employers engineers (min. 3 nos.) shall include a
training module in the areas of Operation & Maintenance. Such training should cover the
following areas as a minimum in order to enable these personnel to individually take the
responsibility of operating and maintaining the wagon tippler system in a manner acceptable
accepta
to the Employer:
The scope of services under training shall also necessarily include training of Employer's
personnel. This shall cover all disciplines viz, Mechanical, Electrical, C&I, & operation etc. and
shall include all the related areas like Design
Design familiarization, training on product design
features and product design softwares of major equipment and systems, engineering,
manufacturing, erection, commissioning, training on operating features of equipment,
quality assurance and testing, plant visits
visits and visits to manufacturer's works, exposure to
various kinds of problems which may be encountered in fabrication, manufacturing,
erection, welding etc. The training module prepared by the contractor, shall be submitted
for the Employers approval, prior
pri to imparting training.
Contractor shall furnish in his offer, details of training module(s) covering above
requirements which shall be subject to Employer's approval. Consolidated training period
included above (for O&M and Engineering) is indicative only. Employer reserves the right to
reappropriate the training period between O&M and engineering depending upon the
details of training module proposed by the Contractor.
Training schedule shall be finalised based on the Contractor's proposal within two (2)
months prior to commissioning.
In all the above cases, wherever the training of Employer's personnel is arranged at the
works of the manufacturer's it shall be noted that the lodging and boarding of the
Employer's personnel shall be at the cost of Contractor.
Co
4.21 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION

In addition to the requirements given in Erection Conditions of Contract (ECC) the following
shall also cover:
1. Working platforms should be fenced and shall have means of access.
2. Ladders in accordance
ccordance with Employers safety rules for construction and erection shall
be used. Rungs shall not be welded on columns. All the stairs shall be provided with
handrails immediately after its erection.
4.22
NOISE LEVEL

Page 23 of 27
The equivalent 'A' weighted sound pressure level measured at a height of 1.5 m above floor
level in elevation and at a distance of one (1) metre horizontally from the nearest surface of
any equipment / machine, furnished and installed under these specifications, expressed in
decibels to a reference of 0.0002 microbar, shall not exceed 85 dBA.
4.23
PACKAGING AND TRANSPORTATION

All the equipments shall be suitably protected, coated, covered or boxed and crated to
prevent damage or deterioration during transit, handling and storage at Site till
t the time of
erection. While packing all the materials, the limitation from the point of view of the sizes of
railway wagons available in India should be taken account of. The Contractor shall be
responsible for any loss or damage during transportation, handling and storage due to
improper packing. The Contractor shall ascertain the availability of Railway wagon sizes from
the Indian Railways or any other agency concerned in India well before effecting despatch of
equipment. Before despatch it shall be ensured
ensured that complete processing and manufacturing
of the components is carried out at shop, only restricted by transport limitation, in order to
ensure that site works like grinding, welding, cutting & pre-assembly
pre assembly to bare minimum. The
Employer's Inspector shall have right to insist for completion of works in shops before
despatch of materials for transportation.
4.24
ELECTRICAL ENCLOSURE
All electrical equipments and devices, including insulation, heating and ventilation devices
shall be designed for ambient
am
temperature (500C) and a maximum relative humidity (75%).
4.25
INSTRUMENTATION AND CONTROL

All instrumentation and control systems/ equipment/ devices/ components, furnished under
this contract shall be in accordance with the requirements stated herein, unless otherwise
specified in the detailed specifications.
All instrument scales and charts shall be calibrated and printed in metric units and shall have
linear graduation. The ranges shall be selected to have the normal reading at 75% of full
scale.
ale. All scales and charts shall be calibrated and printed in Metric Units as follows:
a) Temperature - Degree centigrade (deg C)
b) Pressure - Kilograms per square centimetre (Kg/cm2). Pressure instrument shall
have the unit suffixed with 'a' to indicate absolute
absolute pressure. If nothing is there, that
will mean that the indicated pressure is gauge pressure.
c) Draught - Millimetres of water column (mm wc).
d) Vacuum - Millimeters of mercury column (mm Hg) or water column (mm Wcl).
e) Flow - Tonnes/ hour
f) Flow (Liquid) - Tonnes / hour
g) Flow base - 760 mm Hg. 15 deg.C
h) Density Grams per cubic centimetre.

Page 24 of 27
All instruments and control devices provided on panels shall be of miniaturized design,
suitable for modular flush mounting on panels with front draw out facility and flexible plugin connection at rear.
All electronic modules shall have gold plated connector fingers and further all input and
output modules shall be short circuit proof. These shall also be tropicalised & components
shall be of industrial grade or better.
bette
4.26
ELECTRICAL NOISE CONTROL

The equipment furnished by the Contractor shall incorporate necessary techniques to
eliminate measurement and control problems caused by electrical noise. Areas in
Contractor's equipment which are vulnerable to electrical
electrical noise shall be hardened to
eliminate possible problems. Any additional equipment, services required for effectively
eliminating the noise problems shall be included in the proposal. The equipment shall be
protected against ESD as per IEC-801IEC
2. Radio Frequency
equency interference (RFI) and Electro
Magnetic Interference (EMI) protection against hardware damage and control system malmal
operations/errors shall be provided for all systems.
4.27
TAPPING POINTS FOR MEASUREMENTS

Tapping points shall include probes, wherever
wherever applicable, for analytical measurements and
sampling. For direct temperature measurement of all working media, one stub with internal
threading of approved pattern shall be provided along with suitable plug and washer. The
Contractor will be intimated
intimated about thread standard to be adopted. The following shall be
provided on equipment by the Contractor. The standard which is to be adopted will be
intimated to the Contractor. Temperature test pockets with stub and thermo well Pressure
test pockets
4.28
ELECTRONIC MODULE/COMPONENT DETAILS

The Contractor shall have to furnish all technical details including circuit diagrams,
specifications of components, etc., in respect of each and every electronic card/module as
employed on the various solid state as well as microprocessor based systems and equipment
including conventional instruments, peripherals etc. It is mandatory for the Contractor to
identify clearly the custom built ICs used in the package. The Contractor shall also furnish the
details of any equivalents
uivalents of the same.
4.29
JUNCTION BOXES
The junction boxes shall be made of minimum 2 mm thick sheet steel. Gland plates shall be
removable type and made of 3 mm thick sheet steel. The boxes shall be provided with
detachable cover or hinged door with captive screws. Top of the box shall be arranged
arran
to
slope towards the rear of the box. The box shall be hot dip galvanized and shall be provided
with suitable neoprene gaskets to achieve degree of protection of IPIP-55 as per IS: 2147.
Adequate spacing shall be provided to terminate the external cables.
cables. The boxes shall be
suitable for mounting on various types of steel structures. The terminal blocks provided shall
be of 650 V grade, rated for 10 A for control cables. Suitable numbering for terminal blocks

Page 25 of 27
shall be done. In case of junction box for power

power cable, the box shall be rated for maximum
current carrying capacity. Terminal blocks shall be of one piece, klippon RSF-1
RSF or ELMEX
CSLT-1
1 type with insulating barriers.
The bidder shall supply the following.
S. NO. DESCRIPTION
OF MANUALS
1.
2.
3.
4.
5.
6.
7.
8
9
10
11
12
13
NO OF PRINTS (SETS)
(SETS)
Drawings "FOR APPROVAL"

4
Drawings "FOR INFORMATION"
4
Drawings "FINAL DRAWING"
10
Drawings "AS BUILT "
10
DATASHEETS,DESIGN
CALCULATIONS, etc. and Other type of documents
i)
For Approval
4
ii)
FINAL
10
iii)
Analysis reports of equipments/
piping// structures components/
systems employing software
packages as detailed in the specifications
a)
Input
4
b)
Output
4
c)
Drawings/ Sketches
4
Erection manual "DRAFT"
Erection manual
nual "FINAL"
Operation & Maintenance manual "DRAFT"
Operation & Maintenance manual "FINAL"
Plant Hand Book "DRAFT"
Plant Hand Book "FINAL"
Commissioning and Performance Procedure manual "DRAFT"
Commissioning and Performance Procedure manual "FINAL"
NO. OF CDROMs
1 CD
1 CD
2 CD-ROMs
ROMs
2 CD-ROMs
ROMs
1 CD
2 CD-ROMs -
2CD ROMS
2CD ROMS
2CD ROMS
2CD ROMS
2CD ROMS
2CD ROMS
2CD ROMS
14
Performance and Functional

GURANTEES TEST REPORT
2 CD
15
16
Progress Reports
Project completion report
4
10
2 CD
2CD ROMS
17
QA programme including Organisation for

implementation and QA system manual
(with revision-servicing)
1
18
Vendor details in respect of proposed

vendors including contractors evaluation
report.

Page 26 of 27
19
20
21
22
23
Manufacturing QPs, Field QPs, Field

weldingg schedules and their reference
documents like test procedures, WPS,
(i) For review/comment
3
(ii) For final approval
4
floppies
Welding Manual, Heat Treatment Manuals,
Storage & preservation manuals
Draft
Final
4 sets
Monthly Vendor Approval
and QP approval status
2
QA Documentation Package for items /
equipment manufactured and dispatched to site 2
QA Documentation Package for field activities
on equipment / systems at site
2

set
4 sets
2 CD ROMS
1 CD
1 CD
2 CD ROMS
2 CD ROMS
Page 27 of 27
SECTION 6
ELECTRICS FOR WAGON TIPPLER SYSTEM
1.0
1.1
SPECIAL INSTRUCTIONS TO BIDDERS

Inspection of site by Bidder
Bidder shall inspect the site and examine and obtain all information required and satisfy
himself regarding all matters such as access to site, communication, transport, right of way,
the availability of local labour, availability and rates of materials, local working conditions,
extreme weather conditions, uncertainty of weather, obstructions and hindrances that may
m
arise, etc, which may affect the work or cost thereof, before the submission of his tender.
Ignorance of site conditions shall not be accepted as basis for any claim for compensation.
The submission of tender by Bidder will be construed as evidence that
that such an examination
was made and any later claims / disputes in regard to price quoted shall not be entertained
or considered.
Bidder shall also indicate in his bid all the major assumptions including major design
assumptions / criteria made by him on which the bid is based.
1.2
Compliance with Specification

All equipment and accessories covered under this specification shall conform to the
Technical Specifications given in this document.
In case alternative type of equipment is offered, all technical particulars of equipment
offered, number of such equipment supplied in India, reference list of installations where
such equipment is in operation as per qualifying requirements, type test certificates
cer
of their
collaborators, type test certificates of indigenously made equipment, extent of import
content and availability of spares indigenously, along with any other data for considering the
alternative equipment shall be furnished with the offer.
offer. The Purchaser, however, reserves
the right to accept or reject the proposal without assigning any reason.
All equipment shall be suitable for voltage/frequency variations and other data given in
Electrical System Design.
The contractor shall be responsible for satisfactory working of system with guaranteed
parameters. All the major equipment shall be installed, tested and commissioned under
supervision of representative of manufacturer of respective equipment.
1.3
Standards and Regulations
Technical Specification:Sec-6, Electrical
Page 1 of 97
The design, manufacture, performance, testing and installation (including earthing and other
essential provisions) of equipment and accessories covered under this specification shall, in
general, comply with the latest issue of the following:
follow
Applicable Standards and Codes of Practices published by Bureau of Indian

Standards.
Central Board of Irrigation and Power
Indian Electricity Act, 2003
Central Electricity Authority
Indian Electricity Rules
Equipment specific statutory regulations
Indian Factory Act

Equipment complying with other recognized Standards such as IEC, BS, VDE, DIN etc. will also
be considered if it ensures performance equivalent to or superior to Indian Standards.
nd accessories for which Indian Standards are not available, shall be designed,
Equipment and
manufactured and tested in accordance with the latest issues of recognized Standards such as
IEC, BS, VDE, DIN etc.
In case of conflict between applicable Standards referred to in this part and technical
specifications, the Technical Specifications shall govern to the extent of such difference.
1.4
Make & Interchangeability

This specification is issued for procurement of specified equipment and system preferably
from indigenous suppliers who may make use of imported systems / sub-systems
sub systems / equipment
/ parts and who have valid collaboration agreement with reputed foreign suppliers
suppl
with
experience in design and supply of similar systems as specified. The Bidder shall furnish
division list of supplies from foreign and Indian sources indicating the name of the agency or
make against the respective items. It shall be the responsibility
responsibility of the successful Bidder to
arrange the import license for the imported items offered and to co-ordinate
co ordinate the supply of
equipment from foreign and Indian sources and execute the contract within the agreed time
schedule.
The make of major equipment shall
shall be limited to preferred makes indicated under List of
preferred makes'. Makes of all other equipment and accessories are subject to prior approval
by the Purchaser/RITES.
Similar equipment and components shall be of same make; equipment of same type and
rating shall be interchangeable.
The Purchaser has the option of selecting the manufacturer of electrical equipment,
instruments and controls and any other specialized items in the interest of standardization and
the successful Bidder shall have to supply equipment of particular make, if so required.
Page 2 of 97
1.5
Safety
All equipment shall be complete with approved safety devices wherever a potential hazard
exists and with provision for safe access of personnel to and around equipment for
operational and maintenance
enance functions.
The design shall include not only those usually furnished with elements of machinery but also
the additional covers, staircases, ladders, etc which are necessary for safe operation of the
plant. All danger and caution notice boards shall
shall be in Hindi, English and Oriya.
The Contractor must take sufficient care in moving his construction plants and equipment
from one place to another so that those may not cause any damage to the property of the
Purchaser particularly to the overhead and underground cables and other service lines.
When the work is carried out at night or in the obscure day light, adequate arrangements for
flood lighting in the working area shall be made by the Bidder.
Bidde
The safely postures/regulations for the prevention of accidents shall be displayed by the
Bidder at appropriate places. Notices and warning signs shall be displayed for all sources of
dangers.
All electrical drives and equipment must be equipped with safety devices. The safety
provisions shall conform to the recognized standards, safety codes and statutory regulations.
All safety measures as required to be adopted as per the statutory regulations
regulati
and the safety
rules of the plant shall be strictly followed by the Contractor during the execution of the
Contract.
Adequate number of first aid boxes as defined in the State Factory Rules shall be provided and
maintained at all the work sites.
1.6
Coding/Numbering
ding/Numbering Scheme
A coding scheme for identifying the drawings, plant and equipment, structures, spares and
shipping documents shall be adopted by the contractor in a sequential manner.
1.7
Contractor's License
The contractor shall possess a valid and
and competent contractor's license of specified voltage
issued by the electrical licensing authorities of the Govt. of Orissa for carrying out electrical
installation work of the type and magnitude covered in this document, in the state of Orissa.
The contractor
ctor shall also be required to obtain labour license from Statutory Authority.
Page 3 of 97
Copy of the license shall be made available to the Purchaser/consultant for verifications during
the execution of contract.
All linemen, wiremen, electricians, supervisors and
and engineers engaged by the Bidder or his
sub-Bidder
Bidder shall possess necessary valid license issued by the statutory authority and the same
shall be submitted for verification, if called for.
1.8
Compliance with rules, regulations, and obtaining statutory approval

appr
All equipment/materials shall be installed in accordance with the requirements of relevant
standards, Indian electricity Rules, Indian Electricity Act, 2003 and also the Factory Act. It is the
responsibility of the Bidder to see that the electrical installation
installation supplied and erected by him
shall be to the entire satisfaction of Chief Electrical Inspector, Central Electricity Authority or
any other statutory body having jurisdiction in the area and also to the Purchaser/ consultant.
btaining all statutory approvals for the installation to be carried out
The responsibility for obtaining
rests entirely with the contractor. It shall be the responsibility of the contractor to prepare and
submit all necessary drawings, calculations, test certificates and relevant details (other than
those given by the Purchaser/consultant) to the Electrical Inspector and obtain prior approval
for commencing the work and for the complete installation work done. The inspection fee for
statutory approvals shall be borne by the bidder.
2.0
SCOPE AND BRIEF DESCRIPTION OF WORK AND ELECTRICAL SYSTEM DESIGN CRITERIA
2.1
General
The scope of work includes the basic engineering, detailed design engineering, manufacture or
procurement of electrical equipment, shop testing, packing, transportation, loading, delivery
at site, unloading, storage at site, handling, erection, pre-commissioning
pre commissioning tests and
commissioning of all equipment/system including preliminary acceptance test, performance
guarantee and post commissioning services, including
including insurance cover during transit, storage,
erection and commissioning. The job shall be done on turnkey basis. Scope of Bidder shall also
include the following:
Supply of commissioning spares
Supply of mandatory spares required for one year normal O&M
Supply of special tools and tackles for the equipment/systems supplied
2.2
Bidder shall provide complete design inputs in form of assignment indicating complete
requirements of civil building to accommodate comfortably an electrical substation consisting
consistin
of electrical equipment under his scope as well as the equipment under scope of the
Purchaser, if any meeting all the required statutory clearances. The building shall be finalized
and constructed by the bidder
Bidder shall also provide the following design
design inputs for detailed design and engineering of
civil and structural works i.e. foundations, room, etc. The same shall be taken into
consideration while designing the civil buildings by the bidder:
Page 4 of 97
Static and dynamic loading of the equipment

Clearances,, approach, safety exits required
Clearances from all the four sides of the walls shall be maintained, wherever applicable in the
electrical premises while considering the design inputs.
The civil buildings for the complete WTP substation (including switchgear
switchgear room, battery room,
transformer rooms, etc), dust suppression MCC room, electric room for WTP, Apron feeder,
feeder
etc shall be under the scope of work. Electrical sub-station
station will be installed in the out door
near the wagon tippler station.
2.3
er shall also take into consideration of various aspects like clearances, approach, roads,
Bidder
safety exits, cable trenches, transmission lines, foundations, floor opening, inserts,
underground GI pipes, office premises, etc while finalizing the designing of civil
c installations
and building within battery limit of the package.
2.4
cope of the Bidder starts from tapping 33KV source including supply of 33KV/415KV
Scope
transformers and corresponding switchboards, bus ducts and down below all the electrical
equipments etc.
For WT System Bidder shall include complete electrics including all the equipment/services on
turnkey basis as per requirement irrespective of the same ass specified in the specification or
not. Separate set of suitable rated 33/0.44 kV transformers,
ormers, dedicated MCC for WT System
machine, PLC, UPS with sealed maintenance free batteries, VVVF drive control system,
junction boxes, other equipment, etc shall be included for smooth operation of wagon tippler
system.
Air conditioning of control room to be done with suitable capacity by air cooled packaged AC.
AC
For other LT drives and mechanism, Bidder shall include dedicated MCCs consisting of required
number and capacity of outgoing feeders.
For dry fog type dust suppression
suppression systems of transfer points in junction houses, Bidder shall
include a dedicated MCC in pump cum compressor house.
For miscellaneous and non-critical
non critical loads like power socket cabinets, ventilation, AC power
requirement of 33KV switchboard / 415V PCC
PCC / transformer marshalling boxes, etc, Bidder
shall include a dedicated PDB.
For illumination of WT System (Wagon Tippler, Apron feeder) including conveyors and
substation, dust suppression room and adjoining areas / sub areas, Bidder shall consider a
dedicated LDB and sufficient number of SLDBs. SLDB shall be timer control. Two numbers
flood light high mast towers 30m high eachshall
shall be included for illumination of WT Area with
metal Halide
lide Lamps. Illumination of street light and conveyor gallery shall be with LED lamps
within a radius of 500m of wagon tippler.
tippler
Page 5 of 97
A separate room shall be provided adjacent to WT control room to house the Dust suppression
MCC, Pumps, compressors etc for the DS System by the Bidder. Bidder shall furnish the
complete requirements
quirements including size, cable trenches/opening, etc. The pressurized ventilation
shall be provided by the Bidder in this Dust Suppression Room.
The number of MCCs / DBs shall be provided as per requirement by the bidder.
Following shall also be included
inclu
in the Bidders scope:
Pressurized ventilation system for the switchgearroom.
switchgearroom
Pressurized ventilation system for the Dust Suppression cum MCC room.
Air conditioning of battery and battery charger rooms.
Exhaust fan in the transformer rooms.
The bidderr shall supply the PLC for safe operation of WT System. Necessary integration with
existing PLC of new coal yard will be scope of tenderer.
tender . Design and installation of electrics shall
ensure operation of complete integrated electrics of the various drives/mechanism
drives/m
without
any constraint during maintenance.
Bidder shall also consider sufficient numbers of local auxiliary PDBs to cater miscellaneous
loads of WT System. These PDBs shall be located at various places and exact locations shall be
finalized duringg detailed engineering.
HT Power cables and LT power/control cables shall be laid in different cable trays. LT power
cables and LT control cables shall also be laid in different trays. 24V DC cables shall be laid
entirely in different dedicated trays.
Cable trays in single tier or in multitier shall be installed in vertical arrangement everywhere to
avert coal accumulation and space reduction. Cable trays shall be supplied by the bidder.
Power supply of all voltage levels including 415V AC or 220V DC, 24V DC etc, shall be arranged
by Bidder himself by providing suitable systems. 24V DC supply shall be through screened
cable to be supplied by the Bidder.
Only at receiving point of 33KV, control supply of 415V AC and 220V DC shall be made
available by the
he purchaser.
purchaser
Following HT cabling shall also be included by the Bidder apart from the above:
1. ACSR conductor for O/H transmission of 33kv line.
2. Cabling required for underground track/road crossings of33 kV System including intake
pump well feeder and ashpond feeder.
feeder
Standard power and control cables (Trailing Cables) of required sizes in adequate quantum
shall be supplied and terminated by the Bidder. Hence, complete HT & LT trailing cables for
Wagon Tippler, etc
tc shall be supplied and laid by the bidder.
Cables used for 24 VDC supply for PLC system shall be laid separately from 230 V AC control
cables.
Page 6 of 97
All cables Power cable, Control Cable, Trailing Cable, instrumentation cables, signal cables,
screened cables,
es, special cables, fibre optic cables shall be supplied, laid and terminated by the
Bidder as per actual site requirement.
Cabling shall include laying and termination at both ends, cable trays and cable accessories for
the cables to be laid by the Bidder.
Bidd
Bidder shall consider all required cables for cable engineering, preparation of cable schedule,
terminal plans, cable support structure layout, cable layout drawings, etc. All cable trays,
accessories, termination kits, glands, lugs, clamps including clamps, etc shall be included in the
scope for all the cables (to be supplied by the Successful Bidder) interconnecting both side
equipment or one side equipment of the Bidders scope.
All drives shall be controlled and monitored at existing WT SYSTEM control room from the PLC.
Bidder shall include PLC and all the interfacing/ interconnecting cabling and cable trays. All
Cables required for this interfacing, shall be supplied and laid by the Bidder. Copper power
cables, if required by the bidder, shall also be under scope of supply and laying of the bidder.
Ampere meters for all conveyor belts are to be installed at the control room for monitoring
the current of each drive.
Bidder shall consider numeric PLC and type of Inputs / Outputs (I/Os) required for WT system
for smooth and trouble free operation of various drives / mechanism from the WT SYSTEM
control room. Sufficient number of I/Os in PLC extension shall be considered as per actual
act
requirement. Exact number and type of I/Os shall be decided during detailed engineering
based on approved schemes.
Bidder shall also consider sufficient number of I/Os in PLC control and monitoring for electrical
power distribution system for the electrical power distribution system starting from 33KV till
the down most voltage level.
New PLC of WT shall be interfaced with existing PLC of Coal Handling Plant for operation of BC
115 and BC 103.
The earthing system shall be provided for complete
complete WT SYSTEM plant. The new earthing
system shall be connected to the existing earthing system.
Bidder shall also consider earthing of following equipment:
33kv substation equipments.
WT LT distribution transformers Neutral as well as body earthing
415
5 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room
Control panel for power distribution equipment at existing WT control room
LT busducts
Charger panels, DCDB, etc at WT substation in switchgear cum MCC room
Underground eart mat.
Page 7 of 97
Bidder shall consider earthing ring mains at each electrical premise and connect the electrical
equipment with the rings. The earthing ring mains shall be connected with underground
earthing mats to be provided by the bidder made of 2x40mm dia solid MS rod. Adequate
number of risers shall be made available for connection with his earthing ring main. For
transformer neutral earthing, bidder shall consider dedicated plate earthing.
Lightning protection shall be provided by the bidder for complete WT SYSTEM including tall
installations covered under the battery limit.
Bidder shall also include complete illumination of the premises under the battery limit and all
the above electrical premises coming at WT SYSTEM substation and adjoining areas.
conditioning, ventilation and exhaust fans for various rooms / premises of WT SYSTEM
Air-conditioning,
along with their complete electrics shall be under scope of the Bidder. The battery and battery
charger room shall be air-conditioned. Switchgear cum MCC room of WT substation shall have
pressurized ventilation. Transformer rooms of the WT substation shall have exhaust fans.
fans
All interconnection for power, control and instrumentation/signal amongst equipment
equipmen
supplied by the Bidder shall be under Bidder's scope of work. Similar interconnections
including power, control and signal between Purchaser's equipment and Bidder's equipment
shall be done by the Bidder. All the cable terminations at both ends, cable trays
tr
and cable
accessories shall be under Bidder's scope.
2.5
Electrical system design criteria

a)
General
The design, manufacture, assembly and testing as well as performance of the equipment shall
conform to the relevant IS : specifications (latest revision) and other relevant standards. In
case IS specifications is not available in respect of certain items, the Bidder may base his
proposals on IEC/BS/VDE/DIN recommendations or other reputed national or international
standards subject to the approval of the Purchaser/RITES.
Purchaser
. All equipment supplied and all work
done including system design and detailed engineering shall also comply with the statutory
requirements of the Government of India and the Government of Orissa.
b)
Climatic Conditions
Electrical Equipment selection and derating shall generally be based on ambient temperature
of 50oC. The equipment offered shall be suitable for smooth, efficient and trouble free service
in the climate prevailing at Angul.
c)
Standard Voltage levels
Page 8 of 97
Following power utilization standard voltage levels shall be adopted for various systems:
1. Station supply
3. Power supply to PLC extension
4. DC control supply
5. Plant illumination
Welding socket / power
6.
receptacles
Special socket outlets for
7.
portable lamps
8. Sockets for electrical tools, etc
9 Emergency illumination
d)
33 kV, 3 phase, 3 wire, unearthed system

415 V, 3 phase, 4 wire, solidly earthed
240 V, 1 phase, 2 wire, 50 Hz, A.C. (from UPS)
220 V, 2 wire, unearthed
240 V, 1 phase, 2 wire, 50 Hz, A.C.
415 V, 3 phase, 50 Hz, A.C. outlets
240 V, 1 phase, 2 wire, 50 Hz, A.C. outlets
24 V, 1 phase, 2 wire, 50 Hz, A.C. through suitable
transformers
240 V, 1 phase, 2 wire, 50 Hz, with one point earthed
220 V DC
Permissible variations
The system / unit / plant / equipment shall be designed suitably for following variation in
voltage and frequency;
Voltage
+/-10%
10%
Frequency
+/-5%
Permissible variation for control and regulation equipment with

rated performance and control quality maintained
+/- 10 %
+/-5%
Permissible voltage dip at HT switchgear bus during starting of

motor
- 15 %
Permissible voltage dip at MCC bus during starting of LT motors
- 15 %
Permissible variation with rated performance and control

effectiveness maintained
e)
Symmetrical short circuit ratings
The short circuit ratings of all the equipment like MCCs, motors, PDBs / LDBs, cables, power
socket & lighting cabinets, etc shall be selected keeping in view the fault level capacities of the
Purchasers electrical equipment.
The three phase symmetrical short circuit rating at 33 kV level shall be 25kA.
25
The three phase
symmetrical short circuit rating at 415 V level shall be 50kA.
The rated short circuit withstand duration for 33 KV shall be 3 sec, whereas for 415 V system,
it shall be 1.0 sec.
f)
Criteria for selection of voltage levels for

f drive motors
Page 9 of 97
All AC squirrel cage induction motors shall be fed at 415V

V from switchboard through air circuit
breakers with numeric type comprehensive
compreh
motor protection relays via power contactor and
overload relay.
g)
System Earthing
33kV system is unearthed,, 415V system is solidly earthed.

2.6
ELECTRICAL SYSTEM REQUIREMENTS

Minimum number of spare feeders in each of the MCC / PDB / LDB / SLDB shall be 10% subject
to minimum one no. of each type and rating in each section. The rating and
a type of spare
feeder shall be decided during detailed engineering stage.
Sizes and requirement of various power and control cables shall be decided and intimated to
the Purchaser well in advance to suit the approved scheme/to achieve scheme requirement.
requiremen
Space heater power supply to the motors shall be fed from the MCC through same cubicle by
415/240 V transformers. Space heaters shall be interlocked with motor main power supply.
Bidder to submit a system wise drive list indicating required process interlocks,
in
permissive
conditions etc. with places and mode of control, control system philosophy with provision of
various control, indication, measuring devices at various places. The Purchaser/RITES
Purchaser
shall
approve this based on above approved philosophy and
and Bidder shall have to provide all
equipment / materials and prepare a control scheme/logic diagram which shall be utilized for
designing the motor feeders at 33 kV switchboard and 415 V MCC at Bidders end.
mentioned control philosophy and interlocking logic shall be prepared as per the
Above-mentioned
technological requirement.
Suitable electrics for all the material handling equipment like hoist, etc shall be provided for
handling the various drives and mechanism.
Warning hooter shall be of brushless type Siren and AC single phase.
All actuators shall be of geared motors.
Complete 24 V system, wherever required, shall be provided by the bidder.
24 V and 230 V AC shall be taken through separate cables. Screened
Screened cables shall be supplied
and used for 24 V power supply.
All the indication lamps shall be LED based with LVGP (Low Voltage Glow Protection) up to 100
V.
All the hoist control panel shall be located at workable height and platform shall be provided
forr each hoist at one point for maintenance purpose.
Page 10 of 97
Ammeter for Wagon Tippler, Apron feeder

feede and Conveyors etc. shall also be provided in
Control Pane for monitoring of currents.
3.0
PERFORMANCE REQUIREMENT AND GUARANTEE

The PG test shall be conducted for overall system of wagon tippler including electrical system
and equipments as mentioned elsewhere.
4.0
TECHNICAL SPECIFICATION
4.1
CONTROL & PROTECTION SYSTEM AND LAYOUT CONTROL PHILOSOPHY

The control, monitoring, interlocking, annunciation and metering functions of various
drives/mechanism shall be performed through PLC at WT SYSTEM control room. All the drives
shall also be operated from local control stations for emergency stop as well as for decoupled
trial run of motors.
ks / alarm, etc shall be provided for various drives/mechanism of cooling
Following interlocks
water system:
When conveyor will trip, Apron feeder will trip.
When apron feeder trips, Wagon tippler will trip.
When any of the running drive trips, the standby drive shall start automatically.
When any of the running conveyor trips, the preceding/succeeding conveyor shall trip
automatically.
A conveyor shall take start only when its preceding conveyor starts
Auto-Tripping
Tripping of conveyor drives through various mechanism like pull chord, belt sway
switch, etc
The above interlocks/alarms and control philosophy are minimum and indicative. The detailed
requirements for the above shall be finalized during detailed engineering.
en
Bidder shall furnish details of control, monitoring, interlocking, protection, annunciation and
metering system for all drive. Bidder shall use state of art technology while fulfilling the
functional requirement of all the equipment for smooth and trouble free operation through
PLC.
20 mA range) as per requirement shall be provided to facilitate control
Various transducers (4-20
and monitoring from PLC. Required transducers and wirings to hook up all analog and digital
inputs / outputs to / from PLC shall be included in the scope.
Interlocking arrangement shall also be furnished to take care of all the approved logic
schemes. Bidder shall provide necessary wiring, control and required items to achieve the
approved logic / scheme. Selecting local
local / remote switch of local control station in local
position shall carry out local mode operation of the drives for test/trial etc. Permissive
Page 11 of 97
conditions for start and tripping of various drives shall be provided as per approved logic
diagrams.
ed hardwired control panel / desk shall also be provided by the bidder at WT control
A dedicated
room to control and monitor electrical power distribution system.
Controls of all equipments of wagon tippler including conveyors all interlocks shall be PLC
based. The PLC system shall be latest version having dual redundant processor with HMI based
control station. There shall be two HMI control system with one operating station and other
an engineering station. The system shall be designed with 10% extra input/output provision.
p
Input/output of PLC(analog & digital) shall have at least 10% extra channel wired up to TBs
TB in
the panels. A portable programming station (Laptop) with all the ladder logic/
programming/software shall be provided for engineering and troubleshooting
troubleshooti functions. The
system shall be capable of communicating with the existing PLC system of the CHP(The
existing PLC is of GE Fanuc makemake Model 90-30,CPU-370).
370). The vendor shall be responsible for
communicating and displaying the important parameters of wagon
wagon tippler PLC system to the
existing CHP PLC through optical fibre cable. All electrical power distribution system shall be
controled and monitored through PLC.
PROTECTION SYSTEM
Protections for the different electrical equipment are enlisted below:
motor comprehensive
omprehensive numeric motor protection shall be provided in the
For Protection of LTT motor,
switchboard.
Laying of control and power cables including supply and laying of signal cables from motors to
switchboard shall be in the scope of Bidder.
ensive numeric motor protection including but not limited to the following:
Comprehensive
Instantaneous over current protection
Differential protection (for rating above 1000 kW)
Instantaneous time over current protection in two phases and definite time delayed over
current
urrent alarm on the third phase
Negative phase sequence protection
Thermal overload taking -ve and +ve phase sequence into account
Earth fault
Locked rotor protection
Winding temp monitoring and alarm for rating beyond 1000 kW
Under voltage protection
protectio
Microprocessor based numeric motor protection relay shall also have following facilities:
Communication facility with open protocol like IEC/Modbus.
Relay should store last five fault records (minimum) with date and time stamping.
Relay should have no.
o. of start menu for start inhibition.
Relay should have facility for displaying three phase and neutral current
Page 12 of 97
Relay should have heavy duty tripping contact which will be used for breaker tripping
Battery backup facilities
The Motor Protection Relays shall also have the following additional features:
Fault recording facility
Password protection
Local/remote communication facility with open protocol
Minimum 4 nos. BI and 4 nos. BO
Protection of LT motor (less than 75 kW)
Motors below 75 kW shall be fed from MCC through MCCB with power contactor and overload
relay.
Motors of 5 kW and above but below 75 kW, shall have fed through MCCBs (for short circuit
protection), numeric motor protection relay like MPR-300
MPR 300 or equivalent
equivalen (for overload and
other motor protection) and power contactors.
For motor below 5 kW, MPCBs may be considered in place of MCCBs.
Single phasing protection shall also be provided in the MCC modules.
METERING
Following metering shall be provided in various MCC/DBs;
415 V MCC
1. 415 V INCOMER (EACH) AMMETER (DIGITAL TYPE)
VOLTMETER
kWH METER
2. BUS COUPLER
AMMETER
3. OUTGOING
AMMETER (DIGITAL TYPE)
MOTOR FEEDER (EACH)
PDB
1. 415 V INCOMER
COMER (EACH)
4.2

VOLTMETER 2. OUTGOING (EACH)
LT MOTOR CONTROL CENTRE (LT MCC)
Constructional Features
Fully drawout type with modules having service, test and isolated positions. Floor mounting,
free standing with base channel 50 mm high for fixing on the inserts on the floor. MCC shall be
single front, totally enclosed, dust and vermin proof.
All the module of the MCCs shall be spacious to facilitate maintenance of equipment inside the
module. Pollution degree applicable shall be pollution degree 4 as per IS-13947
IS 13947 (Pt-I),
(Pt 1993.
Page 13 of 97
Incomer and bus coupler panels

MCC incomers and bus couplers shall have Air circuit breakers. Incomers and bus couplers
shall be rated for at least 125% of maximum demand
demand taking into account the spare feeders
and shall be suitable for the specified fault level.
Incomers and bus coupler shall be electrically interlocked to prevent parallel operation.
However, a definite delay defeat Interlock switch shall be provided to facilitate parallel
operation. Auto changeover facility shall also be provided between the two incomers and bus
coupler.
Feeder Modules
Feeders for motors of 75 kW and above shall be fully drawout type air circuit breakers (ACBs)
with numeric type comprehensive
mprehensive motor protection relays. Other motor feeders shall be
consisting of MCCB, contactor, overload relay as main power components to ensure type 2
protection. The short circuit release of MCCBs shall be suitably selected to the applications
concerned.
At least 10% spare feeders (minimum one spare feeder of each type and rating bus sectionsection
wise) shall be provided. Ammeters with selector switches shall be provided for all continuous /
intermittent running motors beyond 15 kW rated drives.
d terminations
Busbars and
Busbars and connection shall be of high conductivity aluminium/aluminium alloy of suitable
hardness and purity complying with as per IS-5082-1981.
IS
1981. Busbars shall be insulated by colour
coded heat shrinkable sleeves.
Busbars shall be rated for the nominal current rating of incoming breaker and for the full
short-circuit
circuit rating. Earth bus shall run throughout the length of MCC at bottom .
Control bus shall be provided in the bus bar chamber isolated with main bus in all the MCCs.
Similarly power and control terminations shall be in separate chambers in the MCCs. Cable
alleyy shall have sufficient space for maintenance and minimum width of cable alley
all shall be
300 mm. Shrouding/isolation shall be provided for outgoing power terminations in the
th cable
alleys.
ys. Modules of MCCs shall be spacious for easy maintenance of the various equipment
inside.
Short circuit strength
Rated short time withstand current shall not be less than 50 kA for 1 second. Rated peak
withstand current not less than 2.1 times the specified short circuit level.
Air circuit breaker (ACB)
Page 14 of 97
Air break, drawout type conforming to IS 13947 (1993) and symmetrical

symmetrical breaking capacity not
less than 50 kA for 1 second shall be provided. Service short circuit breaking capacity (Ics) shall
be 100% of rated ultimate short circuit breaking capacity (Icu). Performance category of the
MCC shall be B. ACB used for incomer
incomer & bus coupler should have numerical feeder protection
relay.
Motor operated mechanism shall be applicable with air circuit breakers. Spring charged stored
energy mechanism shall be there to ensure high speed closing and tripping independent of the
operating
perating forces. Electrical anti pumping and trip free feature shall also be provided. Spring
charging universal motor suitable for rated control voltage (220 DC). The closing coil and trip
coil shall be suitable to DC operation.
Closing and tripping of ACB shall be by closing coil (operating range 85% to 110% of rated
voltage) and tripping by trip coil (operating range 70% to 110% of rated voltage) respectively.
Built-in
in direct acting type microprocessor based numerical releases for short circuit, over
current and earth fault shall be provided.
Auto changeover shall be done through under voltage relays and check synchronization relay
with time delay. All the relays shall be microprocessor based numerical relays.
Motor protection moulded case circuit breaker (MCCB)

The characteristic shall match the motor duty application. Rated ultimate short circuit
breaking capacity (Icu) shall be 50 kA. Ratings selected shall be at least 125% of the full load
current of the motor.
otor. For small rating drives such as valves, Siemens 3UV13 type (or
equivalent) or motor protection circuit breaker (MPCB) shall be used. Utilisation category shall
be A.
Magnetic contactors
Pick up shall be positively at voltage between 85% to 110% of rated value. For frequently
reversing drives, AC 3 rating selected shall be 50% higher than full load current of the motor at
the specified duty cycle shall be provided. For reversible drives, mechanically as well as
electrically interlocked contactors shall
sh be used.
Thermal overload relay
Thermal overload relay shall be triple pole, ambient temperature compensated, inverse time
lag, hand reset type, bimetallic with adjustable setting and built in single phase protection. The
relay shall be able to withstand prospective short circuit-current
circuit
without damage or injurious
heating till the motor protection MCCB clears the fault. Tripping indication and reset push
button operable from outside shall be provided.
Push Buttons / Indicating Lamps / Indicating instruments
Page 15 of 97
Push buttons shall be spring

ng return, push to actuate type and their contacts shall be suitable to
carry and break 240 V AC, 10 A and 220 V DC, 1 A. Indicating lamps shall be LED LVGP (Low
Voltage Glow Protection up to 100V) type. Standard colours shall be applicable for push
buttonss and for indicating lamps. Indicating instruments shall be flush mounting, square dial
with 900 scale with zero adjusting device for external operation. Accuracy class shall be 1.0 or
better. KWh meter shall also be provided with incomers.
MCC shall havee run / start, stop, tripped, and ready to start push button cum indication lamp
for motor feeders.
Current transformers
The thermal and dynamic stability current for CTs and CT ratio shall be as per requirement.
Protection and measuring current transformer
transformer shall be bar primary/ window type with 1A
secondary. Burden of CTs shall be as required by the associated measuring equipment.
Potential transformers
Potential transformers shall be provided on incomers as well as on buses and shall be in same
circuit
rcuit breaker cubicle. 415 V side of PTs shall have fuses. Accuracy class 1.0 shall be used. VA
burden shall be selected based on meters and relays connected with the PT.
Control transformer
Control transformers shall be dry type 415V/240V, primary taps at +2.5 %, +5 % and shall be
mounted in drawout trolley if outgoing feeders are in drawout execution. Control supply shall
have supervision facility, alarm shall be provided for non availability
availability of any one of the control
supply. Automatic/manual changeover facility shall also be provided. Auto-changeover
Auto
shall be
blocked if power supply to respective section is not available.
For capacity consideration of control transformers, each shall be capable
capable to meet 100 % load
including spare feeders and 10 % cushion for future and 15 VA for each module for remote
aux. relays and indication lamps. Separate DC and AC control (3 ph & neutral) copper busbars
shall be considered for each MCC. From AC control
control bus, motor space heater supply shall be
tapped with suitable control and interlocking arrangement.
220V DC Control supply
220V DC supply is required for electrically controlled ACBs. For two sections, two DC buses
shall be there. In bus coupler panel, manual switch shall be there for changeover of one supply
to other section. Non-availability
availability of DC supply shall be annunciated in MCC or nearby control
room.
Internal Control Wiring and external Terminations
Page 16 of 97
Internal control wiring shall be by 1100V

V grade PVC insulated, single core stranded copper
conductor of minimum cross section 2.5 sq.mm. for CTs and space heater circuits and 1.5
sq.mm for other circuits. For CT secondary wiring, disconnecting type terminal blocks (CAD
type) shall be considered..
For external terminations,, DIN rail mounting type bakelite type terminal blocks shall be used
complete with insulated barriers, stud type terminals, washers, nuts and lock nuts and
identification strips. Power and control terminals segregated.
Other accessories
Following items shall be provided for the MCCs under the scope of the Bidder:
Breaker lifting/handling trolley (for ACBs) : 1 No. per MCC Room
Breaker racking handle (for ACBs)
: 4 Nos. per MCC Room
Panel key (if applicable)
: 5 Nos. per MCC Room
Selection of power components & wiring for continuous duty cage motor drives is given below:
Motor
Rating
at S1
Duty
(KW )
Up to
3.7
5.5
7.5
11
15
18.5
22
30
37
45
55
75
90
110
125
135
160
Minimum size for internal

power connections
Copper
Aluminium flat
wire
(mm x mm )**
(sq.mm)
Minimu
m
rating
of
MCCB
Minimum
rating of
contactor
(AMPS) AC3
duty
*
*
*
25
40
40
4
4
6
4x 2.5(copper)
4x 2.5(copper)
4x6
*
*
*
*
*
*
*
*
*
*
*
*
*
*
40
63
63
63
100
100
160
160
200
400
400
400
400
400
6
10
16
16
25
35
50
70
95
12 x 2
12 x 2
12 x 2
15 x 3
15 x 3
20 x 3
20 x 5
20 x 5
30 x 5
40 x 5
40 x 5
40 x 5
4 x 16
4 x 16
3.5 x 35
3.5 x 35
3.5 x 70
3.5 x 70
3.5 x 95
3.5 x 120
3.5 x 185
3.5 x 185
2(3.5 x 120)
2(3.5 x 120)
2(3.5 x 120)
2(3.5 x 185)
Minimum size of
power cable
Aluminium
(sq.mm)
*Minimum rating of MCCB shall be selected to achieve type 2' protection.
Page 17 of 97
** Copper flat of equivalent size can be used instead of aluminium flat.

NOTES : Overload relay shall be selected based on actual full load current and starting time.
GENERAL TECHNICAL PARTICULARS OF MCC
GENERAL
1. System
2. Type
3. Pollution degree
4. Creepage distance
5. Enclosure
6. Mounting
: 415V, 3 phase, 4 wire, 50 Hz. Solidly earthed neutral

: Indoor type, cubicle construction, free standing
:4
: As per IS-13947 (1993), Part-I
: IP54
: I/C & B/C in single tier and O/G in multi-tier
tier arrangement
execution
7. Neutral earthing
: Effectively earthed
8. Control supply : 240V AC / 220 DC for ACB
9. Short time rating
: 50 kA for 1 sec
10. Autochangeover required?
:Yes
11. Delay drop off required?
uired?
:Yes
12. Control supply
: 220 V DC for ACB, 240V AC/220 DC for spring charge motor and
240 V AC for MCCB, etc.
AIR CIRCUIT BREAKER
: Indoor
1. Service
2. Type
: Air break
3. Insulation level
: 6 kV (1.2x50 micro Sec) Impulse withstand
withsta
4. Utilization Category
:B
5. Operating mechanism : Stored energy type
I. Closing
: Motor wound spring operated
II. Opening
: Shunt trip coil
III. Latching
: Mechanically and electrically trip free arrangement
6. Auxiliary Voltage
: DC (85% - 110%)
I. Closing
II. Tripping
: DC (70% - 110%)
III. Spring charging
: 240V + 10% AC or DC motor
IV. Space heater & Lamp : 240V + 10% AC 50 Hz
7. No. of poles of C.B
:3
CURRENT TRANSFORMERS
1. Type
: Resin cast, window type
2. Rated voltage
: 415 V +10%
3. C.T. secondary
: 1 Amp rating
4. Accuracy
i. Protection
: 5P10 or better for protection
ii. Metering
: Class - 1
Page 18 of 97
POTENTIAL TRANSFORMERS
1. Type
: Cast Resin
2. Primary/secondary
voltage ratio
415V
3
110V
3
3. Method of connection :Star/Star connection

4. Rated voltage
: 1.2 continuous, 1.9 for 30 Sec factor
5. Class of insulation
: Class E or better
CONTROL TRANSFORMER
1. Type
: Dry cast resin, class B or better
2. Voltage ratio
: 415V/240V
3. Rated burden
: As per requirement (Minimum 1.5 kVA)
4. Quantity
: 2 nos. per board and minimum capacity shall be 1 kVA
MOULDED CASE CIRCUIT BREAKER
1. Type
: Air break (Motor duty)
2. Rated service
: 415 V +/+/ 10% voltage
3. Utilization Category : A
4. Protection
: Type `2 to the contactor
CONTACTORS
:3
1. No. poles
2. Rated service
: 415 V + 10% voltage
3. Control circuit : 240V +10% 1ph, 50Hz +5%
4. Utilisation category
: AC23A for uni-directional
uni
motors
5. Limits of operation
: 85% to 110%
i. Closing (pick-up)
ii. Dropout
: Shall not be higher than 75%
RELAYS/RELEASE
1. Relay type
2. Release type
: Numeric
: Microprocessor based.
THERMAL OVERLOAD RELAYS

1. Type
: Ambient temperature compensated bimetal operated hand reset type (direct or
C.T. operated)
2. Hand resetting
: To be provided at the front of the panel feature
3. Single phasing protection
: Built in
4.3
CABLE AND CABLE ACCESSORIES
TYPES OF CABLES
Page 19 of 97
All cables viz.power

power and control cables, trailing cables, signal, instrumentation, screened, fire
optics, copper power cables and special purpose cables required for applications concerned
and for satisfactory operation of the all the drives at Wagon Tippler plant shall be in the scope
of the Bidder. All power cables(XLPE)
cables
should be FRLS (Fire Retardant low sulphur) type (inner
& outer sheath) and shall have round armouring.
armouring
Bidder shall include all the cable accessories in his scope of supply as
as well as installation as per
actual requirement at site.
Trailing Cables
All the trailing cables shall be 4 core XLPE. The cable for application in 33 KV supply system
shall conform to IS:7098(Part
(Part-2)
2) 1985 and for low and medium voltage including 1100v shall
conform to IS: 7098(part I)),1988.
HT trailing cables shall be 33 KV (UE) heavy duty power cable 4 core, flexible. The detailed
specification for the HT trailing cables required shall be furnished
furnished by the Bidder along with the
tender.
1.1 kV grade flexible trailing cable shall be of heavy duty type having tinned annealed high
conductivity flexible copper conductors, butyl rubber or ethylene propylene (EPR) insulation
and CSP or PCP sheathing. The conductor shall conform to IS:8130 - 1984 and insulation and
sheathing shall be as per IS:6380 - 1984. For high temperature zone and side-arm-charger
side
the
insulation shall be of silicone rubber.
For all the cabling, Bidder shall include laying
laying including all the GI prefabricated cable trays/hot
dip galvanized perforated trays and other cable accessories like cable termination/jointing kits,
glands, cable identification tags, connectors, ferrules, clamps, etc
HT Cable End Termination & Straight through jointing kits

All high voltage cable terminations shall meet the test procedures and requirements stipulated
in IEEE 48-1990 as class-II termination.
Heat shrinkable type of cable termination and joints shall be used for HT cables in indoor
i
and
outdoor applications as specified.
The stress control and grading wherever necessary shall be by means of semi conducting heat
shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces
shall be achieved by using
ng hot melted sealants or adhesives.
Page 20 of 97
Where such sealants or adhesives shall be exposed to high electrical stress, same shall be track
resistant type.
Straight through joints and end sealing termination kits of 33 KV (UE) grade cross-linked
cross
polyethylene cables shall be of well tried out design compatible for XLPE insulation. The
joints/ends sealing kits shall be of heat shrinkable type and shall be complete with stress
grading material, protective and lug sealing sleeves, self tightening earthing clamp, slide angle
sleeve etc. Outdoor termination shall have necessary skirting over protective sleeving to
increase the creepage distance and the sleeves shall ensure total protection against ingress of
moisture. Straight through joints shall feature moisture proof
proof environmental seal, mechanical
protection and impact resistance envelope around the joined cables.
The end termination and straight through joints shall conform to the relevant standards. The
complete termination / joint kits shall be of reliable and field proven design having been fully
type tested and relevant type test reports shall be furnished.
In addition the termination and joint shall be tested for various accelerated aging tests such as
thermal aging, weathering etc. to have long and trouble
trouble free service. Necessary type test
certificates for aging tests shall also be furnished.
Following type of cable termination and joints shall be used for HT cables in indoor and
outdoor applications:
1.
2.
3.
Tapex type
Heat shrinkable type
Pre moulded push on type
Tapex type system

The stress grading material shall be wrapped around the cable core, over lapping the edge of
the outer conducting layer. The tape layer shall fuse together to form a compact rubber body
around the stress grading
ng material and cable core and thereby exert an active pressure on
cable. This system shall be used for straight through joint only.
Heat Shrinkable type system
The stress control and grading wherever necessary shall be by means of semi-conducting
semi
heat
shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces
shall be achieved by using hot melted sealants or adhesives.
Where such sealents or adhesives shall be exposed to high electrical stress, same shall be track
resistant type.
moulded Push On type system
Pre-moulded
Page 21 of 97
Premoulded refers to moulded Ethylene Propylene Diene monomer rubber components.

Sealing between the pre--moulded
moulded push on material and cable surface shall be achieved by
semi conducting pad which has cold flow
f
properties.
Cable trays
All the cable trays shall be prefabricated hot dip galvanised sheet steel trays.
Prefabricated GI ladder type / perforated type cable racks/trays shall be used for laying of
cables in cable trenches, cable spreader floors, cable cellers, through piping and while routing
cables along technological structures etc. The factory made system of cable trays shall be
complete in all respects with all standard accessories like reducers, bends, tees, risers etc. and
shall be suitable for bolted type assembly at site so as to avoid any welding.
The GI ladder type factory fabricated cable trays made
made from 2.5 mm thick hot welded steel
sheets grade o shall be provided as per IS : 2062. Hot dip galvanizing of 86 micron thick as per
IS-2629, IS-4759 and IS- 209. Trays shall be of standard length of 3 M / 2.5 M with max
deflection not exceeding 1/400 of span with sufficient load bearing capacity.
Sheet steel thickness shall be minimum 2.5 mm. Rung hall be provided at every 250 mm. At
one meter interval two rungs shall be provided side by side to facilitate clamping. Beside,
Bidder shall also provide suitable pre-fabricated
pre fabricated bends of cable trays at all the bending points
as per actual site requirement.
Horizontal tees and 900 bends shall be provided for each size of cable trays as per actual
requirement at site.
Lugs/connectors
hall be made with aluminium / tinned copper crimped type solderless lugs
Cable termination shall
of approved make for all aluminium conductor and stud type terminals. The lugs shall be
tinned copper compression type.
Glands
Cable glands to be supplied shall be nickel plated brass
brass double compression type. Glands for
classified hazardous areas shall be certified by CMRS and approved by CCE, Nagpur.
Cable glands for terminating PVC insulated armoured/unarmoured cables (as applicable) shall
be made of brass and shall be of double compression type with necessary provision for armour
earthing.
Cable clamps
All cables shall be clamped with GI (minimum size of 25x3mm) / Al (minimum size of 25x4)
clamps and single core cables shall be clamped with trefoil clamps made of non-magnetic
non
materials.
Page 22 of 97
Specifications for miscellaneous materials

Cable identification
Cable tags shall be of 2 mm thick, 20 mm wide aluminium strap of suitable length to contain
cable number as per cable schedule.
Ferrules
Ferrules shall be approved interlocked type & size to suit core size mentioned and shall be
employed to designate the various cores of control cable by the terminal numbers to which
the cores are connected, for ease in identification and maintenance.
LT BUS DUCTS
Electrical design
Bus duct shall be suitable for 33KV/415
415 V, 3 phase, 50 Hz. neutral solidly grounded system and
shall be covered with canopy if required to be installed outdoors.
outdoors. Rated short time withstand
current not less than the system short circuit level specified for 1 sec for 415V. Rated peak
withstand current not less than 2.1 times the system short circuit level.
Rated continuous current shall be as per requirement while in enclosure and at specified
ambient temperature with maximum temperature
temperature of bus bars limited to 85C.
85 Neutral bus in
LT with rating not less than half the rating of phase bus.
The bus duct shall be rectangular, non-segregated
non segregated phase, totally enclosed type.
Insulation level
Rate insulation voltage, one minute PF withstand
withstand voltage & impulse withstand voltage shall be
as specified in technical particulars.
Clearance in air (minimum)

Clearance shall meet the minimum requirement specified in the technical particulars.
Short circuit strength

Rated short time withstand current not less than the system short circuit level specified for 1
sec for 415V.
Rated peak withstand current not less than 2.1 times the system short circuit level.
Rate current
Rated continuous current as specified while in enclosure and at specified ambient
temperature with maximum temperature of bus bars limited to 85C.
85
Neutral bus in LT with rating not less than half the rating of phase bus.
Type test certificates

Tenderer shall have type test certificates for similar bus ducts (same voltage level and same or
higher current rating/fault level)
Page 23 of 97
Construction details
Degree of protection for enclosure IP 52 or better for indoor installation.
Enclosure material:: The minimum thickness shall be 2.5 mm. Tender shall include enclosure
with the thickness required
red for the shape and mechanical/ electrical strength point of view.
Aluminium enclosure shall be provided for rating equal or more than 3000A. MS enclosure
may be provided for LT bus ducts of rating less than 3000A. Provision shall also be provided
for draining moisture.
Maximum temperature of enclosure under rated operating conditions limited to 70C.
70 Rubber
bellows shall be provided at transformer end to take care of vibration.
GI supporting structures, wherever required, shall be provided with necessary hardwares. In
horizontal run of more than 10 mtr of bus ducts expansion joint with copper flexibles shall be
provided at every 10 mtr interval.
Maximum temperature of enclosure under rated operating conditions limited to 70C.
70
Bolted covers with gaskets shall
shall be provided for easy inspection and access to insulators and
bus bar joints.
Gasketted (Neoprene) connections shall be provided between adjacent sections of metallic
enclosure.
Tinned copper flexible shall be considered for connection of bus ducts at transformer end as
well as PCC end.
Rubber bellows at transformer end shall be provided to take care of vibration.
Seal off bushing and frames complete with bolts.
Provision shall be provided for draining the moisture.
Provision shall be provided for mounting the bus ducts on brackets.
The bus duct shall include straight run, 90 degree bend, Phase crossover chamber,
transformer end chamber, tinned copper flexible, wall frame assembly, rubber bellows and
other accessories as per the requirements.]
Busbars
rs and connections.
Bus bar material shall be EC grade aluminium alloy equivalent to E91E WP conforming to IS
5082-1981.
Final operating temperature of both bus bars and joints under continuous operation in
enclosure limited to 85C
C by thermometer method. While designing the bus duct, site
condition and solar radiation shall be taken care of.
Bus bar arrangement shall be as per IS 5578-1991.
5578 1991. Phase identification shall be by colour at
ends and at regular intervals. Busbar joints shall be of bolted type, cadmium
cadmium plated with zinc
bichromated high tensile steel bolts, nuts and spring washers and coated with oxide inhibiting
grease prior to jointing.
Copper flexible busbars shall be tinned. Copper flexible connections shall be provided for
termination on equipment as well as on expansion joints.
Bimetallic joints /strips shall be provided for jointing between dissimilar metals (if required).
Bus bar support insulators of non-hygroscopic
non hygroscopic material having impact and di-electrical
di
strength with an anti-trackin
tracking contour.
Bus duct of 3000 A and above rating shall be interleaved type.
Bus conductor shall be given a coat of black mat point.
Protective earthing
Double earthing shall be provided for enclosure of bus ducts.
Page 24 of 97
Two numbers 50 x 6 mm GI flat earth buses shall

shall be provided running separately throughout
the length of the bus duct, positively connected to the enclosure body of the bus ducts.
Provision shall be there at each end of bus duct for terminating external earth conductor.
Surface treatment
Two Coats of synthetic enamel paint for indoor application shall be provided. Various standard
procedures shall be followed in this regard for a quality work.
Shade of paint
Interior
Black/white/light yellow
Exterior
As per technical particulars
Technical particulars of LT busducts

Applicable standard
IS - 8623
Rated system voltage & frequency
415V, 50 Hz
Maximum ambient temperature
50C
System earthing
Solidly grounded
System short circuit level(kA rms)
50 KA
Maximum voltage at which bus duct can operate :

continuously
Location of bus duct
:
500 V
Type of bus duct
Non Phase segregated
Material of main busbar
Aluminium Alloy
Rated continuous current
As specified
Earth bus material
Aluminium
Bus duct support structure required
:`
To be provided
Rated continuous current
As specified
Rated short time withstand capacity
50 kA
Rated short time withstand duration
1 sec
Indoor
Page 25 of 97
Insulation level
Insulation class
1.1 kV
1 minute dry power frequency withstand
2.5 kV
1 minute wet power frequency withstand
2.5 kV
Support insulator
Type
Maximum distance between supports
Non: hygroscopic SMC

moulded/FRP
To be worked out based on
short circuit calculation.
Clearance
Phase to Phase
25.4m
Phase to earth
19.0m
Material
Degree of protection (Minimum )
Thickness of material
AI (for >/= 3000 A) / MS

(For < 3000A)
IP52 Indoor
IP55-Outdoor
Outdoor
2.5 mm (minimum)
Sea- Off bushing with wall frame (for wall crossing)
Only wall frame required
Silica gel breather
Required
Space heaters
Required
Maximum temp allowed at max. ambient temp
Bus conductor
85C
Bus enclosure and support structure
70C
Enclosure
Accessories
Page 26 of 97
Paint shade
Phase crossover chamber/section
Interior:
yellow
Black/white/light
Exterior: Approved
One set in one of the bus
duct portion of each
PCC/board.
ERECTION, INSTALLATION ACCESSORIES

All erection & installation accessories required for erection/installation of equipment are
included in the scope of the tenderer.
All the accessories and other erection materials required to complete the erection job in all
respect shall be considered as part of the tenderers scope.
Safety insulating mats of minimum thickness of 2 to 3 mm and of suitable voltage grade in
front of all the PCCs/board and control panels shall be provided by the tenderer.
4.4
ELECTRIC MOTORS
General
All motors shall generally conform to IS 325 and CBIP publication No. 140. Motors shall run
continuously at rated output with + 5 % variation in frequency and + 10 % variation in voltage
and + 10 % combined
ned variation of frequency and voltage (absolute sum). Motor shall not stall
due to momentary drop in voltage up to 70 % of rated value and shall run satisfactorily for five
minutes at a supply voltage of 75 % of rated value.
The limiting value of voltage at rated frequency under which motor will successfully start and
accelerate to rated speed with load shall be assumed to be a constant value of 80 % rated
voltage throughout the starting period.
All motors shall be supplied with foundation bolts (if applicable),
applicable), drain holes with plugs.
Motors shall be designed for 50oC ambient temperature.
Motors supplied shall be complete with required double compression cable glands, crimp type
cable lugs and first filling of lubrication, name plate, etc. Lifting facility
facility to be provided for all HT
motors and big size LT motors. Guards shall be provided to prevent accidental touch for
couplings and for free shaft ends shall be provided.
Degree of protection for motor and bearings shall be IP-55
IP 55 for indoor and IP55 with
wit rain
canopy and weather proof construction for outdoor. Motor shall be suitable to withstand at
least three successive starts from system cold condition and two starts from hot condition at
normal system voltage and frequency.
The drive motor shall havee at least 15 % margin over the maximum power requirement of the
driven equipment after considering all losses, de-rating
de rating due to temperature and specific site
and operating conditions.
Page 27 of 97
The motor may be subjected to sudden application of 150% rated voltage

voltage during bus transfer,
due to phase difference between the incoming voltage and motor residual voltage.
Motor handling facility and canopy
Handling facility and space shall be provided for all the LT motors. Mono rail shall be provided
and shall be extended up to open maintenance space for each of the LT
L motors. Canopies
made of GI sheet of minimum thickness of 2 mm shall be provided to each of the LT motors
located outdoor.
All motors, in general, including conveyor motors shall be 4 pole construction, hence speed of
maximum 1500 rpm. However, motors for travel drives of yard machines shall be of 6 pole
construction, hence speed of 1000 rpm.
rpm
LOW VOLTAGE INDUCTION MOTORS
Frame sizes shall be as per IEC. Casing feet shall be integral with the motor body. For motor of
rating up to 5 kW, ball bearings shall be used for both DE & NDE end. For ratings above 5 kW
the DE end shall be provided with ball/roller bearing and NDE end shall be provided with ball
bearing. Bearings shall be suitable for running of motor in either direction. Motors 110 kW and
above shall be provided with bearing
bearing temperature indicators. Explosion proof/increased safety
design for explosion hazardous areas as per requirement.
Terminal box shall be of suitable dimension to receive aluminium cables and shall be rotatable
by 4x90o
Cooling of motors shall be of TEFC
TEFC (IC0141) design. Ventilation shall be effective irrespective of
direction of rotation.
Motors shall be dynamically balanced. Vibration intensity shall be limited as per IS 12075
(1987). Continuous noise level should not exceed 75 dBA at a distance of 1.0 m from motor
body.
Starting current shall be less than or equal to six times the rated current with IS tolerance.
Motors shall have class ' F' insulation with temperature limited to class B. Permissible
temperature shall be limited to 120oC in case of class 'B' insulation and 130oC in case of class F
insulation as measured by resistance method. Class H insulation shall be considered in specific
cases. Limiting temperature shall also be limited to 130 deg C in case of Class H insulation as
measured byy resistance method.
Space heaters shall be provided for all motors rated above 30kW. Adequate handling space
shall be provided for all the big LT motors.
HIGH VOLTAGE MOTORS
Page 28 of 97
Degree of protection for motor and bearings shall be IP-55

IP 55 for indoor use and
a IP-55 with
removable rain canopy for outdoor use.
Vibration monitor with contacts shall be provided at the DE end of motor bearing for motors
of ratings 1000 kW and above. On line vibration measurements shall be provided for larger
and critical motors.
All motors shall be provided with Bearing (DE & NDE) temperature detectors and 6 nos. stator
winding temperature detectors, RTDs for monitoring alarm and trip conditions. Temperature
shall be displayed on VDU's. RTD's shall be of PT100 type and suitable for digital scanner or
PLC input requirement.
igital type bearing temperature indicator for all motors shall be provided for local
Digital
measurement with adjustable alarm contacts.
Each terminal box shall have fault withstand capacity equal to at least rated short circuit level
of the system voltage for 0.25
0.25 sec and shall have pressure relief device. Terminal boxes shall
be suitable for termination of FRLS, XLPE cables with cable end seals. Separate terminal boxes
shall be provided for space heaters, RTDs for winding/ bearings temperatures, vibration
monitors etc.
All terminal boxes shall be provided with two earthing studs for termination of protective
earth conductor. Box covers shall be provided with handle to facilitate easy removal.
Low kW range machines may be of TEFC (IC0141) design. For higher rating,
rating, type of cooling
shall be CACA (IC0151). General accessories like flow switches, space heater, terminal boxes,
drain plug, dowel pipe cable lugs, glands clamp etc. shall be provided.
Vibration intensity shall be limited to values as stipulated in the
the IS. Motor shall be designed to
withstand the vibration produced by the driven equipment. Continuous noise level should not
exceed 75 dBA at a distance of 1.0 m from the motor body.
Electrical design shall be same as in case of low voltage induction motors
motors except the following:
All motors shall have class F insulation but with total permissible temperature limited to 1300C
(as measured by resistance method). Starting current of the drives shall be limited to six times
of full load current.
Motors of rating 1000 kW and above shall be provided with differential protection. Matching
CT and cabling up to switchgear shall be provided by the Bidder.
Motors shall be capable of withstanding locked rotor current at 110 % rated voltage for at
least 2.5 sec (for
or motors having staring time up to 20 sec) or 5 sec (for motors having staring
time more than 20 sec) longer up to than starting time under rated load condition at 80 %
voltage. If above condition is not possible then, centrifugal type speed switch to be provided
Page 29 of 97
which has to be connected to the motor protection relay. Speed switch shall be capable to
withstand 120 % of the overspeed in either direction.
Insulation of motors shall be designed conforming to IEC 34-15/
34 15/ 1990. Gland plate for single
core cable shall be non-magnetic
magnetic type.
All motors shall have individual dedicated handling and lifting facilities preferably by dedicated
electric hoist.
4.5
POWER DISTRIBUTION BOARD /AUXILIARY POWER DISTRIBUTION BOARD

POWER DISTRIBUTION BOARD
PDB shall be suitable for 415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec) indoor
type.
Board shall be single front, metal clad, front matched, dust and vermin proof, draw-out
draw
(incomer & bus coupler) / fixed (outgoing), fully compartmentalized
compartmentalized and extensible on both
sides, IP54 type enclosure.
Shall have isolated busbar chamber for main busbar at the top, running throughout the length
of the board. Chamber shall have removable cover.
Busbars shall have same cross section throughout the length . Rating of the neutral busbar
shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the
length of the panel.
Shall have Moulded case circuit breaker (MCCB) triple pole, air break type with independent
manual quick make and quick break type. MCCB shall be capable of breaking rated current at
0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system.
Generally PDB will have following feeder arrangement. However, details of feeders e.g no.
type and capacity, etc shall be finalized during detailed engineering:
Incomer
Outgoings
:
:
ACB of 630A (or as per requirement)

MCCBs of 400/250/125A/63A/16A (or as per requirement)
Number and capacity of PDB given in the enclosed Single Line Diagram is minimum and
indicative. Bidder shall provide as per actual load requirement and same shall be finalized
during detailed engineering.
AUXILIARY POWER DISTRIBUTION BOARD
Aux. PDBs shall be suitable for 415V, 3 phase, 4 wire,
wire, 250A, 50 kA (short time rating for 1 sec.)
indoor type. Board shall be single front, metal clad, front matched, dust and vermin proof,
non-drawout,
drawout, fully compartmentalized and extensible on both sides, IP54 type enclosure.
Page 30 of 97
The other technical particulars

particulars of aux. PDBs shall be similar to PDB. The tentative feeder
arrangement shall be as follows. However, details of feeders e.g no. type and capacity, etc
shall be finalized during detailed engineering:
Incomer
:
MCCB of 250A (or as per requirement)
Outgoings
:
MCCBs of 125A/63A/16A (or as per requirement)
4.6
LOAD ISOLATOR WITH EARTH SWITCH

33 KV ON-LOAD
Technical features
Triple pole air break, fault make load break type.
Independent manual, quick make, quick break type
Mechanical trip device
Mechanical ON- OFF indicator
Suitable to connect cables on incoming and outgoing side.
Shall have 3 NO and 3 NC aux. contacts.
Earthing switch shall be provided on transformer side having rating same as that of main
switch.
outdo kiosk type with IP-55
55 protection along with a
Totally enclosed, floor mounted, outdoor
canopy
Shall have padlocking facility
Panel door shall be mechanically interlocked so that isolator cannot be closed on open
position of door and door cannot be opened on close position of isolator.
Earthing switch shall be interlocked with isolator blades to prevent simultaneous closing of
both.
Isolator shall be interlocked with Purchasers upstream breaker.
Technical particulars
:33kV
1. System voltage
2. System earthing
: Resistance earthed
3. Type
: Air break, fault make & load break type
4. Nos. of poles
: Three
5. Continuous current
: As per requirement
6. carrying capacity
7. S/c withstand capacity : 25KA for 3 sec/43.7 kA for 3 sec.
8. Pf withstand voltage
: 75/20 kV
9. Impulse withstand voltage
: 170/60 kV
10. Termination
: To accept cables of required size
11. Incomer
12. Outgoing
: To accept cables of required size
4.7
OIL IMMERSED TYPE)

HT/LT TRANSFORMERS (OIL
4.7.1
Design
Design shall be generally as per IS 1886. Transformer shall be suitable for rated frequency 50
Hz, -5%,
5%, +5%. Insulation level shall be designed according to the voltages specified below:
Description
33/.415 kV
Page 31 of 97
Capacity
Nominal voltage (kV)
Max system voltage (kV)
Power frequency withstand voltage (kV)
System earthing
No. of phases
Frequency
Impulse test withstand voltage (kV)
Short time current rating (for all current
carrying parts)
Fault level (3 phase symmetrical)
Type of Cooling
Connection HV winding
Connection LV winding
Connection Symbol
33
35
75
Low resistance earthed
3
50 Hz
170
25 kA for 3 sec
25kA
ONAN
DELTA
STAR
Dyn 11
HT/LT transformers shall be of the latest design, oil immersed type as per IS : 1886 and testing
as per IS 2026 part I.. All dry type air natural transformers shall be suitable for indoor use line
up with power control centre as unit type.
Bidder shall ensure that manufacturer shall have his own in-house
in house core cutting facilities on
CNC machines.
ken to make enclosed equipment proof against entry of rats, lizards and
Special care shall be taken
other creeping reptiles which may create electrical shortshort circuits inside live equipment. The
design of each transformer shall be such that the risk of accidental short-circuits
short
due to
reptiles or vermin shall be obviated.
The transformer shall be of cast resin type. The tap changing arrangement shall be of
removable link type.
Each transformer shall be suitable for operation at full rated power on all tappings without
exceeding the temperature rise of 800C over the ambient of 50oC. Minimum class of Insulation
shall be F.
The transformers shall be designed to be capable of withstanding, without injury, the thermal
and mechanical effects of short-circuits
short
between phases or between
n phase and earth at the
terminals of any winding with full voltage applied across the other winding. All transformers
shall be capable of withstanding specified through fault current for minimum of 2 seconds as
per IS: 2026 (Part-1).
The transformers shall
all be designed to suppress harmonic currents, especially the third and
fifth, so as to eliminate distortion in the wave form and consequent additional insulation
Page 32 of 97
stress, noise on communication system and undesirable circulating currents between the
neutrals
ls at different transformer stations.
The Transformers shall operate with minimum noise and vibration. The cores, protective
housings and other structural parts shall be properly constructed and windings properly
braced so that the mechanical vibrations are kept to the minimum, thus reducing the noise. To
this effect, the laminations shall also be bonded together with appropriate resin. The core-coil
core
assembly shall also be fixed in such a manner that no shifting or deformations occur during
shipment or installation.
Each transformer shall be designed for minimum no-load
no load and load losses within the economic
limit.
All electrical connections and contacts shall be of ample section for carrying the rated current
without excessive heating.
all be of stainless steel, brass, gunmetal or other suitable material to prevent
All mechanism shall
sticking due to rust or correction. If any temporary fitting is fixed to the protective housing of
the transformer for transporting / handling purpose, these shall be identical
identica as well as
instructions and illustrated drawings shall be furnished to facilitate their removal at site after
erection.
4.7.2
Core
The framework, clamping arrangement and general structure of the cores of each transformer
shall be of robust construction and shall be capable of withstanding any shock to which they
may be subjected during transport, installation and operation. The assembled core shall be
securely clamped on the limbs and the yoke to build up a rigid structure. The clamping
pressure
sure shall be uniform over the whole of the core and so adjusted as to minimize noise and
vibration in the core when the transformer is in operation. The framework and the core bolts
shall be effectively insulated from the core so as to reduce the eddy-currents
eddy
rents to the minimum.
The magnetic circuit shall be built of high quality, low loss, non-ageing.
non ageing. Cold rolled, grain
oriented, silicon steel laminations (CRGO Prime Grade) having excellent magnetic properties
and specially suitable as core material. Laminations
Laminations shall be insulated from each other with
material having high inter-lamination
inter lamination insulation resistance and rust inhibiting property and
also capable of withstanding stress and mechanical vibration.
Necessary cooling ducts shall be provided for heat dissipation
dissipation from the core so that the
anticipated maximum hot spot temperature in the core shall not be injurious to any material
used in the core assembly.
clamping frame shall be provided with lifting eyes having ample strength to lift the
The core-clamping
complete
te core and winding assembly.
Suitable provision shall be made in the dry type transformers for effective core earthing.
Page 33 of 97
4.7.3
Winding
The coils used for transformer winding shall be made of insulated, continuous and smooth
electrolytic copper conductors of high conductivity and of 99.9% purity. Similar coils shall be
connected by accessible joints brazed or welded and finished smooth. No corona discharge
shall result on the winding during induced voltage test as specified in applicable standard.
The insulating materials for dry type transformers shall be of type not inferior to Class F. All
insulating materials shall be of proven nature
nature and shall be suitable for the suitable for the
limits indicated in the applicable standards as well as the maximum possible winding
temperature and shall not deteriorate when the transformer is operated continuously at its
specified rating at the specified
specif ambient temperature.
coil insulation shall be so designed that the dielectric stress is
The inter-turn and inter--coil
uniformly distributed throughout the winding under all operating conditions.
The windings shall be dry cast resin type.
er windings shall be designed for basic Impulse insulation level not lower than
The transformer
those specified above.
4.7.4
Protective Housing for Dry type Transformer
Dry type transformer shall be provided with suitable protective sheet steel housing, with
minimum IP
P 23 degree of protection for the enclosure. The housing shall have ventilation
louvers provided with wire mesh screens and shall be supplied with suitable lifting lugs. Safety
limit switches shall be provided and wired in such a way that the incoming supply
supp may be
disconnected whenever any one of the sides of the enclosures are opened with the
transformer in energized condition.
Sufficient precautions shall be taken so that doors are closed fully. Door locks shall be
provided and keys shall be universal type.
4.7.5
Circuit Links
Off-Circuit
circuit tapping links shall be provided on the HV side with appropriate register plate to
The off-circuit
show the link location. The links shall be provided with a separate door for access. The door
shall be provided with appropriate safely limit switches which will trip the transformer HV / LV
sides in open condition.
4.7.6
Cooling
or dry type transformers shall have Air-Natural

Air Natural (AN) cooling.
The cooling system for
4.7.7
Neutral Bushing Current Transformers
Page 34 of 97
CTs for back up earth fault (51N) as well as for restricted earth fault (64) shall be provided on
the neutral end.
Neutral bushing CT shall be removable
removable at site without opening transformer tank cover/active
part. Secondary leads of 4 sq.mm shall be brought to a weatherproof terminal box and from
there to the marshalling box.
Neutral bushing CTs of suitable ratio, class and adequate burden shall be provided by the
Bidder to cater to the requirement of all standard protection associated with the transformer
of this capacity. CTs for REF shall be PS class.
4.7.8
Marshalling Box
Enclosure mounted marshalling box to be supplied with all controls instruments, protection,
accessories & fitting as required for the transformer and its associated ancillaries. The box
shall be made of 2 mm sheet steel with IP 54 degree of protection.
heet steel marshalling box of dust-proof
dust proof design shall be provided to accommodate
Sheet
temperature measurement as well as control system, as may be necessary. The box shall be
mounted on the transformer enclosure and shall be provided with internal lighting, space
spa
heater and thermostat with their controls accessible from outside.
The box shall be provided with suitable hinged steel doors at the front and all equipment shall
be so placed as to accessible from the front. Provision shall be made for padlocking the doors.
Suitable glazed windows shall be provided at appropriate positions to give an unrestricted
view of the temperature indicators etc, without opening the door.
All initiating
tiating contacts of shall be wired up to the terminal block in the box. All control wiring
shall be with 1.1kV grade stranded PVC insulated armoured copper cable of 2.5 sq.mm.
Terminal blocks shall have 20% spare capacity.
The external connections between
between the apparatus on the transformer and the marshalling box
shall be done with suitable heat resisting copper conductor cables of core size not less than
2.5 sq. mm. The cables required to connect the marshalling box and transformer accessories
shall be adequately
dequately protected against mechanical damage. There shall be no joints or tappings
between two terminations of any cable. Not more than two terminations shall be made at any
one terminal. All terminations at various devices and terminal blocks shall be provided
pr
with
plastic ferrules having engraved numbers. All terminals and links shall be so arranged as to
facilitate easy checking and testing of relays, instruments etc. Provision shall be made for
termination of power cables as well as multi-core
multi
control cables in the marshalling box.
The control circuit terminal blocks provided for external cable connections shall be provided
with screw type terminals and shall be complete with terminal screws, links, cable carries etc,
Each terminal block shall have 20%
20% spare terminals and all wiring shall be such that it is easily
identifiable and accessible for maintenance.
Page 35 of 97
All devices, wires and terminal blocks within the marshalling box shall be clearly identified by
symbols corresponding to those used on relevant schematic or wiring diagrams.
Enclosure class of marshalling box shall be IP-55.
IP
Terminal Arrangement HV/LV terminals shall be suitable for cables considered.
4.7.9
Transformer Fittings & accessories
Each transformer shall be fitted with all standard

standard and special fittings and accessories and shall
include but not be limited to the following:
Inspection covers.
Off circuit links in the primary for voltage variations.
Rating, diagram and tap connection plates.
Terminal marking plate
Two nos. earthingg terminals with lugs.
Winding temperature detectors with microprocessor based Temperature scanners with
digital read out and requisite set of remote signaling contact for alarming/tripping
operation.
bi directional rollers with locking and bolting devices.
Under carriage with bi-directional
Marshalling box complete with all instruments, accessories and fittings as required for the
transformer.
Off load tap changers with position indicators and padlocking faciliy
Neutral
eutral bushing CTs with terminal arrangement
HV cable box with disconnecting chamber and supporting arrangement
LV side flanges suitable to receive busducts
Jacking pads
Haulage lugs
required
Flat base, foundation bolts and clamps and other accessories as required
4.7.10
Details of Fittings
Requisite number of Resistance type temperature detectors shall beprovided with solid state
type temperature signaliser for dry type transformer. The temperature signaliser shall be
provided with two sets of contacts, one
one for alarm and the other for circuit-breaker
circuit
trip. The
signaliser shall be provided with digital read out for the temperature being measured and for
the zone where the current measurement.
Two nos. earthing terminals of adequate mechanical and electrical capacity shall be provided.
Separate earthing terminals shall also be provided on the enclosure, marshaling box and
terminal boxes.
Rating and diagram plates shall be provided as per adopted
adopted standards for each transformer.
Lifting lugs and hauling holes as required shall be provided for the transformer as well as for
the enclosure.
Page 36 of 97
Suitable under-carriage
carriage fitted with flat rollers shall be provided. The rollers shall have
adequate mechanical
ical strength and shall be so designed that the transformer shall roll without
undue effort after it has remained immobile for a long period. The edges of rollers shall be
duly rounded off to permit skidding of transformer on flat surface.
(33KV/
4.7.11 Technical Particulars of HT Transformers (33KV/440V)
1.0
1.1
1.2
1.3
1.4
1.5
1.6
2.0
2.1
2.2
2.3
2.4
General
Make
Type
Service
Duty
Degree of Protection
Reference Standard
Rating
Rated output
Quantity
Type of cooling
Rated voltage Volt
H. V.
L. V.
2.5
No. of phases
2.6
Rated Frequency Hz
2.7
Vector group reference
2.8
Connection
H. V.
L. V.
LVn
2.9
Insulation
H. V.
L. V.
2.10 Insulation level kVp/kV
H. V.
L. V.
3.0
Temperature
3.1
Reference ambient temp.
3.2
Temp. rise over reference ambient
a)
Top Oil measured by
b)
In winding by
4.0
Tappings
4.1
Type
4.2
Taps
4.3
Taps provided on HV winding
5.0
Method of earthing
:
:
:
:
:
:
Reputed Make
Two winding
Outdoor
Continuous
IP:55
IS/IEC Equiv
:
:
:
:
:
:
:
:
:
As per load calculation

2 nos
ONAN
:
:
:
Delta
Star
Grounded through NGR
:
:
Uniform
Uniform
:
:
:
:
75/28
40/10
:
:
500C Thermometer
550C Resistance
:
:
:
:
33kv
440V
3
50
Dyn11
500C
Off circuit Tap Changer (OCTC)

10% in steps of 2.5%
Yes
Neutral Grounding Resistor
Page 37 of 97
6.0
6.1
6.2
6.3
6.4
6.5
6.6
7.0
7.1
7.2
8.0
9.0
10.0
10.1
10.2
11.0
Neutral grounding Resistor

Rated current
: Less than 100A for 10 seconds
Application
: Grounding through Resistor
Service
: Outdoor
Resistor material & connection
: Punched stainless steel grid element type
Maximum allowable temperature rise : As per Standards
over ambient 500C
Enclosure degree of protection
: IP - 55
System Fault Level
H. V.
: 25kA
L. V.
: 50kA
Conductor material
: Electrolytic grade copper
Creepage distance mm/KV
: 3lmm/kV
Terminal connections
H. V.
: Segregated phase bus duct/Cable
L. V.
: Segregated phase bus duct/Cable
Marshalling box Degree of protection
: IP:55
Power frequency to withstand voltage of 33 KV system should be 75KV.Impulse

KV.Impulse test voltage
should be 170KV for system voltage of 33 KV.
4.7.12 Technical Particulars of Dry type transformers (LT)
: AN
: Indoor
: 33/0.440kV
: As per IS
: Delta/star
: Dyn11
: HV : 33KV cable
LV : Cable
9. Tap changer
: OFTC
10.Range of tap changer
: +5% in 5 steps @2.5%
11. Short circuit level
: 25 kA (33kV) for 3 sec
12. Earthing system (33 kV)
: Low Resistance earthed
13. Earthing system (415 V)
: Solidly earthed
14. Bushing CTs
: On neutral
15. Ratio of neutral
al bushing CTs
: As required for Standby E/F Restricted E/F
16. Impulse test withstand voltage (HT/LT)
: As per IS/IEC
17. Power frequency rated short duration : As per IS/IEC withstand voltage (HT/LT)
18. Temp. rise above 500C
: 800C
19. Overload capacity
: As per ANSI standard
20. Auxiliary supply voltage
: 240V AC
1. Rated capacity
2. Cooling
3. Duty
4. Voltage ratio (HV/LV)
5. Impedance
6. Winding connection
7. Vector group
8. Termination
Page 38 of 97
21. Suitable for parallel operation

4.8
: Yes
VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVE

Basic design particulars
All VVVF Converters shall have Digital Control Technology with vector less control. VVVF shall
communicate to basic automation system.
Type of connection
Three phase frequency converters with rectification and inversion i.e. variable voltage and
variable frequency output with current source / voltage source (PWM) inverters.
Line reactors for harmonic and noise suppression
Suitable for 415 V , 3 phase ,50 Hz , 4wire neutral earthed system
Overload capacity
following 100% load & to meet the drive overload
150% of the rated current for 1 minutes following
capacity.
Efficiency more than 95% at full load
Suitable to withstand vibrations more than 0.59.
Output frequency
:
5-50 Hz (Constant torque)
50-100 Hz (Constant power)
Ramp rate: Linear acceleration and deceleration
deceleration adjustable independently.
Power components
The main power components of the VVVF equipment shall have the following incoming AC
side:
Matching input power transformer / reactor
AC line surge suppression network.
ACB/MCCB
Line contactors
Inverter Equipment
Converter Inverter
Thyristor converter bridge for AC/DC
DC link circuit with reactor/capacitor
Inverter bridge for DC/AC
PLC to take care of interlocking and sequencing etc.
Mimic panel where drive is HT

Load side
Filter network
up transformer, as required
Step-up
Isolator and over-load

over
relay for each motor.
By-pass Arrangement
Page 39 of 97
By-pass
pass arrangement shall be provided to operate the motor in case of failure in
frequency converter.
Thyristor converter
Minimum ratings of thyristor cells
PIV rating
:
2.5 times the peak value of line voltage
dv/dt rating
:
200V/microsecond for voltage control and
1000V/microsecond for inverter control.
di/dt rating
:
100A/ microsecond.
Protective features
AC line surge suppression network
net
Under voltage in supply network
Phase sequence protection and monitoring
RC snubber network across each thyristor cell
Thyristor fuse failure
Under voltage in Dc line
Over voltage in Dc line
Over speed monitor
Over load
Earth fault
Instantaneous over current
Transformer fault
Cooling fan failure Stall monitor for motor Alarms

Above condition shall be annunciated. Following warning signals shall also be provided as
minimum in addition to above.
te
vibration) as applicable
Motor fault (winding / bearing temperature,
Loss of frequency command
Meters, Switches, Lamps
Following shall be provided as minimum meters:
Input volt meter and ammeter with selector switches
Output voltmeter and ammeter with selector switches.
Output frequency
ncy meter
Selector switches, pushbuttons, and lamps as required.
kW meter for drive ratings above 200 kW Regulation and controls
Control facilities shall include following but not limited to:
Reference speed setter
Ramp generator
Speed feed back
Current feed back
Trigger module
Pulse transformers
Logic control module
Page 40 of 97
Sequence module
Zero speed/over speed monitor as applicable
V/f control
Current limiter
Counter current/ regenerative braking unit as applicable
active electronic components used shall be of industrial grade hermetically sealed
Regulated power supply for reference setting:
Voltage variation of (+/-)) 0.1 % with an input variation of +10% - 15%
Steady state regulation of (+/-)0.25%
(+/
% guaranteed against 100 to 200 % load disturbance and +
3%, -6%
6% input supply frequency variation.
Facility to accept speed reference from computer/ programmable controller
Construction features
Floor mounted, free standing
Dust and vermin proof
Sheet steel clad
Minimum 2.5 mm thick for panels.
Minimum 2.0 mm thick for doors and side covers.
Suitable to withstand vibrations to be encountered in steel plant application.
Cubicles with illumination lamps, door switches, space heaters and adequate sockets
for soldering.
All control blocks plug in-type with necessary test sockets.
Units shall be self contained and serviceable.
Enclosure and Ventilation
Enclosure conforming to IP-52
IP
or more with weather proof enclosures
Units shall be provided with cooling fans and louvers at the bottom sides. All louvers shall
have fine mesh behind them.
Ventilation through individual ventilation ducts, from bottom not acceptable.
4.9
RELAY PANELS
Relay panels (RP) housing aux. contactors, timers, relays, etc. shall be provided for equipment
control, sequential control, monitoring, safety alarm signals, annunciation signals, interlocking
of drives ,signal exchange, interface with future system etc. shall be provided. Constructional
features of R.P. shall be similar to MCC. At least 10 % spare auxiliary contactors, timers &relays
shall be provided in the relay panel whose contacts and coils shall be wired up to terminals.10
terminals.
% spare terminals shall also
als be provided. 10 % of auxiliary contactors, timer and relays shall be
provided as spares which will be wired upto terminals.
4.10
PROGRAMMABLE LOGIC CONTROLLERS (PLC)

Power supply system
Page 41 of 97
Input power supply shall be fed through UPS system. However, PLC shall be capable of
withstanding power supply from electrical feeder. Alternate source of power supply
arrangement or second UPS shall be provided to take care of the situation when the original
UPS fails.
in power supply units
Built-in
Suitable for thee power supply system as specified above.
Independent units for the following:
CPU and associated electronic units
i)
sensing the status of input devices
ii) driving outputs if outputs are relays
iii) Insulation level 2.5 kV for 1 minute.
Protection againstt surge protection & short circuit
Electronic over current protection with feedback feature.
Central processor unit
in type
Modular and plug-in
32 bit microprocessor based
Scan time 2 m sec per one K Words of instructions or better
Provision to latch desired outputs.
The processor shall have in-built
in built provision for examining input conditions, compare,
compute, logical, conversion from/ to BCD, bit manipulation, block memory manipulation,
diagnostic, shift, sequencing, conditional jumping, subroutine instructions.
In-built
built PID instruction shall be preferred over separate PID hardware Module.
Timer & counter modules shall be provided wherever required.
Memory units
Modular and plug-in type
Word length 32 bit as per CPU
Expandable in blocks of 4K Words
Minimum size 16K Words
EPROM/ RAM with battery back-up
back
Back-up
up battery shall be as follows:
i) Rechargeable Ni-Cd
Cd batteries with necessary charging circuit, Lithium or any other
internationally acceptable type.
ii) Able to retain memory for a minimum of 1 year with no power applied to the controller.
Input units
High density (32/16 Channels), modular and plug-in
plug type
Insulation level of 1.5 kV
Input interrogation voltage 24V DC
Discrete input units shalll have the following:
i)
Filter to take care of contact bounce
ii) Opto-isolation
isolation to isolate the input device from the controller
Page 42 of 97
iii) LED status indication iv) BCD input units suitable for four digit input
Analog input units shall be as follows:
i) Suitable for 4-20
20 mA / 0-10V
0
/ +/-10V inputs
ii) With necessary A/D converter
Pulse/ frequency input module shall have range up to 50 kHz. For very high frequency
applications, the range shall be up to 1 MHz.
Output units
plug type
High Density (32/16 Channel), modular and plug-in
Discrete output units shall be as follows:
i) Opto-isolated
isolated outputs with insulation level of 1.5 kV
ii) Rated for 24V DC, 2A
Power devices like contactor or odd voltage actuating device shall be
b actuated through
relays
LED status indication
BCD output units shall be as follows:
i) Suitable for four digit output
ii) Rated to drive seven segment LED displays
iii) With insulation level of 1.5 kV
Analog outputs shall be as follows
i) Suitable for 4-20mA/
20mA/ 0-10V/
0
+/-10V
10V outputs capable of driving Digital / Analog Panel
Meters
ii) With necessary D/A converters
iii) With insulation level of 1.5 kV
iv) Any special requirement to control field devices shall be met by using separate
interface modules
PC based programming unit:
PC used for Programming Terminal shall be commercial grade and latest available in the
Suitable for developing programs in ladder diagram/ block diagram or statement form
With facility for loading the program from floppy
The terminal shall be capable of developing multiple programs offline without connecting to
the programmable controller.
Self diagnostic features
Parity errors, cycle errors and under voltage
Failure in central processor unit, memory and power supply.
sup
Indication of type of failure
Automatic turning OFF of all outputs or optionally holding of all outputs in their last state on
failure detection.
Additional features
Fully pre-programmed
Connection of field devices with input units through
throu ordinary multi--core copper control
cables of 1.5 sq. mm size, upto a length of 500 m.
Page 43 of 97
Connection of remote input/ output units to programmable controller through remote I/O
units, wherever substantial saving in cabling is envisaged.
Serial interface,
ce, RS232C and better shall be provided
High speed communication among PLC and operator consoles/ display units shall be
provided through ethernet
Latest appropriate model of HP Inkjet Printer to get hard copy of the program dump/ data
logging / alarm
m logging / event logging / data trending etc. [Printer covered also under
Programming Unit. Only one printer shall be supplied.]
Special features
Switch to disable all outputs of the controller during start-up/
start up/ debugging
Fuse failure indication for outputs Mounted spares
Min of 30 % of I/O modules used of each input & output type (with at least one module of
each type) shall be offered as unused spare for each I/O rack. Minimum of 30% I/O rack
slots shall be kept reserved
rved for future expansion.
30 % spare memory capacity shall be provided
Constructional features
Unitised construction
Floor mounted, free standing and indoor type
Bottom cable entry
Sheet steel clad
Dust and vermin proof
Suitable to withstand vibrations as per application
All modules plug-in
in type
Enclosure
42 class
Conforming to IP-42
Conforming to IP-54
54 class for remote I/O cubicles located in shops/ bays.
Miscellaneous
air
ditioned enclosure, shall be suitable for
Programmable controllers, even if housed in air-conditioned
normal industrial environment and ambient temperature upto 500C. A suitable fan with inlet
air filter shall be provided at the top of each PLC panel for proper air circulation.
Dual redundant processor shall be envisaged. Redundancy shall be provided in such a way
that in case of failure of the main processor, the standby shall takeover automatically. The
changeover shall be bump less and the system shall be fail proof. Redundancy
Redundan shall be
provided for complete processor system including CPU, Memory, Power supply and
Communication sub system.
Failure of a single processor shall not affect the system.
In case of failure of complete processor system, outputs shall take fail safe state
st
automatically.
It shall be possible to generate the first out alarm contact by the PLC in case where a group
of parameters are likely to trip a system.
Page 44 of 97
4.11
The communication subsystem between PLC processor and I/O subsystem shall be dual
redundant.
munication subsystem between processor subsystem and PLC console shall be dual
The communication
redundant, consisting of two separate communication interfaces and two buses, each one
configured in redundant mode.
No hardwired alarm system is required. All the alarms are to be displayed in OWS of PLC
with multi tone buzzer and with alarm history provision.
The software provided at the time of supply should be of latest version.
Necessary license to be provided along with the software.
The OS (Operator Station) desk and operator
operator chair to be supplied by the bidder.
UNINTERRUPTIBLE POWER SYSTEM (UPS)
General System Description
The required kVA, 50 Hz, single phase UPS system shall provide continuously operating
uninterrupted power supply to critical AC loads such PLC,
PLC, instrumentation, etc.
The capacity of UPS shall be suitable to feed power requirement of the PLC which shall control
and monitor all the drives/mechanism of proposed additional coal handling system.
The UPS system shall include but not necessarily limited to the following equipment:
One 100% rated battery bank
One set of Float Charger (FC) and one set of Float cum Boost Charger (FCBC) complete
with associated incoming AC switchgear.
Two nos. 100% capacity inverter banks.
One no. DC switchgear, connecting
connecting above and also inverter banks stated above
One no. 3 phase to 1 phase transformer and associated AC switchgear, 230V, 1 phase
voltage stabilizer and backup source static switch.
One no. 240 V UPS ACDB
One no. four way manual bypass switch
Static switches
All inter connecting cables/wiring with connection accessories and other required items
to make the system complete.
Mode of Operation
Normal Mode
During the normal operation the UPS shall be used to provide power to the critical loads.
loa The
primary AC source shall be used to supply power to the rectifier charger. Two (2) no. chargers
shall feed regulated DC power to their individual inverter banks and simultaneously float
charge the backup batteries.
Emergency Mode
Page 45 of 97
Upon failure of primary AC source supplying three phase power to the battery chargers, the
input power to the inverters shall be supplied from the back up batteries. When the AC power
is restored, input power for the inverter and power for recharging the battery
b
shall
automatically be supplied from the rectifier charger. The batteries shall supply the inverter
whenever the chargers are unable to supply the sudden load demand or their response to the
load change is slow.
The output of the UPS shall feed all
all the essential loads through the ACDB. The connection
from the UPS to ACDB shall be through a switch and fast acting semiconductor fuses, trip fuses
and micro switch with alarm contacts. The feeders shall be designed by the bidder to suit the
load requirements.
Battery Charger
Two (2) nos. each of 100% capacity, battery chargers shall be provided for each UPS system.
These chargers shall be of static type and shall be provided with suitable transformer and full
wave, SCR type rectifiers. Chargers shall share automatically the load during parallel operation
of the inverter system and shall maintain output voltage within plus or minus one percent of
the nominal value from no load to full load.
Suitable ripple filtering circuits shall be provided to give a smooth DC output. The ripple
content shall be limited to less than +5% on resistive load.
The rectifier charger shall have float, equalising and boost charging facility as well as furnish
the inverter input current. In the `Boost' mode, the boost' chargers
chargers shall recharge the
completely discharged battery to full capacity in eight (8) hours.
In charger system, all the standard protection, metering and static annunciation shall be
provided.
Static Inverters
The two (2) nos. 100% capacity, (IGBT) required
required kVA inverters shall be static type consisting of
SCR type inverter, static filters, integrated control modules including necessary oscillators,
voltage regulators, current limiting and surge suppression networks. In addition, the inverters
shall have
ve features of soft start, wave shaping, transient recovery etc. Any other equipment
required for normal operation of the inverter shall be included irrespective of whether
specified or not.
The output from the inverter shall be 240V AC, sine wave 1 phase.
phase. The output of the UPS shall
be distributed to the essential loads through the AC switchgear. The connection from the UPS
to the AC switchgear shall be through a switch and a quick acting fuse. The feeders shall be
designed by the bidder to suit the load requirements.
Page 46 of 97
Static Transfer Switches

The static transfer switches shall use SCRs and other static devices, for automatic transfer of
load from the Normal source to the Alternate source. The continuous capacity of each static
switch shall be equal to the full load capacity of one inverter. Maximum transfer time including
sensing shall not be more than 1/4 cycle. The transition shall be "make before break" in both
directions. The static switch shall be provided with fuses in both `normal' and àlternate'
àlternat
power source. Provision for annunciation of failure of fuse or failure of alternate source shall
be made. The switch shall be provided with surge suppression networks and shall also be rated
to withstand transient voltages upto 150% of rated voltage. The
The short time rating of the switch
shall be 150% of the rated full load current for two (2) minutes.
Three phase/single phase Transformer and voltage stabilizer
The transformer connection shall preferably be of Le Blanc type with delta connected winding
on the three phase side or of open delta connection type. Other alternatives shall also be
considered, provided the connection has minimum unbalance on the primary side. The
transformer shall be encapsulated in Class B insulation. The transformer shall be adequately
rated for the duty involved. The actual value may be slightly increased to take care of any
losses in the static voltage stabiliser.
The voltage stabiliser shall employ silicon solid state circuitry and shall maintain the specified
output voltage for 0 to 100% load, with maximum input voltage variation as specified.
specified
Manual Bypass
Switch The manual bypass switch shall be a four (4) position switch.
switch. It shall be used to isolate a
static switch from its load and alternate power supply and to take it out of service without
power interruption to the load. It shall be make before break type contacts, so that power
supply to the loads is continuous during
during switch operations. It shall be capable of carrying rated
continuous full load inverter current.
Fault Diagonistic Unit
Unit Fault diagonistic unit shall be provided to supervise UPS operation. Facility to take print
out and recording of important parameters
parameters shall be provided. All the alarms shall be interfaced
with DDCMIS.
Battery
DC battery shall be VRLA, sealed maintenance free type. Battery capacity should be 500Amp
Hr with float charger of 110 Amps. Float cum boost charger should be 110Amps also. Battery
shall be located in the battery room. Battery shall be suitable to maintain the power supply for
at least 60 minutes (battery back time) in the event of mains failure.
Page 47 of 97
Necessary distribution board for distribution of power from UPS output to

t individual
consumers.
Permissible variations for mains power supply system shall be as follows:
: + 10 % , -15 %
Voltage
Frequency
: As per IS
Harmonic distortion
: < 5%
Output of the uninterruptable power supply system while delivering a load of its rated
capacity (P.F of load shall not effect its output) shall have following variations;
Voltage regulation
:1% (For 0-100% load)
Frequency
: (+/-) 0.5% (For 0-100% load)
Efficiency
:Above 80%
100% to 0% and 0% to 100% load
: Volt dip +10%
Enclosure and ventilation
Enclosure conforming to IP-41
IP 41 class. Units shall be provided with cooling fans and louvers at
the bottom sides. Individual ventilation ducts for each
each unit shall be provided.
Distribution Board
The DB shall have two buses, main and standby and shall be protected by semiconductor fuses
with fuse monitoring device, bus healthy lamps, voltmeters and ammeters. Each load shall be
fed by two independent feeders. Isolating and buscoupling switches shall be provided.
The enclosure sheet steel thickness shall be 2.0 mm. with cold rolled sheets and 2.5 mm for
hot rolled sheets and enclosure class protection shall be IP-54.
IP
TECHNICAL PARTICULARS
1. Application
2. Capacity
3. Degree of protection
4. Cable entry
5. Input Supply Voltage
: Uninterruptible Power supply for PLC and

and other essential loads
: 200 % of PLC load
: IP 54
: Bottom
: 415V+/415V+/ 10%, 3 phase 4 wire, 50 Hz +/- 5%
Batteries
1. Type
2. Application
3. Number of cells in each bank in series
4. Ambient temperature
5. D.C. nominal system voltage
6. Ampere hour capacity
7. Charging method proposed
8. Emergency load duration
: VRLA, SMF
: UPS System
: Min.temp. :5.0 deg.C Max.temp. :50 deg. C
: Suitable to inverter system
: Bidder to furnish along with calculations
cal
: . Float and boost
: 60 Minutes (battery back up time)
Page 48 of 97
9. Continuous load/duration
Battery chargers
: 2 nos. (1 FC + 1 FCBC)
1. Number required
2. Type
: Static
3. Method of charging
: Float and boost charge type
4. DC system voltage
: To suit the system
5. Automatic voltage regulator required(AVR)
: Yes
6. Regulation with AVR
: +/-1%
7. Permissible harmonics at rated continuous load : +/-2%
+/
8. D.C. load requirement
a) Momentary : As per requirement
b) Emergency : As per requirement
c) Continuous : As per requirement
9. Maximum time for boost charging
: 8 Hours
Inverters
1. Type
2. Suitable for parallel oper
3. Service
4. Output rating
5. Output Voltage
6. Phase
7. Frequency
8. Total harmonic content
any single harmonic.
9. Duty
10. Overload capacity
11. Efficiency
12. Cooling
13. Synchronization with source
: Continuous.
: 125% for 15 minute at 0.8 p.f
: Not less than 80% at rated load
: Natural air cooled
: Yes
Static transfer switch

1. Capacity Continuous
2. Type
3. Voltage
4. Frequency
5. Transfer time
: Make and carry F.L. current of inverter at 0.8 p.f.

: Make before break
: 240V, single phase
: 50 Hz
: 1/4 cycle maximum
Manual bypass switch

1. Capacity Continuous
2. Type
3. No. of positions
5. Transfer
: Static
: suitable for parallel operation
: Indoor
: As required
: 240 V A.C.
: Single phase
: 50 Hz
: 5% RMS maximum not more than 3% distortion
distort
in
: Make and carry F.L. current of inverters at 0.8 p.f.

: Make before break.
:4
: Short time rating of the inverter for 1Sec & 150% of full load
current for 2 minutes.
: Manual.
Page 49 of 97
4.12
RESISTORS AND RESISTANCE BOXES

The resistors offered shall be arduous duty, industrial application, shock and vibration proof,
unbreakable, rigid and rust proof punched chromium steel alloy grid and conforming to the
requirements stipulated in IPSS 1-10-002-82
1
82 "Specification for resistance boxes for power
circuits" with latest amendments. Cast iron resistors shall not be acceptable.
The resistors shall be assembled on high quality asbestos or mica insulated high tensile steel
tiee rods and separated from one another by mica or asbestos washers in required numbers
and rigidly supported to eliminate vibration, breakage, displacement or deformation. Tappings
shall be provided with every resistance element indicating resistance value to enable
adjustments, if required. Individual grids shall be TIG welded at the junctions and terminal taps
shall be welded to grids, ensuring a consistent current path.
The grids shall be assembled on heavy steel frames which shall be suitably stacked, housed
and mounted in minimum 2.5 mm CRCA sheet steel enclosed cubicles with louvers along with
wire mesh to ensure good ventilation and mounted on a base frame of ISMC 125 . The panel
of resistor units shall be free standing, floor mounting type and provided
provided with two numbers of
grounding pads, tapped holes and bolts suitable for connection of grounding conductor of
50x6 mm G.I flat. Enclosure shall be in single front execution.
Individual banks shall be mounted on bracket welded to the frame, as such individual bank can
be withdrawn out from enclosure without disturbing other banks. All resistor banks shall be
provided with adequate lifting facility for handling during installation and over hauling.
The terminals shall be brought out in the separate terminal box (IP-55)
55) on one side and
marked with metallic tags for external connection with AYFY cables.
The current carrying capacity of the resistor shall be so selected that the temperature shall not
exceed 370 deg. C.
4.13
PLANT ILLUMINATION SYSTEM

The scope includes complete plant illumination system to achieve required illumination levels
as per IS or as per CBIP guidelines. The scope shall cover the following illumination systems:
Normal AC lighting
DC Emergency lighting.
light
Maintenance lighting
Peripheral, road/street and area lighting within battery limit
Illumination shall be provided in all the following premises:

1.
2.
3.
Switchgear room at WT substation

Battery room at WT substation
Transformer rooms
Page 50 of 97
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
A/C & ventilation Room

R
Peripheries of buildings
Coal conveyor galleries
Dust suppression MCC room
Junction houses and transfer towers
Wagon Tippler System
Control room of WT
MCC room for WT
Roads/streets within battery limit
Area/sub areas within battery limit
Any other premise coming under the battery limit
The illumination system shall include the following in required quantities:

Lighting DBs/ Sublighting DBs
Light fittings with lamps
Lighting fixtures and accessories
Cables and wiring
Ceiling fans
Receptacles
For street light LED lamps preferable

High mast system should have Metal Halide Lamps
Steel tubular poles

Switches
Conduits & brackets
Hangers & clamps
JBs
Timers/photocell
All lighting in outdoor area such as cWT

c
areas, road/street and area lighting as well as
peripheral lighting shall have auto ON/OFF facility with suitable 24 hrs timer. All the light
fittings shall be dust and weather proof.
Illumination levels envisaged for different areas will be as indicated

indicated below:
S.N. Area
1
Switchgear room
Lux
250
Fitting type
FTL
2.
Battery room
100
FTL
3.
4.
Transformer room
MCC room
FTL
FTL
5.
WT Control Room
200
250
lighting
250
6.
7.
8.
9.
Junction house
Conveyor gallery
Peripheral lighting
Street / road / area lighting
200
100
20
20
MH
MH
MH
SV
FTL
Remarks
AC normal lighting DC
emergency lighting
emergency lighting
AC normal lighting
emergency
emergency lighting
AC normal lighting
AC normal lighting
AC normal lighting
AC normal lighting
Page 51 of 97
Lighting DBs of all the areas shall preferably be located inside the rooms like switchgear cum,
control room, etc.
Sufficient numbers of LDBs, SLDBs, lighting poles, 415/240 V switch socket outlets, ceiling fans
with regulators, earthing pits, MCB controlled socket outlet, junction boxes, etc shall be
considered under scope of the Bidder as per actual requirement.
DC emergency lights shall be fed from separate DCELDB. Similarly, power receptacles shall be
fed from dedicated Receptacles DB. DCELDB at WT SYSTEM substation shall be fed from
Purchasers DCDB. Receptacle DB shall be fed from Bidders PDBs/aux. PDBs.
icient numbers of DCELDBs and Receptacles DBs shall be considered by the Bidder as per
Sufficient
requirement.
LIGHTING DISTRIBUTION BOARD (LDB)
415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec.) indoor type.
Board shall be single front, metal clad,
clad, front matched, free standing, floor mounted, dust and
vermin proof, non-draw-out,
out, fully compartmentalized and extensible on both sides, IP54 type
enclosure. Incomers shall be draw out type. LDBs shall have a series of panels of uniform
height placed side
de by side having front access for operation as well as cabling and access for
maintenance of busbars. LDBs shall have two incomers and one bus coupler.
Separate busbar compartments provided on the top shall have bolted covers in the front and
rear. The main busbars shall have continuous current rating as required. The rating of the
neutral busbar shall be 50 % of the phase busbars. The busbars shall be of aluminum alloy
conforming to IS 5082. The busbar sizes shall be so selected that with the passage of rated
current, the temperature rise over 500C ambient does not exceed 400C as measured by
thermometer.
Each cubicle shall have segregated feeder compartments arranged in tier formation with each
compartment housing one feeder circuit with lockable hinged
hinged door having neoprene gasket all
around. Modular construction shall be adopted to cater for different sizes of feeders. The
cubicles shall have common horizontal busbar chamber at the top and vertical risers at the
back. The cable compartment shall be provided
provided on the side with cable entry arrangement from
bottom. The busbar and cable compartments shall be provided with bolted cover plates. The
rear cover shall be easily removable type construction.
The LDBs shall conform to IS 8623 for factory built assemblies,
assemblies, IS 13947 for general
requirement of switchgear and IS 5578 & IS 11353 Guide for making and identification of
conductors and apparatus terminals.
Page 52 of 97
The LDBs shall be fabricated from CRCA sheets with 2 mm thickness for all members except
the doors of the modules, the rear covers, the covers of cable chambers and busbar chambers
which may be of 1.6 mm with adequate stiffeners to prevent buckling. Non-load
Non
bearing
partition walls may be of 1.6 mm thick sheet steel.
The cubicles shall be made up of bolted sheet steel members and side panels of pressed sheet
steel with neoprene gasket at all joints and openings including doors.
Bus bars shall have same cross-section
cross section throughout the length. Rating of the neutral bus bar
ba
shall be 50% of the main bus bar. Earth bus bar shall run in bottom chamber throughout the
The LDBs shall have necessary provision at either end for future extension by bolting
additional section.
The busbar shall be supported with
wi high quality non-hygroscopic,
hygroscopic, insulating, self extinguishing
and fire retardant insulating material, of adequate mechanical strength so as to withstand,
without damage, effects of available short-circuit
short circuit current. The busbars shall also be properly
spaced
d of facilitate taking vertical connections to individual units. The connections to
individual units shall be taken by taped busbars. The busbars shall be of uniform cross-section
cross
and the main busbars shall run throughout the length of the board. Similarly vertical droppers
shall extend for the full height of the panel except the bottom chamber. The connection
between busbars of different metals as well as their connection with the terminals of the
equipment shall be made in such a way to prevent corrosion and local heating.
Liberal space shall be provided for cabling and to accommodate any conventional type of cable
glands for PVC insulated and PVC sheathed armoured aluminum conductor cables.
The cables compartment shall have provision for clamping of cables
cables inside compartment on
perforated sheet steel sections.
The LDB shall have following meters in each of the two incoming feeders:
One no. digital type voltmeter with accuracy class of 1.0
One no. digital type ammeter with accuracy class of 1.0
One no. digital energy meters with accuracy class of 1.0
Suitable CTs with accuracy class of 1.0 shall be provided in the incomer modules for the above
metering.
Moulded Case Circuit Breakers
LDBs shall have moulded case circuit breaker triple pole, air break type with independent
0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system and
shall be current limiting type. All outgoing
outgoing feeders shall have earth fault protection.
Page 53 of 97
The MCCBs shall be suitable for panel mounting and shall be fixed type. All live parts shall be
enclosed in moulded case and all contacts shall be silver plated. The breakers shall be trip-free
trip
and with quick make & break operating mechanism. The MCCBs shall
sha be provided with
ambient temperature compensated bi-metal
bi metal overload releases and a magnetic short-circuit
short
release with inverse time characteristic. Releases shall be either static or microprocessor
based.
The operating handle shall be included with module
module door such that the door can be opened
only with the breaker in the OFF position. The MCCB handle after the breaker tripped due to
a fault shall occupy an intermediate position. The breaker shall be capable of interrupting a full
fault current corresponding
onding to the fault level specified.
MCCBs shall have a breaking capacity of 50kA at 415V. Current limiting MCCBs are not
permitted.
The LDB shall be consisting of following feeders:
Incomer
:
Bus coupler
:
Outgoing
:
63 A MCCB 10 Nos.
2 Nos. each of 600 A MCCB with over current and earth protection.
p
1 No. of 600 A MCCB
125 A MCCB
SUB LIGHTING DISTRIBUTION BOARD (SLDB)

415V, 3 phase, 4 wire, 125/63A (as applicable), indoor/outdoor type (as applicable) generally
conforming to IS 13947 and IS 8623 as applicable.
The SLDB shall comprise of one number of incoming TPN MCCB, three nos. of DP MCBs, and
requisite number of outgoing SPN MCBs (as specified) and adequately rated bus bars. The
SLDBs shall also have timer, contactors, A/M switch, etc as per requirement. The enclosure
class of SLDB shall be IP 54. The terminals of MCCB shall be fully shrouded. The boards shall be
of industrial, totally enclosed dust-proof,
dust proof, wall mounted, sheet steel cubicle design. The
thickness of the sheet steel shall be 2 mm. The boards shall have welded back and sides and
gasketted hinged door at the front with door handle and suitable locking devices. For boards
with incoming isolating switch the access to the operating handle shall be from the front of the
cubicle without opening the front door. Operating knobs of outgoing MCBs shall be accessible
only after opening the front door of the cubicle. Protective insulated cover plate shall be
provided inside the cubicle to shroud all the live parts with only the operating
operatin knobs of the
MCBs protruding outside the cover plate. The boards shall also be dust-proof
dust
in door-open
position. Adequate space shall be provided within the boards to facilitate termination of
incoming and outgoing cables. The boards shall be factory wired
wired and assembled. Where
specifically called for, the boards shall be of special weather-proof
weather proof design suitable for outdoor
installation.
Page 54 of 97
The miniature circuit-breakers

breakers (MCBs) shall be heat resistant plastic moulded type generally
designed, manufactured and
and tested as per IS 8828. Unless specified otherwise all MCBs shall
be provided with quick break trip free mechanism and direct acting thermal overload and
short-circuit
circuit trip elements. The short-circuit
short circuit breaking capacity of the MCBs shall not less than 9
kA at 0.8 power factor. Single-phase
Single phase MCBs which are not provided with built-in
built phase barriers,
and mounted adjacent to each other and connected to different phases, shall be provided
with adequate insulated phase barriers, shall be selected from standard current
cur
rating.
The TPN busbars shall have continuous current rating as required. The busbars shall be of
copper and sizes shall be so selected that with the passage of rated current, the temperature
rise over 500C ambient does not exceed 400C as measured by thermometer. The minimum
size of busbars shall be 25 x 3 mm. The busbars shall be properly supported with high quality
non-hygroscopic,
hygroscopic, self extinguishing and fire retardant insulating material of adequate
mechanical strength so as to withstand, without damage,
damage, effects of available short circuit
current. The busbars shall also be properly spaced to facilities mounting of MCBs and taking
connections to individual units.
Detachable cover plate shall be provided at top and bottom for cable glands suitable for
f PVC
insulated, PVC sheathed armoured aluminum conductor cables or for direct entry of conduit.
Cable terminals shall be suitable for aluminum conductor cables and so arranged to enable
connecting of each circuit without disturbing any other circuits.
Identification labels, inscription plates, danger boards, etc shall also be provided as per
requirement. Earthing arrangement and danger plates shall be as specified.
SLDBs shall have automatic group switching arrangement for which timer of robust
construction
uction and suitable contactors shall be provided in each board. Bypass arrangement of
timer in form of auto/manual switch shall also be provided in the SLDBs. The controller shall
sense the outdoor light and shall switch ON through auxiliaries contacts when
w
the sunlight
falls bellow a present value. It shall remain in this position till dawn when it shall switch OFF
when the sunlight remains a preset level.
Suitably engraved identification labels and inscription plates shall be provided for each circuit.
circu
The same shall also be provided for the boards.
One continuous G.I earth bus shall be provided in the bottom part of SLDB along the full length
of the board with two bolted type earthing terminals to comply with the requirements of
Indian Electricity Rules. Proper danger plates shall also be provided on each board.
Each SLDB shall be provided with padlocking facility with sufficient number of keys. The
following types of SLDBs shall be provided:
SLDB, Type A (To be used for 2x40 W FTL light fittings)
fittin
Incomer
MCCB, 4 POLE, 63 A : 1 No.

Page 55 of 97
Outgoing
Outgoing
:
:
MCB, DP (63 A) : 3 Nos.

MCB, SPN (10 A) : 10 Nos./Phase (Total 30 Nos.)
SLDB, Type B (To be used for 250 W HPSV/MH light fittings inside the building)
Incomer
:
Outgoing
:
MCB, DP (63 A) : 3 Nos.
Outgoing
:
MCB, SPN (16 A) : 6 Nos. per phase (Total 18 Nos.)
SLDB, Type C (To be used for 250W/150W/70 W HPSV/MH light fittings outside building)
Incomer
Outgoing
Outgoing
:
:
:

No
MCB, DP (63 A) : 3 Nos.
MCB, SPN (20 A) : 5 Nos. per phase (Total 15 Nos.)
SLDB, Type D (To be used for 250 W HPSV/MH street light fittings)
Incomer
Outgoing
:
:

MCB, TPN (63 A) : 8 Nos.
Sufficient number of SLDBs of different types (A, B, C and D) shall be used as per requirement
of different areas and sub-areas
sub areas of the coal handling plant. Exact quantity of SLDBs of various
types shall be finalized during detailed engineering. Bidder shall
shall consider as per requirement
subject to minimum one number of each type of SLDB.
RECEPTACLE DISTRIBUTION BOARD
Receptacles DB shall be suitable for 415V, 3 phase, 4 wire, 125 A, indoor type.
Board shall be single front, metal clad, front matched, dust
dust and vermin proof, draw-out,
draw
fully
compartmentalised and extensible on both sides, IP54 type enclosure.
Shall have isolated busbar chamber for main busbar at the top, running through out the length
of the board. Chamber shall have removable cover.
usbars shall have same cross section through out the length . Rating of the neutral busbar
Busbars
shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the
Shall have Moulded case circuit breaker (MCCB) triple
triple pole, air break type with independent
0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system.
Generally all boards will have following
f
feeder arrangement.
Incomer
MCCB TPN of 125A : 1 Nos.

Page 56 of 97
Outgoings
MCCB TPN of 32 A : 10 Nos.
220V DC Emergency LDB (DCELDB)

The DCELDB used for emergency lighting distribution shall be industrial heavy duty type
suitable for 2-wire 220V DC operation, and shall have a DC double pole power contractor and
requisite number of auxiliary contractors and timers and outgoing feeders protected with DP
MCBs of suitable ratings.
The incomer shall be of double pole load break design suitable for
for operating on 220V DC. The
enclosure shall be made of 2 mm thick sheet steel and shall have requisite number of cable
glands and terminal strips for incoming and outgoing cables. The control circuit voltage shall
be of 220V DC.
The DCELDBs which feed all
all the emergency lighting points shall be automatically switched on
the event of power failure through a separate circuit which sense under voltage of normal AC
supply at the specified location. These emergency lighting fittings shall glow for a preset time
tim
and shall be switched OFF automatically through a time relay in case the normal AC power
supply is not restored within that time.
Feeder configuration of DCELDB shall be as follows:
MCCB, DP (63 A) 1 No.
Incomer
:
Outgoing
:
MCB, DP (10 A) 16 Nos.
Supply of battery, battery charger(FC & FCBC, DCDB for 220V DC system shall be in bidders
scope.
415 V switch outlets
Switch socket outlets and plugs for 415 V, 3-phase
3 phase circuits shall be of four-pin
four
(three pole and
one earth), non-reversible
reversible type
typ enclosed in dust-proof
proof 2 mm thick sheet steel enclosures. The
socket outlets shall be provided with fuses and shall have isolating switch interlocking as per
IS:4160 such that it can be switched ON only when the plug has been inserted and plug can
be provided
rovided for the socket outlets. The isolating switches shall be of category AC 23
conforming to IS 13947 (Part 3). The socket outlet shall be suitable for terminating aluminum
conductor cables either directly or through GI pipe and shall be provided with compression
c
type lugs. The socket outlet shall be supplied with metal clad plug. The socket outlets and
plugs shall have porcelain base and shall be of 32A rating.
proof enclosure shall be used for outdoor installation. Inscription plate shall be
Weather-proof
provided indicating the voltage rating for the switch outlet.
240 V switch socket outlets
Socket outlet for 240 V supply shall be of 3-pin
3
(two-pole
pole and one earth) nonreversible, metalmetal
clad, dust-proof,
proof, industrial type suitable for horizontal insertion generally as per IS 1293. 240 V
Page 57 of 97
socket outlets shall be controlled by rotary type switch mounted flush in the socket outlet box.
Operating handle of the rotary switch shall be fixed in such a manner that it will not be
possible either to insert or to withdraw
withdraw the plug without switching off the supply. All socket
outlets shall be supplied with heavy duty type plug and cap with chain. The isolating switches
shall be of industrial type of category AC 23. The isolator shall be housed in dust and verminvermin
proof sheet
heet steel enclosure suitable for terminating aluminum conductor cables either directly
by means of cable gland or through conduits. The current rating for the socket outlets shall be
20 A. Wherever called for HRC fuses shall be incorporated in the socket outlet box.
Inscription plate shall be provided indicating the voltage rating and feeder identifications for
the switch socket outlet.
MCB Controlled Socket Outlet
The MCB controlled socket outlet shall be similar to the above switch socket outlet and
provided with industrial type socket outlet with cover suitable for 240V, 20A single phase AC
and controlled through single pole 20A MCB.
Ceiling Fans and Regulators
Ceiling fans regulators shall be designed, manufactured and tested as per IS:374. The fans shall
have totally enclosed, capacitor start and run motors, suitable for operation on 240V, single
phase, 50 Hz AC system. The electronic type regulator shall have ON OFF position next to
the lowest speed contact, shall be provided with necessary harmonic filters and shall be
suitable for operation at 500C ambient temperature.
Down rods required for installation of ceiling fans shall be included by the Bidder.
Bidde
Lighting Poles
Steel tubular road lighting poles with single outreach shall be of swaged and welded
construction conforming to IS:2713-1969
IS:2713
with latest amendments.
The outer surface of pole above foundation shall be painted with two coats of red oxide
o
zinc
chromate primer paint as per IS:2713 and finished with two coats of synthetic enamel paint of
approved shall not be less than 100 microns.
The outer surface of the pole embedded in concrete foundation as well as the entire inner
surface shall bee painted with two coats tar based general type black paint.
The poles shall be provided complete with fixing arrangement for loop-in
loop in and loop out box and
lighting fittings. The Bidder shall submit a drawing indicating the general arrangement and the
finall design and arrangement shall be subject to purchasers approval.
The 415 loop-in loop-out
out box shall be weather-proof,
weather proof, dust tight, sheet steel enclosure suitable
for outdoor installation. The box shall have hinged front with front locking device. 3 Nos. open
Page 58 of 97
type terminals for taking looping connection of 4C x 16 sq.mm Al conductors. Conductor

power cables and 2C x 2.5 sq.mm PVC copper wiring cable through rewirable fuse cutout to
the control gear. The box shall be supplied complete with 63A terminal block,
blo 5A rewirable
fuses cutouts, brass / aluminum alloy cable gland, clamps, lugs, earthing terminals, danger
plates and other required hardwares.
Street lighting pole shall have a single outreach suitable to hold the street lighting fitting.
Flood lighting
ng pole shall have a cross bar on top of the pole and shall be suitable for fixing the
flood light fitting.
Earthing provision of lighting poles
2 Nos. 8 SWG GI wire shall run throughout along with street light poles in loop in loop out
arrangement. One number of earth pit shall be provided for every 5 nos. of lighting poles. Each
earth pit shall be consisting of 40 NB GI pipe of 3 mtr length, funnel,
funnel, salt, charcoal, cast iron
cover, clamps, etc.
Junction Box
The 415/240V, TPN junction boxes shall be of fabricated from 2mm thick sheet steel suitable
for mounting on wall / column. The box shall have suitable provision for entry and termination
of aluminum conductor, PVC insulated cable supplied complete with terminal blocks, earthing
terminal, wire support etc. The box shall be painted with anti-corrosive
anti corrosive primer both inside and
outside and furnish with two coats of approved colour paint. The junction
junct
boxes used
outdoors shall be with suitable canopy arrangement. The junction boxes shall be suitable for
terminating one (1) incoming cable and two outgoing cables.
Lighting Fittings
High Mast light fittings shall be with Metal Halide (MH) lamps).All
lamps).Al other fittings shall be with
LED lamps.
All lighting fittings and accessories shall be manufactured from best quality materials and shall
be completed in all respect ready for installation at site.
Unless otherwise stated lighting fittings shall have provision for 25 mm / 19 mm dia conduit
(as applicable) entry for low-bay
low bay fittings. Medium bay fittings shall have eyebolt suspension
arrangement.
Terminals off all fittings shall be suitable for connecting 2.5 sq mm flexible, copper conductor,
PVC insulated
ted and PVC sheathed cable for low-bay
low bay fittings and 2.5 sq mm flexible copper
conductor cable for high bay fittings.
All the LED fittings and MH fittings shall be non-integral
non integral type. Control gear boxes shall be
mounted at man height for ease of maintenance.
maintenanc
Page 59 of 97
High mast fittings (Non-integral

integral type) : 2 nos
integral type asymmetrical beam flood light fittings with 2x400W MH lamps complete
Non-integral
with control gear, accessories, etc suitable for installation on 30 M high lighting mast as per
technical specification
ion (Bajaj BGENF 22 or equivalent with MH lamps) shall be mounted on the
lantern carriage of each of the high lighting mast.
Lamps
All lamps shall be of high lumen output and with long life.
Incandescent Lamp
All general service incandescent lamps shall be gas filled, clear finished and coiled coil type
where possible. Incandescent lamp cap shall be of screwed type having GES/ES thread
depending on the sizes of the lamp.
Fluorescent Lamp
mps shall be of day-light
day light type unless otherwise specified and shall be suitable
All fluorescent lamps
for suitable for switch-start
start with bi-pin
bi
type cap.
Sodium vapour lamps shall be suitable for universal burning position. The elliptical outer bulb
shall be coated inside the diffusing powder and shall have good colour appearance. The
sodium vapour lamp shall be of screwed type E40/E27 base depending upon the wattage of
the lamp.
Ballast
The ballast shall be of electronic type and well tried out design to give trouble-free
trouble
operations
with long service life having provisions for suitable tappings in steps.
Capacitor
Capacitor shall consist of element wound from layers of higher purity aluminum foil and
capacitor paper contained in aluminum cylindrical can. The capacitor shall
sh be vacuum dried
and impregnated. The can shall be hermetically sealed and terminals provided over porcelain
insulations. The capacitor shall conform to IS 1569.
Lamp Holder
The lamp holders shall have spring loaded contacts for positive contact with
wit pins so as to
prevent the lamp from being extinguished due to vibration. The holder shall be such that the
lamps can be removed easily whenever required for cleaning or replacement purposes.
For fluorescent lamp, bi-pin
pin lamp holder shall be provided. The
The holder of incandescent lamps
upto 200 W shall be of ES type.
Page 60 of 97
The starter holders shall be of well tried-out

tried out design and of robust construction with provisions
for easy insertion and removal of the starter ensuring correct contacts by means of strong
spring action.
Push button for group switching of lights
h buttons (one no. ON and one no. OFF) shall be mounted on cast iron box with
The push
2NO+2NC contacts and terminal block.
Conduits and Conduit Fittings
Surface conduit installation shall be carried out using hot dip / electro galvanised rigid steel
seamed by welding, screwed type, designed, manufactured and tested in accordance with IS
9537. The various conduit accessories like couplers, bends, elbows, reducers, saddles, clamps,
lock nuts, junction boxes etc. shall conform to IS 3837 shall be supplied and erected
erec
as per
requirement along with the conduits.
Point wiring materials and Accessories
The point wiring materials and accessories for lighting for installation, fan points, sockets etc.
where specified shall include wiring cables, conduits and conduit fittings, wiring accessories
inclusive of switches, sockets, fan regulators, switch boxes, junction boxes etc.
Point wiring
The wiring cables used in point wiring installation shall be 1100 volts grade PVC insulated
single core flexible stranded copper conductor type confirming to IS:694. The size of
conductors to be adopted shall be 2.5 sq.mm for lighting, fan and 5/15A socket outlet circuit
and 2.5 sq.mm for 15A socket power circuits.
Wiring Accessories
The various electrical wiring accessories viz.
viz. Switch boxes, switches and sockets shall confrom
to IS 5133, IS 3854 and IS respectively. The switch boxes shall preferably be of passed sheet
steel cadmium coated and passivated or galvanised with knockouts at the top and the bottom
for conduit entry. The surface mounted type boxes shall have necessary provisions for
mounting on the wall. Earthing terminals shall be provided in the box. Junction boxes provided
at intermediate points shall also be identical in construction to the switch boxes. The switch
and junction boxes shall be of standard dimensions with adequate wiring space. The switches
and sockets shall be made of superior quality engineering plastic with excellent dielectric
properties. The switches shall be of piano key design and shall have adequately
adequately rated switch
contacts. The switch contacts shall be silver tipped electrolytic grade copper. The switch plate
forming part of the switch box cover shall be made of plastic material and shall be made with
Page 61 of 97
number of slots in which the switches and sockets

sockets shall be assembled. The sockets shall be of
three pin design with phase neutral and earth conducts.
Earthing
All electrical equipment shall be effectively earthed as to meet the requirements to Indian
Electricity Rules and IS:3043.
IS:3043. Earthing conductors for individual equipment shall be of either
galvanised mild steel flat or stranded/solid G.I. wire as specified.
Earth pits for street/area lighting poles
The earth pits shall be consisting of 40 NB GI pipe of 3 mtr length, funnel,
funnel salt, charcoal, cast
iron cover, clamps, etc. The Bidder shall include all civil work as per requirement. All
accessories shall be included as per requirement.
4.14
LIGHTING HIGH MAST WITH FLOOD LIGHT FITTINGS

General
lighting shall be factory fabricated mild steel plates welded,
a. High mast tower for floor lighting
polygon section, hot dip galvanized and provided in standard lengths.
b. The structure shall be 30 meter high, well tried, proven design to withstand high wind
speed of 180KM/ hr.
ave a movable lantern carriage tower from the top of tower to bottom and
c. The mast shall have
vice-verse
verse with the help of a motorised winch arrangement (with motor of minimum 2.2
kW capacity) and shall be provided with suitable gears, pulleys and ropes. The reeling of
ropes shall
all be such that to prevent twisting & tangling. Means shall be provided for normal
operation of the winch in case of failure/ non availability of power to the motors. Safety of
lantern carriage in case of breakage of the rope shall be ensured by arresting free fall of the
lantern carriage to the ground by providing Safety locking arrangements.
d. All the carriage components shall be galvanised and mounted inside the tower. The tower
shall be provided with a suitable man entry door at the bottom section to facilitate
inspection and maintenance. The door shall be weather proof and provided with safety
safet lock
to prevent unauthorised access.
e. The lantern carriage shall be symmetrical, robust construction housing the luminaire and
control gear boxes. The cables to the luminaries shall be run inside the tubes of the lantern
with junction boxes provided for branch off cables.
f. Proper luminaries carriage ring support arms shall be provided for supporting the
luminaries carriage ring when the latter is lowered for maintenance of luminaries. Lantern
carriage ring should be in channel tube and with concealed wiring
wiring the carriage should be
Page 62 of 97
essentially have a 3 points suspensions system. The mobile luminaries carriage shall be
evenly balanced Rubber Paddle Guide Ring shall be incorporated as a buffer arrangement
between mobile luminaries carriage and mast shaft. This
This is to prevent damage to mast
surface during raising and lowering operation of mobile luminaries carriage.
g. The winch shall be provided with a separate control panel housing the control for the winch
drive motor and controls for switching the luminaries.
luminaries. It shall be complete with switch fuse
units/MCCBs, starters, contactors, etc that may be necessary to the operation of the light
tower. It shall be suitable for outdoor installation with IP-65
IP 65 degree of protection. It shall
be suitable for mounting on a suitable plinth adjacent to the high mast tower.
self sustaining type without the need
h. The winch must be of robust design and completely self-sustaining
for brake -shoe,
shoe, springs or clutches. It can be removed from the mast for maintenance if
the need arises in the future
future with the lower carriage on the top. The reduction gear of the
winch shall be of endless worm gear, operating in oil bath. The minimum safe working limit
of the winch shall not be less than 750 Kg.
when the mobile luminaries ring is
i. A minimum 6 turns of wire rope shall be on the drum when
fully lowered to rest on the luminaries supporting arms.
j. The winch is entirely selfself sustaining under all normal circumstances and it is not
dependent on the brake or restraining device that uncontrolled or dangerous runaway
runaw
speed shall occur in the event of the total failure of this device. Slip test on winch is carried
out by the manufacturer. Test certificate and report shall be submitted up, on request.
shall be at least 1.5 meter Per
k. The speed of the raising and lowering of lantern carriage ring shall
minute.
l. The high mast shall be fitted with flexible standard G.I / S.S. hoisting wire ropes of 7 x 19
construction with a minimum breaking strength of 1900 kgs. The combine lifting capacity of
the hoisting wire ropes shall have
have a factor of safety not less than 5 times the safe working
load (SWL) of the winch and shall be entirely suitable for the design application.
m. A transition plate shall be incorporated to balance the carriage from below of the mast.
n. Cable for lighting and winch control shall be as per approved scheme. The cables shall be
clamped or rolled so that no twisting of cables happens while the winch is hoisted or
lowered. Electrical cable shall be PVC coated round flexible cable suitable for small bending
radius. One standard multi core flexible electrical cable with 4 sq mm conducting areas
shall be provided for connecting of power supply to the light source and shall terminate at
the stationary connecting board in the base compartments.
o. The high mast shall be suitable for asymmetrical loading of with 16 nos. of 2 x 400 W MH
luminaries mounted on the lantern carriage. The luminaries shall be grouped in individual
240V RYB circuits fed through time switches. It shall be possible to switch the
t
lamp
bypassing the timer. The timer shall be programmable digital/analogue quartz controlled,
Page 63 of 97
high accuracy real time clock. It shall be set from 6 PM to 6 AM or any other intermediate
time. The tendered shall indicate the controls offered by him clearly
clearly in the offer.
p. The successful Bidder shall submit design and preliminary data for the design of foundation
of the high mast tower indicating the requirements of embedded inserts etc. The
foundation shall be designed and provided by the purchaser. Bidder to include foundation
bolts etc which shall be embedded in the foundation. Grouting of the bolts shall be done by
the Bidder.
q. The high mast shall be provided with lightning protection with airair termination and downdown
comers as per requirements of BIS and aviation warning lamps as per statutory and civil
aviation requirements. All metallic portions of the high mast shall be effectively earthed
and provided with two earth pits near the base. Effective earthing for luminaries shall be
provided during normal operation
o
and in lowered position.
(Part
r. Mast structure is designed to withstand wind velocity conforming to IS 875 (Part-III)-1987.
Mast Design Criteria
The high mast and the lowering system with the required number of floodlights and lamp
controls gears etc.
tc. In place shall be capable of withstanding a sustained basic wind speed of
180 Km/ hrs.
The design shall be in such a manner that it is capable of withstanding external forces exerted
by wind pressure and should have a minimum wind load factor of 1.25 and material factor of
1.15. Design life of mast shall be 25 years.
CONSTRUCTIONAL FEATURES OF MAST
The mast shaft shall be made with the best steel grade, in compliance with MS ISIS 2062/BSEN
10025 having adequate characteristics w.r.t. minimum yield strength, tensile strength and
minimum elongation for thickness.
The steel grade for accessories shall also be MS IS 2062 or equivalent, having adequate
characteristics w.r.t. minimum yield strength, tensile strength and minimum elongation for
thickness.
Each mast section to be delivered to site shall have a minimum length of 10.7 Mtrs. The Mast
sections shall have Single longitudinal weld from Bottom to Top.
The base shall have a flange plate for high mast onto the concrete foundation by anchor bolts.
The mast shall be fabricated and welded longitudinally to form a tapered section with
telescopic friction
on slip joints. All welding shall be to IS 816 / 82 having the following basic
requirements.
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The wall thickness of each section shall be designed to withstand the loads to which the high
mast shall be subjected to, but shall not be less than 8 mm for base section and 6 mm for
other sections and minimum base dia shall not be less than 530 mm.
Connection between the various sections, shall be achieved by telescopic slip joints, the
overlapping length being at least 1600mm slip joint assembly shall be perform at site. Shaft
section shall not be joined by circumferential weld or bolting at site.
The base plate shall be free from lamination
lamination and shall be single flange constructed with holes
jig drilled for anchor bolts passage. The bottom of the base mast section shall be securely
welded to the base plate by complete penetration fillet welding. The welded connection of the
base plate to the mast section shall fully develop the strength of the section.
The base section shall be equipped with a hinged service door. The service door opening shall
be complete with a close fitting weatherproof and equipped with a vandal resistant lock. The
service
ervice door shall not be smaller than 1400 mm x 300 mm the opening shall be reinforced by a
thick steel door frame.
Base plate of suitable dimensions and thickness, diameter, size and the placement of anchor
bolts shall be determined by calculations. Anchor
Anchor bolts shall be of deformed steel
reinforcement bars having the adequate characteristics w.r.t. tensile strength.
Welding of two or more anchor rods of shorter lengths to achieve the design length shall not
be permitted. No welding shall be allowed on
o the anchor rod body.
Adequate earthing and earthing terminal shall be provided within the access door area of each
Mast. All high mast shall be hot dip galvanized, in accordance with IS 2629 / TR 7 Timer control
panel shall be provided with overload and single phase preventor. Timer control panel shall
be outdoor type.
Motor capacity of the winch
Motor shall be of hoist duty and of adequate capacity with 15 % minimum margin over
mechanical power requirement. Minimum capacity of 2.2 kW shall be considered.
consi
4.15 EARTHING AND LIGHTNING PROTECTION
EARTHING PROTECTION
Bidder shall include complete earthing of WT substation, MCC rooms, Wagon tippler,
apron feeder & conveyor drives
etc. The
underground earthing mats also
shall be done by the Bidder. Risers shall be available at all the premises for
interconnection of own earthing network. However, Bidder shall provide
provide complete separate
earthing for transformer neutrals.
Bidder shall include the following in each and every substation:
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1.
2.
3.
Earthing ring mains at WT substation and all the electrical rooms/premises

Equipment earthing
Transformer neutral earthing providing
prov
dedicated pits
Bidder shall include complete earthing material including earthing strips, earth electrodes
other accessories for treated earth pits, etc. and carry out earthing ring mains, earth pits,
interconnections, equipment earthing, all associated
associated civil works, etc at all the ubstations.
All the connections of earthing ring mains with available underground earthing grid of
respective substation/premise shall be under scope of the Bidder.
Separate dedicated treated earth pits shall be provided
provided for transformer neutrals. Two nos.
such earth pits shall be provided for each of the transformers. The treated earth pits shall be
consisting of 3 mtr 65 NB GI pipes, funnels, clamps, 3 mtr long 40 mm MS rod electrodes, MS
cover with lifting lugs, associated
assoc
civil works, etc.
All the equipment located in the WT premises / sub-premises
sub
e.g. 33 KV switchboard, LT PCCs,
busducts, transformer bodies, charger panels, DCDBs, LDBs, SLDBs, receptacles, control panels,
MCCs, etc shall be connected by the Bidder with earthing ring mains at least two different
points.
Electronic earthing shall be considerd for PLC, etc
Bidder shall also consider earthing of following equipment to be installed by the bidder.
33kV
kV WT switchboard at WT substation in switchgear cum MCC room
WT distribution transformers (2 nos.) Neutral as well as body earthing
415 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room
Control panel for power distribution equipment at existing WT control room
LT busducts (2 sets)
Charger panels, DCDB, etc at WT substation in switchgear cum MCC room
Bidder shall consider earthing ring mains at each electrical premise and connect the electrical
equipment with the rings. The earthing ring
ring mains shall be connected with underground
earthing mats (consisting of 2x40MM dia to be installed by the bidder.. For transformer neutral
earthing, bidder shall consider dedicated plate earthing.
Bidder shall include complete earthing material including
including earth electrodes, risers, GI earthing
strips, other accessories, etc. and carry out main earth grid mat, earthing ring mains, earth
pits, risers, interconnections, equipment earthing, all associated civil works, etc within battery
limit of the package. Allll the interconnections with other earthing systems of the plant and
with existing systems shall be under scope of the Bidder.
The Bidder shall obtain the actual soil resistivity of the plant area by carrying out soil resistivity
tests and design the earthing
thing system accordingly.
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While designing the earthing system, Bidder shall note the following fault levels at 415 V bus
shall be 50 kA. Plant earthing system shall be designed such that overall earthing resistance is
less than 1(One) Ohm without interconnections.
interco
The materials shall be galvanized steel laid over the ground and mild steel buried inside the
ground/concrete.
Fault clearing time for sizing of earth conductors and for calculations of the maximum
allowable step and touch potential shall be taken 1 sec. Maximum allowable temperature rise
for steel bolted joints shall be taken as 3100C taking ambient temperature of 50oC.
The earthing system shall be generally designed on the basis of the following codes &
standards:
IS 3043 Code of practices for safety and standards
IEEE 80 Guide for safety in AC substation grounding
Entire system shall be earthed so that the values of the step and contact potentials in case of
faults are kept within safe permissible limits.
limit
Parts of all electrical equipment and machinery not intended to be alive shall have two
separate and distinct earth connections each to conform to the stipulation of the Indian
Electricity Rules.
In case of HT system, E/F current will be made to flow through copper screen tape provided
over inner sheathing. Screen will be connected to earth bus at both ends. In case of LT the TNTN
S system will be followed, i.e. neutral bus of the switchgear shall be connected to switchgear
earth bus and then to DBs shall
sha be through armouring of cable.
Bidder shall submit the layout drawings of earthing network with supported calculations for
approval of purchares/consultant. Taking approval of Electrical inspector/CEA and providing all
inputs to them like data/drawings
data/drawing are under scope of the Bidder.
The materials shall be galvanized steel laid over the ground and mild steel buried inside the
ground/concrete.
Earthing of SLDBs, power receptacles, etc shall be connected with respective source LDBs
through armouring off cables.
Earthing conductors run on walls/floors/cable and equipment structures etc. shall be
supported at suitable intervals and painted with black oxide paint.
The armour of cables and all conduits for cables shall also be connected to the earthing mains.
m
A continuous earth strip shall run in each side of cable channel and in cable ducts/tray route.
All joints in the branch connections except at earthing electrode shall be welded and painted
black. At road/rail crossings earthing strips/rods shall be laid through conduits/concrete ducts.
Page 67 of 97
The armour of cables and all conduits for cables shall also be connected to the earthing mains.
A continuous earth strip shall run in each side of cable trenches.
All joints in the run of the main earthing conductors will be welded or brazed type. Connection
to equipment structure shall be bolted type. All welded joints
joints shall be protected from
corrosion by applying bitumen paint.
Earthing system shall be distinct and separate from the lightning equipment earthing system.
Earthing Conductors and Installation Accessories for Equipment Earthing System
All electrical equipment installed by the successful Bidder as well as equipment installed by
Purchaser shall be effectively earthed in conformity with relevant clauses of Indian Electricity
Rules (1956) and in accordance with IS: 3043 to the complete satisfaction
satisfaction of the Chief
Electrical Inspector to Government of Orissa State. All non-current
non current carrying metallic conduit
parts of various electrical equipment as well as cable armouring, metallic conduits, GI pipe,
cable racks, trays, brackets, supporting structures
structures etc. shall be effectively earthed.
Main earth mat comprising 40 mm dia MS rods and earth electrodes and riser upto + 1.0 M
level shall be supplied and installed by the ownr. All other equipment to complete the earthing
of equipment installed by the Bidder shall be in the scope of the Bidder. The Bidder shall also
connect his sub earth mat to the main earth mat provided by the Bidder.
Conductor size adopted for earthing ring shall in no case be less than that of the earth
continuity conductors connected
connected to it. The size of conductors used for overground sub earth
mat in switchgear rooms/ control rooms/ plant buildings/ areas shall be 65 mm x 8 mm
galvanized mild steel strips. 50 mmx 6mm galvanized MS strips will be used for earth buses
inside the buildings/
ldings/ floors/ platforms etc. and also for earth conductors laid along cable trays.
For buildings having a number of floors, separate earthing ring shall be established in each
floor and shall in turn be connected to the Purchasers earth mat.
Separate earthing system shall in no case have cross-sectional
cross sectional area less than 6 sq mm stranded
GI wire.
Size of earth conductors selected for system earthing and earthing of various equipments shall
be as follows.
Galvanized Iron flat conductor strips shall be used for neutral earthing. The minimum size of
conductors for neutral earthing of various transformers shall be as given below unless a higher
size is required from the viewpoint of higher available fault current.
tran
: 75mm x 10mm
LV neutral of 33/0.440 kV, 1600 KVA transformers
The minimum size of galvanized Iron flats for earthing of various equipment shall be as
follows:
Page 68 of 97
Ring mains
LT PCCs/board
Control Panels
LT Busducts
DC Distribution Board
LDB
SLDB
Push button station
Transformer bodies
Cable tray (running earthing)
:
:
:
:
:
:
:
:
:
:
75mm x 10mm
65mm x 8mm
50mm x 6mm
50mm x 6mm
50mm x 6mm
50mm x 6mm
25mm x 3mm
6 sq mm stranded
50mm x 6mm
50mm x 6mm
LIGHTNING PROTECTION
d plant structures including switchgear building and junction houses shall be
All buildings and
protected against atmospheric flash over and lightning strokes in such a manner as to
eliminate any danger to the personnel employed therein. Stipulations of IS : 2309 - 1969 shall
be followed.
A 'Faraday Cage' made of hot galvanised strip steel connected to all buried pipes and steel
structures crossing this cage ring shall be laid around plant as earthing device. This shall be
separate from the electrical equipment earthing ring
ri main.
Design shall be as per the standard like IS 2309 (latest revision) and Indian Electricity Rules.
All lightning arrestor earth leads of the plant shall be connected to this cage ring.
Air termination network should cover all salient points of the structure. All metallic structures,
ducts and the like above the roof of the structure shall be bonded to and form part of the air
termination network. Vertical air termination points shall project at least 30 cm above the
object on which it is fixed.
Down conductors shall follow the most direct path possible between air termination and earth
termination avoiding sharp bends. Down conductor shall have a testing point adjacent to the
earth electrode. Each conductor shall have an independent earth termination. All earth
terminations shall be interconnected.
Earthing electrodes and grid for lightning protection will be distinct separate from the earthing
system for earthing of electrical equipment and at no place will be connected to other
earthing system.
4.16
MISCELLANEOUS ELECTRICS
SAFETY
Page 69 of 97
All equipment shall be complete with approved safety devices wherever potential hazard to
personnel exists and with provision for safe access of personnel to and around equipment for
operational and maintenance functions. The design shall include all reasonable
reaso
precautions
and provisions for the safety of operating and maintenance personnel.
Special care shall be taken to make enclosed equipment proof against entry of rats, lizards and
other creeping reptiles which may create electrical shortshort circuits inside
side live equipment.
MINOR CIVIL WORKS
Minor civil works associated with cabling, earthing, conduit installation, illumination systems,
lighting poles, for buried cables, for erection of equipment supplied by the Bidder, foundation
of lighting masts/poles,
es, etc shall be included under scope of bidder. Similarly minor civil works
like widening of floor openings / cable trenches, wall opening for cables, minor chipping, etc
shall be included under scope of bidder.
LOCAL CONTROL STATION
Near all drives local
cal control stations shall be provided. Local stations shall have Cast
Aluminium body, dust and vermin proof, and structure mounting. Stat and stop push buttons
shall be mounted on front hinged gasketted and lockable door. Local/remote selector switches
shall
all be provided on local control stations. Stop push button shall be lockable type. In addition,
ammeters shall be provided on local control stations for HT drives. Suitable knockouts with
glands shall be provided on the bottom or top cover for cable entry.
entry. Terminals shall be suitable
for 2 cores of 2.5 sq.mm conductors with 10% spare terminals. Enclosure shall be conforming
to IP55 with proper rain canopy.
ELECTRICS OF DUST SUPPRESSION SYSTEM
Bidder shall include complete electrics of dust suppression systems coming in the scope within
the battery limit. Bidder shall provide complete electrics including MCC, drives/mechanism,
associated cabling & their termination, local DBs, all power and control ccessories, all related
annunciations, etc.
ELECTRICS OF AIR-CONDITIONING
CONDITIONING AND VENTILATION SYSTEM
Bidder shall include complete electrics of air-conditioning
air conditioning system and ventilation system.
Complete electrics for the following shall be included:
Ventilation system for the switchgear cum MCC room at WT SYSTEM substation
Exhaust fans for the two numbers transformer rooms at WT SYSTEM substation
Air-conditioning
conditioning system for the battery and battery charger room at WT SYSTEM
substation
stem for dust suppression MCC room
Ventilation system
WT SYSTEM ELECTRICS OF HOISTING AND HANDLING EQUIPMENT

Page 70 of 97
Bidder shall include complete electrics of hoists coming in the scope within the battery limit.
Bidder shall provide complete electrics including source feeders, associated cabling & their
termination, local DBs, all power and control accessories, all related
related annunciations, etc.
All the hoist control panel shall be located at workable height and platform shall be provided
for each hoist at one point for maintenance purpose.
33 KV OVERHEAD LINES
In coming power supply to Wagon tippler, apron feeder, & conveyor system will be taken
from 33KV Lean Slurry substation located near the 220KV switch yard with provision of
lighting arrester, load brake switch, 33KV VCB, CT,PT relay and control panel housed in a
suitable building comes under bidders scope. Laying
Laying Power cable/Transmission line from
the substation to wagon tippler area along with provision of transformer, switch gear system
& panels will be the scope of the bidder. Approximate distance from the substation to the
wagon tippler area will be 2.00 Km.
Km. However, actual distance & Suitable route for laying of
cable will be assessed by the party in consultation with NALCO. The transmission line(33 KV)
where ever crossing roads shall be through double run underground cabling arrangement as
per relevant regulations.
gulations.
The bidder shall also execute underground cabling and other necessary work for crossing
railway track of the existing Intake Pump House and Ash pond 33KV overhead transmission
lines with provision of DP,lighting arrester and associated switchgear.
switchge
Cost of power cable/transmission line shall be in scope of bidder.
RS joist poles of size to 200 X 100 mm shall be erected by excavation of pit size 700 mm X
700 mm to a depth of 1/5th of the pole. The pole shall be erected upright to the plumb. MS
channel shall, be used for V type cross arm of size 100 X 50 X 6.4 mm. The spacing between
two extreme conductors shall be 1100 mm and the 3rd conductor shall be provided on the
top of the mast. Suitable porcelain pin type insulators shall be used. A continuous
con
earth wire
shall be provided for RS joist pole earthing and securely fastened to each pole and
connected to earth, at 4 points in every 1.6 km, the spacing between the points, being as
nearly equidistant as possible. Galvanized steel guard wire mesh
mesh having breaking strength of
635 kg shall be connected to earth at different points and shall be used in over head while
crossing street/passage. Suitable lightening arrester shall be provided in the four pole
structure.
V overhead transmission line will be decided by the bidder in

Suitable route for 33KV
consultation/coordinating with NALCO to avoid any local/field interference.
HT transformer of suitable capacity (33KV/0.44KV)
KV) will be supplied by the bidder confirming to
latest features. Supplyy of associated switch gear and measuring equipments will be supplied
by the bidder for the HT system.
Page 71 of 97
Technical details of HT transformer and other switch gear will be submitted to NALCO / RITES
for its approval. The conductor for 33KV line shall be of ACSR
ACSR (dog/Rabbit) type.
The HT transformer (33KV/0.44KV)
(33KV/
shallll be located in the near the wagon tippler area. The
switch gear will be designed in conformity to CEA norms having provision of LA, PT, CT, ISO etc.
Fencing and development of switch gear will be the scope of the bidder. The switch gear will
be located near wagon tippler area.
Room size to be decided by the bidder to house all required equipments (HT & LT switch
gears) at the ground floor.
WT Control room and operating panel will be located at
at first floor of the building.
Bidders are also advised to visit the site and assess the actual quantum of work to be done for
this diversion and include accordingly.
The operation of the WT SYSTEM plant shall be monitored and controlled from the proposed
WT control rooms by means of VDU operator interface on a microprocessor based
programmable logic controller (PLC). The system shall be envisaged for the purpose of initial
operation, protection and interlock, data acquisition, close loop control, data archiving,
a
etc for
fully automatic operation. The system shall be capable of monitoring and displaying the status
of equipment, including the analog and digital signal displaying of status in the form of
diagram, trend bar chart, overview, logs, etc with the
the help of CRT, keyboard, mouse and
printers.
Necessary hardware and software license of the proposed PLC shall be provided.
provided PLC
programme, ladder logic and control philosophy shall be submitted by the bidder for approval
of NALCO/RITES.
The preferred make of PLC shall be GE-FANUC
GE
make.
33 kV Unit Vacuum Circuit Breaker

33 kV indoor Vacuum Circuit Breaker shall conform to the following technical particulars:
i)
ii)
iii)
iv)
v)
vi)
vii)
Type
Quantity
System Voltage
Maximum system voltage
Continuous current
Rated short time current rating
Interrupting capacity at 36 kV
Indoor, Vacuum type, electrically operated,

trip free type, panel mounted
33 kV
36 kV
As per requirement
31.5 kA for 3 sec
31.5kA
Page 72 of 97
The VCB shall be indoor drawout type with numerical type over current (50+51), earth fault
(51N) relay with timer for instantaneous overcurrent protection as we as master
trip and trip circuit supervision relay. The VCB shall be capable of withstanding through fault
current of 31.5kA for 3 sec. and shall be provided
with
remote
closing
and
tripping facilities. Under voltage relay with timer shall be provided in line PT.
transformer
nsformer differential protection shall also be provided. PT shall be provided with protection
core of 3P class and metering core of CL 0.5. CT shall be provided with protection core of
5P20 class and metering core of CL 0.5. For transformer
transformer differential protection PS class CT shall
be considered.
The closing coil of the breaker shall be suitable for operation between 85 to 110 percent
of 220 V DC control power supply voltage available from batteries.
The circuit breaker shall have redundant shunt trip device. The trip coil shall be designed
to operate satisfactorily when the voltage at the terminals of the shunt trip coils is
between 70 to 110 per cent of 220 V DC control power supply voltage available from
batteries. VCB
B shall be provided with dual trip coil. For actuation of trip coils, similar set of
contacts shall be provided separately for each trip coil. Hence, necessary arrangement for
duplication of contacts shall be done inside the panel
panel if multiple No. of similar contacts are not
available.
The circuit breaker shall be power operated with motor wound spring closing mechanism with
electrical spring release coil. The motor shall be suitable for operation on 240 V AC single phase
supply. Means shall however be provided for manual operation of the breaker under
emergency or for testing and adjustments.
The operating mechanism shall be anti pumping and trip free type.
perated mechanism shall be so designed that the spring gets
The spring operated
recharged immediately after closing.
automatically
Imploding type surge suppressor and earthing truck with full capacity circuit breaker, three
(3) Nos. single phasee PT, selector switch and test plugs shall be considered at the outgoing side of
VCB.
Both incoming and outgoing terminals of VCB shall be suitable for terminating 33 kV (E)
grade XLPE insulated PVC sheathed, 3core, aluminium conductor
condu
cables.
The circuit breaker shall be provided with necessary auxiliary switches for indication,
control, interlocking, protection and alarm. Six spare auxiliary contacts, three (3) NC and
three (3) NO shall be left
eft free in the breaker. All the contacts shall be wired to the terminal
block.
Space heaters to prevent moisture condensation within the enclosure shall be provided in
relay and control cubicle. Heaters shall be suitable for operation
operation from 230 V, AC 50 Hz, single
phase supply.
Page 73 of 97
33kV Control and Relay Panel
One (1) set of relay and control panels consisting of two (2) feeders and PT complete
with mimic buses, instruments, controls, indication, alarm annunciation relays and
alarm facia and protection relays as required for the
the 33 kV feeder for the proposed plant and
as described below shall be provided.
The mimic
diagram
shall
provide
single
line representation of the 33 kV
system. The control and relay panel shall be located inside the room for new 33 kV VCB
panel.
The relay and control panel shall be floor mounted type, having sheet steel of 2.5 mm
thickness. A equipment shall be mounted such that removal and replacement
replacement may be
accomplished individually without interruption of service to adjacent equipment. The relay and
control panel shall have rear access.
Test devices shall be provided for C.T. circuits. CTs shall not be open circuited
circuited during testing
operation.
Adequate illumination shall be provided inside each cubicle. CFL lamps suitable for 230 V,
50 Hz, single phase supply shall be provided.
Potential circuits for
suitable MPCB/MCB.
instrumentation and
and for metering each shall be protected
by
Annunciator shall be suitable for 220 V DC operation. It shall have a single DC alarm common to
all points.
Space heaters to prevent moisture condensation within
within the enclosure shall be provided in
relay and control cubicle. Heaters shall be suitable for operation from 230 V, AC 50 Hz, single
phase supply.
A relay shall be numerical type having communication port conforming
protocol as per IEC61850 for direct interfacing with plant
commun
communication
PLC/DCS/SCADA system. Numerical relay shall be capable to receive minimum adequate

nos. inputs and output contacts.
(ACDB
415-240 V AC Distribution Board (ACDB)
415 V, 3phase, 4wire ACDB shall be provided which will be fed from the secondary side of
33/0.433kV auxiliary control transformer. The auxiliary transformers shall
be
tapped from before the incoming HT circuit breakers over HT load break isolator, HRC fuse
and voltmeter. The distribution board shall be provided with two incoming feeders, each
comprising one MCCB and one magnetic contactor connected to one common
comm set of busbars.
ACDB shall be floor mounted, totally enclosed, fully compartmentalised, multitier single
Page 74 of 97
front design. The distribution board shall be suitable for cable entry from the bottom.
Devices requiring operation shall
shall be located in between 450 mm and 1900 mm from the floor
level .
The ACDB shall have indicating voltmeter with selector switch, PT, MPCB & MCB at the line
side of the distribution board. Ammeter with selector switch, CT, MPCB &
MCB shall
also be provided. These instruments shall be flush type located on the front door of the
compartments. The sizes of ammeter and voltmeter shall be 96 mm x 96 mm. Phase
indicating lamps shall be provided
vided at the bus side of incomer.
The ACDB shall be fabricated from minimum 2.0 mm thick CRCA sheet steel with load
bearing members comprising 2.5 mm thick CRCA sheet steel. The degree of
protection
shall be IP:54.
A the outgoing feeders shall be of MCCB/MCB unit.
Power circuit isolation shall be possible without opening the front door and shall have
provision for padlocking in OFF position with the door closed. ON/OFF indications
shall be provided for a feeders by means of cluster LED lamps.
The main phase busbars and tappings shall be made of aluminium having cross sectional
areas to be substantiated during engineering
engineering but in no case the current density shall
be more than 80 A/sq cm. The busbars shall be suitably supported on non hygroscopic
moulded glass reinforced plastic insulators so as to be capable of withstanding
withstand
dynamic
forces due to 50 kA through fault short circuit. All joints shall be coloured PVC taped.
Temperature rise of busbars/joints while carrying the rated current shall not be more
than 45C over maximum ambient
ambient temperature of 45C when measured by thermometer.
Tappings from the main busbars to individual feeder compartments shall be by means of
insulated single core copper cables with stranded conductor for feeders upto 100 A ratings
above which aluminium busbars shall be used. All copper to aluminium joints shall be
provided with bimetallic nuts/bolts/washers.
A continuous 50 mm x 10 mm aluminium earth bus shall be provided throughout the
length
gth of the panels and shall be located in a separate chamber at the bottom with
removable front cover. Provision shall be kept for taking earth connections to external earth
mat. PVC insulated (Green coloured) copper wires shall
shall be used to connect all noncurrent
carrying metallic parts, doors, etc to the earth bus.
All relays, instruments, meters, pushbuttons, switches and other devices of any feeder
shall be located on the respective compartment only.
All operating handles, control switches, pushbuttons, indicating lamps, instruments, meters
etc shall be mounted on the front of the cubicles.
220 V DC Control Battery Bank

Battery bank shall consist
st of plante type lead acid cells in transparent plastic containers
with sufficient quantity of electrolyte, acid level indicating floats, intercell connectors,
cell support insulators, cell number plates, properly treated
treated and acid resistant painted
wooden stand supported on porcelain insulators, terminal connectors for external
connections etc. as required to make the installation complete in all respects. The wooden
Page 75 of 97
stands shall
be made of good quality teak wood suitably treated with two coats of
linseed oil and three coats of antisulphuric acid paint.
coated
Inter row and intertier connectors for the batteries shall be made of copper
with lead. The terminals of each cell shall be indelibly identified for polarity. The
terminals of battery outgoing leads shall have provision for connecting lead coated
copper bars which shall be suitably extended upto the room wall for termination of external
aluminium conductor, XLPE insulated cables. Suitably terminals shall also be provided for taking
takin
external connections from cell by aluminium conductor XLPE insulated cables.
The cells shall be delivered in dry and discharged condition. Sufficient quantity of electrolyte
ready to fill condition shall be supplied for the
the first filling of the batteries in nonreturnable
airtight plastic/polypropylene containers. Ten (10) percent extra electrolyte shall
also be
provided.
Complete battery maintenance equipment required for convenient

convenient and safe handling and
preparation of electrolyte shall
be supplied with the battery bank. These shall include
but
not
be
limited
to
items
like
syringe
type
hydrometer,
mercury in glass thermometer calibrated 0 to 100o C, wall mounted holder for one hydrometer
and one thermometer, syringe, level testing tube, 150 mm dia glass funnel, spanners, centre
zero cell testing voltmeters, PVC gloves,
gl
PVC jug, etc.
Load Break Switch (LBS)
Load break switch panel shall consist of the following:
33 KV, 31.5 KA rated HT air break/load break switch suitably interlocked with earth switch shall be
provided. It shall be with front operated spring assisted
assisted manual mechanism with 2 N/O and 2 N/C
auxiliary contacts. It shall contain:
ON/OFF indication lamp 2 Nos.
Suitably rated copper busbar 1 set
Space heater with thermo start and switch control
Mechanical interlocks
Provision of receiving incoming
coming 33 KV XLPE cable at bottom.
Ring Main Gear (RNG):
The ring main gear shall be indoor type and shall consist of one No. 33 KV suitably rated, short
rating 31.5 KA, load breaks switch with interlocked earth switch front operated spring assisted
manual closing mechanism horizontal draw out, horizontal isolation VCB fitted with motor
operated charging mechanism for controlling the outgoing supply.
Rated voltage 33 KV
Rated Current- as per requirement
Frequency 50 Hz
Cubicle Floor mounted free
fr standing dust and vermin proof.
Page 76 of 97
Encl: IP-45
Control voltage 220 V DC
BELT SWAY SWITCH

The belt sway switch shall be shall be auto reset type and provided at both ends and at an
interval of 50 mtrs (for conveyor length greater that 200 mtrs) on both sides of conveyors and
also before and after belt weighing system on both sides. It shall be of auto reset type.
The belt sway switch shall be industrial heavy duty type housed in dust and vermin proof box
with degree of protection IP-54.
IP 54. The switch shall be designed that conveyor does not come in
direct contact with the switches and mechanism shall have strong rest spring to absorb high
impact of loaded belt edge.
The switch element shall be self rest type and shall have 2NO+2NC contacts each rated for
10A, 240V AC. It shall be suitable for ambient temp. of 600C. Resetting spring mechanism,
built in terminal box, actuating
ctuating rollers, roller shafts, supporting frame, etc shall be provided as
per requirement. Belt sway switch shall be J&N make.
PULL CHORD SWITCH
Pull chord switches shall be auto reset type industrial heavy duty enclosed in dust and vermin
proof enclosure with degree of protection IP-65.
IP 65. They shall be provided with following
facilities;
Switch elements shall be 2NO+2NC each rated for 10A, 240V AC.
Automatic locking arrangement in the operated position with manually reset
Snap action type for positive
posi
operation of contacts
Number of position shall be 1-0-1
1
Separate compartment for built in terminal box
Suitable base plate Pull rope shall be stranded galvanized steel wire with at least 1
mm thick PVC cover and having overall diameter of 6mm to 7mm.
7mm.
Pull rope switch shall be placed at an interval of 25 mtr on both sides of conveyor with
minimum of one pair for conveyor length less than 25 mtr.
ZERO SPEED SWITCH
The unit shall be provided with MS flags, sensing probes, monitoring unit and interconnecting
inte
special cables. The unit shall be of multi speed range with setting facility and shall be provided
with output contacts (2NO+2NC) with facility for initial bypass adjustable time delay, nuisance
tripping delay and analog/digital speed display. 4-20mA
20mA isolated DC signal shall be applicable
for external metering. Sensing probe shall be provided with metallic enclosure of degree of
protection IP-67
67 and LED lamp for visual indication of correct functioning of sensing probe.
Page 77 of 97
PASSIVE FIRE PROTECTION

Fire protection for cables at entry/exit points of the wall shall be provided with proper sealing
by fire sealing material. The fire sealing compound shall be rated for minimum 2 Hours. Fire
retardant painting shall also be provided on cables for 2 Mtrs on both sides of the wall/floor
crossing.
ERECTION & INSTALLATION ACCESSORIES
All cable accessories like conduits, inserts, cable tag markers, clamps, sealing compound, pull
boxes, marshalling boxes etc. shall be considered as part of the Bidders scope
scop to complete the
erection job in all respect.
OTHER ITEMS
Bidder shall provide all required switches, cabling and other devices needed for proper
control, operation, interlocking and sequencing of the any other offered systems and
technological mechanism, if specified in technological, e.g. hanging magnets and wipers
wi
(if
applicable), roof exhaust fans & wall exhaust fans (if applicable), etc.
All required safety items like rubber mats in front of MCC/DB/Panel, shock treatment chart,
first aid boxes, danger boards, boards indicating 'Man on Work, Do not switch ON',
ON 'Do not
switch OFF', 'EARTHED' etc. shall be provided in each electrical premises.
Wall mounted aux. AC and DC distribution boards shall be provided in sufficient number to
facilitate proper distribution of the power supply to various users.
Bidder to include closing of all cable and panel openings through a Fire sealing material. This
shall include closing of all bottom opening of control room panels/desks, MCC switch boards,
wall openings in all the areas, etc. Bidder shall also include earthing of all equipments/system,
wherever required, under his scope of supply.
Bidder shall include painting of all the plant and equipment with approved shades and include
primers as well as finishing paints.
Sufficient quantity of GI ladder type factory fabricated
fabricated cable trays made from 2.5 mm thick hot
welded steel sheets grade o as per IS: 2062 shall be provided. Hot dip galvanizing of 85
micron thick as per IS-2629,
2629, IS-4759
IS
and IS- 209. Trays shall be of standard length of 3 m with
max deflection not exceeding
ding 1/400 of span with sufficient load bearing capacity.
4.16 ERECTION OF ELECTRICAL EQUIPMENT
Bidder shall include erection of all the equipment under his scope of supply. Erection of
equipment shall have to be carried out as follows:
Page 78 of 97
1. Procedure mentioned in manufacturers manual

2. Under the expert supervision
3. Sequence and plan of erection as per the guidance of Purchasers Site In charge or their
consultant
4. During erection of suppliers equipment, existing equipment /system shall not be
disturbed.
5. Erection shall be in accordance with approved layout drawing and installation details.
6. Cable laying shall be as per approved cable layout drawings and work shall be carried
out in a neat manner.
installation accessories required for erection/installation
erection/installation of equipment and
All erection-installation
handling equipment required for handling of equipment from store to installation site are
included in the scope of work of Bidder as a whole.
Bidder shall ensure that the work erection and erected equipment shall comply with
wit all
statutory norms, regulations and standards applicable to the works/equipment and any
additional work/equipment required, if any, shall be under scope of the Bidder.
Necessary clearance from the wall shall be maintained as per IS/IE Rules from front/rear/
front/
side
of all the panels inside a room.
HT Power cables and LT power/control cables shall be laid in different cable trays. LT power
cables and LT control cables shall also be laid in different trays, however, if necessity arises
due to space constraints
ints or lesser number of cables, LT power cables and LT control cables can
be put on the same trays keeping sufficient gap between them. 24V DC cables, if required,
shall be laid entirely in different dedicated trays.
Cable trays in single tier or in multitier
multitier shall be installed in vertical arrangement everywhere to
avert coal accumulation and space reduction.
Fire Prevention:Proper design and use of quality material, equipment so as to avoid overloading in
Distribution board, wiring system including sub main, switch & sockets shall be ensured by the
bidder.
Insulating mats in front of PCC, MCC or control panel, protective rubber gloves, earth rods,
artificial respiration apparatus, line mans belt etc shall be provided in substations by the
bidder.
re extinguishers for various switch gear location, substations, PCC, MCC suitable for
Fire
electrical fire (class C)
C) like dry chemical powder, carbon-dioxide,
carbon dioxide, carbon-tetra
carbon
chloride type
shall be provided along with fire buckets filled with sands.
Comprehensive fire protection system in conformity with the requirements of national
building code, ECBC 2007 shall be ensured by the bidder.
5.0
INSPECTION AND TESTING
Page 79 of 97
5.1 Inspection
Extent of inspection
The extent of inspection & testing by the Purchaser shall vary from equipment to equipment
as per design requirements.
However, indicative extent of inspection for electrical equipment is furnished below:
Extent of inspection to be carried out shall be finalised with the Contractor after award of the
contract on the basis of scope of supply, technical specification and approved GA drawings.
However, in case of similar bulk manufactured items, methods of sampling for inspection of
different lots shall be governed by relevant Indian or international
international standards.
In case of critical components, the Purchaser reserves the right to undertake 100% inspection.
Final inspection & testing shall be done as per the following:
Verification of test certificates
Visual, Workmanship & painting
Dimensional
Witnessing of routine/acceptance/type/special tests as per relevant standards.
Witnessing of proto-type
type tests, as applicable
Verification of type test certificates for identical equipment
Approved QAP
The inspection shall be carried out on the basis of QAP dully approved by Purchaser /
consultant.
INSPECTION CATEGORIES
All the electrical equipment have been classified in three categories for inspection and issuing
dispatch clearance by the Purchaser/consultant. The three categories are:
Category-A
All the tests shall be inspected by the Purchaser/Consultant. Dispatch clearance shall be given
by Purchaser/Consultant
haser/Consultant after the equipment is inspected and found as per requirement and
as per TS. All types tests certificates shall e submitted by the Bidder in this case.
Category-B
Inspection shall be carried out by prime bidder and inspection waiver certificate
certificate shall be issued
by Purchaser/Consultant based on type test certificates and routine tests certificates furnished
by the Bidder. Purchaser/Consultant shall issue dispatch clearance accordingly.
Category-C
Page 80 of 97
Dispatch clearance shall be given by Prime bidder without any certificates based on technical
data sheet furnished by the Bidder.
5.2
S. N.
DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
HT CABLE
LT MOTORS
LT POWER AND CONTROL CABLES
MCC
TRANSFORMER
PLC & CONTROL DESK
UPS
ON LOAD 33 kV ISOLATOR
TRAILING CABLE / FLEXIBLE (EPR) CABLE
PDB/LDB/SLDB/AUX. PDB
SIGNAL, INSTRUMENTATION AND OTHER SPECIAL CABLES
CABLE ACCESSORIE
LIGHT FITTINGS
EARTHING AND LIGHTNING PROTECTION MATERIALS
FIRE SEALING MATERIALS
LOCAL PUSH BUTTON STATIONS
POWER SOCKET CABINET AND LIGHTING CABINET
CONTROL AND RELAY PANEL
415V FEEDER PILLAR
33KV VCB
LT DISTRIBUTION BOARD
33KV LIGHTENING ARRESTER
33KV ISOLATOR AND EARTH SWITCH
33KV CT,PT
BATTERY,BATTTERY CHARGER,DCDB
FIRE EXTINGUISHER
JB,RUBBER MAT,DANGER BOARD,FIRE BUCKET,FIRST AID
BOX,HAND GLOVES,SHOCK TREATMENT CHART,DISCHARGE
ROD.MEGGAR
INSPECTION
CATEGORY
A
B
B
A
A
A
A
A
A
B
B
C
C
C
C
B
B
A
A
A
A
B
B
B
A
C
C
Testing
General
Test of all equipment shall be conducted as per latest BIS. Wherever no such standard exists,
tests shall be as per International Standards like IEC/DIN/BS/IEEL/JIS, etc.
All routine tests shall be carried out at manufacturer's works in presence of Purchaser or his
representative.
Page 81 of 97
The Bidder shall submit type test certificates (not more than 5 years old) for similar equipment
supplied by him elsewhere. In case type test certificates
certificates for similar equipment is not available,
the same shall be conducted in presence of Purchaser or his representative, without any
financial implications to Purchaser.
The Bidder shall be responsible for satisfactorily working of complete integrated
integr
system and
guaranteed performance.
Site Tests and Checks
General
All the equipments shall be tested at site to know their condition and to prove suitability for
required performance.
The test indicated in following pages shall be conducted after installation. All tools, accessories
and required instruments shall have to be arranged by contractor. Any other test which is
considered necessary by the manufacturer of the equipment, contractor or mentioned in
commissioning manual has to be conducted at
a site.
In addition to tests on individual equipment, some tests/checks are to be conducted /
observed from overall system point of view. Such checks are highlighted under miscellaneous
tests but these shall not be limited to as indicated and shall be finalized
finalized with consultation of
client before charging of the system.
The contractor shall be responsible for satisfactory working of complete integrated system and
guaranteed performance.
All checks and tests shall be conducted in the presence of clients
clients representative and test
results shall be submitted in six copies to client and one copy to Electrical Inspector. Test
results shall be filled in proper Performa.
After clearance from Electrical Inspector system/ equipment shall be charged in step by step
method.
Based on the test results clear cut observation shall be indicated by testing engineer with
regard to suitability for charging of the equipment or reasons
reasons for not charging are to be
brought by the contractor.
Trial Run Test
After the successful test of each equipment as per standard test procedure the entire control
system shall be put on trial run test on actual site conditions and operation of the system.
sy
Acceptance Test
Page 82 of 97
The acceptance test on the system shall be carried out by the supplier as per mutually agreed
test procedures to establish satisfactorily functioning of the system as a whole and each
equipment as part of the system.
Site Tests
The tests to be carried out on the equipment at pre-commissioning
pre commissioning stage shall include
following but not limited to the following:
MCC
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
IR test before and after HV test.

HV test with 2.5 kV megger
Functional test for all feeders
Testing and calibration of all meters
Checking and calibration of protective relays as per supplier's commissioning manuals
Check operation of contactors from local and remote points
Checking of interlockings between incomers/bus coupler and other feeders.
Test to prove interchangeability of similar parts
Tests to prove correct operation of breakers at minimum and maximum specified
control voltages
Checking of earthing connection for
fo neutral-earth
earth bus, cable armour, location of E/F CT
etc. as per the scheme.
Check test, service and drawout position of all the breakers and operations of
mechanical flag indicator and electrical indication lamps.
Check functioning of various elect. schemes
schemes like autochangeover signalling etc.
Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and
between phases in off position
MOTORS
1. IR test of stator and rotor windings.
2. Ensure that checking/testing of associated switchboard,
switchboard, cables, relays /meter
interlocks as mentioned in relevant are completed.
3. Check tightness of cable connection
4. Winding resistance measurement of stator and rotor.
5. Checking continuity of winding.
6. Check tightness of earth connections.
7. Check space heaters and carryout heating of winding (if required)
8. Check direction of rotation in de-coupled
de coupled condition during kick start
9. Measure no load current for all phases.
10. Measurement of temperature of body during no load and load conditions.
11. Check for tripping of motor from local/remote switches and from
electrical/technological protection.
12. Checking of vibration
13. Checking of noise level
14. Shaft voltage measurement (if required)
15. Tan delta test, if required
Page 83 of 97
16. During load running, measurement of stator and bearing temperatures (if applicable)
for every half an hour interval till saturation comes.
17. Checking tightness of foundation bolts
18. Check operation of speed switch (if there)
19. Check continuity of temp. detectors.
20. Check alignment, paralleling of
of shafts, level of lubricating oil etc. as per manufacturer's
manual
21. Check for polarisation index of stator winding, R10/R1 by motorised megger (The value
should not be less than 2.0). R60/R10 absorption co-efficient
co efficient shall not be less than 1.5.
TRANSFORMER
IR test on each winding to ground and between windings.
1.
2.
Turns ratio test on each tap
3.
Polarity and vector group test
4.
Measurement of winding resistance by Kelvin bridge
5.
IR, wiring and operational tests on all control devices in control cabinet,
cabi
oil level
indicator, winding and oil temp. indicators etc.
6.
Checking of earthing wrt transformer tank (flexible from top cover to tank) other
parts, neutrals.
7.
Testing of buchholz relay for alarm and trip conditions.
8.
For bushing CTs, tests applicable shall be as for current transformers.
9.
Setting of oil/winding temperature indicators, level gauge and checking of alarm/trip
circuits.
10. Check insulators for cracks.
11. Checking for oil leakage and arresting of leakages (if there)
t
12. Checking of operation of all valves.
13. Checking for open position of all the valves (except drain and filter valves)
14. Filtration of oil by using line filter, vacuum pump, and heater set.
15. BDV test on oil samples from top and bottom.
16. Checking of oil for acidity, water content tan delta etc. as per IS 335.
17. Measurement of magnetising current and no load loss.
18. Measurement of PI value.
19. Checking of silica gel breather.
20. Checking of noise level at no load and at full load.
21. Checking of air circulation conditions
c
for indoor transformers.
22. Conducting magnetic balance test
23. Checking of other points given in manufacturer's commissioning manual.
24. Frequency response analysis for HT transformers (at manufacturers works)
UNINTERRUPTED POWER SUPPLY (UPS)
1.
Visual check
IR value by megger
2.
3.
Current limit test
4.
Ripple test
5.
Supply variation
Page 84 of 97
6.
7.
Functional test
Capacity test wrt time
PDB/LDB/SLDB/AUX.PDB
1. IR test before and after HV test.
2. HV test with 2.5 kV megger
3. Functional test for all feeders
4. Testing and calibration of all meters
5. Checking and calibration of overload relays and protective relays as per supplier's
commissioning manuals.
6. Check operation of contactors from local and remote points
7. Checking of interlockings between incomers/bus coupler
coupler and other feeders.
8. Test to prove interchangeability of similar parts
9. Tests to prove correct operation of breakers at minimum and maximum specified
control voltages
neutral earth bus, cable armour, location of E/F
E/ CT
10. Checking of earthing connection for neutral-earth
etc. as per the scheme.
11. Check test, service and drawout position of all the breakers and operations of
mechanical flag indicator and electrical indication lamps.
12. Check functioning of various elect. schemes like autochangeover signalling etc.
13. Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and
between phases in off position
CABLES & CABLE SUPPORTING STRUCTURES
1. Checking of continuity/phasing and IR values for all the cables before and after HV test.
2. Checking of earth
arth continuity for armour.
3. Check for mechanical protection of cables.
4. Check for identification (tag number system) distance placement of cable marker, cable
joint etc. as per the cable layout drawing.
5. Check earthing of cable structures.
6. Check clearances
ces from light fittings for cable structures
7. Check proper fixing of cable structures.
8. Check for proper drainage and removal of water from cable trenches
EARTHING & LIGHTNING PROTECTION

1. Check tightness of all earth connections
2. Check earthing of all metallic equipment, cable trays, busbar supporting structures, all
elect. equipments, etc. as per the requirement of IE rules and IS 3043
3. Measurement of earth resistance for each electrode.
4. Measurement of total earth resistance.
5. Measurement
easurement of earth loop resistance for E/F path of biggest LT drive.
ILLUMINATION
1. Lux level measurement in each area/premise
2. Test for black spot, if any
Page 85 of 97
3. Check operation of complete lighting system

MISCELLANEOUS
1. Checking of continuity of the system
2. Checking
hecking safe accessibility of all operating points
3. Ensure availability of first aid box, rubber glove, etc.
4. Check for safe movement of operators to pump house w.r.t. proper illumination, light,
uncovered openings, etc
5. Placement of shock treatment chart, danger boards, provision of boards indicating Man
on Work, Do not switch ON', 'Do not switch OFF', 'EARTHED' etc.
6. Check proper dressing of cables, mechanical protection of cables, placement of cable
markers
7. Check sealing of all cable openings including conduit opening with fire resistance
material
8. Check sealing of all openings at bottom of panels
9.
Check proper road crossing of cables/earthing materials.

LIST OF IMPORTANT INDIAN STANDARDS
SN
IS Standard with Latest

Amendment
1 IS : 732 1989
Title
Code of practice for electric al wiring installations.
2 IS: 4648 1968
Guide for electrical layout in residential buildings.
3 IS : 8081 1976
Code of practice for design, installation and

maintenance of service lines upto and including 650
V.
4 IS : 8884 1978
Code of practice for installation of electrical bells and

call system.
5 IS: 5578 1985

6 IS : 11353 1985
Guide for marking of insulated conductor.

Guide for uniform system of marking and
identification of conductors and apparatus terminals.
7 IS: 5728 1970

8 IS:7752(Part 1) 1975
Guide for short-circuit calculations.

Guide for improvement of power factor in consumer
installation : Low and medium supply voltages.
9 IS:3646(Part 1) 1966
Code of practice for interior illumination : Principles

for good lighting and aspects of design.
10 IS:3646(Part-3) 968
Code of practice for interior illumination: Schedule of

illumination and glare index.
11 IS:3646(Part-3)-1968
Code of practice for interior illumination: Calculation

of coefficients of utilization by the BZ method.
12 IS:4347 1967
Code of practice for hospital lighting.
Page 86 of 97
SN

Amendment
13 IS:6665 1972
14 IS:2672 1966
15 IS:10118(Part 1) 1982
Title
Code of practice e for industrial lighting.
Code of practice e for library lighting.
Code of practice for selection, installation and
maintenance of switchgear and control gear; General
16 IS:10118(Part-2)-1982
1982
Code of practice for select ion, installation and

maintenance of switchgear and control gear
selection.
17 IS:101118(Part-3)-1982
1982

Installation.
18 IS:10118(Part 4) - 1982

selection.
19 IS:4146 1983
20 IS: 4201 1983
21 IS:5547 1983
Application guide for voltage transformers.

Application guide for current transformers.
Application guide for capacitor voltage transformers.
22 IS:2309 1989
Code of practice for the protection and allied

structures against lightening
23 IS:3043 1987
24 IS:5216(Part01) 1982
Code of practice for earthing.

Guide for safety procedures and practices in electrical
work : General.
25 IS: 5216(Part 1) 1982
Guide for safety procedures and practices in electrical

work : Life saving techniques.
26 IS:3696(Part-2) 1966
Safety code for scaffolds and ladders: Ladders Electric

fans.
27
28
29
30
IS: 555 1979

IS:1169 1967
IS:374 1979
IS:2997 1964
Electric table type fans and regulators.

Electric pedestal type fans and regulators.
Electric ceiling type fans and regulators.
Air circulator type electric fans and regulators.
31
32
33
34
35
36
37
38
IS: 2312 1967

IS:3588 1987
IS:3963 1987
IS:4283 1981
IS:6272 1987
IS:4894 1987
IS:11037 0 1984
IS:12155 1987
Propeller type AC ventilating fans.

Electrical axial flow fans.
Roof extractor units.
Hot Air fans.
Industrial cooling fans (man coolers)
Centrifugal fans.
Electronic type fan regulators.
General and safety requirements for fans and
regulators for house hold and similar purposes, Low
voltage switch gear and control gear.
Page 87 of 97
SN

Amendment
SWITCH GEAR
Title
39 IS:4237 1983
General requirements for switch gear and control

gear for voltages not exceeding 1000 V ac or 1200v dc
40 IS:675(Part-1) 1973
Control Switches (switching devices for control and

auxiliary circuits including contractor (relays) for
voltages upto and including 1000 v AC and 1200 v DC:
41 IS:6875(Part2) 1973

auxiliary circuits including contractor (relays) for
42 IS:6875(Part-3)-1980

auxiliary circuits including
ncluding contractor (relays) for
43 IS:10027-1981
Composite unit o air break switches and rewireble

type fuses for voltages not exceeding 50 V AC.
44 IS:4064(Part 1) -1978
1978
Air break switches, air break disconnectors, air break

switch disconnectors and fuse combination units for
voltages not exceeding 1000 v AC or 1200 v AC :
General requirements.
45 IS:2675 1983
Enclosed distribution fuse boards and cutouts for

voltages not exceeding 1000 V.
46 IS:8828 1978
Miniature air break circuit breakers for voltages not

exceeding 1000 volt.
47 IS: 13032 1991
Miniature circuit breaker boards for voltages upto

and including 1000 volts AC.
48 IS:12640 1988
49 IS:2959 1985
Residual current operated circuit breakers.

Voltages not exceeding 1000 v AC or 1200 v DC.
50 IS:2516(Part01/Sec 1
1985
Circuit breakers: Requirements and tests: Voltages

not exceeding 1000 v AC or 1200 v DC.
51 IS:12021 1987
Specifications for control transformers for switch gear

and control gear for voltages not exceeding 1000
volts AC.
52 IS:5039 1983
Distribution pillars for voltages not exceeding 1000 V.
Page 88 of 97
SN

Amendment
53 IS:8623 (Part 1) 1977
Title
Factory built assemblies of switch gear and control
gear for voltages up to and including 1000 v AC and
1200 v DC : General requirements.
54 IS:8623 (Part 2) 1980.
Factory built assemblies of switch gear and control

gear for voltages up to and including 1000 v AC and
1200 v DC : Particular requirements for bus bar
trunking system (busways)
55 IS:8544(Part 1) 1977
Motor starters for voltages not exceeding 1000 v :

Direct on line AC starters.
56 IS:8544(Part 2) 1977
Motor starters for voltages not exceeding 1000 v :

Star-delta starters.
57 IS:8544(Part 4 ) 1979
Motor starters for voltages not exceeding 1000 v:

Reduced voltage ac starters, two step auto
transformer starters.
POWER CABLE
58 IS:694 1990
PVC insulated cables for working voltages upto and

including 1100 V.
59 IS:1554(Part 1) -1988
1988
PVC insulated (heavy duty) electric cables: For

working voltages upto and including 1100 v.
59 IS:3961 (Part 5) 1968
Recommended current ratings for cables: PVC

insulated light duty cables.
60 IS:4288 - 1983
PVC insulated (heavy duty) electronic cables with

solid aluminum conductors for voltages up to and
including 1100 v
60 IS:4289(Part 1) 1984
Flexible cables for lifts and other flexible connections:

Elastomer insulated cables.
Electrical Wiring Accessories

61 IS:9537(Part 1) 1980
Conduits for
requirement.
electrical
installations:
General
62 IS:9537(Part 2) 1981
Conduits for electrical installations: Rigid steel

conduits.,
62 IS: 3480 1966

63 IS:2667 1988
Flexible steel conduits for electrical wiring.

Fittings for rigid steel conduits for electrical wiring.
63 IS: 3837 1976
Accessories for rigid steel conduits for electrical

wiring.
64 IS:9537 (Part 4) 1983
Conduits for electrical installations: Pliable self

recovering conduits of insulating materials.
Page 89 of 97
SN

Amendment
64 IS:6946 1973
Title
Flexible (pliable) non-metallic
metallic conduits for electrical
installations.
65 IS:3419 1989
65 IS:5133 (Part-1) 1969
Fittings for rigid non-metallic conduits.

Boxes for enclosure of electrical accessories: Steel
and cast iron boxes.
66 IS:5133 (Part 2) 1969
Boxes for enclosure of electrical accessories
66
67
67
68
68
69
Link clips for electrical wiring.

Ceiling roses.
Switches for domestic and similar purposes.
Switch socket outlets (non-interlocking
interlocking type).
Interlocking switch socket outlet.
Plugs and socket outlets of rated voltage upto and
including 16 amperes.
IS:2412 1975
IS: 371 1979
IS: 3854 1988
IS: 4615 1968
IS:4160 1967
IS:1293 1988
Electric Lamps and their Auxiliaries

70 IS: 418 1978
Tungsten filament general service electric lamps.
71 IS:2418 (Part 1 ) 1977
Tubular fluorescent lamps for general lighting service

: Requirements and tests.
71 IS: 990(Part 1) 1981
High pressure mercury vapor lamps: Requirements

and tests.
72 IS:9974(Part 1) -1981
1981
72
73 IS: 1258 1987
73 IS: 3323 1980
High pressure sodium vapor lamps :

General requirements and tests.
Bayonet lamp holders.
Bi-pin
pin lamp holders for tubular fluorescent lamps.
74 IS: 3324 1982
Holders for starters for tubular fluorescent lamps.
74 IS: 2215 1984

75 IS: 1534 (Part 1) 1977
Starters for fluorescent lamps.

Ballast for fluorescent lamps: For switch start circuits.
75 IS: 1569 1976
Capacitors for use in tubular fluorescent high

pressure mercury and low pressure sodium vapor
discharge lamp circuits.
76 IS:6616 1982
Ballasts for high pressure mercury vapor lamps. Light

fittings and luminaries.
76 IS: 1913 (Part 1) 1978
General and safety requirements for luminaries

Tubular fluorescent lamps.
77 IS: 10322 (Part 1 ) 1982

77 IS: 10322(Part 2) - -1982
1982
78 IS: 10322 (Part5 / Sec 1 )
1987
Luminaries : General requirements.

Luminaries : Constructional requirements.
Luminaries : Particular requirements: Recessed
luminaries
Page 90 of 97
SN

Amendment
78 IS:10322 (Part 5 / Sec. 3)
1987
Luminaries : Particular requirements: luminaries for

road and street lighting.
79 IS:10322 (Part 5 / Sec.4)

1987
Luminaries : Particular requirements: luminaries for

road and street lighting.
79 IS: 10322(Part 5 / Sec 5)

1987
Luminaries : Particular requirements: Flood lights.
80 IS: 3287 1965
Industrial lighting fittings with plastic reflectors.
81 IS: 2206 (Part 1) 1984
Flame proof electric lighting fittings : Wall glass and

bulk head types.
82 Is:3528 1966
83 IS: 3553 1966
84 IS: 9030 1976
85 IS: 7537 1974
86 IS: 9583 1981
87 IS: 9583 1981
Electric Appliances
88 IS: 6236 1971
89 IS: 1248 (Part 1) 1983
Title
Water proof electric lighting fittings.

Water tight electric lighting fittings
Luminarires for hospitals.
Road traffic signals.
Emergency lighting units.
Emergency lighting units.
Direct recording
Direct acting indicating analogue electrical measuring
instruments and their accessories: General
requirements.
90 IS:1248 (Part 2) 1983

instruments and their accessories: Ammeters and
voltmeters.
91 IS:1248 (Part 3) 1983

instruments and their accessories: Wattmeters and
Varmeters.
92 IS: 1248 (Part 3) 1983

instruments and their accessories:
ssories: Frequency meters.
93 IS: 1248 (Part 5) 1983

instruments and their accessories: Phase meters,
power factor meters and synchronoscope.
94 IS: 722 (Part 1) 1988
AC electricity meters: General requirements and

tests.
95 IS: 722 (Part 2) - 1977
AC electricity meters: Single-phase

phase whole current
watt hour meters, class 2.
96 IS:722 (Part 3) 1977
AC electricity meters: Three phase whole current and

transformer operated and single phase transformer
operated watt hour meters, class 2.
Page 91 of 97
SN

Amendment
97 IS: 722(Part 5) 1980
Title
AC electricity meters: Volt-ampere
ampere hour meter for
restricted power factor range : General requirements.
98 IS:722 (Part 7)/Sec.1 - AC electricity meters : Volt-ampere

ampere hour meter for
1987
full power factor range: General requirement
99 IS: 722 (Part 8) 1972
AC electricity meters: Single phase 2 wire whole

current watt-hour meter (Class 1.0).
100 iS: 722 (Part 9) 1972
AC electricity meters: Three phase whole current and

transformer operated Watt-hour
hour meters, and single
phase two wire transformer operated watt-hour
watt
meters (Class 1.0).
101 IS: 8530 1977

102 IS: 2992 - 1987
Instrument Transformers
103 IS: 2705 (Part 1) -1981
1981
104 IS: 2705 (Part 2) -1981
1981
Maximum demand indicators.

Insulation testing testers
Current transformers: General Requirement
Current
transformers:
Measuring
transformers.
105 IS: 2705 (Part 3) -1981

1981
Current
transformers:
transformers.
106 IS: 2705 (Part 4) -1981

1981
Current
transformers:
Protective
current
transformers for specific purpose applications.
107 IS:6949 1973
Summation current transformers.
Fuses
108 IS: 9224 (Part 1 ) 1979
109 IS: 9224 (Part 2 ) 1979
Protective
current
current
Low voltage fuses : General requirements.

Low voltage fuses : Supplementary requirements for
fuses for Industrial applications.
110 IS: 2086 1982
Carriers and bases used in rewireable type electrical

fuses upto 650 volts.
111 IS: 9926 1981
Fuse wire used in rewireable type electric fuses upto

650 volts.
112 IS: 8187 1976

Miscellaneous
113 10000/1980/Pt.1to12
114 10028/Pt.1/1985
D Type fuses
Methods of tests for IC Engines
Code of Practice for Selection ,installation &
maintenance of Transformers - Selection
Page 92 of 97
SN

Amendment
115 10028/Pt.2/1981
Title
Code of Practice for Selection ,installation &
maintenance of Transformers - Installation
116 10322/Pt.3/1984
Specification for Luminaries :Screw & Screw less

Terminals
117 10322/Pt.4/1984
Specification of Luminaries :Methods of Tests
118 10322/Pt.5/ Sec.2/1985
Luminaries :Particular Requirements : Portable

general purpose Luminarie
119 1239/Pt.1/1990
Mild Steel Tubes ,Tubulars & other wrought Steel

Fittings : Mild Steel Tubes
120 1239/Pt.2/1992
Mild Steel Tubes ,Tubulars & other wrought Steel

Fittings : Mild Steel Tubulars and other wrought steel
pipe fittings
121 1255/1983
Code of Practice for installation maintenance of

power cables upto and including 33KV rating
122 12640/Pt2/2001
Residual Current Operated Circuit Breaker for

household and Similar uses : Circuit Breakers with
Integral Over Current Protection (RCVOs)
123 13118/1991
Specifications for High Voltage Alternating Circuit

Breakers
124 1367/Pt.3/1991
Fasteners -Threaded steel -Technical

Technical Supply
Conditions - Mechanical Properties and test methods
for bolts ,screws and studs with full load ability
125 1367/Pt.XIII/1983
Technical Supply Conditions for Threaded steel

Fasteners --- Hot dip Galvanized coating on threaded
fasteners
126 13925/Pt1/1998
Shunt Capacitors for ac power system having a rated

voltage above 1000v : General performance ,testing
rating safety requirements - guide for installation and
operation
127 13925/Pt2/2002
Shunt Capacitors for ac power system having a rated

voltage above 1000v : Endurance testing
Page 93 of 97
SN

Amendment
128 13947/Pt.1/1993
Title
Specification for Low voltage switchgear and control
gear - General Rules
129 13947/Pt.2/1993
Specification for Low voltage switchgear and control

gear - Circuit Breakers
130 13947/Pt.3/1993
Specification for Low voltage switchgear and

controlgear -Switches
Switches ,Disconnectors ,Switch
Disconnectors and Fuse combination Units
131 1445/1977
Porcelain insulators for overhead power lines with a

nominal voltage voltage up to and including 1000
volts
132 1460/2000
133 14772/2000
Diesel Fuels : Specification

General requirements for enclosures for accessories
for house hold and similar fixed Electrical installations
- Specification
134
135
136
137
Specification for plain washers

Power Transformers :General
Power Transformers :Temperature rise
Power Transformers :Insulation Level and dielectric
tests
2016/1967
2026/Pt.1/1977
2026/Pt.2/1977
2026/Pt.3/1981
138 2026/Pt.4 / 1977
Power Transformers :Terminal marking ,tappings and

connections
139 2086/1982
Carrier and based used in rewireable type electric

fuses for voltage up to 650 volts
140 2121/Pt.1/1981
Conductors and earthwire accessories for overhead

power lines : Armour rods ,winding wires and tapes
for conductors
141 2121/Pt.2/1981
Conductors and earthwire accessories for overhead

power lines : Mid span jionts and repair sleeves for
conductors
142 2268/1994
Electric call bells and buzzers for indoor use
143 2551/1982
144 2713/Pt.1 to 3
Danger Notice Plate

Specifications for Tubular Steel Poles for overhead
Power Lines
145 3043/1987
146 3419/1988
Code of Practice for Earthing

Fittings for non metallic conduits
Page 94 of 97
SN

Amendment
147 3427/1969
148 3764/1992
149 3837/1976
Title
AC Metal Enclosed Switchgear and controlgear for
rated voltage Above 1kV and upto and including 52kV
Code of Safety for excavation work
Accessories for rigid steel conduits for electric wiring
150 3842/Pt1 to Pt.12/1967Pt.12/1967 Application guide for electrical Relays for ac system
1977
151 3854/1997
Switches for domestic and similar purpose
152 398/Pt.1/1976
Aluminium Conductor for Overhead transmission

purpose : Aluminium stranded conductors
153 398/Pt.2/1976

purpose : Aluminium conductors, galvanised steel
reinforced
154 398/Pt.3/1976

purpose :Aluminium conductors, aluminised steel
reinforced
155 398/Pt.4/1994

purpose : Aluminium alloy stranded conductors
156 398/Pt.5/1992

purpose : Aluminium Conductor galvanised steel
reinforced for extra high voltage
157 4540/1968
Monocrystalline semiconductor rectifier assemblies

and equipment
158 4722/2001
Rotating Electrical Machines - Specifications
159 4794 (Pt.1)/1968
Push Button Switches -General

General Requirement and test
160 4794 (Pt.2)/1986
Push Button Switches -Push

Push Button Switches - type 1
161 5300/1969
Specification for Porcelain Guy Strain Insulators
162 5613/Pt.1/Sec.1/1985
Code of Practice for Design , Installation and

Maintenance of over head power lines - Lines upto
and including 11kV: Design
Page 95 of 97
SN

Amendment
163 5613/Pt.1/Sec.2/1985
Title
Maintenance of over head power lines - Lines upto
and including 11kV: Installation and Maintenance
164 5613/Pt.2/Sec.1/1985

Maintenance of over head power lines - Lines above
11kV and upto and including 220kV: Design
165 5613/Pt.2/Sec.2/1985

Maintenance of over head power lines - Lines above
11kV and upto and including 220kV: Installation and
Maintenance
166 5613/Pt.3/Sec.1/1989

Maintenance of over head power lines -400
kV Lines
: Design
167 5613/Pt.3/Sec.2/1989

Maintenance of over head power lines - 400 kV
Lines : Installation and Maintenance
168 6639/1972
Specification for Hexagonal bolts for steel structure
169 7098/Pt.1/1988
Crosslinked polyethylene insulated PVC sheathed

cables : For Working voltage upto and including 1100
volts
170 7098/Pt.2/1985

cables : For Working voltage from 3.3 kV upto and
including 33kV
171 7098/Pt.3/1992

cables : For Working voltage from 66 kV upto and
including 220 kV
172 7935/1975
Insulator fittings for overhead power lines with a

nominal voltage up to and including 1100 V
173 808/1989
Dimentions for Hot Rolled Steel Beam , column ,

Channel Angle Sections
Page 96 of 97
SN

Amendment
174 8623/Pt.3/1993
Title
Specifications for Low Voltage Switchgear and
Controlgear Assemblies : Particular requirements for
Equipments Where unskilled Persons have access for
their use
175 9537/Pt.3/1983
Conduit for Electrical Installation :Regid plain

Conduits of insulating Materials
176 9537/Pt.4/1983
Specification for Conduit for Electrical Installations

:Pliable self - recovering Conduits of insulating
Materials
177 9537/Pt.4/1984
Specification for Conduit for Electrical Installations

:Pliable Conduits of insulating Materials
178 9974/Pt.1/1982
High Pressure Sodium Vapour Lamps :Standard lamp

data sheet
179 IS: 1885 (Part 1) - 1961
Electrotechnical
definitions.
180 IS: 1885 (Part 9) 1966
Electro technical vocabulary: Electrical Relays.
181 IS: 1885 (Part 11) 1966
Electro
technical
Measurements.
182 IS: 1885 (Part 16) Sec 1)

1968
Electro technical
aspects.
183 IS: 1885 (Part 16) Sec-2)

Sec
1968
Electro technical vocabulary lighting: General

illumination, lighting fittings and lighting for traffic
and signaling.
184 IS: 1885 (Part 16/Sec.3)

1967
Electro Technical vocabulary Lighting: Lamps and

Auxiliary apparatus.
185 IS: 1885 (Part 17 1979
Electro Technical vocabulary Lighting : Switch gear

and control gear
186 IS: 1885 (Part 32 1971
Electro Technical vocabulary Lighting: Cables,

conductors and accessories for electricity supply.
187 IS: 4770 1991

188 IS: 56424 1969
Rubber gloves for electrical purposes.

Rubber mats for electrical purposes.
vocabulary
Fundamental
vocabulary:
vocabulary:
Lighting
Electrical
General
Page 97 of 97
SECTION 7
(CIVIL)
1.0
1.1
1.2
GENERAL
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 Engineer, fabrication, erection and construction of the necessary civil,
structural
tural and architectural works associated with the wagon Tippler plant.. 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) and all other civil
and structural works associated with the wagon Tippler
Tip
Plant.
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
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
respect of interpretation of any portions of this document.
2.0
LAYOUT AND LEVELS
2.1
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.
The contractor has to mobilize well qualified survey team along with the survey equipment
for day today survey work. They should use Total Station survey instrument for this
purpose.
The contractor has to setup his own laboratory to facilitate the checking of quality of civil
works with equipments for checking of aggregate,
aggregate, sand, concrete cube, etc.
Area cleaning including jungle,rubbish,grass,trees etc are to be included in the scope of
bidder.
2.2
2.3
2.4
3.0
3.1
3.2
3.3
DRAWINGS / DOCUMENTS
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
co
and approved by the Engineer.
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.
Design calculations shall be done in STRAPP / M.S. Office (latest version) and Drawings shall
Technical Specification:Sec-7, Civil
Page 1 of 21
3.4
3.5
3.6
3.7
4.0
be prepared in Auto Cad (latest version). The analysis

analysis shall be done by using STADD PRO /
ANSYS / STRAPP (latest version). However design may be carried out by manually, using
computer worksheets or by using suitable software programmes, as mutually agreed by
Employer/RITES. Final calculations and drawings
drawings shall be submitted in Compact Disc (CD) (2
Sets
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
Consolidated B.O.Q. for major items of all Architectural, Civil and Structural works shall be
submitted structure wise and area wise for Employers record. However each drawing shall
indicate
te approximate quantity of structure (Sectionwise) Concrete (Grade wise) and
reinforcement Diameterwise.)
Structural steel fabrication drawings to be prepared by the contractor will not be approved
by the Employer/RITES. However, the Contractor for Employers
Employers 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
Approval of construction drawings prepared
prepared by the contractor shall not relieve the
Contractor of his responsibility regarding the adequacy of design and correctness of the
drawing.
WORK DESCRIPTION.
It includes the Civil, Structural and Architectural works related mainly to the following areas
(but not limited to):
4.1
Wagon Tippler Hopper, Machinery Hatches and Underground Tunnel
Wagon Tippler hopper and machinery hatches shall consist of underground portion, which
shall be of R. C. C., and above ground portion, which shall be of structural steel shed covered
with Aluminium Industrial troughed sheets. It essentially consists of R. C. C. frames with R. C.
C. wall panels on the sides and R. C. C. raft at the bottom, fixed to the frames. The top beam
of the R. C. C. frame supports the rail supporting beams and the hopper. Minimum thickness
of R. C. C. raft at bottom shall be 600 mm. Minimum thickness of RCC side walls shall be 600
mm at bottom and 300 mm at top.
No columns shall be provided inside the Machinery Hatches.
The vertical and inclined portion of coal hopper shall be provided with 50 mm thick guniting
(shotcreting). Details of shotcreting have been given elsewhere in this specification
Expansion joints shall be provided at a maximum distance of 40m unless otherwise
otherw
instructed. 600 mm wide water stop fabricated with 22G copper plate with bitumen board
fillers and polysulphide sealing compound as specified elsewhere shall be used as expansion
joint material. Floor shall be provided with cross slope not flatter than 1 in 50 towards side
drains. Side drains shall be sloped towards sump where sump pumps as specified elsewhere,
shall be provided. The slope of side drains shall not be flatter than 1 in 400. Arrangement
shall be made for disposal of water right up to the discharge point. Side drains and sump
shall have removable type steel grating cover. Gratings shall be galvanized to grade 610
gm/m.2 Water proofing / Damp proofing of under ground portion of hopper and machinery
hatches, tunnels, underground (i. e. basement)
basement) portion of transfer houses shall be done by
providing the following treatments: Chemical injection grouting for inner faces (details as
specified elsewhere). Polymer modified cementitious coating on earth side face as per the
following :
ter surface of walls, frames and roof slabs coming in contact with earth,
1). On the outer
polymer modified cementitious coating in two layers as specified and as per manufacturers
specifications shall be provided directly on the concrete surface.
(2.) 50 mm thick P. C. C. (1 : 2 : 4 with 10 mm nominal size stone aggregates) shall be
provided under the raft i.e. over the lean concrete, followed by polymer modified
Page 2 of 21
cementitious coating in two layers ( slurry mix application ) as per manufacturers

specification. 50 mm thick
ck P. C. C. ( 1 2 : 4 ) with 10 mm nominal size stone aggregates shall
then be laid over the polymer modified cementitious coating before laying the raft.
Hopper shall have removable type steel grating cover. The opening size for the grating shall
be 300 mm x 300 mm. Machinery hatches shall have removable steel chequered plate cover.
Hopper grating shall be built of min. 200mm x 36mm thick flats. No painting/galvanization
shall be provided in gratings. However, two coats of red oxide primer to be provided
immediately after fabrication.
Catwalk shall be provided along the hopper. Each machinery hatch shall be provided with a
pair of R. C. C. stair for providing access to the base of track hopper / machinery hatch. Both
the stairs shall be interconnected at suitable
s
height.
Plinth protection along with drains shall be provided along the Hopper and around
machinery hatches. However, paving shall also be provided around machinery hatches.
The wagon tippler hopper is a deep underground structure which is subjected
subjecte to direct load
from the loaded wagons / loco due to the rake movement over it, in addition to load due to
coal filled hopper and lateral earth pressure. The railway loads, analysis and design of
hopper, machinery hatches, transfer point and the portion of
of tunnel subjected to rail loads
shall be as specified in design criteria. Coefficient of dynamic augmentation shall be worked
out for a train speed of 30 kms per hour.
Earth pressure to be considered for design shall be due to earth pressure at rest (K
0)condition
condition only. Earth pressure due to surcharge intensity of Railway Loads (where
applicable) or Uniformly Distributed Load (U. D. L) of intensity 2 T / Sq. M. whichever is
critical, shall be considered in the design.
A minimum safety factor of 1.2 against uplift of hopper, machinery hatches, wagon tippler,
transfer points (underground or with basement) and tunnels, due to ground water shall be
ensured during execution and after execution, considering dead weight of the structure to
be 0.9 times only, ground
ground water table at adjoining formation level and soil wedge angle of
not more than 15 degrees.
Also, FOS against uplift, to be taken as 1.0, considering the dead wt. of structure and soil
resting on side projections if any in the vertical plane. Inclined wedge
wedge action of soil shall not
be considered in this case.
Walkway width and hand railing shall be provided as specified in the tender drawing.
Wherever, slope of tunnel exceeds 10 o, R. C. C. steps shall be provided for the entire width
of each walkway.
n Tippler hopper structure shall be analyzed and designed for the worst load
Wagon
combinations.
4.2
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 trussshall be provided at upper
upp node points of
latticed girders to form an enclosure. Themaximum span of overhead gallery shall be limited
to 25 meters unless higher spanis 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 thevertical and horizontal bracing tied in proper position. The gallery should be
checkedfor all erection stresses that are likely to develop during handling and erection and
ifrequired, temporary strengthening
strengthening of gallery members during erection shall be made.Seal
Page 3 of 21
plates under the conveyor galleries shall be provided in such a way thatcomplete 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. Hand railing
r
should
not be supported on conveyor supporting stringers. The walkways shall be chequered plate
construction with anti - skid arrangement.
Conveyor gallery shall have Aluminum industrial troughed sheets conforming to IS:1254 on
roof & both sides. Adequate provision of windows shall be kept on both sides of conveyor
gallery as appended in Mechanical Section. 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
four
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
during execution and afterwards.
However at the location where the overhead conveyor gallery crosses road, minimum
clearance of 8.0m above the road crest shall be provided.
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.
a)
In between transfer houses / buildings, four legged trestles
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
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
four legged trestle can have either ends hinged or one hinge and
the other on slide type depending
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
ferred 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,
struc
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
columns / ground conveyor portal
column base shall be kept 300 mm higher than the existing ground level.
4.3
Transfer Houses
The over ground portion of the transfer house shall be framed structure of structural steel
work with Aluminium Industrial troughed sheet
sheet side cladding and R. C. C. floors and roof
over structural beams. However the lower portion of side cladding for a minimum height of
0.9 m above the finished floor level 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. Roof shall be provided with water proofing treatment as specified
elsewhere. Adequate steel doors and windows for proper natural lighting and ventilation
Page 4 of 21
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
d on the side cladding for natural lighting.
4.4
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
pro
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
oned 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.
4.5
Pump Houses
Thesee shall be of R.C.C. or steel framed structure with columns, beams, slab andfoundations
etc. cladding shall be of brick work with plastering on both sides. Roofshall 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
ofthe pump house and water tanks.
4.6
Pent House
These shall be of R. C. C. framed structures with columns, beams, slabs andfoundations etc.
Cladding shall be of brickwork with plastering on both sides. Roofshall be provided with roof
water proofing treatment as specified elsewhere. Adequate nos. of steel doors and windows
window
shall be provided for natural lighting and ventilation.
4.7
Toilets
Toilet with potable water line facilities shall be provided in each of the following locations:
In all M. C. C. Rooms Control Building Each unit shall have brick enclosure, and the following
fittings.
i ) Squatting type, white, vitreous china Orissa 1 No. pattern, W.C. pan with high level
flushing cistern ( C.I. ) and all requisite fittings
ii ) Bowl type Urinal with automatic flushing 2 Nos. cistern ( C.I. ) and all requisite fittings
iii ) Wash Basin 630 mm x 450 mm with 2 Nos.two taps and all requisite items
iv ) Mirror 600 mm x 450 mm x 5.5 mm thick 2 Nos.with bevelled edges ( Superior sheet
glass )
v ) C.P. Brass Towel Rod 600 x 20 mm 1 No.
vi ) Liquid Soap Container 2 Nos.
vii ) Washing Tap ( CP Brass ) 2 Nos.
viii ) Overhead Polyethylene water tank 1 No.(min. 500 litres capacity)
ix ) Suitable provision for installation of water coolers.
4.8
Staircase
All roofs & 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
(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
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
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
Page 5 of 21
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
ncluding 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. 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
RCC slab shall be provided at the top. 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.
4.9
Trenches
All trenches for cables or any other underground facility as detailed out elsewhereshall 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 providedwith edge protection
protectio
angles and lifting hooks. All embedments / block outs asrequired and specified elsewhere in
these specifications shall be provided. Properdrainage arrangement shall be provided.
Trench pre - cast cover weight shall not bemore than 65 Kgs. Trench covers near
n
entry or at
road crossings shall be designedfor 10 T wheel load at centre. Pre - cast covers shall be
designed for central pointload of 75 Kgs. R. C. C. cable trenches shall be filled with sand after
erection ofcables, up to top level and covered with pre - cast R. C. C. covers. For
cabletrenches 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 protectionall 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.
4.10
Approach Road
All approach road required within battery limit is under the scope of the agency with its
connection
ion to main road. All approach roads shall be constructed with RCC over suitable
hard sub base.
5.0
5.1
Drainage & Water Supply Works

Drainage System:System:
The drainage arrangements shall be so planned so as to ensure quick disposal of drainage

water without stagnation
tagnation and / or overflow. The water shall overflow into contractors R.C.C
drain, which will lead the discharge finally into owners drain. Contractors scope shall also
include construction of necessary culverts under the rail lines / roads as per railway
rai
/ I. R. C.
standards and approval of Railway culverts from concern Railway authorities
5..2
Internal and external water supply, drainage etc.:etc.:
The scope for potable water supply includes all distribution systems, tanks, pipes, fittings
etc. as required
ed 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 and drains required for wagon tippler area. All
buildings (including transfer houses and crusher house) shall be provided with open surface
Page 6 of 21
drains of minimum size of 300 mm width and 300 mm depth all around the periphery. All
drains shall be of R. C. C. construction. All open drains shall have removable steel grating
designed for loads as specified under loading clause.
clause. Minimum thickness of grating
(Galvanised to 610 gm/m) 2 shall be 12 mm. However at entry or road crossing points
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
vers shall be provided with edge protection
angles and lifting hooks. However, drains in coal stockyard area shall have pre cast R. C. C.
covers. RCC pre - cast cover weight shall not be more than 65 Kgs. RCC pre-cast
pre
covers near
entry or at road crossings shall be designed for 10 T wheel load at centre. RCC pre cast
covers shall be designed for central point load of 75 Kgs. The scope for foul water from
toilets shall include layout and laying of sewers up to the Employers main sewer line for
sewerage system
stem together with all fittings and fixtures and inclusive of ancillary works such
as connections, manholes and inspection chambers within the building and from the
building to the Employers sewer line. For rain water down comer and those to be used for
conveying
onveying 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
contro
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 TPs, 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 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
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
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
sing R.C.C. box culvert to be provided. For sewerage below ground
stoneware pipes conforming to IS: 651 with concrete bedding and haunch.
6.0
COLOUR COATED AND OTHER SHEETING WORK
Permanently colour coated sheet of approved shade and colour using galvanized
galvanize mild steel
sheet of minimum 0.6mm BMT(bare metal thickness i.e. metal thickness excluding thickness
for coating and galvanizing) galvanised to grade 275 as per IS 277,of minimum yield strength
of 250 Mpa of drawing grade as per IS 513 or high tensile steel
steel of minimum 0.5mm
BMT(bare metal thickness i.e. metal thickness excluding thickness for zinc aluminium
coating and colour coating ) coated with zinc aluminium alloy @ 150gm/sq.m.of minimum
yield strengthof 350 as per AS1397. Steel shall be colour coated
coated with total coating thickness
of 35 microns (nominal) comprising of silicon modified polyester (SMP with silicon content of
30% to 50%) paint or Super Polyester paint, of minimum 20 microns (nominal) dry film
thickness (DFT) on external face on 5 microns (nominal) primer coat and 5 microns (nominal)
SMP or super polyester paint over 5 microns (nominal) primer coat (or 10 micron SMP/super
polyester paint) on internal face. SMP and Super polyester paint systems shall be of category
3 as per AS2728. Coated surface
surface shall be provided with a protected guard film (polyethylene)
of about 40 microns to avoid any damage to the coating during handling. For metal deck,
minimum 0.8 mm (bare metal thickness i.e. metal thickness excluding thickness for coating
and galvanizing)
izing) galvanised to grade 275 as per as per IS 277, of minimum yield strength of
250 Mpa of drawing grade as per IS 513, troughed profile having nominal trough depth 44
mm and pitching of 130 mm shall be used. However alternative profile meeting the strength,
stren
defection and other functional requirements such as sections modulers and moment of
inertia shall be provided. To minimize the number of joints, the length of the sheet shall
Page 7 of 21
preferably be not less than 4.5 cut pieces shall not be used, unless specifically
specifi
approved by
the Engineer. However, the actual length shall be such so as to suit the purling / runner
spacing. No negative tolerance shall be allowed in bare metal thickness. The nominal depth
of trough shall be 30 mm. The polycarbonate sheet to be used
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. Polycarbonate sheet
sheet minimum 6mm thick multi (twin) wall fire retardant
(Continuous use under temperature 100 oC), impact resistant and ultraviolet resistant sheet
shall be provided (as glazing) in transfer houses, pump houses, etc.
7.0
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
ided either in structure or subsequently by screed concrete M-15
M
(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
col
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
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 provided
ided using high solid
content liquid applied urethane based elastomeric water proofing membrane to give
uniform joint less dry film thickness of minimum 1.5 mm (as per ASTM C 836 and C 898),
with separate wearing course as per ASTM C - 898. This treatment shall also include
application of polymerized mastic over the roof to achieve smooth surface and primer coat.
Wearing course on the top of membrane shall consist of 25 mm thick P. C. C. (M-15)
(M
cast in
panels of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized
chickenwire 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 awidth of
1000 mm in place of P. C. C.
8.0
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 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
minimum 6 mm thick o/p or as
indicated on drawings. The chequered plate pattern shall be approved by Employer / RITES.
Mild steel flats/angles of suitable size shall be welded to the bottom portion of chequered
plates at a designed spacing to stiffen chequered
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
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
Page 8 of 21
periphery of R. C. C. floors (where no brick masonry walls are provided)shall be provided

with one brick thick
hick 300 mm high brick wall and 700 mm high steel hand rails all around over
this brick work. All buildings (including track hopper and machinery hatches, penthouse,
transfer houses ) and ground conveyors shall be provided with 750 mm wide plinth
protection
n all around. It consists of 50 mm thick P.C.C. M-20
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
shall bee paved. This paving will be in addition to plinth protection. Plinth level of all buildings
shall be kept at least 500 mm above the finished grade / formation level.
9.0
Brickwork and allied masonry works
All brick walls shall be non - load bearing in-filled
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
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
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. 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.
10.0
Earthing Mat
2X40 mm Dia MS rod 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
around the periphery of buildings,
structures, and outdoor equipment, as per the approved drawings. Risers of 40 mm Dia MS
rod and connecting to the above Earthing mat shall also be supplied and laid in position by
the Contractor, as per the approved drawings.
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
necessary number of 3.0 M deep vertical 40 mm Dia MS rod
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
r's earthing mat separately at two locations.
11.0
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
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.
Page 9 of 21
12.0
LOADING
For consideration of loads on structures IS : 875 - Code of practice for structural safety
sa
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
Annexure A and B respectively in Civil Section,
whichever is governing. Wind and seismic forces shall not be considered to act
simultaneously. The following minimum live loads shall be adopted for the design of various
structures. If actual expected load is more than the specified load, then actual load is to be
considered
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 of 150 Kgs.
Kgs. / sq. m. 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 300 Kgs. / Sq.
Sq. M.conveyor galleries )
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
Roof
members are to
o be checked for supporting fire fighting
pipes/Service water pipes.
h ) Road Culverts and its allied For class 'AA' loading and checked for structures including R.
C. C. pipe class A loading as per IRC standard crossing & road crossing of trenches.
i ) Channels / trenches In addition to earth pressure and water pressure, etc. additional
earth pressure due to surcharge of 2T / Sq. M. shall
j ) Covers for trenches/channels Covers for channels & trenches, shall be designed for a live
load of 0.4T Sq.M.
M. &loading mentioned under clause in trenches, whichever is critical.
k ) Sumps and tanks and other In addition to earth pressure with a underground basement
type
surcharge of 2T / Sq. M. (or surcharge structures due to Railway loading whichever
is critical for Railway load bearing 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 shallbe taken as 1100 Kgs. / cum. Fordesign purposesIf the erection
er
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 windload or seismic load shall be as per relevant I. R. S. and I.
S. code.
13.0
DESIGN CRITERIA
The loads for all railway load bearing structures e. g. track hopper includingmachinery
hatches, wagon tippler, tunnel and under ground transfer houses etc. and the analysis and
the design of these structures shall be made strictly in accordancewith the provisions
pr
of
Indian Railway Bridge rules (latest edition), and Indian RailwayCodes of practice (latest
Page 10 of 21
edition) with all amendments up to the date of opening ofbids. However, the axle load for
analysis and design shall be considered as 35 MT.Coal heap of 1.2m
1.2m height shall be
considered above hopper top for design of, hopper and supporting elements of hopper. The
analysis, design anddetail drawing for the structure coming below the railway track shall be
got approvedby the contractor from the concerned railway
railway authorities before taking
upconstruction. All necessary payment for the above work shall be made by the bidder to
the railway authority.The design of all R. C. C. structures shall be carried out as per code of
practice forplain 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
mum size of the angle section to be used as structural members shall be
50X50X6. Minimum weld size shall be 6 mm. Connections shall bedesigned 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.
supp
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. The
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. Horizontal
bracing system shall be provided at floor
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
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
struct
/
foundations, ground water table shall be assumed at the formation level ( i. e. the adjoining
ground level ). Design of Hopper walls shall be done for both Static & Dynamic flow condition
using Walkers theory. 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
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
14.0
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 ) M35 - For all railway load bearing structures
b ) M25 - For underground / sub structural R. C. C. work (other than railway load bearing
structures).
C ) M20 - For R. C. C. superstructure works including ground floor slabs, trenches & drains.
Minimum 75 mm thick P.C.C M-7.5
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 directed. Batching plant
or reversible drum mixer with weigh batcher and concrete pumps must be used for all
concreting works(RCC).
15.0
15.1
Excavation Details
Excavation in soil
Excavation for foundation shall be to the bottom of lean concrete and as shown on drawing
Page 11 of 21
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:
(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,
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 within 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.
15.2
Excavation
avation in rock
For the work of excavation in rock, Contractor shall engage specialized 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
details of relevant experience in
support while seeking approval for the agency.
agency Only Control Blasting shall be resorted
resort to
with the written permission of the Engineer. In case blasting method can not be adopted
considering the safety aspect of the existing rail
rail network, buildings, structures etc, hard rock
shall be excavated by using expansive chemical or any other suitable means.
means 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 as per
Explosives
es 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 within plant boundary wall as directed by the
th 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,
shuttering, concreting, backfilling is
completed.
15.3
De-watering
watering of Deep Excavations
For deep underground structures like wagon tippler hopper, machinery hatches, tunnels and
underground transfer houses, requiring open excavation with extensive de - watering,
completely
letely 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.
15.4
Backfilling,
ng, 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. 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
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. If directed by the Engineer this material shall be
used directly for filling
illing 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
Page 12 of 21
maintaining of the Kuccha roads shall be the responsibility of the Contractor. The
transported material shall be neatly stacked as directed by the Engineer. Double handling of
materials shall be avoided as far as possible. However, depending on site condition
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,
m
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 Contractors responsibility for identification ion 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 utilizationof borrow areas.
16. 0
GALVANISING
SING
All burrs and irregular edges of the structural steel members to be galvanized shallbe ground
smooth before galvanizing.Purity of Zinc to be used for galvanizing shall be 99.5 % as per IS :
209 ( latestedition ).The weight of the zinc coating shall be at least 610 Gms. /m2unless
noted otherwise.
17.0
CHEMICAL INJECTION GROUTING
Minimum, 12 mm dia ( NB ) threaded nozzle of suitable length, shall be provided over the
surface and along the construction joint line in a grid pattern at a spacing not exceeding
excee
1.5
m c / c before concreting operation. Adequate precaution shall betaken to keep the nozzles
plugged at both ends to prevent them from getting closedby concrete. For fixing of any
nozzle in set concrete suitable size hole shall be drilled, preferably
preferably by using repercussive
hammer drill electrically operated, in grid pattern and grouting nozzle shall be fixed in these
holes. After the nozzles are fully set, neat cement slurry admixed with water soluble non shrink polymer / monomer based chemical shall
shall be injected through the net - work of
nozzles with low pressure grout pumps at a pressure of about 2.0Kgs. /cm2. Cement slurry
shall be prepared by mixing cement with non-shrink
non shrink polymer/monomer @ 500 gm/50 kg bag
of cement and water, ensuring that Water: Cement ratio does not exceed 2 (by weight).
Wetter the structure, lesser should be the water cement ratio. The property of the
polymer/monomer should be such that when it is mixed with water @0.5% by weight of
water, the viscosity of the resultant solution
solution (water and polymer/monomer) should not be
more than 1.2 centipoises. Plasticizing agent shall be added wherever required. The grouting
shall be started at very low pressure and increased gradually to a required pressure. The
grouting shall continue, till
till the hole refuses to take any further grout, even at an increased
pressure. Applied pressure shall not be more than the designed strength of the concrete.
After completion of grouting operation, the nozzles shall be sealed properly to the
satisfaction of the Engineer.
18.00 POLYMER MODIFIED CEMENTITIOUS COATING

18.1 Materials
Modified liquid polymer blend shall be a dispersion containing 100 % acrylic based polymer
solids. Polymer shall be mixed in the ratio of 1 cement: 0.5 polymer (for minimum solid
content of polymer 30%). Portland cement based dry powder. Clean, fine specially prepared
quartz sand approximately 0.6 mm size.
18.2
Mixing
The liquid polymer shall be stirred well and cement based powder shall then be added
Page 13 of 21
slowly to make a Slurry Mix. For preparation of Brush Topping Mix, quartz sand shall be
added slowly and mixed well till a homogeneous mixture is obtained. The mix shall be used
within half an hour of the preparation. Addition of quartz sand may not be necessary, in case
dry power contains the same.
18.3
Properties of Coating
It must adhere to wet surface. It should develop adequate bond strength, with the concrete
surface, not less than 2N / Sq. mm.Co - efficient of permeability shall be about 5x10Cm /
Sec.-1 0 Waterr absorption after continuous soaking shall not be more than 1 %. The
materials shall be permeable under water vapor. The material shall be resistant to acids and
alkalis present in the soil and underground water with normal pH value between 4 and 14.
The co - efficient of thermal expansion of the material shall be close to that of concrete
18.4
Application
The concrete surface shall be cleaned and made free from grease, oils or loosely adhered
particles. The surface shall be damp without any free water. For
For exterior underground part,
application (b) pertaining to Brush topping Mix shall be followed.
(a) For Slurry Mix

A minimum of 2 coats shall be applied on the surface. The first coat being applied, when
the surface is still damp and left to harden for 4 to 6 hours. After 4 to 6 hours of the
application of second coat, it shall be finished by rubbing down with a soft dry sponge.
The coverage shall not be less than 1 : 1 Kgs. / m in the 2 coats. A lap of 75 2 mm shall be
provided at the joints. The coating shall
shall be air dried for 4 to 6 hours and, thereafter,
cured for 7 days after the application of last coat.
(b) For Brush Topping Mix

This shall be applied in two coats. A primary coat of slurry mix can also be firstapplied on the
surface as first coat. After the coating has dried up, a coat of BrushTopping Mix shall be
applied over it with a push broom or any other similar brush. Itshall be left in broom finished
condition. The nominal thickness shall be 1.5 mm andminimum thickness shall be 1.0 mm. A
lap of 75 mm shall be provided at the joints. Itshall be ensured that no pinhole exists and
rebrushing shall be done to cover thepinholes, if any.The Coating shall be air dried for 4 to 6
hours and thereafter cured for 7 days afterthe application of last coat.Rate of application of
coating shall be established to achieve the required thickness.
19.0
Architectural Features
All architectural features of buildings like control rooms, M. C. C.rooms, transfer houses and
conveyor galleries etc. shall be detailed by contractorsqualified
contractorsqualified architect. Necessary
projections, fins etc. in addition to the minimumspecified elsewhere in this specification
shall be provided as required. The Contractor for Employer/RITESs 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
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
skinreinforcement of the encasing.
20.0
Glazing
Window glazing for various locations shall be as below:

(i)In transfer
er houses and pump houses etc: Polycarbonate sheet.
(ii)In Switchgear / M. C. C. buildings
(a) In air conditioned (A / C) areas: Double glazing with two 6 mm thick clear toughened
safety glass hermetically sealed and separated by 12 mm thick gap for thermal
therma insulation at
partition of A / C and non A / C areas.
Page 14 of 21
(b) In toilets: Ground glass of minimum thickness 4 mm.

(c) In other areas: Toughened glass of minimum thickness 4 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.
21.0
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
m
thickness 0.5 mm. 50 mm thick mineral wool insulation (as per IS: 8183) having a density of
32 kg/cum for glass wool or 48 kg/cum for rock wool, bound in polythene bags shall be laid
on top of panels. Additional hangers and height adjustment clips shall be provided for
returns air grills, light fixtures, A. C. ducts etc. Suitable M. S. channel (Minimum ISMC 75)
grid shall be provided above the false ceiling level for movement of personnel to facilitate
maintenance of lighting fixtures, AC 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
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.
22.0
Acid / Alkali Resistant

Resis
Lining
Battery Room For Floor and dado, bitumen primer followed by 12 mm thick bitumastic 6 mm
thick potassium silicate mortar bedding and 20 mm thick A. R. tiles shall be provided. Dado
height shall be minimum 2.0 m from floor. M. S. Grating / Chequered
Chequered plate cover and any
other steel structure likely to come in contact with chemicals shall be provided with epoxy
coating 150 microns thick over epoxy primer. Acid / Alkali resistant lining material shall
conform to the following: Bitumen primer shall conform
conform to IS: 158. Bitumastic compound
shall conform to IS: 9510. Where the height of bitumastic layer on vertical surface is more
than 2.0 m, the bitumastic layer shall be reinforced with diamond pattern expanded metal
steel sheets conforming to IS: 412. A. R. tiles shall conform to IS: 4457. Mortar: Potassium
silicate and resin type mortars shall conform to IS : 4832 Parts I and II respectively.
23.0
FINISHING SCHEDULE
The contractor's scope also includes all doors, windows, glazing, rolling shutters, finishes,
f
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.
23.1
Flooring
I. P. S. ( cement concrete flooring ) with metallic hardener topping shall be provided for all
floors in 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
enance 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 ) shall
be provided for toilets, office rooms, laboratories, control rooms and control equipment
eq
rooms. Well polished Kota stone shall be provided for staircases, passages, lobbies and
general circulation areas. The floor shall be laid on an already laid and matured concrete
base. Sunken R. C. C. slab shall be provided in 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 thick using uniformly graded iron particles, properly
treated. Wherever specified Heavy duty ceramic tiles of size
size 300 x 300 x 7 mm thick
(minimum) of reputed manufacturer (Kajaria, Spartek or equivalent) of approved finish,
shade and colour to be used. The tiles shall have a scratch resistance of minimum 5 on
Mohrs scale and shall have a bending strength of 350 Kgs.
Kgs. / cm.2 Paving details shall be
similar to grade slab excluding metallic hardener. Skirting in general shall be 150 mm high.
Page 15 of 21
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.
f
23.2
Interior Wall / Ceiling Finish
For all air - conditioned areas and stair case acrylic emulsion paint of approved make and
shade over 2-3 mm cement based putty of approved make shall be provided.
provided For toilets
minimum 5 mm thick decorative coloured
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 2-3 mm cement based putty of approved make above 2.10 m height shall be
provided. For all other areas
areas oil bound distemper ( IS : 428 ) of approved shade over cement
based putty of approved make shall be provided. For battery room and other areas coming
in contact with acid / alkali fumes, chemical resistant chlorinated rubber paint shall be
provided abovee 2.1 m height. Up to 2.1 m height from finished floor level acid alkali resistant
tiles shall be provided as specified elsewhere. All R. C. C. ceilings shall be oil bound
distemper over cement based putty.
putty
23.3 Exterior Finish

Aluminium Industrial troughed sheet 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. Exterior weathered coat paint
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
Projections and facia : R. C. C. parapets ( excepting parapets of buildings
(d)
(e)
where metal cladding is specified )Exterior brick walls.
24.0DOORS,
DOORS, WINDOWS AND ROLLING SHUTTERS.
24.1 Doors and Windows
All doors, windows and ventilators
venti
of control room building 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 prepre laminated particle board (M D F exterior grade). All
other buildings shall have steel doors, windows and ventilators. Single glazed
glaz panels with
aluminium framework shall be provided as partition between two air - conditioned areas
wherever clear view is necessary. Coal conveyor galleries shall have steel windows of
openable type. The window shutters shall be provided with M. S. louvers.
louv
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,
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 electrically
ctrically operated. 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
ovided with suitable stays. All windows and ventilators onground floor of all switchgear
Page 16 of 21
and M. C. C. buildings shall be provided with suitable anodized aluminium grill. Fire - Proof
doors with panic devices shall be provided at all fire exit points as per
per the recommendations
of statutory regulatory bodies These doors shall generally be as per IS : 3614 ( Part I and Part
II ). Fire rating of the doors shall be as per requirements of statutory regulatory bodies.
However minimum rating shall be 2 hours. These
These doors shall be double cover-plated
cover
types
with mineral wool insulation. Hollow extruded section of minimum 3 mm wall thickness as
manufactured by INDAL or equivalent shall be used for all aluminium doors, windows, and
ventilators. Doors and windows on external
external walls of the buildings having brick enclosures i.e.
enclosure other than with Aluminium Industrial troughed sheet cladding, shall be provided
with sunshade over the openings with width 600 mm more than the opening width.
Projections from the wall for
for the sunshade shall be 450 mm over window openings and 750
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 areaa ) 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
als
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
The frames shall be of ISMC
100.
24.2
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
f
performance.
25.0 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 as per
specification mentioned elsewhere in this document.
26.0 Miscellaneous
26.1 Ordinary form work shall be used in roofs and floor slabs in transfer houses, footings,
pedestals, cable trenches, pits etc., Plywood form work shall be used for all over ground
exposed work like columns, beams, floors and
and ceilings in control room and M. C. C. buildings.
26.2 Monorail girders and fixtures shall be provided for monorails at the locations as
required and as described elsewhere in these specifications or drawings. Monorail openings
in the walls shall be provided
provided with steel frame doors preferably sliding type or otherwise
open able inside, access platforms and ladders.
26.3Steel
Steel frame around openings in roof and on external walls for mounting of exhaust
fans shall be provided.
nk cementitious grout of reputed manufacturer as approved by
26.4 Ready mix non - shrink
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.
26.5The
The bottom of steel in case of cable / pipe galleries and trestles shall be generally 3m
Page 17 of 21
abovee 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.
26.6Polysulphide
Polysulphide Sealing Compound shall be two-part
two part polysulphide sealant and shall be
from
om approved manufacturer, conforming to IS : 12118. Materials shall consist of
polysulphide polymer and a curing agent. Gun grade material shall be used unless otherwise
specified. The application of the sealant shall be strictly followed as per manufacturers
manufactur
guidelines
27.0 SHOTCRETING
27.1 General Requirements
27.2 Generally, shotcreting shall be done in accordance with IS : 9012.
27.3 Reinforcement for shotcreting shall be as detailed below, unless specified otherwise.
(i) Reinforcement in one direction
direction consisting of 6 mm M. S. bars at 750 mm c / c shall be
connected to the lugs for fastening of the wire fabric. This shall be used in case of 50 mm or
above thick shotcreting.
(ii) Wire fabric conforming to IS : 1566 shall be used as reinforcement and shall
sh consist of
wire, 3 mm diameter, spaced 50 mm both ways and shall be electrically cross welded. Wire
fabric shall be securely tied to 6 mm bars for 50 mm thickness. Adjacent sheet of wire fabric
shall be lapped at least 100 mm and tied.
(ii) Clear coverr to reinforcement mesh shall not be less than 15 mm. 22.01.03
Minimum
thickness of shotcreting shall be 50 mm. for abrasion resistant work and 25mm for ordinary
surface protection work.
27.4
Material
Generally, the materials shall be in accordance with

with aggregates specification given
hereunder.
Fine aggregate shall consist of natural sand or crushed stone from a known source and shall
be strong, hard, coarse, sharp, chemically inert, clean and free from any coating. It shall be
free from clay, coal or coal residue, organic or any other impurities that may impair the
strength or durability of the concrete and shall conform to IS :383.Fine aggregate (Sand)
shall be well graded and particles shall range in size within the following limits. The Engineer,
may
ay approved the use of any other grading as per requirement or as erIS : 9012.
The fineness modulus shall be preferably between 2.5 and 3.3. Any other value an be used,
with prior approval of the Engineer.
27.5
Application
After the placement of reinforcement and / or welded mesh and not more than six ours
prior to the application of shotcrete, the surface shall be thoroughly cleaned of all loose
aterials and dirt. The Contractor shall properly prepare the surfaces, reinforcement
reinfo
and / or
welded esh to receive the shotcrete. Cleaned surfaces shall be wetted not more than hour
prior to hotcreting.
The mix as placed on surface shall be one part cement to three parts approved sand by
mass. Cement and sand shall be dry mixed;
mixed; not water shall be added after mixing and before
sing in the gun. The quantity of water when added shall be only that which is sufficient to
hydrate the cement. For average atmospheric conditions, the water cement ratio for
shotcrete in place shall be between 0.35 and 0.5 by mass.Suitable admixture shall be used
wherever required.
A uniform pressure of not less than 25 Kgf / Cm2 at the nozzle shall be maintained.
Necessary adjustments shall be made to ensure this pressure, taking into account the length
of ose and height of the place to be shotcreted, above location of the machine.
The application shall proceed in an upward direction. Beams, stiffeners andintermediate
walls, if any, shall be wrapped with wire fabric and completely covered with hotcreting.
hotcreting All
rebound shall be removed from the area of application as the work progresses andsuch
rebound material shall not be reused.
Page 18 of 21
As soon as the freshly shotcreted surface shows the first dry patches, a fine spray 0f water
shall be applied to keep too moist.
moist. After the surface has hardened, it shall be kept
continuously moist for minimum seven days. If there is extreme heat, especially when
ccompanied by hot winds, the shotcreted surface, immediately upon completion, shall be
covered with burlap or similar covering,
covering, which must be kept continuously moist for 14 days
after shotcreting. The temperature of the lining shall not be permitted to exceed 38 oC
during placing and curing.
28.0 PTFE (Poly Tetra Fluoroethylene) Bearing

The bearing shall be of reputed make and manufacturer as approved by theEngineer, for
required vertical load and end displacement/rotation. PTFE bearingshall be sliding against
highly polished stainless steel and the coefficient of frictionbetween them shall be less than
0.06 at 55 kg/sq.cm. In order to prevent cold flow inPTFE surface it shall be rigidly bonded by
a special high temperature resistanceadhesive to the stainless steel substrata. The stainless
steel surface that slidesagainst the PTFE is mirror polished. The stainless steel shall be
bonded to the topplate by special high strength adhesive. The thickness of stainless steel
plate shallbe between 1.0 mm to 1.5 mm.
29.0
TESTS FOR MATERIAL / WORKMANSHIP
All tests required for all materials, quality of workmanship or any other tests asdesired by
the Engineer shall be at contractors cost.
30.0 MATERIALS
30.1 For Civil, Structural and Architectural works
Employer will not supply any material. All materials including cement, reinforcementsteel
and structural steel, whatsoever required for
for execution and completion of theentire scope
of work covered under this specification shall be arranged by thecontractor at his own cost.
All materials procured by the contractor shall meet thequality requirements specified in this
specification.The contractor
ractor shall keep sufficient stock of cement and steel at site at any
point oftime when the work is in progress excluding what has been already incorporated
inthe works, so that any disruption / delay in availability of these materials
duringprocurement willll not affect the progress of work at site. The minimum quantity
ofsuch materials in stock at site shall not be less then the Requirement of one( 1 )month in
case of Cement and Requirement of two ( 2 ) Consecutive months in caseof Steel.
30.2 Cement
The contractor shall use cements conforming to, IS: 455, IS: 8112. Higher grade of cement
namely GR - 53 of ordinary portland cement conforming to IS: 12269 can also be used.
30.3 Reinforcement steel shall conform to:
to
a) Mild steel grade I of IS: 432 Part I and grade A of IS: 2062.
b) High yield deformed bar of IS: 1786 (Gr. Fe 415 and Fe. 500).
30.4 Structural steel:
olled sections and plate shall conform to Grade A as per IS: 2062-1992
2062 1992 and/or as per
Rolled
specification specified at relevant clauses.
clauses
31.0
Guarantee for water proofing
The contractor shall furnish guarantee for the water proofing or similsr work wherever it is
included in civil work for three years. The contractor shall furnish a Bank Guarantee
equivalent to 105 of the value of water proofing work to be valid additional two years
beyond the defect liability period of the contract. The BG/SD towards the defect liability
period can be returned only on submission of bank guarantee for water proofing as stated
above.
32.0
CODES AND STANDARDS
Page 19 of 21
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
thi specification shall
also be deemed to be part of this list. In case of conflict between this specification and those
(IS standards, codes etc.) referred to herein, the former shall prevail. Some of the relevant
Indian standards, Acts and Codes applicable to this section of the specification are listed
below
IS : 383 Specification for coarse and fine aggregates from natural sources for Concrete.
IS : 432 Specification for mild steel and medium tensile steel bars and hard drawn steel wire
for concrete reinforcement.
nforcement.
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.
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
ows 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
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
ethods of test for soils - determination for water content
IV TO VIII, XIV, etc code of practice for earth work on canals. XXI, XXIII, XXIV, XXVII TO XXIX,
XL)
IS : 2911 Code of practice for design and construction of pile foundations.
(Part-1/Sec.1) Driven
iven cast in situ concrete piles. (Part-1/Sec.2)
(Part 1/Sec.2) Bored cast-in-situ
cast
concrete
piles. (Part-IV)
IV) Load test on piles. IS : 2974 (Part I Code of practice for design and
construction of machine TO V) foundations.
IS : 3370 (Part I to Code of practice for concrete
concrete structures for the storage of IV) liquids.
IS : 3658 Code of practice for liquid penetrant flaw detection.
IS : 3664 Code of practice for ultra sonic testing by pulse echo method.
IS : 4326 Code of practice for earthquake resistant design and construction
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.
Cement
IS : 9103 Specification for admixtures for concrete.
Page 20 of 21
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
89 Standard guide for use of high solid content, cold liquidliquid-applied elastomeric
water proofing membrane for use with separate wearing course. AS/NZS 2728 Pre finished
finis
/
pre painted sheet metal product for interior / exterior building applications Performance
requirements.
AS : 1365 Standards for steel manufacturing.
AS : 1397 A steel sheet & strip hot dipped-zinc-coated or Aluminium--Zinc coated.
AS : 3566 Self drilling screws for building and construction industry.
IRC : 37 Guidelines for the design of flexible pavements. - Manual on sewerage and sewage
treatment (Published by CPH & EEO) As updated. Indian Explosives Act. 1940 as updated
Page 21 of 21
SECTION 8
1.0
GENERAL
1.1
The following provisions shall supplement the conditions already contained in the other parts
of these specifications and documents and shall govern that portion of the work of this
contract which is to be performed at site. The erection requirements and procedures not
specified in these documents shall be in accordance with the recommendations of the
equipment manufacturer, or as mutually agreed to between the Employer and the Contractor
prior to commencement of erection work.
1.2
The Contractor upon signing of the Contract shall, in addition to a Project Coordinator,
nominate another responsible officer as his representative at Site suitably designated for
fo the
purpose of overall responsibility and co-ordination
co ordination of the Works to be performed at Site. Such
a person shall function from the Site office of the Contractor during the pendency of Contract.
2.0
REGULATION OF LOCAL AUTHORITIES AND STATUTES
2.0.1 In
n addition to the local laws and regulations, the Contractor shall also comply with the
Minimum Wages Act and the Payment of Wages Act (both of the Government of India) and
the rules made there under in respect of its labour and the labour of its sub-contractors
sub
currently employed on or connected with the contract.
2.0.2 All registration and statutory inspection fees, if any, in respect of his work pursuant to this
Contract shall be to the account of the Contractor. However, any registration, statutory
inspection
pection fees lawfully payable under the provisions of the Indian Boiler Regulations and any
other statutory laws and its amendments from time to time during erection in respect of the
plant equipment ultimately to be owned by the Employer, shall be to the account of the
Employer. Should any such inspection or registration need to be re-arranged
re arranged due to the fault
of the Contractor or his Sub-Contractor,
Sub Contractor, the additional fees for such inspection and/or
registration shall be borne by the Contractor.
2.1
ation of Weld Procedures

Qualification
Only qualified welding procedures as per ASME Section IX shall be used by contractor at site.
Procedure qualification records along with WPS shall be submitted to NALCO for review.
Welding procedure shall indicate all essential and
a non-essential
essential parameters as per ASME
Section IX. Makes of welding consumables shall be subject to employers approval.
3.0
SITE RUN MISCELLANEOUS PIPING

Sketches or diagrams of the proposed routings of all piping, not already indicated and routed
on the shop drawings which were reviewed by the Employer, shall be submitted to the
Technical Specification:Sec-8l
Page 1 of 23
Employer for review, Employer's acceptance of such site routings shall be obtained
obta
before the
piping is erected. All these site run piping shall be installed in such a manner as to present an
orderly and neat installation. They shall be located as to avoid obstruction of access and
passages. Valves, instruments or any other special items shall be located convenient for
operation by the operating personnel. Pipe runs shall be plumb or level except where pitch for
drainage is required. Pipe runs that are not parallel to the building structure, walls or column
rows shall be avoided. No miscellaneous pipe shall be routed and installed above or adjacent
to electrical equipment.
4.0
PIPING SUPPORTS
4.1
Hangers, supports and anchors shall be installed as required to obtain a safe, reliable and
complete pipe installation. All supports shall be properly levelled and anchored when
installed. The anchors shall be so placed that thermal expansion will be absorbed by bends
without subjecting the valves or equipment to excessive strains.
4.2
The hanger assemblies shall not be used for the attachment

attachment of rigging to hoist the pipe into
place. Other means shall be used to securely hold the pipe in place till the pipe support is
completely assembled and attached to the pipe and building structures and spring support is
set to accommodate the pipe way. All temporary rigging shall be removed in such a way that
the pipe support is not subjected to any sudden load. All piping, having variable spring type
supports, shall be held securely in place by temporary means during the hydraulic test of pipe
system. Constant
onstant support type spring hangers used during hydraulic test shall be pinned or
blocked solid during the test. After complete installation and insulation of the piping and filling
of the piping with its normal operating medium, the pipe support springs shall
s
be adjusted to
the cold positions. If necessary, the spring support shall be re-adjusted
re adjusted to the hot positions
after the line has been placed for service at its normal maximum operating temperature
conditions. Electric arc welding only shall be used to weld all pipe supports to structural steel
members that form part of the building supporting structure. The structural beams shall not
be heated more than necessary during welding of supports and such welds shall run parallel to
the axis of the span. All lugs or any other attachments welded to the piping shall be of the
same material as the pipe.
5.0
CODE REQUIREMENTS
The erection requirements and procedures to be followed during the installation of the
equipment shall be in accordance with the relevant Indian Electricity Rules & Codes, Indian
Boiler Regulations, ASME codes and accepted good practices, the Employer's Drawings and
other applicable Indian recognised codes and laws and regulations of the Government of
India.
6.0
ELECTRICAL SAFETY REGULATIONS

REGULATION
6.1
In no circumstances will the Contractor interfere with fuses and electrical equipment
belonging to the other Contractor or Employer.
Page 2 of 23
6.2
Before the Contractor connects any electrical appliances to any plug or socket belonging to
the other Contractor or Employer, he shall:
a) Satisfy the Employer that the appliance is in good working condition;
b) Inform the Employer of the maximum current rating, voltage and phases of the
appliances;
appli
may
c) Obtain permission of the Employer detailing the socket to which the appliances
be connected.
6.3
No repair work shall be carried out on any live equipment. The equipment must be declared
safe by the Employer and a permit to work issued before any work is carried out.
6.4
The Contractor shall employ the necessary number of qualified, full time electricians to
maintain his temporary electrical installation.
7.0
REMOVAL OF MATERIAL
No material brought to the Site shall be removed from the Site by the Contractor and/or his
Sub-Contractors
Contractors without the prior written approval of the Employer.
8.0
INSPECTION, TESTING AND INSPECTION CERTIFICATES

The provisions of the clause entitled Inspection, Testing and Inspection Certificates given in
General Technical Requirement, shall also be applicable to the erection portion of the Works.
The Employer shall have the right to re-inspect
re inspect any equipment though previously inspected
and approved by him at the Contractors works, before and after the same are erected at Site.
If by the above inspection, the Employer rejects any equipment, the
the Contractor shall make
good for such rejections either by replacement or modification/ repairs as may be necessary
to the satisfaction of the Employer. Such replacements will also include the replacements or
re-execution
execution of such of those works of other Contractors
Contractors and/or agencies, which might have
got damaged or affected by the replacements or re-work
re work done to the Contractors work.
9.0
ACCESS TO SITE AND WORKS ON SITE
9.1
Suitable access to site and permission to work at the Site shall be accorded to the
th Contractor
by the Employer in reasonable time.
9.2
In the execution of the Works, no person other than the Contractor or his duly appointed
representative, Sub-Contractor
Contractor and workmen, shall be allowed to do work on the Site, except
by the special permission,
sion, in writing by the Employer or his representative.
10.0 CONTRACTORS SITE OFFICE ESTABLISHMENT

The Contractor shall establish a Office at the Site and keep posted an authorized
representative for the purpose of the Contract. Any written order or instruction of the
Employer or his duly authorised representative, shall be communicated to the said authorised
Page 3 of 23
resident representative of
of the Contractor and the same shall be deemed to have been
communicated to the Contractor at his legal address.
OPERATION WITH OTHER CONTRACTORS
11.0 CO-OPERATION
operate with all other Contractors or tradesmen of the Employer, who
11.1 The Contractor shall co-operate
may be performing other works on behalf of the Employer and the workmen who may be
employed by the Employer and doing work in the vicinity of the works under the Contract. The
Contractor shall also arrange to perform his work as to minimise, to the maximum extent
ex
possible, interference with the work of other Contracts and their workmen. Any injury or
damage that may be sustained by the employees of the other Contractors and the Employer,
due to the Contractors work shall promptly be made good at his own expense.
expen The Employer
shall determine the resolution of any difference or conflict that may arise between the
Contractor and other Contractors or between the Contractor and the workmen of the
Employer in regard to their work. If the work of the Contractor is delayed
delayed because of the any
acts of omission of another Contractor, the Contractor shall have no claim against the
Employer on that account other than an extension of time for completing his works. Employer
shall have full access to visit the contractors site
site at any time for inspection and surveillance
checks.
11.2 The Employer shall be notified promptly by the Contractor of any defects in the other
Contractors works that could affect the Contractors Works. The Employer shall determine
the corrective measures
res if any, required to rectify this situation after inspection of the works
and such decisions by the Employer shall be binding on the Contractor.
12.0 DISCIPLINE OF WORKMEN
The Contractor shall adhere to the disciplinary procedure set by the Employer in
i respect of his
employees and workmen at Site. The Employer shall be at liberty to object to the presence of
any representative or employee of the Contractor at the Site, if in the opinion of the Employer
such employee has mis-conducted
mis
himself or is incompetent,
mpetent, negligent or otherwise
undesirable then the Contractor shall remove such a person objected to and provide in his
place a competent replacement.
13.0 CONTRACTORS FIELD OPERATION
13.1 The Contractor shall keep the Employer informed in advance regarding his field activity plans
and schedules for carrying out each part of the works. Any review of such plan or schedule or
method of work by the Employer shall not relieve the Contractor of any of his responsibilities
towards the field activities. Such
Such reviews shall also not be considered as an assumption of any
risk or liability by the Employer or any of his representatives and no claim of the Contractor
will be entertained because of the failure or inefficiency of any such plan or schedule or
method of work reviewed. The Contractor shall be solely responsible for the safety, adequacy
and efficiency of plant and equipment and his erection methods.
Page 4 of 23
13.2 The Contractor shall have the complete responsibility for the conditions of the WorkWork Site
includingg the safety of all persons employed by him or his Sub-Contractor
Sub Contractor and all the
properties under his custody during the performance of the work. This requirement shall
apply continuously till the completion of the Contract and shall not be limited to normal
working hours. The construction review by the Employer is not intended to include review of
Contractors safety measures in, on or near the WorkWork Site, and their adequacy or otherwise.
14.0 PHOTOGRAPHS AND PROGRESS REPORT
14.1 The Contractor shall furnish
furnish three (3) prints each to the Employer of progress photographs of
the work done at Site. Photographs shall be taken as and when indicated by the Employer or
his representative. Photographs shall be adequate in size and number to indicate various
stages of erection. Each photograph shall contain the date, the name of the Contractor and
the title of the photograph.
14.2 The above photographs shall accompany the monthly progress report detailing out the
progress achieved on all erection activities as compared
compared to the schedules. The report shall also
indicate the reasons for the variance between the scheduled and actual progress and the
action proposed for corrective measures, wherever necessary.
14.3 The Contractor shall submit the progress of work in video cassettes
cassettes (2 copies) quarterly
highlighting the progress and constraints at site.
15.0 MAN-POWER REPORT
15.1 The Contractor shall submit to the Employer, on the first day of every month, a man hour
schedule for the month, detailing the man hours scheduled for the month, skill-wise
skill
and areawise.
15.2 The Contractor shall also submit to the Employer on the first day of every month, a man
power report of the previous month detailing the number of persons scheduled to have been
employed and actually employed, skill- wise and the areas of employment of such labour.
16.0 PROTECTION OF WORK
The Contractor shall have total responsibility for protecting his works till it is finally taken over
by the Employer. No claim will be entertained by the Employer or the representative of the
Employer for any damage or loss to the Contractors works and the
the Contractor shall be
responsible for complete restoration of the damaged works to original conditions to comply
with the specification and drawings. Should any such damage to the Contractors Works occur
because of other party not being under his supervision
supervision or control, the Contractor shall make
his claim directly with the party concerned. If disagreement or conflict or dispute develops
between the Contractor and the other party or parties concerned regarding the responsibility
for damage to the Contractors
Contractors Works the same shall be resolved as per the provisions of the
as specified at clause no 11 of this chapter entitled Co-operation
Co operation with other Contractors.
The Contractor shall not cause any delay in the repair of such damaged Works because of any
Page 5 of 23
delay in the resolution of such disputes. The Contractor shall proceed to repair the Work
immediately and no cause thereof will be assigned pending resolution of such disputes.
17.0 EMPLOYMENT OF LABOUR
In addition to all local laws and regulations pertaining to the employment of labour to be
complied with by the Contractor pursuant to GCC, the Contractor will be expected to employ
on the work only his regular skilled employees with experience of the particular work. No
female labour shall be employed
employed after darkness. No person below the age of eighteen years
shall be employed.
All travelling expenses including provisions of all necessary transport to and from Site, lodging
allowances and other payments to the Contractors employees shall be the sole responsibility
of the Contractor.
The hours of work on the Site shall be decided by the Employer and the Contractor shall
adhere to it. Working hours will normally be eight (8) hours per day Monday through
Saturday. Contractors employees shall wear identification
identification badges while on work at Site.
In case the Employer becomes liable to pay any wages or dues to the labour or any
Government agency under any of the provisions of the Minimum Wages Act, Workmen
Compensation Act, Contact Labour Regulation Abolition
Abolition Act or any other law due to act of
omission by the Contractor, the Employer may make such payments and shall recover the
same from the Contractors payments.
18.0 FACILITIES TO BE PROVIDED BY THE EMPLOYER
18.1 Space
The Contractor shall advise the Employer
Employer within thirty (30) days from the date of acceptance
of the Notification of Award about his exact requirement of space for his office, storage area,
pre-assembly
assembly and fabrication areas, labour and staff colony area, etc. The above requirement
shall be reviewed by the Employer and space as decided by Employer will be allotted to the
Contractor for construction of his temporary structures/ facilities like office, storage sheds,
pre-assembly
assembly and fabrication areas, labour and staff colony, toilets, etc. for Contractor's as
well as his Sub-Contractors
Contractors use.
18.2 Electricity
The Contractor shall submit to the Employer within thirty (30) days from the date of
acceptance of the Notification of Award, his electrical power requirements, if any, to allow the
planning
anning of the same by the Employer. The Contractor shall be provided with supply of
electricity on chargeable basis for the purposes of the Contract, only at two locations in the
Employers Site and at 415V level. The Contractor shall make his own further distribution
arrangement. All temporary wiring must comply with local regulations and will be subject to
Employers inspection and approval before connection to supply. The free supply of power will
not be provided for the use in the labour and staff colony.
colony. Power supply for labour and staff
colony shall be provided at one point and the Contractor shall be charged at rates prevalent at
Page 6 of 23
the site. Illumination of wagon tippler and the conveyor area shall be the scope of the
tenderer.
18.3 Water
Contractor shall make all arrangements himself for the supply of construction water as well as
potable water for labour and other personnel at the worksite/colony.
18.4 Communication
The Employer will extend the telephone facilities, if available at Site, for purposes
purpos of Contract.
The Contractor shall be charged at actuals for such facilities.
19.0 FACILITIES TO BE PROVIDED BY THE CONTRACTOR
19.1 Contractor's site office Establishment
The Contractor shall establish a site office at the site and keep posted an authorized
autho
representative for the purpose of the contract, pursuant to GCC.
19.2 Tools, tackles and scaffoldings
The Contractor shall provide all the construction equipments, tools, tackles and scaffoldings
required for pre-assembly,
assembly, installation, testing, commissioning and conducting Guarantee
tests of the equipments covered under the Contract. He shall submit a list of all such materials
to the Employer before the commencement of preassembly at Site. These tools and tackles
shall not be removed from the Site
Site without the written permission of the Employer. The
Contractor shall arrange Dozer, Hydra, Cranes, Trailer, etc. for the purpose of fabrication,
erection and commissioning.
19.3 Testing Equipment and Facilities:
The contractor shall provide the necessary
necessary testing, equipment and facilities.
19.4 Site laboratory for civil works:
Contractor shall provide and maintain a site laboratory for the testing of construction material
under the direction and general supervision of employer.
19.5 First-aid
19.5.1 The Contractor shall provide necessary first-aid
first aid facilities for all his employees, representatives
and workmen working at the Site. Enough number of Contractors personnel shall be trained
in administering first-aid.
Contractor, in case of any emergency, the services of an
19.5.2 The Employer will provide the Contractor,
ambulance for transportation to the nearest hospital.
19.6 Cleanliness
19.6.1 The Contractor shall be responsible for keeping the entire area allotted to him clean and free
from rubbish, debris etc. during the period of Contract. The Contractor shall employ enough
number of special personnel to thoroughly clean his work-area
work area at least once in a day. All such
rubbish and scrap material shall be stacked or disposed in a place to be identified by the
Page 7 of 23
Employer.
oyer. Materials and stores shall be so arranged to permit easy cleaning of the area. In
areas where equipment might drip oil and cause damage to the floor surface, a suitable
protective cover of a flame resistant, oil proof sheet shall be provided to protect
prote the floor
from such damage.
19.6.2 Similarly the labour colony, the offices and the residential areas of the Contractors
employees and workmen shall be kept clean and neat to the entire satisfaction of the
Employer. Proper sanitary arrangements shall be
be provided by the Contractor, in the workwork
areas, office and residential areas of the Contractor.
20.0 LINES AND GRADES
All the Works shall be performed to the lines, grades and elevations indicated on the
drawings. The Contractor shall be responsible to locate and layout the Works. Basic horizontal
and vertical control points will be established and marked by the Employer at Site at suitable
points. These points shall be used as datum for the works under the Contract. The Contractor
shall inform the Employer
yer well in advance of the times and places at which he wishes to do
work in the area allotted to him so that suitable datum points may be established and checked
by the Employer to enable the Contractor to proceed with his works. Any work done without
being
ng properly located may be removed and/or dismantled by the Employer at Contractors
expense.
21.0 FIRE PROTECTION
21.1 The work procedures that are to be used during the erection shall be those which minimise
fire hazards to the extent practicable. Combustible
Combustible materials, combustible waste and rubbish
shall be collected and removed from the Site at least once each day. Fuels, oils and volatile or
flammable materials shall be stored away from the construction and equipment and materials
storage areas in safe
fe containers. Untreated canvas, paper, plastic or other flammable flexible
materials shall not at all be used at Site for any other purpose unless otherwise specified. If
any such materials are received with the equipment at the Site, the same shall be removed
re
and replaced with acceptable material before moving into the construction or storage area.
21.2 Similarly corrugated paper fabricated cartons etc. will not be permitted in the construction
area either for storage or for handling of materials. All such materials used shall be of water
proof and flame resistant type. All the other materials such as working drawings, plans etc.
which are combustible but are essential for the works to be executed shall be protected
against combustion resulting from welding
welding sparks, cutting flames and other similar fire
sources.
21.3 All the Contractors supervisory personnel and sufficient number of workers shall be trained
for fire-fighting
fighting and shall be assigned specific fire protection duties. Enough of such trained
personnel
ersonnel must be available at the Site during the entire period of the Contract.
Page 8 of 23
21.4 The Contractor shall provide enough fire protection equipment of the types and number for
the warehouses, office, temporary structures, labour colony area etc. Access to such fire
protection equipment, shall be easy and kept open at all time.
22.0 SECURITY
The Contractor shall have total responsibility for all equipment and materials in his custody
stores, loose, semi-assembled
assembled and/or erected by him at Site. The Contractor
Contrac
shall make
suitable security arrangements including employment of security personnel to ensure the
protection of all materials, equipment and works from theft, fire, pilferage and any other
damages and loss. All materials of the Contractor shall enter and leave the Employer Site only
with the written permission of the Employer in the prescribed manner.
23.0 CONTRACTORS AREA LIMITS
out the boundary limits of access roads, parking spaces, storage and
The Employer will mark-out
construction areas for the Contractor and the Contractor and his personnel shall not trespass
the areas into other areas of the plant. In case of a need for the Contactors personnel to work
in the areas beyond that marked out for him, the same shall be done only with the written
permission of the Employer.
OPERATION WITH THE EMPLOYER
24.0 CONTRACTORS CO-OPERATION
In case where the performance of the erection work by the Contractor affects the operation of
the system facilities of the Employer, such erection work of the Contractor shall be scheduled
to be performed only in the manner stipulated by the Employer and the same shall be
acceptable at all times to the Contractor. The Employer may impose such restrictions on the
facilities provided to the Contractor such as electricity, etc. as he may think fit in the interest
of the Employer and the Contractor shall strictly adhere to such restrictions and co-operate
co
with the Employer. It will be the responsibility of the Contractor to provide all necessary
temporary instrumentation and other measuring devices required during start-up
start
and
operation of the equipment systems which are erected by him. The Contractor shall also be
responsible for flushing and initial filling of all the oil and lubricants required for the
equipment furnished and installed by him, so as to make such equipment ready for operation.
The Contractor shall be responsible for supplying such flushing oil and other lubricants.
COMMISSIONING AND COMMISSIONING ACTIVITIES
25.0 PRE-COMMISSIONING
(a)
GENERAL
The Contractor upon completion of installation of equipments and systems, shall conduct
pre-commissioning
commissioning and commissioning activities, to make the equipment/systems ready for
safe,
reliable
and
efficient
operation
on
sustained
basis.
All
pre
precommissioning/commissioning
/commissioning activities considered essential for such readiness of the
equipment/systems including those mutually agreed and included in the Contractors quality
Page 9 of 23
assurance programme as well as those indicated in clauses elsewhere in the technical

specifications
cations shall be performed by the contractor.
(b)
commissioning and commissioning activities including Guarantee tests, checks and

The pre-commissioning
trial operations of the equipment/systems furnished and installed by the contractor shall be
the responsibility of the
he Contractor as detailed in relevant clauses in Technical Specification.
The Contractor shall provide, in addition, test instruments, calibrating devices etc. and labour
required for successful performance of these operations. If it is anticipated that the
th above test
may prolong for a long time, the Contractors workmen required for the above test shall
always be present at site during such operations.
(c)
The following activities shall be carried out by the contractor, prior to schedule date of
commissioning
ioning of the equipment/systems installed by him.
The contractor shall furnish the organization chart of his operation and commissioning
engineers for the acceptance of employer. Adequate number of operation and
commissioning engineers shall be deployed
deployed by the contractor to effectively meet the
requirement of round the clock operation in shifts also, till the plant is taken over by the
employer.
(ii) The contractor shall submit the bio-data
bio data containing the details of experience of his
operation and commissioning
mmissioning engineers for the acceptance of employer.
(iii) The contractor shall furnish the deployment schedule of his operation and commissioning
engineers for the acceptance of the employer.
(iv) Apart from above, contractor shall ensure deployment of sufficientskilled/semisufficientskilled/semi
skilled/unskilled manpower during pre-commissioning
pre commissioning and commissioning activities.
(i)
(d)
It shall be the responsibility of the Contractor to provide all necessary temporary

instrumentation and other measuring devices required during start-up
s
up and initial operation of
the equipment/systems which are installed by him.
(e)
The Contractor shall also be responsible for flushing and initial filling of all oils and lubricants
required for the equipment furnished and installed by him so as to make such equipment
ready for operation. The Contractor shall be responsible for supplying such flushing oil and
other lubricants unless otherwise specified elsewhere in these specifications and documents.
26.0 COMMISSIONING DOCUMENTATION

(a) The contractor shall submit the commissioning documentation, comprising of Standard
checklists, pre-commissioning
commissioning procedures, testing schedules, commissioning schedules and
commissioning networks for various equipment/systems covered under the contract, for
f the
approval of employer.
(b) Standard checklist, as the name suggests, shall be a fairly general documents, containing
the list of all checks required to be carried out for similar and repetitive type of equipment to
ensure consistent and thorough checking.
Page 10 of 23
shall be prepared for systematic commissioning of individual

(c) The testing schedule shall
equipment/sub-system
system Commissioning. The format of testing/Commissioning schedule shall
be such as to maintain consistency of presentation, content and reporting
list of commissioning documentation to be submitted by
(d) The contractor shall submit the list
him, alongwith their submission schedule for various equipment/systems covered under the
contract, with in 6(six) month from the date of award of contract, for the acceptance of
employer.
(e) The Contractorr shall submit the commissioning documentation, for various
equipment/covered under the contract, for the approval of employer, at least 18 months
before the scheduled date of commissioning of the equipment/systems.
27.0
COMMISSIONING ACTIVITIES
ompletion of pre-commissioning
pre commissioning activities/tests, the contractor shall initiate
(a)
Upon completion
commissioning of facilities. During commissioning the Contractor shall carry out system
checking and reliability trials on various sub-systems
sub
of the facilities.
(b) Contractor shall carry out the checks/tests at site to demonstrate to the Employer that
each of the equipment of the supplied complies with requirements stipulated and is installed
in accordance with requirements specified.
Before the plant is put into initial operation
operation the Contractor shall be required to conduct
(c)
test to demonstrate to the Employer that each item of the plant is capable of correctly
performing the functions for which it was specified and its performance, parameters etc. are
as per the specified/approved
specified/approved values. These tests may be conducted concurrently with those
required under commissioning sequence.
(d) Other tests shall be conducted, if required by the Employer, to establish that the plant
equipment are in accordance with requirements of the specifications.
specifica
The Contractor shall conduct all the commissioning tests and undertake commissioning
(e)
activities pertaining to all other auxiliaries and equipments including all electrical
equipment/systems not specifically brought out above but are within the scope
sco of work and
facilities being supplied and installed by the Contractor and follow the guidelines indicated
above or elsewhere in these technical specifications(Sectionspecifications(Section VI)
(f)
Initial Operation
Upon completion of system checking/Tests as above and as a part

part of commissioning of
facilities, complete plant/facilities shall be put into initial operation as stipulated in General
Technical Requirements.
Page 11 of 23
28.0 MATERIALS HANDLING AND STORAGE

(a) All the equipments furnished under the Contract and arriving at Site shall be promptly
received, unloaded and transported and stored by the Contractor.
(b) Contractor shall be responsible for examining all the shipment and notify the Employer
immediately of any damage, shortage, discrepancy etc. for the purpose of Employer's
Employe
information only. The Contractor shall submit to the Employer every week a report detailing
all the receipts during the week. However, the Contractor shall be solely responsible for any
shortages or damage in transit, handling and / or in storage and erection
erection of the equipment at
Site. Any demurrage, wharfage and other such charges claimed by the transporters, railways
etc. shall be to the account of the Contractor.
(c) The Contractor shall maintain an accurate and exhaustive record detailing out the list of
all equipment received by him for the purpose of erection and keep such record available for
the inspection of the Employer.
(d) All equipment shall be handled with care to prevent any damage. No bare wire ropes,
slings, etc. shall be used for unloading
unloading and/or handling of the equipment without the specific
written permission of the Employer. The equipment stored shall be properly protected to
prevent damage to the equipment. The equipment from the store shall be moved to the
actual location at the appropriate time so as to avoid damage of such equipment at Site.
(e) All electrical panels, controls gear, motors and such other devices shall be properly dried
by heating before they are installed and energised. Motor bearings, slip rings, commutators
and
nd other exposed parts shall be protected against moisture ingress and corrosion during
storage and periodically inspected. Heavy rotating parts in assembled conditions shall be
periodically rotated to prevent corrosion due to prolonged storage.
ontractor shall ensure that all the packing materials and protection devices used for
(f) The Contractor
the various equipments during transit and storage are removed before the equipment are
installed.
(g) The consumables and other supplies likely to deteriorate due to storage
sto
must be
thoroughly protected and stored in a suitable manner to prevent damage or deterioration in
quality by storage.
(h) All the materials stored in the open or dusty location must be covered with suitable
weatherproof and flameproof covering material
mater wherever applicable.
(i) If the materials belonging to the Contractor are stored in areas other than those
earmarked for him, the Employer will have the right to get it moved to the area earmarked for
the Contractor at the Contractors cost.
Page 12 of 23
(j) The Contractor shall be responsible for making suitable indoor storage facilities to store
all equipment which require indoor storage. Normally, all the electrical equipments such as
motors, control gear, exciters and consumables like electrodes, lubricants
lubricants etc. shall be stored
in the closed storage space . The Employer, in addition, may direct the Contractor to move
certain other materials, which in his opinion will require indoor storage, to indoor storage
areas which the Contractor shall strictly comply with.
29.0 CONSTRUCTION MANAGEMENT
(a) The field activities of the Contractors working at Site, will be coordinated by the Employer
and the Employer decision shall be final in resolving any disputes or conflicts between the
Contractor and other Contractors
Contractors and tradesmen of the Employer regarding scheduling and
co- ordination of work. Such decision by the Employer shall not be a cause for extra
compensation or extension of time for the Contractor.
Contractors working at Site, at a time
(b) The Employer shall hold weekly meetings of all the Contractors
and place to be designated by the Employer. The Contractor shall attend such meetings and
take notes of discussions during the meeting and the decisions of the Employer and shall
strictly adhere to those decisions in performing
performing his Works. In addition to the above weekly
meeting, the Employer may call for other meeting either with individual Contractors or with
selected number of Contractors and in such a case the Contractor if called, will also attend
such meetings.
(c) Time is the essence of the Contract and the Contractor shall be responsible for
performance of his works in accordance with the specified construction schedule. If at any
time, the Contractor is falling behind the schedule, he shall take necessary action to
t make
good for such delays by increasing his work force or by working overtime or otherwise
accelerate the progress of the work to comply with the schedule and shall communicate such
actions in writing to the Employer, satisfying that his action will compensate
compensate for the delay. The
Contractor shall not be allowed any extra compensation for such action.
(d) The Employer shall however not be responsible for provision of additional labour and/or
materials or supply or any other services to the Contractor except
except for the coordination work
with other Contractors, if necessary.
30.0 FIELD OFFICE RECORDS
The Contractor shall maintain at his Site Office up-toup
date copies of all drawings,
specifications and other Contract Documents and any other supplementary data complete
with all the latest revisions thereto. The Contractor shall also maintain in addition the
continuous record of all changes to the above Contract Documents, drawings, specifications,
supplementary data, etc. effected at the field and on completion of his total assignment under
the Contract shall incorporate all such changes on the drawings and other Engineering data to
indicate as installed conditions of the equipment furnished and erected under the Contract.
Page 13 of 23
Such drawings and Engineering data shall be submitted to the Employer in requisite number
of copies.
31.0 CONTRACTORS MATERIALS BROUGHT ON TO SITE
(a) The Contractor shall bring to Site all equipment, components, parts, materials, including
construction equipment, tools and tackles for the purpose of the Works under intimation to
the Employer. All such goods shall, from the time of their being brought vest in the Employer,
but may be used for the purpose of the Works only and shall not on any account be removed
or taken away by the Contractor
Contractor without the written permission of the Employer. The
Contractor shall nevertheless be solely liable and responsible for any loss or destruction
thereof and damage thereto.
(b) The Employer shall have a lien on such goods for any sum or sums which may at any time
be due or owing to him by the Contractor, under, in respect of or by reasons of the Contract.
After giving a fifteen (15) days notice in writing of his intention to do so, the Employer shall be
at liberty to sell and dispose off any such goods, in such manner as he shall think fit including
public auction or private treaty and to apply the proceeds in or towards the satisfaction of
such sum or sums due as aforesaid.
(c) After the completion of the Works, the Contractor shall remove from the Site under
u
the
direction of the Employer the materials such as construction equipment, erection tools and
tackles, scaffolding etc. with the written permission of the Employer. If the Contractor fails to
remove such materials, within fifteen (15) days of issue of
of a notice by the Employer to do so
then the Employer shall have the liberty to dispose off such materials as detailed under as
specified at clause no 31 (b) above and credit the proceeds thereto to the account of the
Contractor.
TY AND CONTRACTORSLIABILITY
32.0 PROTECTION OF PROPERTY
(a) The Contractor shall be responsible for any damage resulting from his operations. He
shall also be responsible for protection of all persons including members of public and
employees of the Employer and the employees of other
other Contractors and SubSub Contractors and
all public and private property including structures, building, other plants and equipments and
utilities either above or below the ground.
(b) The Contractor will ensure provision of necessary safety equipment such as barriers, sign
- boards, warning lights and alarms, etc. to provide adequate protection to persons and
property. The Contractor shall be responsible to give reasonable notice to the Employer and
the Employers of public or private property and utilities
utilities when such property and utilities are
likely to get damaged or injured during the performance of his Works and shall make all
necessary arrangements with such Employers, related to removal and/or replacement or
protection of such property and utilities.
utilities
Page 14 of 23
33.0 PAINTING
All exposed metal parts of the equipment including pipings, structure railings, etc. wherever
applicable, after installation unless otherwise surface protected, shall be first painted with at
least two coats of suitable primer which matches
matches the shop primer paint used, after throughly
cleaning all such parts of all dirt, rust, scales, greases, oils and other foreign materials by wire
brushing, scraping or sand blasting and the same being inspected and approved by the
Employer/RITES for painting.
nting. Afterwards, the above parts shall be finished painted with two
t
coats of synthetic enamel paint.
paint. The minimum thickness of paint film shall not be less than
100 microns. The quality of the finish paint shall be as per the standards of Bureau of Indian
Standards (BIS) or equivalent and to be of the colour as approved by the Employer.
34.0 INSURANCE
34.1 In addition to the conditions covered under the Clause entitled Insurance in Section General
Conditions of Contract (GCC), the following provisions will also apply to the portion of works
to be done beyond the Contractors own or his Sub-Contractors
Sub Contractors manufacturing Works.
34.2 Workmens Compensation Insurance
This insurance shall protect the Contractor against all claims applicable under the Workmens
Workmen
Compensation Act, 1948 (Government of India). This policy shall also cover the Contractor
against claims for injury, disability disease or death of his or his Sub-Contractors
Sub Contractors employees,
which for any reason are not covered under the Workmens Compensation
Compensati Act, 1948. The
liabilities shall not be less than the following:
Workmen's Compensation - As per Statutory Provisions
Employee's Liability - As per Statutory Provisions
Property Damage: Rs.100,000 for each occurrence
34.3 Comprehensive General Liability Insurance
34.3.1 The insurance shall protect the Contractor against all claims arising from injuries, disabilities,
disease or death of members of public or damage to property of others, due to any act or
omission on the part of the Contractor, his agents, his employees, his representatives and
Sub-Contractors
Contractors or from riots, strikes and civil commotion. This insurance shall also cover all
the liabilities of the Contractor arising out of the Clause entitled Defence of Suits in Section
General Conditions
nditions of Contract (GCC).
34.3.2 The hazards to be covered will pertain to all the Works and areas where the Contractor, his
Sub-Contractors,
Contractors, his agents and his employees have to perform work pursuant to the
Contract.
illustrative list of insurance covers normally required and it will be the
34.4 The above are only illustrative
responsibility of the Contractor to maintain all necessary insurance coverage to the extent
Page 15 of 23
both in time and amount to take care of all his liabilities either direct or indirect, in pursuance
pursuanc
of the Contract.
35.0 UNFAVOURABLE WORKING CONDITIONS
The Contractor shall confine all his field operations to those works which can be performed
without subjecting the equipment and materials to adverse effects during inclement weather
conditions, likee monsoon, storms, etc. and during other unfavourable construction conditions.
No field activities shall be performed by the Contractor under conditions which might
adversely affect the quality and efficiency thereof, unless special precautions or measures are
taken by the Contractor in a proper and satisfactory manner in the performance of such
Works and with the concurrence of the Employer. Such unfavourable construction conditions
will in no way relieve the Contractor of his responsibility to perform the Works as per the
schedule.
36.0 PROTECTION OF MONUMENTS AND REFERENCE POINTS
The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc. which he
may come across during the course of performance of his Works either during excavation or
elsewhere, are properly protected and handed over to the Employer. Similarly the Contractor
shall ensure that the bench marks, reference points, etc., which are marked either with the
help of Employer or by the Employer shall not be disturbed in any way during the
performance of his Works. If, any work is to be preformed which disturb such reference, the
same shall be done only after these are transferred to other suitable locations under the
direction of the Employer. The Contractor shall provide
provide all necessary materials and assistance
for such relocation of reference points etc.
37.0 WORK & SAFETY REGULATIONS
37.1 The Contractor shall ensure proper safety of all the workmen, materials, plant and
equipments belonging to him or to Employer or to others, working at the Site. The Contractor
shall also be responsible for provision of all safety notices and safety equipment required both
by the relevant legislation and the Employer as he may deem necessary.
37.2 All equipment used in construction and erection by Contractor shall meet Indian/International
Standards and where such standards do not exist, the Contractor shall ensure these to be
absolutely safe. All equipments shall be strictly operated and maintained by the Contractor in
accordance with
th manufacturers operation Manual and safety instructions and as per
Guidelines/Rules of Employer in this regard.
37.3 Periodical Examinations and all tests for all lifting/ hoisting equipment & tackles shall be
carried-out
out in accordance with the relevant
relevant provisions of Factories Act 1948, Indian Electricity
Act 1910 and associated Laws/Rules in force from time to time. A register of such
examinations and tests shall be properly maintained by the Contractor and will be promptly
produced as and when desired by Employer or by the person authorised by him.
Page 16 of 23
37.4 The Contractor shall provide suitable safety equipment of prescribed standard to all
employees and workmen according to the need, as may be directed by Employer who will also
have right to examine these
these safety equipments to determine their suitability, reliability,
acceptability and adaptability.
37.5 The Contractor shall provide safe working conditions to all workmen and employees at the
Site including safe means of access, railings, stairs, ladders, scaffoldings etc. The scaffoldings
shall be erected under the control and supervision of an experienced and competent person.
For erection, good and standard quality of material only shall be used by the Contractor.
37.6 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical
equipment belonging to the Employer or other Contractors under any circumstances,
whatsoever, unless expressly permitted in writing by the Employer to handle such fuses,
wiring or electrical equipment.
equipment
37.7 No electric cable in use by the Contractor/Employer will be disturbed without prior
permission. No weight of any description will be imposed on any cable and no ladder or
similar equipment will rest against or attached to it.
37.8 The Contractors shall employ necessary number of qualified, full time Electricians/ Electrical
Supervisors to maintain his temporary electrical installations.
37.9 In case any accident occurs during the construction/ erection or other associated activities
undertaken by the Contractor thereby causing any minor or major or fatal injury to his
employees due to any reason, whatsoever, it shall be the responsibility of the Contractor to
promptly inform the same to the Employer in prescribed form and also to all the authorities
authoritie
envisaged under the applicable laws.
37.10 The Employer shall have the right at his sole discretion to stop the work, if in his opinion the
work is being carried out in such a way that it may cause accidents and endanger the safety of
the persons and/or property, and/or equipments. In such cases, the Contractor shall be
informed in writing about the nature of hazards and possible injury/accident and he shall
comply to remove shortcomings promptly. The Contractor after stopping the specific work
can, if felt
elt necessary appeal against the order of stoppage of work to the Employer within 3
days of such stoppage of work and decision of the Employer in this respect shall be conclusive
and binding on the Contractor.
for any damages/ compensation for stoppage of work due
37.11 The Contractor shall not be entitled for
to safety reasons as provided above and the period of such stoppage of work will not be taken
as an extension of time for completion of the facilities.
38.0 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT BASES
Page 17 of 23
38.1 The surfaces of foundations shall be dressed to bring the top surface of the foundations to the
required level, prior to placement of equipment/equipment bases on the foundations.
38.2 All the equipment/ equipment bases, shall be grouted and finished as per these specifications
unless otherwise recommended by the equipment manufacturer.
38.3 The concrete foundation surfaces shall be properly prepared by chipping, grinding as required
to bring the top of such foundation to
to the required level, to provide the necessary roughness
for bondage and to assure enough bearing strength.
38.4 Grout
The grout shall be high strength grout having a minimum characteristic compressive strength
of 60 N/mm2 at 28 days. The grout shall be chloride - free, cement based, free flowing, nonnon
metallic grout. The Grout shall have good flowability even at very low water/ grout powder
ratio. The Grout shall have characteristics of controlled expansion to be able to occupy its
original volume to filll the voids and to compensate for shrinkage. Grout shall be of pre-mix
pre
variety so that only water needs to be added before use. The mixing of the Grout shall
conform to the recommendations of the manufacturer of the Grout.
t Grout
38.5 Finishing of the Edges of the
The poured grout should be allowed to stand undisturbed until it is well set. Immediately
thereafter, the dam shall be removed and grout which extends beyond the edges of the
structural or equipment base plates shall be cut off, flushed and removed.
removed. The edges of the
grout shall then be pointed and finished with 1:2 cement mortar pressed firmly to bond with
the body of the grout and smoothened with a tool to present a smooth vertical surface. The
work shall be done in a clean and scientific manner and the adjacent floor spaces, exposed
edges of the foundations, and structural steel and equipment base plates shall be thoroughly
cleaned of any spillage of the grout.
38.6 CHECKING OF EQUIPMENT AFTER GROUTING
After the grout is set and cured, the Contractor
Contractor shall check and verify the alignment of
equipments, alignment of shafts of rotating machinery, the slopes of all bearing pedestals,
centering of rotors with respect to their sealing bores, couplings, etc. as applicable and the like
items to ensure that
hat no displacement had taken place during grouting. The values recorded
prior to grouting shall be used during such post grouting checkcheck up and verifications. Such pre
and post grout records of alignment details shall be maintained by the Contractor in a manner
acceptable to the Employer.
39.0 SHAFT ALIGNMENTS
All the shafts of rotating equipment shall be properly aligned to those of the matching
equipments to as perfect an accuracy as practicable. The equipment shall be free from
excessive vibration so as to avoid overheating of bearings or other conditions which may tend
to shorten the life of the equipment. The vibration level of rotating equipments measured at
Page 18 of 23
bearing housing shall not exceed forty (40) microns and shall conform to VDI 2056.All
bearings,
gs, shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated
before starting.
40.0 DOWELLING
All the motors and other equipment shall be suitably doweled after alignment of shafts with
tapered machined dowels as per the direction
directi of the Employer.
41.0 CHECK OUT OF CONTROL SYSTEMS
After completion of wiring, cabling furnished under separate specification and laid and
terminated by the Employer, the Contractor shall check out the operation of all control
systems for the equipment
equipment furnished and installed under these specifications and documents.
42.0 COMMISSIONING SPARES
42.1 It will be the responsibility of the Contractor to provide all commissioning spares including
consumable spares required for initial operation till the Completion of Facilities. The
Contractor shall furnish a list of all commissioning spares within 60 days from the date of
Notification of Award and such list shall be reviewed by the Employer and mutually agreed to.
However. such review and agreement will not absolve the Contractor of his responsibilities to
supply all commissioning spares so that initial operation
operation do not suffer for want of
commissioning spares. All commissioning spares shall be deemed to be included in the scope
of the Contract at no extra cost to the Employer.
42.2 These spare will be received and stored by the Contractor atleast 3 months prior to the
schedule date of commencement of initial operation of the respective equipment and utilised
as and when required. The unutilised spares and replaced parts, if any, at the end of
successful completion of guarantee tests shall be the property of the Contractor and he will be
allowed to take these parts back at his own cost with the permission of Employer. Employer
will be informed of the list of commissioning spares brought to site by the contractor before
bringing the same to the site.
43.0 CABLING
43.1 All cables shall be supported by conduits or cable tray run in air or in cable channels. These
shall be installed in exposed runs parallel or perpendicular to dominant surfaces with right
angle turn made of symmetrical bends or fittings. When cables
cables are run on cable trays, they
shall be clamped at a minimum intervals of 2000mm or otherwise as directed by the
Employer.
43.2 Each cable, whether power or control, shall be provided with a metallic or plastic tag of an
approved type, bearing a cable reference number indicated in the cable and conduit list
(prepared by the Contractor), at every 5 meter run or part thereof and at both ends of the
Page 19 of 23
cable adjacent to the terminations. Cable routing is to be done in such a way that cables are
accessible forr any maintenance and for easy identification.
43.3 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC insulted
cables 1100 V grade shall be 15 D where D is the overall diameter of the cable. Installation of
other cables like high
igh voltage, coaxial, screened, compensating, mineral insulated shall be in
accordance with the cable manufacturers recommendations.
43.4 In each cable run some extra length shall be kept at a suitable point to enable one or two
straight through joints to be made, should the cable develop fault at a later date.
43.5 Control cable terminations shall be made in accordance with wiring diagrams, using
identifying codes subject to the Employers approval. Multicore control cable jackets shall be
removed as required
equired to train and terminate the conductors. The cable jacket shall be left on
the cable, as far as possible, to the point of the first conductor branch. The insulated
conductors from which the jacket is removed shall be neatly twined in bundles and
terminated.
inated. The bundles shall be firmly but not tightly tied utilizing plastic or nylon ties or
specifically treated fungus protected cord made for this purpose. Control cable conductor
insulation shall be securely and evenly cut.
rol cables shall be covered with a transparent insulating sleeve so as to
43.6 The connectors for control
prevent accidental contact with ground or adjacent terminals and shall preferably terminate in
Elmex terminals and washers. The insulating sleeve shall be fire resistant and shall be long
enough to over pass the conductor insulation. All control cables shall be fanned out and
connection made to terminal blocks and test equipment for proper operation before cables
are corded together.
44.0 EQUIPMENT DELIVERY AND ERECTION
44.1 General Requirements
(a.) This part covers Contractor's responsibilities for packing, shipping, warehousing and the
installation of all equipment and materials furnished and installed under this specification.
(b.) The Contractor shall submit for Employer's approval draft manual for Equipment Delivery
and Erection covering detailed instructions, write up, technical data, drawings, check-lists,
check
documentation formats for all activities after equipment manufacture upto installation of
equipment. This manual shall cover general
general instructions for all equipment and specific
instructions for individual equipment wherever required and shall include at least the
following :
ware housing and storage.
i. Instructions for packing, shipping, receiving handling, ware-housing
ii. Instructions for location and
and installation of equipment furnished by this specification.
iii. Installation drawings for field mounted equipment, panels, cubicles and other
equipment covered under this specification.
iv. Instruction relating installation of piping/ tubing, support and routing drawings of
impulse pipes/signal tubes and tube/cable trays.
Page 20 of 23
v. Check lists and quality assurance hold points.

vi. Format for all related documentation.
(c.) The Manual shall conform to the requirements of this specification, all applicable codes and
standards, recommendations
mendations of equipment manufacturers and accepted good engineering
practices and shall be subject to Employer approval during detailed engineering.
(d.) The Contractor shall ensure that all work under this part shall be performed as per the
requirements of this
is specification, Employer approved Manual and drawing/documents
approved by the Employer during detailed engineering stage of work.
44.2 Crating
(a) All equipment and materials shall be suitably coated, wrapped, or covered and boxed or
crated for moist humid tropical shipment and to prevent damage or deterioration during
handling and storage at the site.
(b) Equipment shall be packed with suitable desiccants, sealed in water proof vapour-proof
vapour
wrapping and packed in lumber of plywood enclosures, suitably braced, tied and skidded.
Lumber enclosures shall be solid, not slatted.
(c) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to provide the
required surface area and activated prior to placing in the packaging. Calcium sulphate
desiccantss shall be of a chemical nature to absorb moisture. In any case, the desiccant shall
not be of a type that will absorb enough moisture to go into solution. Desiccants shall be
packed in porous containers, strong enough to withstand handling encountered during
dur
normal shipment. Enough desiccant shall be used for the volumes enclosed in wrapping.
(d) Review by the Employer of the Contractor's proposed packaging methods shall not relieve
the Contractor of responsibility for damage or deterioration to the equipment and materials
specified.
(e) All accessory items shall be shipped with the equipment. ; Boxes and crates containing
accessory items shall be marked so that they are identified with the main equipment. The
contents of each box and crates shall be indicated by markings
markings on the exterior.
(f) All boxes, crates, cases bundles, loose pieces, etc. shall be marked consecutively from No.1
upward throughout all shipments from a given port to completion of the order without
repeating the same number.
(g) An itemized list of contents shall be enclosed inside each case and one other copy securely
fastened to the outside of the case in a tin or light weight sheet metal envelope or pocket.
The lists shall be plainly marked and placed in accessible locations to facilitate receipt and
inspection. The packing list shall indicate whether shipment is partial or complete and shall
incorporate the following information on each container, etc., according to its individual
shipping number :
1. Export case markings
2. Case number
3. Gross weight
eight and net weight in Kilograms
4. Dimensions in centimeters
5. Complete description of material
Page 21 of 23
(h) Packaging or shipping units shall be designed within the limitations of unloading facilities
and the equipment which will be used for transport. Complications
Complications involved with ocean
shipment and the limitations of ports, railways and roads shall be considered. It shall be the
Contractor's responsibility to investigate these limitations and to provide suitable packaging
to permit safe handling during transit and at the job site.
(i) Electrical equipment, control and instrumentation shall be protected against moisture and
water damage. All external gasket surfaces and flange faces, couplings, motor pump shafts,
bearing and like items shall be thoroughly cleaned and coated
coated with rust preventive
compound as specified above and protected with suitable wood, metal or other substantial
type covering to ensure their full protection.
(j) Equipment having antifriction or sleeve bearings shall be protected by weather tight
enclosures.
(k) Coated surfaces shall be protected against impact, abrasion, discolouration and other
damage. Surfaces which are damaged shall be repaired.
(l) All exposed threaded parts shall be greased and protected with metallic or other substantial
type protectors. All female threaded openings shall be closed with forged steel plugs. All
pipings, tubing, and conduit equipment and other equipment openings shall be sealed with
metallic or other rough usage covers and tapped to seal the interior of the equipment
piping, tubing,
ing, or conduit.
(m) Provisions shall be made to ensure that water does not enter any equipment during
shipment or in storage at the plant site.
(n) Returnable containers and special shipping devices shall be returned by the manufacturer's
field representative at the Contractor's expense.
(o) While packaging the material, care shall be taken for the limitation from the point of view of
availability of railway wagon sizes in India.
44.3 Equipment Installation
(a.)
General Requirements
The Contractor shall furnish all construction materials, tools and equipment and shall perform
all work required for complete installation of all control and instrument equipment furnished
under this specification. Contractor shall prepare detailed installation
installation drawings for each
equipment furnished under this specification for Employer's approval. Installation of all
equipment/systems furnished by this specification shall be as per Employer's approval.
Erection procedures not specified herein shall be in accordance
accordance with the recommendations of
the equipment manufacturers. The procedures shall be acceptable to the Employer. The
Contractor shall coordinate his work with other suppliers where their instruments and devices
are to be installed under specifications.
specifications
(b.) Installation Materials
All materials required for installation, testing and commissioning of the equipment shall be
furnished by the Contractor.
(c.) Regulatory Requirements
Page 22 of 23
All installation procedures shall confirm with the accepted good engineering practice
practi and with
all applicable governmental laws, regulations and codes.
(d.) Cleaning
All equipment shall be cleaned of all sand, dirt and other foreign materials immediately after
removal from storage and before the equipment is brought to installation site.
(e.) Equipment Assembly
Equipment installed under these specifications shall be assembled if shipped unassembled.
The equipment shall be dismantled and reassembled as required to perform the installation
and commi ssioning work described in these specifications.
specifications
(f.) Defects
All defects in erection shall be corrected to the satisfaction of the Employer and the Project
Manager. The dismantling and reassembly of Contractor furnished equipment to remove
defective parts, replace parts, or make adjustments shall be included
included as a part of the work
under these specifications. The removal of control and instrument equipment in order to
allow bench calibration, if required, and the re-installation
re installation of the said equipment after
calibration shall also be included as a part of the work under these specifications.
45.0 DEVIATIONS DISPOSITIONING:
Any deviation to the contract and employer approved documents shall be properly recorded
in the format prescribed by NALCO. Al the deviations shall be bought to the knowledge of
employers representative for suitable dispositioning.
DESTRUCTIVE TESTING ( NDT):
46.0 NON-DESTRUCTIVE
The contractor shall record results of NDTs carried out at site in the format acceptable to
employer. All the radiographs & its report duly signed & correlated to the job shall
sh be handed
over to the employer. Sensitivity of all the test equipment shall be compatible to the job &
acceptance norms agreed.
47.0 TESTING EQUIPMENT & FACILITIES:
Contractor shall provide the testing equipment and facilities necessary to carry out tests &
inspections.
Page 23 of 23
SECTION 9
(MISCELLANEOUS)
PAINTING
1.0
1.1
GENERAL
This specification covers the materials, tools, facilities and quality requirement for surface
preparation and painting of steel structures, equipment, piping including supports, hangers,
gas and air ducts including hangers, chutes etc.
g" referred herein covers rust preventive, preventive and decorative coating
The term "painting"
along with surface protection.
1.2
Surfaces in direct bonded contact with concrete, aluminium, asbestos, brass; bronze,
galvanized steel, stainless steel, cast iron and other corrosion
corrosion resistant alloys,
rubber/synthetic polymers are not required to be painted unless specified except for aesthetic
purposes or for identification bands. Except for such surfaces, painting and surface
preparation shall be provided to protect all surfaces
surfaces that shall be subjected to atmospheric
action and exposed to corrosive medium.
All machined mating surfaces (eg. flanges) shall be properly cleaned, greased and protected
before dispatch.
1.3
The complete paint system for any item includes the following
fo
activities:
i) Proper surface preparation
ii)
Application of primer coats
iii)
Application of intermediate coats
iv)
Application of finished coats
All the above coats shall be of quality paint products and of approved make as stipulated in
this specification. The
he work shall also include supply of all paint materials as per specification
described herein and of approved quality.
2.0
SURFACE PREPARATION
2.1
Surface preparation being a pre requisite for any paint application, shall be such as to clean
the surface
ace thoroughly of any materials which will be conducive to premature failure of the
paint substrates.
All surfaces shall be cleaned of loose substances and foreign materials, such as dirt, rust, scale,
oil, grease, welding flux, etc. irrespective of whether the same has been spelt out in the
standards in order that the prime coat is rigidly anchored to the virgin metal surface. The
surface preparation shall conform to pictorial representation of surface quality grade of DIN
2.2
Technical Specification:Sec-9,Miscellaneous
Page 1 of 55
55928 (Part 4) or BS 4232 or IS 1477 - 1971 ( Part I ). Any grease, oil, dust or foreign matter
deposited on the surface after preparation
preparation shall be removed and care taken that the surface is
not contaminated with acids, alkalis moisture or other corrosive chemicals. The prime coat
shall be applied as soon as possible after the surface preparation is completed.
2.3
The acceptable surfacee preparation quality / grades are described under each painting system.
The procedures covered are solvent cleaning, hand tool cleaning, power tool cleaning and
blast cleaning.
2.4
Solvent cleaning
The surface shall be cleaned by wiping, immersion, spraying
spraying or vapor contacting of a suitable
solvent or washing with an emulsion or alkaline solution to remove oil, grease, dirt, old paint,
etc. Solvent cleaning shall not remove rust, scales, mill scales or weld flux. Therefore, before
application of paint,, solvent cleaning shall be followed by other cleaning procedures as stated
elsewhere.
2.5
Hand tool cleaning

The surface shall be cleaned by vigorous wire brushing done manually to St-2
St quality. This
method effectively removes loosely adherent materials,
materials, but would not affect residues of rust
or mill scales that are intact and firmly adherent.
2.6
Power tool cleaning

Electric or pneumatic tools shall clean the surface to St - 3 quality. The tools shall be used
carefully to prevent excessive roughing
roughing of surface and formation of ridges and burns. This
method will remove loosely adherent materials but would not affect residues of rust or mill
scales that are firmly adherent.
2.7
Blast cleaning
3.0
The surface shall be cleaned by impingement of abrasive

abrasive materials, such as graded sand at
high velocity created by clean and dry compressed air blast. This method will remove loosely
adherent materials as well as adherent scales and mill scales. Prior to application of blast,
heavy deposit of oil and grease are removed by solvent cleaning and excessive surface scales
are removed by hand tools or power tool cleaning. The surface shall be cleaned to Sa - 2 1/2
quality i.e. 95 % of surface area is free from all rust, mill scales and visible residues, foreign
materials,
erials, etc. The blast cleaning is not recommended for sheet metal work.
PRIMER PAINTS (P)
Primer paints shall be applied only on dry and clean surfaces.
3.1
Primer paint P1 - (Phenolic - Alkyd based)
Page 2 of 55
A single pack air drying phenolic modified alkyd composition with zinc phosphate as
a primer paint.
Air drying time
- About 60 minutes (touch dry)
-Overnight (hard dry)
Dry film thickness
- 40 microns (min)
(DFT / Coat)
4.0
3.2
Primer paint P2 - (Epoxy based)

A two pack air drying Epoxy polyamide with zinc dust of at least 92 % zinc dust on
the dry film.
Epoxy content (% wt.)
- 8 to 10
Air drying time
- 10 minutes (touch dry)
- 2 hours (hard dry)
DFT / coat
- 40 microns (min)
3.3
Primer paint P3 - (Ethyl zinc silicate, EZS, based)

A two pack heavy duty zinc dust rich silicate primer which protects the surface with
just a single coat.
Total solids ( % wt )
- 84 +/- 2
Density ( g / cc )
- 3.07 +/- 0.05
Air drying time
- To top coat 16 hours
DFT / coat
- 60 microns
INTERMEDIATE PAINTS ( I )
These paints shall be applied over primer coats as an intermediate layer to provide
weatherproof seal of primer coats.
4.1
1 (Phenolic alkyd based)

Intermediate Paint I-1
A single pack high build phenolic based paint of synthetic micaceous iron oxide.
Air drying time
-4 to 6 hours (touch dry)
-2 days (hard dry)
DFT / coat
-75 microns (min)
Temperature resistance -upto
100 deg C dry heat
Compatible with
-Primer
P1
4.2
Intermediate Paint I-2

I
pack air drying high build epoxy resin based paint with MIO.
A two-pack
Air drying time
- 6 to 8 hours (touch dry)
- 7 days (full cure)
DFT / coat
- 100 microns
Compatible with
- Primer P2
Page 3 of 55
5.0
FINISH PAINTS (F)

Finish paint coats shall be applied over primer coats and intermediate coats after proper
cleaning and touch up of primed coats.
5.1
Finish Paint F1
A single pack air drying high gloss phenolic alkyd modified synthetic enamel paint suitably
pigmented.
-3 to 4 hours (touch dry) -24
24 hours (hard dry)
Air drying time
DFT / coat
- 25 microns (min)
Compatible with
Intermediate I1
- Primer P1
Colour
- generally all shades
5.2
Finish Paint F2
A two pack air drying epoxy polyamide enamel suitably pigmented.
Air drying time
- 2 to 3 hours (touch dry)
- 7 days (full cure)
DFT / coat
- 40 microns (min)
Compatible with
Intermediate I2
- Primer P2
Colour
- generally all shades
5.3
Finish Paint F3
A single pack heat resistant silicon resin based paint with leafing Aluminium powder.
Air drying time
- 3 to 4 hours (touch dry)/24 hrs (hard dry)
DFT / coat
- 20 microns (min)
Compatible with
- no primer paint except P3
(shalll be applied on blast cleaned steel surface)
Colour
- smooth aluminium
6.0
PAINT APPLICATION
6.1
Paint shall be applied in accordance with paint manufacturer's recommendations.

Manufacture of paints, mixing of paints, etc. shall be as per the IS codes of practice. The work
shall generally follow IS 1477 -1971
1971 (Part II) for jobs carried out in India and or DIN 55928
(latest) or equivalent for jobs carried out outside India.
6.2
Paint shall not be applied when the ambient temperature is 500 C and
d above or 450 C and
below.. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and
above unless the manufacturer's recommendations permit. Application of paint shall be only
by spraying or brushing as per IS 486 - 1983 and IS 487 - 1985.
Page 4 of 55
6.3
Each coat of paint shall be continuous, free of pores and of even film thickness without thin
spots.
6.4
Each coat of paint shall be dry sufficiently before application of next coat.
6.5
The colour code to be followed during painting shall be intimated to the successful Tenderer
during finalization of order.
6.6
In the event of conflict between this general procedure for painting and the paint
manufacturer's specification, the same shall
shall be immediately brought to the notice of the
Purchaser. Generally in cases of such conflicts, manufacturer's specifications /
recommendations shall prevail.
6.7
General compatibility between primer and finishing paints shall be certified by the paint
manufacturer
anufacturer supplying the paints.
6.8
Areas that become inaccessible after assembly shall be painted before assembly (after
painting clearance has been given by the inspecting authority) after requisite surface cleaning
as specified.
h cannot be painted but require protection shall be given a coat of rust inhibitive
Surfaces which
grease according to IS 958 - 1975 or solvent deposited compound according to IS 1153 - 1975
or IS 1674 - 1960.
6.9
6.10 Parts of steel structures embedded in concrete shall be given a protective coat of Portland
cement slurry immediately after fabrication and after surfaces of this part is thoroughly
cleaned from grease, rust, mill scales, etc. No paint shall be applied on this part.
shade of the paint shall have the approval of the Purchaser.
6.11 The proposed make, quality and shade
6.12 Zinc rich primer paints which have been exposed several months before finishing coat is
applied shall be washed down thoroughly to remove soluble zinc salt deposits.
6.13 The machine finished
hed surfaces shall be coated with white lead and tallow before shipment or
before being put out into the open air.
6.14 Total DFT for heat resistant paints should not exceed 100 -120
120 microns, otherwise flaking
occurs ( as per paint manufacturer's recommendations
recomme
).
6.15 Heat resistant paints should be applied by brush.
7.0
PAINTING SCHEME
7.1
For a complete painting scheme of any item being painted, all types of paints are to be
procured from the same manufacturer as approved by the Purchaser.
7.2
Legend
Page 5 of 55
SP
Surface preparation quality
2P1
Two (2) coats of primer paint type P1
1I1
One ( 1 ) coat of intermediate paint type
I1 2F1 - Two ( 2 ) coats of finish paint type F1
DFT
Dry film thickness
Type of paint products like P1, P2, P3, I1, I2, F1, F2 and F3 have been specified under sl.
nos.03, 04 and 05 of this specification.
7.3
The painting scheme to be followed for various equipment/ structures is briefly given below
for guidance to the Tenderer.
Painting scheme
Sl. No.
Description
DFT
Total
At shop
At site
SP - St 3
1.
Steel structure
2P1+1I1
2F1
100
2.
3.
Mechanical
SP - Sa 2 1/2 (or St 3)
equipment(temp.
not over 80 deg C)
Both static and
2P1+1I1
2F1 & 2F2
rotary equipment
or 2P2+1I2
for
indoor
or
outdoor duty
Equipment
with
hot
surfaces SP- Sa 2 1/2
(temp. 200 deg C
and above)
P3
2F3
205
(260)
100
8.0
Colour code
For painting certain standard colour as listed below, shall be used by the bidder.
8.1
For electrical equipment
DESCRIPTION
COLOUR
11 kV, AC machine
3.3 kV, AC machine
400 V, AC machine
460 V, DC machine
250 V, DC machine
230 V, AC equipment
110 V, AC equipment
All indoor control and switchgear panels
Light grey
Post office red
Brilliant green
Azure blue
Oriental blue
Light orange
Canary yellow
Grey
SHADE
IS:5
631
538
221
104
174
557
309
697
AS
Page 6 of 55
All outdoor transformers, switchgear, control Dark admiralty

632
panel etc.
grey
Instrumentation panels
Opaline green
275
Telecommunication panels
Smoke grey
692
8.2
For mechanical equipment

-Indoor
Indoor and outdoor mechanical equipment excepting cranes : Grey.
8.3
For pipes, ducts, conduits and others

Service
River water (untreated)
Cooling Water
Boiler feed water
Condensate
Drinking water
Industrial water
Hydraulic power water
Compressed air
Instrument air
Vacuum
Steam below 3.5 kg/cm2 (g)
3.5-20 kg/cm2 (g)
21-40 kg/cm2 (g)

Above 40 kg/cm2 (g)
Drainage
Lubricating oil
Hydraulic oil
Colour
Base - Sea green
Band - White
Base - Sea green
Band - French blue
Base - Sea green
Base - Sea green
Band - Light brown
Base - Sea green
First band - French blue Second
band - Signal red
Base - Sea green
Band - Light orange
Base - Sea green
Band - Black
Base - Sky blue
Base - Sky blue
Band - Light brown
Base - Sky blue
Band - Black
Base - Silver grey if Bitulac or AlAl
jacket
Band - Brilliant green
Base - Silver grey if Bitulac or AlAl
jacket
Band - French blue
Base - Al-jacket
Band - Dark violet
Base - Al-jacket
Band - Signal red
Base - Black
Base - Light brown
Band - Light grey
Base- Light brown
Shade as IS:5
217
217
166
217
217
410
217
166
537
217
557
217
101
101
410
101
628
221
628
166
796
537
410
631
410
Page 7 of 55
Transformer oil
Fuel oil
Coke oven/coal gas/other fuel gases
Freon (chlorofluore
methane and ethane)
derivative
Argon
Acetylene
LP gas
Nitrogen
Oxygen
Regenerated acid (dilute) (1)
Hydrochloric acid (conc.) (1)
Spent liquor
Wash liquor
Dilute acidic liquor
Hydrofluoric acid (conc.) (1)

Acidic slurries
Alkalis
Non-acidic slurries
Fire fighting system
Rain water down pipes
Band - Dark violet

Base - Light brown
Band - Light orange
Base - Light brown
Band - Signal red
Base - Canary yellow
Band - Signal red
of Base - Canary yellow
Band - Light grey
Band - French blue
Band - Dark violet
First band - Signal red
Second band - Traffic green
Band - Black
Band - White
Base - Dark violet
Band - Light brown
Band - Dark violet
First band - Light brown Second
band - Light brown
Base - Dark violet
First band - Light brown
Second band - Light brown
Base - Dark violet
Band - Light grey
Base - Dark violet
First band - Light grey
Second band - Brilliant green
Base - Dark violet
Band - Silver grey
Base - Dark violet
Band - White
Base - Dark violet
Band - Deep buff
Base - Sea green
Band - White
Base - Signal red
Base - Sea green
Band - Sky blue
796
410
557
410
537
309
537
309
631
309
166
309
796
309
537
267
309
309
796
410
796
410
410
796
631
410
796
631
796
631
221
796
628
796
796
360
217
537
217
101
Page 8 of 55
Duct work
Lighting conduits
Instrument conduits
Power conduits
Base - Aluminium
Base - Black
Band- Yellow
Base - Black
Band - Red
Base - Black
309
537
Page 9 of 55
LIST OF MANDATORY SPARES

A.
1.0
MECHANICAL
Belt Conveyor
Sl.No.
QTY.
2.
3.
4.
5.
6.
DESCRIPTION
Pulleys
-Driving Pulley
-Non-Driving
Driving Pulley
Idlers
Input shaft assembly (only pinion & input shaft)
1st Reduction Gear
Oil seal
Coupling
7.
Hold back
1 no. each type
8.
Safety devices
- Pull chord switches
- Belt sway switches
- Zero speed switches
5% of total quantity
1.
2.0
1 no. of each size & type

1 no. each type
1 no. each type
2 nos. each type
1 no. each type
Actuator operated flap gate

SL. NO.
1.
2.
3.
4.
5.
6.
3.0
1 no. of each size & type.
DESCRIPTION
Plummer box
Self aligning ball bearing
Gaskets
Limit Switch
Sealing
Oil Seal
QTY.
1 set.
1 set.
1 set.
1 set.
1 set.
1 set.
Side Arm Charger

SL. NO. DESCRIPTION
1.
Gear box spares (complete gear box assy., oil seal and
bearing)
2.
Carriage wheels a) Bearings b) Oil Seals c) Plummer
block d) Carriage wheel fitted with shaft (without
Plummer Block)
3.
Coupling
4.
Travel wheel assembly
5.
Bearing
6.
Motor including slip ring motor, Bearings and Oil seal
QTY.
1 set.
a)1 set. b) 2 sets
c) 1 set d) 1set
1 set.
1 No.
1 set.
1 set.each of
type and size
Page 10 of 55
7.
8.
9.
Brakes complete assembly with lining and springs

1 set.
Couplings with complete assembly, pins, bushes, and 1 set.
nuts
Hydraulic power Pack with all accessories
1 set.
Wagon Tippler and Accessories
3.0
SL. DESCRIPTION
QTY.
NO.
1.
Speed Reducers (a)complete gear box assy., (b)oil seal and a)1 set. b) 4 sets
(c) bearing)
c) 2 set of each type and
rating
2.
Motor a) Motor including slip ring motor, b)Bearings c) Oil a)1 set. b) 1 sets
seal
c) 1 set of each type and
rating
3.
Brakes a) Complete assembly b) Linings and springs
1 set. of each type and rating
4.
Couplings with complete assembly, pins, bushes, and nuts
1 set. each type and
rating/sise
5.
a) Thyristor /VVVF cards/ Modules
a) 1 No. of each type. B) 2
b) Relays
No. of each type and rating
6
5.0
(a) Hydraulic Pump with electric motor, coupling, valves

(mounted on pump) etc:
(b) Hydraulic Motor
(c) Valves
(d) O.P. Coolers
(e) Filter Elements
(f)Pressure Switch
(g)Temperature Switch
Bearings (not covered separately)
1 Set of each type and size
1 No. of each type and size

1 No.
10 Nos. of each type
1 No. of each type
1 No. of each type
7
1 Set of each
type and size
8
Limit Switches
2 Nos. of each type.
9
Cylinder Manifold block with all valves mounted on it
1 Set
10
Hydraulic cylinder with piston
11
Seals of hydraulic cylinder and pumps etc.
2 Sets of each type
12
Hydraulic hoses
2 sets
13
Gear box total
1 set
14
Gear flexible coupling
1set
15
Rod end bearings with housing
1 set for all four clamps
16
Pressure Switches, Common manifold block complete with 1 no. each
all valves mounted on it, Main Pivot bearing,
17
Pinion support & bearing
1 No each type
18
Pinion
2 nos
19
Latch (Pinion & rack segment locking device)
1 No.
20
Chain & Sprocket
1 set
Apron Feeder
Page 11 of 55
SL. NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
14
15
16
17
6.0
QTY.
1 No.
1 No.
1 No. of each type and size & direction.
20% of population
20% of population
20% of population
2 Sets of each type and size
20% of each type and size
10%
1 set of each type and size
1 set
Electric Hoist
SL. NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
7.0
DESCRIPTION
Head Pulley complete with shaft
Tail pulley complete with shaft
Drive Motor
Gear Box
Complete internals of gear box
including input and output shafts
Reduction gears
Fluid coupling, flexible coupling etc.
Traction rollers
Carrying idlers
Return Rollers
Sprocket segments
Link Chain
Pans (flights)
Hydraulic cylinder
Seal kit of hydraulic cylinders
Plummer blocks
Bearings
DESCRIPTION
Ball bearing
Needle bearing with inner race
Bush bearing
Rope tightener
Rope guide
Rope sheave
Thrust bearing
Roller bearing with inner race
Brake lining
Limit switch complete
Rotor pinion
QTY.
1 set.
1 set.
1 set.
1 set.
1 set.
1 set.
1 set.
1 set.
1 set.
1 set.
1 set.
DESCRIPTION
Grooved sheave
Pinion
Bearing
QTY.
2 sets
1 set
1 set
Manual Hoist
SL. NO.
1.
2.
3.
Page 12 of 55
4.
B.
Shaft pin
1 set
ELECTRICAL
Sl. No.
MCC
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
DESCRIPTION
QUANTITY
14.
Busbar support insulators

Current transformers
Potential transformers 415/110V
Male contact of ACB (main and aux.)
Female contact of ACB (main and aux.)
Limit switch of ACB
Spring charging motor of ACB
Closing coil of ACB
Tripping coil of ACB
Breaker control switch
Relays
Auxiliary relay
Indicating Lamp assembly (LED LVGP
type)
Phase sequence meter
10 Nos. of each type / MCC

1No. of each type & rating / MCC
1 No. / MCC
1 set /MCC
1 set / MCC
3 Nos. /MCC
3 Nos. /MCC
2 Nos. /MCC
2 Nos. /MCC
2 Nos. /MCC
1No. of each type/ MCC
2 Nos. of each type / MCC
10 Nos. of each type & colour
/MCC
2 Nos.
Sl. No.
1.
DESCRIPTION
Lightning arrester
2.
Isolator with earth heel
3.
Relays
QUANTITY
1 set each at receiving and WT
substation
1 set each at receiving and WT
substation
1No. of each at receiving and WT
substation
1.
2.
3.
4.
5.
6.
7.
Bearing (drive end)

Bearing (Non-drive
(Non
end)
End shield (DE and NDE)
Cooling fan of motors
Fan cover
Bearing puller
Grease gun
33 KV SYSTEMS
MOTORS
1 No. of each type

1 No. of each type
1 set of each type
1 No. of each type
1 No. of each type
1 Nos. of each type
2 Nos.
Page 13 of 55
PDB/LDB/SLDB/AUX. PDB
1.
2.
3.
4.
5.
Bus bar support insulators

MCCB
MCB
Breaker control switch
Control switch
3 Nos. of each type / DB

2 Nos. of each rating/DB
2 Nos. of each rating/DB
2 Nos. /DB
2 Nos. of each type/DB
1.
2.
3.
4.
HV bushing (1 set = 3 nos.)

LV bushing (1 set = 3 nos.)
Temp. scanner
Neutral bushing CT
1 set
1 set
1 no.
1 no. of each type/ ratio
1.
2.
3.
Thyristor fuse
Electronic logic card for UPS
Electronic logic card for PLC
1 no. of each rating

1 no. of each type
1 no. of each type
LT TRANSFORMER
UPS/PLC
CONTROL DESK/ AMMETER CONTROL PANEL

1.
2.
3.
4.
Ammeter
Indicator Lamp Assembly
Control switch
Push button
1 No. of each range

5 sets
1 no. of each type
1 no. of each type
1.
2.
3.
4.
Lamps
Fittings
Control gear complete
Timer
4 Nos. of each type

2 Sets of each type
2 Sets of each type
1 No.
ILLUMINATION
C.
VENTILATION, AIRCONDITIONING & DRY FOG DUST SUPPRESSION SYSTEM

SYSTEM / EQUIPMENT
DESCRIPTION
Air Washing type Ventilation Systems.
Centrifugal Fans & Filters
V -Belt
Bearings
Flexible
Connection Filter element
Water Pump
Impeller
QUANTITY
1 set of each type
1 set of each type
1 set of each type
20% of requirement
1 set of each type
Page 14 of 55
Coupling
1 set of each type
Bearings
1 set of each type
2 sets of each type
Gland Packing
Nozzles
Nozzles
10% of requirement
Valves
Valves
1 set of each type
Exhaust Fans
Bearings
1 set of each type
Dry Fog & Plain Water Sprinkling type Dust Suppression Systems
Water Pump
Impeller
1 set of each type
Coupling
1 set of each type
1 set of each type
Bearings
2 sets of each type
Gland Packing
Nozzles
Nozzles
10% of requirement 20%
Nozzle tips
of requirement
Sprinklers
Nozzles
10% of requirement
Solenoid Valves
Solenoid Valves
10% of requirement
Pressure gauges
Pressure Gauges
1 set of each type
Sensors and Instruments
Sensors & Instruments
1 set of each type
Valves
Valves
1 set of each type
Pressure Regulating Units PRU
1 set of each type
(PRU)
Flow Activation Station FAS
1 set of each type
(FAS)
Compressor
Bearings
1 set of each type
Couplings / V Belts
1 set of each type
1 set of each type
Pulleys
1 set of each type
Filters
1 set of each type
Gaskets / O Rings
1 set of each type
Valves /Safety valves
1 set of each type
Piston rings
Page 15 of 55
INFORMATIONS TO BE FURNISHED BY THE BIDDER

Check List for Bid submission
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17
2.0
All drawings and documents duly signed as per TS submitted along

with Bid
Clause wise list of deviations from TS furnished
Time bar chart and level of PERT network furnished as per the TS
Separate price bid submitted
Necessary particulars to establish the possession of technical knowknow
how and facilities available furnished as per TS
Reference list for supply of similar equipment along with users
certificate furnished as per the TS
Write up of testing facilities available at works furnished as per the TS
Brief scope of collaboration for collaboration agreement furnished as
per the TS
Clause wise list of deviations / exclusions furnished as per the TS
Delivery schedule indicated as per TS
Bought out items conforms to TS
Location and size of MCC & control room indicated
List of tools furnished as per TS
List of commissioning spares furnished as per TS
List of spares for two years operation along with item wise price
furnished as per TS
List of insurance spares with price furnished as per TS
Erection plans furnished as per TS
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
- Yes/ No
Questionnaire
The Bidder shall fill in this questionnaire and submit in hard as well as a soft copy with their
Bid. This data shall form a part of the contract with successful Bidder.
2.1
General
1.
2.
3.
4.
5.
6.
Name and address of the Bidder

Previous experience of the Bidder
List of similar equipment supplied
Whether the Bidder has any technical collaboration with any other
company / organization for his equipment
If answer to question 4.0 is yes, furnish the following details.
a) Name and address of the collaborator
b) Nature of the collaboration in detail
c) Previous experience of the collaborator
List of drawings literatures enclosed with the offer
Page 16 of 55
Is it the Bidder's intention, if awarded the contract, to comply fully in

all respects with owners specifications covering the work? If not, he
shall state specific exception in details
A. WAGON TIPPLER
GENARAL
Type:
Designed capacity
Guaranteed capacity
Make:
Capacity:
Angle of tipping:
Drive:
Tippler drive:
Side arm charger:
Indexer:
Clamping:
Wt. of the machine
Tippling time cycle:
Rail Gauge:
Drive Rack Assembly
Spherical roller bearing SKF NO.24168
ECACK30/W33/Equivalent.
CLAMP CYLINDER
Bore
Rod
Stroke
Tippler Ballast-25T
25T at each end frame Made
from concrete with steel scrap
DRIVE PINION
P.C.D
Face width
No.of teeth
Pressure angle
Material
CYLINDER FOR INHAUL CLICKING STOP
Bore
Rod
Stroke
Page 17 of 55
HYD.POWER PACK DETAILS FOR WT

Type
Oil pump proportional control of capacity
Tank capacity
Electric motor for WT main drive
Electric motor for WT clamp
Cooling
HYDRAULIC MOTOR DATA FOR WAGON
TIPPLER
Type
Model
Displacement
Speed
Details of Motor
Pressure (Max)
Torque theoritical
Power theoritical (Max)
Speed (Max)
HYDRAULIC CYLINDER DATA FOR WAGON
TIPPLER
Bore
Rod
Stroke
SIZE OF WAGON TO BE HANDLED
Length
Width
Height
B.
APRON FEEDER:
GENERAL
Make:
Capacity:
Pan width:
Length:
Motor
DRIBBLE CONV.
GENERAL
Conv.Belt
Belt width
Belt length
Page 18 of 55
C.
WEIGHBRIDGE
GENERAL
Make
Quantity required
Carrying capacity /strength
Weighing capacity
Type
Platform size
Mounting
Resolution
Taring facility
Auto tare
Purpose
Cycle of weighment
Duty
Power supply required
Operating temp.range
Platform size
Material of construction
Load cell
Load cell capacity
D.
SPECIFICATION OF LOAD CELL

GENERAL
Characterstic
Make
Type
No.of loadcells
Capacity of each loadcell
Rated output
Combined error
Repeatability
CREEP ON LOAD (30min)
Zero balance voltage
Input resistance
Output resistance
Compensated temp.range
Operating temp.range
Temp.effect on span
Temp.effect on tare
Specification
Page 19 of 55
Excitation voltage
Safe overload
Ultimate overload
Insulation resistance
Protection
Cable
E.
F.
CONTROLLER
GENERAL
CHARACTERISTIC
Model no.
Type
Power supply
Operating temperature
Range
Resolution
Non - linearity
Repeatability
Excitaton to transducer
Display
Input
Output
Programmable parameters
Casing dimension
SPECIFICATION
SIDE ARM CHARGER

Type of side arm charger (sac)
Sac pulling capacity
SAC total travel
Max.wagon size that sac can handle
Type of luffing system for sac
Track gauge
Operating speed of sac in m/s
Forward with single wagon
Return
Type of power supply system for sac
Support roller wheel
Guide roller wheel
Feston support post
Electric motor for sac
Cooling
DRIVE PINION
P.C.D
Face width
Page 20 of 55
No.of teeth
Pressure angle
Material
RACK FOR SAC TRAVEL
Total nos
Pitch
Pressure angle
Teeth per rack
Material
HYD.POWER PACK DETAILS FOR SAC
TYPE
Tank capacity
Electric motor for SAC
Cooling
HYD.MOTOR DETAILS FOR SAC
Hyd.motor double displacement type
Motor model:
Displacement:
Details of Motor
Pressure (Max)
Torque theoritical
Power
Speed (Max)
SAC RAISE & LOWER CYLINDER
Bore
Rod
Stroke
SAC UNCOUPLING CYLINDER
Bore
Rod
Stroke
SAC DELATCH CYLINDER
Bore
Rod
Stroke
G.
INDEXER
Type of side arm charger (sac)
Max.rake (Train) size that Indexer can handle
Type of luffing system for Indexer
Track gauge
Page 21 of 55
No.of wagon handled by Indexer

Operating speed of Indexer in m/s
Forward with rake
Return
Type of power supply system for Indexer
Fixed support roller wheel
Guide roller wheel
Sprung support roller assembly
Feston support post
Indexer normal travel
DRIVE PINION
P.C.D
Face width
No.of teeth
Pressure angle
Material
RACK FOR INDEXER TRAVEL
Total nos
Pitch
Pressure angle
Teeth per rack
Material
HYD.POWER PACK DETAILS FOR INDEXER
TYPE
Electric motor for Indexer
Cooling
HYD.MOTOR DETAILS FOR INDEXER
Hyd.motor double displacement type
Motor model:
Displacement:
Details of Motor
Wt
Pressure (Max)
Torque theoritical
Power theoritical (Max)
Speed (Max)
INDEXER ARM RISER CYLINDER
Bore
Rod
Stroke
INDEXER UNCOUPLING CYLINDER
Page 22 of 55
Bore
Rod
Stroke
2.2
BELT CONVEYORS
Sl. No
1
2
3
4
5
6
7
10
11
Description
Belt Conveyor System
Conveyor capacity, Mt/h
a) Rated (guaranteed)
b) Design
Belt width, mm
Belt speed, m/sec
Length, centre to centre, m
Lift, m
Max. angle of inclination, degree
Radius of curvature for :
a) Concave
b) Convex
Details of take-up
i) Type of take-up
a) For Boom conveyor of stacker / reclaimer
b) For Intermediate Conveyor of stacker
c) For all other conveyors
Belting
i) Type of fabric
ii) Cover grade
iii) Cover thickness, mm
- Face cover, mm
- Back cover, mm
iv) No. of plies
v) Troughing angle
vi) Factor of safety
vii) Normal working tension
viii) Type of belt joint
i) Idler type:
a) Carrying (except in case of reversible conveyor)
b) Return
c) At loading point
ii) Idler Spacing
a) Carrying
b) Return
c) At loading point
d) Self aligning (carrying side)
e) Self aligning (return side)
Pulleys :
i) Minimum shell thickness
ii) End disc thickness
Page 23 of 55
12
13
14
15
16
17
18
19
20
21
22
23
iii) Shaft deflection at hub

iv) Lagging thickness
v) Lagging
vi) Pulley Material (For ILMS conveyor)
vii) Shaft material
Drive Pulleys
i) Lagging
ii) Diamond pattern groove
iii) Minimum angle of wrap
iv) Maxm. out of roundness
Rubber for pulley lagging
i) Type
ii) Shore Hardness
iii) Elongation
iv) Strength
v) Abrasion loss
vi) Specific gravity
vii) Adhesion Strength
Emergency Stop Switch & Belt Sway Switch System
i) Spacing (Emergency stop)
ii) Spacing (Belt Sway Switch)
iii) Degree of protection
Zero Speed Switch
i) Type
ii) Mounting location
Conveyor Gallery
a) Walkways width
b) Side windows in staggered fashion
i) Spacing (c/c)
ii) Size
Deck plates
a) Material
b) Thickness, mm
Seal plates
a) Material
b) Thickness
Stone picking arrangement
Chute Jamming Detector
(a) Type
(b) Degree of Protection
Reduction gears
a) Type
b) Size
Fluid Couplings
a) Type
b) Rating, kW
Brakes
Page 24 of 55
a) Type
b) Rating
c) Protection
Flexible couplings
a) Type
b) Rating
Drive motors
a) Type
b) Make
c) Insulation class
d) Motor nameplate rating, kW at 500 C ambient
e) Protection Class
24
25
2.3
CHUTES, HOPPERS,SKIRT BOARD

Sl. No
1
2
3
2.4
Description
Chutes & hoppers construction
Minimum valley angle (from the horizontal), degree
Material & Plate thickness
a) Sliding zones and adjacent sides
b) Non striking/ non sliding zones
c) Chute with valley angle 80 and above
d) In the zone of magnetic field of ILMS
e) In the zone of flap gates
f) Discharge Hoods over head pulleys
g) Location of Inspection door/sealing
Skirt board
a) Plate thickness, mm
b) Length of each skirt board, m
c) Height, mm
d) Width, mm
e) Top cover plate thickness , mm
ACTUACTOR OPERATED FLAP GATE

Sl. No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Description
Make
Dimensions
Material of construction of the gate
Liner plate specification
Method of fixing of liner plates
Type and make of drive and rating
Capacity and designation of the equipment
Total weight and weight of individual parts
Type of actuator and thrust in kg of each actuator
Stroke in mm of each actuator
Velocity mm per of each actuator
Motor: Type, rating, power supply, class of duty, insulation, make
number of starts/ hours
Page 25 of 55
13.
14
15.
2.5
Make, ratings, type of limit switches

Effort required for manual operator, kgf
Type of limit switches
ELECTRIC HOISTS
Sl. No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Description
Location
Capacity
Duty classification as per IS:3938-1983
IS:3938
Total weight of hoist including electrical equipment
Make of hoist block
Speeds with safe working load
Lifting height
a) Above floor level
b) Below floor level
Wire ropes
a) Type of construction
b) Size
c) Number of falls
d) Factor of safety
Rope drum
a) Materials
b) Diameter
Drives
a) Type & material of gear box
b) Gear & pinion
c) Material & hardness
Motors
a) Type & number
b) Kw rating
c) Synchronous speed
d) Class of insulation
e) Pull out torque
f) Frame size
Brakes
a) Type
b) size
c) Torque rating
Type & details of limit switches
Type of couplings
Type of bearings
Lifting hook
a) Type
b) Material
Type & details of control
Trolley Speed with safe working load
Wheels
Page 26 of 55
20.
21
22.
23.
24.
25.
26.
27.
28.
29.
30.
2.6
a) Numbers
b) Diameter
d) Max. wheel load
e) Wheel base
Drive
a) Type & material of gear box
b) Gears & pinions
d) Kw rating
e) Synchronous speed
f) Class of insulation
g) Pull out torque
h) Frame size
Brakes
a) Type
b) Size
c) Torque rating
Type & details of limit switches
Type of coupling
Type of bearings
Type & details of controls
Clearance diagram indicating the basic dimensions
Type & lubrication provided
Type & size of cables
Location & control details of hoist block power feeding
Any other information
EOT CRANE
Sl. No.
Description
(a)
During participation in technical Bid:
1.0
2.0
3.0
G.A. Drawing. VENDER TO CONFIRM

Wheel Load Diagram (Wheel Distance & Wheel Load).
Sketches showing full details of cranes with dimensions/ end clearances
(between centre of LT rails to column face of building), overhead clearance
from LT rails, hook approach limits, lift
lift height, Details of Web thickness baffle
plates, Stiffeners ,of Girder section , End carriage (Boggies) Trolley Section etc.
Vendor to submit appropriate Q.A. Plan.
4.0
(b)
1.0
After Receipt of Order:

Calculation for Box Girder, End Carriage structural plates/ Web / Stiffener
plate, Wheel Load calculation & Calculation for selection of Diameter of
Wheel, Motor, Gearbox and Brake etc. 3 - sets of followings documents like
G. A Drawings, Structural drawings
drawin like End-carriage,
carriage, Box Girder, Assembly
Drawings/ Sub-- assembly Drawings, Gear Box Drawings (specially of Typical
Gears having Helix Angle, Pressure Angles, Modules etc.) ,Bracket/ Current
Collector System, Hook Block, LT & CT wheel, Main Hook assembly LT
machinery, Hoisting machinery, Electrical Drawings comprising Power ,
Page 27 of 55
(c)
1.0
2.0
3.0
4.0
5.0
6.0
2.7
MANUAL HOISTS
Sl. No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
11.
12.
13.
3.0
Control Circuits , Electronic Circuitry diagram for RRC etc. No fabrication /

purchase of BO. Items should be taken up before the approval of the
drawings.
With the supply of crane:
c
Operating manuals of Crane - 3 Sets.
Detailed Maintenance manual of Crane. SparesSpares part list / concerned drawing
of the spares -3
3 Sets.
Maintenance, Interface & commissioning manuals for Controller & drives - 2
Sets along with drive parameterisation software.
Catalogues, O&M Manuals of all bought out items including drawings,
wherever applicable.
Detailed specification of all rubber items like OilOil Seals / O- Rings etc.
One Soft copy for the above requisites shall also be supplied in CD.
Description
Name of the manufacturer, type & model no
Numbers offered & their location
Safe working load for each hoist (in tones)
Duty class as per IS:3832-1983
IS:3832
Head room, mm
Lift, mm
Minimum radius of curvature of which this hoist can negotiate (mm)
Weight of each hoist
Specification of each chain
Tools & tackles included in offer
Commissioning spares & 2 years
Operating spares included in offer
Any other information
DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE BIDDER

Drawings /Data along with the Bid
1) Schematic drawings showing flow of materials.
2) Layout drawings of Additional Coal Storage and Handling System showing clearly the Major
Equipment, Junction Houses, Conveyor Galleries, Approach Road, Rail Track for Yard
Equipment, Yard Drainage Scheme etc.
3) General Arrangement Drawing of Additional Coal Storage and Handling System showing
clearly the Major Equipment, Junction Houses, Conveyor Galleries, Belt Conveyor with drive,
tail and take up arrangement, hoisting & handling facilities envisaged for maintenance of
equipment.
tional Coal Storage Yard showing the coal stock pile, yard equipment,
4) Cross Section of Additional
track rail for stacker and reclaimer, yard drainage system etc.
Page 28 of 55
5) General Arrangement of Major Equipment showing plan, elevation, cross sections along with
mounting details, with broad dimensions
d
and technical parameters.
6) Basic calculation substantiating selection of all major equipment, motors, gear boxes,
couplings, brakes etc.
7) Equipment wise List of commissioning spares and consumables with item wise description and
quantity included
d in the main offer.
8) Equipment wise list of 2 years operational spares (un-priced).
(un priced). The list shall indicate description
and quantity for each item.
9) List of special tools and tackles
10) Details /drawings for Civil & Structural Engineering works.
11) Single line diagram of power distribution system.
12) Electrical schematic diagrams
13) Cable specifications, cables schedule and cable layout drawings.
14) Any other structural / mechanical / electrical etc. drawings / data mentioned elsewhere in
the technical specification as well as considered necessary by the Purchaser/ Consultants.
15) List of exclusion, if any from Bidders Scope of Work.
16) List of deviations from technical specification.
4.0
4.1
ELECTRICS
DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE TENDERER
Drawings / Data / Documents along with the Bid
1.
Detailed scope of work with general description of the system & equipment offered
specifying the important features and detailed design criteria and design philosophy
including full details of reference data, assumptions, etc.
2.
Description to be accompanied by single line diagrams and equipment layout to enable

owner to have proper appreciation of equipment offered and its operation.
3.
-priced) in specified format, with division list of supplies from foreign

Bill of Quantities (un -priced)
and indigenous sources.
4.
List of specific exclusions, if any, from Bidders Scope of Work.
5.
List of deviations from technical specifications,
Page 29 of 55
6.
Equipment wise List of commissioning spares and consumables with item wise
description and quantity included in the main offer.
7.
List of 2 years operation spares, equipment wise (un-priced).

(un priced). The list shall indicate
description and quantity for each item.
8.
List of special tools and tackles
9.
Work Schedule with bar chart indicating all activities for electrics.
wise construction power requirements for erection / testing activities.

10. Phase-wise
filled
11. Questionnaire as asked, duly filled-in.
12. Reference list of similar jobs carried out
13. Dimensional details & weights of each equipment offered (tentative)
Technical Data to be submitted with the Bid.
4.2
1.
Name and capacity of MCC considered
2.
List of LT drives of each MCC along with single line diagrams
3.
Connected load and Maximum demand of each section of 33 kV switchboard/ 415 V PCC
4.
Connected load and Maximum demand of each section of MCC.
5.
List of motors with ratings ( working+

working+ standby) 6. List of performance tests proposed by
the tenderer to demonstrate the guaranteed parameters for the electrical equipments. 7.
Specific energy consumption, maximum demand and annual energy consumption. 8.
Type test certificates for major categories
categories of equipment, issued by independent testing
authority. 9. Technical catalogues of major equipment offered. 10. Services to be
provided by owner at battery limit with specification 11. Single Line Diagram of each
MCC/ DB 12. Capacity of UPS for stacker
stacker & reclaimer 13. Capacity of PLC for stacker &
reclaimer 14. Size of HT/LT trailing cables considered 15. Rating of 33 kV on load isolators
considered
TECHNICAL PARTICULARS TO BE SUBMITTED BY THE BIDDER ALONG WITH THE BID

GENERAL
data asked under this section shall be furnished by the tenderer along with
The information /data
the offer. In the event of the contract being awarded , the data/technical particulars furnished
here under and accepted by the owner shall be deemed to form a part of the contract.
contract
Design Considerations
1. List of Drives/ Mechanism with kW Rating
:
:
Page 30 of 55
2. Aux. Power Consumption
Spares and tools & tackles

1 .List of commissioning spares
2. List of mandatory spares
3. List of special tools and tackles
: List to be submitted
Summary Of Technical Parameters Of Major Electrical Equipment

Sl.
Equipment
Make & type Total
Dimension Rating
as Guaranteed
No.
Description
/ Country of Weight
per design Tech Data
manufacture
condition of
& Qty
Tender
MOTOR
1. Make, type & applicable standard
2. Furnish following for all drives
Sl. No
Application
Working
/Standby
Rated Parameters
kW
Voltage
MCC
1. Make, Type & Applicable Standard
2. Rated Voltage, current & Frequency
4. Bus bar material & type of sleeving
5. Protection class
Components of MCC
1 Air Circuit Breaker
2. MCCB
3. AC Contactor
4. DC Contractor
5. Thermal Relay
6. Control Devices
7. Meters
Speed
Enclosure
Qty
:
:
:
:
:
Make & Type
:
:
:
:
:
:
:
Page 31 of 55
MCC WISE DATA

Sl.
MCC
No Designation
Rating of Single
Volt,
Front/
Amps
Double
Front
No. of Connected Max.

No. of Overall
bus
load
per load
d per panels dimensi
section
ons
sections section
RELAYS
1.
2.
3.
4.
Make
Type
Draw out type with built in test facility
Relay details
1.
2.
3.
4.
Make
Type
Reference standard
Size
METERS
CURRENT TRANSFORMER
1.
Make, type & applicable standard
2.
Ratio & accuracy class: metering/protection
3.
Rated voltage short time rating
POTENTIAL TRANSFORMER
1.
2.
3.
4.
5.
Type
Primary/secondary voltage ratio
Method of connection
Rated voltage factor
Class of insulation
PDB/LDB/SLDB/AUX. PDB (SEPARATELY FOR EACH DB)

1.
2.
3.
4.
5.
Make, Type & Applicable Standard

Rated Voltage, current & Frequency
Short time rating
Bus bar material & type of sleeving
Protection class
Page 32 of 55
Components of DB
1.
2.
3.
4.
5.
6.
Breaker
MCCB/MCB
AC Contactor
Thermal Relay
Control Devices
Meters
DB-WISE DATA
Sl.
No
DB
Designation
Rating
of
Volt,
Amps
Single
No.of
Front / bus
Double sections
Front
Connected Max.
load
per load
per
section
section
No. of Overall
panels dimensions
TRANSDUCER (For each type)

1.
2.
3.
4.
5.
6.
Make
Output range
Accuracy
Maximum burden on CT/PT
Nominal input/rated I/V
Overload capacity without loss in accuracy
LIGHTNING PROTECTION
1.
2.
3.
4.
5.
6.
Whether lightning conductors have been

envisaged for the lightning protection
Angle of protection
Whether building is also protected
Number of electrodes provided
Earthing resistance value
Size of down conductors
: Places to be indicated
:
: Yes/No
:
:
:
EARTHING
1.
2.
3.
Material and size of earth strip for the

various places
Size of main outer strip
Galvanising content on GI strip
:
:
:
Page 33 of 55
4.
5.
6.
Value of earthing resistance

(proposed to be achieved)
Type & size of electrodes
Construction of earthing mat, etc as per TS
:
:
: Included
UPS SYSTEM
1. Make of the system
2. Capacity in kVA
3. Battery back up time
4. Make & type of battery
5. Number of cells per battery
6. Overall dimension(L x B x H) mm of battery
7. Ventilation requirements
8. Make, Rating & type of charger
9. Make, Rating & type of rectifier transformer
10. Make & current rating of SCR & Diode
11. Make & rating of inverter
12. Make & type of static transfer switch
13. Make & rating of manual bypass switch
TRANSFORMER
1. Name of manufacturer
2. Service-whether
whether indoor or outdoor
3. Type of cooling
4. Rating
a. Rated KVA
b. Rated current, amp (rms), HV/LV
c. Rated voltage, kV (HV/LV)
5. Temperature rise above 500C ambient
a. In oil by thermometer, 0C
b. In winding by resistance, 0C
c. Hot spot temperature in winding limited to, 0C
6. Insulation class
7. Vector group
8. Type of tap changer with capacity/steps/range
9. Tapping provided on HV side?
10. Losses
load loss at rated voltage and frequency
a. No-load
b. Load loss at rated load
c. Cooler loss
11. Impedance at rated current frequency
12. Reactance at rated current and frequency, %
13. Efficiency at 0.80 p.f lag % at 100%/75%/50% load
14. Load/p.f. at which max. efficiency occurs, % full load
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
: Yes/No
:
:
:
:
:
:
:
Page 34 of 55
15. Maximum efficiency, %

:
16. Minimum clearances in mm
HV
LV
a. Between phases
:
b. Between phase and ground
:
17. Withstand time without injury for 3 ph short circuit, sec :
18. Insulation strength
:
a. one minute power frequency test KV rms
b. Impulse withstand voltage, KV
:
19. Tap changer provided with
i. Tap position indicators ?
: Yes/No
ii. Operation counter ?
: Yes/No
iii. Padlocking provisions ?
: Yes/No
20. Details of tank
:
i. Material
ii. Maximum internal withstand pressure of tank kg/cm2:
21. Enclosure details (for dry type transformer)
i. Material
:
ii. Thickness
:
iii. Degree of protection
:
22. Details of core material
:
23. Insulation material
:
24. Details of bushings
HV
LV
LV- Neutral
a. Make
:
b. Type
:
c. Voltage class, KV
:
25. Insulating oil
a. Approx volume of oil, liter
:
b. Whether first filling of oil with 10% excess included ? :
c. Oil conforms to IS:335
:335 ?
:
26. Marshalling Box
a. Weatherproof, suitable for outdoor for oil filled type ?: Yes/No
b. Degree of protection
:
27. Each transformer with fittings andaccessories : Yes/No
28. Approximate overall dimensions, (LxBxH) mm :
29. Approximate weights, Kg
:
a. Core and coil
:
b. Tank and fittings
:
c. Oil
:
d. Total weight
:
30. List of special maintenance tools and accessories : Furnished
Neutral CT of transformers (for each type)
cable standard
1. Make, type & applicable
2. Ratio & accuracy class: metering/protection
3. Rated voltage short time rating
:
:
:
Page 35 of 55
LIGHTING MAST
General
1. Make
2. Material of construction
3. Cross section of mast in polygon (No. of sides)
4. Thickness in mm (bottom/middle/top sections)
5. Length of individual sections (mm)
6. Base dia & top diameter (OAF)
7. Type of joints
8. Length of overlap (joint at site mast Section in mm):
9. Thickness of galvanization (minimum)
10. Size of opening door at base (mm)
11. Type of locking arrangement & door construction:
12. Weights in kgs of 30 mtrs high mast
13. Dynamic loading as prevailing actual at site
14. Maximum wind pressure (Basic wind speed)
15. Maximum gust speed
ed time
16. Factor of safety for wind load
17. Factor of safety for other loads
:
:
:
:
:
:
Lantern Carriage
1. Diameter of carriage ring (mm)
2. Load carrying capacity
3. Total weights of assembly with fittings
4. Number of fittings
:
:
:
:
Winch
1. Make of winch, number of drums per winch
2. Capacity
3. Operating speed
4. Method of operation
5. Tested load per drum (kg)
Wire Rope
1. Grade
2. Number of ropes/thickness
3. Construction
4. Breaking load capacity
5. Factor safety
Cable
1. Type
2. Make
3. Current carrying capacity
4. Cable size
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Page 36 of 55
5.0
5.2
Power Supply arrangement

1. Input supply
:
2. KW rating of motor
:
3. Speed of motor
:
4. Reversible / Non reversible
:
5. Remote control switch type
:
6. Lifting capacity of torque Limiter
:
Ventilation, Air Conditioning and Dust Suppression System.
5.1
Bidders shall furnish all information as stipulated in relevant chapter. Bidders shall
also furnish the following information:
a)
Process flow, process instrumentation and control diagram and water and
compressed air balance diagrams.
b)
Dimensioned general arrangement and relevant cross sectional drawings of the

pump house, compressed air
air station etc. with specification and bill of material.
c)
Dimensioned general arrangement drawings of all equipment.
d)
All relevant basic design calculations supporting the selection of equipment, location
of valves, specials and supports along with forces and moments of fixed support.
Ducting including Supply Air Diffusers with Volume Control Dampers

a) Duct : Material, thickness & quantity
b) Damper: material, thickness, size, quantity
c) Supply Air Diffuser: material, thickness, size, quantity
5.3
Ventilation Systems
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Type of ventilation system

Capacity of each ventilation system
Make of equipment
Design heat load for each premise
Indoor climatic condition to be maintained
Power requirement of each system
Air change/hr
Any specific design consideration
Noise level at 1 m distance from the ventilation equipment
Noise level at served premises
Page 37 of 55
5.4
Centrifugal Fan
a) Make & Model No
b) Quantity, no.
c) Type of blade
d) Capacity, m3/h
e) Total pressure, mm WC
f) Speed, rpm
g) Shaft power, KW
h) Total Efficiency, %
i) Motor rating, KW/ pole
j) Fan Characteristic Curve
k) Impeller Diameter, mm
l) Velocity at inlet & outlet of fan, m/sec m
m) Weight of fan and motor, kg
n) Coupling details
o) Vibration isolator type & quantity
p) Thickness of scroll, blade, Back plate, shaft mm
q) Noise level at 1m distance
r) Overall size
s) Drive Motor rating suggested
5.5
Fan Drive Motor Details

a) Type & make
b) Voltage, phase & frequency
c) Rated power
d) Speed
e) Starting/ pull out torque
f) Line current
g) Starting current
h) Overall efficiency
i) Class of insulation
j) Type of enclosure
k) Any other information
5.6
Exhaust fan
a) Make & Model
b) Capacity in m3/h.
c) Total Pressure, mm WC
d) Material of construction and its thickness
e) Speed in rpm.
f) Drive details.
g) Shaft Power consumption.
h) Wheel diameter
i) Efficiency
j) Static & Dynamic weight of fan & motor assembly
Page 38 of 55
k) Critical speed of fan

l) Noise level at 1m distance in dB(A
m) Performance curve. n
n) Air flow direction. o
o) Fixing details. p
p) Vibration level.
5.7
Dry Panel type filter

a) Make & Model
b) Capacity in m3/h
c) Pressure drop in mmWC. both in clean & in dirty condition
d) Effective cross sectional area in m2
e) Velocity through filter in m/sec.
f) Material of filtering panel.
g) Cleaning efficiency Vs particle size
h) Methods of surface regeneration.
i) Filter box construction details.
j) Overall dimensions & no. of filters.
k) Fixing frame details.
l) Total weight.
5.8
Air Washer Unit

a) Make & Model No.
b) Type of unit (Horizontal/vertical)
c) Overall dimensions (mm)
d) Weight (kg) with and without water Capacity in m3/h.
e) Total Pressure drop, kgf/ m2 g
f) Material, dia and nos. of nozzles
g) Make up water requirement
h) Details of makeup, overflow, drain, supply & return water pipe lines
i) Saturation efficiency
j) Amount of water and its pressure at the nozzle
k) Casing and tank thickness
l) Water tank capacity
5.9
Centrifugal Pump (indicate separately for ventilation and dust suppression)

a)
Make and model no.
b) Type of pump
c) Capacity in m3/hr.
d) Total head in m WC.
e)Quantity
f) Material of construction
g) Shaft
h) Impeller Casing
i) Pump speed (rpm)
Page 39 of 55
j) Shaft power
k) Drive details
a. Motor make
b. Motor KW
c. Insulation class
d. Frame size
l) Bearing type & make
m) Type of coupling
n) Vibration level
o) Noise level at 1 m distance from pump set
5.10 Dry Fog & Plain Water Sprinkling type Dust Suppression Systems
a) Technical details and quantity of main equipment including Nozzles, PRU, FAS and
Instrumentation for Auto Operation.
b) Technical details and quantity
quantity of auxiliary equipment including air compressors, pumps,
etc.
c) Technical details of circular swiveling sprinklers
d) Compressed air & water requirement, capacity of compressor, air receiver, capacity of
water pump unit etc.
e) Total power consumption. Capacity of each motor for pump and compressor.
f) Details of air & water pipelines with sizes and quantities.
g) Details of valves and fittings
h) Details of solenoid valves, sensors, pressure gauges and other instruments.
i) Details of tanks
j) Details of hood / skirt boards modification
k) Size of compressor cum pump house.
l) Size of only pump house (In case compressed air is not provided)
5.11 Split Air Conditioner
a) Make & Model
b) Quantity
c) Capacity in TR (Nominal / Actual
d) Air Flow m3/h
e) Flow direction and volume control grill
f)
Material of construction
g) Compressor type
h) Drive details and total power consumption
i)
Overall dimensions
j)
Refrigerant type
k) Filter efficiency
Page 40 of 55
l)
m)
n)
o)
p)
Weight of unit
Noise level at 1m distance in dB(A)
Fixing details.
Vibration level.
Accessories included
Drawings/documents for Fire Protection System
6.0
Drawings/documents to be furnished with offer

The tenderer shall submit the offer along with the following drawings / documents.
a)
Scope of work with general description of the system

system and equipment offered specifying the
important features. The tenderer has to give a confirmation with respect to the scope of
work as detailed in this specification excepting for the deviations, if any, to be listed in the
schedule of deviation. The description
description to be accompanied by single line diagrams, and
equipment layout to enable the Purchaser to have a proper appreciation of the equipment
offered and its operation.
b)
Specific exclusions, if any, from scope of work .
c)
Block Scheme diagram for all fire protection system along with tentative BOQ for major
equipments.
d)
Specification of equipment along with their makes/catalogues and material of construction.
e)
Reference list of job executed for each type of system.
f)
List of mandatory spares as per requirement

requirement for 2 years operation and maintenance.
g)
List of special tools and tackles.
h)
Amp. hour capacity of DC battery required for MFAP.
i)
Write up with control schematic on working of all fire protection systems.
j)
Detector type and Catalogues
k)
Linear heatt sensing cable details
Page 41 of 55
Format - 1
1.0
FORMAT FOR GENERAL AND COMMERCIAL PARTICULARS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14
15.
16.
17.
18.
19.
20.
21.
Name and Address of Bidder.

Telegraphic Address of Bidder
Name and designation of the person to whom all
references shall be made to expedite technical
coordination
Place of Manufacturer
Proposal No. & Date
Current Registration No. with D.G.S. & D
Whether all service facilities available?
Whether necessary spare parts available?
Has tenderer paid Earnest Money Deposit?
Is offer valid for four (4) months from Price bid
opening?
Has bidder quoted F.O.R site prices?
Is price break up given in Price Bid?
Are prices quoted FIRM? (Price should be firm.)
Is the tenderer agreeable to the terms of payment? If
not, has terms of payment acceptable to him been
indicated?
Does the tenderer agree to the delivery periods
indicated?
Are the delivery periods guaranteed under penalty
clause?
Is the tenderer agreeable to pay 10% Security
Deposit?
Are all schedules for technical particulars and prices
filled in?
Has tenderer brought out all deviations in schedule of
deviations?
Warranty period from takeover of plant / equipment.
Are equipment guaranteed as per various guaranteed
clauses of tender documents?
SIGNATURE ___________________
DESIGNATION ___________________
COMPANY ____________________
DATE ____________________
COMPANY SEAL
Page 42 of 55
Format - 2
2.0
FORMAT FOR BIDDERS EXPERIENCE LIST

Sl.
No
Purchaser
Location
& Customers
PO No. and
Date
4
Period
& Details
Year
of of work
Completion
5
6
7
Capacity
of plant
8
Total cost of
work done by
bidder
9
NOTE: Bidder may also furnish the above details for ongoing assignments.
SIGNATURE ___________________
DESIGNATION ___________________
COMPANY ____________________
DATE ____________________
COMPANY SEAL
Page 43 of 55
Format - 3
8.0
LIST OF DRAWINGS ENCLOSED WITH BID

Sl. No.
1
Drawings
2
Title
3
SIGNATURE ___________________
DESIGNATION ___________________
COMPANY ____________________
DATE ____________________
COMPANY SEAL
Page 44 of 55
SCHEDULE OF COMPONENTS IN USE AT NALCOS EXISTING COAL HANDLING PLANT, CPP, ANGUL
Components schedule given below are for information to Bidders for standardization and
interchangeability with existing Coal Handling Plant only. Bidders must take a note of
o these
components details while selecting a new supply to control the inventory level.
A)
Conveyor Pulley Schedule

Pulley
Type
Pulley
Diameter
(mm)
Drive/
630
Discharge 630
Pulley
630
800
Non Drive 400
Pulleys
400
500
B)
C)
Face
width
(mm)
1150
1150
1150
1150
1150
1150
1150
Shaft
Diameter
(mm)
125
150
165
175
90
100
115
Bearing
Diameter
(mm)
115
140
150
160
75
90
100
Shaft
length
(mm)
1690
2095
2100
2120
1760
1760
1770
PlummerBlockCenter
(mm)
1550
1650
1650
1650
1650
1650
1650
Bearing & Plummer Block Schedule.

Shaft diameter (mm)
Bearing size
65
75
90
100
115
125
140
150
160
22215K
22217K
22220K
22222K
22226K
22228K
22232K
22234K
22236K
Plummer Block Schedule

Drive Pulleys
Non Drive Pulley
1 1328 - AL
1 1328 - AL
1 149 - AL
1 149 - AL
M 1034 - BL
M 1034 - BL
M 1033 - CL
M 1033 - CF
M 1035 - AL
M 1036 - AF
M 1036 - BL
M 1036 - BL
M 1035 - CL
M 1036 - CF
1 829 - AL
1 1330 AF
1 1487 - L
1 1488 - F
Gear Box Schedule.

Gear box size
SZN-200
SZN-225
SZN-250
SZN-280
SZN-320
SZN-250
KDA-200
200
Reduction Ratio
16 : 1
16 : 1
16 : 1
20 : 1
20 : 1
16 : 1
125:1
Page 45 of 55
D)
Fluid Coupling Schedule
Fluid coupling size

FCU-16.25
16.25
FCU-17.75
17.75
FCU-23
FCU-41
E)
Baffle Ratio
1.5B
1.5B
1.5B
1.5B
Idler Schedule
The idlers are drop in slot type.
Page 46 of 55
LIST OF PREFERRED MAKES

1.1.
MECHANICAL
SL. NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21
22
EQUIPMENT
GEAR BOXES
CONVEYOR BELTS
MAKE
ELECON, FLENDER, SHANTHI, SEW, NAW, GRAEVES
DUNLOP, NIRLON, MRF, PHOENIX, NORTHLAND, FORECH, ANIL
RUBBERS, ORIENTAL.
IDLER
ELECON, TRF, KALI, KRUPP, MACMET, HINDUSTAN UDYOG
PULLEY
ELECON, TRF, KALI, HEC, HINDUSTAN UDYOG, McNALLY
BHARAT, HITECH, MASYC, KRUPP, SIMPLICITY, ARUDRA,
MACMET.
BEARINGS
SKF, FAG, NTN, NBC, NORMA, TATA, EAST EUROPIAN,
EUROPIAN ZKL
SLEW RING BEARINGS ROTHE ERDE, TITANUS, LYC-CHINA
FLEXIBLE COUPLING
FMG, DAVID BROWN, HICLIFF, CONCORD, ROMA, WELLMAN
INCAD. GREAVES LTD., NAW, GBM, ALLFLEX
FLUID COUPLING
PEMBRIL, FLUDOMAT, VOITH, ELECON
FASTENERS
GKW, SUNDERAM, PRECISION FASTENERS
MANUAL HOISTS
WH BRADY, KANUBHAI, HERCULES, TRACTEL TIRFOR, REVA
ENGG. MM ENGRS, BRADY&MORRIS
OIL SEALS
VACCA, RUBBER EQPT. & ENGG. CO. L TD
LUBRICATION
TECALEMIT, SURMAC, LUBCON, PRAKASH, AFMC, HELIOS
PROTOS, LINCOLN HELIOS
POWER PACK
REXROTH, PARKER, ETON, YUKEN, VICKERS, HAGGLUNDS
HYDRAULICS
REXROTH, YUKEN, CARTER, VELJAN CYLINDERS UTL,
MONTECH, WIPRO, OSCAR, HAGGLUNDS, PARKERCALZONI
HOSES
AEROLEX, GATES INDIA PVT. LTD
a) BELT CLEANERS
a) HOSCH, KAVERI,TECHNOFAB, PROMAC, BMH CONCARE
b) SKIRTS AND SKIRT b) UNITED TECHNO MECH, TEGA, KAVERI, HOSCH
SEALING
ARRANGEMENT
ACTUATOR OPERATED UNITED TECHNOMECH, PREPEC, PEBCO
FLAP GATES
IN LINE MAGNETIC ELECTRO-ZAVOD,
ZAVOD, MBIL, ELECTROMAG, POWER BUILD, MCI,
SEPARATORS
ELECTROMAGNETIC INDUSTRIES
BELT WEIGH SCALES
SCHENK-JENSON,
JENSON, TRANSWEIGH, IPA, SARTORIUS
BELT SWITCHES
JAYSHREE, SCHNEIDER, TELEMECHANIC, INDUSTRY SYNDICATE,
PROTO CONTROL
BRAKES
BCH, INDUSTRIES SYNDICATE, STORM KRAFT, ELECTROMAG,
SPEED O CONTROL, STROMAG
ELEC. HOISTS
ARMSEL, SHIVPRA, WH BRADY, BRADY & MORRIS, GRIP
ENGRS., HI-TECH,
TECH, CENTURY CRANE, TUOBRO FURGUSON,
UNITECH
Page 47 of 55
In case the Tenderer/ Contractor intends to substitute any particular make of equipment /
components/
ents/ materials by their/ his own make other than that listed in this document, the
Tenderer shall clearly bring out the same in his tender along with justification and indicate the
makes offered by him. It will be prerogative of the Purchaser to accept or reject the tenderers
own makes so offered.
1.2.
ELECTRICAL
Sl.No
1.
ITEM
415 V MCC/ (Drawout type)
2.
415 V PDB/DB (Fixed type)
3.
HT Cables
4.
LV Motors
5.
Local Control Stations (Weather

Proof)
6.
Bimetal Relays
7.
Contactors
Control
Switches
Switches/Selector
APPROVED SUB VENDORS

1. ABB
2. GE Power Control Ltd
3. L&T
4. Siemen Ltd
5. Schneider Eectric India Pvt.Ltd
1. Control & Switchgear Co. Noida
2. GE Power Control Ltd
3. L&T
5.ABB
6.SIEMENS
1. CCI
2.Universal
3.Polycab
4.NICCO
5.KEI
1. Alstorm
2. Asea Brown Boveri Ltd, Faridabad
3. Bharat Bijlee
4. Kirloskar Electric Co.Ltd, Banbalore & Hubli
5. Siemens
6. CGL
1. Bhartiya Industries
2. Baliga Lighting Eqpt(p)Ltd
3. Ex-protecta
4. Electrical Equpt.Corporation
5. Flexpro Electricals Pvt.Ltd
6. Prompt Engineering Works
1. ABB,Bangalore
2. Bhartiha Industries
3. L&T
4. Siemens
1. ABB,Bangalore
3. Control & Switchgears Contactors Ltd.
4. GE Power Control India Ltd
5. L&T
6. Siemens Ltd
7. Schneider Electric India Pvt.Ltd
1. Alstom Ltd
2. Havells India
3. Hotline Switchgear &Controls
4. Kaycee Industries
5. L&T
Page 48 of 55
9.
Fuse Switch
10
Timers
11
Fuse
12
ELCBs
13.
MCBs
14
MCCBs
15
Meters
16
Push Buttons & Indicating Lamp
6. Reliable Electronic Components Pvt. Ltd

7. Siemens Ltd
8. Switron Devices
1. ABB Ltd, Bangalore
2. Control & Switchgears Co Ltd
3. Havells India
4. Indo Asian Fuse Gear
5. L&T
6. Siemens Ltd
7. Standard Electricals
8. Alstom
2. Concord Controls
3. Electronic Automation Pvt Ltd
4. L&T
5. Siemens Ltd
1. GE Power Controls
3. L&T
4. Siemens Ltd
5. Ferraz
6. Bussman
1. Datar Switchgear Pvt Ltd
3. Legrand India
4. ABB
5. Siemens
7. GE
1. Datar Switchgear Pvt Ltd
2. Havells India
4. Indian Current Control
5. Legrand India
7. ABB
8. Siemens
9. GE
10.L&T
1. GE Power Controls
2. L&T
4. Siemens
5. ABB
1. Automatic Electric
2. Meco Instruments Pvt Ltd
3. Nippen Electrical Instruments Co
4. Risabh Instruments Pvt.Ltd
5. Industrial Meters(P) Ltd
2. Concord Controls
4. Hotline Switchgears & Controls
5. L&T
Page 49 of 55
17
Lighting & Power panels
18
Lighting Fixtures
19
Terminal Blocks
20
Switch socket outlets
21
Transducer
22
LT Transformer
23
PLC
24
UPS
25
Control Desk
27
VVVF Drive
29.
33 K V Isolator
30
Trailing Cables
6. Precifine Products Pvt. Ltd

7. Siemens
8. Shri Tulsi Switchgears
9. Teknick Controls
11. Binoy Opto Electrics,Kolkata
2. Havells India
3. Masstechm Switch gear
4. Legrand India
1. Bajaj Electricals
2. Comptron Greaves 3. Philip India
1. Essen
2. Connect well
3. Elmex
1. ALSTOM
2. CGL
3. B & C
4. ESSEN
1. ABB
2. MECO
1.CGL
2.KEC
3.BBL
4.BHEL
5.AREVA
6.BMCC
7.T&R
8.VIJAY ELECTRICAL
1.GE-FANUC
2. ALLEN BRADLY
3.SCHNEIDER
1.EMERSION
2.HI-REL
3.NUMERIC
4.TATA LIBERT
1. SIEMENS
2. ALSTOM
3. L&T
4. ABB
1. ALSTOM
2. BHEL
3. DANFOS
4. L&T
5. NELCO
6. ROCKWELL
7. SIEMENS
8. ABB
9. SCHNEIDER
10. YASKAWA
1. PANICKER
2. BOND STRANDS
3. DRISCHER
1. KEI
2. NICCO
Page 50 of 55
3. UNIVERSAL
31
HT Switch gear
32
HT Transformer
33
33KV VCB
34
Protection relays
35
Breaker Control switches
36
LV CT/PT
37
HVCT/PT
38.
Solid State Annuncitaor
39.
Lightning Arrests
1.WSI
2.ELPRO.
40.
41.
33KV Air Break switch

High Mast Tower
42.
43.
44.
Cable accessories
ACSR/AAAC Conductor
415V PCC
45.
Cable termination 7 jointing

kits
LT power and control cables
1.DRIESCHER PANNIKER
1.BAJAJ
2.PHILIPS
1.DOWELLS
1.RELIANCE CONDUCTORS
1. L&T
2.SIEMENS
1.RAYCHEM RPG
46.
1. BHEL
2 Siemens
3. ABB
1. BHEL
2
Siemens
3
TELK
4
ABB
5
AREVEA
1. ALSTOM
2.ABB
3.SIEMENS
1.ABB
2.ALSTOM
3EASUN REY ROLLE LTD
4L&T (FOR NUMERICAL RELAYES ONLY) .
5SIEMENS (FOR NUMERICAL RELAYES ONLY) .
1.ALSTOM
RELIABLE ELECTRONIC COMPONENT PVT.LTD.
2.RELIABLE
3.SWITORN DEVICES
1.COTROL AND SWITCH CO.LTD.
2.GEILBERT & MAXWELL ELECTRICAL
3.KAPPA ELECTRICALS
4.L&T
5.NARYAN POWER TRON PVT.LTD.
6.SILKAANS ELECTRICAL
7.PRECISE ELECTRICAL
8.PROGATI ELECTRICAL PVT.LTD.
1.AE
2.BHEL
3.CGL
4.SILKAANS
5.JYOTI
6.KAPPA
7.ABB
8.PROGATI.
1.APLAB
2.MINILEC
3.IL
1.CCI
2.UNIVERSAL
3.POLYCAB
4.NICCO
Page 51 of 55
1.3.
1.3
47.
Signal
cable
and
48.
VRLA battery
49.
Battery charger
Instrumentation
5.KEI
6.CORDS
7.GEMSCAB
1.CCI
2.UNIVERSAL
3.POLYCAB
4.NICCO
5.KEI
6.CORDS
7.GEMSCAB
1.AMAR RAJA
2.EXIDE
1. AMAR RAJA
2.CHABI ELECTRICAL
3.CALDYNE
4.HBL NIFE
AIR CONDITIONING, VENTILATION & DUST SUPPRESSION SYSTEM

- EFE, C. Doctor, Voltas
Ventilation system
Dust Suppression System
- TPS, Kaveri, F. Harley
Air Conditioning system
- Blue Star, Voltas, Carrier
CIVIL
CEMENT- ACC,L&T Ultra Tech, Zuari, RAASI GOLD or equivalent approved manufacturer.
REINFORCEMENT STEEL-SAIL,Tata
STEEL SAIL,Tata Steel, RINL, or equivalent approved manufacturer.
Note:
elsewhe in
1. Makes indicated above shall also be read with preferred makes as listed elsewhere
this specification.
2. For make of any item, not appearing in the above list, specific approval shall be taken by
the bidders from Purchaser.
Page 52 of 55
1.0
LIST OF TOOLS AND TACKLES

S.NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11
12.
13.
14
15.
DESCRIPTION
QUANTITY
Manually operated Hydraulic Jack
2 Nos
i) 50T X 150 mm stroke
Bastard (Rough Cut) Files 250 mm size
i)
Flat
1 No.
ii)
Round
1 No.
1 No.
iii)
Half Round
1 No
iv)
Triangular
Fine Cut Files 250 mm size
i)
Flat
1 No.
ii)
Round
1 No.
iii)
Half Round
1 No.
iv)
Triangular
1 No
Adjustable Outside Micrometer Interchangeable Anvil
Type
i)
0-150 mm
1 No.
ii)
150 600 mm
1 No
Inside Micrometer
i) 50 150 mm
1 No
Vemier Calipers
i)
0-150 mm size
1 No.
ii)
0 300 mm size
1 No
Feeler Gauge
i)
10 mm thk. 6 inch
1 No.
ii)
10 mm thk. 12 inch
1 No
Sprit Level
i) 150 mm
2 No
Torque Wrench with socket
75 150 kg.m
1 set
Standard Ring spanners
(Upto 32 mm )
1 set
Standard D.E. spanners
(Upto 32 mm )
1 set
Adjustable spanners
(Upto 50 mm each set of 3 Nos.)
1 set
Socket Head Spanners
(Box Spanners 10 to 32 mm )
2 set
Sledge Hammers
i)
5 kg.
2 Nos.
ii)
10 kg
2 Nos
Nylon Faced Hammers (4 Sizes)
1 set
Page 53 of 55
16.
17
18.
19.
20
21.
22.
23
24
25.
26.
27
28.
29
30.
31
32
33
34.
35.
36.
37
38
39
4 dia portable motor operated grinding m/c with flexible

grinder
Ball Pein Hammers in different sizes.
Dial Gauge 0-10
0
mm LC-0.01 mm with mag.
Stand
Steel Tapes
i)
3 m Size
ii)
6 m Size
Steel Scales
i)
0.3 m Size
ii)
0.5 m Size
Internal Calipers
i)
150 mm Size
ii)
300 mm Size
External Calipers
i)
150 mm Size
ii)
300 mm Size
Hand operated Hacksaw Frame with 1 Doz. Blades (12)
Tri-square
square (6 x 12)
Screw Operated Coupling and Bearing Puller 300 mm
Size
Grease Gun with hose & adopter (Manual)
Bucket Grease Gun (Manual)
Self supporting, extendable aluminum ladder with
maximum height of 6m
Hydraulic flange puller of reputed make
Pipe Wrenches 6 & 12
Digital Tachometer (0 3000 rpm)
Screw Drivers
i)
150 mm Size
ii)
300 mm Size
Sling with Eye Bolt and D-Shackle
D
of 2,3,5 &10 tonnes
Plum Bobs
All types of Pliers of different size of reputed make to suit
the eqpt.
i)
Cutting pliers
ii)
Internal Circlip
iii)
External Circlip
Adjustable Pliers
Marking Punches
Scribers
Insulation resistance Tester (Megger)
i)
500 V
ii)
1000 V
2 Nos
6 Nos
2 Nos
1 No.
1 No
1 No.
1 No
1 No.
1 No
1 No.
1 No
1 Set
2 Nos
2 Nos
2 Nos
1 No
2 Nos
2 Sets
4 Nos
2 Nos
2 Nos.
2 Nos
2 Sets
2 Nos
2 Nos.
2 Nos.
2 Nos
2 Nos
2 Sets
4 Nos
1 No.
1 No
Page 54 of 55
40.
41.
42.
43.
44.
45
46
47
48.
49
50
51
52
53.
2.0
Tong Tester
Portable Emergency Light (Hand Torch with Dry Cells)
100 W Hand Lamp with 50 M Flexible Wire
Hand drills (pistol)
Digital Multimeter
Digital Clamp meter
Hand drill Electrical & 1
Crimping Tool ( Hand Operated) - 5 mm2 to 16 mm2
Crimping Tool ( Hand Operated) -16 mm2 to 240 mm2
Milli Ohm Meter
Combination Plier
Nose Plier
Earth Megger
Phase Sequence meter (0 415V)
2 Nos
2 Nos
2 Nos
2 Nos
1 No
1 No
2 Sets
1 Set
1 Set
1 No
2 Nos
2 Nos
1 No
1 No.
LIST OF TENDER PURPOSE DRAWINGS FOR BIDDERS REFERENCE

SL. NO.
1
DESCRIPTION
DRAWING NO
Layout of Coal Storage Yard & 1034/Q6Q3/A-02A/LO
02A/LO-001 Rev 05
Handling System
(Set of three drawings)
Coal Flow Diagram
FD-CHP
General Layout of CPP, NALCO
6-08-0-07734-01
G.A. & Marking of Conveyor BC-115

BC
02728-M-BM-CS-GA--0027 Rev C
G.A. & Marking of Conveyor BC-103

BC
CKIH-3901-M0-B057
B057 Rev D
G.A. of Junction House JH-1

JH
CKIH-3901-M0-B004
B004 Rev C
G.A. of wagon tippler & receiving RITES/PORTS/NALCO/FS/L-01

RITES/PORTS/NALCO/FS/L
7
conveyor
(Set of five drawings)
Page 55 of 55
Annexure - II
Special Instructions to Bidders
1.0
COMPLETION SCHEDULE
The schedule for completion in all respect as per Tender Documents from Brief Order (BO) date is
specified in Instruction to Bidders.
2.0
DUE DATE
Please ensure your offer, complete in all respects reaches us by the bid due date specified in
Instructions to Bidders. Offers received after the bid due date and time will be considered as Late
Offers and will not be considered.
3.0
PRICE FORMAT
Please furnish the prices strictly as per the format enclosed. Prices shall not appear any where
else in the offer, and if prices are mentioned any where else the same shall not be considered.
Prices should be submitted in duplicate sealed super scribed envelope along with un-priced copies
as per Tender documents (Un-priced copy of price bid should also be enclosed with un-priced
copies with prices blanked out but Quoted/ Not Quoted marked against respective clauses).
4.0
VALIDITY OF BIDS
The bid should be kept valid for acceptance for a period of 4 (four) months from the final due date
for bid submission.
5.0
EVALUATION/ LOADING/ REJECTION CRITERIA
5.1
All evaluation shall be made on landed and erected on destination basis including design and
engineering, supply of equipment, spares etc. (excluding One Year O&M Spares) and all other
erection, construction, installation, supervision and commissioning charges along with the taxes
and duties for the same, as per scope of Tender Documents.
5.2
Supply prices shall be evaluated as follows:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
FOT Despatch Point

Add ED & E-cess
Add CST/ LST/ VAT
Total Price
Transit Insurance
Freight Charges
Total FOT Site
Entry Tax
Total Price
Technical loadings, if any
Annexure II, Special Instructions to Bidders
:
:
:
:
:
:
:
:
:
:
As quoted
As Quoted
As Quoted
1+2+3
0.25% on (4)
As quoted
4+5+6
@ 2% on (7)
7+8
On FOT Despatch point price
Page 1 of 9
11.
12.
13.
5.3
Commercial loading, if any

CENVAT Benefit
Total Comparable Price
: On FOT Despatch point price

(-) 2
: 9+10+11+12
Price loading on account of payments and other conditions required by various vendors will be
based on following:(i)
Payment terms:
a)
(ii)
Price loading on account of payment terms at variance with Bidding Document

payment terms will be loaded @ 12% per annum for the relevant period.
Price Variation:Terms offered by vendor price loading

(a)
Firm Price
No loading
(b)
In case of ceiling on
Price Variation Clause
Loading by ceiling percentage offered
(c)
No ceiling on the formula
Offer may be rejected
(d)
No formula and no
ceiling specified by vendor
- do -
(iii)
Vendors should quote firm inland freight charges from dispatch point to Site at Angul,
Orissa. If a vendor does not quote firm inland freight charges then their offer will be loaded
with maximum of the inland freight charges as quoted by the other bidders from that region
or based on estimation by NALCO in case there is no other offer from that region.
(v)
Any differential in taxes and duties will be cost loaded on case-to-case basis. If a vendor
states that taxes/duties are not applicable at present and will be charged as applicable at
the time of delivery then no advantage will be given.
(vi)
All materials are required to be transported by Bank-approved carriers, preferably having

an office at the place of concerned unit.
(vii)
Cost loading in respect of utilities will be considered where guaranteed consumptions have
been asked in NIT as per methodology defined in the NIT.
5.4
All cost loadings will be calculated on F.O.T. despatch point prices.
5.5
No deviation to terms & conditions of the bid documents is allowed. Further Non acceptance of
following commercial clauses shall lead to rejection of bid:
Page 2 of 9
(i)
Bids that do not meet the qualification criteria as specified in the NIT/ bid documents shall
be summarily rejected.
(ii)
A bid with incomplete scope of work and / or which does not meet the technical
specifications and requirements as specified in the NIT documents shall be considered as
non-responsive and rejected.
(iii)
Prices must be furnished in accordance to the price schedule format enclosed and strictly
based on the terms specified related to the bid prices in the instructions / conditions. Non
compliance to this requirement shall make the bid liable for rejection.
(iv)
Bidders are requested to note that exceptions / modifications taken by them to the
following clauses of Tender Documents - Commercial may result in rejection of their bid :(a)
(b)
(c)
(d)
(e)
(f)
6.0
Proforma of Bank Guarantee for Advance Payment, if any, and Contract - cum Performance Bank Guarantee
Contract Performance Guarantee clause
Completion Schedule
Period of validity of bid
Guarantee / Warranty
Replacement of Defective parts and materials
REFERENCE LIST
The bidders are requested to submit a list of buyers to whom the same or similar type of equipment
have been supplied by them and which are under operation. The detailed addresses of such
buyers office/works including Telephone, Fax Nos. and Contact Person and Order Reference are
to be mentioned.
Page 3 of 9
APPENDIX - A
TO
SPECIAL INSTRUCTIONS TO BIDDERS
INDEX
SL. NO.
DESCRIPTION
1.0
COST OF BIDDING
2.0
SITE VISIT
3.0
BIDDING DOCUMENT
4.0
CLARIFICATION OF BIDDING DOCUMENT
5.0
AMENDMENT OF BIDDING DOCUMENT
6.0
CONFIDENTIALITY OF BIDDING DOCUMENT
7.0
LANGUAGE OF BID
8.0
FORMAT AND SIGNING OF BIDS
9.0
MODIFICATION & WITHDRAWAL OF BIDS
10.0
OPENING OF UN-PRICED BIDS
11.0
OPENING OF PRICE BIDS
12.0
COMPARISON OF BIDS
13.0
CONTACTING THE OWNER/CONSULTANT
14.0
AWARD CRITERIA
15.0
OWNERS/CONSULTANTS RIGHT TO ACCEPT ANY BID AND TO REJECT ANY

OR ALL BIDS
17.0
ISSUE OF ORDER
Page 4 of 9
1.0
COST OF BIDDING
1.1
All direct and indirect costs associated with preparation and submission of bid (including clarification
meetings and site visit, if any) shall be to bidders account and NALCO / RITES, will in no case, be
responsible or liable for these costs, regardless of the conduct or outcome of the bidding process.
2.0
SITE VISIT
2.1
Bidder is advised to visit and examine the Site, its surrounding and familiarize himself of the
existing facilities and environment and collect all other information which he may require for
preparing and submitting the bid and entering in to the contract. Claims and objections due to
ignorance of existing conditions or inadequacy of information will no be considered after
submission of the bid and during implementation.
2.2
The bidder or any of his personnel or agents will be granted permission by the Owner to enter upon
his premises and land for the purpose of such inspection but only upon the explicit condition that
the bidder, his personnel or agents will release and indemnify the owner and his personnel or
agents from and against all liability in respect thereof and will be responsible for personnel injury
(whether fatal or otherwise), loss of or damage to property and any other loss, damage, cost and
expenses incurred as a result thereof.
2.3
For site visit, the intending bidder may contact General Manager (CPP), NALCO, Angul, Orissa
Phone- 06764- 220 158, Telefax 06764- 220 646 or General Manager (Projects), RITES Ltd,
Bhubaneswar, Phone: 0674 2572690, 09438677075. Fax 0674 2575 284. or Sr.
DGM(Civil)/RITES, Bhubaneswar, phone-09437283829.
3.0
BIDDING DOCUMENT
3.1
The Bidder is expected to examine all instructions, forms, terms and specifications in the
Bidding Document. The Bidding Document together with all its attachments thereto, shall be
considered to be read, understood and accepted by the Bidder, unless deviations are specifically
stated in seriatim (giving reference s. no. of Bidding Document) by the Bidder. Failure to furnish all
information required by the Bidding Document or submission of a bid not substantially responsive to
the Bidding Document in every respect will be at Bidders risk and may result in the rejection of his
bid.
3.2
The Bidders must fulfill the Qualification Criteria given in the Instructions to Bidders and furnish all
necessary documentary evidence in support of Bidders experience/ capability as required, along
with the bid. In the absence of the requisite documents, NALCO / RITES reserves the right to reject
the bid without making any reference to the Bidder. Bidders must make their own judgment on
the adequacy of the documents/ information they provide. In case any information provided by
Bidder is found to be incorrect, the bid will be rejected, and the Earnest Money Deposit of
such Bidder will be liable for encashment.
Bidder must buy Bidding Document by paying the requisite document fee before the sale
closing date & time. In case the Bidding Document is downloaded from website t h e requisite
Bidding Document Fee in the form of DD payable to NALCO shall accompany the bids.
3.3
Page 5 of 9
4.0
CLARIFICATION OF BIDDING DOCUMENT AND PRE-BID MEETING
4.1
Bidder shall examine the bidding document thoroughly in all respect and if any conflict, discrepancy,
error or omission is observed, bidder may request clarification within the cutoff date and 3 weeks
prior to the bid closing date. Such clarifications request shall be addressed to the following:
GM (Projects), RITES Ltd.,Regional Project Office, Bhagwan Tower(1st Floor), Cuttack Road,
Bhubaneswar -751006, Phone:-0674-2575493, Fax:0674-2575284, E-mail : bbsrpo@rites.com
4.2
Any failure by bidder to comply with the aforesaid requirement shall not excuse the bidder, after
subsequent award of contract, from performing the work in accordance with the contract.
4.3
Response to queries/ clarifications raised will be sent as expeditiously as possible. The response
shall not form part of the bidding document unless issued as an addendum/ amendment.
4.4
Bidders are expected to resolve all their clarification/ queries to the bidding document and submit
their bid in total compliance to biding document without any deviation/ stipulation/ clarification.
4.5
PRE-BID MEETING
The Tenderer or his official representative is invited to attend a pre-bid meeting which will take place at
the Office of General Manager(Project), CPP, Nalco,Angul on 10.09.2012 at 10.30 hours.
The Tenderers are required to submit any question on issues relating to the tender, in writing or by
telefax or by E-mail so as to reach general Manager(Project), RITES Ltd.,Regional Project Office,
Bhagwan Tower(1st Floor), Cuttack Road,Bhubaneswar -751006 not later than 3 (three) days before
the date fixed for the meeting.
The purpose of the meeting will be to clarify the issues raised and to answer supplementary questions
on such issues.
Minutes of the meeting including the text of the questions raised (without identifying the source of
enquiry) and the responses given will be uploaded on RITES website. Any modifications of the
Tender Document which may become necessary as a result of the Pre-bid Meeting shall be made
exclusively through the issue of an Addendum / Corrigendum and not through the Minutes of the PreBid Meeting. The Minutes of the Meeting as described above and the Addendum / Corrigendum, if
any, will be uploaded on RITES website only.
Non-attendance at the Pre-bid Meeting will not be a cause for disqualification of a tenderer.
5.0
AMENDMENT OF BIDDING DOCUMENT
5.1
At any time prior to the bid due date, NALCO / RITES may, for any reason, whether at its own
initiative or in response to a clarification requested by a prospective Bidder, modify the Bidding
Document and issue amendment in the form of Addendum.
Page 6 of 9
5.2
Any addendum thus issued will become part of bidding document and bidder shall submit original
addendum/ compliance letter duly signed and stamped in token of his acceptance.
5.3
In order to afford prospective Bidders, reasonable time in which to take the amendment into account
in preparing their bids, NALCO /RITES may, at its discretion, extend the bid due date.
6.0
CONFIDENTIALITY OF BIDDING DOCUMENT
6.1
Bidders shall treat the biding documents and contents therein as strictly confidential.
6.2
The bidding document is and shall remain the exclusive property of the OWNER without any
right to bidder to use them for any purpose except for the purpose of bidding.
7.0
LANGUAGE OF BID
7.1
The bid prepared by the Bidder and all correspondence/ drawings and documents relating to
the bid exchanged by Bidder and NALCO /RITES shall be written in ENGLISH language. Any
printed literature furnished by the Bidder written in another language should be accompanied
by an ENGLISH translation. In case of any conflict, for the purpose of interpretation of the bid, the
ENGLISH translation shall govern.
8.0
FORMAT AND SIGNING OF BID
8.1
The Bidder shall prepare required number of copies of the bid, clearly marking each Original
Bid and Copy of Bid as appropriate. In the event of any discrepancy between them, the Original
Bid shall govern.
8.2
The original and all copies of the bid shall be typed or written in indelible ink and shall be signed
by the Bidder or a person duly authorized to bind the Bidder to the Contract. The name and
position held by each person signing must be typed or printed below the signature. The person
or persons signing the bid shall initial all pages of the bid, except for unamended printed
literature.
8.3
The complete bid shall be without alterations, interlineations or erasures, except as may be
necessary to correct errors made by the Bidder, in which case such corrections shall be rewritten &
initialed by the person or persons signing the bid.
9.0
MODIFICATION AND WITHDRAWAL OF BIDS
9.1
The Bidder may modify or withdraw his bid after the bids submission, provided that the
modification/ withdrawal notice is received by the Owners/ Consultant prior to the bid due date &
time.
The Bidders modification or withdrawal notice shall be prepared, sealed, marked and despatched
in accordance with the provisions of Bidding Document. A withdrawal notice may also be sent
Page 7 of 9
by Cable or Telefax but must be followed by a signed confirmation copy dated not later than
the deadline for submission of bids.
9.2
No bid shall be modified subsequent to the due date & time or extension, if any, for submission
of bids.
9.3
No bid shall be allowed to be withdrawn in the interval between the deadline for submission of
bids and the expiration of the period of bid validity specified by the Bidder. Withdrawal of a bid
during this interval shall result in the forfeiture of Bidders Earnest Money Deposit .
10.0
OPENING OF UN-PRICED BIDS
10.1
Un-priced part of the Bid shall be opened in the RITES, Bhubaneswar Office, in the presence
of Bidders representatives (duly authorized by a competent person and having the Letter of
Authority who choose to attend, on date, time as mentioned in the Instructions to Bidders. The
Bidders representatives, who are present, shall sign a register evidencing their attendance.
Bidders whose bids are not opened for any reason, including non-receipt of original Earnest
Money Deposit, will not be allowed to be present during bid opening.
10.2
The Bidder(s) names, modifications, bid withdrawals and the presence or absence of the
requisite Earnest Money Deposit and such other details as the NALCO/RITES, at its discretion,
may consider appropriate will be announced and recorded at the time of opening of un-priced
bids as specified in the Instruction to Bidders/ Tender Documents.
11.0
OPENING OF PRICE BIDS
11.1
Bidders found to be substantially responsive a n d t e c h n o - c o m m e r c i a l l y a c c e p t a b l e

will be advised of date & venue for the priced bid opening. Bidders may depute their
authorized representative, along with letter of authority to attend price bid opening. The price bids
of those Bidders determined to be not substantially responsive will be rejected and will not be
called for price bid opening.
The Bidders names, bid prices, modifications and bid withdrawals and such other details as the
Consultant, at its discretion, may consider appropriate, will be read out at the time of opening of
priced bids of technically and commercially acceptable Bidders.
12.0
COMPARISON OF BIDS
12.1
The Consultant will evaluate and compare bids previously determined to be substantially responsive
pursuant to the provisions of the Bidding Document.
12.2
Arithmetical errors will be rectified on the following basis:If there is a discrepancy between the unit price and the total price that is obtained by
multiplying the unit price and quantity, the unit price shall prevail and the total price will be
corrected. If there is a discrepancy between the total amount and the sum of total prices, the sum
of the total prices shall prevail and the total bid amount will be corrected. Further, if there is a
Page 8 of 9
discrepancy between the quoted lump sum price, and its separate break-up prices (if any), the
quoted lump sum price shall prevail.
13.0
CONTACTING THE OWNER/ CONSULTANT
13.1
No Bidder shall contact the NALCO / R I T E S on any matter relating to its bid, from the time
of bid opening to the time the Contract is awarded.
13.2
Any efforts by a Bidder to influence the NALCO / RITES in the Owners/ Consultants bid
evaluation, bid comparison or contract award decisions may result in the rejection of the Bidders
bid.
14.0
AWARD CRITERIA
The Owner will award the Contract to the successful Bidder whose bid has been determined to
be the lowest evaluated, responsive bid, provided further that the Bidder is determined to be
qualified to satisfactorily perform the Contract.
15.0
OWNERS/CONSULTANTS RIGHT TO ACCEPT ANY BID AND TO REJECT ANY OR ALL

BIDS
15.1
NALCO / RITESO reserves the right to accept or reject any bid, and to annul the bidding process
and reject all bids, at any time prior to award of contract, without thereby incurring any liability to
the affected Bidder or Bidders or; any obligations to inform the affected Bidder or Bidders of the
ground for the Owners/Consultants action.
15.2
The submission of any bid connected with these documents and specifications shall
constitute an agreement that the Bidder shall have no cause for action or claim, against the
Owner for rejection of his bid. The Owner shall always be at liberty to reject or accept any bid or
bids at his sole discretion and any such action will not be called into question and the Bidder shall
have no claim in that regard against the Owner.
ISSUE OF ORDER
The Owner will send to the successful bidder B rief Order/ Work Order incorporating all
the terms and conditions agreed between the parties.
Within 15 days of receipt of the Order, the Bidder shall sign and return it to the Owner for their
records.
16.0
16.1
16.2
17.0 In case of contradiction between relevant Indian Standards, General Conditions of Contract,
Special Conditions of Contract, Specifications, Drawings, Schedule of Prices / Rates, the following
shall prevail in order of precedence:
i) Brief of Order, Detailed Letter of Acceptance along with Statement of Agreed Variations (if any) and
its enclosures.
ii)
Schedule of Rates.
iii)
Technical Specifications
iv)
Drawings.
v)
Addendum to Tender Documents (Commercial).
vi)
Tender Document Commercial(Indigenous).
vii) Relevant Indian Standards / Specifications
Page 9 of 9
TENDER DOCUMENTS
COMMERCIAL (INDIGENOUS)
NATIONAL ALUMINIUM COMPANY LIMITED

(A GOVT. OF INDIA ENTERPRISE)
REGISTERED OFFICE: NALCO BHAVAN,
P/1, NAYAPALLI,
BHUBANESWAR - 751 061
Tender Documents Commercial (Indigenous)
Page 1 of 56
CONTENTS
GENERAL CONDITIONS OF CONTRACT
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Page No.
APPLICATION
DEFINITION OF TERMS
CONTRACTOR TO INFORM HIMSELF FULLY
SCOPE OF WORK
DESIGN REQUIREMENTS
CONTRACT PRICE
TAXES
PERFORMANCE BOND
PROTECTIVE PAINTING, PACKING & MARKING
SHIPMENT PARTICULARS
INSURANCE
DELIVERY
LIQUIDATED DAMAGES FOR DELAY IN COMPLETION
IMPORT LICENSE AND FOREIGN EXCHANGE
CONTRACTORS DOCUMENTS, DRAWINGS AND
INSTRUCTION MANUALS
MISTAKES IN DRAWINGS
MATERIALS AND WORKMANSHIP
SPARE PARTS AND SPECIAL MAINTENANCE TOOLS
COMPLETENESS OF EQUIPMENT
INSPECTION AND TESTING AT CONTRACTORS PREMISES
TESTS ON COMPLETION AND TRIAL RUN AT SITE
TAKING OVER
REJECTION OF DEFECTIVE PLANT
COMPLETION CERTIFICATE & FINAL CERTIFICATE
ENGINEERS DECISION
CERTIFICATE NOT TO AFFECT THE RIGHTS OF THE
PURCHASER OR THE CONTRACTOR
MINTENANCE AND GUARANTEE - WARRANTY PERIOD
NEGLIGENCE
POWER TO VARY OR OMIT WORK
SETTLEMENT OF DISPUTE
TERMINATION OF CONTRACT
DEDUCTION FROM CONTRACT PRICE
CO-OPERATION WITH OTHER CONTRACTORS AND
CONSULTING ENGINEERS
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Page 2 of 56
34.00 ASSIGNMENT OF CONTRACT

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Page No.
35.00 SUBLETTING OF CONTRACT

36.00 SUSPENSION OF WORK
37.00 FORCE MAJEURE
38.00 PROGRESS REPORT AND PHOTOGRAPHS
39.00 PATENT RIGHTS
40.00 TRAINING OF ENGINEERS
41.00 EFFECT AND JURISDICTION OF CONTRACT
42.00 TIME IS THE ESSENCE OF CONTRACT
43.00 ERECTION SUPERVISION SERVICES
44.00 ERECTION PLANT AND MATERIALS
45.00 FOREIGN PERSONNEL
46.00 DEATH, BANKRUPTCY ETC.
47.00 GRAFTS AND COMMISSION ETC.
48.00 COMPLETION OF CONTRACT
49.00 DEFENSE OF SUITS
50.00 ARBITRATION
51.00 CORRESPONDENCE
52.00 CONTRACT AGREEMENT
53.00 PAYMENTS
54.00 MISCELLANEOUS
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Page 3 of 56
1.00
APPLICATION
Unless otherwise provided in the Contract Agreement, these General Conditions of Contract shall
govern the work of the annexed Specification.
2.00
DEFINITION OF TERMS
In construing these General Conditions and the annexed Specification, the following words shall
have the meanings herein assigned to them unless there is something in the subject or context in
consistent with such construction.
2.01
The Owner/Purchaser shall mean the National Aluminium Company Limited , a company
incorporated in India, whose Registered Office is situated at NALCO BHAVAN, P/1, Nayapalli,
Bhubaneswar - 751 061.
2.02
The Contractor shall mean person, firm or a company whose tender has been accepted by the
Purchaser and shall include his/its heirs, executors, administrators, representatives and permitted
assigns.
2.03
The term Sub-Contractor used herein refers to a party or parties having a direct contract with the
Contractor to whom any part of the contract has been sublet by the Contractor with the consent in
writing of the Owner and shall include his heirs, executors, administrators, representatives and
assigns.
2.04
The Engineer shall mean an officer of the owner/purchaser as may be duly appointed and
authorized in writing by the purchaser to act as the Engineer on its behalf for the purpose of the
contract.
2.05
The Èngineers Representative shall be the person nominated by the Engineer in writing to act on
his behalf.
2.06
The term `Consultants/Consulting Engineer refers to consultant(s) nominated by the Engineer in

writing for the contract and referred to throughout in the Contract Documents by `Consulting
Engineer or `Consultant.
2.07
The Inspector shall mean any firm or person including any employee of the owner/purchaser as
may be duly appointed and authorized in writing by the owner/purchaser to inspect plant,
equipment and works included by the Contractor.
2.08
`Plant, Equipment, Works shall mean and include plant, stores and materials to be provided and
work to be done by the Contractor.
2.09
Contract means the Notice Inviting Tenders, Conditions of Tendering, and Tender Form, General
Conditions of Contract, Supplementary Conditions of Contract, Technical Specifications, price
Page 4 of 56
Schedule of Prices & Quantities, Letter of Intent of Purchaser, Drawings, Subsequent amendments
mutually agreed upon, and agreement to be entered under clause Contract Agreement of this
General Condition.
2.10
The `Specification shall mean the Specification annexed to these General Conditions and any
subsequent modifications thereof and the drawings and Schedules attached thereto (if any).
2.11
`Site means the lands and other places on, under, in or through which the Works are to be
executed or carried out and any other lands or places provided by the Owner for the purpose of the
Contract.
2.12
`Tests on Completion shall mean such tests as are prescribed by the Specification and/or tests
mutually agreed upon by the Purchaser and the Contractor to be made by the Contractor after
erection of the equipment to prove satisfactory operation as required by the Specification.
2.13
`Commissioning shall mean the first successful operation of the plant and equipment after all initial
adjustments, trials, cleaning and reassembly required at site, if any, have been completed.
2.14
Àcceptance Tests shall mean such tests as are required to prove the performance guarantees of
the plant given by the Contractor, before taking over of the plant by the Purchaser.
2.15
Initial Operation, `Reliability Run or Trial Operation shall mean continuous operation of the
contract plant and materials under varying loads to furnish proof of satisfactory operation for a
specified period which shall not be less than two (2) weeks.
2.16
Commercial Use shall mean that use of the equipment which the Contract contemplates or of
which it is to be commercially capable.
2.17
Warranty Period shall mean the period of guarantee as explained under clause `Maintenance and
Guarantee of these General Conditions.
2.18
Codes shall mean the applicable codes of State or Orissa as on the date of Letter of Intent and
any subsequent modification thereof before the plant has been delivered.
2.19
Month shall mean calendar month.
2.20
Notice of Award of Contract / Letter of Intent/ Award Letter shall mean the Purchasers letter /
Telex conveying his acceptance of the Tender subject to such reservations as may have been
stated therein.
2.21
Erection Supervision shall mean the supervision services rendered or exercised by the Contractor
during the erection of the plant as explained under clause Èrection Supervision Services of these
General Conditions.
Page 5 of 56
2.22
`Writing shall include any manuscript, typewritten or printed statement under or over signature or
seal as the case may be.
2.23
Approved, Subject to Approval, Satisfactory, Equal to Proper, As directed, Where directed,

When directed Determined by, Accepted, `Permitted, To approval, or words phrases of like
import are used, the approval, judgment, direction, etc. is understood to be a function of Consulting
Engineer or Purchaser.
2.24
Words importing `Persons shall include firms, companies, corporations and other bodies whether
incorporated or not.
2.25
Words importing the singular only shall also include the plural and vice versa where the context
requires.
2.26
F.O.B. shall mean delivery free of expenses to the Purchaser on board the vessel at the port of
shipment.
2.27
F.O.R. Destination shall mean delivery free of expenses to the purchaser on rail wagons at
destination Railway Station/Siding as may be named.
2.28
F.O.R. Works shall mean loaded and stowed or trimmed, free of expenses to the Purchaser on
board rail wagons at the Contractors siding or at the nearest Railway Station for transportation.
2.29
Tonne shall mean 1000 kilogram weight, `Gallons shall mean imperial gallons unless mentioned
specifically.
2.30
`Manufacturers works or `Contractors works shall mean the place of work used by the
manufacturer, their collaborators or approved sub-contractors for the performance of the works.
2.31
Construction of Contract
Terms and conditions not herein defined shall have the same meanings as are assigned to them in
the Indian Sale of Goods Act (Act III of 1930) falling that in the Indian Contract Act (Act IX of 1872)
and falling that in the General Clause Act 1897.
3.00
CONTRACTOR TO INFORM HIMSELF FULLY

The Contractor shall be deemed to have carefully examined the General Conditions, Specification,
Schedules and Drawings and also to have satisfied himself as to the nature and character of the
work to be executed and, where necessary, of the site conditions and other relevant matters and
details. Any information thus had or otherwise obtained from the Purchaser, Consulting Engineer or
the inspector shall not in any way relieve the Contractor from his responsibility for supplying the
plant and equipment and executing the work in terms of the specification including all detail and
incidental works and supply of the all accessories or apparatus which may not have been
Page 6 of 56
specifically mentioned in the specification or drawings, but otherwise necessary for ensuring
complete erection and safe and efficient commercial working of the plant and equipment. If he shall
have any doubt as to the meaning of any portion of these General Conditions and/or specification,
he shall set forth the particulars thereof and submit them to the Engineer in writing for clarification.
4.0
SCOPE OF WORK
4.01
For Manufacture, Supply & Delivery of Plant & Materials

The Contractor shall design, manufacture and deliver suitably packed the plant, equipment and
materials as described in the attached specification F.O.R. Works/F.O.R. Destination and, if of
foreign origin, F.O.B. port of shipment, as the case may be.
The Contractor shall sell and deliver the said plant, equipment and materials to the Purchaser and
Purchaser shall accept the delivery of and pay for at the price agreed upon between the Purchaser
and the Contractor and upon fulfillment of the terms and conditions hereinafter specified or
subsequent agreed modification thereof.
The Contractor shall inform the Purchaser if the plant, equipment and materials or any part thereof
to be supplied under the scope of work shall be of origin and/or manufactured outside the Union of
India in which case the Contractor shall give a certificate to this effect in the form required by the
Purchaser. This certificate shall be called the `Certificate of Origin. The foreign currency
component for importing of plant and materials manufactured outside of India shall be specified
and the estimated total C.I.F. value shall also be stated. It is clearly understood that the owner shall
not give any of its import licenses for importation of these items.
The Contractor shall also supply the spare parts and special tools at the quoted price and in
quantities mentioned in clause `Spare Parts and Maintenance Tools or subsequent modifications
thereof.
The Contractor shall undertake that supply of necessary spare parts and special tools will be made
available at any time later during the life of the plant. The price of the imported spare parts shall not
be in excess of the landed cost plus a reasonable percentage towards handling charges. The price
for indigenous spare parts shall be at fair market price.
The Contractor shall also undertake that before going out of production of any of the spare parts,
he shall give adequate advance notice to the Purchaser so that sufficient quantity of spare parts
might be procured if the Purchaser so desires. Further, the Contractor shall supply the necessary
drawings and specifications of these spare parts which the Contractor proposes to take off his
production range to enable the Purchaser to arrange manufacture of the spa re parts by other
agency.
Page 7 of 56
4.02
For Erection Supervision Services

The Contractor has to supply erection supervision personnel to supervise the work of erection of
the plant and equipment to be conducted even by other agencies including owner. Classification
and number of personnel required shall be mutually agreed to. The services would be generally as
specified in Clause Èrection Supervision Services hereinafter at Clause No. 43.00
4.03
For Erection of Plant & Materials

The Contractor shall render complete erection services of the plant and materials supplied under
the Contract if so required by the Purchaser. The services to be rendered shall be as generally
described in clause Èrection of Plant and Materials hereinafter.
5.00
DESIGN REQUIREMENTS
5.01
All equipment and materials shall be designed and manufactured in conformance with standards
stated hereinafter.
5.02
Wind Load
Structures and outdoor equipment shall be designed to withstand a wind load as set forth in the
latest revision of Indian Standards IS: 875 of the Indian Standards Institution.
5.03
Earthquake
In general IS: 1893 shall be followed. Specific conditions/technical specification shall be referred
for specific design criteria.
5.04
Safety Features
The Contractor shall provide adequate guards for all couplings and other moving parts which could
be considered a hazard. Safety, sentinel and relief valves are to be located or piped in such a
manner as to safeguard personnel and property. All safety devices shall be in accordance with the
applicable Government regulations and requirements.
5.05
Language & Measurement System

All documents pertaining to the contract including specifications, schedules, notices,
correspondence, operating and maintenance instructions, drawings or any other writing shall be in
English language.
All instruments, recorders, etc. will be calibrated in the metric (C.G.S./ M.K.S.) system of units.
Details of calibration will be provided later.
Page 8 of 56
In drawings or specifications wherever both Metric and British units are indicated, the Contractor
shall indicate the equipment dimensions on both the units. Location marking of all equipment shall
be in Metric Units.
5.06
Accessibility
Special attention shall be given to the design, arrangement and assembly of all equipments to
ensure ease of maintenance and renewal of parts.
5.07
5.08
Standard Equipment & Materials and Alternates

a)
Equipment, material and erection and other services shall be completed in all respects and
in strict accordance with the specifications, except that alternative proposals may be
submitted where stipulated provisions depart from the Contractors Standards, provided
that the substitutions are approved as equivalent by the Engineer and the reasons
therefore are stated by the Contractor in his proposal as a result of such substitution.
b)
Any request for substitution after the contract is awarded, shall be accompanied with the
difference in price and such substitution can only be made on approval by the Engineer on
behalf of the Purchaser in writing, provided that such substitution does not cause any
addition to the contract price.
a)
All work shall be done in accordance with the applicable portions of the current editions of
the codes and standards of the respective U.S.A., U.K. National and Technical Societies or
equal or with the standards and codes of the Government of India, and in accordance with
the applicable portions of the following codes and standards in particular:
Indian Boiler Regulations
Indian Electricity Act
Indian Factories Act
Indian Explosives Act
Indian Standard Institution (IS)
British Standard Institution (BS)
American Society of Mechanical Engineers (ASME)
Institute of Electrical & Electronics Engineers Inc. (IEEE)
Page 9 of 56
American Petroleum Institute (API)

American Society of Testing Materials (ASTM)
Hydraulic Institute
National Electrical Manufacturers Association (NEMA)
American Water Works Association (AWWA)
American Standards Association (ASA)
American Institute of Steel Constructions (AISC)
National Board of Fire Underwriters
Insulated Power Cable Engineers Association (IPCEA)
All the work must be in accordance with the above mentioned codes or equivalent.
b)
6.00
Where conflicts occur between any of the laws, rules, regulations, standards, and so forth,
specified herein, the more stringent requirements shall govern the work.
CONTRACT PRICE
The lump sum prices quoted by the Contractor in his bid with additions and deletions as may be
agreed before signing of the Contract, for the entire scope of the work viz. supply and erection of
equipments covered under the specification and documents shall be treated as the Contract Price.
7.0
TAXES
7.01
The Contractor shall include all taxes, duties, royalty of whatever nature, octroi, other local taxes,
etc., if any, in the quoted price.
7.02
Sales tax or any other tax on material required for the work as also tax on works contract shall be
payable by the Contractor and Owner will not entertain any claim whatsoever.
7.03
Notwithstanding anything contain elsewhere in the contract the Owner shall deduct at source from
the payment due to the contractor the taxes as required under 13(A) of Orisaa Sales Tax Act or
amended from time to time or under any other statute. The amount so deducted shall be paid by
the Owner to the Sales Tax authority as per law. This is for the Contractor to deal with the Sales
Tax authority directly in respect of any claim or refund relating to the above tax and Owner shall not
be liable or responsible for any type of payment or reimbursement in this regard.
Page 10 of 56
7.04
All benefits of taxes duties by way of credit under CENVAT shall be passed on to the
Owner/Purchaser
8.0
CONTRACT - CUM - PERFORMANCE BOND

GUARANTEE FOR DUE EXECUTION OF THE CONTRACT AND PERFORMANCE DURING THE
GUARANTEE PERIOD
The Contractor within thirty (30) days of award of contract shall furnish a Bond by way of a bank
guarantee to be kept alive till 12 months after successful completion of contract in all respects and
equal to ten percent (10%) of the contract price for faithful and due fulfillment by the Contractor of
all obligations under the terms and conditions of the contract and for fulfilling the terms of
guarantee for a period of 12 months after successful completion.
If during the contract period the bond amount gets reduced on account of any recoveries or
otherwise, the contractor shall furnish a bond covering short fall to bring it to 10% of the contract
value. The form of the aforesaid Bond is enclosed.
9.00
PROTECTIVE PAINTING, PACKING & MARKING

The Contractor and/or Manufacturer shall properly clean and/or send blast equipment and apply an
initial coat of rust inhibitor and a flat shop coat of paint (except shop finished equipment). All shop
primer and paints shall be subject to approval of the Engineer. All closely machined parts shall be
covered with an approved protective coating to prevent deterioration of surfaces during
transportation and storage.
The Contractor shall include and provide for securely protecting and packing the equipment so as
to avoid damage in transit under proper conditions and he shall be responsible for all losses or
damage caused or occasioned by any defect in packing.
All equipments shall be packed in accordance with approved packing specifications. All
equipments and parts susceptible to corrosion by exposure to moisture and all electrical
equipments shall be thoroughly protected against damage during transit and storage. The
Purchaser will take no responsibility for any damage done to the equipment enroute to the site of
work, or place of delivery whichever may be specified due to the packing being faulty. Special
packing with identification mark on packages should be provided for fragile materials. The
identification marking indicating the name and address of the consignee shall be clearly marked in
indelible ink on two opposite side and top of each of the packages. In addition, the Contractor shall
include in the marking gross and net weights, outer dimensions and cubic measurements.
Each bale or package shall be accompanied by a packing Note quoting specifically the name of the
Contractor, the number and date of contract, the name of the office placing the contract and
nomenclature of contents.
Page 11 of 56
Dimensions of each package shall not exceed the maximum dimensions of packages which can be
accepted for transport over the `broad gauge system of the Railway concerned.
10.0
SHIPMENT PARTICULARS
10.01 Shipments
a)
Foreign Items
Responsibility of shipment of plant and equipment shall lie with the Contractor wherever
the contract is for complete supply and installation or supply delivered at site basis. The
Contractor shall notify the Purchaser of the date of each shipment from the port of
embarkation as well as date of arrival of such shipment at designated port of arrival for
information.
Responsibility of cleaning the same in the port including all handling shall lie with the
Contractor. Purchaser will only arrange to pay the customs duty as per information on CIF
values given by the Contractor sufficiently in advance.
The Contractor shall give complete shipping information concerning the weight, size,
content of each package including any other information the Purchaser may require.
b)
Indigenous Item
For all contracts for supply and installation or supply delivery at site basis, responsibility of
all transportation from works to site shall lie with the Contractor.
The Contractor shall notify the Owner of the date of each shipment from his works and the
expected date of arrival at the site for information of the Purchaser.
The Contractor shall also give all information concerning the weight, size and content of
each packing including any other information the Purchaser may require.
c)
The Contractor shall further be responsible for all inland transportation up to site for foreign
items after clearing through the port. Contractor shall also be responsible for making all
necessary arrangements for loading, unloading and other handling right from his works till
the site and also till the equipment is erected, tested and commissioned. He shall be solely
responsible for proper storage and safe custody of all equipment.
10.02 Shipping Documents

After shipment is affected following documents shall be forwarded to the Purchaser:
Page 12 of 56
a)
Foreign Items
Within seven (7) days of shipment following shall be airmailed to the Purchaser for
purpose of progress payment and necessary arrangement of payment of customs duty.
- Application of payment in standard format of the Owner (3 copies)
- Bill of Lading (5 non-negotiable copies)
- Invoice including break-up for customs purposes (6 copies)
- Packing list (6 copies)
- Pre-dispatch clearance certificate or shipping release, if any (3 copies)
- Test certificates, wherever applicable (3 copies)
- Certificate of origin
b)
Indigenous items
- Application for payment in standard format of Purchaser (3 copies)
- Invoice (6 copies)
- Packing list (6 copies)
- Pre-dispatch clearance certificate or shipping Release, if any (3 copies)
- Test Certificates wherever applicable (3 copies)
10.03 Demurrage, Wharfage etc.

All demurrage, wharfage and other expenses incurred due to delayed clearance of the material or
any other reason shall be to the account of the Contractor.
10.04 Consignee
All consignment shall be addressed to and the Bill of Lading and other shipping documents shall be
made in the name of the Purchasers Office as may be advised.
Page 13 of 56
11.0
INSURANCE
11.01 The Owner will arrange for INSURANCE of equipment and material, included under the scope of
contract, to cover a)
Risk in transit by ship/air between Contractors port of shipment/air port and Indian port of
entry.
b)
Risks in transit by rail/road during inland transportation up to the Project Site.
c)
Risks during storage and erection at the Project Site till the plant is fully commissioned
under an open general insurance policy. The Owner shall intimate the name of Insurance
Company and other details in due course.
11.02 The Contractor shall furnish dispatch particulars of each consignment including its value
immediately to the Insurance Company. If for any delay in intimating of dispatch particulars to the
Insurance Company on the part of the Contractor the claims for damages are rejected, the
contractor shall be fully responsible for replacement of the damaged equipment.
11.03 The risks that are to be covered under the insurance shall include, but not limited to, the loss or
damage in transit, theft, pilferage, riot, civil commotion, weather conditions, accidents of all kinds,
fire, war risk, etc. The scope of such insurance shall cover the entire value of the Works from time
to time.
11.04 In respect of equipment damaged in transit or during erection and commissioning, the Contractor
shall replace them expeditiously and the replacement cost payable by the Owner shall be limited to
the invoice of damaged equipment. In case of consignment received at the project site in outwardly
sound condition of package but found shortage/damage on being opened the liability for free
replacement will be accepted by the Contractor.
It is the responsibility of the Contractor to lodge a claim on the Insurance Co. on behalf of the
Owner. On receipt of all relevant document relating to the claim, Owner will pursue the matter with
the Insurance Co.
12.00 DELIVERY
Notification of delivery or dispatch in regard to each and every consignment shall be made to the
Purchaser immediately after dispatch or delivery. The Contractor shall further supply to the
Consignee a price invoice and packing account of all stores delivered or dispatched by him. All
packages, containers, bundles and loose materials forming part of each and every consignment
shall be described fully in the packing account, and full details of the contents of packages and
quantity of materials shall be given to enable the Consignee to check the stores on arrival at
destination.
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12.01 Passage of Risk/Ownership

The title to all Indian materials, delivered by the contractor, shall pass on to the Purchaser on its
being handed over to the nominated transporter.
13.00 LIQUIDATED DAMAGES FOR DELAY IN COMPLETION (LD)
If the contractor fails in the due performance of the contract to supply / erection/ testing/
commissioning the equipment within the time fixed by the contract or any extension thereof, he
shall be liable at the discretion of the Engineer to the Liquidated damages and not by way of
penalty amounting to one half of one percent (1/2%) of the contract price per week. The
contractors liability for delay shall not in any case exceed ten percent (10%) of the total contract
price.
If the Contractor shall fail to supply the equipment or any part thereof within a reasonable period
after the expiry of the appointed time or extended time as may be provided for in the contract, the
provisions in Clause No. 28 Negligence shall become operative, in addition to the liability of L.D.
as above.
14.00 IMPORT LICENCE AND FOREIGN EXCHANGE
In case of supply of equipment of indigenous manufacture including any imported components, the
Contractor shall arrange for necessary Import License & Foreign Exchange.
In the event of Contractor requiring Actual Users for import of equipment and/components,
Purchaser shall arrange for obtaining necessary assistance in this regard. Government
authorization may be required to permit the manufacture of certain equipment. The parties shall
assist each other in every manner possible in securing such authorization.
15.00 CONTRACTORS DOCUMENTS, DRAWINGS AND INSTRUCTION MANUALS
15.01 The Contractor shall be responsible for developing detail drawings to adapt his equipment and
materials to the requirement indicated in the tender specification.
15.02 Within a reasonable time not exceeding thirty days from the date of receipt Purchasers Letter of
Intent, the Contractor shall provide the Purchaser with the following drawings and data:
a)
Six (6) marked up copies of technical particulars to make them conforming to accepted
proposals.
b)
Outline drawings of all equipment together with weights and sufficient overall dimensions
to enable the Purchaser to design foundations and structures and associated equipment.
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c)
Drawing submission schedule indicating list of all drawings with their respective titles and
dates shall be submitted to the Purchaser. The schedule shall also indicate the latest date
by which Contractor shall furnish all design calculations. The schedule shall be amended
or extended by the Contractor in consultation with the Purchaser as and when necessary.
15.03 Within a stipulated time period the Contractor shall submit for approval of the Purchaser the
following drawings and technical data:
a)
Dimensional layout drawings of the plant and equipment to be supplied under the contract
and all certified data relating to the design on foundation structures to enable the
Purchaser to arrange for construction of the necessary foundations and civil works.
All information regarding material and size of anchor bolt, nuts, sleeves, inserts and
supports which shall have to be embedded in concrete shall be furnished in the detailed
foundation drawing.
b)
Dimensional drawings showing individual equipment being supplied under the contract,
method and sizes of connections to the Purchasers other equipment, giving also the limits
of variations of the dimensions.
c)
All efficiency and characteristic curves required under the specification.
d)
Schematic drawings of all wirings, connections and interlocking diagrams showing the
points where the connections have to be made by the Purchaser.
e)
Necessary structural and other calculations and data required for demonstrating fully that
all parts of the equipment to be furnished shall conform to the provisions and intent of the
contract.
The Contractor shall submit six (6) prints of each drawing for approval. Two (2) prints shall be
forwarded to the Purchaser and four (4) prints shall be forwarded to the Consulting Engineer.
When prints of drawings have been marked Approved except as noted, Resubmission required
the Contractor shall make necessary corrections and again submit corrected copies for approval as
per details stipulated. Further revision will be shown by number, date and subject in a revision
block.
Upon receipt of the prints which have been marked Approved or Approved except as noted:
Forward Final drawing the Contractor shall furnish within a reasonable time fourteen (14)
additional prints of each of drawings and one (1) reproducible transparency after minor corrections,
if any, to the Purchaser.
Relevant civil construction drawings if felt necessary by Consulting Engineer, shall be forwarded to
the Contractor in triplicate. He shall review incorporation of information furnished by him, such as,
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anchor bolt location, elevation etc. and return one certified copy each to the Purchaser and to the
Consulting Engineer.
Any manufacturing work in connection with the equipment prior to the approval of drawings shall be
at the Contractors risk. The Contractor shall make any change in the designs, with prior approval
of the Engineer, which are necessary to make the equipment conform to the provisions and intent
of the contract, without additional cost to the Purchaser. Approval of Contractors drawings shall
not be held to relieve the Contractor of any part of Contractors obligations to meet all the
requirements of the contract or of the responsibility for the correctness of the Contractors
drawings.
15.04 The details to be furnished shall include, but not restricted to the following:
a)
Finals plans and layout giving complete details against the above mentioned arrangement
plans including foundations plans.
b)
Assembly, sub-assembly and sectional drawings of every equipment.
c)
Complete cabling drawing giving details of cables required, terminal details, layout of
trenches etc.
Detailed wiring diagrams and arrangements of conduits for wiring various controls and
instruments up to the required points.
d)
e)
Shop drawings of all parts of equipment requiring repairing or replacements.
f)
A complete list of special erection tools and tackles required for complete assembly.
15.05 Complete spare part hand books with details and diagrams, separate recommendations shall be
made for the parts required for first one year of operation of important equipment and sent to
Engineer for approval. Parts requiring frequent replacement shall be listed separately from parts
required for ensuring reliability in unforeseen emergencies. On finalization ten (10) set of such
spare part hand books shall be furnished to the Engineer.
15.06 Assembly and erection instruction within a reasonable time after signing of the contract but at least
three (3) months before starting erection the Contractor shall furnish ten (10) sets of the following
for the use of Purchasers field Engineers:
a)
Descriptive literature and drawings to illustrate the working principles, method of assembly
and dismantling.
b)
Instruction book for proper erection and assembly of all equipment and necessary
instructions for checking and recording proper assembly of the plant.
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Erection schedule giving the sequence of erection with reference to package/ assembly/
sub-assembly identification.
c)
Instruction sheets for proper balancing, alignment, adjustment, checking and calibrations
as may be necessary.
15.07 All drawings and technical data are to be furnished in English language only.
15.08 Final Drawings and Operation Maintenance Manuals
Before completion of the work, the Contractor shall furnish fourteen (14) complete sets of prints
and one (1) reproducible transparency of all detailed drawings of the equipment actually supplied
and as erected and assembled at site. In addition ten (10) sets of comprehensive manuals for use
in the operation and maintenance of the plant shall be supplied at least six (6) months before the
actual commissioning date to the Engineer.
15.09 Seven (7) copies of monthly fabrication progress report for all equipment and material shall be
supplied to the Engineer.
16.00 MISTAKES IN DRAWINGS
The Contractor shall be responsible for and shall pay for any alterations of the work due to any
discrepancies, errors or omissions in the drawings or other particulars supplied by him whether
such drawings or particulars have been approved by the Engineer or not.
If any dimensions figured upon a drawing or a plan differ from those obtained by scaling the
drawing or plan the dimensions as figured upon the drawing or plan shall be taken as correct.
17.00 MATERIALS AND WORKMANSHIP
All materials used in the manufacture of the equipment shall be selected from the best available for
the purpose, considering strength, durability and best engineering practice. Liberal factors of safety
shall be used through out the design and specially in the design of all parts subject to alternating
stresses or shocks.
All the work shall be performed and completed in a thorough workmanship like manner and shall
follow the best modern practice in the manufacture of high grade equipment notwithstanding any
omissions in the specifications.
Castings shall be free from holes, flaws, cracks or other defects and shall be smooth, close grained
and of true forms and dimensions. No plugged or filled up holes or other defects will ordinarily be
allowed. Such castings are liable to be rejected.
However, the Contractor may rectify minor casting defects by welding or other method in
accordance with the standard manufacturing practice provided such rectification does not affect the
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strength of the casting or impair the efficient working of the plant and prior approval of the
Purchaser is obtained for the same.
18.00 SPARE PARTS AND SPECIAL MAINTENANCE TOOLS
18.01 The spare parts as required for the equipment under supply are listed in respective specification.
The list is not exhaustive but only indicative.
The Contractor shall also supply list of Guaranteed Spares for two years normal operation
indicating parts name, catalogue no., quantity and unit prices on project site delivery basis. If any
short fall is noticed during 2 years from the date of commissioning the same shall be supplied free
of cost by the Contractor.
18.02 In case of machinery and plant, the Contractor shall include provision for such tools as he
recommends to be absolutely essential for proper maintenance and repair of the plant. A detailed
list of the tools along with the itemized prices shall be submitted along with the tender. In the
absence of this list, the tender is liable to be rejected. One new set of all special tools for
maintenance for each type of equipment shall be furnished by the Contractor at his own expense
and shall be dispatched along with the equipment.
18.03 The contractor shall also undertake that supplies of necessary maintenance equipment and spare
parts will be made available for the life of the plant offered through his Agents on a continuous
basis at reasonable price.
19.00 COMPLETENESS OF EQUIPMENT
The equipment shall be complete in every respect with all mountings, fixtures and standard
accessories which are normally supplied even though not specifically detailed in the specification.
The Contractor shall not be eligible for any extra payment in respect of such mountings, fittings,
fixtures and accessories which are needed for safe operation of the equipment as required by
applicable codes of the country though they may not have been included in the contract.
All similar component parts of similar equipment supplied shall be interchangeable with one
another.
The various equipment supplied under this contract shall be subject to the Purchasers approval
20.00 INSPECTION AND TESTING AT CONTRACTORS PREMISES
The Engineer and his duly authorized representative shall have at all reasonable times access to
the Contractors /Sub-contractors premises of works, and shall have the power at all reasonable
times to inspect drawings of any portion of the work or examine the materials and workmanship of
the plant during its manufacture there and if part of the plant is being manufactured on other
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premises, the Contractor shall obtain for the Engineer and his duly authorized representative
permission to inspect as if the plant is manufactured on the Contractors premises.
The Engineer shall on giving seven (7) days notice in writing to the Contractor setting out any
grounds of objections which he may have in respect of the work, be at liberty to reject any drawings
& all or any part of workmanship if the subject of any of the said grounds of objection, which in his
opinion are not in accordance with the contract. The Contractor shall give due consideration to
such objections and shall either make the modifications that may be necessary to meet the said
objections or shall confirm in writing to the Engineer giving therein that no modifications are
necessary to comply with the contract.
The Contractor shall give the Engineer and his duly authorized representatives notice of any
material being ready for testing and the Engineer or the said representative shall (unless the
inspection of tests is voluntarily waived), on giving twenty four (24) hours previous notice in writing
to the Contractor, attend at the Contractors premises (as the case may be) within fifteen (15) days
of the date on which the material is notified as being ready failing which visit, the Contractor may
proceed with the tests which shall be deemed to have been made in the Engineers presence. All
standard shop tests, physical and chemical tests required by the Standards or as may be
prescribed or approved by the Engineer shall be conducted by the Contractor. The Engineer
reserves the right to waive any of the above test requirement and to prescribe new test required if
found necessary to expedite the work or to conform to the latest and best practice. Definitions,
methods of measurement, calibration of instruments and required procedure as referred in the
above standard and/or those approved by the Engineer as equivalent shall be followed. The
Contractor shall forthwith forward to the Engineer duly certified copies of the test certificates in
quadruplicate (one copy to the Purchaser and three copies to the consulting Engineer) for
approval. Further ten (10) copies of the shop test certificate shall be bound with the instruction
manuals referred to in clause Contractors documents, drawings and instruction manuals.
In all cases where contract provides for tests, whether at the premises or works of the Contractor
or any sub-contractor, the Contractor, except where otherwise specified shall provide free of
charge to the Purchaser, such labor, materials, electricity, fuel, water, stores, apparatus and
instruments as may reasonably be demanded to carry out efficiently such tests of the plant, in
accordance with the contract and shall give facilities to the Engineer or his authorized
representative to accomplish such testing.
When the tests have been satisfactorily completed in the Contractor/Sub-contractors Works, the
Engineer shall issue a certificate to that effect within fifteen (15) days after completion of test, but if
the tests were not witnessed by the Engineer or his representative the certificate would be issued
within fifteen (15) days of the receipt of the test certificates by the Engineer. No plant shall be
transported before such a certificate has been issued. The satisfactory completion of these tests or
the issue of this certificate shall not bind the Purchaser to accept the plant should it on further tests
after erection, be found not to comply with the contract provisions.
Page 20 of 56
21.00 TESTS ON COMPLETION AND TRIAL RUN AT SITE

Where possible all tests shall be carried out before dispatch. Should, however, it become
necessary for the final tests as to performance and guarantees to be held over until the plant is
erected at site, they shall be carried out as per agreed procedure within two (2) months or such
time as may be considered reasonable by the Purchaser after commissioning of the equipment.
Inspection and test at site during erection and on completion of erection shall be carried out on any
plant and equipment to satisfy the guaranteed performance of each equipment and the whole
installation as set forth below:
Individual equipment tests:
(I)
Inspection and checking of units
(II)
Placing in operation
(II)
Initial operation
(IV)
Reliability tests
(V)
Efficiency and consumption tests
(VI)
Load tests
The sequence of tests for individual equipment shall be as mutually agreed to between the
Contractor and the Engineer.
Duration of the trial operation of the complete equipment shall be 30 continuous days with available
wagon rakes during this period as mutually agreed and decided. The acceptance test shall be
carried out within two (2) months after the trial run has been satisfactorily completed. Any delay for
carrying out these works for force majeure reasons shall be given due consideration. Should the
result of these tests not come within the margin specified, the test shall, if required, be repeated
after necessary rectification measures recommended by the Contractor within one (1) month from
the date of plant is ready for retest, and the Contractor shall repay to the Purchaser all reasonable
expenses which he may be put to by such tests.
The performance and acceptance tests of the complete installation shall be carried out to prove the
guarantees specified for different equipment. These tests shall be made in accordance with
established and approved procedures. The Contractor shall submit within reasonable time after the
award of contract, detailed procedure for conductance of all tests for approval of the Engineer. The
procedure shall include the following information for such test:
Page 21 of 56
(I)
Loads at which tests will be conducted.
(II)
Time and durations of each test.
(II)
Instrument locations shown by a schematic diagram for each test. (Calibration certificates
for each instrument shall be furnished before commencement of test).
(IV)
All formulas, calculations, conversion factors, correction curves, etc. to be used for test
conductance.
(V)
Sample test report forms, and data sheet that will be used to record test results and
valuation of final results.
On completion of all tests, the overall efficiency of the plant shall be determined in accordance with
the procedure mutually agreed upon between the Contractor and the Engineer unless otherwise
covered under the Standards and Specification.
In all cases, where the contract provides for test at the site, the Purchaser, except where otherwise
specified, shall provide, free of charge, such labor, materials, fuel, water, electricity, lubricants as
may be required from time to time and as may reasonably be demanded to carry out such tests of
the plant, material or workmanship in accordance with the contract. Any special apparatus and
precision instruments required for site test shall be provided by the Contractor.
If for any reason, other than the fault of the contractor performance and acceptance tests for any
unit shall not be carried out within sixty (60) days of notice by the Contractor to the Purchaser of
the unit being ready for tests, then the Purchaser will issue an acceptance certificate on the last
day of such period and payments due to the Contractor on acceptance shall be made, but
nevertheless the Contractor, shall if called upon to do so by the Purchaser, within a period twelve
(12) months from the said last date, make the said tests on the same terms as provided in the
contract.
22.00 TAKING OVER
Upon successful completion of all the tests to be performed at site on equipment and systems
furnished and erected by the Contractor, the Engineer shall Issue to the Contractor a taking over
certificate as a proof of the final acceptance of the equipment. Such certificate shall not relieve the
Contractor of any of his obligations which otherwise survive by terms and conditions of the contract
after issuance of such certificate.
23.00 REJECTION OF DEFECTIVE PLANT
If the completed plant or any portion thereof, it is taken over under the clause Taking Over, be
found defective or fails to fulfill the requirements of the contract, the Engineer shall give the
Contractor notice selling forth particulars of such defects or failure, and the Contractor shall forth
Page 22 of 56
wile make the defective plant good or to make it comply with the requirements of the contract.
Should he fail to do so within a reasonable time, the Purchaser may reject and, replace at the cost
of the Contractor the whole or any portion of the plant as the case may be, which is defective or
fails to fulfill the requirements of the Contract. Such replacement shall be carried out by the
Purchaser within a reasonable time and at a reasonable price, and where reasonably possible to
the same specification and under comparative condition. The Contractors full and extreme liability
under the clause shall be satisfied by the payment to the purchaser of the original contract price
including charges of erection and/or supervision of erection plus the difference if any between the
replacement price of the equipment including charges for erection and /or supervision of erection
and the original contract price including charges for erection and / or supervision of erection in
respect of such defective plant.
In the event of such rejection, the Purchaser shall have the right to operate any and all equipment
as soon as and as long as it is in operating condition, whether or not, such equipment has been
accepted as complete and satisfactory, to enable him to obtain necessary replacement, except that
this shall not be construed to permit operation of any equipment which may become damaged by
such operation before any required alternations or repairs and/or replacement have been made. All
repairs or alternations or replacement required of the Contractor shall be made by the Contractor at
such times as directed and in such manner as will cause the minimum interruption in the use of the
equipment by the Purchaser. Should the Purchaser not so replace the rejected plant within a
reasonable time, the Contractors full and extreme liability under his clause will be satisfied by the
repayment of all money paid by the Purchaser to him in respect of such plant.
Nothing in this clause shall be deemed to deprive the Purchaser or affect any rights under the
contract which he may otherwise have in respect of such defects or deficiencies or in any way
relieve the Contractor of his obligations under the contract.
24.00 COMPLETION CERTIFICATE & FINAL CERTIFICATE
24.01 Application for Completion Certificate
When the contractor fulfils his obligation under the contract he shall be eligible to apply for
completion certificate in respect of the work by submitting the completion documents along with
such application for completion certificate.
The owner or his representative shall normally issue to the Contractor the completion certificate
within one month after receiving an application from the Contractor after verifying from the
completion documents and satisfying himself that the work has been completed in accordance with
and as set out in the construction and erection drawings, and the contract documents.
The contractor, after obtaining the completion certificate, is eligible to present the final bill for the
work executed by him under the terms of contract.
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24.02 Completion Certificate

Within one month of the completion of work in all respects the Contractor, shall be furnished with a
certificate by the owner or his representative of such completion but no completion certificate shall
be give nor shall the work be deemed to have been executed until all scaffoldings surplus material
and rubbish is cleared off the site completely nor until the work shall have been measured by the
Engineer, whose measurement shall be binding and conclusive. The work will not be considered as
complete and taken over by the Owner, until all the temporary works, labor and staff colonies etc.
constructed are removed and work site cleared to the satisfaction of the Engineer.
If the Contractor shall fall to comply with the requirements of this clause on or before the date fixed
for the completion of the work, the Engineer may at the expenses of the Contractor remove such
scaffoldings, surplus materials and rubbish and dispose off the same as he thinks fit and clean off
such dirt as aforesaid, and the Contractor shall forthwith pay the amount of all expenses so
incurred and shall have not claim in respect of any such scaffolding or surplus materials as
aforesaid except for any sum actually realized by the sale thereof.
Completion Certificate shall be in 3 parts as follows:
1)
2)
3)
Physical/Mechanical completion work.

Satisfactory completion of commissioning of equipment with load.
Satisfactory completion of guarantee.
The Contractor shall clearly indicate the 3 dates separately.

24.03 Completion Documents
For the purpose of clause 24, the following documents will be deemed to form the completion
documents:
(i)
The technical documents according to which the work was carried out.
(ii)
Three sets of construction drawings showing therein the modification and corrections
made during the course of execution and signed by the Engineer.
(ii)
Completion Certificate for embedded and Covered-up works.
(iv)
Certificates of final levels as set out for various works.
(v)
Certificates of test performed for various works.
(vi)
Materials appropriation statement for the materials issued by the owner for the works and
list of surplus materials returned to the owners store duly supported by necessary
documents.
Page 24 of 56
(vi)
Physical / Mechanical completion work.
(viii)
Satisfactory completion of commissioning of equipments with load.
(ix)
Satisfactory completion of guarantee.
The contractor shall clearly indicate the 3 dates separately.

24.04 Final Decision and Final Certificate
Upon the expiration of the period of liability and subject to the Engineer being satisfied that the
works have been duly maintained by the Contractors during monsoon or such period as herein
provided in clause 8.00 and that the Contractor has in all respect duly made up all subsidence and
performed all his obligations under the contract, the Engineer shall (without prejudice to the right of
the Owner to retain the provision of relevant clause hereof) otherwise give a certificate, herein
referred to as the final certificate, to that effect and the Contractor shall not be considered to have
fulfilled the whole of his obligations under the contract until Final Certificate shall have been given
by the Engineer not withstanding any previous entry upon the work and taking possession, working
or using of the same or any part thereof by the Owner.
24.05 Certificate and Payments No Evidence of Completion
Except the final certificate, no other certificates or payment against a certificate or on general
account shall be taken to be an admission by the Owner of the due performance of the Contract or
any part thereof or of occupancy or validity of any claim by the Contractor.
25.00 ENGINEERS DECISION
In respect of all matters which are left to the decision of the Engineer the Engineer shall, if so
required to do so by the Contractor give in writing a decision there on to the Contractor. All
decisions of the Engineer shall be binding on the Contract.
26.00 CERTIFICATE NOT TO AFFECT THE RIGHTS OF THE PURCHASER OR THE CONTRACTOR
No Certificate of the Engineer on account, nor any sum paid on account by the Purchaser, nor any
extension of time for the execution of the works by the Contractor shall affect or prejudice the rights
of the Purchaser against the Contractor or relieve the Contractor of his obligations of the materials
supplied and no certificate shall create liability for the Purchaser to pay for alterations,
amendments, variations of additional work, not ordered in writing by the Engineer or discharge the
liability of the Contractor for payment of damages, whether due, ascertained or certified or not to
any sum against the payment of which he is bound to Indemnify the Purchaser, nor shall any such
certificate nor the acceptance by him or any sum paid on account or otherwise, affect or prejudice
the rights of the Contractor against the Purchaser.
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27.00 MAINTENANCE AND GUARANTEE WARRANTY PERIOD

The Contractor shall guarantee in respect of the plant and materials to be furnished by him the
following:
(a)
All equipment shall be free from any defect due to faulty design, materials and/or
workmanship.
(b)
The equipment shall operate satisfactorily and the performance and efficiencies of the
equipments shall not be less than the respective guaranteed values.
(c)
The efficiencies, temperature rises and other performance data furnished for the
equipment.
The guarantees have to be furnished on forms approved by the Engineer and shall be signed by
the Contractor and / or his sub-contractor.
If the Contractor finds, after his tender is accepted, that a variation in work, construction technique
or the quality of materials is necessary to fulfill the guarantees called for, such variations may be
made with the approval of the Engineer, provided the request for changes is made before signing
the contract the changes are to be made without any increase in the contract price.
The above guarantees shall be valid for a period of twelve (12) calendar months commencing
immediately on the satisfactory completion of the final tests at site or thirty six (36) months after
the last consignment to complete the plant is received at site,, whichever may be earlier. This
period of the guarantee shall be called the Warranty period. During this period, the contractors
liability shall be limited to the replacement of any defective parts that may develop in plant of his
own manufacture of those of his sub-contractors under the conditions provided for by the contract
under proper use and arising solely from faulty design, materials or workmanship provided always
that such defective parts as are not repairable at site, and are not essential in the meantime in the
commercial use of the plant, are promptly returned to the Contractors Works unless otherwise
arranged. All such replacements of defective parts mentioned above shall be made free of costs at
site by the Contractor and the return of the defective parts to the Contractors works shall be the
Contractors responsibility and shall be made at his expense. The Purchaser will, however, render
such assistance in this matter as well expedite the same. In the case of defective parts not
repairable at site but essential in the meantime for the commercial use of the plant, the Contractor
shall replace at site free of cost to the Purchaser the said defective parts before the defective parts
are removed to his Works.
If for rectification or replacement of any part of equipment or work due to defective materials,
manufacture or design, the services of the Contractor personnel are requisitioned within the
guarantee period, these services shall be made available free of any cost to the Purchaser.
Page 26 of 56
If it becomes necessary for the contractor to replace or renew any defective portions of the plant
under this clause, the provisions of this clause will apply to the portions of the plants so replaced or
renewed until the expiration of six (6) months from the date of such replacement or renewal or until
the end of the above mentioned period of twelve (12) months, whichever may be later. If any defect
be not remedied within a reasonable time, the Purchaser may proceed to do the work at the
Contractors risk and expenses but without prejudice to any other rights which the Purchaser may
have against the Contractor in respect of such defects.
If the replacement or renewals are of such character as may affect the efficiency of the plant, the
Purchaser shall have the right to give the Contractor within one month of such replacement or
renewal, notice in writing that tests on completion be made in which case such tests be carriedout as provided in clause tests a completion and trial run at site hereof. Should such test show
that the plant sustains the guarantee given in the Contract; the cost of the tests will be borne by the
Purchaser. Should the guarantee be not sustained, the cost of the test shall be borne by the
Contractor.
All replacement or renewals to be carried out by contractor during the maintenance period shall be
subject to such clauses of these general conditions as may be considered reasonable by the
Engineer.
Until the final certificate has been issued, the Contractor shall have the right of entry, at his own
risk and expenses by himself or his duly authorized representatives whose names shall previously
have been communicated in writing to the Engineer, at all reasonable working hours upon all
necessary parts of the works, for the purpose of inspecting the working and the records of the plant
and taking notes there from and, if he desires, at his own expense making any tests, subject to the
approval of the Engineer that work will not be unreasonably withheld.
The issue of the Engineers Certificate referred to in clause Certificate of Engineer shall in no way
expect the contractor from the provision of this clause.
At the end of the maintenance period, the liability ceases. In respect of goods not covered by the
first paragraph of this clause, the Purchaser shall be entitled to the benefit of any guarantee given
to the Contractor by the original supplier or manufacturer of such goods.
28.00 NEGLIGENCE
If the Contractor neglects to execute the work with due diligence and expedition or refuses or
neglect to comply with any reasonable orders given to him in writing by the Engineer in connection
with the work, or contravene the provisions of the contract, the Purchaser may give notice in writing
to the Contractor calling upon him to make good the failure, neglect or contravention complained or
should the Contractor fail to comply with such notice within a period considered reasonable by the
Purchaser from the date of service thereof, in the case of failure, neglect or contravention capable
of being made good within that time or otherwise within such time as may in the opinion or the
Purchaser be reasonably necessary for making it good, then and in such case the Purchaser shall
Page 27 of 56
have the option and be at liberty to take the work wholly or in part, out of the Contractors hand and
may carry on the work envisaged in the contract at a price with any other person or persons to
execute the same or any part thereof and provide any other materials, tools, tackle or labor for the
purpose of completing the works or part thereof. In such event the Purchaser shall without being
responsible to the Contractor for fair wear and tear of the same be entitled to seize and take
possession and have free use of all materials, tools, tackle or other things which may be on the
site, for use at any time in connection with the work to the exclusion of any right of the Contractor
over the same and the Purchaser shall be entitled to retain and apply and balance sum which may
otherwise be then due on the contract by him to the Contractor or such part thereof as may be
necessary, to the payment of the cost of execution of such work as aforesaid.
If the cost of executing the work as aforesaid shall exceed the balance due to the Contractor and
the Contractor fails to make good the deficit, the said materials, tools, tackle, construction plant or
other things, the property of the Contractor as may not have been used up in the completion of the
works, may be sold by the Purchaser and the proceeds applied towards the payment of such
difference and the cost of an incidental to such sale. Any outstanding balance existing after
crediting the proceeds of such sale shall be paid by the Contractor on the certificate of the
Engineer. But when all expenses cost and charges incurred in the completion of the work are paid
by the Contractor, all such materials, tools, tackle, construction plant or other things not used up in
the completion of the works and remaining unsold shall be removed by the Contractor. If the
proceeds of the above sale of the Contractors materials, tools, tackle, construction plant etc. are
insufficient to cover the executing the aforesaid work, the balance remaining after crediting the
proceeds of such sale shall be recoverable from the Contractor by encashing the Bank
Guarantee/available/ any other money payable by Purchaser or by action of law.
Not withstanding anything contained above, the Purchaser may determine the contract due to any
breach or failure of the Contractor, without notice before determining the contract as above, if in the
opinion of the Purchaser, the default or defaults committed by the Contractor is/are curable and
can be cured by the Contractor if an opportunity is given to him, then the owner may issue a notice
in writing calling upon the Contractor to cure the default within such time as may be specified in the
notice.
In the event of termination, the security deposit will be forfeited without reference to the Contractor
and if no amount is available towards Security Deposit, an identical amount is recoverable from the
contractor.
29.00 POWER TO VARY OR OMIT WORK
No alternations, amendments, omissions, additions, suspensions or variations of the work
hereinafter referred to as Variations, under the contract shall be made by the Contractor except as
directed in writing by the Engineer, but the Engineer shall have full power, subject to the provision
hereinafter contained from time to time during the execution of the contract by notice in writing, to
instruct the Contractor to make such variation without prejudice to the contract and the Contractor
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shall carry out such variation and be bound by the same conditions as far as applicable, as though
the said variation occurred in the contract.
If any suggested variations would, in the opinion of the Contractor, if carried out prevent him from
fulfilling any of his obligations or guarantees under the contract, he shall notify the Engineer thereof
within 10 days in writing and the Engineer shall decide forthwith whether or not the same shall be
carried out and if the Engineer confirms his instructions, the contractors obligations and
guarantees shall be modified to such and extent as may be justified. In the absence of any such
notification, the Contractor shall be bound to carry out the suggested variations without any
additional financial implication to Purchaser and it will amount to an absolute waiver of any claim
whatsoever.
30.00 SETTLEMENT OF DISPUTE
30.01 Except as otherwise specifically provided in the Contract all disputes concerning question of fact
arising under the Contract s hall be decided by the Engineer subject to a written appeal by the
Contractor to the Engineer, whose decision shall be final to the parties hereto.
30.02 Any disputes or differences including those considered as such by only one of the parties arising
out of or in connection with the Contract shall be to the extent possible settled amicably between
the parties.
30.03 If amicable settlement can not be reached then unresolved disputed issues may be settled by
arbitration as provided subsequently.
31.00 TERMINATION OF CONTRACT
Notwithstanding anything contained elsewhere in this contract, if at any time during the term of this
contract the plans of the Government of India and/ or the State Government change for any
reason, the Purchaser shall have the right to terminate the Contract by notice to the Contractor by
a registered letter. In respect of such changes the material that is complete as ready for
transportation within thirty (30) days after such notice, Purchaser agrees to accept delivery thereof
at the contract price and terms. In the case of the remainder of the undeliverable material, the
Purchaser may elect (a) to have any part thereof completed and take delivery thereof at the
contract price and (b) to cancel the residue (if any) and pay to the Contractor aprorated amount of
the contract price based upon the state of completion to be certified by him. The Contractor shall
deliver all such material in process of manufacture to the Purchaser and shall return to the
Purchaser any funds remaining to the Purchasers credit. No payment shall be made by the
Purchaser for any material not yet in process of manufacture on the date of notice of cancellation is
received.
32.00 DEDUCTION FROM CONTRACT PRICE
All costs, damages or expenses which the Purchaser may have paid, for which under the contract
Contractor is liable, may be deducted by the Purchaser from any money due or be coming due by
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him to the Contractor under the contract, or may be recovered by action of law or otherwise from
the Contractor. Further all legal and statutory deductions will be made and the Contractor is not
entitled to any reimbursement or claim what-so-ever except only a tax deduction certificate.
In the event of recovery to the necessary extent becoming impossible owing to insufficiency of the
performance bond and withheld amounts, the balance due to the purchaser, may be recovered in
any way the Purchaser may deem fit.
33.00 CO-OPERATION WITH OTHER CONTRACTORS AND CONSULTING ENGINEERS
The Contractor shall agree to co-operate with the Purchasers other contractors and Consulting
Engineers for associated equipment and freely exchange with them such technical Information as
is necessary to obtain the most efficient and economical design and to avoid unnecessary
duplication of equipment. No remuneration shall be claimed from the Purchaser for such technical
cooperation. The Purchaser and consulting Engineer shall be provided with two (2) copies each of
all correspondence addressed by the Contractor to other Contractors in respect to such exchange
of technical information.
If any part of the Contractors work depends for proper execution or results upon the work of any
other Contractor, the Contractor shall inspect and promptly report in writing to the engineer any
defects; in such works that render it unsuitable for such proper execution and results. His failure to
so inspect and report shall constitute an acceptance of the other Contractors work as fit and
proper for the reception of his work, except as to defects which may develop in the other
Contractors work after the proper execution of his work.
34.00 ASSIGNMENT OF CONTRACT
Any assignment of the contract or any part thereof or any rights or obligations there under, by the
Contractor without the prior written consent of the Purchaser shall be void.
The purchaser shall be at liberty to transfer and assign the contract only to Government Company
as defined in the Indian Companies Act-I of 1956, and such Company shall exercise all the rights
and be liable for all obligations of the Purchaser contained herein in the same manner as if the
agreement had been entered into between the said Company and the Purchaser. The purchaser
shall be also at liberty to entrust the carrying out of the agreement only to a Government Institution
and upon the Instructions of the purchaser, the Contractor undertakes to do all things necessary to
carry out of his obligations under the agreement with such institution as may be entrusted by the
purchaser as agent or otherwise. The Purchaser, however, shall not be in either case relieved or
discharged from any of his obligations and liabilities under the contract.
The contractors shall be advised in writing of the date of any such substitution.
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35.0
SUBLETING OF CONTRACT
The Contractor shall not without the consent in writing of the Purchaser, which shall not be
unreasonably withheld, assign or sublet his contract or any substantial part thereof other than for
raw materials, for minor details, or for any part of the works of which the makers are named in the
contract, provided that any such consent shall not relieve the Contractor from any obligation, duty
or responsibility under the contract.
For components/equipments procured by the Contractors for the purpose of the Contract; after
obtaining the written approval of the Owner, the Contractors purchase specifications and enquiries
shall call for quality plans to be submitted by the suppliers along with their proposals. The quality
plans called for from the vendors shall set out, during the various stages of manufacture and
installation, the quality practices and procedures followed by the Vendors quality control
organization, the relevant reference documents/standards used, acceptance level, inspection of
documentation raised, etc. Such quality plans of the successful vendors shall be discussed and
finalized in consultation with the Engineer and shall form a part of the purchase order/contract
between the Contractor and the vendor. Within 3 weeks of the release of the same purchase
order/contracts for such bought out items/components, a copy of the same without price details but
together with detailed purchase specifications, quality plants and delivery conditions shall be
furnished to the Engineer by the Contractor.
36.00 SUSPENSION OF WORK

The owner reserves the right to suspend and reinstate execution of the whole or any part of the
works without invalidating the provisions of the contract. Orders for suspension or reinstatement of
the works will be issued by the Engineer to the Contractor in writing. The time for completion of the
works will be extended for a period equal to duration of the suspensions. Any necessary and
demonstrable costs incurred by the contractors as a result of such suspension of works other than
force majeure conditions will be paid by the owner, provided such costs are substantiated to the
satisfaction of the Engineer. The owner shall not be responsible for any liabilities if suspension or
delay is due to some default on the part of the Contractor or his sub- Contractor.
37.00 FORCE MAJEURE
37.01 Any delays in or failure of the performance of either parties thereto shall not constitute default here
under or give rise to any claims for damages, if any, to the extent such delays or failure of
performance caused by occurrences such as acts of God or the public enemy, expropriation or
confiscation of facilities by Government authority, compliance with any order or request of any
Government authorities, act of war rebellion, sabotage, fire, floods, explosions, riots or illegal
strikes, provided always that such occurrence result in impossibility of performances of the
contract.
37.02 Only events of Force Majeure which impedes the execution of the contract at the time of its
occurrence shall be taken into cognizance.
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38.00 PROGRESS REPORTS AND PHOTOGRAPHS

The Contractor shall furnish six (6) prints each of progress reports and photographs of the work
done in his shop. Photographs shall be taken when the where indicated by the Engineer or his
representative. Photographs shall be approximately 100 mm x 125 mm in size including a margin
of 5 mm side of fixing. Adequate number of photographs shall be submitted indicating various
stages of manufacture. Each photograph shall contain the date the name of the Contractor and the
title of the view taken.
Monthly progress reports shall be submitted. These shall detail the status of design, procurement
of raw materials and manufacture of the equipment. The Engineer shall advise the Contractor
about the number of copies of progress schedule and photographs he has to submit each month
together with the names and address of persons to whom they are to be sent.
39.00 PATENT RIGHTS
Royalties and fees for patents covering materials, articles, apparatus devices, equipment and
processes used in the plant and equipment shall be deem to have been included in the Contract
Price. The Contractor shall defend any claims which alleged in a suit or proceeding against the
Purchaser that the equipment or any part thereof constitutes an infringement of any patent, it
notified promptly in writing and given authority, Information and assistance for the defense and the
Contractor shall pay all damages and costs awarded against the Purchaser in such suit or
proceeding for the patent infringement. In case the equipment in such suit or proceeding is held to
constitute infringement and the use of the equipment or part is prohibited, the Contractor shall, at
his own expenses, either procure for the Purchaser the right to continue using the equipment or
replace same with a non-infringing equipment or modify it so it become non-infringing or remove
the equipment and refund the purchase price plus the transportation and installation costs thereof.
The foregoing states entire liability of the Contractor for patent infringement and the Purchaser
shall be kept indemnified in this regard.
Notwithstanding any dispute regarding patents Purchaser will have a right to the use of materials,
articles, apparatus, devices, equipment and process till final adjudication of such dispute.
40.00 TRAINING OF ENGINEERS
It so desired by the Purchaser, the Contractor shall undertake to train Engineers to be nominated
by the Purchaser in the manufacture, testing, erection and operation of similar equipment as
covered by the contract. The period of training, number of engineers to be trained, program of
training will be mutually agreed upon. Cost of to and fro traveling for each engineer to the
manufacturers factory and their living expenses shall be borne by the Purchaser.
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41.00 EFFECT & JURISDICTION OF CONTRACT

41.01 The contract shall be considered as having come into force from the date of the acceptance of
Letter of Intent.
41.02 The laws applicable to this contract shall be in the laws in force in India. The courts of Orissa shall
have exclusive jurisdiction in all matters arising under the contract.
42.00 TIME IS THE ESSENCE OF CONTRACT
42.01 The time and the date of completion of the works as stipulated in the contractors proposal and
accepted by the owner without or with modifications, if any, and so incorporated in the Letter of
Intent, shall be deemed to be the essence of the contract. The Contract shall so organize his
resources and perform his work as to complete it not later than the date agreed to.
42.02 The Contractor shall submit a detailed PERT Network within the time frame agreed above covering
various key phases of the works such as design, procurement, manufacturing, shipment and field
erection activities within thirty (30) days after the date of Letter of Intent. This network shall also
indicate the interface facilities to be provided by the Owner and the dates by which such facilities
are needed.
Contractor shall discuss the network so submitted with the owner. The agreed network which may
be in the form as submitted or in revised form in line with the outcome of discussions shall form
part of the Contract to be signed within sixty (60) days from the date of acceptance of Letter of
Intent. During the performance of the contract, if in the opinion of the Engineer proper progress is
not maintained suitable changes shall be made in the contractors operations to ensure proper
progress.
42.03 The above PERT network shall be reviewed and periodic review reports shall be submitted by the
Contractor as directed by the Engineer.
42.04 Within a month of the award of the contract, the Contractor shall make available to the Engineer, a
detailed manufacturing programme, in line with the agreed contract network. Such manufacturing
program shall be reviewed, updated and submitted to the Engineer once every two months
thereafter.
43.00 ERECTION SUPERVISION SERVICES
The Contractor, if required by the Purchaser, shall furnish the services of one or more supervisors,
to render technical advice, assistance and guidance to the Purchaser in connection with the
erection and/or commissioning of equipment subject to the provisions herein after set forth. In case
of complete erection of plant and materials such services shall automatically be included in the
scope of the Contractor and no extra charges shall be applicable.
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The Purchaser; shall pay the Contractor for the service of each supervisor as follows:
(a)
As agreed rate; per-calendar day from the date on which supervisor leave his
headquarters up to and including the date of his return thereto. This rate is based up on a
normal 48 hours work-week of six (6) eight-hour workdays, Monday through Saturday.
Sunday will be normally a holiday but any other day of the week may be made a normal
holiday depending upon working conditions.
(b)
The Purchaser shall in addition to the charge specified in paragraph above, pay the
Contractor for any overtime work authorized by the Purchaser and performed by the
supervisor at an agreed overtime rate per hour for hours worked in excess of 8 hours per
day and all hours worked on the seventh day. There will be no overtime charge for work
performed on locally recognized or national holiday or time spent in traveling to and from
the supervisors headquarters.
(c)
Hours during which the supervisor is ready, willing and able to work up to 48 hours per
week shall be regarded as having actually been worked by him even though his services
are not in fact utilized.
The Purchaser shall secure any labor permit or any other authorization which may be required to
permit the Erection Supervisor to perform the services and any loss of the supervisors services
pending the procurement of any such permit or authorization shall be to the Purchasers account
and shall be paid for by the Purchaser.
The Purchaser shall furnish, at his own expenses, and assume responsibility for all labor and labor
supervision and shall make available all necessary installation to tools, except such special tools
as may be supplied by the Contractor pursuant to written agreement between the parties. The
supervisor may elect to bring certain personal tools which tools are to remain his property at all
times. The Purchaser shall assist the Supervisor in arranging entry and exit permit for such tools.
If any portion of the work of supervision by the Contractor proves to be defective within one (1)
year from the date of completion of supervision, the Contractor, if promptly notified thereof in
writing, will at his own expense, and at his option, with make repairs or supply replacement parts
directly to or for the equipment and necessary to correct any defect or defects in such equipment
directly resulting from such defective work of supervision on the part of the Contractor and will at
his own expenses, furnish the necessary supervision for such corrections. The contractors liability
in connection with his furnishing a supervisor hereunder shall in no event exceed the cost of
correcting any such defective work of supervision in the manner herein provided and upon the
expiration of the said one (1) year, all such liability shall terminate. In no event shall the Contractor
be liable for special, indirect or consequential damages.
The Contractor shall not be liable for loss of damage due to delays in furnishing the services or in
the work resulting form any cause beyond the Contractors reasonable control including
compliance with any Government regulations, orders or instructions, acts of God, acts of omission
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of Purchaser, acts of civil or military authority, fires, strikes, war earthquake, storm, volcanic
eruptions, landslide, riot or delays in transportation. The Purchaser shall advise the Contractor in
writing reasonably in advance of the date that the supervisor shall be required to start performance
of the services.
44.00 ERECTION OF PLANT AND MATERIALS
44.01 General
Unless otherwise mutually agreed to the provisions of this clause shall apply where the services for
erection of plant & material supplied by the contractor are included in the scope of work.
If so desired by the Purchaser, the Contractor shall receive the imported equipment, if any, at the
port of entry, clear them through Customs and make damage report through port broker. The
Contractor shall arrange for payment at prescribed rate of Customs Duty which will be reimbursed
by the Purchaser against Contractors valid documents.
The Contractor shall transport all imported equipment from port of entry to the site and unload all
Imported/Indigenous equipment at site. Escort service shall be provided, if necessary and called
for. All storage at port of entry or at railway station will be at Contractors charge.
The Contractor shall be responsible for complete installation of the equipment start-up and testing
at site.
All equipment and tools for transportation and erection shall be provided by the Contractor.
All materials and /or equipment, after receipt at site, shall be checked and verified against shipping
documents and all claims against loss or damage in transit shall be intimated to the purchaser. The
materials and/or equipment shall remain under the custody of the Contractor until the plant as a
whole is taken over by the Purchaser upon completion of the work. The Contractor shall take
adequate steps to ensure safety of such materials and / or equipment. Necessary stores receipt
certificates shall be issued to the Purchaser after the stores are checked and certified. No materials
and/or equipment pertaining to the Contract shall be removed from site without the consent in
writing of the Purchaser.
The Contractor shall be responsible for obtaining the correct reference lines for purposes of fixing
the alignment of various equipment.
44.02 Regulation of Local Authorities and Statues
The Contractor shall comply with the rules and regulations of local authorities during the
performance of his field activities. He shall also comply with the minimum wages Act, 1948 and the
payment of wages act (both of the Government of India) and the rules made there under in respect
of any employee or workmen employed or engaged by him or his sub-Contractor.
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All registration and statutory inspection fees, if any, in respect of his work pursuant to this contract
shall be to the account of the Contractor. However, any registration, statutory inspection fees
lawfully payable under the provisions of the Indian Boiler Regulations and any other statutory laws
and its amendments from time to time during erection in respect of the plant equipment ultimately
to be owned by the Purchaser, shall be to the account of the Purchaser. Should any such
inspection or registration need to be re-arranged due to the fault of the Contractor or his subContractor, the additional fees of such inspection and/or registration shall be borne by the
Contractor.
44.03 Work at Site
In the execution of work, no persons other than the Contractor or his appointed representative,
sub-Contractor and workmen shall be allowed to do work at site, except by the special permission
in writing of the Engineer or his representative, but access to the Works at all times shall be
accorded to the Engineer and his representative and other authorized officials or representatives of
the Purchaser.
Nevertheless, the Contractor shall not object to the execution of work by other Contractors or
tradesmen whose names shall have been previously communicated in writing to the Contractor by
the Engineer and afford them every facility for the execution of their several works simultaneously
with his own.
The Contractor shall at all times provide sufficient fencing, notice boards, lights and watchmen to
protect and warn the public and guard the works, and in default thereof the Purchaser may
provided such fencing, notice boards, lights and watchmen as he may deem necessary and charge
the cost thereof to the Contractor.
The work so far as it is carried out on the Purchasers premises shall be carried out at such time as
the Purchaser may approve and so as not to interfere unnecessarily with the conduct of the
Purchasers business but the Purchaser shall give the Contractor all reasonable facilities for
carrying out the work. No female labor shall be employed during dark hours.
The Contractor shall not employ for the purpose of the contract any person who is below the age of
eighteen years and shall pay to each laborer, for the work done by such laborer, wages not less
then the wages paid for similar work in the neighborhood. The Engineer shall have the right to
enquire into and decide any complaint alleging that the wages paid by the Contractor to any laborer
for the work done by such laborer is less than the wages paid for similar work in the neighborhood,
and to refuse appointment of labor less than eighteen years of age.
The Contractor shall make regular and prompt payment of wages to the laborers engaged on the
work and in not case the payment shall be delayed more than seven (7) days following the period
for which the wages are due. If it is found the workers are not paid regularly the contract is liable to
be rescinded. The Contractor shall comply strictly with the provisions of Labor Laws in this behalf.
Page 36 of 56
44.04 Manufacturers Supervision

The Contractor may be required to work under the supervision of the manufacturers Engineers,
where the Contractor is not the manufacturer. However, this will not relieve the Contractor of his
responsibility of the correctness of quality of workmanship.
44.05 Engineers Supervision
All the works shall be carried out under the direction and to the satisfaction of the Engineer. The
Contractor shall be responsible for the correctness of the positions, levels and dimensions of the
works according to the drawings, notwithstanding that he may have been assisted by the Engineer
in setting out the same.
44.06 Contractors Representative
The Contractor shall employ at least one competent representative, whose name or names shall
have previously been communicated in writing to the Engineer by the Contractor for approval to
superintend the erection of the plant and carrying our of the work. The said representative, or if
more than one be employed, one of the representative, shall be present at the site, during working
hours, and any written orders or instructions which the Engineer or his authorized representative
may give to the said representative of the Contractor, shall be deemed to have been given to the
Contractor.
The Engineer shall be at liberty to object to any representative or person employed by the
Contractor in the execution of or otherwise of the work who shall misconduct himself or be
incompetent, or negligent, and Contractor shall remove the person so objected to, upon receipt
from the Engineer or notice in writing requiring him to do so and shall provide; in his place a
competent representative at the Contractors expenses. The Contractors representatives to be
employed for the purpose of the work at site shall be made available when the Purchaser shall
inform the Contractor in writing to the effect. The services of the Contractors representative shall
be made available for such period as the Engineer may require and they shall work at all
reasonable times as may be necessary to complete the work within the period specified in the
Contract.
44.07 Program of work and Progress Reports
The Contractor shall submit at such times as may be required by the Engineer, schedules showing
the program and order in which the Contractor proposes to carry out the work, with dates and
estimated completion times of various parts of the work. Such schedules shall be approved by the
Engineer, prior to starting the erection. Such times shall be binding on the Contractor for purpose
of assessing the penalty as called for under subsequent clause. The Engineer may not allow the
Contractor to start work for non-submission of the time schedule of the erection program.
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During the progress of work the Contractor shall submit monthly progress reports and photographs
and such other reports on the erection work and organization, as the Engineer may direct. The
progress indicated be arrived by agreement between the Contractor and the Engineer. The
Contractor shall also submit an anticipated one (1) month progress schedule at the beginning of
each month describing in detail the anticipated progress for the following month. The Contractor
shall also submit every week a list of various categories of men working under him. Monthly
progress reports shall be submitted within the tenth day of the month following the reporting month.
44.08 Man - Power Report
The Contractor shall submit to Engineer, on the first day of every month, a man hour schedule for
the month, detailing the man hours scheduled for the month, skill wise and are wise.
The Contractor shall also submit to the Engineer on the first day of every month, a man power
report of the previous month detailing the number of persons scheduled to have been employed
and actually employed, skill wise and the areas of employment of such labor.
44.09 Extension of Time
The application for extension of time is to be given to owner/purchaser through the Engineer and
the owner/purchase may authorize extension of time after considering the due merits.
Whenever extension of time is granted by the owner/purchaser, the same shall be on the existing
terms and conditions of the contract and without any additional financial liability to the Owner. The
Contractor in any case shall have no claim whatsoever for any type of compensation on account of
any delay attributable to any one.
44.10 Liability for Accident and Damage
The Contractor shall Indemnify the Purchaser against any claims which may be made under the
workmans Compensation Act, 1923, or any statutory modification thereof or otherwise for or in
respect of any damages or compensation payable in consequence of any accident or injury
sustained by any workman or other person whether in the employment of the Contractor or not. In
every case in which by virtue of the provisions of sub-section (1) of Section 12 of the Workmans
compensation Act, 1923, the Purchaser is obliged to pay compensation to a workman employed by
the Contractor in execution of the works, the Purchaser will recover from the Contractor the amount
of the compensation so paid and without prejudice to the rights of the Purchaser under sub-section
(2) of Section 12 of the said Act. The Purchaser shall be at liberty to recover such amount or any
part thereof by deducting it from the Performance Bond or from any sum due by the Purchaser to
the Contractor whether under the contract or otherwise.
The Purchaser shall not be bound to contest any claim made against it under Section 12, subsection (1) of the said Act, except on the written request of the Contractor and upon his giving to
the Purchaser full security for all costs for which the Purchaser might become liable in
consequence of contesting such claim. In the event of claim being made or action brought against
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the Purchaser involving the Contractor and arising out of the matters referred to and in respect of
which the Contractor is liable under this clause, the Contractor shall be immediately notified thereof
and he shall with the assistance, if so required by the Purchaser, but at the sole expense of the
Contractor, conduct all negotiations for the settlement of the same, or of any litigation that may
arise there from. In such case the Purchaser, at the expenses of the Contractor, afford all available
assistance for any such purpose.
The Contractor shall be responsible for all loss, damage or depreciation to the plant until the plant
is taken over in accordance with clause Taking Over. The Contractor shall, during the progress
other work, properly cover up and protect the plant from injury by exposure to weather and; shall
take every reasonable, proper, timely and useful precaution against accident or injury to the same
from any cause shall be and remain answerable and liable for all accidents or injuries thereto
which, until the same be or be deemed to be taken over under clause Taking Over may arise or
be occasioned by the acts or omissions or the Contractor of his workmen or sub- Contractors, and
all losses and damage to the Plant arising from such accidents or injuries as aforesaid shall be
made good in the most complete and substantial manner by and at the sole cost of the Contractor
and to the reasonable satisfaction of the Engineer.
Until the plant shall be or deemed to be taken over as aforesaid the Contractor shall also be liable
for and shall be deemed to have agreed to indemnity the Purchaser in respect of all damage to any
property of the Purchaser or of others occasioned by the negligence or fault of the Contractor or
sub-contractor or his or their workmen or representatives or by defective design, work or material
or otherwise.
The Contractor shall pay all taxes due in India for the personnel employed by the Contractor work
arising out of their services in connection with the contract and obtaining at his (Contractors) own
cost work permits from competent authorities to enable any foreign personnel to work in India.
The Contractor shall be responsible for all formalities in connection with the passport, obtaining of
visas, police permits, and expenses for customs duties related to personal goods of foreign
personnel to be employed in the erection work. However, the Purchaser shall If requested, assist
the Contractor in obtaining visas and work permits for the foreign personnel to be deputed for the
erection work.
44.11 Cleanliness
During erection, the Contractor shall, without any additional payment, at all times keep the working
and storage areas used by him free from accumulation of waste materials or rubbish. If the
Contractor fails to remove the rubbish, within forty eight (48) hours, after being requested by the
Engineer, the rubbish will be removed by others and cost back charged to the Contractor. Any
inflammable material should be removed forthwith on request by the Engineer.
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Before completion of erection, the Contractor shall remove or dispose of in a satisfactory manner
all temporary structures, packing cases, waste and debris and leave the premises in a condition
satisfactory to the Engineer.
Similarly the labor colony, the offices and the residential areas of the Contractors employees and
workmen shall be kept clean & neat to the entire satisfaction of the Engineer. Proper sanitary
arrangements shall be provided by the Contractor, in the work areas office and residential areas of
the Contractors.
44.12 Co-ordination with the Purchasers Engineers
The Contractor shall at all times work in co-ordination with the Purchasers Engineers and afford
them every facility to become familiar with the erection and maintenance of the equipment.
In respect of observance of local rules, administrative matters, co-ordination with other Contractors
and the like, the Contractor and his personnel shall work under the Purchasers Engineer in charge
of the work.
44.13 Work and Services to be provided by the Purchaser
Unless otherwise agreed upon, the following works and services shall be provided by the
Purchaser for carrying out complete erection work:
(a)
Water Supply
Water supply for construction purpose will be provided by the Purchaser at one mutually
agreed point at site. Drinking water will also be made available at one central point at site.
The Contractor shall make his own arrangement for any further distribution. Such
distribution pipe network shall have the prior approval of the Engineer at site so as not to
interfere with the layout and progress of other construction works. The water supply shall
be free of cost. Contractor shall ensure that there is no wastage of water. On completion of
the work, the Contractor shall remove all such work and shall reinstate and make good any
work disturbed to the satisfaction of the Engineer.
(b)
Power Supply
(I)
Electric power will be supplied at 400/440 V and shall be metered and charged at
applicable rates.
(II)
Supply for execution of work will be made available at one point only. This point
will not be more than 500 meters away from the Contractors premises. The
Contractor shall make his own arrangement at his own cost for distribution of
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power to different worksites. This arrangement shall however, be coordinated and

laid with approval of the Engineer. Any change in the alignment of the Contractors
distribution lines necessitated by his work or another work must be done at
Contractors cost. The Engineer also reserves the right to change the location of
point of supply whether necessitated by his work or another work and the
Contractor shall make his own arrangement at his own cost for extending his
distribution line to the new location of supply point. A 3 phase armored cable shall
be used by the Contractor for connecting their equipment to Purchasers point
supply.
(III)
The Purchaser shall not however, guarantee the supply of electricity and no
compensation for any failure or short supply of electricity will be entertained and
this does not relieve the Contractor of his responsibility for timely completion of the
work as stipulated in the Contract.
(IV)
It shall be the responsibility of the Contractor to provide and maintain the complete
installation on the load site of the supply with due regard to safety requirement at
site. All cabling, equipment, installations etc. shall comply in all respects with the
latest statutory requirements and safety provisions, i.e. as per given in the
Central/State Electricity Acts and Rules etc. The Contractor will ensure that his
equipment and Electricity wiring etc. are installed, modified and maintained by a
licensed Electrician / Supervisor and before power is supplied, a test certificate is
to be produced to the Engineer for his approval.
(V)
At all times, IEA Regulations shall be followed failing which the Purchaser has a
right to disconnect the power supply without any reference to the Contractor. No
claim shall be entertained for such disconnection by the Engineer. Power supply
will be reconnected only after production of fresh certificate from authorized
electrical supervisors.
The Purchaser will not liable for any loss or damage to the Contractors equipment
as a result of variation in voltage or frequency or interruption of power supply or
other loss to the Contractor arising there from.
(VI)
(VII)
The Contractor shall ensure that the Electrical equipment installed by him are such
that average power factor does not fall below 0.9 at this premises. In case P.F.
falls below 0.9 in any month, he will reimburse to the purchaser at the rate same
as OSEBs rate for per unit fall of P.F. determined from time to time by Purchaser
all units consumed during the month.
(VIII)
The power supply required for Contractors colony near the plant site will be
determined by the Purchaser and shall be provided as per State Electricity Boards
Rules and other Statutory provisions applicable for such installations from time to
time. In case of power supply to Contractors colony, the power will be made
available at a single point and the Contractor shall make his own arrangement at
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his own cost for distribution to the occupants of the colony as per Electricity Rules
& Acts. The site area and colony shall be sufficiently lighted to avoid accidents.
(IX)
The Contractor will have to provide and install his own light and power meters
which will be governed as per Central/State Govt. Electricity Rules. The meters
shall be sealed by the Purchaser.
(X)
In case of damage to any of the Purchasers equipment on account of fault,

intentional or unintentional on the part of the Contractor, the purchaser reserves
the right to recover the cost of such damage from the contractors bill.
(XI)
After completion of work, the Contractor shall promptly dismantle, at his own cost
distribution and other facilities that he may have erected and shall also remove the
same within a reasonable time fixed by the Engineer and on his failure to do so the
Purchaser will be entitled to realize from his reasonable compensation fixed by the
Engineer and also to remove them at the cost of the Contractor.
(XII)
Only motors up to 3HP will be allowed to be started direct on line. For motors
above 3 HP and up to 100 HP suitable starting devices approved by the Purchaser
Engineer, shall be provided by the Contractor. For Motors above 100 HP slip ring
induction motors with suitable starting devices as approved by the Engineer shall
be provided by the Contractor.
(XIII)
The single line distribution system with loadings and specifications shall be
submitted to the Engineer for his approval before the system is installed. The
system shall conform to Central/State Statutory provisions Act, with latest
amendments and to the Approved specifications of the company. The installations
have to be inspected and approved by the Electrical Inspector, Govt. of Orissa
before energisation.
The total requirement of power shall be indicated by the tenderer in his tender and
confirmed within thirty days from the date of Letter of Intent.
(XIV)
(d)
Land for Contractors Use

(I)
The Purchaser will at his own discretion and convenience and for the duration of
the execution of the work make available near the site, land for construction of
Contractors field office, godowns, workshops and assembly yard required for the
execution of the contract. The Contractor shall at his own cost construct all these
temporary buildings and provide suitable water supply and sanitary arrangement
approved by the Engineer.
(II)
On completion of the works undertaken by the Contractor, he shall remove all

temporary works erected by him and have the site cleared as directed by
Engineer. If the Contractor fails to comply with these requirements, the Engineer at
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the expenses of the Contractor will remove such surplus and rubbish materials
and dispose off the same as he deems fit and get the site cleared as aforesaid,
and the contractor shall forthwith pay the amount of all expenses so incurred and
shall have no claim in respect of any such surplus materials disposed off as
aforesaid. But the Purchaser reserves the right to ask the Contractor any time
during the pendency of the contract to vacate the land by giving 7 days notice on
security reasons on national interest or otherwise. A token rent of Rs. 100/(Rupees one hundred only) per hectare or part thereof per annum or part thereof
shall be charged for the land so occupied.
(III)
Land for residential accommodation for staff and labor will be made available at
the discretion of the Engineer and rent for the same will be as decided by the
Engineer according to location and area taken by the Contractor.
(e)
Electricity and drinking water at normal charges for labor quarters at a central point within
the land provided by the Purchaser. The cost of distribution, if any, shall be borne by the
Contractor.
(f)
Assistance to the Contractor in obtaining Indian visas, residential or working permits for the
permits for the personnel, if necessary.
(g)
Water and electricity as may be required for the initial starting up of the equipment free of
charge to Contractor.
(h)
Necessary Engineers, operators and other personnel for start up commissioning and
acceptance tests of the equipment free of charge to Contractor.
(i)
(J)
Assistance in obtaining priorities for transportation, customs permit etc.

Suitable access to site and possession of the site shall be afforded to the Contractor by the
Purchaser.
44.14 Work and Services to be provided by the Contractor

Unless otherwise agreed upon, the following work and services shall also be provided under the
erection contract.
(i)
Clearing, unloading the equipment from the rail or road transport to Contractors
transport/vehicle and delivery the same to storage area. Demurrage charges, if incurred at
rail head or at site for default of the Contractor shall be paid by him
(ii)
Opening of packing cases, Inspection and checking of materials. Repair and replacement
of contract material damaged or lost in transit or at site.
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(iii)
Final adjustment of foundation levels by chipping and dressing, checking location,

elevation etc. of anchor bolts and grouting or anchor bolts and base plates.
(iv)
Complete erection of the equipment covered under the contract, final preparation for
testing, commissioning, final run and acceptance tests and putting the plant into
commercial operation.
(v)
All consumable stores required for the above work, except those mentioned under Clause
44.13 (i).
(vi)
Watch and ward to ensure security and safety of materials under the custody.
(vii)
Furnishing of residential accommodation to erection labor and other personnel.
(viii)
Daily transport for his erection personnel to and fro between residence and site.
(ix)
All erection tools and lifting tackles, also all equipment, tools and tackles for transportation
of all equipment to site. A list of such tools and tackle and equipment shall be submitted to
the purchaser before commencement of site work. These tools and tackle shall not be
removed from the site without written permission of the Engineer.
(x)
All ladders, platforms, temporary supports and facilities required for handing of heavy
packages at site required for erection.
(xi)
Necessary clerical staff, supervisory personnel skilled and unskilled labor.
(xii)
Third Party Insurance at site and insurance of Contractors personnel employed at site as
required under Workmens Compensation Act.
(xiii)
Site offices and covered storage as required.
(xiv)
Postage, telephone and telegraph expenses.
(xv)
Cleaning up of site during and after erection.
(xvi)
Applying final paint to all equipment, piping, hanger etc. covered under the contract.
(xvii)
Necessary supervisory personnel with approved license as per provisions of Indian

Electricity rules.
(xviii)
If the Contractor uses his own crane, he must have a skilled crane operator.
(xix)
Contractor must take all safety precautions during work and the workmen must use safety
belts, tested gloves, masks and other devices as necessary for safety of personnel
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(xx)
Contractor should provide identity badges for his employees. These should be properly
displayed during working hours.
(xxi)
The Contractor shall employ only competent and skilled workmen fully experienced and
capable of performing duties assigned for them. When local laws required the employee
shall be required to acquire certificate of competency for his work from the competent
authority.
(xxii)
Communication
The Contractor will make his own arrangement for all his communications needs such as
telephone, telex etc. at his site office and his residential area. Purchaser will assist in
getting the above facilities, in case he finds and difficulty.
(xxiii)
First Aid
The Contractor shall provide necessary first-aid facilities for all his employees,
representatives and workmen working at site. Enough number of contractors personnel
shall be trained in administering first-aid.
(xxiv)
Welfare facilities
Contractor shall provide in his labor colony all necessary standard welfare facilities like
canteen, shopping facility etc.
44.15 Lines and Grades

All the works shall be performed to the lines/alignments, grades and elevations indicated on the
drawing. The Contractor shall be responsible to locate and layout the works area. Basic horizontal
and vertical control points will be established and marked by the Engineer at site at suitable points.
These points shall be used as datum/reference points for the works under the contract. The
Contractor shall inform the Engineer well in advance of the times and places at which he wishes to
do work in the area allotted to him, so that suitable datum reference points may be established and
checked by the Engineer to enable the Contractor to proceed with his works. Any work done
without being properly located may be removed and/or dismantled by the Engineer at Contractors
expenses.
44.16 Fire Protection
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(a)
The work procedures that are to be used during the erection shall be those which minimize
fire hazards to the extent practicable. Combustible materials, combustible waste and
rubbish shall be collected and removed from the site at least once each day. Fuels, oil and
volatile or flammable materials shall be stored away from the construction and equipment
and materials storage area in safe containers. Adequate precaution shall be taken in
handling and storage of flammable gas. Care shall be taken to avoid and reduce hazards
from electrical short circuits and faults. Untreated canvas paper, plastic or other flammable
flexible materials shall not at all be used at site for any other purpose unless otherwise
specified. If any such materials are received with the equipment at the site, the same shall
be removed and replaced with acceptable material before moving into the construction
area of storage.
(b)
Similar corrugated paper fabricated cartons etc. will not be permitted in the construction
area either for storage or for handling of materials. All such materials used shall be of
water proof and flame resistant type. All the other materials such as working drawings
plans etc. which are combustible but are essential for the works to be executed shall be
protected against combustible resulting from welding sparks, cutting flames and other
similar fire sources.
(c)
All the Contractors supervisory personnel and sufficient number of workers shall be
trained for fire - fighting and shall be assigned specific fire protection duties. Enough of
such trained personnel must be available at site during the entire period of the Contract.
(d)
The contractor shall provide enough fire protection equipment of the types and number for
the ware - houses, office, temporary structures, labor colony area etc. Access to such fire
protection equipments shall be easy & kept open at all times.
44.17 Materials Handling & Storages

(a)
All the equipments furnished under the Contract and arriving at site shall be promptly
received, unloaded and transported and stored in the storage spaces by the contractor.
(b)
The Contractor shall be responsible for examining all the shipment and notify the engineer
immediately of any damages, shortages; discrepancy etc. for the purpose of Engineers
information only. The Contractor shall submit to the Engineer every week a report detailing
all the receipts during the week. However, the Contractor shall be solely responsible for
any shortages or damage in transit, handling and/ or storage & erection of the equipment
at site. Any demurrage, wharfage and other charges claimed by the transporters, railways
etc. shall be to the account of Contractor.
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(c)
The Contractor shall maintain an accurate & exhaustive record detailing out the list of all
equipment received by him for the purpose of erection & keep such record open for the
inspection of the Engineer at any time.
(d)
All equipments shall be handled very carefully to prevent any damages or loss. No bare
wire, rope, slings etc. shall be used for unloading and/ or handling of the equipment
without the specific written permission of the Engineer. The equipment stored shall be
properly protected to prevent damages either to the equipment or to the floor where they
are stored. The equipment from the store shall be moved to the actual location at the
appropriate time so as to avoid damage of such equipment at site.
(e)
All electrical panels, control gear, motors and such other devices shall be properly dried by
heating before they are installed and energised. Motor bearings, slip rings, commutators
and other exposed parts shall be protected against moisture ingress and corrosion during
storage and periodically inspected. Heavy rotating parts in assembled conditions shall be
periodically rotated to prevent corrosion due to prolonged storage.
(f)
All the electrical equipment such as motors, generators, etc. shall be tested for insulation
resistance at least once in three months from the date of receipt till the date of
commissioning and a record of such measured insulation values maintained by the
Contractor. Such records shall be open for inspection by the Engineer.
(g)
The Contractor shall ensure that all the packing materials and protection devices used for
the various equipment during transit and storage are removed before the equipment are
installed.
(h)
The consumables and other supplies likely to deteriorate to storage must be thoroughly
protected and stored in a suitable manner to prevent damage or deterioration in quality by
storage.
(i)
All the materials stored in the open or dusty location must be covered with suitable
weatherproof and flame-proof covering material wherever applicable.
(j)
If the materials belonging to the Contractor are stored in areas other than those earmarked
for him the Engineer will have the right to get it moved to the area earmarked for the
Contractor at the Contractors cost.
(k)
The Contractor shall be responsible for making suitable indoor storage facilities to store all
equipment which required indoor storage. Normally, all the electrical equipment such as
motors, control gear, generators, exciters and consumables like electrodes, lubricants etc.
shall be stored in the closed storage space. The Engineer, in addition, may direct the
Contractor to move certain other materials which in his opinion will require indoor storage
areas which the Contractor shall strictly comply with.
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44.18 Construction Management

(a)
The field activities of the Contractors working at site will be coordinated by the Engineer
and the Engineers decision shall be final in resolving any disputes or conflicts between the
contractors and tradesmen of the Purchaser regarding scheduling and co-ordination of
work. Such decision by the Engineer shall not be a cause for extra compensation or
extension of time for the Contractor.
(b)
The Engineer shall hold weekly meetings of all the Contractors working at site, at a time
and a place to be designated by the Engineer. The Contractor shall attend such meetings
and take notes of discussions during the meeting and the decisions of the Engineer and
shall strictly adhere to those decisions in performing his works. In addition to the above
weekly meetings, the Engineer may call for other meetings either with individual
contractors or with selected number of contractors and in such a case the Contractor, if
called, will also attend such meetings.
(c)
Time is the essence of the Contract and Contractor shall be responsible for performance of
his woks in accordance with the specified construction schedule. If at anytime, the
Contractor is falling behind the schedule, he shall take necessary action to make good for
such delays by increasing his work to comply with the schedule and shall communicate
such actions in writing to the Engineer, satisfying that his action will compensate for the
delay. The Contractor shall note be allowed any extra compensation for such action.
(d)
The Engineer shall however not be responsible for provision of additional labor and/ or
materials or supply or any other services to the Contractor except for the co-ordination
work between various entities as set out earlier.
44.19 Safety Regulations

(a)
Without prejudice to the general obligation under the statutes the Contractor shall ensure
the safety of all the workmen, materials and equipment either belonging to his or to others
working at site.
b)
The Contractor will notify the Engineer of his intention to bring on to site any equipment or
any container, with liquid or gaseous fuel or other substance which may create hazard.
The Engineer shall have the right to prescribe the conditions under which such equipment
or container may be handled and used during the performance of the works and the
Contractor shall strictly adhere to such instructions. The Engineer shall have the right to
inspect any construction plant and to forbid its use, if in his opinion it is unsafe. No claim
due to such prohibition shall be entertained by the Purchaser.
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c)
Where it is necessary to provide and / or store petroleum products or petroleum mixtures

and explosives, the Contractor shall be responsible for carrying out such provision and / or
storage in accordance with the rules and regulations laid down in Petroleum Act, 1934,
Explosive Act 1948 published by the Chief Inspector of Explosives of India. All such
storage shall have prior approvals of the Engineer. In case any approvals are necessary
from the Chief Inspector of Explosives or any statutory authorities, the Contractor shall be
responsible for obtaining the same.
d)
The Contractor shall be responsible for provisions of all safety notices and safety
equipment required both by the relevant legislations and the Engineer as he may deem
necessary.
e)
The Contractor shall be responsible for the safe storage of his and his sub - contractors
radioactive sources, if any.
f)
In no circumstances will the Contractor interfere with fuses and electrical equipment
belonging to the Purchaser or other Contractors.
g)
Before the Contractor connects any electrical appliances to and plug or socket belonging
to the other Contractor or Purchaser, he shall -
h)
i)
Satisfy the Engineer that the appliance is in good working condition;
ii)
Inform the engineer of the maximum current rating, voltage and phases of the
appliances;
iii)
Obtain permission of the Engineer detailing the sockets to which the appliances
may be connected.
The Engineer will not grant permission to connect until he is satisfied that i)
The appliance is in good condition and fitting with a suitable plug;
ii)
The appliance is fitting with a suitable cable having two earth conductors, one of
which shall be an earthed metal sheath surrounding the cores.
i)
No electric cable in use by the Contractor/Purchaser will be distributed without prior

permission. No weight of any description will be imposed on any such cable and no ladder
or similar equipment will rest against or he attached to it.
j)
No work shall be carried out on any live equipment. The equipment must be made safe by
the Engineer and permit - to - work issued before any work is carried out.
k)
The Contactor employs the necessary number of qualified, full time electricians to maintain
his temporary electrical installation.
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45.00 FOREIGN PERSONNEL

45.01 The Contractor shall submit to the purchaser data on all personnel he proposes to bring into India
for the performance of the works under the contract at least sixty (60) days prior to their departure
to India. Such data will include for each person the name, his present address, his assignment and
responsibility in connection with the works, and a short resume of his qualification, experience etc.
in relation to work to be performed by him.
45.02 Any person unsuitable and unacceptable by the purchaser shall not be brought to India. Any
person brought to India, if found unsuitable or unacceptable by the purchaser, the Contractor shall
within a reasonable time make alternative arrangements for providing a suitable replacement and
repatriation of such unsuitable personnel.
45.03 No person brought to India for the purposes of the works shall be repatriated without any consent
of the purchaser in writing, based on a written request from the Contractor for such repatriation
giving reasons for such an action to the Engineer. The purchaser may give permission for such
repatriation that the progress of work will not suffer due to such repatriation.
45.04 The Contractor and his expatriate personnel shall respect all India Acts, Laws, rules and
regulations and shall not in any way interfere with Indian political and religious affairs and shall
conform to any other rules and regulations the Government of India, the purchaser and the
Engineer may establish from time to time, on them.
The Contractor expatriate personnel shall work and living in close coordination and coordination
with their co workers and the community and shall not engage themselves in any other
employment either part - time or full - time nor shall they take part in any local politics.
45.05 The purchaser shall assist the Contractor, to the extent possible in obtaining necessary permits to
travel to India and back by issue of necessary certificates and other information needed by the
Government agencies.
46.00 DEATH, BANKRUPTCY ETC.
If the Contractor shall die or dissolve or commit any act of bankruptcy or being a Corporation,
commence to be wound up except for reconstruction purposes or carry on its business under a
receiver, the executors, successors or other representatives in law of the estate of the Contractor
or any such receiver, liquidator or any person in whom the contract may become vested, shall
forthwith give notice thereof in writing to the purchaser and shall for one month, during which he
shall take all reasonable steps to prevent a stoppage of the work, have the option of carrying out
the contract subject of the approval of Purchaser and subject to his or their providing such
guarantee as may be required by the Purchaser but not exceeding the value of works for the time
being remaining unexecuted, provided however that nothing above said shall be deemed to relieve
the Contractor or his successors of his or their obligations under the contract under any
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circumstances. In the event of stoppage of the works the period of the option under this clause
shall be fourteen (14) days only, provided that should be above option be not exercised, the
contract may be terminated by the purchaser by notice in writing and the same power and
provisions reserved to the Purchaser in clause `Negligence in the event of taking the work out of
the Contractors hands shall immediately become operative.
47.00 GRAFTS AND COMMISSION ETC.
Any graft, commission, gift or advantage given promised or offered by or on behalf of the
Contractor or his partner, agent, officers, director, employee or servant or any one on his or their
behalf in relation to the obtaining or to the execution of this or any other contract with purchaser,
shall in addition to any criminal liability which it may incur, subject the contractor to the cancellation
of this and other contracts and also to payment of any loss or damage to the purchaser resulting
from any cancellation. The purchaser shall then be entitled to deduct the amounts so payable from
any money otherwise due to the Contractor under the contract.
48.00 COMPLETION OF CONTRACT
Unless otherwise terminated under the provisions of any other relevant clause, this contract shall
be deemed to have been completed all the expiration of the guarantee period as provided for under
the clause entitled `Guarantee Period as provided for under the clause entitled `Guarantee and
only on issue of a certificate to that effect and not otherwise.
49.00 DEFENCE OF SUITS
In any action in court is brought against the purchaser or Engineer or an officer or agent of the
purchaser, for the failure or neglect on the part of the contractor to perform any acts, matters,
convenants or things under the contract, or for damage or injury caused by the alleged omission or
negligence on the part of the Contractor, his agents, representatives or his sub-contractors,
workmen, suppliers, or employees, the Contractor shall in all such cases indemnify and keep the
purchaser, and the Engineer and / or his representative harmless from all losses, damages,
expenses or decrees arising of such action.
50.00 ARBITRATION
All disputes or differences arising under the contract whether during or after completion of the
contractor or whether before or after determination, for closure or breach of the contract (other than
those in respect of which the decision of any person is by the contract expressed to the final and
binding) shall after written notice by either party to the contract to the other of them and to the
Appointing Authority hereinafter mentioned be referred for adjudication to a sole Arbitrator to be
appointed as hereinafter provided.
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For the purpose of appointing the sole Arbitrator referred to above, the CMD NALCO who shall be
Appointing Authority will send within thirty days of receipt of the notice to the Contractor a panel of
three names of persons.
The Contractor shall on receipt of the names as referred select any one of the person names to be
appointed as a sole Arbitrator and communicate his name to the Appointing authority within thirty
days of receipt of the names. The Appointing Authority shall there upon appoint the said person as
the sole Arbitrator. If the Contractor fails to communicate such selection as provided above within
the period specified, the Appointing Authority shall make the selection and appoint the selected
person as the Sole Arbitrator.
If the Arbitrator so appointed is unable to / unwilling to act or resigns his appointment or vacates his
office due to any reason whatsoever sole arbitrator or shall be appointed as aforesaid. The work
under the contract shall not be stopped during the arbitration proceedings.
The Arbitrator shall be deemed to have entered on the reference on the date he issues notices to
both the parties fixing the date of first hearing.
The Arbitrator may, from time to time, with the consent of the parties, enlarge the time for making
and publishing the awards.
The Arbitrator shall give a separate award in respect of each dis pute or difference and shall give a
reasoned and speaking award / awards.
The venue of arbitration shall be at Bhubaneswar. However, if the situation so warrants, it may as
and when required, he held at the place where the site of work is situated.
The fees, if any, of the Arbitrator shall, if required to be paid before award is made and published,
be paid half and half by each of the parties. The cost of the reference and of the award including
the fees, if any, of the Arbitrator shall be in the discretion of the Arbitrator who may direct to and by
whom and in what manner, such costs or any part thereof shall be paid and may fix or settle the
amount of costs to be so paid.
The award of the arbitrator shall be final and binding on both the parties.
Subject to aforesaid the provisions of the Arbitration Act 1940 or any statutory modification or reenactment thereof and the rules made there under, and for the time being in force, shall apply to
the arbitration proceeding under this clause.
For Public Sector Enterprises guidelines as per circular of BPE No. 15.9.86 - BPE (FIN) dtd.
30.03.1989 as amended from time to time will be applicable for resolving any disputes.
51.00 CORRESPONDENCE
The Purchaser shall ordinarily correspond with the Contractor at the address furnished by the
Contractor.
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The Contractor shall ordinarily forward two (2) copies of all correspondence relating to this contract
to the Purchaser and two (2) copies to the Consulting Engineer or his representative as may be
requested.
Two (2) copies of all correspondence from the Contractor to Purchasers other Contractors for
associated plants shall be forwarded to the Purchaser and the Consulting Engineer.
All drawings and correspondence to the Purchaser and the Consulting Engineer shall be
transmitted by the Contractor via Air Mail or alternatively by means involving the minimum time of
transit.
52.00 CONTRACT AGREEMENT
If so desired by the Purchaser, a formal Agreement shall be entered into by the Contractor with the
Purchaser for the proper fulfillment of the Contract.
The expenses of completing and stamping the Agreement shall be paid by the Contractor, and the
Purchaser shall be furnished free of charge with an executed stamped counterpart of the
Agreement as also copies of the Agreement as may be required by the purchaser.
Any tender drawing, technical data and / or correspondence which forms the basis of an order or a
contract aforesaid, or which may be furnished by the Contractor for the Purchasers approval or
information as provided under the said order or contract, shall be in English and it is in any other
language, a complete translation in English shall have to be duly furnished. The Purchaser shall
not be bound to consider any tender drawing, technical data or correspondence which is not
furnished in English.
53.00 PAYMENTS
53.01 The payment to the Contractor for the performance of the works under the contract will be made by
the purchaser as per the guidelines and conditions specified herein. All payments made during the
contract shall be on account of payments only. The final payment will be made on completion of all
the works and on fulfillment by the Contractor of all his liabilities under the contract.
53.02 Currency of Payment
The payments for the foreign currency potion of the contract price will be made in the currency of
the bid. If the bid is in a currency other than that of the country of origin of goods, payment may be
made in an amount equivalent to the bid price in the currency of the country of origin. The Indian
Rupees portion of contract price stated in the contractors bid will be paid in Indian Rupees.
53.03 Payment Schedule
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The Contractor shall prepare and submit to the Engineer for approval, break-up of the contract
price. The contract price break-up shall be interlinked with the agreed detailed PERT Network of
the Contractor setting forth his starting and completion dates for the various key phases of works.
Any payment under the contract shall be made only after the contractors price break-up is
approved by the Engineer. The aggregate sum of the contractors price break down shall be equal
to the lump sum contract price.
53.04 Application for Payments
The Contractor shall submit application for the payments in the prescribed proforma of the
purchaser.
The foreign contractor shall submit to the Engineer separate applications for payment in different
currencies whenever payment is to be made in more than one currency.
Each such application shall state the amount claimed and shall set forth in details, in the order for
the payment schedule particulars of the works including the works executed at site and of the
equipment shipped/brought on to the site pursuant to the contract up to the date mentioned in the
application and for the period covered since the last preceding certificate, if any.
Every interim payment certificate shall certify the contract value of the works executed up to the
date mentioned in the application of the payment certificate, provided that no sum shall be included
in any interim payment certificate in respect of the works that, according to the decision of the
Engineer, does not comply with the contract, or has been performed, at the date of certificate
prematurely.
53.05 Terms of Payment

Subject to any deduction which the Purchaser may be authorized to make under the contract, the
Contractor shall, on the certificate of the Engineer be entitled to payments generally as follows:
A)
Supply
-
80% shall be paid for each consignment dispatched pro-rata against presentation
of each invoices and evidence of shipment/dispatch.
10% shall be paid after completion of erection.
10% shall be paid after completion of satisfactory commissioning and performance

guarantee tests.
Page 54 of 56
B)
Marine Freight and Insurance

The ocean freight wherever payable shall be paid on production of invoices, evidence of
shipment and other supporting documents for ocean freight and marine insurance
components. In case of contracts inclusive of ocean freight and marine insurance total of
the payments shall not exceed the total amount quoted by the Contractor in his bid.
C)
Inland Transportation and Inland Insurance

Inland transportation (including port handling) shall be paid after the equipment has been
received at site on production of invoices for such charges. Wherever this is included in the
contract the aggregate of all such invoices shall not exceed the total amount indicated by
the Contractor in his proposal.
D)
Erection Services
-
80% shall be paid for the progress made during the month on monthly progress
bills against certification by the Engineer.
10% shall be paid on completion of erection and Tests on Completion.
10% shall be paid on completion of the successful commissioning and guarantee

tests.
54.00 MISCELLANEOUS
54.01 Entire Agreement
These General Conditions together with the specification, tender drawing and guaranteed technical
particulars, tender data with subsequent agreed modification thereof shall constitute the entire
Agreement between the parties in respect of the subject matter hereof. No variation or modification
of the contract or waiver of any of the terms and conditions thereof shall be deemed valid unless in
writing and signed by the parties hereto.
54.02 General Conditions of Contract, the tender specifications and other contract / tender documents
are to be taken as mutually explanatory to one another. However, in case of conflict between these
documents, the technical specification, special conditions of the contract and general conditions of
the contract shall have precedence in that order.
54.03 Endorsement of Terms
The failure of either party to endorse at any time any of the provisions of the contract or any rights
in respect thereto or to exercise an option herein provided shall in no way be construed to be a
Page 55 of 56
waiver of such provisions, rights or option or in way to effect the validity of the Contractor. The
exercise by either party of any of his rights here in shall not preclude or prejudice either party from
exercising the same or any other right it may have hereunder.
54.04 Contract Labor Regulation & Abolition
The Contractor shall be responsible for all statutory obligations under Contract Labor (Regulation &
Abolition) Act 1970. E.S.I. and Provident Fund Acts, as applicable, for their labor and staff engaged
in executing this work. The Contractor will also keep the Purchaser indemnified against all claims
and disputes arising out of death or injury to their workmen and staff. It will be necessary for the
contractor to ensure that proper safety measures are followed by their workmen to avoid
accident/damage/loss to life and property. Approved safety belts must be used by their workmen
when working at any height. Charges for above are deemed included in the quoted rates and
accepted amount.
54.05 Recover of Damages
Nothing contained in the conditions or in any other part of this Contract shall be construed as
preventing the Purchaser from the Contractor any damages to which the purchaser may be entitled
in law as a consequence of any breach by the Contractor of any of the terms of this Contract.
Page 56 of 56
Tender Notice No. - ..............
ANNEXURE - IV
ADDENDUM TO TENDER DOCUMENT (COMMERCIAL)
1.0
SCOPE
1.1
The subject enquiry is being issued on turnkey basis with entire responsibility of design,
engineering up to Commissioning and handing over of plant / equipment / system to the Owner.
Owner intends to enter into two separate contracts (if placed) as follows to rationalize tax liability as
per legal provision of country and also for operational convenience.
(a)
Basic design, engineering, supply of equipments and materials including all necessary
accessories, Spares at Site
(b)
Unloading, storage, handling of equipments at site, complete Construction, Erection, Testing and
Commissioning services, Supervision and Training Services
1.2
The Contract-cum-Performance Bank Guarantee for 10% of Total Order Value for both the
contracts shall be furnished by the vendor to the Owner.
2.0
PAYMENT TERMS
2.1
Following Payment Terms will be applicable:
(i)
For Supply (including Design & Engineering):
(ii)
(i)
80% payment on prorate basis against presentation of dispatch documents.
(ii)
10% payment shall be made after completion of erection.
(iii)
Balance 10% payment shall be made after final handing over of equipments to the Owner
at site.
Inland Transportation
Charges for inland transportation shall be paid after the equipment is received at Site against
invoices.
(iii)
2.2
Site Work
(i)
90% against monthly progressive billing duly certified by Site In- charge.
(ii)
10% within 30 days of final handing over of the equipment to Owner at site.
Invoices should be submitted along with certificate stating It is certified that Cenvatable/ VAT
Invoices have been issued in the name of consignee, for full amount of Excise Duty/ Sales Tax/
Service Tax charged in the Invoice, as per rules in force. Vendor agrees to reimburse Excise Duty/
Page 1 of 11
Sales Tax/ Service Tax, if documents are not found to be in order for claiming Cenvat/ VAT
benefits.
2.3
NOTE:
(i)
Final Handing Over:

Final Handing Over shall mean Commissioning including acceptance of PG Tests. However, in
case PG Test could not be conducted within 6 months from commissioning, for reasons not
attributable to vendor, last 10% payment will be released against a Bank Guarantee of equal
amount valid for 12 months initially and extendable thereafter.
(ii)
Payment for indigenous supply shall be through Bank against dispatch documents. Payment
through bank shall be as per normal banking procedure.
Direct Payment can be made through e-payment mode through SBI as well as NEFT/RTGS mode
through designated enabled branches. In case of Direct Payment, duly filled Bank Mandate form in
duplicate should be furnished with due authentication from bidders Banker
3.0
TAXES & DUTIES
3.1
All taxes and duties including Excise Duty and concessional CST/ VAT but excluding Sales Tax on
Works Contract will be paid against Documentary Evidence at actuals limited to amount quoted in
price bids. However, statutory variations (on finished products) will be allowed against
documentary evidence. Vendor shall provide break up along with billing schedule subject to ceiling
limit quoted in price bid.
3.2
Service Tax and E-cess applicable should be clearly indicated with ceiling limit to be paid against
documentary evidence and invoice raised in line with Service Tax Rule to enable NALCO to avail
Cenvat.
3.3
Vendors are required to quote prices inclusive of Works Contract Tax and no variation is payable
on this account. In case vendor insists on WCT variation, rate of WCT and amount should be
mentioned in the bid, without which statutory variation will not be admissible.
3.4
It is to be noted that the Contractor shall be required to submit the documentary evidence(s) for
Excise Duty paid by them to concerned authorities for Owner to claim CENVAT benefit.
3.5
Necessary Cenvatable documents such as Transporters copy of Challan / Bill of Entry Triplicate
Copy for availing Cenvat benefit to be given in NALCOs name indicating consignee as NALCO for
availing Excise Duty, Copy of Registration with Central Excise Authority and any other document
required by the Owner shall be furnished by Contractor to enable Owner to claim CENVAT.
3.6
The classification of goods as per Central Excise Customs Tariffs should be correctly done to
ensure that CENVAT benefits is not lost by the Owner on account of any error on the part of the
Contractor. The Owner shall be at liberty to withhold the payment of cenvatable duties (viz. Central
Page 2 of 11
Excise Duties, Countervailing Duties of Customs etc.) If the requirements as specified in the clause
are not fulfilled by the Contractor. The price of materials shall stand reduced accordingly.
3.7
The Contractor shall furnish the details of Excise Duty and CD/CVD component included his price
for the purpose of cenvat benefit.
The amount of ED and CVD indicated as part of Quoted Price is for information only. Contractor is
required to pay all taxes & duties nevertheless and must furnish Cenvatable documents for the
amount of ED and CVD paid by him, subject to minimum of the amount of ED and CVD indicated
by him in his bid.
3.8
Entry Tax shall be paid by NALCO for consignments coming from outside Orissa. For supplies to
be made from Orissa, Entry Tax shall be paid by Seller and should be mentioned in the Invoices for
reimbursement by NALCO.
4.0
INSURANCE
4.1
The Owner will arrange for insurance of equipment and material under the scope of the Contract as
detailed in Tender Documents - Commercial.
4.2
The Contractor shall deal directly with the Insurance Company. The Contractor will be required to
lodge all the claims of his part of the contract directly and arrange settlement as expeditiously as
possible by complying with the required formalities and proper follow ups.
4.3
The contractor shall bear the entire cost of corresponding with the Insurer and arrange all
documents/informations facilitating inspection/discussions by the officials/surveyors deputed by the
Insurer. The Contractor shall make all efforts to get settlement of claim at the earliest and no time
extension for completion of work will be given for delay on this account.
4.4
In respect of equipment damaged in transit or during erection & commissioning, the contractor shall
arrange for replacement/ repair expeditiously. The replacement cost payable by the owner shall be
limited to the invoice cost of damaged equipment. The cost payable for repair shall be mutually
settled.
4.5
Contractor shall be liable solely to adhere to the requirements of the insurer for settlement of
claims without prejudice to the rights of Contractor / NALCO / Insurer. Following steps are listed,
however not exhaustively, for the information of contractor.
(a)
(b)
(c)
(d)
(e)
Timely information for conducting survey.

Protecting the rights of insurer while issuing acknowledgments.
Lodging of monitory claims in time and furnishing of requisite documents to surveyors /
insurers.
Taking necessary precautions so that the loss/damage is not aggravated further.
Damaged goods to be protected fully.
Page 3 of 11
4.6
Employees State Insurance Act
(i)
The Contractor agrees to and does hereby accept full and exclusive liability for the compliance with
all obligations imposed by the Employee State Insurance Act 1948 and the Contractor further
agrees to defend, indemnify and hold Owner harmless for any liability or penalty which may be
imposed by the Central, State or Local authority by reasons of any asserted violation by Contractor
or his Sub-contractor of the Employees State Insurance Act, 1948 and also from all claims, suits or
proceeding that may be brought against the Owner arising under, growing out of or by reasons of
the work provided for by this Contractor, whether brought by employees of the contractor, by third
parties or by Central or State Government authority or any political sub-division thereof.
(ii)
The Contractor agrees to fill in with the Employees State Insurance Corporation, the Declaration
forms, and all forms which may be required in respect of the Contractors or his Sub-contractors
employees, who are employed in the WORK provided for or those covered by ESI from time to
time under the Agreement. The Contractor shall deduct and secure the agreement of his subcontractor to deduct the employees contribution as per the first schedule of the Employees State
Insurance Act from wages and affix the Employees Contribution Card at wages payment intervals.
The contractor shall remit and secure the agreement of his sub-contractor to remit the State Bank
of India, Employees State Insurance Corporation account the Employees contribution as required
by the Act. The Contractor agrees to maintain all Cards and Records as required under the Act in
respect of employees and payments and the contractor shall secure the agreement of his subcontractor to maintain such records. Any expenses incurred for the contributions; making
contributions or maintaining records shall be to the Contractors or his Sub-contractors account.
(iii)
Owner shall retain such sum as may be necessary from the total value of contract until the
Contractor shall furnish satisfactory proof that all contributions as required by the Employees State
Insurance Act, 1948 have been paid. This will be pending on the Contractor when the ESI Act is
extended to the place of work.
4.7
Workmens Compensation & Employers Liability Insurance

Insurance shall be effected by Contractor for all their employees engaged in the performance of
this Contract. If any of the work is sublet, the Contractor shall require his sub-contractor to provide
workmans Compensation and employers liability insurance for the laters employees if such
employees are not covered under the Contractors insurance.
4.8
Comprehensive Automobile Insurance

This insurance shall be in such a form to protect the Contractor against all claims for injuries,
disability, disease and death to members of public including the Owners men and damage to the
property of others arising from the use of motor vehicles, during on or off the Site Operations,
irrespective of the ownership of such vehicles.
4.9
Comprehensive General Liability Insurance

This insurance shall protect the Contractor against all claims arising from inuries, disabilities,
disease or death of members of public or damage to property of others, due to any act or omission
Page 4 of 11
on the part of the Contractor, his agents, his employees, his representative and Sub-Contractors or
from riots, strikes and civil commotion. This insurance shall cover all the liabilities of the contractor
arising out of the relevant clauses of enquiry documents.
The hazards to be covered will pertain to all the works which and areas where, the Contrctor, his
Sub-Contractors, his agents and his employees have to perform work pursuant to the contract.
The above are only illustrative list of insurance covers normally required and it will be the
responsibility of the contractor to maintain all necessary insurance coverage to the extent both in
time and amount to take care of all his liabilities either direct or indirect, in pursuance of the
contract.
4.10
Any other Insurance required under Law or Regulations or by Owner

Contractor shall also carry and maintain any and all other Insurance(s) which he may be required
under any law or regulation from time to time without any extra cost to Owner. He shall also carry
and maintain any other insurance which may be required by the Owner.
4.11
Accident or Injury to Workmen

Owner shall not be liable for or in respect of any damages or compensation payable at law in
respect or in consequence of any accident or injury to any workman or other person in the
employment of the Contractor or his Sub-Contractor and the Contractor shall indemnify and keep
indemnified the Owner against all such damages and compensation and against all claims,
demands, proceedings, costs, charges and expenses, whatsoever in respect or in relation thereto.
5.0
CONSTRUCTION, ERECTION OF PLANT AND MATERIAL
5.1
Contractors Material brought on the Site

The Contractor shall bring to Site all equipments, components, parts, materials, including
construction equipment, tools and tackles for the purpose of the Works under intimation to the
Owner. All such goods shall, from the time of their being brought vest in the Owner, but may be
used for the purpose of the Works only and shall not on any account be removed or taken away by
the Contractor without the written permission of the Owner. The Contractor shall nevertheless be
solely liable and responsible for any loss or destruction thereof and damage thereto.
5.2
Work & Services to be provided by the Owner

Works and services which shall be provided by the Owner for carrying out complete work at Site
shall be as defined in the technical part of the Enquiry Documents and its clarification up to award
of Contract.
(a)
Water supply for construction purpose may be provided by the Owner at one mutually
agreed point at Site. Drinking water will also be made available at one central point at
Site. The Contractor shall make his own arrangement for any further distribution. Such
distribution pipe network shall have the prior approval of the Engineer at Site so as not to
Page 5 of 11
interfere with the layout and progress of other construction works. Supply of water shall be
charged from Contractor at the rates prevailing at Site.
Contractor shall ensure that there is no wastage of water. On completion of the work, the
Contractor shall remove all such work and shall reinstate and make good any work
disturbed to the satisfaction of the Engineer.
(b)
5.3
Cranes, if available, will be provided by Owner on payment of rent to the Owner.
Work and Services to be provided by the Contractor

The following work and services shall also be provided under the contract :
5.4
(i)
Material transportation to erection site at Contractors risk and cost.
(ii)
All construction activities to complete the plant as per the specifications agreed by the
Owner. The activities shall be included but not limited to building structures, rooms,
foundations for equipments and accessories and stack etc.
(iii)
Labor license for contractor and sub-contractors labor if required / applicable as per State
Govt.
Owners Lien on Equipments

The Owner shall have lien on all equipments including those of the Contractor brought to the Site
for the purpose of construction, erection, testing and commissioning of the plant. The Owner shall
continue to hold the lien on all such equipments throughout the period of Contract. No material
brought to the Site shall be removed from the Site by the Contractor and / or his Sub-contractors
without the prior written approval of the Owner.
5.5
Protection of Work
The contractor shall have total responsibility for protecting his Works till it is finally taken over by
the Owner. No claim will be entertained by the Owner or the Consultant for any damage or loss to
the Contractors Works and the Contractor shall be responsible for the complete restoration of the
damaged works to its original condition to comply with the specifications and drawings. Should any
such damage to the Contractors Works occur because of other party not under his supervision or
control, the Contractor shall make his claim directly with the party concerned. If disagreement or
conflict or dispute develops between the Contractor and the party or parties concerned regarding
the responsibility for damage to the Contractors Works the same shall be resolved as per the
provisions of the clause entitled Co-operation with other Contractors. The Contractor shall not
cause any delay in the repair of such damaged works because of any delay in the resolution of
such disputes. The Contractor shall proceed to repair the work immediately and no cause thereof
will be assigned pending resolution of such dispute.
Page 6 of 11
5.6
Security
The Contractor shall have total responsibility for all equipments and materials in his custody stored,
loose, semi-assembled and / or erected by him at Site. The Contractor shall make suitable security
arrangements including employment of security personnel to ensure the protection of all materials,
equipment and works from theft, fire, pilferage and any other damages and loss. All materials of
the Contractor shall enter and leave the Project Site only with the written permission of the Owner
in the prescribed manner.
Contractors employees shall wear identification badges while on the work at Site.
5.7
Contractors Area Limits

The Owner will mark-out the boundary limits of access road, parking spaces, storage and
construction areas for the Contractor and the Contractor shall not trespass the areas not so
marked out for him. The Contractor shall be responsible to ensure that none of his personnel
move out of the areas marked out, for his operation. In case of such a need for the Contractors
personnel to work, out of the areas marked out for him, the same shall be done only with the
written permission of the Owner.
5.8
Contractors Co-operation with the Owner

In cases where the performance of the Site Work by the Contractor affects the operation of the
system facilities of the Owner such Site Work of the Contractor shall be scheduled to be performed
only in the manner stipulated by the Owner and the same shall be acceptable at all times to the
Contractor. The Owner may impose such restriction on the facilities provided to the Contractor
such as electricity, water, etc. as he may think fit in the interest of the Owner and the Contractor
shall strictly adhere to such restrictions and co-operate with the Owner. It will be responsibility of
the Contractor to provide all necessary temporary instrumentation and other measuring devices
required during start-up and operation of the equipment systems which are erected by him. The
Contractor shall also be responsible for flushing and initial filling of all the oil and lubricants
required for the equipment supplied and erected by him, so as to make such equipments ready for
operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants
unless otherwise specified elsewhere in these documents and specifications.
5.9
Protection of Property and Contractors Liability
5.9.1
The Contractor shall be responsible for any damage resulting from his operations. He shall also be
responsible for protection of all persons including members of public and employees of the Owner
and the employees of other Contractors and Sub-Contractors and all public and private property
including structurs, building, other plants and equipments and utilities either above or below the
ground.
5.9.2
The Contractor will ensure provisions of necessary safety equipment such as barriers, sign-boards,
warning lights and lamps, etc. to provide adequate protection to persons and property. The
Contractor shall be responsible to give reasonable notice to the Owner and the Owner of public or
private property and utilities when such property and utilities are likely to get damaged or injured
Page 7 of 11
during the performance of his works and shall make all necessary arrangements with Owners,
related to removal and/or replacement of such property and utilities.
5.10
Painting
All exposed metal parts of the equipment including piping, structures railing, etc. wherever
applicable, after installation unless otherwise surface protected, shall be first painted with at least
one coat of suitable primer which matches the shop primer paint used, after thoroughly cleaning all
such parts of all dirt, rust, scales, greases, oil and other foreign materials by wire brushing,
scraping or sand blasting, and the same being inspected and approved by the Engineer for
painting. Afterwards, the above parts shall be finished with two coats of a alloyed resin machinery
enamel paints. The quality of the finish paint shall be as per the standards of ISI or equivalent and
to be of the colour as approved by the Owner.
5.11
Unfavorable Working Conditions

The Contractor shall confine all his field operations to those works which can be performed without
subjecting the equipment and materials to adverse effects, during inclement weather conditions,
like monsoon, storms, etc. and during other unfavourable construction conditions. No field
activities shall be performed by the Contractor under conditions which might adversely affect the
quality and efficiency thereof unless special precautions or measures are taken by the Contractor
in a proper and satisfactory manner in the performance of such works and with the concurrence of
the Consultant/Owner. Such unfavorable construction conditions will in no way relieve the
contractor of his responsibility to perform the works as per the schedule.
5.12
Protection of monuments and reference points

The Contractor shall ensure that any finds such as relic, antiquity, coins, fossile, etc. which he may
come across during the course of performance of his works either during excavation of elsewhere,
are properly protected and handed over to the Owner. Similarly, the Contractor shall ensure that
the bench marks, reference points, etc. which are marked out either with the help of Owner or by
the Owner shall not be disturbed in any way during the performance of his works. If any work is to
be performed which may disturb such reference, the same shall be done only after these are
transferred to other suitable locations under the direction of the Owner.
6.0
CONSTRUCTION
6.1
Rules and Regulations

Contractor shall observe all national and local laws, ordinaces, rules and regulations pertaining to
the work, and shall be responsible for extra costs arising from violations of same.
6.2
Safety
Contractor shall take all necessary measures to protect the work and workmen against accidents
and occupational disease. They shall observe and comply with all Government safety regulations
as specified by the Owner.
Page 8 of 11
The Contractor shall be responsible for following the proper procedures in reporting accidents or
incident.
The Owners Safety Engineer located in Site will be immediately notified by faster means possible
of any accident which involves the following:
(a)
(b)
(c)
(d)
(e)
(f)
Death from any cause whatsoever.

A fractured skull, arm, thigh or spine, fore-arm or leg.
A dislocated shoulder.
The amputation of arm or hand, or of one or more fingers on the same hand, or of a leg or
a foot.
The loss of sight of an eye.
Any other serious bodily injury, including internal bleeding or burns or asphyxia where such
injury is likely to endanger life, cause permanent incapacity or temporary incapacity of 5
days or more.
6.3
In case of death, the Contractor shall be responsible for immediately notifying the nearest Indian
Police so that they can make the proper investigation in accordance with the law.
7.0
FOREIGN LIABILITY CLAUSE

It is expressly understood and agreed by and between (the Corporation0 and M/s National
Aluminium Company Limited (The Indian PSU) that M/s National Aluminium Co. Ltd. (the Indian
PSU) is entering into this agreement solely on its own behalf and not on behalf of any other person
or entity. In particular, it is expressly understood and agreed that the Government of India is not a
party to this agreement and has no liabilities, obligations or rights hereunder. It is expressly
understood and agreed that M/s National Aluminium Co. Ltd. (the Indian PSU) is an independent
legal entity with power and authority to enter into contracts solely in its own behalf under the
applicable Law of Indian and General Principles of Contract Law. The (Company) expressly
agrees, acknowledges and understands that M/s National Aluminium Co. Ltd. (the Indian PSU) is
not an agent, representative or delegate of the Government of India. It is further understood and
agreed that the Government of India is not and shall not be liable for any acts, omissions,
commissions, breaches or other wrongs arising out of the Contract. Accordingly (corporation)
hereby expressly waives, releases and foregoes any and all actions or claims including cross
claims, impleader claims or counter claims against the Government of India arising out of this
contract and covenents not to sue the Government of India as to any manner, claim, cause of
action or thing whatsoever arising of or under this agreement.
8.0
CLAUSE 44.02: REGULATION OF LOCAL AUTHORITIES & STATUES (TENDER DOCUMENT

COMMERCIAL - INDIGENOUS)
8.1
The following is to be read along with Clause 44.02:(a) The payment of minimum wages to Contract Labour shall be as per the rates notified by the
central Government as per Minimum Wages Act,1948 and as adopted by the NALCO
Management from time to time plus any additional element and statutory dues thereon.
Page 9 of 11
(b) The Minimum wage as notified by the Chief Labour Commissioner (central) has a variable
component as Special allowance which is linked to average AICPI for Industrial Workers,
which keeps on changing every six months. The Contractor has to absorb all such variations
due to increase in Minimum wage in their quoted price and no claim whatsoever on this
account shall be entertained.
(c) Where the Minimum wages notified by the concerned State Government are higher than the
rates notified by the Central Government, the States Government rates should apply in
concerned scheduled employment as long as the same remains higher than the Central
Government rates.
(d) The classification on workers in different categories will be as per the notification issued by the
Central Government fixing the minimum wages for the above scheduled appointment.
8.2
The classification of workers in different categories will be as per the notification issued by the
Central government fixing the minimum wages for the above scheduled appointment. Where the
minimum wages notified by the concerned State Government are higher than the rates notified by
Central Government, the State Government rates should apply in concerned scheduled
employments.
9.0
GUARANTEE PERIOD
Guarantee Period shall be 12 months from commissioning (including acceptance of
Performance Guarantee Tests) or 24 months from completion of erection, whichever is earlier.
All other provisions of the clause remain unaltered.
10.0
CONTRACT PERFORMANCE GUARANTEE

Supplier will be required to submit Contract - cum - Performance Bank Guarantee (CPBG) for 10%
of Total Order Value (Supply + Transportation + Supervision + Site Work) for the complete
package within 30 days of placement of order with validity up to 3 months beyond Guarantee
Period. All payments shall be released after receipt of CPBG.
11.0
CONSTRUCTION POWER
Construction power rate indicated in Tender Documents Commercial is modified as As applicable
at Site in place of Rs. 1/- per KWH.
12.0
PRICE REDUCTION SCHEDULE
(i)
Liquidated Damages (LD) wherever mentioned in NIT documents, is to be read as Price Reduction
Schedule (PRS).
(ii)
The Contractors liability for delay shall not in any case exceed five percent of the total contract
price.
All other provisions of these clauses remain unaltered.
Page 10 of 11
13.0
POWER TO VARY OR OMIT WORK
13.1
In partial modification to clause No. - 29 of GCC - Indigenous the last sentence of this clause is
amended as follows:
In the absence of any such modification, the contractor shall bind to carry out the suggested
variations. Any addition or deletion to price will be discussed between purchaser and contractor
and settled.
13.2
All other provisions of this clause remain unaltered.

Note: The terms and conditions mentioned herein will prevail over the terms mentioned in tender
document commercial (indigenous).
Page 11 of 11
ANNEXURE - V
AGREED TERMS & CONDITIONS (INDIGENOUS)
NALCO, SMELTER PLANT
(FOR INDIGENOUS BIDDERS)
IMPORTANT
1.
This questionnaire must be filled in against all Serial nos. & enclosed with the Un-priced offer.
Non submission or submission of incomplete questionnaire may lead to rejection of the offer.
2.
All commercial terms except the deviations to Tender Documents - Commercial (Indigenous),
Addendum to Tender Documents and other attachments of NIT must be given in this
questionnaire itself and not elsewhere in the quotation. In case of contradiction, the terms
given below shall prevail. The deviations to Tender Documents - Commercial (Indigenous),
Addendum to Tender Documents and other attachments of NIT, if any must be listed in a
separate Annexure.
Sl.
No.
Descriptions
Vendors confirmation
with details
(A)
TECHNICAL:
1. (i)
Acceptance of Technical specifications and scope

of supply as per attached Annexure - I Technical Specification.
(ii)
In case of deviations, confirm that the same has

been highlighted separately.
2.
Confirm that data sheets/ technical questionnaire

duly filled in are attached, wherever required.
3.
Confirm Spare parts list, wherever required with

item wise prices have been submitted for
following categories of Spares.
(a)
(b)
(c)
(d)
4.
Mandatory Spares
Commissioning Spares
Recommended Spares for One Year
normal operation and maintenance
Special Tools & Tackles
It is noted that deviations to terms & conditions

shall lead to loading of prices or rejection of offer.
Page 1 of 7
Sl.
No.
Descriptions
with details
5.
Confirm that the quoted prices are based on FOR/

FOT Despatch point including packing &
forwarding.
(i)
If quoted on Ex- works basis, indicate P&F

charges in terms of percentage.
(ii)
Indicate despatching station.
6.
Confirm you have quoted prices strictly in the

price schedule format enclosed with NIT
documents.
7.
Please confirm that firm freight charges inclusive

of applicable Service Tax and E-cess up to Site is
quoted in price bid.
(a)
In case you have not quoted the freight charges

separately in the Price Schedule, please quote
the same in terms of % of the quoted price.
(b)
Confirm that freight charges for Recommended

Spares for One Year normal O&M have been
quoted separately and the freight for all other
supplies are included in freight of Main
Equipment.
8.
Confirm Transit insurance is excluded from the

quoted prices. If inclusive, indicate rebate for
excluding the same.
9.
Indicate rate of Central Sales Tax/Orissa VAT

payable extra.
(i)
(ii)
(iii)
CST without concessional Form.

CST with concessional Form.
Orissa VAT
Page 2 of 7
Sl.
No.
Descriptions
with details
10(a)
Statutory increase in Excise Duty & Education

cess beyond contractual delivery date shall be to
vendors account but any reduction up to actual
date of despatch shall be to owners account.
(b)
Indicate present rate of Excise Duty & Education

Cess applicable on the supplies (including
Spares) and whether the same is included/
excluded from quoted prices.
(c)
If there is any increase in ED & E-cess at the time

of supplies for any reasons, other than statutory,
including turnover, confirm the same will be borne
by the vendor.
(d)
If ED & E-ces is presently not applicable, confirm

whether the same will be borne by the vendor in
case it becomes leviable later.
(e)
In case (c) or (d) is not acceptable, advise

maximum rate of ED & E-cess chargeable.
11.
Entry Tax on supplied items shall be paid by

Nalco directly to Tax Authorities. However, any
Entry Tax applicable for items and consumables
etc used for Erection/ Commissioning shall be to
Sellers account.
12.
Confirm submission of following documents with offer:

1) Valid Excise Regn. Certificate.
2) Valid Sales Tax Regn. Certificate.
3) Valid Service Tax Regn. Certificate.
4) TIN (Tax Identification No.)
13.
Confirm in case of delay on a/c of vendor, any

new or additional taxes and duties imposed after
contractual delivery shall be to vendors account.
Page 3 of 7
Sl.
No.
Descriptions
with details
14.
Confirm acceptance to delivery/ Completion

period as mentioned in NIT documents.
15.
Confirm acceptance to Price Reduction Schedule

clause specified in Tender Documents.
16.
Confirm acceptance of relevant terms of payment

as per the NIT documents attached.
17.
Confirm that the quoted prices are firm and fixed

till complete execution.
18.
Confirm that Contract cum Performance/

Performance Bank Guarantee wherever required
will be furnished for value and terms & conditions
as per document attached with NIT.
19.
Confirm that Bank Guarantee for equivalent

amount of Free Issue Materials, wherever
applicable, shall be furnished.
20.
Confirm acceptance of Guarantee/ Warranty as

per documents attached with NIT.
21.
Confirm that quoted prices are inclusive of all

Testing charges as required in the NIT.
22(i)
All other Commercial terms & conditions shall be

as per Tender Documents - Commercial
(Indigenous), Addendum to Tender Documents Commercial and other documents attached with
the NIT. Confirm.
(ii)
In case of deviations, confirm clause wise

comments have been specified in a separate
Annexure.
(iii)
All the terms & conditions have been indicated in

this format including Annexure and have not been
repeated elsewhere. It is noted that terms &
conditions indicated elsewhere shall be ignored.
Page 4 of 7
Sl.
No.
Descriptions
with details
23.
Confirm that all taxes, duties and levies of any

kind payable by Seller up to the stage of handing
over of the system to Owner shall be borne by
you.
25.
Import permit/ Licence, if required shall be the

responsibility of the Seller and any expenditure
towards the same shall be borne by you. Please
confirm.
26.
In case of any Imported supply to be quoted in

INR by Indian Associate, confirm that all
variations in Customs Duty and Foreign
Exchange till complete execution of the contract
shall be to Sellers account.
27.
The vendor is required to state whether any of the

Directors of vendor is a relative of any of the
Directors of Owner or the vendor is a firm in which
any Director of Owner or his relative is a partner
or the vendor is a Private Company in which any
of the Directors of Owner is a member or Director.
28.
Confirm that the offer shall be valid up to 4

months from the bid due date/ extended bid due
date.
29.
Please furnish Annual Report containing Balance

Sheet and Profit and Loss Account for the last
three years.
30.
Confirm that net worth of your company during

the last financial year is positive.
31.
As soon as shipment/ dispatch is made, the Seller

shall intimate NALCOs Underwriters the dispatch
details t the address which shall be furnished
later.
32.
The Vendor is required to state whether M/s AP/

ALCAN has any shareholding/ management
control in your Company.
Page 5 of 7
Sl.
No.
Descriptions
with details
33.
Please note that you have not been banned or

de-listed by any Government or Quasi
Government agencies or PSU.
34.
Confirm that in case of conflicting version of

various terms & conditions at different places,
Owner can choose any version.
35.
Please furnish name and address of the official to

whom correspondence should be sent including
telephone number/ fax number and e-mail id. If email id is not available, an undertaking is to be
given that e-mail id is to be registered within 2
weeks of bid submission
Place:
Signature:
Date:
Name :
Page 6 of 7
Designation
Seal
DEVIATIONS TO NIT DOCUMENTS
SL.
NO.
REFERENCE OF NIT DOCUMENT

DOCUMENT
SUBJECT
DEVIATIONS
CLAUSE NO.
NOTE: This shall be submitted along with the Un - priced Offer. Deviation mentioned anywhere else in the
offer shall not be considered.
Signature:
Date:
Name :
Page 7 of 7
Designation
Seal
Tender Notice No. - ...............
Annexure - VI
PRICE SCHEDULE FORMAT
ITEM:
WAGON TIPPLER AND CONVEYOR SYSTEM
IDDER TO QUOTE IN EACH COLUMN FOR SCOPE AS PER NIT
1.0
1.1
1.2
1.3
2.0
2.1
2.2
2.3
INDIGENOUS SUPPLY (IN INDIAN

Rs.)
(M/s ..)
SUPPLY OF MAIN EQUIPMENT

Design, Engineering, Manufacturing, Procurement,
Inspection, Assembly, Painting, Testing at Suppliers
works, Packing & Forwarding and Supply of Wagon
Tippler & Accessories including Commissioning & Start-up
Spares, Tools & Tackles , first fill of oil & lubricants/ oil and
consumables as per Annexure - I - Technical Specification
of NIT on FOT Dispatch point basis including packing &
forwarding (break - up of prices to be submitted as per
Annexure - A attached herewith)
Supply of Mandatory Spares, as per NIT (itemized prices to
be furnished along with the price bid) on FOT dispatch
point basis including packing & forwarding
Others if any to complete the Scope (Pl specify)
SUB TOTAL (1.0)
FREIGHT, INSURANCE, TAXES & DUTIES ON ITEMS
UNDER SUB HEADING 1.0
Total & maximum Excise Duty & E-cess on ED (Amount
payable against Cenvatable Invoices )
Total & maximum Central Sales Tax (Considering CST
Declaration form to be furnished by NALCO, wherever
applicable/ admissible)
Total & Maximum Orissa VAT applicable for items to be
supplied from within the state of Odisha
Page 1 of 7
ERECTION/ TESTING/
COMMISSIONING SERVICES AT
SITE , SUPERVISION & TRAINING
SERVICES (IN INDIAN Rs.)
(M/s .)

2.4
2.5
2.6
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7

Rs.)
(M/s ..)
All other taxes & duties currently applicable (Please specify

the nature of Tax/ Duty & its rate)
Inland freight charges up to Site including Service Tax & Ecess on same
Transit Insurance up to Site (Optional) inclusive of all
taxes
SUB TOTAL (2.0)
SUPPLY OF ONE YEARS O&M SPARES FOR
TROUBLE FREE OPERATION - OPTIONAL
Supply of vendor recommended Spares for One year O&M
on FOT dispatch point basis (itemized prices to be
furnished along with the price bid, list of spares to be
furnished along with un - priced bid)
Total & maximum Excise Duty & E-cess on ED (Amount
payable against Cenvatable Invoices )
Total & maximum Central Sales Tax (Considering CST
Declaration form to be furnished by NALCO, wherever
applicable/ admissible)
Total & Maximum Orissa VAT applicable for items to be
supplied from within Orissa
All other taxes & duties currently applicable (Please specify
the nature of Tax/ Duty & its rate)
Inland freight charges up to Site including applicable
Service Tax & E-cess
Transit Insurance up to Site (Optional) inclusive of all
taxes
SUB TOTAL (3.0 )
Page 2 of 7
ERECTION/ TESTING/
(M/s .)

4.0
4.1
UNLOADING,
STORAGE,
HANDLING
&
TRANSPORTATION OF EQUIPMENT/ MATERIALS AT
SITE
For Main Equipment under Sl. No. - 1.0 above
4.2
For One Year O&M Spares under Sl. No. - 3.0 above
4.3
Total & Maximum Service Tax for 4.1

Total & Maximum E-cess for 4.1
Total & Maximum Service Tax for 4.2
Total & Maximum E-cess for 4.2
4.4
4.5
4.6

Rs.)
(M/s ..)
SUB TOTAL (4.0)

5.0
CONSTRUCTION,
ERECTION,
TESTING,
COMMISSIONING AND PERFORMANCE GUARANTEE
TESTS
5.1
Civil & Structural Work as per NIT
5.2
Erection - Mechanical
5.3
Electrical and Instrumentation works
5.4
Testing, Commissioning and Performance Guarantee

Tests.
5.5
All statutory/contingency insurance coverage e.g. third

party liability, ESI, workmen compensation etc.
5.6
Total
for
Construction,
Erection,
Testing,
Commissioning and Performance Guarantee Tests
5.7
Insurance coverage for storage erection & commissioning

etc. (Optional)
5.8
Orissa VAT on Works Contract (Works Contract Tax) as

currently applicable
Page 3 of 7
ERECTION/ TESTING/
(M/s .)

5.9
Any other Indian taxes/ duties currently applicable
5.10
Total & maximum Service Tax.
5.11
Total & maximum E- cess on Service Tax.
5.12
Others, if any.

Rs.)
(M/s ..)
ERECTION/ TESTING/
(M/s .)
SUB TOTAL (5.0)

GRAND TOTAL ( SUM OF 1.0 T0 5.0 )
NOTES:
1.
The Price Schedule shall be made available in Un-priced offer also with prices blanked out and written Quoted/ Not Quoted/ Not Applicable, as
the case may be.
2.
In the Price Schedule no column should be left blank.
3.
The quoted prices shall include charges towards testing & all documentation required as per NIT.
4.
Any correction in the quotation shall be initialed by the bidder, otherwise the offer shall be rejected.
5.
Bidders are required to quote prices inclusive of Works Contract Tax or Orissa VAT on Works Contract and any variation is not payable on this
account. Liability of Works Contract Tax on Erection/ Testing/ Commissioning for Service Contract i.e. Contract C shall be solely of Contractor.
NALCO would deduct WCT in line with NIT provisions while releasing payment to Contractor and deposit the same with Sales Tax Authority and
issue TDS to Contractor from time to time. Contractor will settle WCT directly with the Sales Tax Authority without any liability on the part of
NALCO. Bidders are required to include the WCT into their price, as applicable, and it would be deemed that the same has been taken into
consideration by them, irrespective of whether such WCT amount has been indicated separately or not. Accordingly, there would be no loading (i.e.
there will be no like to like comparison) even if any agency does not indicate such amount or such percentage in their price bid. However, WCT
mentioned in the price schedule by a bidder shall be considered for evaluation of his price.
6.
Applicable Service Tax & E-cess on Service Tax will be paid at actuals subject to documentary evidence limited to the maximum amount quoted.
Page 4 of 7
7.
Entry Tax on supplies against supply of items shall be paid by NALCO directly to Tax authorities.
8.
The sum of quoted prices for relevant divisible package (s) shall be treated as the Contract price(s) for concerned package(s) on lump sum basis.
The contract vis-- vis payment operations shall be done, however, as per approved Billing schedules only.
9.
The Contract (s) prices, will remain firm & unchanged until complete execution excepting for statutory variations, if any on the rates of taxes &
duties included in the Contract price ( as per break ups specified in the Billing schedule) and also excepting for imposition of any fresh statutory
levy/ tax.
10.
In case of award of work, the Contractor has to submit a Billing Schedule for approval of NALCO/RITES. The payment of bills involving Excise duty
shall be made at actuals against submission of Cenvatable ED invoices but limited to the quoted ED & E-cess on ED.
11.
Optional prices shall not be considered for evaluation. However, the optional prices shall be valid during execution of Contract and could be
exercised by NALCO, in case NALCO decides the same.
12.
Supply of spares parts for One Year normal operation and maintenance as per Sl. No. - 3.0 of Price Schedule shall not be considered for
evaluation. However, the prices shall be valid and separate order shall be placed for such spares which are decided by NALCO. Sl. No. - 4.2, 4.5 &
4.6 shall not be considered for evaluation.
Bidder shall submit Price break - up along with quantity and unit price for the Spares for 1 year normal operation and maintenance in priced and un
- priced format.
13.
14.
Bidder shall submit Price break - up along with quantity and unit price for the following in Priced & Un-priced format:
(a)
(b)
(c)
(d)
Mandatory Spares
Commissioning & Start-up Spares
Tools & Tackles
Spares for One Year O&M
Bidders Signature:
Bidders Stamp:
Date:
Page 5 of 7
ANNEXURE-A TO PRICE SCHEDULE FORMAT

Description of Item
01. Design, Manufacture and Supply of Wagon Tippler System 25 tips / hour design
capacity (20 tips per hour guaranteed output) complete with tippler platform with rails,
cradle, top & side clamps, etc. including all electricals and instrumentation and required
other connected accessories.
02. Design, Manufacture and Supply of Side Arm charger (25 wagons per hour) 20 wagons
per hour guaranteed capacity complete with all rails and travel mechanism.
Unit of
measurement
Lump sum
Quantity
1
Lump sum
03. Design, Manufacture and Supply of Apron feeder (1200 TPH) complete with dribble
conveyor, feeder pans, suitable for underground hopper of tippler complete with drives,
base plates and accessories required for fixing in foundation and other connected
accessories complete.
Lump sum
04. Design, Manufacture and Supply of Receiving belt conveyor system 1200 TPH
guaranteed capacity, 1200 mm belt width suitable for transport of coal received from
apron feeder to existing conveyors BC-103 & BC-115 in plant including pent house,
junction tower complete with stringers, supports, Idlers, Belt, Pulleys, chutes and safety
devices, foundations, supports overhead gallery and trestle etc. with all electricals and
plc control accessories.
05. Design, Manufacture and Supply of Dust control system at Wagon Tippler House,
transfer points of conveyor complete with all civil, mechanical and electricals works.
Lump sum
Lump sum
06. Design, Manufacture and Supply of E.O.T.

Crane 25T / 5T capacity suitable to handle the erection and Maintenance requirements
of wagon tippler, apron feeder, etc.
Lump sum
07. Design and supply of Mono rail hoists of appropriate capacity for equipments, drivers,
pulley and Gear reducers, apron feeder at various location within the terminal points
complete with all accessories.
Lump sum
08. Design and supply of Fire hydrant system covering Wagon Tippler House, Conveyor
Galleries, Transfer House etc. extending from existing fire water grid in the vicinity
within Plant area with all necessary accessories complete.
Lump sum
Page 6 of 7
Unit Price
Description of Item
09. Design and supply of Service water connections at Transfer Towers, tippler house, at
each floor level complete system extending from the existing header near the new track
hopper with all accessories for complete system.
Unit of
measurement
Lump sum
Quantity
1
10. Design and supply of Illumination and lighting system for Wagon Tippler House,
Transfer Towers, Conveyor Galleries and control rooms etc. with all accessories.
Lump sum
11. Design and supply of ACSR cables, rail poles, insulators, hardware fittings, 33KV/6.6KV
transformer complete, breakers, isolators, CT, PT, LA, switch gear, etc. for HT system
as per scope of work.
Lump sum
12. Design and supply of cables, 6.6KV/415V transformer complete, switch gear, panels,
etc. LT system as per scope of work.
Lump sum
13. Supply of all control cables, Panels, PLCs etc. complete for the system.
Lump sum
LUMP SUM PRICE TOTAL
Page 7 of 7
Unit Price
ANNEXURE - VII
PROFORMA OF CONTRACT CUM PERFORMANCE GUARANTEE BY SELLER/CONTRACTOR
(To be executed on non-Judicial stamped paper of appropriate value)
B.G. No. -
Date:
WHEREAS National Aluminium Company Limited (A Government of India Enterprise), having its Office at
Nalco Bhavan, P/1, Nayapalli, Bhubaneswar - 751 061, Orissa (hereinafter called "the Company/Owner")
which expression shall unless repugnant to the subject or context includes its legal representatives,
successors and assigns), has entered into a contract with M/s. ../ has placed a purchase
order on M/s. (hereinafter referred to as Contractor(s)/Seller(s)) which expression shall
unless repugnant to the subject or context includes their legal representatives, successors and assigns) for
.............................. on the terms and conditions as set out inter alia, in the company Contract No/P.O.
No.............................. dt............. and various documents forming part thereof herein after referred to as the
said contract which expression include all amendments, modification and/or variation thereto and where
as the Contractor/Seller has agreed for due execution of the entire contract and guarantees its performance
including any parts executed through any others agencies/sub-contractors.
AND WHEREAS one of the conditions of the said contract is that contractor/seller shall furnish to the
owner a Bank Guarantee from a bank for ......% (............. percent) of the total value of the said contract
against due and faithful performance of the said contract including defects liability obligations and the
performance guarantee obligations of the contractor/seller for execution/supplies made under the said
contract.
2.
We .. Bank having its branch office at . do hereby agree and undertake

to pay the amount due and payable under this guarantee without any demur merely on a demand from the
Company stating that in the opinion of the company which is final & binding, the amount claimed is due by
reason of default made by the Contractor(s)/ Seller(s) in performing any of the terms and conditions of the
said Contract including defects liability obligations, in fulfilling the performance Guarantee obligation or loss
or damage caused to or would be caused to or suffered by the Company by reason of any breach by the
said Contractor(s)/Seller(s) of any of the terms and conditions of the contract. Any such demand made on
the Bank by the owner shall be conclusive as regards the amount due and payable by the Bank under this
guarantee. However our liability under this guarantee shall be restricted to Rs..................
(Rupees........................... only)
3.
We undertake to pay to the Company any money so demanded not withstanding any dispute or disputes
raised by the Contractor(s)/Supplier(s) in any suit or proceeding pending before any office, court or Tribunal
relating thereto, our liability under this present being absolute and unequivocal. The payment so made by
us under this bond shall be a valid discharge of our liability for payment there under. Our liability to pay is
not dependent or conditional on the owner proceeding against the contractor(s)/seller(s).
4.
The guarantee herein contained shall not be determined or affected or suspended by the liquidation or
winding up, dissolution or change of constitution or insolvency of the said Contractor(s)/ Seller(s) but shall
in all respects and for all purposes be binding and operative until payment of all money due or liabilities
under the said Contract(s)/Order(s) are fulfilled.
Page 1 of 2
5.
We Bank further agree that the guarantee herein contained shall remain in full force
and effect during the period that would be taken for the performance of the said Contract(s)/Order(s) and
that it shall continue to be enforceable till all the dues of the Company under or by virtue of the said
Contract(s)/Order(s) have been fully paid and its claims satisfied or discharged or till a duly authorised
officer of the Company certifies that the terms and conditions of the said Contract(s)/Order(s) have been
fully and properly carried out by the said Contractor(s) and accordingly discharge this guarantee.
6.
We ................................. Bank further agree with the Company that the Company shall have the fullest
liberty without our consent and without affecting in any manner our obligations hereunder to vary any of the
terms and conditions of the said Contractor(s)/ Order(s) or to extend time of performance by the said
Contractor(s)/Seller(s) from time to time or to postpone for any time or from time to time any of the powers
exercisable by the Company against the said Contractor(s)/Seller(s) and to forbear or enforce any of the
terms and conditions relating to the said Contractor(s)/Seller(s) and we shall not be relieved from our
liability by reason of any such variation or extension being granted to the said Contractor(s)/Seller(s) or for
any forbearance, act or omission on the part of the Company or any indulgence by the Company to the said
Contractor(s)/Seller(s) or by any such matter or thing whatsoever which under the law relating to sureties
would but for this provision have effect of so relieving us.
7.
Notwithstanding anything contained herein before, our liability shall not exceed Rs..
(Rupees .. only) and shall remain in force till .. unless a demand or claim under
this guarantee is made on us within three months from the date of expiry we shall be discharged from all
the liabilities under this guarantee.
8.
We Bank, lastly undertake not to revoke this guarantee during its currency except with the
previous consent of the Company in writing. We further undertake to keep this Guarantee renewed from
time to time at the request of Contractor(s)/Seller(s).
Date:
Corporate Seal of the Bank
......................Bank
By its constitutional Attorney
Signature of duly
Authorised person
on behalf of the Bank
With seal & signature code
BG is to be furnished from any of Nalco approved banks, listed as per Annexure - IX.
Page 2 of 2
Tender Notice No. - .
ANNEXURE - VIII
PROFORMA FOR BANK GUARANTEE FOR EARNEST MONEY DEPOSIT
(To be executed on non-Judicial stamped paper of appropriate value)
B.G. No_____________
Date____________
1.
WHEREAS National Aluminium Company Limited (A Government of India Enterprise), having its
Office at Nalco Bhavan, P/1, Nayapalli, Bhubaneswar - 751 061, Orissa (hereinafter referred as
"The Owner/ Company" which expression shall unless repugnant to the subject or context includes
its legal representatives, successors and assigns), has issued tender paper vide its Tender No.
.............. for................................... (hereinafter called the said tender) to M/s............................
(hereinafter called the said Tenderer(s) which expression shall unless repugnant to the subject or
context includes their legal representatives, successors and assigns) and as per terms and
conditions of the said tender, the tenderer shall submit a Bank Guarantee for Rs.____________
(Rupees ___________________________ Only) towards earnest money in lieu of cash.
2.
We___________________ Bank having its branch office at _________________ do hereby

undertake to pay the amounts due and payable under this guarantee without any demur merely on
a demand from the Company stating that in the opinion of the company, which is final & binding,
the amount claimed is due because of any withdrawal of the tender or any material alteration to the
tender after the opening of the tender by way of any loss or damage caused or would be caused or
suffered by the Company by reason of any breach by the said tenderer(s) of any terms and
conditions contained in the said tender or failure to accept the letter of Intent/Agreement or that the
amount covered under this Guarantee is forfeited. Any such demand made on the Bank by the
owner shall be conclusive as regards the amount due and payable by the Bank under this
Guarantee. However our liability under this guarantee shall be restricted to an amount not
exceeding Rs........................... (Rupees. Only).
3.
We undertake to pay to the Company any money so demanded notwithstanding any dispute or
disputes raised by the tenderer(s) in any suit or proceeding pending before any office, court or
Tribunal relating thereto, our liability under this present guarantee being absolute and unequivocal.
The payment so made by us under this bond shall be a valid discharge of our liability for payment
there under. Our liability to pay is not dependant or conditional on the owner proceeding against
the tenderer(s).
4.
The guarantee herein contained shall not be determined or affected or suspended by the
liquidation or winding up, dissolution or change of constitution or insolvency of the said tenderer(s)
but shall in all respects and for all purposes be binding and operative until payment of all money
due or liabilities under the said tender are fulfilled.
5.
We _________________ Bank Ltd., further agree that the guarantee herein contained shall remain
in full force and effect during the period that would be taken for the finalisation of the said tender
and that it shall continue to be enforceable till the said tender is finally decided and order placed on
Page 1 of 2
Tender Notice No. - .
the successful tenderer(s) and/or till all the dues of the Company under/or by virtue of the said
tender have been fully paid and its claims satisfied or discharged or till a duly authorised officer of
the Company certifies that the terms and conditions of the said tender have been fully and properly
carried out by the said tenderer(s) and accordingly discharges the guarantee.
6.
That the Owner/Company will have full liberty without reference to us and without affecting this
guarantee to postpone for any time or from time to time, the exercise of any of the power of the
owner under the tender.
7.
Notwithstanding anything contained herein before, our liability shall not exceed Rs.__________
(Rupees________________________________ Only) and shall remain in force till
__________unless a demand or claim under this guarantee is made on us within three months
from the date of expiry, we shall be discharged from all the liability under this guarantee.
8.
We __________________ Bank, lastly undertake not to revoke this guarantee during its currency
except with the previous consent of the Company in writing. We further undertake to keep this
Guarantee renewed from time to time on the request of the Tenderer(s).
Date:
Corporate Seal of the Bank
......................Bank
By its constitutional Attorney
Signature of duly
Authorised person
on behalf of the Bank
With seal & signature code
BG is to be furnished from any of Nalco approved banks, listed as per Annexure - IX.
Page 2 of 2
Tender Notice No. - ..
ANNEXURE - IX
LIST OF STANDARDISED BANKS
SCHEDULED PUBLIC SECTOR BANKS (INDIAN)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24
State Bank of India

State Bank of Bikaner and Jaipur
State Bank of Hyderabad
State Bank of Mysore
State Bank of Patiala
State Bank of Travancore
Allahabad Bank
Andhra Bank
Bank of Baroda
Bank of India
Bank of Maharashtra
Canara Bank
Central Bank of India
Corporation Bank
Dena Bank
Indian Bank
Oriental Bank of Commerce
Punjab National Bank
Punjab and Sind Bank
Syndicate Bank
Union Bank of India
UCO Bank
Vijaya Bank
IDBI Bank
(Twenty Four Banks)
Page 1 of 3
LIST OF STANDARDISED BANKS

SCHEDULED PRIVATE SECTOR BANKS (INDIAN)
1.
2.
3.
4.
5.
6.
7.
8.
ING Vysya Bank

Axis Bank
SBI Commercial & International Bank Ltd.
ICICI Bank
HDFC Bank
Yes Bank
Indus Ind. Bank
Kotak Mahindra Bank
(Eight Banks)
SCHEDULED FOREIGN BANKS

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
American Express Bank Ltd.

Bank of American NT & SA
Bank of Tokyo Ltd.
BNP Paribas
Barclays Bank Plc
Citi Bank NA
Deutsche Bank AG.
Hongkong and Shanghai Banking Corporation
Standard Chartered Bank
JP Morgan Chase Bank NA
(Ten Banks)
Page 2 of 3
ECS MANDATE FORM

ELECTRONIC CLEARING SERVICES/ELECTRONIC FUND TRANSFER/INTERNET
BANKING MANDATE FORM
To
National Aluminium Company Limited,
NALCO Bhawan,
Plot No. P/1, Nayapalli,
Bhubaneswar - 751061
Dear Sir,
Sub:
Authorization for release of payment due from NALCO, Corporate Office, Bhubaneswar through Electronic Clearing Services (RBI)/
Electronic fund transfer (RBI/SBI)/ Internet Banking (SBI).
Refer Order No..dtand/or Tender/Enquiry/Letter No..dt..
(Please fill in the information in CAPITAL LETTERS. Please TICK wherever it is applicable)
1.
2.
Name of the Party

Address of the party
:
:
.
City:. Pin Code:..

E-mail Id:
3.
Particulars of Bank:
Bank Name
Branch Name
Branch Place
Branch City
Pin Code
Branch Code
MICR No.
(9 Digits code number appearing on the MICR Band of the cheque supplied by the Bank. Please attach Xerox copy of a cheque of
your bank for ensuring accuracy of the bank name, branch name and code number)
Account Type
?
Savings
?
Current
?
Cash Credit
?
Account Number(as appearing in the Cheque
Book)
4.
Date from which the mandate should be effective:

I hereby declare that the particulars given above are correct and complete. If any transaction is delayed or not effected for
reasons of incomplete or incorrect information, I shall not hold National Aluminium Company Limited responsible. I also undertake to advise any
change in the particulars of my account to facilitate updation of records for purpose of credit of amount through RBI ECS/RBI EFT/SBI NET.
Place:
Date:
Signature of the party/Authorized
Signatory
----------------------------------------------------------------------------------------------------------------------------- -----------------------------------------------------------------------Certified that particulars furnished above are correct as per our records.
Banks Stamp:
Date:
(Signature of the Authorized Official from the Banks)
Page 3 of 3
Annexure - X
Social Accountability 8000 Compliance Format
A.
Basic information
Name of the organization
Address
Telephone No
Name of the Proprietor
Nature of Business
License Number and date of
expiry
Employees
Permanent
Casual
Badli
Temporary
Contracted
Staff (Total Number)
Workmen (Total Number)
B.
Information regarding Social Accountability
What is the minimum age required to join

your organization?
What types of certificates (Like mark sheet,

birth certificate) you keep with you?
Do you require to keep any kind of deposit

inform of cash at the time of employment?
Yes/No
Do you provide safe & healthy work environment

as per statutory requirement?
Yes/No
If directly not provided by you, do you get

health & safety benefits from NALCO?
Yes/No
Page 1 of 5
___________ Years
Original Copy / Xerox
Are you certified for SA 8000?

If Yes, please submit a copy of SA8000 Certificate along with this
filled up questionnaire
Have you undergone Code of Conduct Audit (COC Audit)
in last 2 years ?
Yes/No
Yes/No
If yes, please submit a copy of Code of Conduct Audit Report

along with this filled up questionnaire
Have your sub-suppliers been certified for SA 8000?
Yes/No
Have your sub-suppliers undergone Code of Conduct Audit

(COC Audit) in last 2 years?
Yes/No
Do you provide personal protective equipment(s)

to your employees free of cost?
Yes/No
Do you provide safety training to your employees?
Yes/No
Do you ensure canteen facility for your employees?
Yes/No
If not, do you get the facilities from NALCO
Yes/No
What types of medical benefits you provide to your employees?
Do you allow trade union and collective bargaining in

your organization?
If no, how do you ensure freedom of expression?
Page 2 of 5
Yes/No
Incase of non-performance of any employee, how do you deal with such situations?
What are the procedures of hiring/promotion/ remuneration in your organization?
Do you provide appointment letter to your employees?
Yes/No
Do you maintain a documented terms and conditions

of employment?
Yes/No
Do you maintain a disciplinary procedure?
Yes/No
If no, how do you terminate your employee?
How do you ensure that your employees are not discrimination on the basis of cast creed, gender,
religion, age and dieses?
Page 3 of 5
How many shift you have?
_______ shifts
What is the official working time?
_______ hours
Which day is off day in your organization?
____________
In case, a person works in off day or holiday, how is he/she compensated?
Do you pay overtime to your employees as per law?
Yes/No
What is the lowest amount (salary/wage) you pay to

your employees?
Rs._______/-
Is there any case of deduction in wage?
In case, it is yes, what are the general reasons for such deduction?
Is there any apprentice period in your organization?
If yes, what is the apprentice period in your organization?
Do you have any international certification
If yes, please specify
Page 4 of 5
Yes/No
Yes/No
___________
Yes/No
Do you receive, handle or promote goods and/or services

from supplier/subcontractors or sub-suppliers
Yes/No
Do you receive, handle or promote goods and/or services

from supplier/subcontractors or sub-suppliers who are
classified as home worker?
Yes/No
If yes, what steps you have taken to ensure that they get similar level of protection as afforded to
directly employed employees?
Have you taken care to look into issues related to child labor
Forced labor, health & safety, working hours and remuneration
of your suppliers
Yes/No
We do hereby declare that our organization is committed to social accountability. We will promptly
implement remedial/corrective actions identified against the requirement and promptly inform your
organization. We also declare that the sub contractors/sub suppliers performances are monitored
by us. Moreover, we declare that if invited, we shall participate in awareness program as well as
monitoring program organized by you.
We declare that the above-mentioned information is correct.
Signature:
Designation:
Date
Seal of the organization
Page 5 of 5
ANNEXURE-XI
PACKING, MARKING, SHIPPING AND DOCUMENTATION
SPECIFICATIONS FOR INDIGENOUS MATERIALS
NALCO
1.0
General
1.1
This specification forms an integral part of the relevant PURCHASE ORDER, in addition to the
specifications, drawings and instructions explicitly listed in the PURCHASE ORDER.
1.2
Seller shall strictly comply with all applicable prescriptions in the specifications. Lack of relevant
information and/or documents shall not absolve the SELLER of his responsibilities and any loss
arising out of non -compliance shall be to suppliers account.
2.0
Project
Name of OWNER, Project location and some other relevant information are as per Bid document.
3.0
Packing
3.1
The packing specifications incorporated herein are supplementary to the internal and external
packing methods and standards as per current rules of IRCA goods tariff Part -I. All packing shall
be done in such a manner so as to reduce volume as much as possible. Fragile articles should
be packed with special packing materials depending on the type of materials.
3.2
Items shipped in bundles must be securely tied with steel wire or strapping. Steel reinforcing
rods, bars, pipes, structural materials, etc. shall be bundled in uniform lengths and the weight
shall be within the breaking strength of the securing wire or strapping.
3.3
All delicate surfaces on equipment/materials should be carefully protected and painted with
protective paint/compound and wrapped to prevent rusting and damage.
3.4
All mechanical and electrical equipment and other heavy articles shall be securely fastened to the
case bottom and shall be blocked and braced to avoid any displacement/shifting during transit.
3.5
Attachments and spare parts of equipment and all small pieces shall be packed separately in
wooden cases with adequate protection inside the case and wherever possible should be sent
along with main equipment. Each item shall be suitably tagged with identification of main
equipment, item denomination and reference number of respective assembly drawing. Each item
of steel structure and equipments shall be identified with two erection markings with minimum
lettering height of 15 mm. Such marking will be followed by connection numbers in indelible
ink/paint. A copy of the packing list shall accompany the material in each package.
3.6
All protrusions shall be suitably protected by providing a cover comprising of tightly bolted
wooden discs on the flanges.
3.7
Wherever required, equipments/materials/instruments shall be enveloped in polyethylene bags

containing silicagel or similar dehydrating compound.
3.8
All pipes shall be packed as under:

a)
b)
c)
Upto 50mm NB in Wooden cases/crates.

Above 50mm NB and upto 100mm NB in Bundles and the bundles should be strapped at
minimum three places.
Above 100mm NB in loose.
Individual cases/bundles must contain the pipes of same size and length.
capped.
Ends should be
Page 1 of 5

3.9
ANNEXURE-XI
Pipes with threaded or flanged ends shall be protected with suitable caps/covers before packing.
Line pipes shall be transported only on Flat bed trailers. Semi low bed/low bed trailer shall not be
used.
The trailers used for transportation of Line Pipes shall be equipped with adequate pipe supports,
having as many round hollow beds as there are pipes to be placed on the bottom of the trailer
bed. Total width of the supports shall be at least 10% of the pipe length. These supports shall be
lined with a rubber protection and shall be spaced in a manner as to support equal load from the
pipes. The rubber protection must be free from all nails and staples where pipes are in contact.
The second layer and the following layers shall be separated from each other with adequate
number of separating layers of protective materials such as straw in plastic covers or mineral
wool strips or equivalent, to avoid direct touch between the coated pipes. All stanchions of
trailers used for transportation shall be covered by non -abrasive material like rubber belts or
equivalent.
Care shall be exercised to properly cover the top of the stanchions and other
positions such as reinforcement of the trailer body rivets etc. to prevent damage to the coated
surface.
3.10
Detailed packing list in waterproof envelope shall be inserted in the package together with
equipment/material. One copy of the detailed packing list shall be fastened outside the package
in waterproof envelope and covered by metal cover.
3.11
The Seller shall be held liable for all damages or breakages to the goods due to the defective or
insufficient packing as well as for corrosion due to insufficient protection.
3.12
Packaged equipment or material showing damage, defects or shortages resulting from improper
packaging material or packing procedures or having concealed damage or shortages, at the time
of unpacking shall be to the sellers account.
4.0
Marking
4.1
Each package shall be marked on three sides with proper paints/indelible waterproof ink as
follows:
OWNER
PROJECT
DESTINATION
Purchase Order No..................................................................................................... Net
Wt......................... Kgs
Gross Wt...................................... Kgs.
Dimensions.......................................................X....................X...........................CM.
Package No. (Sl. No. of total packages).........................................................................
Sellers Name.............................................................................................................
4.2
Additional marking such as HANDLE WITH CARE, THIS SIDE UP, FRAGILE or any other
additional indications for protection and safe handling shall be added depending on the type of
material.
4.3
Specific marking with paint for SLINGING and CENTRE OF GRAVITY should be provided for all
heavy lifts weighing 5 Tons and above.
Page 2 of 5

ANNEXURE-XI
4.4
In case of bundles/bags or other packages, wherever marking cannot be stenciled, the same
shall be embossed on metal or similar tag and wired securely at two convenient points.
5.0
Shipment
5.1
Despatch of materials shall be made in accordance with the relevant terms of the Purchase
Order. Any change in mode of transport shall be resorted to only after prior approval in writing.
Seller shall ensure despatch of equipments/materials immediately after they are inspected and
released. All consignments shall be booked in the name of Owner and not under self-basis.
5.2
Despatch by Road
(a)
The Seller shall be responsible for despatch of materials on DOOR-DELIVERY basis

through a reliable Bank -Approved transport company unless otherwise the transport
company is named by OWNER/CONSULTANT.
(b)
The SELLER shall ensure with Transport Company the delivery of materials within a
reasonable transit period. SELLER shall also obtain from transporter, particulars of Lorry
Number, Transporters Challan Number, destination of lorry (if transshipment is involved),
Transporters Agent at destination, if any, etc. and intimate same to General
Manager (Projects), CPP, Nalco, Angul with copy to Resident Construction Manager at
RITES, (respective Project Site).
5.3
Despatch by Rail
5.3.1
The SELLER shall be responsible for:

(a)
Despatch by the shortest possible route. The Seller shall as far as possible, despatch
the materials by the fastest goods train like QTS, Super Express Goods, etc. wherever
such facilities exist.
(b)
Correct classification of goods and freight charges.
(c)
Obtaining clean Railway Receipts without any qualifying remarks.

Should there be any restriction for movement by a particular route, the Railway
authorities should be requested to move goods by the next alternative route, subject to
prior consent of NALCO/RITES.
5.3.2
As SMALLS
When the materials that are ready do not make up a wagonload by weight/volume or for minimum
freight payable for a wagon the despatch should be affected as smalls.
SELLER should obtain from the Railway, the particulars of wagon in which the Smalls have
been loaded, station at which sealed, train Number and date/time of movement and transmit the
same to the Resident / Visiting Inspector, General Manager (Projects), CPP-Nalco , RCM-RITES
(concerned Site) for monitoring their movement.
5.3.3
As Wagon Loads
Consignments, though of lesser weight, but otherwise constituting a wagon load by volume
should be dispatched as wagon load paying the freight applicable to a minimum wagon load or
at the smalls rate, whichever is advantageous, as per Rule-164 of IRCA Goods Tariff Part -I (Vol.I)
When consignments call for full wagon(s), indents should be placed with the Railway Station
concerned after predetermining accurately the type and number of wagons required. In case of
Page 3 of 5

ANNEXURE-XI
covered wagons, it should be ensured that the same are watertight. If a particular type of wagon
is in short supply, request should be made to the Railway Authorities to supply the next suitable
type of wagon. Suitable packing in the wagon shall be done, wherever necessary, to ensure
maximum safety of the material in transit.
When ODC packages are involved, the SELLER shall apply to the Railway Authorities with
loading sketches showing overall dimensions and the wagon proposed to be utilized sufficiently in
advance for obtaining movement sanction and to establish firm transportability. Copies of all
such correspondence together with loading sketches should be sent to NALCO and Consultant
RITES. ODC packages shall be loaded, packed and lashed strictly in accordance with the
Railway Regulations. Should there be any delay/difficulty in obtaining the required wagon(s), the
SELLER shall inform Resident Inspector and General Manager (Projects), CPP-Nalco , RCMRITES immediately giving details of the required number of wagons, type, carrying capacity, etc.
and indent number so that the matter may be taken up with the Railway Authorities concerned.
After despatch, SELLER shall obtain from the Railway Authorities, particulars of the wagon/train
number, date of movement and destination junction for the particular train and furnish the same to
General Manager (Projects), CPP-Nalco , RCM-RITES for follow-up action on movement, as
may be necessary.
After despatch of the equipment from dispatching station, if movement of the wagon is held-up
due to improper/loose lashing resulting in shifting of the load and consignment is required to be
readjusted/refixed the vendor shall be responsible to arrange for the same as per Railway
requirements. Similarly, in case some infringement in dimensions of the loaded consignment is
detected by Railway Authorities after its movement from despatching station and if it is required to
be corrected either by adjustment of the load or by cutting a few protrusions the same shall be
arranged by vendor at their cost.
5.4
Shipment by Air
Wherever SELLER is instructed by OWNER/CONSULTANT to airfreight any material, the
SELLER shall take prompt action for the same. Immediately after air shipment is effected, the
Seller shall intimate by Fax / E-mail, the details of airway bill number and date, flight number,
number of packages etc. to the Resident Inspector, Consultant RITES, General Manager
(Projects), CPP-Nalco , Resident Construction Manager -RITES, (respective Project Site).
5.5
Destination
The consignments should be despatched as indicated in bid document/Purchase Order.
5.6
Advance Information
Immediately after a shipment is made, SELLER shall send advance information as to the
particulars of materials, value, Purchase Order Number, date of despatch, railway receipt
number, wagon number/goods consignment note number, truck number, name of transport
company and their destination office/associates address etc./Airway Bill Number and flight details
by way of Fax / E-Mail to Resident / Visiting Inspector, Consultant RITES, Resident
Construction Manager- RITES, (respective Project Site) and NALCO.
5.7
Transmission of Despatch Documents

Seller shall, within 48 hours of the despatch of the material depending upon the payment terms of
the Purchase Order, either negotiate through OWNERs Bankers or forward direct by Registered
Post, the railway receipt/consignment note/Airway Bill to the Owner at project site accompanied
by the original invoices, packing lists and challans.
Page 4 of 5

ANNEXURE-XI
The SELLER shall be responsible for any delay in clearance of the consignment at destination
and consequent wharfage/demurrage, if any, due to delay in transmittal of the Railway Receipt,
Consignment Note/Air Way Bill. Copies of such despatch advise together with 2 copies of
invoices and packing lists shall be simultaneously distributed to OWNERs (HO & Site),
Consultants (HO & Site) etc.
6.0
Transit Risk Insurance

All equipments/ materials will be insured for transit risk by OWNER unless otherwise specified.
The Insurance cover will be provided from warehouse - to - warehouse.
7.0
Despatch through Approved Transporters

All materials must be despatched through OWNER/CONSULTANT approved transporters, list of
which may be obtained from the OWNERs/CONSULTANTs nearest branch/regional office.
--x--
Page 5 of 5

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Annexure I-Technical Specification

NATIONAL ALUMINIUM COMPANY LIMITED

BID DOCUMENT No. :OT/05/2012-13/WT/RITES-BBSR/NALCO

TENDER DOCUMENT FORDESIGN, MANUFACTURE, SUPPLY, ERECTION,

SPECIAL STIPULATIONS TO BIDDERS

SYSTEM PARAMETERS, OPERATION AND

CONDITIONS OF CONTRACT FOR FIELD SERVICES

Uncrushed coal (Grade E / F / G)

DESCRIPTION OF EXISTING SYSTEM

mm size is brought from coalfields in Bottom Discharge Captive Railway

Coal from coalfield is received through a Merry Go-round

Technical Specification:Sec-1 General

house is provided on conveyor path

& associated equipment installed on parallel

Technical Specification:Sec-1 General

Additions to existing system currently under development:

Presently an additional coal storage and handling system is being implemented

The terminal points for Additional

Modification and shifting of discharge end of existing belt conveyor BC-115

Modification of existing Junction House JH-7

Provision of new Junction House JH-7A

Extension of tail end of existing conveyor BC-116

Technical Specification:Sec-1 General

with new chute arrangement

120 will convey reclaimed material to new Junction House JH-12.

Conveying of uncrushed coal to new Crusherhouse.. Uncrushed coal received on conveyor

Technical Specification:Sec-1 General

existing conveyor BC-104.

Technical Specification:Sec-1 General

provided sufficient information is furnished so as to enable the Owner/consultant

installation. The cost of such Geo-technical

cifications of equipment / system indicated in various sections as above

BRIEF DESCRIPTION OF PROPOSED

Technical Specification Sec-2,:Intent

Technical Specification Sec-2,:Intent

One (1) no. Rotaside Wagon Tippler/Rotary

Receiving Belt Conveyors RC-1

A new pent house along with over ground structures,

1 complete with civil, structural and electrical works and associated

Technical Specification Sec-2,:Intent

3.1.13 Air conditioning of Wagon Tippler control room,

Technical Specification Sec-2,:Intent

Electrical System / Equipment

CABLING, EARTHING AND LIGHTNING PROTECTION

Technical Specification Sec-2,:Intent

Technical Specification Sec-2,:Intent

JH 1 and shall ensure that the proposed

Regarding erection of transfer point on existing junction house-1,

Technical Specification Sec-2,:Intent

SYSTEM DESIGN BASIS

Following shall be considered while designing the Conveyors :

Coal Flow paths

Technical Specification Sec-2,:Intent

Apron feeder will feed coal unloaded at WT-1

GUARANTEE AND LIQUIDATED DAMAGES

Flow Path Capacity

Technical Specification Sec-2,:Intent

PERFORMANCE & GUARANTEE TEST PROCEDURE

Liquidated Damages for Shortfall in Performance

The following equipments/streams shall be subjected to performance and guarantee test in

Conveyors (R1 & R2)

Technical Specification Sec-2,:Intent

COMMISSIONING (SYSTEM TRIAL OPERATION)

TYPE TESTS AND TYPE TEST CHARGES