Schedule ETechnical Specification NTPCHQ120111

NTPC Limited
(A Government of India Enterprise)
FARAKKA SUPER THERMAL POWER PROJECT
TECHNICAL SPECIFICATION
FOR
COAL CONVEYING PLANT PACKAGE

BIDDING DOCUMENT NO. :
NTPC Limited
(A Government of India Enterprise)
FARAKKA SUPER THERMAL POWER PROJECT
TECHNICAL SPECIFICATION
FOR
COAL CONVEYING PLANT PACKAGE

BIDDING DOCUMENT NO. :
This document is meant for the exclusive purpose of bidding against this specification and shall not be transferred, reproduced or otherwise used for purposes other than that for which it is specifically issued.
TABLE OF CONTENTS
PART PART-A SECTION NO TITLE
Sub Section II : Scope of Supply & Services IIA-01 Intent of Specification
PART-B
Sub Section III : Technical Parameters IIIA IIIA-01 IIIA-02 IIIA-03 IIIA-04 IIIA-05 IIIA-06 IIIA-07 IIIA-08 IIIA-09 IIIA-10 IIIA-11 IIIA-12 IIIA-13 IIIA-14 MECHANICAL System Parameters and Operation & Control Philosophy Brakes & Clamps Monorails and Hoists Chutes & Hoppers Belt Conveyor System Drive Equipment Belt Scale Dust Control & Miscellaneous System Ventilation System CHP Building Inline Magnetic Separator Metal Detector Coal Sampling Unit Vibrating Feeder
PART-B
III-B IIIB-01 IIIB-02 IIIB-03 IIIB-04 IIIB-05 IIIB-06 IIIB-07 IIIB-08 IIIB-09 IIIB-10 IIIB-11 IIIB-12
ELECTRICAL Motors LT Switchgear & Bus Duct LT Power Cables H T Cables Control Cables Instrumentation cables Illumination System Cabling, Earthing & Lightning Protection Transformers H T Switchgear PLC Control Cables Battery
Page : 1 of 2
PART
SECTION NO IIIB-13 IIIB-14 IIIB-15
TITLE Battery Charger Measuring Instruments CCTV CIVIL CHP System - Civil Works Foundation System and Geotechnical Data (Turnkey)
PART-B
III-D IIID-01
PART-B
IIID-02
PART-B
III-E E-01 E-02 E-03 E-04 E-05 E-06 E-07 E-08 E-09
QA & I SECTION Coal Conveyors Belt Motors LT Switchgear LT Busduct LT Power Cables LT Control Cables Instrumentation Cables Station Lighting Cabling, Earthing & Lightning Protection H T Cables H T Switchgear HT Capacitor Bank Measuring Instruments Power Supply For C&I System Transformer Battery Battery Charger Control Panels Control System CHP System - Civil Works
PART-B
E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20
PART-E
List of Tender Drawings
Page : 2 of 2
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES
1.00.00
INTENT OF SPECIFICATION This specification is intended to cover the following activities and services in respect of all the equipment of Coal Conveying Plant from jetty to plant site to be installed for Farakka Super Thermal Power Project, of the NTPC Limited, located in Murshidabad district,in the state of West Bengal, India. (a.) (i) Detailed design and engineering of all the equipment and equipment system(s). Complete manufacture including shop testing/ type testing. Providing engineering data, drawings, Commissioning procedures and O & M manuals, etc. Packing and transportation from the manufacturers works to site including transit insurance, customs clearance/ port clearance, if required. Receipt, unloading, storage, preservation, conservation and insurance of equipment at site. Fabrication, pre-assembly, (if any), erection, testing and putting into satisfactory operation of all the equipment including successful completion of facilities. Associated civil, structural, architectural and electrical works. Commissioning and completion of facilities and Performance Guarantee Tests after successful completion of initial operation. Furnishing of spares on FOR site basis and handing over to NTPC stores. Reconciliation with custom authorities, if applicable. Satisfactory completion of the contract.
(ii) (iii)
(iv)
(v)
(vi)
(vii) (viii)
(ix)
(x) (xi) (b.)
The Contractor shall be responsible for providing all materials, equipment and services, specified or otherwise (unless specifically excluded) which are required to fulfill the intent of ensuring operability and the reliability of the complete system covered under this specification. It is not the intent to specify completely herein, all aspects of design and construction of equipment. Nevertheless, the equipment shall conform in all
TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.: SUB-SECTION-IIA-01 INTENT OF SPECIFICATION
(c.)
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE
PAGE 1 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation. (d.) Whenever a material or article is specified or described by the name of a particular brand, manufacturer or trade mark, the specific item shall be understood as establishing type, function and quality desired. Other manufacturers products may also be considered provided sufficient information is furnished so as to enable the Employer to determine that the products are equivalent or superior to those named. Before submitting his bid, the Bidder should inspect and examine the site and its surroundings and should satisfy himself as to the nature of the ground and subsoil, the quantities and nature of work, materials necessary for completion of the work and their availability, means of access to site and in general shall himself obtain all necessary information as to risks, contingencies and other circumstances which may influence or affect his offer. No consequent extra claims on any misunderstanding or otherwise shall be allowed by the Employer. For all the related buildings and facilities in Employers scope and not covered under the scope of this package, the contractor shall furnish all the related input data/ details for preparation of Mechanical/ Electrical/ Civil Drawings within 45 days of award of contract. The sizes of various buildings/conveyor galleries indicated in the tender drawings and the parameters of equipment indicated in various sections of technical specifications are the minimum requirements of the employer. Any increase in these sizes or the parameters, if required to meet the system/maintenance/operational requirement shall be supplied by the contractor without any extra cost implication to the employer. Bidder shall take all necessary precautions to protect all the existing equipment, structures, facilities and buildings etc. from damage. In case any damage occurs due to the activities of the contractor on account of negligence, ignorance, accidental or any other reason whatsoever, the damage shall be immediately made good by the contractor at his own cost to the satisfaction of the Employer. The contractor shall also take all necessary safety measures with specific reference to excavation in rock, at his own cost, to avoid any harm or injury to his workers and staff from the equipment and facilities of the power plant. Bidder should note that the existing rail lines within the plant area are operational with rail traffic of coal and liquid fuel rakes. Bidder shall take all precautions to ensure the safety of existing rail tracks and other associated facilities as well as the safety of his men, material and equipment from the
TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:
(e.)
(f.)
(g.)
(h.)
(i.)
SUB-SECTION-IIA-01 INTENT OF SPECIFICATION
PAGE 2 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES operating rail traffic. The bidder shall plan and make all arrangements to ensure that disruption to the existing rail traffic is minimum and shall follow the instructions of the Employer in this regard. Further, bidder shall plan and co-ordinate all his activities considering restrictions, if any, on free access to his work areas due to the rail traffic. (j.) After award of work, before finalising his layout especially the layout / levels of conveyors, cable / pipe routes and other services, the contractor shall carry out a site survey to identify the location & details of existing facilities that may interfere with his proposed facilities. The contractor shall suitably modify his layout / levels to prevent dislocation of existing facilities and any cost / time implication arising out of such modifications will be to his account. Contractor shall also be responsible to determine and obtain the necessary details at site as required for interfacing and interconnection with the existing system / facilities. If during the execution of works it is found that there is interference with the existing facilities / structures, the contractor shall revise his design / detailed drawings to clear the interference and shall provide all necessary measures for the safety of existing structures. No claim in terms of cost or relaxation in time shall be entertained for any redesign, rework and for safety measures provided. If at any stage of work, any dismantling or modification or relocation of any existing facility is required to be done to complete the work in bidders scope and which has been agreed by the Employer, the same shall be done by the bidder at no extra cost or time implication to the Employer. All such changes will be as per drawings and work plan approved by the employer.
1.02.00
Equipment and services covered under COAL CONVEYING PLANT package are described in the following sub-sections : MECHANICAL III-A-01 : System parameters and Operation & Control Philosophy III-A-02 : Brakes and Clamps III-A-03 : Monorails and Hoists III-A-04 : Chutes and Hoppers III-A-05 : Belt Conveyor System III-A-06 : Drive Equipment III-A-07 : Belt Scales
PAGE 3 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES III-A-08 : Dust Control & Miscellaneous Systems III-A-09 : Ventilation System III-A-10 : CHP Buildings III-A-11 : Inline Magnetic Separator III-A-12 : Metal Detector III-A-13 : Coal Sampling Unit IIIA-14: Vibrating Feeder ELECTRICAL IIIB-01: Motors IIIB-02 : LT Switchgear & Bus Duct IIIB-03 : LT Power Cables IIIB-04: HT Cables IIIB-05 : Control Cables IIIB-06 : Instrumentation cables IIIB-07 : Illumination System IIIB-08 : Cabling, Earthing & Lightning Protection IIIB-09 : Transformers IIIB-10 : HT Switchgear IIIB-11 : PLC CONTROL PANEL IIIB-12 : Battery IIIB-13 : Battery Charger IIIIB-14 : MEASURING INSTRUMENTS IIIB-15: CCTV
PAGE 4 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES CIVIL III-D-01 : CHP System Civil and Structural Works III-D-02 : Foundation System and Geotechnical Data QUALITY ASSURANCE E-01 : Coal Conveyors Belt E-02 : Motors E-03 : LT Switchgear E-04 : LT Busduct E-05 : LT Power Cables E-06 : LT Control Cables E-07 : Instrumentation Cables E-08 : Station Lighting E-09 : Cabling, Earthing & Lightning Protection E-10 : H T Cables E-11 : H T Switchgear E-12 : HT Capacitor Bank E-13 : Measuring Instruments E-14 : Power Supply For C&I System E-15 : Transformer E-16 : Battery E-17: Battery Charger E-18 : Control Panels E-19 : Control System E-20 : CHP System - Civil Works
PAGE 5 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES TENDER DRAWINGS The drawings listed in the specification at Part-E, form part of the specification and shall supplement the requirements specified herein. The scope and terminal points for the equipment to be furnished under this package shall be as identified in these drawings and read in conjunction with the text of these specifications. These drawings are preliminary drawings for bidding purpose only and subject to changes that may be necessary during the detailed engineering.
1.03.00
1.04.00
In case of any conflicts / contradiction among various volumes / sections / annexures / chapters / appendices / tender drawings of bid documents, the same shall be referred to the Employer for clarifications whose decision shall be final and binding. No extra claims shall be allowed on this account. SCOPE The scope of Coal Handling Plant to be furnished, erected and commissioned under this specification shall be as detailed hereinafter. The Contractor shall be fully responsible for system and detailed design, engineering, manufacture, shop fabrication, assembly, testing and inspection at manufacturers works, packing, dispatch, transportation, transit insurance, custom clearance etc. as applicable, delivery to site, unloading, handling and storage at site, insurance during storage, construction, erection, including erection supervision, testing, inspection, commissioning and handing over to Employer and Guarantee testing including all associated electrical, civil, structural & architectural works as specified, unless specifically excluded as per Section-Terminal Points & Exclusions. 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 as per Section Terminal Points & Exclusions. The general description of the proposed system and the broad scope of work under the specification shall include but not be limited to as elaborated below. DESCRIPTION, SCOPE AND TERMINAL POINTS BRIEF DESCRIPTION OF PROJECT Farakka Super Thermal Power Project (STPP) was originally conceived as a pit head coal based power plant of 2100 MW (3x200 MW+3x500 MW + 1x500MW) capacity to be implemented in three stages. Stage-I comprising three units of 200 MW and Stage-II comprising two units of 500 MW of the plant which are under commercial operation. Presently Stage-III comprising one unit of 500 MW is under commissioning and on implementation of the same, the overall plant capacity would thus become 2600MW i.e. the planned ultimate capacity.
1.05.00 1.05.01
1.05.02
2.00.00 2.01.00
PAGE 6 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES The present proposal of Coal Conveying Plant is for carrying coal as received from Jetty to the plant site and feeding all the stages through various interconnection in the existing Coal handling Plant.
2.01.01
Brief description of proposed Coal Conveying Plant. This shall be read in conjunction with Coal Flow Diagram and the Coal Conveying Plant layout enclosed else where in the specification. PHASE-I (i) Coal as received from barges shall be unloaded by either slewing type grab cranes or mobile type grab cranes to an feed hopper. From feed hopper the coal shall be conveyed through series of Conveyors of 800 TPH capacity (Conveyor A, Conveyor B, Conveyor C) through Junction house JH-1, JH-2 and shall drop coal at existing Stockyard no. 4 & 5 of Stage-I & Stage-II. From Stockyard 4 & 5, coal shall be bull dozed to stockyard for further conveying to bunker of Stage-I, II & III via existing stacker reclaimer and Conveyors.
PHASE-II (ii) At Junction House JH-2 Conveyor D shall receive coal from conveyor B and shall convey coal through series of conveyors of 800 TPH capacity (Conv. E, Conv. F, Conv. G) through junction houses JH-3,JH-4,JH-5 & JH-6.
2.02.00
DETAILED SCOPE PHASE-I
2.02.01
Non drive house(NDH), feed hopper with grating, complete with civil, structural, architectural and electrical works including vibro feeder, equipment handling facilities for feeders and other equipment/systems such as DS system, ventilation system, drinking water system, drainage system etc. as specified elsewhere in the specification. Conveyor A complete with conveyor gallery along with its supporting structures, short supports, stringers, deck-plate, seal-plate, conveyor foundations, drive motors, pulleys, idlers, gravity take ups, take up structure, internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals and accessories. including all civil, structural and architectural works for tunnel, conveyor gallery, gallery supporting trestle and their associated foundation etc. Belt Conveyors B & Conveyor C complete with conveyor galleries, conveyor supporting structures, short supports, stringers, deck plate, seal plate, conveyor
TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.: SUB-SECTION-IIA-01 INTENT OF SPECIFICATION
2.02.02
2.02.03
PAGE 7 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES foundations, drive motors, drive units, pulleys, idlers, gravity take ups including guides, pits etc., internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals etc. including all civil, structural and architectural works for conveyor gallery, gallery supporting trestles and their associated foundations.
2.02.04
Junction Houses JH-1 & JH-2, complete with all civil, structural, architectural and electrical works including chutes, monorails, hoists/chain pulley blocks, hoist maintenance platforms, external staircases, dust debris chutes etc. All overground junction houses shall have separate debris disposal chute up to the ground floor. Two (2) nos. Vibro feeders to feed the coal on to Conveyor A complete with drives, all mechanical, electrical accessories and supporting structures etc. One (1) No. coal sampling unit, for (-) 50 mm size coal in Junction house-1 complete with all accessories, and electrical, civil, structural works, supporting structures, approach/maintenance platforms, hoists etc. One(1) No. In-line Magnetic Separators on Conveyor A complete with reject chutes, reject trolleys, supporting arrangement, and all mechanical, electrical, civil, structural works and accessories. One(1) No. Electronic Belt weighers complete with all mechanical, supporting arrangement, electrical, and accessories on conveyors A. One(1) No Metal Detector complete with all mechanical, electrical, civil, structural works and accessories on Conveyor B. One (1) No. belt vulcanizing machine of adequate size complete with all mechanical, electrical, accessories and consumables for one year consumption. Further, belt jointing facilities as specified shall be provided. PHASE-II
2.02.05
2.02.06
2.02.07
2.02.08
2.02.09
2.02.10
2.02.11
Belt Conveyors D, Conveyor E, Conveyor F & Conveyor G complete with conveyor galleries, conveyor supporting structures, short supports, stringers, deck plate, seal plate, conveyor foundations, drive motors, drive units, pulleys, idlers, gravity take ups including guides, pits etc., internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals etc. including all civil, structural and architectural works for conveyor gallery, gallery supporting trestles and their associated foundations. Junction Houses JH3, JH-4, JH-5 & JH-6, complete with all civil, structural, architectural and electrical works including chutes, monorails, hoists/chain pulley blocks, hoist maintenance platforms, external staircases, dust debris chutes etc. All
2.02.12
PAGE 8 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES overground junction houses shall have separate debris disposal chute up to the ground floor.
2.02.13
Modification of existing conveyor 24A/B alongwith its gallery in order to retrofit junction house JH-6. Common for Phase I and II
2.02.14
Complete chute work along with chute block switches and actuator operated flap gates (as applicable) in all Junction Houses between various conveyors. Pressurized Ventilation system for all Switchgear rooms, MCC rooms complete with all mechanical, electrical, accessories, civil and structural works. Exhaust fans to be provided in all battery rooms, all toilets complete with electrical, civil & structural works etc. Exhaust fans along with required ducting shall also be provided for all underground Structures/Junction Houses. Air conditioning of Coal conveying plant control room and office room, RIO room , complete with all electrical, civil & structural works etc.
2.02.15
2.02.16
2.02.17
Complete plain water dust suppression system for control of fugitive dust in underground feed hopper complex, junction houses complete with enclosed pump houses, water tanks, pumps, drives, hoisting arrangements, piping, valves etc. electrical, accessories, civil, structural and architectural works. Service water, potable water system and cooling water system for complete coal conveying plant. Cooling water system for scoop couplings, for complete coal conveying plant as specified elsewhere in the specification. Monorails and electrically operated hoist blocks as well as hand operated chain pulley blocks for servicing/installation/easy replacement of drive machinery, different types of pulleys for all conveyors, GTU and other equipment from ground level to their locations and vice-versa & landing inside the respective Buildings. All buildings in contractors scope shall be complete with all electrical, civil, structural, architectural works, cable trenches, fire safety walls, foundation, earth mat, fencing, earthing for transformers. All cables, duct banks, trenches, cable trestles shall be complete with associated civil/ structural work and necessary civil foundations. Drainage of all coal conveying buildings, conveyor galleries including all civil & structural works as detailed out elsewhere in the specification.
2.02.18
2.02.19
2.02.20
2.02.21
2.02.22
PAGE 9 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES All equipment/fittings, supporting structure, along with insert plates, bolts, accessories, MS sleeves, base plates, grouting as may be required and proper alignment etc. Complete unused set of all special tools and tackles, which are necessary or convenient for erection, commissioning and overhauling of any equipment, covered under the scope. First fill of all consumables e.g.; oils and lubricants for one year toppings requirements. Preservative shop coating, final painting of all structures and equipment under the scope. All inserts, anchor bolts, foundation bolts for Contractors equipment, platforms etc. in the entire Coal conveying plant. All necessary grouting & finishing of the floor after welding at all such pockets & else where is in Contractors scope. (i) All inserts, anchor bolts, foundation bolts for Contractors equipment, platforms etc. in the entire Coal conveying plant. All necessary grouting & finishing of the floor after welding at all such pockets & else where is in Contractors scope.
2.02.23
2.02.24
2.02.25
2.02.26
2.02.27
2.02.28
2.02.29
(ii) 2.02.30
FIRE DETECTION AND PROTECTION SYSTEM The scope of equipment to be furnished and erected under this specification shall cover all the systems and equipments detailed hereunder. For the basic Fire Detection and Protection System specified, any other items, needed to make the system complete, safe and sound in operation shall be included under the scope of work by the Bidder at no extra cost to the Owner. Fire Water Storage and Pumping System Complete fire water storage and pumping system consisting of MS construction fire water storage tank, spray pumps & drives and Battery Chargers for the diesel engines drives, required instruments, controls, and panels as per detailed specifications. Tapping from nearby water source shall be taken to fill the fire water storage tanks. Further, suitable capacity monorail electic hoist inside fire water pump house shall also be provided by the Contractor. MVW & Hydrant System Automatic MVW system shall be provided for conveyors & JH/DH protection. Further, hydrant valves (taped from spray header) at strategic location shall be provided as per detailed specifications. Fire Extinguisher To be provided by the bidder at MCC, RIO rooms & Control room.
PAGE 10 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES Analogue addressable type Fire Alarm System / Annunciation Panels a) LHSC, IRD, cabling, junction boxes, instrumentation, etc. for various areas/equipments as detailed out elsewhere. For long distance transmission Booster / Repeater station (if applicable) suitable for field shall be provided. PLC based Control Panels complete with all accessories for Fire detection and protection system shall be provided in Fire water pump house. This PLC panel shall also be connected with Fire alarm panel at Control room. Fire alarm panel along with PC & Printer in Control room. Further, due to long distance between fire alarm panel at control room and various field devices, suitable qty. of fire alarm panels shall be required at intermediate locations. These panels shall be located at RIO room envisaged in JHs. All these fire alarm panels shall be interconnected with each other as well as with fire alarm panel at Control room through fibre optic cables. Manual call points, hooters etc., shall be provided as per system requirements. All interconnection cables (instrumentation cables from instruments to panels, control cables to MCC, instrument cables from MCC to control panel, power cables to drives, network cables and fibre optical cables, etc.) shall be provided by the Contractor.
b)
c)
c) d)
Guarantee tests for PLC with HMI system Set of commissioning spares as may be required during erection and commissioning. One (1) set Special tools and tackles required for maintenance of all the mechanical, electrical and C & I equipments under the scope of Contractor. Any additional item/ equipment required to make the system complete. All other services described under Intent of Specifications. All civil works related to fire detection and protection system shall be in the scope of works of Contractor. Supply of all consumable materials like initial fill of lubricants, grease, etc. required to complete the erection and commissioning of the total fire protection system. Further, all consumables required for PG test shall also be in Bidders scope of supply. Preparation of necessary detailed drawings including schematics, layouts, isometrics, fabrication drgs, erection drgs, etc. as required and also development of As Built Drawings. Conductance of Performance and Guarantee test as per Standard Guaranteed test procedure to be finalized during detailed engineering. 2.02.31 2.02.31.01 Electrical System / Equipment ELECTRICAL SYSTEM / EQUIPMENT (FOR PHASE-I & PHASE-II) : Unless specifically excluded in clause no. 2.04.00, contractors scope of work shall include all electrical works, as required for putting into successful operation of the
PAGE 11 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES Coal handling plant covered in this specification. The sizing of various equipments shall be as defined in the specification. Main equipment included in the scope is given below.
2.02.31.02
6.6KV Switchgear :6.6KV switchgear as indicated in enclosed single line diagrams. Two (2) spare feeders (one transformer feeder and one motor feeder of highest rating) shall also be provided on 6.6 KV switchgear. In addition to this Owner's/ nos. 1000A feedershall addition to this two (2) future use feeders for owners use as peralso be provided. shall Electrical SLD be provided
2.02.31.03
Motors :All HT and LT motors along with lugs and glands.
2.02.31.04
415V MCCs / Switchgear / Distribution boards :415V Motor control centers (as indicated in the electrical single line diagram), AC & DC Distribution boards / Fuse boards, Local push button stations for all drives and local motor starters as required for the system and equipment. In each MCC contractor shall provide 20% spare feeder(minimum One (1) no) for each type and rating of the outgoing feeders provided in that MCC. Two (2) nos. of 125A Switch fuse feeders (total load 50KVA) shall be provided in each bus of the above indicated MCCs for Owners future use.
2.02.31.05
Cables :All HT/LT Power cables, LT control cables, instrumentation cables, fiber optic cables, signal cables and any special cables for the completeness of the system. a) b) Required for connection between equipment / devices in Contractors scope. Required for connection between Contractors equipment and Owners equipment.
2.02.31.06
Illumination system :AC Illumination system for complete internal and external lighting of associated plant and equipment like JHs, Conveyors, transformer yards, switchgear & control buildings, Drive houses, Pump houses etc. and roads under Contractors Scope.
2.02.31.07
Cabling, Earthing and Lightning Protection :Cabling viz., cable laying along with cable accessories, cable trays with supporting structure, terminations & jointing kits, trenches, trestle, duct banks etc required for the cables to be supplied by the contractor. Earthing / Grounding and lightning protection for the plant and equipment under contractors scope.
PAGE 12 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES Transformers :6.6KV/0.433KV, ONAN, Outdoor transformers as indicated in the single line diagram.
2.02.31.08
2.02.31.09
Battery :220V DC, 150 AH (min.) Lead acid plante type / 90 AH (min.) Ni-Cd Battery as per electrical single line diagram.
2.02.31.10
Battery Charger :One (1) sets of 220V, 40A (min.) float cum boost chargers as per electrical single line diagram. Each set consists of two (2) nos. battery chargers.
2.02.31.11
PLC and Control panels :Main control desk with HMI, Large video Screens, PLC panels, Remote I/O stations, UPS, 24V DC battery and battery chargers, for the control of entire Coal handling equipment & HT/ LT Switchgear. Local control panels for ILMS, Belt weighers, Metal detectors, Coal sampling units sump pumps, DS/DE, ventilation etc. as required for the system. Local control desks with HMIs shall be provided in main control room as per PLC configuration drawing.
2.02.31.12
Closed circuit TV(CCTV) System, Telephone & Public address system :CCTV system with 3 nos. of cameras in each JH & 2 nos. in each switchgear room. Public address and telephone system for entire phase-I & phase-II shall also be provided by contractor.
2.02.31.13
Electrical buildings :i) Phase-I

i) One(1) no HT/LT Switchgear room shall be provided near Jetty area to accomodate 6.6KV switchgear, 415V MCC, MLDB, WDB, DCFBs etc. One air conditioned control room shall be provided adjacent to HT/LT switchgear room to accomodate CHP control desk,operator work station, processor panels,I/O panels, EPABX panels UPS, printers, etc. One (1) no. 6.6/0.433KV transformer shall be located adjacent to switchgear building.
ii) One(1) no Switchgear room shall be provided near JH-2 to accomodate 415V MCC, MLDB, WDB, DCDB, battery charger panels etc. One air conditioned RI/O room shall be provided near switchgear room. A separate battery room shall also be provided to accomodate 220V dc battery. One(1) nos. 6.6/0.433KV transformer shall be located adjacent to switchgear room. ii) Phase-II
PAGE 13 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES i) One(1) no Switchgear room shall be provided near JH-5 to accomodate 415V MCC, MLDB, WDB, DCFBs etc. One air conditioned RI/O room shall be provided near switchgear room.
2.02.32.00 2.02.32.01
CIVIL The work to be performed under this specification consists of providing all labour, materials, construction equipment, tools and plant, scaffolding, supplies, transportation, all incidental items not shown or specified, but reasonably implied or necessary for successful completion of the work including Contractors supervision and in strict accordance with the drawings and specifications. The nature of work shall generally involve earthwork in excavation including controlled blasting & very deep underground excavation, extensive de-watering, shoring and strutting, sheet piling, back filling around completed structures and plinth protection, area paving , disposal of surplus excavated materials, piling, concreting including reinforcement and form work, brick work, fabrication and erection of structural / miscellaneous steel works, inserts, architectural items & finishes such as plastering, painting, flooring, doors, windows & ventilators, glass and glazing, rolling shutters etc., permanently colour coated profiled steel sheeting, anchor bolts, R. C. C. trenches with covers, laying and testing of water pipes, sanitation, water supply, drainage, damp proofing, water proofing and other ancillary items. The work shall have to be carried out both below and above ground level and shall be involving, basements, equipment foundations including grounding, slabs, beams, columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, access roads, culverts, conveyer galleries, trestles, penthouses, underground tunnels, junction house, finishes, complete architectural aspects, drainage, sanitation, water supply (from terminal points to various buildings, conveyor galleries) and all other civil, structural and architectural works associated with the complete Coal Conveying Plant. Scope of the Contractor shall also include supply and laying earthing mat all around the periphery of buildings, structures, and outdoor equipments, as per the approved drawings. The analysis design and detailed drawing for Underground JH, tunnels, culverts, etc. coming directly below the railway track shall be got approved by the Contractor from the Concerned railway authority before taking up construction. All necessary payment for above work shall be made by the contractor to the Railway authority. The work shall also involve arranging construction water from underground sources, storage in underground/ overground tanks and taking the water to construction site through pipelines by pumping or by road tankers etc., including all necessary accessories, tools & tackles etc.
2.02.32.02
2.02.32.03
2.02.32.04
2.02.32.05
PAGE 14 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES Access roads 4m wide bituminous roads to all buildings/facilities (in Contractor Scope) will be in the Scope of Contractor. TERMINAL POINTS Broad terminal points for coal conveying plant have been indicated in the tender drawings. Within these terminal points, all equipment and services, civil, structural and architectural works, electrical distribution, piping network etc. as required for coal handling plant will be furnished and erected by the contractor unless specifically excluded as follows:
2.02.32.06
2.03.00
2.03.01.01
Wherever Contractor is permitted by Employer to take support from any of the Employers Structures, the Contractor shall ensure that no damage is done, to the Employers Structures including Painting thereof. In case of any damage to the Employers Structure and/or Painting, then the Contractor shall rectify the same to the complete satisfaction of the Employer. Water supply connections for dust suppression, service water system, and potable water shall be provided at one location by the employer, details of which are given in the tender drawing. Further network of piping including all pumps, tanks, necessary accessories, supports and fittings etc. for distribution of potable water, water for dust suppression and service water system in all JHs, non drive house, control rooms, MCC rooms, toilets, shall be under the scope of the contractor. Electrical Terminal Points (a) Owners 6.6 KV switchgear/415V MCC as indicated in electrical single line diagram.
2.03.01
2.03.02
2.04.00
EXCLUSIONS Nil
3.00.00 3.01.00
SYSTEM DESIGN BASIS The rated capacity of the Coal conveying plant shall be 800 TPH. The mechanical and structural / civil system shall be designed for 880 TPH capacity and round the clock operation with both the streams operating simultaneously. Following shall be considered while designing the CHP: a) The Coal delivered to the power station shall be of size (-)50 mm & below. However occasionally 1-2% coal above (-) 50 mm lump size may also be encountered.
3.02.00
PAGE 15 OF 16
CLAUSE NO.
SCOPE OF SUPPLY AND SERVICES b) HGI of the Coal shall be between 44 to 65. Normally moisture content in coal will vary between 12% to 15%. However for design purposes, moisture content of 20% shall be considered. The coal as received shall contain varying percentage of fines. Coal with such fines may tend to form adhesive lumps, particularly during monsoon when surface moisture is at its maximum value. The sizing and selection of the vital equipment viz. vibro feeders, etc. covered under the system shall be based on the above characteristic of coal and operating conditions. Contractor shall ensure that equipment/ system efficiency shall not be affected particularly during monsoon when surface moisture is at its maximum value.
c)
d)
3.03.00
For the purpose of volumetric computation, the bulk density of the coal shall be taken as 800 kg/m3. Therefore for calculation of belt conveyor capacity, for their drives & drive motors kW requirement, and sizing (volume calculations) of chute, hoppers etc. the above bulk density shall be considered. For all other purposes viz. for stresses/ load on structures, torque calculations of VF tables, sizing of actuators for flap gates, calculations of plugged chute/ hopper loads etc. the bulk density of the coal shall be taken as 1100 kg/ m3.
PAGE 16 OF 16
CLAUSE NO.
TECHNICAL REQUIREMENTS
A-01 :
SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY
1.00.00
The specifications as brought out in various Sub-sections for mechanical equipment shall be applicable to the system of proposed coal handling plant and specifically to all mechanical including their operation & control philosophy. However, some specific parameters of the entire system as a whole and the major equipment are brought out as under. PARAMETERS Conveyor System i. ii. iii. iv. Rated Capacity (Guaranteed) Design capacity Belt width Maximum Belt speed : 800 TPH : : : 880 TPH Minimum 1000 mm 3.2 M/sec.
2.00.00 2.01.00
2.01.01
Belting and Pulleys (a.) Belt ratings shall be selected in such a way that there are only three (3) ratings for Nylon/Nylon/polyester/polyamide belting. (Belting shall be completely interchangeable among same rating of belt.) Minimum number of plies for belting shall be four (4). Other details of belting shall be as specified else where in the specification. (b) For Pulley, following minimum parameters shall be followed: (1.) Shell thickness (2.) End disc plate thickness : : 16 mm (Min.) 24 mm(Min.) 5 Minutes
(3.) Maximum allowable deflection of shaft at hubs : (4.) Diameter : (i) All drive pulleys (ii) All balance pulleys : :
800 dia (min.) 630 dia (min)
Further approval from belt manufacturers shall be obtained by the contractor regarding the adequacy of the pulley diameters. c) Maximum type of pulleys permitted based on pulley diameter and shaft diameter shall be limited to five (5). These shall comprise of two (2) nos. drive pulleys and three (3) nos. for all balance pulleys. Pulleys for SS pulleys are not included in the above categories.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B
SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERTION & CONTROL PHILOSOPHY
PAGE 1 OF 4
CLAUSE NO.
2.01.02
Vibrating Feeders (a) (b) Nos. required Guaranteed (rated) capacity : : Two (2) each 400 MTPH
2.01.03
Dust Control System The capacity of the dust control system specified hereinafter is for Contractors guidance only. Contractor shall provide adequately sized and fool proof dust control system, the performance of which should be guaranteed by the Contractor as required in the Technical specifications. The performance guarantee test procedure is to be submitted by the Contractor. However, the capacity of the offered system shall not be less than the specified values below. a) Dust Suppression System (Dry fog type) (1) Operation : Water & air sprayed by Fogging nozzle. At all coal discharge & receipt point on all transfer point & crusher house 0.5 Kg/cm2 for water (min.) 5.0 Kg/cm2 for air (min.)
(2)
Location of spray
(3)
Capacity & Pressure at inlet of spray head
2.01.04
Service Water System Service water connections are to be provided in conveyor galleries & tunnels at 50 meter interval and one (1) no. on each floor of Transfer Points, toilets. (a.) Flow at each valve (b.) Minimum discharge Pressure at tap point (c) No. of valves operated simultaneously : 5 cub.m/hr
: :
2 kg/sq.cm 6 nos.
2.01.05
Potable Water System
: As specified elsewhere in the spec.
2.01.06
Ventilation System
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERTION & CONTROL PHILOSOPHY
PAGE 2 OF 4
CLAUSE NO.
Mechanical Ventilation System
Battery rooms/ Toilet: B. C. Pressurized Ventilation System: Air Conditioning System :
Minimum 10 supply air changes per hour. Minimum 15 supply air changes per hour Adequate number of air changes to Maintain in uniform temp. & humidity as specified elsewhere.
2.01.07
Chutes Minimum clear cross section of chute : 650 mm x 1000 mm (inside both ways).
2.01.08
Hoists Suitable hoists as specified elsewhere shall be provided for erection & servicing of all major equipment. The equipment to be covered shall include (but not limit to) all conveyor drive units, all pulleys, along with drive units, in line magnetic separators, sampling units, various DS/service water/potable water pumps, gravity take up units, lifting of belt drum at all transfer houses etc.
2.01.09
All other equipment under the scope shall be suitable to the system capacities parameters as specified above. OPERATION AND CONTROLS This section is intended to cover control/instrumentation and operational philosophy as specified hereinafter complete in all respects, required for complete coal handling plant. 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)
3.00.00 3.01.00
3.02.01
PAGE 3 OF 4
CLAUSE NO.
Institute of Electrical & Electronic Engrs. (IEEE) Instrument society of America (ISA) National Electrical Code (NEC) National Electrical Manufacturers Association (NEMA) United States of America standards (USAS) Bureau of Indian Standards (BIS) Conveyor Equipment Manufacturers Association (CEMA) 3.02.02 3.03.00 3.03.01 This Sub-section shall be read in conjunction with Electrical Sub-sections. General Construction and Design General Construction Control desks/panels and annunciation system shall be as per the requirement of electrical Section. Annunciations, indications, electrical meters and instrumentation shall be provided as specified. 3.03.02 Design The complete coal handling plant shall be controlled from PLC system as detailed elsewhere.
PAGE 4 OF 4
CLAUSE NO.
A-02: BRAKES AND CLAMPS 1.00.00 GENERAL Brakes shall be provided for decelerating of driven equipment/conveyors as per requirement. Rail clamps shall be provided for various mobile machines traveling on rails. 2.00.00 STANDARDS The design, manufacture, inspection and testing of Brakes & Clamps shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Brakes & Clamps shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. 3.00.00 3.01.00 DESIGN REQUIREMENT Electro Hydraulic Thruster Brakes/Disc Brakes The necessary Electro Hydraulic Thruster (AC) brakes / disc brakes, totally enclosed and fail safe, shall be provided as required for various equipments. Braking torque shall be adjustable from 0 to 100% of rated braking torque. The thruster brake shall be actuated by compression springs. 3.02.00 3.02.01 Clamps Electro-hydraulic thruster and manual rail clamp shall be designed for holding the machine stationary. Electro-hydraulic thruster and manual rail clamp shall be actuated by compression springs, the spring shall apply the clamping force directly on the Rail clamp mechanism once power supply is cut-off. The force transmission mechanism from spring to rail clamp faces shall be very simple with minimum linkages. CONSTRUCTION REQUIREMENT Thruster Brakes The electro hydraulic thruster shall be fitted with the brake. Limit switches shall be provided for brake applied/released positions. The windings shall be provided with class-B insulation suitable for 415V 10% at 50 Hz 5% and combined variation of 10%. Brake lining shall be asbestos with inter woven brass wires capable of withstanding 200C temperature.
3.02.02
3.03.00 3.03.01 3.03.01.01
DATA SHEET: BRAKES AND CLAMPS

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-02 BRAKES AND CLAMPS PAGE 1 OF 2
CLAUSE NO.
1.0.0 1.1.0
GENERAL Brakes (i) For decelerating of conveyors & rotating equipments. Brakes are mandatory for H.T. drives involving scoop type coupling except crusher motor.
(ii)
1.2.0
Rail Clamps
For various mobile equipment travelling on rails.
2.0.0 2.1.0 2.1.1
DESIGN & CONSTRUCTION REQUIREMENT Brakes Type Electro Hydraulic Thruster brakes A.C. operated or Disc brakes. Adjustable from 0 to 100% of rated braking torque. Operated directly by spring Asbestos with interwoven brass wires. 200 degree C. Class-B insulation, IP-65 protection.
2.1.2
Braking Torque
2.1.3 2.1.4 2.1.5 2.1.6
Brake Shoes Shoe lining Max. Temperature for shoe lining Thrustor
SUB-SECTION-IIIA-02 BRAKES AND CLAMPS
PAGE 2 OF 2
CLAUSE NO.
A-03: MONORAILS AND HOISTS 1.01.00 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 Employer. For this purpose Contractor shall provide monorails and hoist blocks with cross travel facility. 1.01.01 CODES AND STANDARDS The design, manufacture, inspection and testing of Monorails and Hoists shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Monorails & Hoists shall conform to the latest edition of the following standards & codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:3938 : Specification for Electric Wire Rope Hoist IS:3832 : Chain pulley blocks IS:2429 : Round steel short link chain IS:6216 :Short link chain grade 80 IS:8610 :Points hooks with shank for general engineering purposes IS:210 : Cast Iron Castings 1.02.00 1.02.01 DESIGN REQUIREMENTS For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift, with the exception of hoists for GTU and bend pulleys motor operated hoist blocks for both long travel and lift shall be provided. Other hoist blocks shall be of hand operated type for both travel and lift. Minimum 3 meter length of Cantilever from edge of building/cladding, shall be provided in monorails coming out of the building to lower the equipment to ground level clearing the building sidewalls / cladding and any other facilities beneath the floor upto ground level. 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 employer at the time of detailed engineering. Clear height shall be maintained when handling one equipment over other, in such case dismantling of any equipment shall not be permitted. The center line of monorail shall not deviate by more than 500 mm from the center of gravity of any equipment that is to be lifted. Contractor shall take clear note of the fact that the number and monorail hoisting systems shall also be
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-03 MONORAIL AND HOISTS PAGE 1 OF 6
1.02.02
CLAUSE NO.
decided considering the movement of the equipment being 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. 1.02.03 Monorails shall be extended outside the building to handle the equipment to ground level. For monorail/hoist routed inside the buildings, suitable machinery well and removable handrailing and grating shall be provided on various floors of buildings, as necessary, to handle the equipment. Electrically operated monogirder type hoists shall consist of following major components. (a.) Electrically operated trolley complete with drive motor (Trolley travel speed maximum 15 m/min.). (b.) Hoist cable, hoisting block and hooks complete with drive motor (Hoisting speed maximum 6m/min.). (c.) Limit switch to prevent overhoisting, over lowering and over travel.
1.02.04
(d.) Festoon arrangement of feeding power to trolley assembly. (e.) Erection hardware. (f.) Pendent control station suspended from hoist.
(g.) Control panel mounted on wall. 1.02.05 The electric hoist shall be designed and constructed in accordance with the latest revision of IS:3938 and shall be suitable for duty class 2. For electric hoists, trolley movement and hoisting shall be effected by using two separate motors. Motors shall be as per technical requirements discussed elsewhere. However the motors shall be suitable for 150 starts per hour at 40% CDF. 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. Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which shall be driven through motor. Wire rope shall be of pre-formed type, hemp cored, regular lay 6/36 construction with a breaking strength of 160 -175 kgf/ sq. mm. Reverse bend of ropes is not acceptable. Minimum number of falls of rope shall be four (4). 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.
1.02.06
1.02.07
1.02.08
1.02.09
1.02.10
SUB-SECTION-IIIA-03 MONORAIL AND HOISTS
PAGE 2 OF 6
CLAUSE NO.
1.02.11 1.02.12 1.02.13 1.02.14
All running shafts and wheels shall be fitted with ball / roller bearings with a rated life not less than 20 years based on equivalent running time as per IS:3938. An electromechanical brake shall be provided for hoisting as well as cross travel. Brake lining shall be of asbestos. Cast iron parts, wherever used, shall be of minimum grade 30, IS:210. All chain pulley blocks shall be designed to IS:3832, the operating hand chain shall conform to IS:2429 grade 30 pitched and polished and the load chain to IS:6216 grade 80. The chain pulley block shall be suitable for duty class 2. Hooks shall be as per IS: 15560 & with antifriction bearing. All hoists/chain pulley blocks shall be selected to have minimum headroom and shall be selected to lift heaviest piece of equipment. Further, it shall be possible to handle any equipment without disturbing other equipment. The hand chain wheels shall be of cast steel, the wheels shall be with flanges and designed to ensure effective operation of hand chain. Further, suitable local brake shall be provided as per IS:3832 to arrest and sustain loads in all working positions. 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. Hoist for Gravity Take up arrangement and bend pulley. For handling bend pulley, take-up pulley and counter weights following hoisting arrangement shall be provided: (1) For handling bend pulleys, hooks of adequate capacity shall be provided at the top of gallery. Further minimum four (4) nos. manually operated chain pulley blocks of adequate capacity shall also be provided for the entire coal handling plant for handling bend pulleys. For handling take-up pulleys, manual hoist along with mono rail beam of adequate capacity having cross travel, arrangement shall be provided at bottom of gallery to handle take-up pulley only of conveyors. For handling take-up weight, a separate manual hoist with mono rail beam of adequate capacity shall be provided to hold complete counter weight (inclusive of all counter weight blocks). This hoist shall be provided for holding the counter weight and shall be located in the zone of counter weight travel.
1.02.15
1.02.16
1.02.17
1.02.18
(2)
(3)
1.03.00 1.03.01
CONSTRUCTION REQUIREMENT The hoist mechanism shall consist of a grooved rope drum driven by electric motor through gears. Each end of the rope shall be anchored to the drum in such a way as the anchorage is readily available for maintenance. Each rope shall have two (2) full turns of the drum when the hook is at its lowest position and one (1) spare groove when the hook is at its highest position. The leading rope taken by the drum should not slope sideways when slack and it should not be caught between the gear wheel.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-03 MONORAIL AND HOISTS PAGE 3 OF 6
CLAUSE NO.
1.03.02 1.03.03
Rope drum, gear box, block etc. should be fabricated out of weldable quality steel. Trolley wheels shall be of single flange type in the taper treads. The wheels shall be mounted on antifriction bearings and shall be easily removable for repair/ replacement. The load hook shall be swiveling type forged circular shank section and shall confirm to IS:15560. All gears and bearings shall be lubricated by grease. All lubricating points shall be grouped together in easily accessible position. 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. All parts requiring replacement/inspection/lubrication shall be accessible without need for dismantling of other parts/structures. All components of hoists of identical capacity and duty shall be interchangeable. Hoists shall have permanent inscription in English on each side readily recognizable from floor level stating safe working load. 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. The control panel shall be wall mounted type & easily approachable from the floor by a standing man. For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x 1.5m) with ladder shall be provided for each electrical hoist. Inline magnetic separator shall have motorised hoist for handling / maintenance purpose. Each suspended magnet shall be provided with a dedicated motorised trolley.
1.03.04
1.03.05
1.03.06
1.03.07
1.03.08 1.03.09
1.03.10
1.03.11
1.03.12
1.03.13
PAGE 4 OF 6
CLAUSE NO.
DATA SHEET : MONORAILS AND HOISTS 1.0.0 1.1.0 GENERAL Functional Requirement : To transfer equipments maintenance area or outside building. to the
2.0.0 2.1.0 2.1.1
DESIGN & CONSTRUCTION REQUIREMENT Hoists Drive (i) More than 2.0 tonne or more than Motor driven for both travel & lift. 10.0 m lift or hoists coming out-side the buildings
(ii) Other hoists including the hoists for Manual for both travel & lift. handling takeup pulley and takeup weight 2.1.2 Maximum trolley travel speed for electric 15m/min hoists Maximum Hoisting speed for electric 6 m/min hoists Drive Motors No. of starts for drive motor Wire Rope (i) Type/Construction Pre-formed type, hemp cored, regular lay 6/36 construction 160-175 kgf/sq. mm SQIM, Separate for travel & lift 150 starts/hr at 40% CDF
2.1.3
2.1.4 2.1.5 2.1.6
(ii)
Breaking Strength
2.1.7
Bearing (i) (ii) Type Life Ball/Roller bearing 20 years Electro Mechanical type with asbestos lining.
2.1.8
Brake
PAGE 5 OF 6
CLAUSE NO.
2.1.9
Load Hook
Swiveling type forged circular shank section. Class 2
2.1.10 2.2.0 2.2.1 2.2.2
Duty Monorail location/layout Cross section Distance between C/L of monorail & C.G. of equipment to be lifted Power Cables Support Manual Hoists Maximum manual effort for operation.
I beam Maximum 500 mm
2.2.3 2.3.0 2.3.1
Festoon type arrangement
30 Kg
PAGE 6 OF 6
CLAUSE NO.
A-04: CHUTES AND HOPPERS 1.00.00 GENERAL Chutes & Hoppers, flap gates shall be furnished integral with coal handling system being supplied. All necessary accessories, electricals etc. shall be provided to ensure proper flow/storage/bifurcation of coal as per system requirements. 1.01.00 CODES AND STANDARDS The design, manufacture, inspection and testing of Chutes & Hoppers shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The chutes, hoppers shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:4682 :Code of practice for lining of vessels and equipment for chemical processes. IS:2062 : Structural Steel (Standard Quality) IS:11592 : Code of practice for selection and design of Belt Conveyors. 1.02.00 1.02.01 1.02.02 1.02.03 DESIGN AND CONSTRUCTION Chutes, Hoppers The minimum valley angle of chutes shall be 60 degrees from horizontal. Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal without any accumulation anywhere. Complete chute work above the drive floor for conveyors provided with In-line belt magnetic separators shall be of 10 mm thick SS - 304 in the zone of magnetic field. Direct impact of material on conveyor belt shall be avoided by providing an inclined surface at 60 degrees valley angle at the feeding point to guide the material in the direction of belt travel. Further, chute construction below flap gate shaft shall be such that there will not be any accumulation of coal dust between chute and flap gate in that zone. Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL / SAILHARD / LSLAS07 or equivalent material. Long chutes guiding flow from considerable height shall be provided with impact plates wherever change in direction of flow takes place. Hinged inspection doors of leak proof construction shall be provided for access/ maintenance purpose, at approachable heights for chutes and flap gates. All
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-04 CHUTES AND HOPPERS PAGE 1 OF 6
1.02.04
1.02.05
1.02.06
CLAUSE NO.
chutes should have one inspection door at every floor and for the ones in between the floors (more then 1.5 meter above the operating floor level) suitable access for trouble free maintenance shall be provided. For sealing of inspection doors labyrinth type arrangement to be provided. In addition to positive locking arrangement, mounting bolts, to tighten the door further against rubber shall also be provided. 1.02.07 Bottom side of the chutes on which the coal slides shall be welded to the side plates to form a trough. Bottom sides along with its adjacent sides shall be flanged and made from TISCRAL or equivalent material of 20 mm thickness. The non-striking surface i.e. the covers of the trough shall be of 10 mm thick mild steel and bolted to the flange provided on the trough. Inside welding shall be provided in the corners for permanent sealing. Further, the chute boxes not more than 1.5 m in length shall be joined through bolted flange connection to form the chute legs. Adequate care shall be taken to locate the flange joint away from floor level for easy maintenance. Bolted flange joints shall be of dust tight construction and necessary sealing material shall be provided in all the flange connections for adequate sealing. Complete chute work in the region of flap gates shall be fabricated from 20 thk TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree) complete chute, work shall be of 20 mm thick TISCRAL or equivalent material. While finalising the chute work inside the building, arrangement for shifting and replacing chute legs, proper handling arrangement/wall openings, trolleys, hoists shall also be provided. 1.02.08 Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum 4 mm M.S. Plates and shall be provided with hinged and gasketed inspection doors with suitable access to them. Further, serrated rubber seal shall also be provided at the very inlet of head chute to minimize dust nuisance. Separate maintenance sealed door shall be provided for access to belt cleaners in head pulley hood, flap gates for maintenance and inspection doors shall be of hinged with positive locking facility. (a) There should be sufficient clear space to install, remove and maintain scrappers without cutting structures. Slope of plates below scrappers to direct coal scrapped by these to the main stream shall be 60O min.
1.02.09
1.02.10
(b) 1.03.00 1.03.01
Skirt Boards Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage. Suitable Skirt Plates shall be provided for entire feeding chute and shall be extended minimum 3m ahead of front edge of chute and 500 mm beyond rear edge of chute. The width of the Skirt Boards shall be two-third the conveyor belt width. In the belts where coal of appreciable lump size (250 mm) is being conveyed, the gap between the bottom of the skirt board and the belt shall be made to increase uniformly in the direction of belt travel. The height of the skirt boards shall be
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-04 CHUTES AND HOPPERS PAGE 2 OF 6
CLAUSE NO.
sufficient to contain the material volume as it is loaded on the belt and shall not be less than 750 mm. The skirt plates shall be fitted with modular segmented and replaceable rubber skirting pads having facility of adjusting the pressure on the belt conveyor and shall have provision of on line removal for the purpose of easy maintenance. Such segmented rubber pads with its holding down adjustment arrangements shall be of proven design. The edges of segmented pads shall be installed at an angle for providing a better seal. All care shall be taken while designing, to combine good sealing with minimum belt wear. 1.04.00 1.04.01 Flap Gates 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. The equipment shall be capable of being operated for at least 15 switchings per hour at rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at rated load and thrust. The motor rating for the actuator shall be so selected as to provide sufficient thrust for operation of the flap gates against the moving weight of coal and/or flap gate. The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight. Lever arm shall be provided between actuator and flap gate shaft for obtaining required thrust. The actuators shall be capable of preventing any over travel. Suitable travel dependent limit switches controlling the travel of the flap gates on either direction shall be furnished. These shall be placed internal to the drive unit and shall be completely dust-proof. The limit switches shall be capable of adjustments to vary the total length of travel of the gates. Suitable thrust dependent limit switches shall be provided in the actuator, which shall trip off the actuator motor in case of excessive thrust due to jamming of the gates during its travel in either direction. The same shall also be integral to the drive unit and shall be dust proof. Provision for alternative manual operation shall also be made using declutchable hand wheel. The diameter of hand wheel shall be selected considering convenient force to be applied by a single operator. However, minimum diameter of hand wheel shall be 500 mm. Limit switch for safety of person operating the hand wheel shall be provided. Manual effort required to operate the flap gate shall not exceed 25 kgs. All the two way chutes, one way of which is leading towards the future conveyor shall be provided with blind flange.
1.04.02
1.04.03
1.04.04
1.04.05
1.04.06
1.04.07
1.04.08
SUB-SECTION-IIIA-04 CHUTES AND HOPPERS
PAGE 3 OF 6
CLAUSE NO.
1.04.09 1.04.10
All the actuators in the plant should be selected based on heaviest loading, but the rating shall not be less than 2500 kg with a lever arm of 1.0 m in any case. Suitable stiffening arrangement shall be provided between the two faces of the gate plate. At the end of the travel the total length of edge of the flap gate shall rest on a suitable projected surface from chute to prevent leakage of coal dust through the available clearance between chute and flap gate. Maximum feasible counterweights shall be provided for better utilisation of system. However, for calculation of thrust required, the benefit of counterweight shall not be taken into considerations. Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft. Suitable provision for regreasing shall be provided. For standardization purposes, only one standard type of actuator for flap gates shall be provided. The standard type actuator shall be selected for maximum thrust as calculated for various locations. Flap gate actuator as a whole and individual component wise shall be completely interchangeable for all locations. The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall be suitable for motor stalled condition and associated twisting. Approach/maintenance platforms complete with the chequered plate floor, hand rails, ladders etc. shall be provided for all flap gates. Shaft & flap gate shall be tightly fitted to each other.
1.04.11
1.04.12 1.04.13
1.04.14 1.04.15 1.04.16
PAGE 4 OF 6
CLAUSE NO.
DATA SHEET : CHUTES AND HOPPERS 1.0.0 1.0.1 2.0.0 2.1.0 2.1.1 2.1.2 GENERAL Coal Parameters DESIGN & CONSTRUCTION Chutes & Hoppers Minimum Valley Angle Material : (a) Chute work 20 mm thk. TISCRAL / equivalent 10 mm thk MS thk. 60 degrees As specified elsewhere
Sliding zones & adjacent sides No striking/ Non sliding zones
Chute with valley angle 80 degree and All four sides of 20 mm above TISCRAL/equivalent material In the zone of magnetic field of ILMS SS-304 10 mm thk. (chute above floor over which ILMS is suspended) In the zone of flap gates Discharge Hoods over head pulleys 2.1.4 2.1.5 Inspection Doors Chute Construction (a) (b) (c) (d) (e) 2.2.0 2.2.1 Corners Joints Bolted Bolt size Bolts spacing Fixing Arrangement
20 thk TISCRAL/ equivalent material 4 mm thk M.S. with rubber curtain Hinged & leak proof construction (min. size 350 x 450 mm)
One face of removable bolted flange connection Flange joints construction Min. M-16 Not more than 125 mm C/C Bolts with plain spring washers of dust tight
Skirt Boards Length Entire feeding chute shall be extended minimum 3mm ahead of front edge of chute & 500 mm beyond rear edge of chute.
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2.2.2 2.2.3
Height Width Side plate Top cover
Not less than 750 mm 2/3 of belt width Min. 10 thk TISCRAL/equivalent 6 mm thk M.S.
2.3.0 2.3.1 2.3.2 2.3.3
Flap Gate Type Travel Automatic operation (i) (ii) (iii) (iv) Drive Minimum Actuator Rating No. of Operation / Hr Protection Dust tight motor driven with suitable linkages 2500 kg with 1 m lever arm 15 (with 10 consecutive switchings) Travel and Thrust dependent limit Switches. Linear actuator operated, 2 position 60 to 70 deg. (with limit switches on both sides).
2.4.4
Manual Operation (a) Maximum effort Convenient for single operator by declutchable hand wheel regardless of electrical power. 500 mm
(b)
Minimum Handwheel Diameter
2.4.5
Flap gate shaft (i) (ii) Diameter minimum Material 150 mm EN-8
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CLAUSE NO.
A-05: BELT CONVEYOR SYSTEM 1.00.00 GENERAL All Belt Conveyors shall be furnished and erected along with necessary supporting structures, platforms, on ground or overhead galleries, trestle structure with foundation footings, carrying and return idlers, automatic take-ups, pulleys, drive motors with suitable reduction units and couplings, belting, feeder hoppers, transfer chutes, flap gates, hydraulic couplings and other necessary accessories as per scope specified elsewhere. 1.01.00 CODES AND STANDARDS The design, manufacture, inspection and testing of the Belt Conveyor System shall comply with all the currently applicable statues, regulations and safety codes in the locality where the equipment is to be installed. The belt conveyor system shall confirm to the latest edition of the following standards & codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. Belt Conveyors for Bulk Manufacturers Association. Materials published by Conveyor Equipment
IS:7155 : Codes of Practice for Conveyor Safety. IS:1891 (Part-I) : General Purpose Belting IS:8598 : Idlers and Idler Sets for Belt Conveyors IS:4009 (Part-II) : Conical Head Grease Nipples IS:8531: Pulleys for Belt Conveyors. IS:226 : Structural Steel (Standard Quality) IS:4682 : Codes of Practice for Lining of Vessels and Equipment for Chemical Processes. IS:11592 :Code of practice for selection and design of Belt Conveyors. CAN / CASA - M422 M87 : Canadian standard association. 1.02.00 1.02.01 DESIGN REQUIREMENT Design of belt conveyor system shall be suitable for coal parameters specified elsewhere.
SUB-SECTION-IIIA-05 BELT CONVEYOR SYSTEM
PAGE 1 OF 15
CLAUSE NO.
1.02.02
Slopes of conveyors, wherever applicable, shall not exceed 16 deg. depending on the lump size, and other governing factors. The guaranteed capacity of all conveyors shall be the rated capacity. All conveyors shall be designed for 110% of rated capacity. Design capacity of the conveyor system shall be considered for the selection of belt width, belt speed and the continuous motor rating at 50 deg C Ambient. The drive chain equipments for various belt conveyor systems shall consist of drive motors, fluid couplings, gear reduction units, low speed flexible couplings and pulleys. For the ratings of various equipments as mentioned above in the drive chain of conveyor systems relevant sections of this specification shall be referred to. Conveyors shall be provided with electro hydraulic thrustor brakes or fly wheels to adjust the coasting time of conveyors such that there will not be any build up of material in the chutes. Further conveyor shall come to halt as early as possible. All conveyors with HT drives (except bunker conveyors) shall be provided with brakes. Belt conveyor system shall be designed as per the latest edition of Belt Conveyors for Bulk Materials published by Conveyor Equipment Manufacturers Association or equivalent International Standard. Ai value for idler shall be considered 2.8lb (min.) for the purpose of conveyor design calculation only. CONSTRUCTION REQUIREMENT Belting The belting shall be of either synthetic fabric such as Nylon-Nylon, polyester, polyamide, etc. with rubber covers of adequate flexibility to give a troughing angle of 35 deg. For all the conveyors the number of plies, cover thickness, factor of safety etc. shall be as per the recommendation of belt manufacturer, but not inferior to the figures as tabulated in data sheet. Idlers Carrying idlers shall be provided with three equal rolls with troughing angle of 35 deg. and 2 deg. forward tilt (except in case of reversible conveyors). In no case, shall the diameter of the idler roll be less than 152 mm for both carrying side and return side. However for impact idlers roll the steel diameter shall not be less then 139 mm and rubber thickness shall be minimum 25 mm. Roller used in idlers shall be made from ERW steel tube. Wall thickness shall be minimum 4.0 mm without any negative tolerance. The rollers shall be mounted on EN-8 or equivalent material spindles by means of ball bearings of either deep groove type or seize resistant type (SKF/Equivalent), of 30 mm size for carrying idlers and 20 mm size for return idlers. The bearings shall be adequately sealed and lubricated for life. The rolls shall be supported from fabricated steel brackets. Fixing
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-05 BELT CONVEYOR SYSTEM PAGE 2 OF 15
1.02.03 1.02.04
1.02.05
1.02.06
1.02.07
1.03.00 1.04.00 1.04.01
1.05.00 1.05.01
1.05.02
1.05.03
CLAUSE NO.
arrangement of rollers with brackets shall be drop-in type. For adjusting the alignment of the idlers, slotted holes shall be provided in idler supporting base plates. Direction of belt travel shall be clearly marked on the brackets of carrying idlers by embossing / punching. 1.05.04 Idler rollers shall be waterproof, dust proof and weather proof against a high velocity water jet. All idlers shall be provided with minimum double labyrinth dust seal. Impact idlers used at the loading and transfer point shall be so designed as to avoid direct loading impact, belt damage and excessive punishment to the carrier. The material used in construction of this type of idlers shall be of resilient type. The return idlers for all conveyors shall be single roll type. For conveyors longer than 400m, two roll return idlers with 10 deg. troughing angle shall be provided. The self-aligning idlers shall be direct acting type, complete with actuating rollers fitted with the ball bearings and mounted inclined towards the belt. The idler frame shall be suitably cradled about a vertical pivot, supported in bearing over a fixed plate. Adequate sealing arrangement shall be provided to prevent contamination of the lubricant by dirt and moisture. Transition type troughing idlers shall be used adjacent to all pulleys to permit proper support of the loaded belt near the pulleys without excessive stretch of the belt edges. The transition idlers shall be provided with preferably adjustable concentrator (end) rolls and long center rolls to suit the troughed belt contour between the last regular troughing idler and the adjacent pulleys. The transition length and the number of the transition idlers shall be selected depending upon the tensions, type and size of belt, number of plies and other necessary governing factors. All the conveyors shall be provided with one self cleaning type rubber disc return idler located near the head pulley for cleaning the return belt. Proper arrangement shall be provided in the brackets of all types of idlers for preventing the rollers from coming out of the brackets during normal / abnormal conditions. Belt Cleaners External Belt Cleaner Spring loaded scraper type cleaner with modular segmented and replaceable polyurethane scrapers blades complete with main cleaner, pre-cleaner (mounted separately) along with accessories and necessary fines (reject of scrapper) chutes shall be provided for all belt conveyors, tripper head pulley and belt feeders at discharge pulleys. The modular units shall be easily replaceable. The scraper assembly shall be easily maintainable from outside without any interference with the chute arrangement and assembly.
1.05.05
1.05.06
1.05.07
1.05.08
1.05.09
1.05.10
1.06.00 1.06.01
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1.06.02
Internal Belt Cleaner V-plough type belt cleaner made of mild steel flats and hard rubber strips with automatic wear adjustment and necessary accessories shall be furnished for cleaning internal surface of the conveyor belt.
1.07.00 1.07.01
Belt Take-up Arrangement Automatic take-up of gravity type shall be generally provided with necessary take-up arrangements complete with bend pulleys, take-up pulley, with its supporting / sliding assembly, wire ropes with turn buckle arrangement (to adjust the level) for suspending the separate take - up weight sliding assembly close to the ground, counter weights and other accessories. Suitable guards marked up scale attached to the frame to monitor belt stretch and access/maintenance platforms with handrails all around etc. shall be provided. Adequate access from conveyor gallery/transfer house/ground etc., as the case may be shall be provided to inspect, repair and maintain the gravity take-up arrangement. Guides of take up pulley/counter weights shall be sufficiently strong so that they do not bend during belt snapping. The prime consideration should be to locate the automatic take-ups at a place where these will work best, in relation to the drive, to keep belt tension at a minimum. Other considerations such as available space, maintenance considerations and the economics of the location should also be taken into account while designing. Take up shall not be located over buildings unless indicated in tender drawings. Height of take-up guide structure shall be sufficient to allow the take-up weight movement up and down for all operating conditions of conveyor and to allow minimum two (2) vulcanizing lengths margin in the belt or percentage of conveyor length (2.5% for synthetic belting) whichever is larger. Suitable guides shall be provided both for take up pulley and take up weight. Two (2) meter safety fencing along with suitable gate and locking arrangement shall be provided around gravity take-up at the base level / ground level. Irrespective of take-up location, the travel zone of take-up weight shall start from a suitable height above ground level. Suitable buffer arrangement shall be provided to arrest the fall of take-up pulley in order to avoid damage of the pulley assembly in case of belt snapping. Similar buffer arrangement shall be provided for take-up weight also, in case of, take-up weight travel zone terminating above a building floor. Sandpits of 600 mm deep shall be provided at ground below the take-up weights. In case of double stream conveyors, a partition of 3 mm steel plate shall be provided between the two take-up pulleys along entire travel zone of take-up pulleys. Intermediate platforms shall be provided in the take-up zone for maintenance of take - up pulleys / counter weight.
1.07.02
1.07.03
1.07.04
1.07.05
1.07.06
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1.07.07
Take-up weight shall consist of multi-blocks of RCC/Cast Iron and not of single block to facilitate adjustment in weight if required during operation. Single heaviest piece shall be suitable for easy handling. Take-up weight block shall be provided with edge protection angle to take care of any damage. Take up weights shall be kept inside a take up weight box frame structure and shall be properly anchored / bolted with the main frame, so that the none of the weight shall be loose/free inside the box. The box shall be painted with counter weight and conveyor number and shall have good aesthetic look. Hold Back Devices Suitable hold back devices for preventing running back of the conveyor belt in case of conveyor being stopped in loaded conditions due to power failure or during normal operational delays shall be provided to give positive protection. The hold back shall instantaneously engage without shock and be capable of protecting equipment and personnel. It shall be released instantly when power resumes or the delay is removed. The holdback devices shall be integral with gearbox. Pulleys Pulleys shall be provided as required for various conveyors. In determination of pulley diameter, no account shall be taken of the pulley lagging. The nominal diameter and face width of the pulleys shall be as stated in IS: 8531. The snub pulleys on each conveyor shall be located to provide a belt wrap on the drive pulleys of not less than 210 deg. wrap is envisaged for single snub drive only. All drive pulley surfaces shall be hot lagged with vulcanised natural rubber lagging grooved in diamond pattern. All non-drive pulleys shall be vulcanised natural rubber lagged (hot) with plain lagging. The rubber to be used for lagging of pulleys shall confirm to specifications listed in data sheet of this section. The rubber lagging of pulleys and method of lagging and testing the same shall conform to IS:4682. The pulleys shall be made from mild steel conforming to IS:2062 (Tested Quality). However, for conveyors with in line magnetic separators, the head end pulleys shall have shell and end disc made of non-magnetic stainless steel material.. All the pulleys shall be mounted on the forged steel shafts of EN-8 or equivalent material of adequate proportion by taper lock arrangement, running in heavy duty roller bearings with proper greasing arrangement. The plummer blocks for pulleys shall be of horizontally split type construction with minimum (4) nos. bolts holding the two split halves and with min (4) nos. foundation bolts. The plummer blocks shall be dust tight with double labyrinth seals. Conical head shape nipples conforming to IS:4009, suitable drain plug and eye bolt shall be provided. Side covers of plummer blocks shall be heavy duty metallic sheets. No plastic components shall be used.
1.08.00 1.08.01
1.09.00 1.09.01
1.09.02 1.09.03 1.09.04 1.09.05 1.09.06 1.09.07
1.09.08
CLAUSE NO.
1.09.09 1.09.10
Pulleys shall be mounted on machined & ground surfaces. Suitable guards shall be provided for all tail pulleys and bend pulleys for safety of operating personnel. Suitable stiffening arrangements shall be provided in all pulleys as required. For selection of pulley shaft dia of all the pulleys, a margin of atleast 20% shall be considered on the maximum tension at designed Conveyor capacity. Selection of pulley diameter, shell thickness, stiffening and shaft diameter shall be subject to approval of Employer during detailed engineering. Belt Protection Equipment Pull chord Switch Pull chord type (manually reset type) emergency stop switches shall be located on both sides of belt conveyors along the walkways for the entire length of conveyors for emergency stopping of conveyor. The enclosure shall be of cast aluminum with degree of protection IP-65. It shall have a separate terminal box with a separate hinged cover which shall be totally sealed from main box containing actuating mechanism / limit switch etc. Local pull chord actuation shall be provided by means of mechanical flap. Each switch shall have two NO and two NC contacts, which shall be wired out to the terminal block. The terminal block shall have facilities of cable looping. The Contact rating of the switches shall be rated for atleast 5 Amps, breaking at 240 VAC at 0.3 p.f. lagging. Adequate length of rope and all accessories shall be furnished. Pull chord in stone picking area shall be routed inside G.I. pipe of 1 size.
1.10.00 1.10.01
1.10.02
Belt Sway Switches Belt sway switches of self resetting type shall be furnished at periodic intervals to limit belt sway to permissible extent. The enclosure shall be of cast aluminum having degree of protection of IP-65. It shall have a separate terminal box with a separate hinged cover totally sealed from the main box containing actuating mechanism/ limit switch etc. Each switch shall have two NO and two NC contacts one for alarm and one for trip, which shall be wired upto terminal block. The terminal block shall have facilities for cable looping. The contacts of the switches shall be rated for atleast 5 Amps. breaking at 240 VAC at 0.3 p.f. lagging. The roller length of the switch shall be at least 150 mm. Belt sway switches shall also be provided at HGTU & VGTU to detect excessive belt away.
1.10.03
Zero Speed Switch Zero speed switch shall be non-contact (proximity) type electronic switch. Mounting arrangement/ location shall be such that operation, effective sensing distance, sensitivity etc. shall not be effected by accumulation of dust on rotating part or surface of probe. Adequate mechanical protection by means of non-metallic shields shall be provided on top of the switch to prevent any damage due to falling coal / metallic pieces etc. In built initial start up delay and nuisance, tripping delay through timers shall be provided. Each switch shall have two NO and two NC contacts wired out to the terminal blocks. The contact of the switches shall be rated for atleast 5 Amps. breaking at 240 VAC at 0.3 p.f. lagging. The monitoring unit shall have cast aluminum body having IP-65 degree of protection. A separate terminal box with a
PAGE 6 OF 15
CLAUSE NO.
separate cover, which shall be totally sealed from main box, shall be provided. Terminal blocks shall be suitable for terminating 1.5 mm sq. standard copper cable. 1.10.04 Chute Blockage Switches One no. chute blockage switch of proven type (subject to approval of the employer) shall be provided at a suitable height on each leg of the conveyors discharge chute, vibrating screening feeders by pass chutes, crusher feeding chutes, tripper discharge and feeding chutes nearest to the skirt boards. Chute blockage switch shall trip the feeding conveyor in case of Chute blockage and protect the feeding conveyor equipment. Chute blockage switch shall also be provided at each leg of mobile tripper and shall trip the tripper conveyor. The switch and its operating arrangement shall be suitable for working in dusty areas. The minimum degree of protection of switch shall be IP-65. Local indication of chute blockage switch actuation shall also be provided. Location of chute block switch shall be such that washing does not affect it. 1.10.05 Sensing arrangement shall be provided in the DDCMIS based control system for detecting the presence of material on the belt which shall in turn be used for operating solenoid valves of dust suppression/extraction system elaborated elsewhere. The arrangement shall detect three events simultaneously as follows: (a.) Belt loaded (b.) Belt running at more than preset speed. (c.) 1.10.06 Preset initial start delay.
The terminal boxes of all the belt protection equipments / switches shall be such that all the components / terminals inside are easily accessible for inspection and maintenance without removing the cables / connections / components. Each pull cord and Belt sway switch shall have necessary chip for using in circuit for the identification of the operated switch in main control room. The scheme for switch identification shall be fail safe and shall have all diagnostic features. The scheme shall have facility to by pass one or more switches, if required. Drive Motors Rating of all drive motors of conveyors shall not be less than 120% of the power required at drive motor output shaft at specified design capacity. The motor rating shall be at 50 deg Cent. ambient. Single LT drive motors shall be used for conveyor drive ratings up to 160 KW. For conveyor drive rating beyond 160 KW, single HT drive shall be used for conveyors. However for boom conveyor drive and intermediate conveyor drive on stackerreclaimer, single LT motor may be used above 160 KW also.
1.10.07
1.11.00 1.11.01
1.11.02
PAGE 7 OF 15
CLAUSE NO.
1.12.00 1.12.01
Conveyor Bridges All overground and overhead conveyors shall be located in suitably enclosed bridge structure. Structural steel bridges of adequate width and depth (2700 mm clear head room) shall be provided complete with conveyor bottom deck plates, seal plates, walkways of chequered plates with anti-skid arrangement(s), hand rails (on both sides of each conveyor belt except where equipment (like paddle feeders, stacker/ reclaimer, trippers etc.) traverse over conveyor supports. The conveyor bridge shall have permanently colour coated steel sheeting covers on roof and both sides, properly screwed or locked to steel structure as required. Adequate provision of windows shall be kept. A continuous slot opening of 500 mm shall be provided on both sides just below the roof sheeting. The floors of outdoor conveyor galleries shall be designed and constructed as follows: The side walkways for single conveyors shall be 800 mm on one side and 1100mm on the other side. However, if the centre to centre of conveyors or the width of the gallery is decided by some other criteria, maximum walkway widths consistent with gallery sizes shall be provided. In the complete length of conveyor gallery minimum walkway clearance as indicated above is to be maintained inclusive of all equipments and clearances. All conveyors shall be provided with 12 G steel seal plates throughout the length of the conveyor gallery in such a way that complete gallery bottom surface area forms a single water proof floor and no water / coal falls down from conveyor gallery incase of cleaning / washing. It is envisaged to clean the conveyor gallery with water periodically. All the water / coal slurry shall be suitably guided to down comers provided at every trestle. Each downcomer shall lead the coal slurry into a 2 cub meter brick wall tank at ground level having 2 Nos. decanting taps at suitable elevations. Decanted water shall be led to the nearest drain in the Contractors scope. Necessary arrangement shall be provided to avoid choking of downcomers by bigger coal lumps and for cleaning of choked downcomers.
1.12.02
1.12.03
1.12.04
The conveyors shall be provided with continuous decking plate of minimum 3 mm thickness plain steel sheet. Structures and floors shall be so designed as to provide suitable space for routing of 200 NB fire fighting pipe with water, cables and conduits. Steel trestles to support the conveyor bridge shall rest upon concrete foundations to be provided by the Contractor. Complete trestle structures shall also be supplied by the Contractor. Suitable approach/access platforms with hand railings shall be provided to approach the conveyor gallery (like in case of fire) through monkey ladders on the trestles. Suitable wire mesh doors on steel frame construction lockable from outside only shall be provided in the conveyor galleries at these locations. All monkey ladders shall have cage for safety of personnel using them.
1.12.05
1.12.06
PAGE 8 OF 15
CLAUSE NO.
1.12.07
Independent supports for walkways, conveyor structures shall be provided. The width of conveyor galleries shall be decided by the Contractors depending on the equipments size and the walkway width as specified. However, in no case the width of gallery shall be less than the width specified in tender drawings. Provision shall be kept with platforms and ladders for crossing over the conveyors at approximately every 100m intervals of route length and minimum one per conveyor. Special Cleaning, Protection and Painting All equipments of Coal Handling Plant inclusive of belt conveyor system and technological structures shall be kept clean. Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire brushing. All ferrous surfaces shall be applied with one shop coat of 35 micron and one 35 micron site coat of red oxide zinc chromate and two coats, each of 25 micron, synthetic enamel finishing paints unless specified otherwise. A minimum of 120 microns Dry Film Thickness (DFT) after finished coat of paint shall be ensured. However for deck plate in track hopper and tunnels, painting specifications mentioned at sub section IIID-01 shall be applicable. However idler rolls shall be applied with two coats & each 35 micron of red oxide zinc chromate only. The painting colour code shall be provided to the Contractor during detailed engineering.
1.12.08
1.13.00
1.15.00 1.15.01 1.15.02 1.15.03 1.15.04 1.16.00
Belt Vulcanizing Machine Belt Vulcanizing Equipment shall be suitable for hot vulcanizing of belt splice and shall be of easy-to-handle type. Equipment should be suitable for vulcanizing of entire splice width in single setting. Equipment should be capable of applying uniform pressure over the splice by pneumatic or hydraulic means. Heating element should be preferably of flexible type. Belt Jointing Facilities For the purpose of jointing the belting or replacement of belting, following belt facilities shall be provided:
1.16.01 1.16.02
5M X 5M paved area near take up to make joints. Hooks shall be provided on TPs, Conv. Gallery to pull the old belt while replacing the same with new belt.
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CLAUSE NO.
DATA SHEET: BELT CONVEYOR 1.0.0 1.1.0 GENERAL Design Capacity 110% of rated (guaranteed) capacity for all conveyors. 16 deg 2%
1.2.0 1.3.0 1.4.0
Maximum slope Max. belt Sag between idlers Minimum Radius (i) Concave curve
250 m (In case of travelling trippers, the requirement of minimum radius shall be decided based on the space availability) 50 m As specified elsewhere
(ii) 1.5.0 2.0.0 2.1.0 2.1.1
Convex Curve
Coal Parameters DESIGN & CONSTRUCTION Belting Type
Synthetic Fabric of Nylon / Nylon,/ Polyester/polyamide a) Flame test : Conforming to ISO:340 b) Drum Friction and Electrical Surface Resistance Test: Conforming to Canadian standard association CAN / CSA M-422- M87 Grade - C.
2.1.2
Cover Grade
2.1.3
Cover Thickness (without ve tolerances). (a) (b) Face Bottom
Synthetic belting 5.0 mm (min.) 2.0 mm (min.) Minimum 4 Snub drive
2.1.4 2.1.5
No. of plies Drive Arrangement
2.1.6
Factor of Safety
- 10 (Minimum) for N-N belt. - 7 (minimum) for Steel Cord Belt.
2.1.7
Normal Working tension at design Less than 80% of max. allowable working
CLAUSE NO.
capacity 2.2.0 2.2.1 Idlers Type (a) Carrying
tension
Three roll, 35 degree troughing, 2 degree forward tilt Single Roll, For conveyors upto 400 m c/c length. Two roll with 10 degree angle for conveyors more than 400 m c/c length Impact type
(b)
Return
(c) 2.2.2
Loading point
Spacing (a) Carrying idlers 1.2 m (0.6 m for convex curves and in the paddle feeder travel range). 3.0 m (for convex curves not more than 1.5 m.) Minimum six (6) with 400 mm spacing. troughing At 10 m distance from head & Tail pulleys with intermediate spacing 15m At 10 m distance from Head & Tail pulleys with intermediate spacing 20m. (Not required for conveyors more than 400m c/c long where 2 roll return idlers are provided).
(b)
Return idlers
(c) (d)
Loading point Self-aligning idlers
(e)
Self - aligning return idlers
2.2.3
Bearings (a) Carrying Ball Bearings of deep groove type or seize resistance type of min. 30 mm size, lubricated for life. Ball Bearings of deep groove type or seize resistance type of min. 20 mm size, lubricated for life.
(b)
Return
2.2.4
Material (a) Roller ERW Steel tube min. wall thickness 4.0 mm
CLAUSE NO.
(b) 2.3.0 2.3.1
Spindle
E.N. 8 or equivalent.
Belt Cleaners External Spring loaded scraper type cleaner with modular, segmented and replaceable PU blades with separate main-cleaner & precleaner etc. V-Plough type, mild steel flats with hard rubber strips.
2.3.2
Internal
2.4.0 2.4.1 2.4.2
Belt Take up Type Location Automatic Gravity Type. In relation to the drive to keep belt tension at minimum. To suit all operating conditions or (2.5% for synthetic belt) of conveyor center to center length whichever is larger. Further the initial location of take-up shall be decided in such a way that it is possible to carryout min. two (2) nos. Vulcanizing Joints without adding any external belt. Integral with gear Box
2.4.3
Take-up travel
2.5.0 2.6.0 2.6.1
Hold Back Device Pulleys General (for all types of Pulleys) Pulley shaft diameter
Margin of minimum 20% shall be Considered on maximum tension at design capacity for arriving at the shaft dia.
2.6.2
Drive Pulleys (1) (2) Lagging Lagging thickness Hot lagged with vulcanised natural rubber 12 mm thick grooved in diamond pattern with grooves 6 mm wide x 6 mm deep 210 degrees 0.5% of nominal diameter
(3) (4) 2.6.3
Minimum angle of wrap Maximum Out of roundness
Other pulleys (1) Lagging Hot lagged with vulcanised natural rubber
CLAUSE NO.
(2) 2.6.4
Lagging thickness
12 mm thick plain
Rubber for lagging (1) Type Natural rubber blended with styrene Butadiene rubber. 55 to 65 durometer (Shore A) Over 300% 160-245 kg/cm2 250 mm3 (max.) as per DIN 53516 Max. 1.5 10 kg/cm (minimum)
(2) (3) (4) (5) (6) (7) 2.6.5
Hardness Elongation Strength Abrasion loss Specific Gravity Adhesion Strength
Bearings for Pulleys (1) (2) (3) (4) Type Casing Sealing Lubrication Heavy duty roller type Horizontal Split Type Dust tight with double labyrinth seals. Greasing arrangement with conical head shape nipples. Mild steel conforming IS:226 / IS : 2062 Forged Steel shaft EN-8 or equivalent material.
2.6.6 2.6.7 2.7.0 2.7.1
Pulley Material Shaft Material Belt Protection Equipment Emergency Stop Switch System (1) (2) Type Location
Pull chord type (manually reset) Both sides of conveyor for entire length
(3) 2.7.2
Spacing
Approx 30 m
Belt Sway Switches (1) (2) Type Spacing Limit switches snap action. One pair at 50m interval (Minimum two (2) pairs)
CLAUSE NO.
2.7.3
Zero Speed Switches (1) Type, Location Proximity switch, mounted on Bend pulley of GTU.
2.8.0 2.8.1
Drive Motors Type Three Phase Squirrel Cage Induction Motors Base mounted
2.8.2 2.8.3
Mounting (for conveyors)
Continuous motor rating (Name 120% of actual power requirement at plate rating) at 50OC Ambient motor output shaft at design capacity. Conveyor Bridges Walkways (a) Construction Chequered plate with antiskid arrangement. Chequered plate steps shall be provided where conveyor slope exceeds 10 degrees. (Totally sealed so that no water falls down while washing.) for single conveyors, the width of side walkways shall be 800 mm on one side and 1100 mm on the other)
2.9.0 2.9.1
(c)
Side walkway width
2.9.2
Side Windows (a) Spacing (Center to center) 25.0 m on each side (in staggered fashion) 1.2 m x 1.5 m Refer Civil Section
(b) (c)
Size Window material
2.10.0 2.10.1
Trestles Spacing of monkey ladders on trestles (a) Where height of conveyor gallery (walkway level) is 10 m or more. Where height of conveyor gallery (Walkway level) is : On every trestle
(b)
: On alternate trestle
SUB-SECTION-IIIA-05 BELT CONVEYOR SYSTEM PAGE 14 OF 15
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less than 10m.
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CLAUSE NO.
A-06: DRIVE EQUIPMENT

1.00.00 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, paddle feeders, crushers, mobile trippers, various pumps of dust suppression/extraction 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 individual equipments shall be taken into consideration while designing the associated drive chain equipments. 1.01.00 CODES AND STANDARDS The design, manufacture, inspection and testing of Drive Equipment shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment in to be installed. The Drive Equipments shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:3688 : Dimensions for shaft ends IS:3681: General plan for spur & helical gears IS:7403 : Code of practice for selection of standard worm and helical gear boxes 1.02.00 1.02.01 1.02.02 1.02.03 DESIGN AND CONSTRUCTION REQUIREMENTS GEAR BOXES Gear Boxes shall be of sealed type and mounted on machined or ground surfaces. The gearboxes shall be designed for 24 hours continuous duty. For thermal and mechanical rating of the gearbox the data sheet shall be referred to. Gearboxes with cooling coils are not acceptable. The gears used shall be helical conforming to IS:3681 (latest revision) or worm reduction units or spiral bevel speed reduction units conforming to suitable Indian Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest revision. Above 40 kW drive rating, all gearboxes shall be helical or bevel helical type only. 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.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-06 DRIVE EQUIPMENT PAGE 1 OF 4
1.02.04
1.02.05
CLAUSE NO.
1.02.06 1.02.07
Couplings Flexible / Rigid Couplings Couplings shall be used for power transmission depending upon duty requirements. The design of the coupling shall be such that it can take shock and misalignment without sacrificing its efficiency. Flexible couplings shall be used for low speed application only. Geared type flexible coupling shall be used on low speed side for all conveyors and other drive chains where gear box is provided. Other couplings in the drive chains shall be either rigid or flexible type, depending upon the requirement of equipment design.
1.02.08
Fluid Couplings Fluid couplings shall be provided in all the drive machinery for belt conveyor systems if the actual power requirement at motor output shaft is more than 40 kW. The fluid coupling for LT motors shall be of traction type. Cooling water coils for traction type fluid coupling shall not be accepted. Scoop tube type fluid coupling shall be provided for conveyors with HT motors and ring granulator type coal crushers. Suitable electrically operated actuators shall be provided for scoop tube operation from local as well as remote. Suitable provision for alternate manual operation shall also be kept. Separate pump with motor or integral shaft driven oil pump shall be provided for circulating the fluid coupling oil through oil cooler. Arrangement for forced cooling water supply to oil cooler shall be provided by Contractor. Suitable interlock using flow switches shall be provided in both oil as well as water lines to trip the drive motor in the event of flow in either lines falling below acceptable levels. Suitable pressure indicators and flow indicators shall be provided in the cooling water lines along with all-relevant valves, and accessories. Necessary isolation valves shall be provided in the oil / water line for maintenance of any equipment in the line. Necessary interlock shall also be provided so that the HT motor cannot be started from remote / local unless position of scoop tube permits no load start of the motor. Tripping of downstream equipment while the system is under normal operation shall result in scoop tube re-positioning to permit no load run of the concerned HT motor. Temperature switch shall be provided in the oil circuit and shall trip the system in case of high oil temperature. Selection of rating & speed of actuator for scoop type fluid coupling shall be made taking into consideration the coasting time of down stream and up stream conveyors and the engagement/disengagement time achievable. The scoop tube operation must be such so to ensure draining of oil from the operating circuit by providing a double speed motor. The speed (for draining) shall be selected to match the coasting time of down stream equipment/conveyor.
DATA SHEET : DRIVE EQUIPMENT 1.0.0 GENERAL
SUB-SECTION-IIIA-06 DRIVE EQUIPMENT
PAGE 2 OF 4
CLAUSE NO.
1.1.0
Continuous Motor Rating (Name Plate Rating) at 50 Degree Centigrade Ambient temp. for Electric Motors a) For conveyors of belt conveyor systems *120% of actual power at drive motor output shaft at specified design capacity *110% of actual power requirement at drive motor output shaft at guaranteed (rated) capacity.
b) Mono-rail hoists (travel and hoisting), elevators, all the drives in sampling units, various pumps of DS systems, service water systems, cooling water system, potable water system and Ventilation Fans.
*The actual power at drive motor output shaft shall be calculated after considering all the losses of down the line equipments of the drive train. 2.0.0 2.1.0 2.1.1 DESIGN & CONSTRUCTION REQUIREMENT Gear Box Type (a) Below 40 KW Helical, worm, bevel as per requirement without cooling coil Helical / bevel helical without cooling coil As per accepted engineering practice / manufacturer's recommendations. 50oC Minimum On Surfaces Machined/Ground
(b)
Equal to and Above 40 KW
2.1.2
Service Factor
2.1.3 2.1.4
Ambient temperature for Thermal rating Mounting
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}
PAGE 3 OF 4
CLAUSE NO.
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 2.1.7 Duty Rating 24 Hrs. Continuous Not less than motor name plate rating
2.2.0 2.2.1 2.2.2 2.3.0
Flexible Couplings Type Rating Fluid Couplings Geared coupling. Not less than motor rating. For all motors having rating more than 40 KW.
2.3.1
Type (a) (b) L.T. Motors H.T. motors Traction type Scoop tube type. Not less than nameplate rating motor
2.3.2
Rating
PAGE 4 OF 4
CLAUSE NO.
A-07: BELT SCALE

1.00.00 GENERAL Belt weigh scale for measurement of coal flow rate and quantity shall be provided at specified locations. System shall be complete with flow rate indicator, totaliser, control panel etc. 1.01.00 Codes & Standards The design, manufacture, inspection and testing of Belt Scales shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Belt Scales shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. NEMA NEC IS:11547 1.02.00 1.02.01 For electronic circuit enclosures. Electronic weighing in motion system.
Design & Construction Requirements The weigh scale shall be automatic and electronic type. It should be designed for continuous automatic weighing, metering and printing of coal flow. Each belt weigh scale shall comprise of a belt weigh scale platform with minimum 4 nos. weighing idlers. It shall have unitised construction for ease of installation and shall be fully floating type (without pivot points). Minimum 4 nos. hermetically sealed load cells of precision strain gauge type shall be applied in tension to support the weigh bridge. The load cells shall have 100% overload protection and shall be structurally safe upto to 250% of rated belt scale capacity. Belt scale shall be electronic microprocessor based with its program stored in nonvolatile memory. It shall be provided with self diagnostic features for trouble shooting of the entire belt scale system. Fully automatic zero and span calibration facility shall be provided. The electronic systems offered by the Contractor shall include all signal conditioning, power amplifiers and printed circuits etc. The printed circuits shall be encapsulated against dust and moisture.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-07 BELT SCALE PAGE 1 OF 3
1.02.02
1.02.03
1.02.04
1.02.05 1.02.06
CLAUSE NO.
1.02.07
The flow rate indicator shall have minimum 4 digits. The flow totalizer should have 8 digits display scale with reset facility. Complete belt scale system shall be suitable for 50C ambient temperature and 100% relative humidity. It shall be suitable for out door installation in a dusty area. The electronic circuit enclosure, sensors housing shall be dust and watertight. The electronic printed circuits shall be encapsulated with epoxy or other suitable material for protection against dust and moisture. Minimum three years battery back up power failure protection shall be provided. Belt scale shall be designed for a range of 20% to 120% of rated capacity with an accuracy of atleast (+) 0.25 percent throughout its range. Per two (2) belt weighers, the contractor shall furnish one (1) necessary test load chain sets required for calibration and periodic testing of the equipment. The test load chain shall be two idler spaces longer than the weighing length of the weighers and shall be complete with chain reset equipment with weight adding reels of adequate size. The calibrated weight parameter length of the test chain shall be stamped at a suitable location on the body of the equipment. The test chain shall be installed near belt weigher with suitable arrangement for easy mounting/dismounting of chain onto/from conveyor belt. Alternatively, supply of test weights for calibration of belt scales is also acceptable. Local panel for belt scale shall be of sheet metal.
1.02.08
1.02.09 1.02.10
1.02.11
1.02.12
SUB-SECTION-IIIA-07 BELT SCALE
PAGE 2 OF 3
CLAUSE NO.
DATA SHEET : BELT SCALE 1.0.0 1.1.0 1.2.0 2.0.0 2.1.0 2.2.0 2.3.0 2.4.0 2.4.1 2.4.2 2.4.3 2.4.4 2.5.0 GENERAL Ambient Temperature Relative Humidity DESIGN & CONSTRUCTION Type Operation No. of floating idlers Load Cells Type Minimum Nos. Overload protection Structural capacity Flow Rate Indicator Strain gauge type hermetically sealed Four (4) 100 % of rated belt scale capacity 250 % of rated belt scale capacity Electronic Digital Display Minimum 4 digits 8 digit display with reset facility. For entire range of 20% to 120% of rated capacity : Minimum + 0.25% Electronic load cell type Microprocessor based fully automatic Minimum four (4) 50C 100%
2.6.0 2.7.0 2.8.0 2.8.1 2.8.2
Flow totalizer Accuracy Calibration Automatic Manual (a) Test load chain length
Zero & span calibration With test load chain Two idler spaces more than weighing lengths Complete with weight adding facility.
(b)
Chain reel equipment
MUZAFFARPUR THERMAL POWER PROJECT STAGE-II (2X195 MW) COAL HANDLING PLANT PACKAGE BID DOCUMENT NO. : CS-0350-155-2
SUB-SECTION-IIIA-08 BELT SCALE
PAGE 3 OF 3
CLAUSE NO.
A-08: DUST CONTROL AND MISCELLANEOUS SYSTEM 1.00.00 1.01.00 1.01.01 GENERAL INTENT OF SPECIFICATION The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete, Dust Control and Miscellaneous Systems as specified hereinafter required for the Coal Handling Plant. The Contractor shall refer to the other sections and scheme indicated in the tender drawings to appraise himself of the work and scope of supply of the other Contractors/Employer's and shall coordinate his work with the work of other Contractors. 1.01.02 1.01.03 General Information/Description Dust Control System The dust control system to be furnished under this specification is required for control of fugitive dust emissions from dust generation points such as transfer points, feeders, crushers etc. Dust control is achieved by dust suppression/extraction system. Contractor shall guarantee and offer dust control system which shall not allow a dust concentration in the ambient air inside the buildings more than acceptable limits as per Employer approved guidelines or any internationally recognized hygienic Standards/Codes. The Capacity of dust control system specified elsewhere is for 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 capacity of the offered system shall not be less than the specified values. Further, for computation of design capacity of the pumps, permanent recirculation lines as shown in tender drawings shall also be considered. 1.01.04 Miscellaneous Systems Service water system, potable water system, cooling water system & sump pumps shall be provided as specified elsewhere in this specification and as indicated in tender drawings. 1.02.00 1.02.01 Dust Suppression System (a) Dry Fog Type Dust Suppression System Complete with water supply system, compressed air system, pressure regulating units, flow activation system, necessary instrumentation for auto & manual operation, drives, pumps, maintenance platforms, alongwith associates civil/structures & electrical works.
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-08 DUST CONTROL & MISCELLANEOUS SYSTEM PAGE 1 OF 15
CLAUSE NO.
1.02.03
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.
1.02.04
Pipings, Fittings, Valves and Specialities The material to be supplied for completing the pipe work shall include but not be limited to the following: (1) Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing unions, couplings, caps, blank flanges, saddles etc. necessary for making reliable piping system. Gaskets, ring joints, jointing material etc. as required. Instrument tapping connections, stubs. Gate / plug, globe and check valves to start/stop, regulate and to prevent back flow. Duplex Strainers. Anchors, hangers and supports as required including secondary steel embedment etc. Bolts, nuts, fasteners as required for interconnection piping, valves and fittings as well as for terminal points. The entire water piping of DS / SW / PW / CW / DE system shall be routed/supported on concrete pedestal and conveyor galleries. Wherever the layout does not permit the pipes to be routed over ground, the same shall be buried in conformity to the relevant standards & shall be provided with necessary protective coating as per relevant standards and as specified elsewhere in the specification. Painting, anti-corrosive coatings etc. outside pipes as necessary. Welding electrodes and welding rods. The area around storage tanks, strainers, valves etc. (located out side pump house) shall be paved.
(2) (3) (4) (5) (6) (7) (8)
(9) (10) (11) 1.03.00
Codes and Standards The design, manufacture, inspection and testing of Dust Control & Miscellaneous Systems shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Dust Control
SUB-SECTION-IIIA-08 DUST CONTROL & MISCELLANEOUS SYSTEM PAGE 2 OF 15
CLAUSE NO.
& Miscellaneous Systems shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:778 : Gun Metal gate, globe & check valves for general purpose. BS:5150 :Cast Iron Gate Valve for water works purposes BS:5152 :Cast Iron Globe Valve for water works purposes BS:5312 :Cast Iron Check Valve for water works purposes S:1239 : Mild Steel tubes & fittings. IS:2379 :Colour for the identification of pipe line. IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm) IS:5312 : Swing check type reflux (non return) valves. IS:1520 : Horizontal centrifugal pump for clean, cold fresh water. IS:5120 :Centrifugal pump for clean, cold & fresh water. BS: 5169 & BS:1123 : Air Receivers. ANSI B 31.1:Code for pressure piping. Hydraulic institute Standards of U.S.A. 1.04.00 DESIGN REQUIREMENT Dry Fog Dust Suppression 1.04.01 At specified locations dry fog dust suppression system shall be provided which comprises spray nozzles discharging plain water & air in a fine spray to form dry fog to capture air borne dust particles and direct them into the main coal flow. This dry fog shall be discharged through spray heads at the dust suppression zones. The dry fog dust suppression system shall consist of the following: (a) Fogging system & controls consisting of: (i) (ii) (iii) (iv) Spray bar assemblies. Pressure regulating units Flow activation system Instrumentation for auto spray
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-08 DUST CONTROL & MISCELLANEOUS SYSTEM PAGE 3 OF 15
CLAUSE NO.
(b)
Compressed air system consisting of: (i) Two (2) nos. (one no. working and one (1) no. standby) air compressors (screw type) for each group of dry fog dust suppression system, alongwith air receivers as specified elsewhere. Air receivers Various instrumentation & valves.
(ii) (iii) 1.04.02
Each spray head in CHP shall have a provision for installing a pressure gauge whenever required. Further, pressure gauges shall be provided at least at two locations. Service Water (SW) System Service water connections are to be provided in conveyor galleries and tunnels at 50 meter intervals. Adequate number of these connections shall be provided in all transfer houses with minimum one no. at each floor and with minimum two (2) nos. at each floor in crusher house. Each connection shall be provided with one (1) no. 32 NB globe valve and quick coupling. One (1) no. hose pipe with nozzle shall be provided in each building. Service water distribution system shall be designed considering the water scheme and water requirement indicated in tender drawings.
1.04.03
1.04.04
Potable water (PW) system Potable water connections are to be provided in all transfer points, wagon tippler top, crusher house, all tripper floors, the machinery well at both ends of track hopper, track hopper top at both ends and all control rooms/MCC rooms and toilets etc. Water shall be drawn from the water storage tank by electric motor driven pumps and discharged via a pipe work system to the overhead drinking water storage PVC tanks of 250 litres capacities. The drinking water storage tanks shall have provision for maintenance & drain.
1.04.05
Hoists with monorail of adequate capacity shall be provided in the service water/dust suppression/potable water pump houses.
1.05.00 1.05.01 1.05.01.01 1.05.01.02
CONSTRUCTION REQUIREMENT Water Supply Pumps Water supply pumps shall be provided as required. The pumps shall be complete with drive motors, baseplate and other accessories. The constructional features of the pump shall be as follows:
CLAUSE NO.
a) b)
Pump casing may be axially or radially split. The casing shall be of robust construction. Casing drain and vent connections shall be provided. 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. Wearing rings shall be of renewable type. Opposed wearing surface shall be of hardened material and shall have a hardness difference of at least 50 BHN. Replaceable shaft sleeves shall be provided to protect the shaft where it passes through bearings and stuffing boxes. The end of the shaft sleeve assembly shall extend through the packing gland. Shaft sleeve shall be securely locked or keyed to the shaft to prevent loosening or rotation. Shaft and shaft sleeves shall be machined and assembled for concentric rotation. The design of the shaft shall take into consideration the critical speed, which shall be at least 20% away from operating speed. Pump bearings shall be of antifriction type. Bearings shall be readily accessible without disturbing the alignment of pump. Packed stuffing boxes shall be of sufficient length to prevent leakage along the shaft and shall be complete with all packing and lantern rings required. Pumps shall be furnished complete with an approved type of flexible coupling. Couplings guards made of expanded metal and bolted to the base plate shall be furnished. The common base plate for pumps and motor shall be in one piece and shall be made of fabricated steel. Pump speed shall be less than 1500 rpm for pumps of capacity more than 10 m3/hr.
c)
d)
e) f) g) h) i) j) k) 1.05.01.03 1.05.01.04 1.05.01.05
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. All rotating parts of the pumps shall be statically and dynamically balanced. The motor shall be rated for continuous operation and confirm to companion electrical specification. However, motor rating shall not be less than the max. power demand throughout the entire range of operation of pump. Design duty point of pump shall match with the average value of maximum and minimum flow rates of the pump in the stable operation zone.
1.05.01.06
CLAUSE NO.
1.05.01.07 1.05.02 1.05.02.01
Materials of construction of pump components shall be as stated in data-sheet to this section. Piping, Fittings, Valves and Specialties Piping & Fittings (a) (b) (c) Material of construction of piping and fittings shall not be inferior to those given in data sheet of this section. All piping shall be capable of withstanding the maximum pressure in the corresponding line at the relevant temperature. In general pipe sizes 65 mm NB and larger are to be joined by butt welding and pipe work of size 50 mm NB and below by socket welding/screwed connections. Joints at valves or specialities shall be flanged for sizes 65 mm NB or large and screwed for sizes 50 mm NB and below. All galvanised piping shall be joined by screwed connections. Minimum pipe diameter selected for DS/SW/PW/Cooling Water System (along with branch pipes) shall be 32 NB. However, for dry fog DS system, the minimum pipe size shall be 15 NB. End preparation for butt welding shall be done by machine/flame cutting. Socket weld and preparation shall be saw/machine cut. Hangers and supports shall be capable of carrying the sum of all concurrently acting loads. They shall be designed to provide the required supporting effects and allow pipe line movements as necessary. All guides, anchors, braces, dampers, expansion joints and structural steel to be attached to the building/structure, trenches etc. shall be provided. All piping shall be routed on ground on concrete pedestals and at road crossings, these shall be buried through hume pipes.
(d) (e)
(f) 1.05.02.02
Valves and Specialities (a) Valves & Specialities shall be used to start, stop or regulate the flow. All valves/specialities below 50 mm size in service water/dust suppression/ potable water lines should be plug type of proven make. All valves shall be suitable for most stringent service conditions i.e. flow, temperature and pressure under which they may be required to operate. Gate/sluice valves shall be used for isolation of flow of pipe lines above 50NB and Globe valves shall be used for regulating the flow. Valves shall be provided with back seating bush to facilitate gland renewal during full open operation.
(b) (c) (d)
CLAUSE NO.
(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. Valves shall be provided with the following as necessary : (1) (2) (3) Hand wheel Position indicator Draining arrangement.
(f)
(g) (h) (i)
Material of construction of valves shall not be inferior to those given in data sheet of this section. Globe valves shall be provided with contoured plug to have well controllability. 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. 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. Bib cocks provided for potable water system shall be made of Copper Alloy / Cast Iron.
(j)
(k)
(l) 1.05.03 1.05.03.01
Special cleaning, protection and painting Piping & Fittings (a) (b) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire brushing. For overground exposed steel pipes, one shop and one site coat of red oxide zinc phosphate and two coats of synthetic enamel finishing paints unless specified otherwise shall be applied. A minimum of 120 microns Dry Film Thickness (DFT) after finished coat of paint shall be ensured. For steel buried pipeline, three (3) coats of heavy duty bitumastic paint shall be applied on the cleaned surface. Finally, it should be wrapped with minimum 3 mm thick bitumen impregnated tar felt. The lap joint of the felt shall be generally touched with heavy duty bitumastic paint.
(c)
CLAUSE NO.
1.05.03.02
Pumps for DS/SW/CW/PW/DE systems shall be selected with minimum 10% margin on capacity and 20% margin on computed head.
CLAUSE NO.
DATA SHEET: DUST CONTROL & MISCELLANEOUS SYSTEM 1.0.0 1.1.0 1.2.0 GENERAL Dust Control Miscellaneous systems Dust suppression/ system extraction
Service water system, Potable water system, Cooling water system.
2.0.0 2.1.0 2.1.1 2.1.2 2.1.3
DESIGN REQUIREMENT Dust Suppression Operation Pumps Spray Head (i) (ii) Minimum No. of nozzles per spray head Pressure at inlet (dry fog) 4 (Four) Min. 0.5 kg/cm2 for water Min 5 kg/cm2 for air (iii) Pressure at inlet (Plain water) Minimum 2.5 kg/sq. cm Water sprayed through nozzles. 2x100% for water
2.3.0
Dry Fog Dust Suppression (i) (ii) Compressor No. of Compressors to be provided Screw Type One working & one Standby, per group One no. of min. 2 cu.m capacity located near compressors & 200 litres capacity at various location Dry fog type
(iii) Air receivers
(iv) Nozzles 2.6.0 2.6.1 Service Water System Water connections (a) (b) (c) Conveyor Galleries and tunnels Transfer points Crusher House
every 50 m Min. 1 no. at every floor Min. 2 nos. at every floor

CLAUSE NO.
2.6.2 2.6.3
Connection details Hose pipes with hose reel
32 NB plug valve One in each building of 25 mtr. Length with nozzle
2.7.0 2.7.1 2.7.2
Potable Water System Pumps Water connections a) (b) (c) Transfer points Crusher house Tripper floor Minimum one (1) no. at each floor Minimum two (2) no. at each floor Minimum one (1) no. at every tripper bay. Minimum one (1) connection at each machinery well in track hopper Minimum one (1) no. at each floor Minimum one (1) no. each Min. one (1) no. at each end. Min. one (1) no. 2 X 100% electric motor driven
(d)
Machinery wells
(e) (f) (g) (h)
Control room MCC rooms and toilets Track hopper Top Wagon tippler top
4.0.0 3.1.0
CONSTRUCTION REQUIREMENTS Water Supply Pumps for DS/SW/PW/CW Casing Axial or radially split with drain & vent connection One piece, keyed to shaft along with locking device Critical speed atleast 20% away from operating speed At bearings & stuffing boxes. Antifriction type Renewable type (preferable)
3.1.1
3.1.2
Impeller
3.1.3
Shaft
3.1.4 3.1.5 3.1.6
Shaft sleeves Bearings Wearing rings
CLAUSE NO.
3.1.7
Pump speed
Below 1500 rpm for capacity more than 10 cub. m/hr. Suitable for parallel operation.
3.1.8 3.1.9
Head flow characteristics Materials (a) (b) Casing Impeller
Cast Iron to IS:210, FG 260 Bronze IS:318 Bronze IS:318 Bronze IS:318 conforming to Gr.I of
(c)
Impeller Wearing ring
conforming
to
Gr.I
of
(d)
Casing Wearing ring
conforming
to
Gr.I
of
(e) (f)
Shaft Shaft sleeve
Medium carbon steel Stainless steel conforming to AISI416 hardened. Impregnated teflon
(g) 3.3.0 3.3.1
Gland packing
Pipings & Fittings Joints (i) Pipe to pipe Pipe size < 50 NB Pipe size > 65 NB (ii) Pipe to valves Pipe size < 50 NB Pipe size > 65 NB Socket welding/screwed Butt welding
Screwed Flanged Plug / Gate / Sluice valves Globe Valve
3.3.2 3.3.3 3.3.4
Isolation of flow Regulation of flow Valves (i) Size > 65 NB
Bolted bonnet outside screw rising type. Union bonnet with screwed ends for Globe valve & screwed ends for plug valve
(iii)
Size < 50 NB
3.3.5
Materials for Pipework

CLAUSE NO.
(a)
For sizes 200 NB and Larger
ERW carbon steel pipes to API-5LGr.B/IS:3589 with minimum thickness 6.35 mm ERW carbon steel black pipes to IS:1239 (Part-Heavy class).
(b)
For sizes 150 NB to 65 NB
(c)
For sizes below 65 NB
ERW carbon steel galvanized pipes to IS:1239 (Part-I) Heavy class.
3.3.6
Materials for Valves & Specialities (a) (i) (ii) Cast Iron Valves Body and bonnet Disc for non- return 65 NB and above Cast Iron to IS:210, Gr.FG-200 Cast Iron to IS:210, Gr.FG-200 valves 13% chromium steel Stainless steel type AISI-316 13% chromium steel 13% chromium steel
(iii) (iv) (v) (vi) (a)
Seating surfaces and rings Hinge pin for non return valves Stem for gate and globe valves Back seat bush Gun metal valves (50 NB & below and upto a working pressure of 10 kg/cm2) Body Trim Duplex Strainer Body Strainer
(i) (ii) (b) (i) (ii)
Gun metal to IS:318, Gr-2. Gun metal to IS:318, Gr-2.
MS fabricated Stainless steel type element AISI316
(c)
Pressure Gauge/Switch (to be provided with isolating valves, gauge cock, snubber and syphon) Dial size 150 mm
(i)
CLAUSE NO.
(ii) (iii) (iv) (v) (vi)
Accuracy Bourdon Block Movement Case and Bezel
(+/-) 1% of range span AISI 316 SS AISI 316 SS AISI 316 SS Die cast Alum. Weather proof case stove enameled block with screwed type inner bezel of ABS plastic and glycerin filled. 2 NO + 2 NC Adjustable throughout the range. IP. 65
(vii) (viii) (ix) (d)
No. of contacts Type of contact Degree of protection Solenoid valve (to be provided with isolating valve) Type
(i)
2/2 way Diaphragm type pilot operated molded synthetic rubber Forged brass / SS 0.5 to 10 kg/cm2 IP 65
(ii) (iii) (iv) (v) (e)
Diaphragm Body Pressure Protection Class Flow Switch (to be provided with isolating valves) Body Extension Rod/wire Sleeve and Sleeve pipe Cover Max. working pressure Repeatability No. of contacts
(i) (ii) (iii) (iv) (v) (vi) (vii)
Forged steel SS-304 SS-304 Die cast aluminum 10 kg/sq.cm 0.5% 2 NO + 2 NC

CLAUSE NO.
(viii) (ix) (f) (i) (ii) (iii) (iv)
Type of contact Protection class Level Switch Type Displacer Wire rope Spring Housing sleeve pipe Cover No. of Contacts Spring
Adjustable throughout the range. IP 65
Displacer operated magnetic type SS 316 SS 316 and SS 316
(iv) (v)
Cast Aluminum 2 NO + 2 NC
(vi) (viii) (g) (i)
Type of Contact Protection class Level gauges Type
Adjustable throughout the range. IP 65
Float type mechanical gauge with arrow scale (+/-)1% of full scale range
(ii) (iii) (aa) (bb) (cc) (dd) (h)
Accuracy Material of construction Float & Guide wire Elbows Housing Cable fastener Plain water Dust Suppression Nozzles Type Material Nozzle housing Y Strainer
316 SS Suitable grade of SS Mild Steel SS 304
(i) (ii) (iii) (i)
Fogging, non-clogging type Stainless Steel To ensure protection of nozzle against damage.
CLAUSE NO.
(a) (b) (c)
Body Plug Filter Element
SS 304 SS 304 SS 316, 60 mesh
CLAUSE NO.
A-09: VENTILATION SYSTEMS 1.00.00 1.01.00 GENERAL 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 CHP. 1.01.01 The Contractor shall refer to the other sections enclosed to appraise himself of the work and scope of supply of the other Contractors and shall coordinate his work with the work of other Contractors. GENERAL DESCRIPTION Mechanical Ventilation system The air quantity for mechanical ventilation system shall be estimated based on equipment and solar heat loads and the temperature rise inside the building. Necessary air filters shall be provided to supply only clean air into building. Exhaust air shall be discharged at a suitable height above building. Exhaust fans shall be provided for tripper floor, Toilets, Battery rooms. All underground structure shall be provided with supply air as well as exhaust air fans. 1.02.02 Pressurised Ventilation System The pressurised ventilation system having adequate nos. of supply air fans with washable metallic pre filters, HDPE fine filters, and self closing flap (gravity louver shutter), ducting along with 3 phase AC motor drives, electricals, supporting structures, access / maintenance platforms shall be provided in all MCC/switchgear room areas of coal handling plant to be furnished under this specification. The pressurized ventilation system shall be designed considering 15 air changes per hour to maintain these areas pressurised slightly above atmospheric pressure to prevent ingress of dust from outside. 1.02.03 Air Conditioning System Air conditioning system shall be furnished for control room area of main CHP control building, office room in main CHP control room and in electrical buildings. It shall be designed considering the equipment heat loads, solar heat loads, heat gain into the room, adequate no. of air changes etc. to maintain a uniform temperature and relative humidity within the air conditioned areas.
1.02.00 1.02.01
SUB-SECTION-IIIA-09 VENTILATION SYSTEM
PAGE 1 OF 11
CLAUSE NO.
1.03.00 1.03.01
VENTILATION AND AIRCONDITIONING SYSTEM Mechanical Ventilation System Exhaust fans shall be provided for tripper floor, Toilets, Battery rooms. The exhaust fans for toilets and battery rooms will be propeller type
1.03.02
Pressurised Mechanical Ventilation System The ventilation system generally consisting metallic pre filters, HDPE fine filters, ducting electricals, supporting structures, approach shed, civil & structural works and necessary MCC/switchgear rooms. of adequate number of supply fans, along with 3 phase AC motor drives, / maintenance platforms, necessary accessories shall be furnished for all
1.03.03 1.03.03.01
Air Conditioning System 2x100% capacity air conditioning packaged units (PAC) with air cooled condensers shall be provided for Main Control Room, office room of Main Control Room & various MCC Rooms as specified elsewhere in spec. complete with supply and return air ducting. Supply and return air distribution ducting complete with insulation, of resin bonded mineral wool equivalent of density at least 24 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. Area around centrifugal fans, filters, motor foundation shall be paved to have a clear surrounding. Codes & Standards The design, manufacture, inspection and testing of Ventilation & A/C System shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Ventilation & A/C System shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. IS:3588 : Specification for electrical axial flow fans. IS:2312 :Propeller type AC Ventilation fans IS:3963 :Specification for roof-extractor units
1.03.03.03
1.03.03.04
1.04.00
PAGE 2 OF 11
CLAUSE NO.
IS:4894 :Centrifugal Fans IS:655 :Specification for Metal Air Duct ARI:210 :Standard for Unitary air conditioning equipment. ARI:270 :Standard for application, installation and servicing of unitary equipment. IS:8183 :Specification for bonded mineral wool. IS:661 :Thermal insulation for cold surfaces. IS:4671:Expanded polystyrene for thermal insulation purpose. IS:8148 :Packaged Air conditioners. 1.05.00 1.05.01 1.05.02 DESIGN REQUIREMENT Axial Fans Design duty point of the fan shall match with the average value of maximum and minimum flow rates of the fan in the stable operation zone. The speed of the fan shall not preferably exceed 960 rpm for fan with impeller diameter above 450 mm and 1440 rpm for fan with impeller diameter 450 mm and less. The first critical speed of rotating assembly shall be at least 25% above operating speed. Impellers shall be axial flow type single piece. Centrifugal Fans The fan units shall be centrifugal type with radial bladed impeller. purpose out door ambient temperature shall be taken as 50 deg.C. For design,
1.05.03 1.05.04 1.05.05
1.05.06
Fans shall be manufactured vibration free in operation and shall be designed to limit noise level within limits specified in Data Sheet. The motor shall be rated for continuous operation and conform to companion electrical specification. However, motor rating shall not be less than the max. power demand throughout the entire range of operation of fan. All fan mountings shall have adequate arrangement for vibration isolation. The reverse flow through non-working fan shall be prevented by dampers. The dampers shall be made out of 18 SWG MS sheets. Design duty point of the fans shall match with the average value of maximum and minimum flow rate of the fan in the stable operation zone.
1.05.07
1.05.08 1.05.09
1.05.10
PAGE 3 OF 11
CLAUSE NO.
1.05.11 1.05.12
Filters Metallic Filters Metallic cleanable filters shall be provided as required. Max. air velocity considered shall be 2 m/sec.
1.05.13
HDPE Filters HDPE filters should have an efficiency of 90% down to 5 microns. Velocity across the filter shall be limited to 2.5 m/sec.
1.05.14
High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99% down to 5 microns. Pr. drop across the filter under clean condition shall not be more than 10 mm w.c. Packaged Air-Conditioning Unit PAC units shall be provided as required.
1.05.15
1.05.16
PAC units shall be factory tested and assembled self contained units complete with refrigerant compressor, coils, fans, insulation and wiring. Various parts of PAC units wherever required shall be insulated with expanded polyethylene conforming to IS:4671. The PAC unit shall comprise of an evaporator (indoor air) blower section and an air cooled condenser (outdoor air) section. Heavy gauge steel cabinet finished with paint of approved colour, shall be used to house components of PAC. The evaporator and condenser coils shall be arranged for direct expansion cooling and shall be formed of aluminum fins mechanically bonded to seamless copper tubes and electrically tinned. The inter-connecting refrigerant circuits shall comprise of hermetically sealed scroll compressor and motor with all necessary isolation valves, with adjustable set point, sight glass, copper tubing and pipeline ancillaries. The condenser coils shall be air cooled by propeller type fans complete with safety guards. The condensing coils shall be suitably arranged to avoid radiant heat pickup from solar sources. Condenser capacity control shall be provided by means of fans and head pressure sensing. The evaporator air blower(s) shall be centrifugal forward curved type belt driven by individual motor(s) and suitable for the external static pressure. The fan assembly shall be isolated from the casing by anti-vibration mounts. The fan/motor drive shall be capable of capacity adjustment by pulley changes within +15% of design duty.
1.05.17
1.05.18
1.05.19
1.05.20
PAGE 4 OF 11
CLAUSE NO.
1.05.21
High efficiency filters shall be provided in the main supply air duct and in the fresh air connection to return air duct. Construction Requirements General construction details of various equipment under Contractors scope shall be as elaborated in subsequent clauses below. Axial Flow Fans Axial flow fans shall be provided as required.
1.06.00 1.06.01
1.06.02
1.06.03
Impellers shall be axial flow type and single piece cast aluminum with aerofoil blades construction. It shall be finished all over and balanced dynamically. Impeller shall be mounted directly on the motor shaft. 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. Rain protection cowls will be designed to suit wall exhausters/supply fans for protecting fans/motors from rain. It will be provided with bird screen. Inlet cone or bell and outlet cone shall be provided as required. It should be made of G.I. or M.S. Motor shall be of totally enclosed type complying with the companion electrical specification. Suitable rain/sun shade for motors shall also be provided. Centrifugal Fan Centrifugal fans shall be provided as required.
1.06.04
1.06.05 1.06.06 1.06.07 1.06.08
1.06.09
The casing shall be of welded construction fabricated with heavy gauge material. It shall be rigidly reinforced and supported by structural angles. The seams shall be permanently sealed airtight. Split casing shall be provided on larger sizes of fans. Casing drain with valves shall be provided wherever required. The impeller shall have die formed curved blades fabricated out of MS heavy gauge welded to the rim and back plate to have a non overloading characteristics of the fan. Rim shall be spun to have a smooth contour. If required intermediate stiffening rings shall be required. The impeller, pulley and shaft sleeves shall be secured to the shaft by key and/or nuts. The impeller along with driven pulley shall be dynamically balanced. Fan shaft shall be of EN-8 equivalent.
1.06.10
PAGE 5 OF 11
CLAUSE NO.
1.06.11
The bearings shall be self-aligning heavy-duty ball or roller bearings. They shall be adequately supported. They shall be easily accessible and lubricated properly from outside. Filters Metallic Filters Metallic cleanable filters shall consist of V-fold galvanised wire mesh inter spaced with a flat layer of galvanised wire mesh. The density of the filter medium shall increase in the direction of airflow. Wire mesh edges shall be suitably hemmed to eliminate the danger of abrasion during handling. Filter medium shall be supported on either side by galvanised expanded metal casing. Filter frame shall be constructed from galvanised sheet of thickness not less than 18 gauge.
1.06.12 1.06.13
1.06.14
HDPE Filters HDPE filters shall be provided as required. To facilitage periodic cleaning of filters by water washing, tap of service water connection near the filters shall be provided.
1.06.15
High efficiency filter (for A/C purpose) The media of the filter shall be made from either special synthetic non-woven bond fiber design or made from micro fiber glass media. It shall be supported with GI wire mesh or aluminum mesh and shall be housed in an aluminum sheet frame. It shall be of washable type several times.
1.06.16 1.06.17
Package A/C Unit A separate cubicle shall be provided within the overall casing to house the thermostatic controls, which shall be electric/electronic solid state, prewired and tested. The refrigerant system shall be protected by pressure limiting devices, electric and thermal overloads and unloading facilities to provide the required control range tolerances. A low voltage room thermostat or RTD based temperature sensing device shall be provided for wall mounting. The casing shall be fitted with all necessary coil drains and service connections/ entries. PAC (duty/standby) units shall be selected manually and be ON/OFF switched. The units shall be fully packaged and incorporate integral room air sensing control thermostats and manufacturers work fitted safety interlocks. All controls shall be prewired to unit mounted control/power terminal boxes. Ventilation and Air Conditioning system ducting All GI sheet metal ductwork required for ventilation and air conditioning system shall be furnished by the supplier. All ducts and plenums unless otherwise noted shall be constructed out of standard quality galvanised steel sheet. All sheet metal ducts
1.06.18
1.06.19
PAGE 6 OF 11
CLAUSE NO.
shall be fabricated and installed in conformity to the requirements of IS:655. Steel supports for the ductwork shall be furnished as required. The thickness of ducting steel shall be 1 mm min. For ducting with large size exceeding 1300 mm it shall be 1.25 mm. The flexible connection between fan and ducting shall be on teflon impregnated canvas. The zinc coating on GI sheet shall be 275 gm/m2.
PAGE 7 OF 11
CLAUSE NO.
DATA SHEET: VENTILATION SYSTEM 1.0.0 1.1.0 GENERAL Mech. Ventilation System To provide ventilation using fans for specified areas.
1.1.1
No. of air changes per hour For overground building Not less than 10 supply air changes
1.1.2
Equipment (1) Underground tunnel (2) All other places Centrifugal fans/Axial Fans Axial fans, roof ventilators To provide clean air to all MCC / Switchgear buildings Not less than 15 Centrifugal fans/Axial Fans
1.2.0
Pressurised ventilation system
1.2.1 1.2.2 1.3.0 1.3.1 1.3.2 1.3.3
No. of air changes per hour Equipment Air-conditioning system Temperature to be maintained Humidity to be maintained Fresh Air intake
24 1 deg. C 60 5% relative humidity Minimum 1.5 air changes per hour. 2 x 100 % roof mounted package AC units along with ducting etc. As per weather data given in project synopsis
1.3.4
Equipment
1.4.0
Outside Ambient Conditions
2.0.0 2.1.0 2.1.1
DESIGN & CONSTRUCTION Roof Ventilators Capacity 10% more requirement of actual
PAGE 8 OF 11
CLAUSE NO.
2.1.2
Head
20% more requirement
of
actual
2.1.3
Speed (a) (b) (c) Impeller dia above 450 mm Impeller dia less than or equal to 450 mm Critical speed Max. 960 rpm Max. 1440 rpm 25% above operating speed.
2.2.0 2.2.1
Axial Fans Capacity 10% more requirement 20% more requirement of actual
2.2.2
Head
of
actual
2.2.3
Speed (a) (b) (c) Impeller dia above 450 mm Impeller dia less than or equal to 450 mm Critical speed Max. 960 rpm Max. 1440 rpm 25% above operating speed.
2.3.0 2.3.1
Centrifugal Fans Capacity 10% more requirement 20% more requirement Max. 1500 rpm 50 deg. C. Continuous of actual
2.3.2
Head
than
actual
2.3.3 2.3.4 2.3.5 2.4.0 2.4.1 2.4.2
Speed Outdoor temperature Rating Packaged Air-Conditioning Unit Type Service/application clock. Capacity
Roof top mounting Continuous, round the
2.4.3
PAGE 9 OF 11
CLAUSE NO.
(i) (ii) 2.4.4
TR CFM
Suitable Suitable Hermetically compressor Air cooled type Forward curved centrifugal fan High efficiency filter sealed scroll
Type of compressor
2.4.5 2.4.6
Condenser Fan
2.4.7 2.4.8
Filter Cooling Coil (a) (b) (c) Type Material Fins
Direct Expansion Copper Aluminum mechanically bonded. Copper Expanded polyethylene of density at least 15 kg/cub.m.
2.4.9 2.4.10
Refrigerant Piping Insulation for PAC parts
2.5.0 2.5.1.
Filters Metallic Filters (1) Max. air velocity 2m/sec.
2.5.2
HDPE filters (1) (2) (3) Efficiency Max. velocity Testing 90% down to 5 microns 2.5 m/sec. As per BS 2831 / Sqv.
2.5.3
High Efficiency Filter (1) (2) (3) Efficiency Pr. drop across Testing
99% down to 5 microns. 10 mm W.C. As per BS 2831 / Sqv.

SUB-SECTION-IIIA-10 VENTILATION SYSTEM PAGE 10 OF 11
CLAUSE NO.
2.6.0
Insulation for A/C Ducting Resin Bonded Mineral wool as per IS:8183 Density Thermal conductivity 24 kg/cub.m 0.49 mw/cm deg.C
2.6.1 2.6.2
PAGE 11 OF 11
CLAUSE NO.
A 10: CHP BUILDINGS 1.00.00 GENERAL Various buildings in coal handling plant like transfer houses, crusher house, control rooms, MCC rooms complete with all associated civil foundations and other civil, structural and architectural works shall be provided by the Contractor as per the specification. Construction/fabrication/erection and designing aspects of various buildings shall be as per the Civil/Structural specifications. 1.01.00 Codes and Standards The design and construction of CHP Buildings shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The CHP Buildings shall conform to the latest edition of the Indian standards and codes. Other internationally acceptable standards/ codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standards and this specification, the decision in the Employer shall be final and binding. 1.02.00 1.02.01 Design Requirements All CHP buildings shall have sufficient space to accommodate the entire equipment like head end, drive unit and tail end of various conveyors, crushers, hoppers, chutes, control equipments, MCCs, batteries, supports for conveyor bridges, tensioning arrangements, approach/maintenance platforms with ladders, external / internal stairs, handrails, RCC floors, foundations etc. Moreover, ample space shall be provided for maintenance purposes. Outside stairs to transfer points and crusher house shall be open type. However, a weather canopy shall be provided at the top. Mechanical Handling arrangements with adequate monorails etc. shall be furnished for servicing and installation of various housed equipment as described elsewhere. Building floors shall be washed periodically with water for which necessary slope & drains shall be provided from each floor leading to minimum 4 nos down comers of minimum 273mm OD each building. However for MCC, control buildings and pump houses, minimum 150 mm dia, 4 nos galvanized MS pipes conforming to IS :1239 shall be provided. The system shall be designed considering water mixed with coal. A drain pit shall be provided near each building to collect water/coal mixture. Overflow from this pit shall be connected to nearest drain. 1 mtr x 1 mtr size dust/debris MS chutes from all the floors to ground floor shall be provided at all buildings/transfer houses and crusher house. The plate thickness shall note be less than 6mm. Various dimensions and relative elevations shown in tender drgs. for various buildings/structures are minimum acceptable to the Employer. However, final dimensions for various buildings/structures and relative elevations shall be decided
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-10 CHP BUILDINGS PAGE 1 OF 5
1.02.02
1.02.03
1.02.04
CLAUSE NO.
based on actual details/maintenance requirements of contractors equipment to meet technical specification requirements without any implication to the Employer. The sizes of these houses shall be approved by the Employer at the stage of detailed employer. Openings in the floors of CHP buildings (i.e. TPs etc.) shall be provided with curb of 100mm high to avoid water falling down to lower floors. 1.02.05 1.02.06 Vertical bracings in transfer points shall be provided only along four sides. bracing system projecting outside the building shall be allowed. No
Floor at ground shall be provided in all transfer points, ground conveyors etc. Level of floor at ground shall be 500 mm above ground/grade level unless noted otherwise. For enclosed ground conveyor 750mm wide plinth protection along with drainage arrangement shall be provided along the conveyor on both sides. Suitable opening at every 50mtr interval shall be provided on either side in a staggered manner for exit / entry of personals. Necessary drains must be provided all along the floors of ground conveyor. The accessories for dust control & miscellaneous system like water pumps etc. shall be housed in separate pump houses. For areas where ground floor is located less than 500 mm above ground level/grade level, outside face of the brickwalls shall be plastered with rich cement-sand mortar (1:4) with neat cement finishing over it for a height of 500 mm above ground level/grade level. Toilet with potable water facilities shall be provided in all MCC Control Rooms, and potable water shall also be provided at all transfer houses, Necessary facilities for ventilation of control/MCC rooms, shall be provided as specified elsewhere. External fire escape stair case alongwith internal staircase(wherever applicable) shall be provided for all MCC/ control rooms & Crusher house. 5 mtr wide paving beyond the surface drains shall be done around all transfer points, Crusher house for movement of trucks. The approach for trucks should be provided around transfer point, crusher house and upto hoist lifting area. All building shall have the fire protection provisions to meet TAC and IS 3034 regulations. Construction Requirements Junction Houses All overground buildings shall be of steel frame construction. All underground & partially underground structures shall be entirely in RCC.
1.02.07 1.02.08
1.02.09 1.02.10 1.02.11 1.02.12
1.02.13 1.03.00 1.03.01 1.03.02 1.03.03
SUB-SECTION-IIIA-10 CHP BUILDINGS
PAGE 2 OF 5
CLAUSE NO.
1.03.04 1.03.05
External staircases shall be provided for all transfer points. The transfer houses shall have permanently colour coated steel sheet enclosure with steel framed doors and louvered windows. Control / MCC Rooms Control rooms, MCC rooms shall be of RCC construction with Brick enclosure. Fire safety wall in/around transformer yards shall be as per detailed engineering. MCC/Switchgear rooms shall be kept pressurised with dust free air by way of pressurized ventilation. Office room and Control Rooms shall be provided with PAC (Packaged Air Conditioning) units. Air-conditioned areas of CHP buildings shall have double glass windows. Roofs/sidewalls shall be provided with insulation to minimise the heat load. All frames of doors and windows shall be of extruded aluminum and shall be capable of isolating the conditioned space. All AC Control rooms & MCC rooms shall have double door entry.
1.04.00 1.05.01
1.05.02
1.05.03
PAGE 3 OF 5
CLAUSE NO.
DATA SHEET : CHP BUILDING 1.0.0 1.1.0 GENERAL Underground/partially underground Transfer Houses Overground Transfer Houses, Crusher House Control/MCC rooms & S&T room DESIGN & CONSTRUCTION REQUIREMENT Junction Houses Space requirement To accommodate all equipments drive units, head/ tail ends of conveyors transfer chutes etc. and to provide adequate space for maintenance. RCC construction with facility to wash the floors. Min. slope of 1:80 for floors in JHs and 1:100 for floors in crusher house shall be provided towards drain pipes. Permanently colour coated cladding Steel construction with minimum 1000 mm width. Steel construction Capacity as per equipment installed From each floor to drain pit suitable to handle coal slurry. Only along four sides. Chequered plate floors Min.1500 mm wide 50 mm thick metallic hardener like ironite floor finish. 500 mm above ground level.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-10 CHP BUILDINGS PAGE 4 OF 5
RCC Construction
1.2.0
Steel Construction
1.3.0 2.0.0
RCC construction
2.1.0 2.1.1
2.1.2
Floors
2.1.3 2.1.4
Walls/Enclosure Stairs
2.1.5 2.1.6 2.1.7
Doors & Windows Monorails Drainage
2.1.9 2.1.10 2.1.11
Vertical bracing Maintenance platform with handrails. Flooring
2.1.12
Level of ground floor
CLAUSE NO.
2.2.0 2.2.1 2.2.2 2.2.3
Control/MCC Rooms Construction MCC Rooms Control Rooms RCC construction with Brick Enclosure Pressurised with dust free air Air conditioned Environment
PAGE 5 OF 5
CLAUSE NO.
A11: IN-LINE MAGNETIC SEPARATOR

1.00.00 GENERAL Inline Magnetic Separators shall be provided for continuous and automatic extraction and discharge of tramp magnetic pieces from coal being discharged from conveyors as specified. The sets shall be complete in all respects with drives, magnets, inline belts, hoppers, chutes, tramp-iron boxes and all electrical ancillaries like control panels etc. 1.01.00 CODES & STANDARD The design, manufacture, inspection and testing of In line Magnetic Separators shall comply with all the currently applicable statutes, regulations and safety codes in The Magnetic Separators shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Engineer shall be final and binding. 1.02.00 1.02.01 1.02.02 DESIGN REQUIREMENT Inline Magnetic Separator Magnet core material shall be pure annealed iron or equivalent high permeability magnetic material. The coil shall be of aluminum wire with class H insulation, to limit the absolute temperature of the winding to 140 deg. centigrade. The oil used for cooling the ILMS shall be silicon based. The Force Index i.e. the product of flux density in gauss and rate of change of flux density w.r.t. distance, at the bottom of falling material trajectory shall be 100,000 (gauss x gauss/inch) minimum in hot condition for mounting height of 400 mm in the conveyors carrying crushed coal. However, the strength of the magnet shall not be less than 1000 gauss in hot running condition at distance of 400mm in the conveyors carrying coal. The minimum strength of the magnet shall be 1000 gauss at the specified mounting height at the centre of Belt width. Contractor shall select magnet width to suit above. Mounting height of 400 mm in the conveyors carrying coal shall be taken between top of conveyor belt or bottom of falling material trajectory and the surface of magnetic separator belt. Characteristic curve of magnet with the value of flux density varying between 50 mm to face of conveyor belt shall be provided. The cross section of magnet shall be suitably designed to provide sufficient area for magnetising the coil effectively covering full cross section of the discharge material. The magnetic separator shall be located such that it picks-up tramp iron from coal trajectory after it has been discharged from head pulley.
1.02.03
SUB-SECTION-IIIA-11 IN LINE MAGNETIC SEPERATOR
PAGE 1 OF 4
CLAUSE NO.
1.02.04
The tramp magnetic pieces buried under coal picked up by the magnetic separator shall be discharged suitably to ensure that it falls into the tramp iron chute, which shall be provided upto ground level. All conveyors with magnetic separator at head end shall have non-magnetic SS pulleys. Head pulleys of all conveyors with in line magnetic separator at head end shall be provided with SS shell and end disc. However, hub and shaft shall be of same materials as in other pulleys. (EN-8 or equivalent). The motor and the gear reduction unit for driving the in-line belt shall be adequately sized with minimum 20% margin to avoid any over loading during operation. Suitable zero speed switch shall be provided. No Chain/belt drives shall be accepted. The belt shall be designed to withstand high temperature at the bottom of the magnet and any serious damage due to the impact of the sharp edges of the tramp iron. The belt shall be provided with rubber cleats spaced suitably. The belt shall be of fire resistant grade. For other details of belt, refer belt specification as specified else where. Side rollers shall be provided to keep the belt aligned. The idlers and the pulleys supporting the belt shall be manufactured to the best engineering practices and shall conform to relevant Indian Standards. For details of idlers & pulleys, refer specification as specified else where. CONSTRUCTION REQUIREMENT In-line Magnetic separator The magnetic separator units shall be supported by suitable structural member from the top by taking support from the operating floor beams with turn buckle arrangement to facilitate the necessary adjustments during operation. Further, electric Hoists operated cross travel arrangement shall be provided to move magnetic separator away to facilitate maintenance of the conveyor discharge pulley/Belt. ON/OFF control push buttons with indicating lamps shall be provided at the local station. The materials of chutes and hoppers associated with magnetic separators above the drive floor shall be SS-304 in the magnetic zone. Other chutes shall be of 1 mtr. sq. dimension and shall be made of MS. chutes shall have poking doors at all floors to clear jammed material. Suitable arrangements shall be provided in the magnet for keeping the coil of the magnet dry from atmospheric condensation when the magnetic separator is not in use. Protection against high oil temperature in magnet shall be provided.
1.02.05
1.02.06
1.02.07
1.03.00 1.03.01 1.03.02
1.03.03
1.03.04
1.03.05
PAGE 2 OF 4
CLAUSE NO.
DATA SHEET : ILMS 1.0.0 1.1.0 2.0.0 2.1.0 2.1.1 2.1.2 2.1.3 GENERAL Type DESIGN & CONSTRUCTION In-line Magnetic Separator Location of ILMS Force index (As defined earlier) Over discharge pulley. Minimum 100,000 In line type as specified.
Strength of magnet at the specified mounting 1000 gauss. height Mounting height Mounting height of In Line Magnetic Separator shall be 400 mm in the conveyors carrying coal (between top of conveyor belt & surface of magnetic separator)
2.1.4
2.1.5
Magnetic Separator Belt (i) Drive Unit Adequately sized with 20% margin. Suitable to withstand high temp. & impact of tramp iron. (FR Grade) Into Tramp iron chute.
(ii)
Belting
(iii) 2.2.0
Discharge
Tramp Iron Items (i) MS cube of 20 mm size
(ii)
Brake shoe of Railway Wagon (Cast Iron 15 Kg.) MS plate of 250 x 250 x 100 mm size. Shovel Teeth and spikes. Material Carbon Steel
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-11 IN LINE MAGNETIC SEPERATOR PAGE 3 OF 4
(iii) (iv)
CLAUSE NO.
Size (v) MS round bar of 50 Kg with L/D ratio not exceeding 5.
Typical
2.3.0
Control Inline Magnetic Separator Local and remote Silicon Rectifier units Nearby control/MCC room
2.4.0 2.5.0 2.6.0
Electric Supply 415V, 3 phase, 50 Hz input Location of silicon rectifier unit Handling Arrangement for inline Magnetic separator (a) (b) Height adjustment Cross-travel
With turn buckle arrangement Electric Hoist operated cross travel facility.
PAGE 4 OF 4
CLAUSE NO.
A12: METAL DETECTOR

1.00.00 GENERAL Metal detectors shall be provided at specified location to detect metallic objects in the coal stream. 1.01.00 CODES AND STANDARDS The design, manufacture, inspection and testing of Metal Detectors shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Metal Detectors shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. 1.02.00 1.02.01 DESIGN REQUIREMENT Metal detectors shall have high reliability with enough sensitivity to detect 25mm aluminum sphere below the burden of coal in case of synthetic belting. However, for steel cord belting the sensitivity shall be 35mm. It shall also detect other metals, like brass, copper, stainless steel, manganese steel, bars, scraps etc. The equipment shall have provision for automatic static calibration with adjustable sensitivity. Metal detectors shall be completely solid state using latest state of art technology. It shall be suitable for 50C ambient and RH of 100%. The search sensor shall be protected from rain and direct sunlight by means of a non metallic covering other than wood. Control unit shall have adjustable controls for sensitivity, ON/OFF push buttons, resettable operation counter, audio-visual alarms local remote selector switch and all other necessary controls for trouble free operation of metal detector. It shall be suitable for mounting on wall, column, structure etc. with IP-65 Degree of protection. It shall be constructed from FRP of thickness not less than 2mm. The metal detectors shall also have the following features : (a.) The coils shall be protected against being struck by an oversized material/coal. The coils should have adjustment for magnetite/iron in incoming coal. It should ignore magnetite/iron and shall distinguish between metal pieces and magnetite/iron. (b.) In order to counteract interference from external sources such as motors, lightning and radio-transmitters, and to nullify the effect of climate changes/aging, dual receiver coils are to be used.
1.02.02
1.02.03
1.02.04
SUB-SECTION-IIIA-12 METAL DETECTOR
PAGE 1 OF 3
CLAUSE NO.
(c.)
In order to allow passing of steel cord belt and metal belt fasteners without giving alarm and at the same time detecting tramps, suitable arrangements shall be provided.
(d.) In case a few non-magnetic idlers or non magnetic deck plates are required, the Contractor shall provide these. However, these shall be metallic. Wood is not to be used. (e.) LED display of COAST COUNT to indicate the number of pieces of tramp iron detected since last reset shall be provided so that the operator is alerted for the pieces of tramps, if any, between tramp marker and coil before restoring conveyor. (f.) TOTAL COUNT, which is not resettable, shall also be provided on the same LED display on demand.
(g.) The location of tramp metal pieces shall be indicated by sand bag marker. 1.03.00 1.03.01 CONSTRUCTION REQURIEMENT Fiber glass enclosure (with IP 65 degree of protection) shall be provided for all type of coils. Sand bag markers shall be provided. Local control panel shall be provided with IP:65 degree of protection.
1.03.02 1.03.03
PAGE 2 OF 3
CLAUSE NO.
DATA SHEET : METAL DETECTOR 1.0.0 1.1.0 2.0.0 2.1.0 GENERAL Type DESIGN & CONSTRUCTION Sensitivity 25 mm aluminum sphere below coal for synthetic belting. 35mm Aluminum sphere below coal for steel cord belting. Coil type
2.2.0 2.3.0 2.4.0
Enclosure Control Calibration
Fiber glass Through local control panel. Provision for automatic static calibration with adjustable sensitivity.
PAGE 3 OF 3
CLAUSE NO.
A13: COAL SAMPLING UNIT

1.00.00 GENERAL a) Coal Sampling Unit shall be complete with necessary samplers, crushers, flap valves, chutes, hoppers, belt feeders and sample collectors etc. to give samples from any of the two streams running at guaranteed capacity. Bidder shall source coal sampling system from a manufacturer / supplier who has engineered and supplied two (2) numbers of coal sampling systems for sampling coal / other bulk mineral from conveyor of 1000 MTPH and above and working successfully for two years as on date of bid opening.
b)
1.01.00
CODES AND STANDARDS The design, manufacture, inspection and testing of Coal Sampling Unit shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Coal Sampling Unit shall conform to the latest edition of standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Employer shall be final and binding. ASTM-D-2234 :Standard Methods for collection of a Gross Sample of Coal. ASTM-D-2013 :Standard Method of Preparing Coal Samples for Analysis.
1.02.00 1.02.01 1.02.02
DESIGN REQUIREMENT Coal sampling unit shall be automatic & provided at place specified elsewhere. The coal sampling units suitable to give Samples conforming to ASTM-D-2234 shall be selected by the Contractor for taking samples from any of the two streams running at guaranteed capacity. The different Equipment selected for coal sampling unit shall be such that there shall be no loss of fines and moisture from the samples. The capacity, make and model of all equipments of coal sampling unit shall be subject to approval of Project Manager. The normal input feed size shall be considered as (-) 50 mm for coal sampling unit. However occasionally (-) 100 mm lumps may also arrive. Primary samplers (separate for each conveyor) shall be rugged, able to withstand severe shock loads and operate trouble free. Belt feeders shall be provided for entire sampling path upto sample collector. The feeders shall meter the flow accurately, produce a non-plugging condition and resist sticky and wet coal.
TECHNICAL SPECIFICATIONS SECTION-VI PART-B SUB-SECTION-IIIA-13 COAL SAMPLING UNIT PAGE 1 OF 3
1.02.03
1.02.04
1.02.05
CLAUSE NO.
For rejects path also, belt feeders shall be preferred. Screw conveyors for the same shall be accepted only where space constraints do not permit distribution of coal rejects to receiving conveyors below. 1.02.06 Sample crushers (make subject to Employers approval) shall be provided for reducing the main input feed coal to 95% minus 8 mesh size and 100% minus 4 mesh size. Single stage crushing shall be provided. There should be no recirculation of fines in the crushers. Lot size shall be equivalent coal quantity handled in 8 hours operation assuming average conveyor loading at 75% of rated conveyor capacity. However sampling system shall also be suitable for taking one gross sample for each lot of 3500 Te coal (approx. equal to one rake load). CONSTRUCTION REQUIREMENT The traversing mechanism and all electric parts shall have dust tight protection. Belt feeders shall be positively self cleaning and have dust tight construction. It shall be provided with flanged belt, rubber lagged head pulleys and inspection doors. No chain/belt drives shall be accepted. The crushers base should be built of reinforced concrete and be sufficiently large in mass. The primary / secondary samplers shall be of dust tight construction and self contained type. The sample chutes shall have minimum valley angle of 60 degrees to horizontal and shall be of stainless steel plates. The chutes shall be suitable to handle wet sticky coal as specified elsewhere. The welding of chutes shall be done externally only. The inside surface of the material near welds shall be smooth. Radius at corners not less than 1" shall be provided in chutework. All solid connected members shall be by means of bolting flanges with atleast 6 mm thick standard grade neoprene gasket material between the metal flanges. No control gates to regulate the flow of material shall be incorporated in the chute work. Bias connections shall be provided at suitable locations. The materials rejected from samplers shall be returned to main conveyor stream. Minimum 4 nos. sample collecting bins shall be provided with auto indexing. The bins shall be provided with air tight connection. The system shall be suitable for operation through Employers DCS/DDCMIS.
1.02.07
1.03.00 1.03.01 1.03.02
1.03.03
1.03.04
1.03.05
1.03.06
1.03.07 1.03.08
SUB-SECTION-IIIA-13 COAL SAMPLING UNIT
PAGE 2 OF 3
CLAUSE NO.
DATA SHEET : COAL SAMPLING UNIT 1.0.0 1.1.0 2.0.0 2.1.0 2.2.0 3.0.0 3.3.1 3.3.2 GENERAL Type DESIGN & CONSTRUCTION Codes & Standard feed coal size CHUTES Min. angle Cross section 60 deg Square/rectangular with rounded corners. Bolted flanges with 6 mm thick standard grade neoprene gasket. ASTM D-2234 (-) 50 mm Automatic
3.3.3
Joints
4.0.0 4.4.1 4.4.3 4.4.3 5.0.0 5.5.1 5.5.2 5.5.3
CRUSHER Uncrushed (as received) feed coal size Output size Stages of size reduction BELT FEEDER Belt Pulleys Drive Flanged type, FR grade Rubber lagged head pulley Electric Motor (-) 50 mm ASTM D-2234 Single stage crushing
SUB-SECTION-IIIA-13 COAL SAMPLING UNIT
PAGE 3 OF 3
CLAUSE NO.
A:14 VIBRATING FEEDER 1.00.00 GENERAL Vibrating feeder shall be provided below each reclaim hopper to feed coal reclaimed by dozers to the conveyor.. 1.01.00 CODES & STANDARD The design, manufacture, inspection and testing of Vibrating Feeder shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Vibrating Feeder shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Project Manager shall be final and binding. IS:3823 - Dimensions for vibrating conveyors and feeders with rectangular or trapezoidal trough. 1.02.00 1.02.01 DESIGN REQUIREMENTS The vibrating feeder shall be of mechanical type and shall be provided below each reclaim hopper to feed coal reclaimed by dozers to the conveyor. The drive unit shall be complete with mechanical type of vibrator. The vibrating feeder shall be suitable for maximum lumps size of 20 mm. The feeder shall be designed to feed coal to the conveyor without material sticking to it. The flow of material shall cease as soon as vibration of the trough or pan ceases. One (1) sets of Gates each comprising of one rod gate and one actuator operated rack & pinion gate at inlet to each of the vibrating screening feeder shall be provided. CONSTRUCTION REQUIREMENTS The vibrating feeders shall be mounted on the floor with the help of helical springs made of alloy steel. No rubber/synthetic material for the support shall be acceptable. Vibrator bearings shall be grease lubricated, double spherical roller type suitable for vibrating equipment. The bearings shall be sized for minimum 8,000 hours of operation Vibrating feeders shall be provided with removable abrasion resistant liner plate.
1.02.02
1.02.03
1.03.00 1.03.01
1.03.02
1.03.03
TECHNICAL SPECIFICATION SECTION-VI PART-B
SUB-SECTION-IIIA-14 VIBRATING FEEDER
PAGE 1 OF 1
CLAUSE NO.
MOTORS 1.00.00 1.01.00 GENERAL REQUIREMENTS For the purpose of design of equipment/systems, an ambient temperature of 50 deg. Centigrade and relative humidity of 95% shall be considered. The equipment shall operate in a highly polluted environment All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3% & -5%, and 10% combined variation of voltage and frequency unless specifically brought out in the specification. Contractor shall provide fully compatible electrical system, equipments, accessories and services. All the equipment, material and systems shall, in general, conform to the latest edition of relevant National and international Codes & Standards, especially the Indian Statutory Regulations. The auxiliary AC voltage supply arrangement shall have 6.6 KV and 415V systems. It shall be designed to limit voltage variations as given below under worst operating condition : (a.) 6.6 KV (b.) 415/240V 1.06.00 +/- 6% +/- 10%
1.02.00
1.03.00 1.04.00
1.05.00
The voltage level for motors shall be as follows (other than VFD motors) :(a.) Upto 0.2 KW : 240V, Single phase AC / 415V AC Three phase
(b.) Above 0.2KW to 200 KW : 415V, Three phase AC (c.) Above 200 KW : 6.6 KV, Three phase AC
For CHP, conveyor motors above 160KW rating, 6.6KV supply shall be used. Voltage rating for special purpose motors viz. screw compressors and those with VFD shall be as per manufacturer standard. 1.07.00 Fault level shall be 40KA RMS for 1 second for 6.6 KV system and 45 KA RMS 1 second for 415V system. 415V system shall be solidly grounded and 220 VDC system shall be isolated type. Paint shade shall be RAL 5012 (Blue) for indoor and outdoor equipment. The responsibility of coordination with other agencies and obtaining all necessary clearances shall be of the contractor. Degree of Protection
1.08.00 1.09.00 1.10.00
TECHNICAL SPECIFICATION SECTION-VI, PART-B
SUB-SECTION-IIIB-01 MOTORS
PAGE 1 OF 9
CLAUSE NO.
Degree of protection for various enclosures as per IS:13947 shall be as follows :i) ii) iii) iv) v) 2.00.00 Indoor motors Outdoor motors CW motors (in case of Screen prot. Drip proof) Cable box indoor area Cable box outdoor area IP 54 IP 55 IP 23 IP 54 IP 55
CODES AND STANDARDS 1.) 2.) 3.) 4.) 5.) Three phase induction motors Single phase AC motors Crane duty motors DC motors/generators Energy Efficient motors : : : : : IS:325, IEC:60034 IS:996, IEC: 60034 IS:3177, IEC: 60034 IS:4722 IS 12615
3.00.00 3.01.00
TYPE AC Motors: (a.) Squirrel cage induction motor suitable for direct-on-line starting. (b.) Continuous duty LT motors upto 160 KW Output rating(at 50 deg.C ambient temperature) ,shall be Energy Efficient motors ,Efficiency class Eff 1, conforming to IS 12615. (c.) Crane duty motors shall be slip ring / squirrel cage type induction motor as per the requirement Shunt wound.
3.02.00 4.00.00
DC Motors RATING
(a.) Continuously rated (S1). However, crane motors shall be rated for S4 duty, 40% cyclic duration factor. (b.) Whenever the basis for motor ratings are not specified in the corresponding mechanical specification sub-sections, maximum continuous motor ratings shall be at least 10% above the maximum load demand of the driven equipment under entire operating range including voltage and frequency variations.
PAGE 2 OF 9
CLAUSE NO.
TECHNICAL REQUIREMENTS TEMPERATURE RISE Air cooled motors 70 deg. C by resistance method for both thermal class 130(B) & 155(F) insulation. Water cooled 80 deg. C over inlet cooling water temperature mentioned elsewhere, by resistance method for both class 130(B) & 155(F) insulation.
5.00.00
6.00.00 6.01.00 6.01.01
OPERATIONAL REQUIREMENTS Starting Time For motors with starting time upto 20 seconds at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be at least 2.5 second more than starting time . For motors with starting time more than 20 second and upto 45 seconds at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be at least 5 second more than starting time. For motors with starting time more than 45 seconds at minimum permissible voltage during starting, the locked rotor withstand time under hot condition at highest voltage limit shall be more than starting time by at least 10% of the starting time. Speed switches mounted on the motor shaft shall be provided in cases where above requirements are not met. Torque Requirements Accelerating torque at any speed with the lowest permissible starting voltage shall be at least 10% motor full load torque. Pull out torque at rated voltage shall not be less than 205% of full load torque. It shall be 275% for crane duty motors. Starting voltage requirement (a) (b) (c) 85% upto 1500KW 80% from 1500KW to 4000KW 75% > 4000KW
6.01.02
6.01.03
6.01.04 6.02.00 6.02.01 6.02.02
6.03.00
7.00.00 7.01.00
DESIGN AND CONSTRUCTIONAL FEATURES Suitable single phase space heaters shall be provided on motors rated 30KW and above to maintain windings in dry condition when motor is standstill. Separate terminal box for space heaters & RTDs shall be provided.
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CLAUSE NO.
TECHNICAL REQUIREMENTS All motors shall be either Totally enclosed fan cooled (TEFC) or Totally enclosed tube ventilated (TETV) or Closed air circuit air cooled (CACA) type. However, motors rated 3000KW or above can be Closed air circuit water cooled (CACW). CW motors can be screen protected drip proof (SPDP) type. Motors located in hazardous areas shall have flame proof enclosures conforming to IS:2148 as detailed below (a) (b) Fuel oil area : Group - IIB
7.02.00
Hydrogen generation plant Group IIC (or Group-I Div-II as area : per NEC)
7.03.00
Winding and Insulation (a) (b) Type Starting duty : : Non-hygroscopic, oil resistant, flame resistant Two hot starts in succession, with motor initially at normal running temperature. However, conveyor motors shall be suitable for 3 consecutive hot starts. Thermal class 155(F) insulation with winding temperature rise limited to thermal class 130(B). The winding insulation process shall be total Vacuum Pressure Impregnated i.e. resin poor method. The lightning impulse & interturn insulation surge withstand level shall be as per IEC-60034 Part-15. Thermal Class 130(B) or better
(c)
6.6 KV motors
AC
(d)
415V AC & 220V DC motors
( e)
Short circuit rings of conveyor motors shall be either joint less or welded type. Brazed joint is not acceptable.
7.04.00 7.05.00
Motors rated above 1000KW shall have insulated bearings to prevent flow of shaft currents. Motors with heat exchangers shall have dial type thermometer with adjustable alarm contacts to indicate inlet and outlet primary air temperature. Noise level for all motors shall be limited to 85dB (A). Bearing housing vibration shall be limited within the limits prescribed in IEC 60034-14/IS: 12075. Motors shall withstand vibrations produced by driven equipment. HT motor bearing housings shall have flats in both X and Y directions suitable for mounting 80mmX80mm vibration pads.
7.06.00
PAGE 4 OF 9
CLAUSE NO.
TECHNICAL REQUIREMENTS In HT motors, at least four numbers simplex / two numbers duplex platinum resistance type temperature detectors shall be provided for each phase of stator winding. Each bearing shall be provided with dia type thermometer with adjustable alarm contract and minimum one(1) number duplex Platinum resistance type temperature detector. Motor body shall have two earthing points on opposite sides. HT motors can be offered with either Elastimold termination or dust tight phase separated double walled (metallic as well as insulated barrier) cable boxes. In case Elastimold terminations are offered, then protective cover and trifurcating sleeves shall also be provided. Removable gland plates of thickness 3 mm (hot/cold rolled sheet steel) or 4 mm (non magnetic material for single core cables) shall be provided in case of cable boxes. The spacing between gland plate & centre of terminal stud shall be as per Table-I. All motors shall be so designed that maximum inrush currents and locked rotor and pullout torque developed by them at extreme voltage and frequency variations do not endanger the motor and driven equipment. The motors shall be suitable for bus transfer schemes provided on the 6.6 KV/415V systems without any injurious effect on its life. For motors rated 2000 KW & above, neutral current transformers of PS class shall be provided on each phase in a separate neutral terminal box. 6.6 KV Terminal Box shall be suitable for fault level of 500MVA for 0.12 second. The size and number of cables ( for HT motors) will be intimated to the contractor during detailed engineering and the contractor shall provide the terminal box, cable gland & lugs suitable for the same. The ratio of locked rotor KVA at rated voltage to rated KW shall not exceed the following (without any further tolerance) except for BFP motor. (a) (b) (c) (d) Upto 110KW Above 110KW & upto 1500KW Above 1500KW & upto 4000KW Above 4000KW 11.0 10.0 9.0 6 to 6.5
7.07.00
7.08.00 7.09.00
7.10.00 7.11.00
7.12.00 7.13.00 7.14.00 7.15.00
7.16.00
PAGE 5 OF 9
CLAUSE NO.
8.00.00 8.01.00 8.01.01
TYPE TEST HT MOTORS The contractor shall carry out the type tests as listed in the LIST OF TESTS TO BE CONDUCTED on the equipment mentioned there in. The Bidder shall indicate the charges for each of these type tests separately in the relevant schedule of BPS and the same shall be considered for the evaluation of the Bids. The type test charges shall be paid only for the test(s) actually conducted successfully under this contract and upon certification by the Employer's Engineer. The type tests shall be carried out in presence of the Employers representative, for which minimum 15 days notice shall be given by the Contractor. The Contractor shall obtain the Employers approval for the type test procedure before conducting the type test. The type test procedure shall clearly specify the test set-up, instruments to be used, procedure, acceptance norms, recording of different parameters, interval of recording, precautions to be taken etc. for the type test(s) to be carried out. In case the contractor has conducted such specified type test(s) within last ten years as on the date of bid opening, he may submit during detailed engineering the type test reports to the owner for waivel of conductance of such type test(s). These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. The owner reserves the right to waive conducting of any or all the specified type test(s) under this contract. In case type tests are waived, the type test charges shall not be payable to the contractor. Further the Contractor shall only submit the reports of the type tests as listed in LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at the third party laboratory or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No Design Change. Minor changes if any shall be highlighted on the endorsement sheet.
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-01 MOTORS PAGE 6 OF 9
8.01.02
8.01.03
8.01.04
8.01.05
8.01.06
CLAUSE NO.
8.01.07
LIST OF TESTS TO BE CONDUCTED The following type tests shall be conducted on each type and rating of HT motor (a) (b) (c) (d) (e) No load saturation and loss curves upto approximately 115% of rated voltage Measurement of noise at no load. Momentary overload test (subject to test bed constraint). Full load test Temperature rise test at rated conditions . During heat run test, bearing temp., winding temp., core temp., coolant flow and its temp. shall also be measured. In case the temperature rise test is carried at load other than rated load, specific approval for the test method and procedure is required to be obtained. Wherever ETD's are provided, the temperature shall be measured by ETD's also for the record purpose.
8.01.08
LIST OF TESTS FOR WHICH REPORTS HAVE TO BE SUBMITTED The following type test reports shall be submitted for each type and rating of HT motor (a) Degree of protection test for the enclosure followed by IR, HV and no load run test. (b)Terminal box-fault level withstand test for each type of terminal box of HT motors only. (c) Lightning Impulse withstand test on the sample coil shall be as per clause 5.1.3.2, IEC-60034, Part-15. Surge-withstand Voltage test on interturn insulation as per IEC 60034-158
(d) 8.02.00 8.02.01
LT MOTORS All equipment to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as per relevant standards and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at third part laboratory or in presence of client/owners representative and submit the reports for approval.
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-01 MOTORS PAGE 7 OF 9
8.02.02
CLAUSE NO.
TECHNICAL REQUIREMENTS All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No Design Change. Minor changes if any shall be highlighted on the endorsement sheet. Drawing Submission Procedure Unique manufacturer specific reference drawing nos. shall be allotted by owner to drawings of the equipment or components. Drawing once approved (for any project) shall be treated as reference drawings for subsequent projects. An endorsement sheet shall be submitted by manufacturer confirming similarity and minor changes if any shall be highlighted on the endorsement sheet. However owner reserves right to get the drawings submitted afresh. The reference drawings so approved once along with endorsement sheet shall be used for factory inspection of equipment whenever package/project specific drawings are not submitted afresh/approved.
8.02.03
8.02.04
9.00.0
PAGE 8 OF 9
CLAUSE NO.
TABLE - I DIMENSIONS OF TERMINAL BOXES FOR LV MOTORS Motor MCR in KW Minimum distance between centre of stud and gland plate in mm As per manufacturer's practice.
UP to 3 KW
Above 3 KW upto 7 KW Above 7 KW - upto 13 KW Above 13 KW upto 24 KW Above 24 KW upto 37 KW Above 37 KW upto 55 KW Above 55 KW upto 90 KW Above 90 KW upto 125 KW Above 125 KW-upto 200 KW
85 115 167 196 249 277 331 203
For HT motors the distance between gland plate and the terminal studs shall not be less than 500 mm. NOTE: Minimum inter-phase and phase-earth air clearances for LT motors with lugs installed shall be as follows: Motor MCR Upto 110KW Above 110KW and Upto 150KW Above 150KW Clearance 10.0mm 12.5mm 19.0mm
PAGE 9 OF 9
CLAUSE NO.
TECHNICAL REQUIREMENTS LT SWITCHGEAR & BUSDUCT
1.00.00 2.00.00
CODES AND STANDARDS IEC: 60947, IS : 13947, IEC: 60439,IS:8623,IEC:61850 TYPE Circuit Breakers Shall be air break, three pole, spring charged, horizontal drawout type, suitable for electrical operation. Fully drawout type single front Fully drawout type single front/Double front. Fixed type single front
Switchgear MCC
ACDB/DCDB 3.00.00 SYSTEM PARAMETERS
415VAC +/- 10 %(SOLIDLY GROUNDED) 50 Hz +3%/-5% 45KA RMS(105 KA PEAK) / 1SEC (FAULT LEVEL) 240V DC ISOLATED TYPE 4.00.00 TEMPERATURE RISE The temperature rise of the horizontal and vertical busbars and main bus link including all power draw out contacts when carrying 90% of the rated current along the full run shall in no case exceed 55 deg. C with silver plated joints and 40 deg. C with all other types of joints over an ambient of 50 deg C. The temperature rise of the accessible parts/external enclosures expected to be touched in normal operation shall not exceed 20 deg.C. The temperature rise of manual operating means shall not exceed 10 deg. C for metallic & 15 deg. C for insulating material. The above temperature rise limits are applicable for busducts also without any current derating. 5.00.00 5.01.00 5.01.01 5.01.02 OPERATIONAL REQUIREMENTS Breakers Breakers shall have anti-pumping feature. The incomer and bus coupler breakers for switchgear shall be electrically operated with Numerical communicable relays. Breakers shall have inherent fault making and breaking capacities. They shall have shunt trip coils. All breakers shall have built in interlocks for equipment and personnel safety.
5.01.03
PART-B SUB-SECTION-IIIB-02 L.T. SWITCHGEAR & BUS DUCT
PAGE 1 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS Paralleling of two supplies shall be avoided by interlocking except for switchgear where auto-changeover is provided. Breaker contact multiplication, if required, shall be through latch relay. Mechanical tripping shall be through red Trip push button outside the panels for breakers, and through control switches for other circuits. Provision of mechanical closing of breaker only in Test and Withdrawn position shall be made. Alternatively, mechanical closing facility should be normally inaccessible, accessibility rendered only after deliberate removal of shrouds. It shall be possible to close the door with breaker in test position. Clear status indication for each circuit shall be provided through lamps, switch positions or other mechanical means. Switches, Contactors and Fuses Incomers for MCCs and DBs rated below 250A could be load break isolators. Motor starter contactors shall be of air break, electromagnetic type suitable for DOL starting of motor, and shall be of utilisation category AC-3 for ordinary and AC-4 for reversing starters. For conveyor motors, minimum rating of power contactors shall be 200% of the full load current of the motors. For other motors minimum rating of power contactors shall be 160% of full load current of motor. DC contactor shall be of DC-3 utilisation category. Fuses shall be HRC type with operation indicator. Isolating switches shall be of AC 23A category when used in motor circuit, and AC 22A category for other applications. Fuse switch combination shall be provided wherever possible. The 250A & above feeders up to 630A shall have MCCB. MCCB shall be provided with Microprocessor based inbuilt front adjustable releases(overload & short circuit) and shall have adjustable earth fault protection unit also . MCCB shall have current limiting feature. ON and OFF position of the operating handle of MCCB shall be displayed and the rotary operating handle shall be mounted on the door of the compartment housing MCCB. The compartment door shall be interlocked mechanically with the MCCB, such that the door can not be opened unless the MCCB is in OFF position. Means shall be provided for defeating this interlock at any time by making use of special tools/tackles. MCCB shall be provided with padlocking facility to enable the operating mechanism to be padlocked. Panels All switchgears, MCCs, DBs, panels, modules, local starters and push buttons shall have prominent engraved indentification plates. Local push button stations shall have metal enclosure of die cast aluminium or rolled sheet steel of 1.6mm thickness & shall be of DOP IP55. The DOP shall be IP-65 in case the same are located in dusty areas. Push buttons shall be of latch type with mushroom knobs.
5.01.04
5.01.05
5.01.06
5.01.07
5.02.00 5.02.01 5.02.02
5.02.03
5.02.04
5.03.00 5.03.01
5.03.02
PAGE 2 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS Where breaker/starter module front serves as compartment cover, suitable blanking covers, one for each size of modules per switchboard shall be supplied for use when carriage is withdrawn. All non-current carrying metal work of boards/panels shall be effectively bonded to earth bus of galavanised steel, extending throughout the switchboard/MCC/DB. Positive earthing shall be maintained for all positions of chassis and breaker frame. Suitable trolley arrangement shall be provided for breaker/starter modules. Two trolleys per switchgear room shall be provided so that top most breaker module of all types, sizes and rating can be withdrawn on trolley and lowered for maintenance purpose. The incoming connection to transformer of more than 1000KVA and inter-connecting sections between switchboards shall preferably be of busducts. The busduct enclosure shall be made of minimum 3mm thick aluminium alloy. The section of the busduct should have adequate strength to withstand internal and external forces resulting from the various operating conditions. Aluminium sheet hood shall be provided for outdoor busduct enclosure joints to provide additional protection against water ingress. The busduct top shall be sloped to prevent retention of water.The busduct enclosure shall have DOP of IP55 and paint shade RAL 5012. It should be possible to carryout maintenance on a feeder with adjacent feeders alive. DC fuse board shall consist of: -1 no.63A switch as incomer with meters, lamps and auxiliary contactors. -8 nos.outgoing feeders with 16A HRC fuses.
5.03.03
5.03.04
5.03.05
5.03.06
5.03.07
5.03.08
5.03.09
AC fuse board shall consist of: -1 no 63A TPN SFU as incomer with lamps and meters. -9 nos.16A SPN SFU & 3 nos.16A TPN SFU as outgoing.
5.03.10
Main lighting distribution board(MLDB) to be located in MCC room shall consist of:a) Two(2) nos. x 100% rated, lighting transformers (415V/433V, delta/star, epoxy insulated, air cooled, dry type). Transformer shall be 50KVA/100KVA rating for 10/15 nos. outgoing feeder. b) TPN SFU on primary and secondary side of the transformer c) 63A TPN SFU as outgoing feeders including 20% spare. d) Voltmeter, ammeter with selector switches, indicating lamps. e) The two incomers (One from Bus-A and One from Bus-B of the MCC) and one bus-coupler for the power supply to each MLDB shall be provided with castle key networks. Welding distribution board(WDB) to be located in MCC room shall consist of:a) One(1) no welding transformer (415V/433V, delta/star, epoxy insulated, air cooled, dry type). Transformer shall be 50KVA/100KVA. b) TPN SFU on primary and secondary side of the transformer c) 63A TPN SFU as outgoing feeders including 20% spare. d) Voltmeter, ammeter with selector switches, indicating lamps.
5.03.11
PAGE 3 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS MCCs located on the Stacker reclaimer, paddle feeders, travelling trippers shall be fixed type, compartmentalized, single front and suitable for the system fault level.No spare feeders are to be provided on these MCCs. Degree of protection for the MCCs mounted on paddle feeders and travelling trippers shall be IP-65. Control, Protection & Metering Requirements Control circuits shall operate at suitable voltage of 110V AC or 240V DC. Necessary control supply transformers having primary and secondary fuses shall be provided for each MCC, 2 x 100% per bus section. However the breakers shall operate on 240V DC The auxiliary bus bars for control supply shall be segregated from main bus bars. The control supplies shall be monitored. DC operated spring charging motor shall be suitable for voltage variation between 198V to 242V DC. The closing coil of circuit breaker shall operate correctly at all values of voltage between 187V-242V DC. The trip coil of circuit breaker shall operate satisfactorily at all values of voltage between 154V-242V DC. DC operated contactor coil shall have an economy resistor and shall be suitable for satisfactory continuous operation at 187V-242V DC.
5.03.12
5.04.00 5.04.01
5.04.02
Contractor shall fully co-ordinate overload and short circuit tripping of breaker with upstream and down stream breakers/fuses/MCCBs motor starters. Various equipments shall meet requirement of Type-II class of coordination as per IEC. The protective relays shall be communicable numerical relays These numerical relays shall be of types as proven for the application and shall be subject to Employers approval Numerical relays shall have appropriate setting ranges, accuracy, resetting ratio and other characteristics to provide required sensitivity. All equipments shall have necessary protections as detailed in the standard scheme drawings. All equipments shall have necessary protections. However, following minimum protections shall be provided: 1) Contactor controlled motor feeders (Motors up to 200 kW) a) Instantaneous short circuit protection on all phases through HRC cartridge type fuses rated for 80 kA rms (prospective breaking capacity at 415V). Thermal overload protection Single phasing protection for motors protected by fuses
5.04.03
5.04.04
b) c) 2)
Incomers / buscoupler / outgoing breaker feeders other than motor feeders. a) b) c) d) Three phase overcurrent protection (50) Three phase earthfault protection (50N3) Restricted earth fault protection for transformer incomers(64R) Sync Check
PAGE 4 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS General requirements of Numerical Relays All relays and timers shall be rated for control supply voltage as mentioned elsewhere under parameters and shall be capable of satisfactory continuous operation between 80-120% of the rated voltage. Making, carrying and breaking current ratings of their contacts shall be adequate for the circuits in which they are used. Interrogation voltage for the binary inputs shall be suitably selected to ensure avoidance of mal operation due to stray voltages. Numerical relays shall have communications on two ports, local front port for communication to laptop and a second port on IEC 61850 to communicate with owners data concentrator through LAN. All Numerical Relays shall have features for electrical measurement including voltage, current, power (active / reactive) and energy parameters. All Numerical Relay shall have key pad / keys to allow relay settings from relay front. All hand reset relays shall have reset button on the relay front. Relay to be self or hand reset shall be software selectable. Manual resetting shall be possible from remote. The protective relays shall have at least 10 Nos. programmable potential free contacts. Programmable Auxiliary relays shall have contacts as required. For control from DDCMIS, 24V DC signal shall be provided from DDCMIS to the numerical relays. Preferably, no separate coupling relays shall be provided. Trip circuit supervision shall be provided for all feeders to monitor the circuit breaker trip circuit both in pre trip and post trip conditions. Schematics requiring auxiliary relays / timers for protection function shall be a part of Numerical Relay. The number of auxiliary relay and timer function for protection function shall be as required by the scheme. Auxiliary relays for interlocking purpose shall be of self reset type. The numerical processor shall be capable of measuring and storing values of a wide range of quantities, all events, faults and disturbance recordings with a time stamping using the internal real time clock. Battery back up for real time clock in the event of power supply failure shall be provided. Sequence of events shall have 1ms resolution at device level. Ethernet switches shall be substation hardened and shall comply to IEC61850-3 for communications and environment requirements. The Ethernet switches shall be of managed type with four(4) no Fibre optic cable ports and sixteen/eight nos. Copper ports to achieve the owners LAN configuration. One (1) no. Ethernet switch per switch board shall be provided & these switches shall be mounted inside the switchgear Panels. Ethernet switches shall be suitable for single mode FO Cable connections.
5.05.00 5.05.01
5.05.02
5.05.03
5.05.04
5.05.05
5.05.06
5.05.07
5.05.08
5.05.09
5.05.10 5.05.11
PAGE 5 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS In case of remote controlled breaker panels, following shall be ensured. The circuit breaker will normally be controlled from remote control panels (employers DDCMIS) through closing and shunt trip coils. The Local control console of the relay flush mounted on the switchgear would normally be used only for testing of circuit breaker in isolated position, and for tripping it in an emergency. Provision for closing & tripping of the circuit breaker locally from laptop through serial port shall be possible to facilitate commissioning activities. The basic control scheme of breaker feeders shall be developed as per the schematic logics in the relay. The schematics shall be developed in soft inside the relay. Numerical relays shall be interfaced with employers DDCMIS through 24V DC signal for closing / opening operations. Hardwired contacts from the relay shall be wired to PLC / DCS system as per requirements. The numerical relay shall be capable of measuring and storing values of a wide range of quantities, events, faults and disturbance recordings. The alarm / status of each of protection function and trip operation shall be communicated to PLC/DCS. The numerical relays shall have built in feature / hardware interface to provide such inputs to PLC / DCS for analog / digital values.. It shall be possible to carryout open / close operation of breakers from a laptop by interfacing from the relay front port (RS232) during initial commissioning. Meters / instruments All meters/ instrument shall be flush mounted on front panel, at least 96 sq.mm. size with 90 degree linear scales and accuracy class of 2.0.
5.05.12
5.05.13
5.05.14
5.05.15 5.06.00
5.06.01
All motors of 30kW and above upto 100 KW shall have an Ammeter & current transducer. Each bus-section shall have bus VT, voltmeter with selector switch, and other relay and timers required for protection. Adequate control and selector switches, push buttons and indicating lamps shall be provided. Thermostatically controlled space heaters with switches shall be provided to prevent condensation. For all motor feeders related to dust suppression system and for all other motor feeders having 100KW & above rating, contractor shall provide multifunction Digital Energy Meter with communication facility to display the current, voltage, power factor, power, energy related data locally and shall communicate these for remote metering /audit/analysis purposes. The technical specification for Digital indicating energy meter shall be as follow: a) b) c) d) e) f) Input Voltage: 110 V AC/ 240 V DC Input Current:1A Size: 96X96 sq. mm Accuracy:1.0% for power & energy Mounting: Flush mounting Type: True RMS 3-PHASE V, I, KW, PF & KWHr indication
5.06.02
PAGE 6 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS g) h) i) j) k) l) m) n) 4 Digit, seven segment LED display/LCD display, with floating decimal Communication: In built RS 485 serial bus port Operating Frequency: 45 HZ-65HZ Dielectric Test: 2KV RMS for 1 minute Over current: 10 times for 3 sec. Aux. supply: 90V-300V AC/DC Compliance: EMC/EMI Field programmable CT ratio
5.07.00
Control from Remote Necessary hardware shall be provided in the switchgear panel like coupling relays (if required ) of 24V DC, with max. burden of 2.5VA, auxiliary relays, current/voltage transducers (4-20 mA, dual output) etc. to effect interlocks, exchange information / status and exercise control from remote.
6.00.00 6.01.00
DESIGN AND CONSTRUCTIONAL FEATURES All 415V switch gear motor control centers (MCCs), AC & DC distribution boards (DB s), etc shall have following features : 1) Shall be of metal enclosed, indoor, floor mounted and free standing type. All frames and load bearing members shall be fabricated using mild steel structural sections or pressed and shaped cold rolled sheet steel of thickness not less than 2mm. Frame shall be enclosed in cold rolled sheet steel of thickness not less than 1.6mm.Doors and covers shall also be of cold rolled sheet steel of thickness not less than 1.6 mm. Stiffeners shall be provided wherever necessary. Removable gland plates of thickness 3mm (hot/cold rolled sheet steel) or 4 mm (non-magnetic material) shall be provided for all panels. All switchboards/panels shall be of dust and vermin proof. All cutouts shall have EPDM/Neoprene gaskets. All switchboards, MCCs and DB s shall have following distinct vertical sections. a) Completely enclosed horizontal and vertical bus bar bus bars. compartment for
2)
3)
4)
5)
PAGE 7 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS b) Completely enclosed switchgear compartments (one for each circuit housing circuit breakers, motor starter or switch-fuse feeder). A full-height vertical cable alley of minimum 250mm width shall be provided for power and control cables. Cable alley shall have no exposed live parts and shall have no communication with busbar compartment. Cable terminations located in cable alley shall be designed to meet the Form IVb Type 7 (as per IEC 60439) for safety purpose. The termination for each module shall have its own integral glanding facility. Wherever cable alleys are not provided for distribution boards, segregated cable boxes for individual feeders shall be provided at the rear for direct termination of cables. For cable connection to circuit breaker, a separately enclosed cable compartment shall also be acceptable. Compartment for relays and other control devices associated with a circuit breaker, wherever necessary. The switchboards/MCC/DBs of 1600A & above rating shall be of DOP IP42 & of IP52 for less than 1600A rating. All 415V switchgears, MCCs, AC & DC distribution boards etc. shall be painted by powder coating process. Paint shade for complete panels excluding end covers shall be RAL9002 & RAL5012 for extreme end covers of all boards. All draw out modules shall have distinct service, test and isolated positions with provision of external pad locking facility in each position. Power contacts shall get disconnected in both test and isolated positions whereas the control contacts shall get disconnected in isolated position only.
c)
d)
e)
f)
g)
h)
6)
Busbars shall be of high conductivity aluminium alloy or copper & entire busbar system shall be insulated with PVC sleeves. The cross section of the horizontal bus bars shall be uniform through out the length of the switchboard and both horizontal as well as vertical bus bars shall be adequately supported and braced to withstand the stresses due to the specified short circuit currents. Neutral bus bar short circuit strength shall be same as the main bus bars. Minimum air clearance in air between phases and phase-earth shall be 25 mm for busbars and cable terminations. For all other components, the Clearances shall be at least 10mm.
TECHNICAL SPECIFICATION SECTION-VI, PART-B PART-B SUB-SECTION-IIIB-02 L.T. SWITCHGEAR & BUS DUCT PAGE 8 OF 11
7)
8)
CLAUSE NO.
TECHNICAL REQUIREMENTS Wherever above is not possible except for horizontal and vertical busbars, insulation shall be provided by anti tracking sleeving or barriers. However for horizontal and vertical busbars, clearances specified above shall be maintained even when busbars are insulated/sleeved. In case of DC DBs/ fuse boards, the busbar system shall be insulated or physically segregated with barriers to prevent interpole short circuit. 9) Busbar insulators shall be of track-resistant high strength nonhygro- scopic, non-combustible type and suitable to withstand stresses due to over-voltages and short circuit current. Insulators and barrier of inflammable material such as Hylam shall not be accepted. All types of relays and timer shall be subject to Employers approval. They shall be flush mounted with connections from inside, and shall have transparent & dust tight cover, removable from front, drawout construction for easy replacemernt and testing facility. The auxiliary relays and timer may be provided in fixed cases. Terminal Blocks Terminal blocks shall be 650V grade, 10Amps rated, made up of unbreakable polyamide 6.6 grade. The terminals shall be either screw type or screw-less (spring loaded) / cage clamp type with lugs. Marking on terminal strips shall correspond to the terminal numbering in wiring diagrams. All metal parts shall be of non-ferrous material. In case of screw type terminals the screw shall be captive, preferably with screw locking design. Maxi terminal / cage clamp type terminal blocks shall be provided for signals to be interfaced with DDCMIS / PLC. 12) The switchgears/MCC shall be designed to offer adequate level of safety to operating/ maintenance personnel. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear/MCC room describing various safe operating procedure/safety precautions for safe operation and maintenance of switchgear/MCC. All current and voltage transformers as required for metering & protection specified shall be completely encapsulated cast resin insulated type. Incomers from transformers shall have CTs for transformer REF protection. The accuracy shall be as follows:
10)
11)
13)
PAGE 9 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS CTs 5P20,5VA 1.0 PS PTs 3P 0.5
Protection Metering REF 6.02.00
Indicating lamps shall be cluster LED type.All overload relays shall have overload reset push button. Switchgear/MCC shall have bottom cable entry. TYPE TESTS GENERAL (a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No Design Change. Minor changes if any shall be highlighted on the endorsement sheet.
6.03.00 7.00.00 7.01.00
(b.)
(c.)
(d.)
7.02.00
BUSDUCTS (as applicable) The following type test certificates on each rating of bus duct shall be submitted. (a.) (b.) Heat run test on an assembly of representative sections and fittings Short circuit test for a duration and current as covered in the specification on an assembly of representative section. One minute high potential power frequency voltage withstand test. Degree of protection test.
(c.) (d.)
PAGE 10 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS L. T. SWITCHGEAR The following type test certificates on each type & rating of L.T. Switchgear and MCC panel shall be submitted. (a.) (b.) (c.) (d.) (e.) (f.) Short time withstand test. Temperature rise test. Type II - Short circuit co-ordination test for any three ratings of MCC module as selected by the Employer. Test sequence 1 & combined test sequence shall be carried out on each rating of circuit breaker mounted inside the panel. Degree of protection tests Type test certificates for numerical relays.
7.03.00
8.00.00
Drawing Submission Procedure Unique manufacturer specific reference drawing nos. shall be allotted by owner to drawings of the equipment or components. Drawing once approved (for any project) shall be treated as reference drawings for subsequent projects. An endorsement sheet shall be submitted by manufacturer confirming similarity and minor changes if any shall be highlighted on the endorsement sheet. However owner reserves right to get the drawings submitted afresh. The reference drawings so approved once along with endorsement sheet shall be used for factory inspection of equipment whenever package/project specific drawings are not submitted afresh/approved.
PAGE 11 OF 11
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10/01/07
10/01/07
10/01/07
10/01/07
CLAUSE NO.
TECHNICAL REQUIREMENTS POWER CABLES
1.00.00 1.01.00
CODES & STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS : codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes: IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V. IS : 3961 IS : 3975 Recommended current ratings for cables Low carbon galvanised steel wires, formed wires and tapes for armouring of cables. IS : 5831 IS:7098 (Part -I) PVC insulation and sheath of electrical cables. Cross linked polyethylene insulated PVC sheathed cables for working voltages upto and including 1100V. IS : 8130 IS : 10418 IS : 10810 ASTM-D -2843 Conductors for insulated electrical cables and flexible cords. Specification for drums for electric cables. Methods of tests for cables. Standard test method for density of smoke from the burning or decomposition of plastics. ASTM-D-2863 Standard method for measuring the minimum oxygen concentration to support candle like combustion of plastics. IEC-754 (Part-I) IEEE-383 Test on gases evolved during combustion of electric cables. Standard for type test of Class IE Electric Cables.
SUB-SECTION-IIIB-03 L.T. POWER CABLE
PAGE 1 OF 8
CLAUSE NO.
IEC -332
Tests on Electric cables under fire conditions. Part-3 : Tests on bunched wires or cables (category -B)
2.00.00 2.01.00
TECHNICAL REQUIREMENTS The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground burried installation with chances of flooding by water. Cables shall be armoured, flame retardant, low smoke (FRLS), type designed to withstand all mechanical, electrical and thermal stresses develop under steady state and transient operating conditions as specified elsewhere in this specification. Aluminium conductor used in power cables shall have tensile strength of more than 100 N/ sq.mm. Conductors shall be multi stranded. XLPE insulation shall be suitable for a continuous conductor temperature of 90 deg. C and short circuit conductor temperature of 250 deg.C. PVC insulation shall be suitable for continuous conductor temperature of 70 deg C and short circuit conductor temperature of 160 deg. C. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831. For single core armoured cables, armouring shall be of aluminium wires. For multicore armoured cables armouring shall be of galvanised steel as follows : Calculated nominal dia of cable under armour i) ii) iii) iv) v) vi) Upto 13 mm Above 13 & upto 25mm Above 25 & upto 40 mm Above 40 & upto 55mm Above 55 & upto 70 mm Above 70mm Size and Type of armour 1.4mm dia GS wire 0.8 mm thick GS formed wire / 1.6 mm dia GS wire 0.8mm thick GS formed wire / 2.0mm dia GS wire 1.4 mm thick GS formed wire /2.5mm dia GS wire 1.4mm thick GS formed wire / 3.15mm dia GS wire 1.4 mm thick GS formed wire / 4.0 mm dia GS wire
2.02.00
2.03.00
2.04.00
2.05.00
2.06.00
PAGE 2 OF 8
CLAUSE NO.
TECHNICAL REQUIREMENTS The aluminium used for armouring shall be of H4 grade as per IS:8130 with maximum resistivity of 0.028264 ohm mm2 per meter at 20 deg C. The sizes of aluminium wires/formed wires for armouring shall be same as indicated above in clause 2.06.00 for galvanised steel. The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wire / formed wire. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface of G.S. wire/formed wire. Outer sheath shall be of PVC as per IS:5831 & black in colour. In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables (including trailing cables) shall have the following FRLS properties. (a.) Oxygen index of min. 29 (As per ASTMD 2863) (b.) Acid gas emission of max. 20% (As per IEC-754-I). (c.) Smoke density rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843.
2.06.01
2.06.02
2.07.00
2.08.00
Cores of the cables shall be identified by colouring of insulation. Following colour scheme shall be adopted: 1 core Red, Black, Yellow, Blue 2 core 3 core 4 core Red & Black Red, Yellow & Blue Red, Yellow, Blue and Black
2.09.00 2.10.00
For reduced neutral conductors the core shall be black. In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath. (a.) Cable size and voltage grade - To be embossed (b.) Word 'FRLS' at every 5 metre - To be embossed (c.) Sequential marking of length of the cable in metres at every one metre-To be embossed / printed
The embossing shall be progressive, automatic, in line and marking shall be legible and indelible. For EPR cables identification shall be printed on outer sheath.
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATION SECTION-VI, PART-B
PAGE 3 OF 8
CLAUSE NO.
TECHNICAL REQUIREMENTS All cables shall meet the fire resistance requirement as per Category-B of IEC 332 Part -3. Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum over the declared value in the technical data sheets. In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc.are not acceptable. Cable selection & sizing Cables shall be sized based on the following considerations: (a) (b) Rated current of the equipment The voltage drop in the cable, during motor starting condition, shall be limited to 10% and during full load running condition, shall be limited to 3% of the rated voltag
2.11.00
2.12.00
2.13.00
2.14.00 2.14.01
(c)
Short circuit withstand capability This will depend on the feeder type. For a fuse protected circuit, cable should be sized to withstand the let out energy of the fuse. For breaker controlled feeder, cable shall be capable of withstanding the system fault current level for total breaker tripping time inclusive of relay pickup time.
2.14.02
Derating Factors Derating factors for various conditions of installations including the following shall be considered while selecting the cable sizes: a) b) c) Variation in ambient temperature for cables laid in air Grouping of cables Variation in ground temperature and soil resistivity for buried cables.
2.14.03
Cable lengths shall be considered in such a way that straight through cable joints are avoided.
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-03 L.T. POWER CABLE PAGE 4 OF 8
CLAUSE NO.
TECHNICAL REQUIREMENTS All power cables of sizes more than 120 sq.mm. shall be XLPE insulated and preferable sizes are 1Cx150, 1Cx300, 1Cx630, 3Cx150 & 3Cx240 sq.mm. CONSTRUCTIONAL FEATURES (a.) 1.1 KV grade XLPE power cables shall have compacted aluminium conductor, XLPE insulated, PVC inner-sheathed (as applicable), PVC outer-sheathed conforming to IS:7098. (Part-I). (b.) 1.1KV grade PVC power cables shall have aluminium conductor (compacted type for sizes above 10 sq.mm), PVC Insulated, PVC inner sheathed (as applicable), PVC outer-sheathed conforming to IS:1554 (Part-I). (c.) Trailing cables shall have tinned copper (class 5) conductor, insulated with heat resistant elastomeric compound based on Ethylene Propyline Rubber (EPR) suitable for withstanding 90 deg.C continuous conductor temperature and 250deg C during short circuit, inner-sheathed with heat resistant elastomeric compound, nylon cord reinforced, outer-sheathed with heat resistant, oil resistant and flame retardant heavy duty elastomeric compound conforming to IS 9968.
2.14.04
3.00.00
4.00.00
CABLE DRUMS (a.) Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS : 10418. (b.) Each drum shall carry manufacturer's name, purchasers name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.
5.00.0
TESTS (a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client.
CLAUSE NO.
TECHNICAL REQUIREMENTS (b.) However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price.
(c.)
(d.)
5.01.00 5.01.01
The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No Design Change. Minor changes if any shall be highlighted on the endorsement sheet TYPE TESTS The reports for the following type tests shall be submitted for one size each of XLPE/PVC Power cables: S.No. Type Test For Conductor 1. 2. 3. Tensile test Wrapping test Resistance test For Armour Wires/ Formed Wires 5. 6. 7. 8. 9. 10. 11.(a) 11.(b) Measurement of Dimensions Tensile Test Elongation test Torsion test Wrapping test Resistance test Mass of Zinc Coating test Uniformity of zinc coating For G.S. Formed wires /wires only. For G.S. Formed wires /wires only. For round wires only For aluminium wires/formed wires only For aluminium conductor only. For aluminium conductor only. Remarks
PAGE 6 OF 8
CLAUSE NO.
S.No. 12.
Type Test Adhesion test
Remarks For G.S. Formed wires /wires only.
For PVC/XLPE insulation & PVC Sheath 13. 14. 15. 16. Test for thickness Tensile strength & elongation tests before ageing and after ageing Ageing in air oven Loss of mass test For PVC insulation and sheath only
17. 18. 19. 20. 21. 22. 23. 24. 25.
Hot deformation test Heat shock test Shrinkage test Thermal stability test Hot set test Water absorption test Oxygen index test Smoke density test Acid gas generation test For completed cables
For PVC insulation and sheath only For PVC insulation and sheath only
For PVC insulation and sheath only For XLPE insulation only For XLPE insulation only For outer sheath only For outer sheath only For outer sheath only
26.
Insulation resistance test (Volume resistivity method)

CLAUSE NO.
27. 28. 5.01.02
High voltage test Flammability test as per IEC - 332 Part-3 (Category -B)
The reports for all the type tests as per IS 9968 (Along with test reports for FRLS Properties and flammability test) shall be submitted for one size of each voltage grade of trailing cables. Acceptance Tests and Routine tests Refer QA table enclosed with specification.
5.02.00
PAGE 8 OF 8
CLAUSE NO.
HT CABLES
1.00.00 1.01.00 CODES & STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS : codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes : IS:7098 (Part -II) IS : 3975 IS : 4905 IS : 5831 IS : 8130 IS : 10418 IS : 10810 ASTM-D 2843 IEC-754 (Part-I) IEC-332 Specification for Cross linked polyethylene insulated PVC sheathed cables. Part-II: For working voltages from 3.3 KV upto and including 33 KV. Low Carbon Galvanized steel wires, formed wires and tapes for armouring of cables. Methods for random sampling. PVC insulation and sheath of electrical cables. Conductors for insulated electrical cables and flexible cords. Specification for drums for electric cables. Methods of tests for cables. Standard test method for density of smoke from the burning or decomposition of plastics. Tests on gases evolved during combustion of electric cables. Tests on electric cables under fire conditions. Part-3: Tests on bunched wires or cables (Category-B).
2.00.00 2.01.00
TECHNICAL REQUIREMENTS The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground (buried) installation with chances of flooding by water. Cables shall be armoured, flame retardant, low smoke (FRLS) type designed to withstand all mechanical, electrical and thermal stresses developed under steady state and transient operating conditions as specified elsewhere in this specification. Aluminium conductor used in power cables shall have tensile strength of more than 100 N/ sq.mm. Conductors shall be multi stranded. XLPE insulation shall be suitable for continuous conductor temperature of 90 deg. C and short circuit conductor temperature of 250 deg C.
2.02.00
2.03.00
2.04.00
SUBSECTION IIIB-04 HT CABLES
PAGE 1 OF 8
CLAUSE NO.
TECHNICAL REQUIREMENTS The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS: 5831. For single core armoured cables, armouring shall be of aluminium wires. For multicore armoured cables armouring shall be of galvanised steel as follows : Calculated nominal dia of cable under armour i) Upto 13 mm ii) Above 13 & upto 25mm Size and Type of armour 1.4mm dia GS wire 0.8 mm thick GS formed wire / 1.6 mm dia GS wire 0.8mm thick GS formed wire / 2.0mm dia GS wire 1.4 mm thick GS wire/2.5mm dia GS wire 1.4 mm thick GS wire/3.15mm dia GS wire formed
2.05.00
2.06.00
iii)
Above 25 & upto 40 mm Above 40 & upto 55mm
iv)
v)
Above 55 & upto 70mm
formed
vi) 2.06.01
Above 70mm
1.4 mm thick GS formed wire / 4.0 mm dia GS wire
The aluminium used for armouring shall be of H4 grade as per IS: 8130 with maximum resistivity of 0.028264 ohm-sq.mm/mtr at 20 deg.C. The types and sizes of aluminium armouring shall be same as mentioned for galvanised steel at 2.06.00 above. The gap between armour wires / formed wires shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wires / formed wires. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface of GS wires/formed wires. Distinct extruded PVC inner sheath of black colour as per IS:5831 shall be provided for the cables as follows: a). For all multicore cables. b). For single core armoured cables , where armouring is not being used as metallic screen.
2.06.02
2.07.00
PAGE 2 OF 8
CLAUSE NO.
TECHNICAL REQUIREMENTS Outer sheath shall be of PVC black in colour. In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables shall have the following FRLS properties. (a.) Oxygen index of min. 29 (Test method as per IS 10810 Part-58) (b.) Acid gas emission of max. 20% as per IEC-754 (Part-I) (c.) Smoke density rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843.
2.08.00
2.09.00
Cores of three core cables shall be identified by colouring of insulation or by providing coloured tapes helically over the cores, with Red, Yellow & Blue colours. In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath : (a.) Cable size and voltage grade - To be embossed (b.) Word 'FRLS' at every 5 metre - To be embossed (c.) Sequential marking of length of the cable in metres at every one metre - To be embossed / printed The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible.
2.10.00
2.11.00
All cables shall meet the fire resistance requirement as per Category-B of IEC-332 Part-3. Allowable tolerances on the overall diameter of the cables shall be +\-2 mm maximum over the declared value in the technical data sheets. In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable. The cross-sectional area of the metallic screen strip/tape/wires shall be considered in sizing calculations. Cable selection & sizing
2.12.00
2.13.00
2.14.00
2.15.00
HT cables shall be sized based on the following considerations:
a)
Rated current of the equipment
PAGE 3 OF 8
CLAUSE NO.
b)
The voltage drop in the cable, during motor starting condition, shall be limited to 10% and during full load running condition, shall be limited to 3% of the rated voltage
c)
Short circuit withstand capability
Derating Factors
Derating factors for various conditions of installations including the following shall be considered while selecting the cable sizes: a) b) c) Variation in ambient temperature for cables laid in air Grouping of cables Variation in ground temperature and soil resistivity for buried cables.
2.16.00
Cable lengths shall be considered in such a way that straight through cable joints are avoided. Cables shall be armoured type if laid in switchyard area, coal handling area or directly buried. The eccentricity shall be calculated as tmax -tmin ------------ x 100 t max and the ovality shall be calculated as dmax -dmin ------------ x 100 d max Where t-max/t-min is the maximum/minimum thickness of insulation and d-max/dmin is the maximum / minimum diameter of the core. The eccentricity of the core shall not exceed 10% and ovality not to exceed 2% .
2.16.01 2.17.00
PAGE 4 OF 8
CLAUSE NO.
3.00.00 3.01.00
CONSTRUCTIONAL FEATURES 3.8/6.6 KV Grade Power Cables: Cables shall conform to IS-7098 Part-II. These cables shall be multi-stranded, compacted circular aluminium conductor, XLPE-insulated, metallic screened, PVC outer sheathed. The conductor screen and insulation screen shall both be of extruded semiconducting compound and shall be applied along with the XLPE insulation in a single operation of triple extrusion process so as to obtain continuously smooth interfaces. Method of curing shall be dry curing / gas curing / steam curing . The metallic screen for each core shall be capable of carrying the system earth fault current of 9kA for 1 seconds, shall consist of copper wires or tape with minimum overlap of 20%. However, for single core armoured cables , the armouring shall constitute the metallic part of the screening.
3.02.00
19/33KV Grade Power Cables: Cables shall conform to IS-7098 Part-II. These cables shall be multi-stranded, compacted circular aluminium conductor, XLPE-insulated, metallic screened, PVC outer sheathed. The conductor screen and insulation screen shall both be of extruded semiconducting compound and shall be applied along with the XLPE insulation in a single operation of triple extrusion process so as to obtain continuously smooth interfaces. Method of curing for 19/33 KV cables shall be dry curing / gas curing .The metallic screen for each core shall be capable of carrying the system earth fault current of 1kA for 1 second, shall consist of copper wires or tape with minimum overlap of 20%. However, for single core armoured cables , the armouring shall constitute the metallic part of the screening.
4.00.00 4.01.01
CABLE DRUMS Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof cover. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS: 10418. Each drum shall carry manufacturer's name, purchasers name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled. The standard drum length for power cables shall not be less than 500 meters. The length per drum shall be subjected to a maximum tolerance of +/- 5% of the standard drum length. The Employer shall have the option of rejecting cable drum with shorter
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUBSECTION IIIB-04 HT CABLES PAGE 5 OF 8
4.01.02
4.01.03
CLAUSE NO.
TECHNICAL REQUIREMENTS lengths. For each size, the variance of total quantity, adding all the supplied drum lengths, from the ordered quantity, shall not exceed +/-2%.
5.00.00 5.01.00
TESTS GENERAL (a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any project shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No Design Change. Minor changes if any shall be highlighted on the endorsement sheet.
(b.)
(c.)
(d.)
5.01.02
Following type tests reports shall be furnished on one size of each type(voltage grade) of cable: S. No 1. Type Test Conductor Resistance test For Armour Wires / Formed Wires 2. 3. 4. 5. 6. 7. Measurement of Dimensions Tensile Test Elongation test Torsion test Wrapping test Resistance test
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUBSECTION IIIB-04 HT CABLES PAGE 6 OF 8
Remarks
For round wires only
CLAUSE NO.
TECHNICAL REQUIREMENTS S. No 8(a) 8(b) Type Test Mass & uniformity of Zinc Coating tests Adhesion test For XLPE insulation & PVC Sheath 9. 10. Test for thickness Tensile strength and elongation test before ageing and after ageing Ageing in air oven Loss of mass test Hot deformation test Heat shock test Shrinkage test Thermal stability test Hot set test Water absorption test Oxygen index test Smoke density test Acid gas generation test Flammability test as per IEC332 Part-3 (Category -B) For PVC outer sheath only. For PVC outer sheath only. For PVC outer sheath only For PVC outer sheath only For XLPE insulation only For XLPE insulation only For PVC outer sheath only For PVC outer sheath only For PVC outer sheath only For completed cable only Remarks For GS wires/formed wires only. For GS wires/formed wires only
11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22
5.01.03
The following type tests shall be submitted for each type(voltage grade) & size of the cable: S. No . 1. 2. Type Test For all cables
Insulation resistance test (Volume Resistivity method) High voltage test
For cables of 6.6 KV & above Grade only. 3. 4. 5. Partial discharge test Bending test Dielectric power factor test
PAGE 7 OF 8
CLAUSE NO.
TECHNICAL REQUIREMENTS a b ) 6. 7. As a function of voltage As a function of temperature
Heating cycle test Impulse withstand test
5.02.00
Indicative list of tests/ checks, Routine and Acceptance tests shall be as per Quality Assurance & Inspection table of H.T. Cables enclosed with this chapter.
PAGE 8 OF 8
CLAUSE NO.
CONTROL CABLES
1.00.00 1.01.00 CODES & STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS: codes, standards, etc.) referred to herein, the former shall prevail. All the cables shall conform to the requirements of the following standards and codes: IS :1554 - I PVC insulated (heavy duty) electric cables for working voltages upto and including 1100V. IS : 3961 IS : 3975 Recommended current ratings for cables Low carbon galvanised steel wires, formed wire and tapes for armouring of cables. IS : 4905 IS : 5831 IS : 8130 IS : 10418 IS : 10810 ASTM-D 2843 Methods for random sampling. PVC insulation and sheath of electrical cables. Conductors for insulated electrical cables and flexible cords. Specification for drums for electric cables. Methods of tests for cables. Standard test method for density of smoke from the burning or decomposition of plastics. ASTM-D-2863 Standard method for measuring the minimum oxygen concentration to support candle like combustion of plastics. IEC-754 (Part-I) IEEE-383 IEC 332 Test on gases evolved during combustion of electric cables. Standard for type test of Class IE Electric Cables. Tests on Electric cables under fire conditions. Part-3 : Tests on bunched wires or cables (category -B)
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-05 CONTROL CABLES PAGE 1 OF 6
CLAUSE NO.
2.00.00 2.01.00
TECHNICAL REQUIREMENTS The cables shall be suitable for laying on racks, in ducts, trenches, conduits and under ground burried installation with chances of flooding by water. Cables shall be armoured. flame retardant, low smoke (FRLS), type designed to withstand all mechanical, electrical and thermal stresses develop under steady state and transient operating conditions as specified elsewhere in this specification. Conductor of control cables shall be made of multi stranded, plain annealed copper. PVC insulation shall be suitable for continuous conductor temperature of 70 deg C and short circuit conductor temperature of 160 deg. C. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath. All the cables, other than single core unarmoured cables, shall have distinct extruded PVC inner sheath of black colour as per IS : 5831. For multicore armoured cables, the armouring shall be of galvanised steel as follows: Calculated nominal dia. of cable under armour 1) 2) 3) 4) 5) 6) Upto 13 mm Above 13 upto 25 mm Above 25 upto 40 mm Above 40 upto 55mm Above 55 upto 70 mm Above 70mm Size and Type of armour 1.4mm dia GS wire 0.8 mm thick GS formed wire / 1.6 mm dia GS wire 0.8mm thick GS formed wire / 2.0mm dia GS wire 1.4 mm thick GS formed wire/2.5mm dia GS wire 1.4mm thick GS formed wire / 3.15mm dia GS wire 1.4 mm thick GS formed wire / 4.0 mm dia GS wire
2.02.00
2.03.00 2.04.00
2.05.00
2.06.00
The gap between armour wire / formed wire shall not exceed one armour wire / formed wire space and there shall be no cross over / over-riding of armour wire / formed wire. The minimum area of coverage of armouring shall be 90%. The breaking load of armour joint shall not be less than 95% of that of armour wire / formed wire. Zinc rich paint shall be applied on armour joint surface. 2.07.00 Outer sheath shall be of PVC (grade as applicable) and grey in colour . In addition to meeting all the requirements of Indian standards referred to, outer sheath of all the cables (including trailing cables) shall have the following FRLS properties.
SUB-SECTION-IIIB-05 CONTROL CABLES
PAGE 2 OF 6
CLAUSE NO.
(a.) Oxygen index of min. 29 (As per ASTMD 2863) (b.) Acid gas emission of max. 20% (As per IEC-754-I). (c.) Smoke density rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843.
2.08.00
Cores of the cables of upto 5 cores shall be identified by colouring of insulation. Following colour scheme shall be adopted. 1 core 2 core 3 core 4 core 5 core Red, Black, Yellow or Blue Red & Black Red, Yellow & Blue Red, Yellow, Blue and Black Red, Yellow, Blue, Black and Grey
2.09.00
For cables having more than 5 cores, core identification shall be done by numbering the insulation of cores sequentially, starting by number 1 in the inner layer (e.g. say for 10 core cable, core numbering shall be from 1 to 10). The number shall be printed in Hindu-Arabic numerals on the outer surfaces of the cores. All the numbers shall be of the same colour, which shall contrast with the colour of insulation. The colour of insulation for all the cores shall be grey only. The numerals shall be legible and indelible. The numbers shall be repeated at regular intervals along the core, consecutive numbers being inverted in relation to each other. When the number is a single numeral, a dash shall be placed underneath it. If the number consists of two numerals, these shall be disposed one below the other and a dash placed below the lower numeral. The spacing between consecutive numbers shall not exceed 50 mm. In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath: (a.) Cable size and voltage grade - To be embossed (b.) Word 'FRLS' at every 5 metre - To be embossed (c.) Sequential marking of length of the cable in metres at every one metre. To be embossed / printed. -
2.10.00
The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible. For EPR cables identification shall be printed on outer sheath. 2.11.00 All cables shall meet the fire resistance requirement as per Category-B of IEC 332 Part -3.
PAGE 3 OF 6
CLAUSE NO.
2.12.00
Allowable tolerances on the overall diameter of the cables shall be +\-2 maximum over the declared value in the technical data sheets.
mm
2.13.00
Inplant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable. Cable selection & sizing Control cables shall be sized based on the following considerations: (a) (b) The minimum conductor cross-section shall be 1.5 sq.mm. The minimum number of spare cores in control cables shall be as follows: No. of cores in cable 2C, 3C 5C 7C-12C 14C & above Min. No. of spare cores NIL 1 2 3
2.14.00
2.14.01
Cable lengths shall be considered in such a way that straight through cable joints are avoided. CONSTRUCTIONAL FEATURES 1.1 KV Grade Control Cables shall have stranded copper conductor multicore PVC insulated, PVC inner-sheathed, PVC outer-sheathed conforming to IS:1554. (Part-I). 1.1KV grade trailing cables shall have tinned copper (class-5) conductor, insulated with heat resistant elastomeric compound based on Ethylene Propyline Rubber (EPR) suitable for withstanding 90 deg C continuous conductor temperature and 250 deg C during short Ckt., inner sheathed with heat resistant, oil resistant and flame retardant heavy duty elastomeric compound conforming to IS 9968. Minimum conductor size shall be 2.5sqmm. CABLE DRUMS (a.) Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood
3.00.00 3.01.00
3.02.00
4.00.00
PAGE 4 OF 6
CLAUSE NO.
preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS : 10418. (b.) Each drum shall carry manufacturer's name, purchasers name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both the sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled. 5.00.00 TESTS (a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No Design Change. Minor changes if any shall be highlighted on the endorsement sheet.
(b.)
(c.)
(d.)
5.01.00 5.01.01
TYPE TESTS The reports for the following type tests shall be submitted for one size of control cables : S. No. Type Test For Conductor 1. Resistance test For Armour Wires / Formed Wires 3. Measurement of Dimensions 4. Tensile Test Remarks
PAGE 5 OF 6
CLAUSE NO.
5. Elongation test 6. Torsion test 7. Wrapping test 8. Resistance test 9(a). Mass of zinc Coating test 9(b). 10. Uniformity of zinc coating Adhesion test For PVC insulation & PVC Sheath 11. Test for thickness 12. Tensile strength and elongation before ageing and after ageing test 13. Ageing in air oven 14. Loss of mass test 15. Hot deformation test 16. Heat shock test 17. Shrinkage test 18. Thermal stability test 19. Oxygen index test 20. Smoke density test 21. Acid gas generation test For completed cables 22. Insulation resistance test(Volume resistivity method) 23. High voltage test 24. Flammability test as per IEC - 332 Part-3 (Category-B) 5.01.02 The reports for all the type tests as per IS 9968 (Along with test reports for FRLS Properties and flammability test) shall be submitted for one size of trailing cables. Acceptance Tests and Routine tests Refer QA table enclosed with specification. . For PVC insulation and sheath only For outer sheath only For outer sheath only For outer sheath only For PVC insulation and sheath only For PVC insulation and sheath only For PVC insulation and sheath only For GS wires/formed wires only For GS wires/formed wires only For GS wires/formed wires only For round wire only
5.02.00
PAGE 6 OF 6
CLAUSE NO.
TECHNICAL REQUIREMENTS INSTRUMENTATION CABLES
1.00.00 1.01.00 1.01.01
INSTRUMENTATION CABLES GENERAL The Contractor shall supply, erect, terminate and test all instrumentation cables for control and instrumentation equipment/devices/systems included under Contractor's scope. Any other application where it is felt that instrumentation cables are required due to system/operating condition requirements, are also to be provided by Contractor. Other type of cables like fiber optic/co-axial cables for system bus, cables for connection of peripherals etc. (under Contractor's scope) are also to be furnished by the Contractor. Contractor shall supply all cable erection and laying hardware trays, supports, flexible conduits, cable glands, lugs, pull boxes etc. on as required basis for all the systems covered under this specification.
1.01.02 1.01.03
1.01.04
1.02.00
1.02.01
Instrumentation Cable Specifications

All the instrumentation cables shall be Armoured, twisted, shielded multipair, pre fabricated, flame retardant low smoke (FRLS) type. The Cables shall be provided in non-returnable drums. The drum length shall be 1000m (+/-5%) up to & including 12 pairs and 500 m (+/- 5%) above 12 pairs. Voltage grade of the instrumentation cables shall be 225V (peak value). All instrumentation cables covered in this specification shall comply with VDE 0815, VDE 0207, Part 4, Part 5, Part 6, VDE 0816,VDE 0472, SEN 4241475, ANSI MC 96.1, IS-8784, IS-10810 (latest editions) and its amendments read along with this specification. The conductor shall be of minimum 0.5-sq.mm size, high conductivity, multi-stranded copper for all types of instrumentation cables where as the same shall be min. 1.5sqmm when used in the trailing cables. The insulation of individual conductor shall be extruded PVC meeting the requirements of VDE 0207 Part 4 compound Y I3. The outer sheath of instrumentation cables shall be extruded PVC (compound YM1) as per VDE 0207 Part 5 and shall be of flame-retardant low smoke (FRLS) type. The cable shall be provided with marking including manufacturer's name, insulation material, and conductor sizes, no of pairs, voltage ratings, type of cable etc. at intervals not exceeding 625mm. Progressive sequential marking of the length of the cable at every one meter & progressive markings to read 'FRLS' at every 5 meters shall be provided on the outer sheath of all instrumentation cables. The colour of outer sheath shall be sky blue.
1.02.02 1.02.03
1.02.04
1.02.05
SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES
PAGE 1 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS Fillers in multiple conductor cables shall be flame retardant and moisture resistant. Cable accessories such as harnessing components, markers, bedding, cable jointer, binding tape etc. shall also have flame retardant quality.
1.02.06
All instrumentation cables shall be provided with overall shielding. However, multipair cables carrying analog signals shall be provided with individual pair shielding in addition to overall shielding. Shielding shall be of Aluminium-Mylar tape with 100% coverage and with atleast 20% overlapping. The thickness of individual pair shield shall be 28 micron (minimum) and that of overall shield shall be 55 microns (minimum). Separate drain wires for individual pair shield (wherever applicable) as well as overall shield shall be provided. Drain wire shall be of seven (7) strand 20 AWG (0.51 Sq.mm) tin coated copper conductor. Maximum lay of individual twisted pair shall be 50 mm. Bidder to ensure that individual core diameter shall be suitable for maxi-termi connection. Insulation thickness of individual core shall be between 0.28 and 0.35 mm for 0.5 mm2 cables. The outer sheath of the instrumentation cables shall meet the following minimum requirements: (i) An Oxygen index of not less than 29% and a Temperature index of not less than 250 deg.C as per ASTMD-2863. Maximum acid gas generation by weight as per IEC-754-I shall not be more than 20%. Smoke Density Rating shall not be more than 60% during Smoke Density Test as per ASTMD-2843. The results of smoke density test shall be plotted on a curve indicating light absorption vs. time as per ASTMD2843. The average area under the curve (smoke density rating) shall not be more than 60%. Complete cable assembly shall pass Swedish Chimney test as per SEN4241475 and flammability test as per IEEE-383.
1.02.07
(ii)
(iii)
(iv)
The thickness of outer sheath shall be as per the guidelines given in VDE 0816. Thickness of outer sheath shall not be less than 1.8 mm in any case. Allowable tolerance of overall diameter of the cables shall be +/-2 mm max. over the declared value in technical data sheets. The variation in diameter and the ovality at any cross section shall not be more than 1.0 mm. 1.02.08 All instrumentation cables shall be suitable for continuous operation at 70 deg.C, except for high temperature resistant teflon insulated cables which shall be suitable for continuous operation at 205 deg.C. The cables shall be suitable for laying in wet or dry locations in trays, conduits, ducts, trenches and under ground buried installations. The thermocouple extension cables shall be of single/multi pair, twisted & shielded, PVC insulated, FRLS PVC sheathed and compatible for the type of thermocouples employed. The material of conductor shall be as per ANSI MC-96.1. The material
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-06 INSTRUMENTATION CABLES PAGE 2 OF 11
1.02.09
CLAUSE NO.
TECHNICAL REQUIREMENTS and requirements of conductor insulation, shielding and outer sheath shall be as per the above clauses.
1.02.10
Cable parameters such as mutual capacitance between conductors, conductor resistance, insulation resistance, characteristic impedance, cross talk and attenuation figures at 20 deg.C ( 3 deg.C) for various types of cables as applicable shall be as specified under Table A. Identification of the cores & pairs shall be done with suitable colour coding & band marking as well as by numbering of cores/pairs as per VDE: 0815. The details of colour coding etc. shall be as approved by Employer during detailed stage. Also refer Table B for description of various type of cables. The Contractor shall furnish all documentary evidence including cross-sectional drgs, test certificates to substantiate the suitability of cables offered for different applications. The contractor shall also clearly bring out the application wise details for each type of cable offered. All prefabricated cables shall have 10% spare cores which will not be connected to pin connectors. CABLE PARAMETER Table A : CABLE PARAMETER Conductor Size Parameter/ Type of Cable Individual and overall shielded (Type F) 120 nF/Km. 0.5 Sq.mm. Overall Shielded(Type-G) Compensating cables (with/without Teflon coating) (Type A,B,C) 200 nF/Km
1.02.11
1.02.12
1.02.13 1.02.14
Mutual capacitance at 0.8 kHz (max.) Conductor Resistance (max.) Insulation resistance Cross-Talk figure at 0.8 kHz (min.) Characteristic impedance (max.)
100 nF/Km.
73.4 ohm/km (loop)For Type F 100 M ohm/ Km 60 dB
73.4 ohm/km (loop) 100 M ohm/ Km 60 dB 100 M ohm/ Km 60 dB
320 ohm
340 ohm
PAGE 3 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS Attenuation at 1 kHz (max.) 1.2 dB/Km 1.2 dB/Km
1.02.15
DESCRIPTION OF VARIOUS TYPE OF CABLES TABLE B Type A B C Conductor Size 0.5 mm2 0.5 mm2 0.5 mm2 Description Two pair shielded and twisted pair T/C extension cable, ANSI type KX, stranded conductor. Two pair shielded & twisted T/C extension cable ANSI type SX, stranded conductor. Two pair shielded & twisted heat resistant teflon insulation & Outer sheath T/C extension cable ANSI type KX, stranded conductor. Multi pair individual pair & overall shielded twisted pair instrumentation cable (4/8/12/24 pair) for analog signals with stranded copper conductor. Multi pair overall shielded & twisted pair instrumentation cable (2/4/8/12/24/48 pair) for binary signals with stranded copper conductor. Type F cable/type G cable with heat resistant teflon insulation & outer-sheath for high temperature application. Multi core/ Multi pair shielded cable for system specific cables. Like conductivity type level switches, Vibration monitoring system cable, System Bus cable, Bus communications cable etc. as applicable.
0.5 mm2
0.5 mm2
0.5 mm2
As per specific Standard/ Requirement for each application
1.03.00 1.03.01
INSTRUMENTATION PHILOSOPHY
CABLE
INTERCONNECTION
AND
TERMINATION
The cable interconnection philosophy to be adopted shall be such that extensive grouping of signals by large scale use of field mounted Group JBs at strategic locations (where large concentration of signals are available, e.g. switchgear) is done and consequently cable with higher number of pairs are extensively used. The details of termination to be followed are mentioned in the given table C.
PAGE 4 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS TABLE C:- CABLE TERMINATION TO BE FOLLOWED Application Type Of Termination Type Of Cable
FROM (A) Valves/dampers drives (Integral Junction box)
TO (B) Marshalling ubicle/local group JB/Termination/Control Cabinets/System Cabinets Local junction box
END A Plug in connector
END B Post moun ted Maxi termi/cage clamp type. G
RTD heads
Plug in connector
Maxitermi/ cage clamp (Rail moun ted) type. Screwed/ Cage clamp Type Screwed/ Cage clamp Type Post moun ted Maxi termi/cage clamp type.
Thermocouples
CJC box
Plug in connector
A,B,C*
RTD thermocouple
Temperature transmitter
Plug in connector
Local Junction box, CJC box, Group JB/ MCC/SWGR
Marshalling Cubicle/local group JB/Termination/ Control Cabinets/System Cabinets Group JB
Maxitermi/ cage clamp (Rail moun ted) type.
F,G
Local Junction box, MCC/SWGR
Maxitermi/ cage clamp (Rail moun ted) type. Maxitermi/ cage clamp (Rail moun ted) type. Post mounted Maxi termi/cage clamp type.
Maxitermi/ cage clamp (Rail moun ted) type. Maxitermi/c age clamp (Rail moun ted) type. Post mounted Maxi termi/cage clamp type.
F,G
Field mounted Instrument
Group JB
F,G
Marshalling cubicle/ Termination Cabinet

Electronic system cabinet
F,G
PAGE 5 OF 11
CLAUSE NO.
Marshalling / Termination system cabinets
UCP mounted equipments
Post moun ted Maxi termi/cage clamp type.
Plug in connector/ Cage clamp type (rail mounted). Plug in connector
F,G (with plug-in connector at one end)
DDCMIS/PLC cabinets Notes
PC, Printers etc.
Plug in connector
Mfr.s Standard
1 Normally 10% spare core shall be provided when the number of pairs of cables are more than four pairs. 2 For analog signals individual pair shielding & overall shielding & for Binary signals only overall shielding of instrumentation cables shall be provided. 3 * For high temperature application only.
2.00.00 2.01.00
TERMINAL BLOCKS All terminal blocks shall be rail mounted/post mounted, cage clamp type/maxi-termi type (MTP) with high quality non-flammable insulating material of melamine suitable for working temperature of 105 deg. C. The terminal blocks in field mounted junction boxes, CJC boxes, etc., shall be suitable for cage clamp/ MTP connections. The terminal blocks in Control Equipment Room logic/termination/marshalling cubicles shall be suitable for post mounted maxi-termi/cage clamp connection at the field input end. The terminal blocks for DDCMIS input/output connections from/to SWGR/MCC, Actuators with Integral Starter (for coupling relays and check back signals of 11 kV and 3.3 kV auxiliaries, LT drives/valves & dampers/solenoids, CT & VT, etc.) shall be provided with built in test and disconnect facilities complete with plug, slide clamp, test socket, etc. The exact type of terminal blocks to be provided by the Contractor and the technical details of the same including width etc. shall be subject to Employer's approval. All the terminal blocks shall be provided complete with all required accessories including assembly rail, locking pin and section, end brackets, partitions, small partitions, test plug bolts and test plug (as specified above for SWGR connections) transparent covers, support brackets, distance sleeves, warning label, marking, etc. The marking on terminal strips shall correspond to the terminal numbering on wiring diagrams. At least 20% spare unused terminals shall be provided everywhere including local junction boxes, instrument racks/enclosures, termination/marshalling cabinets, etc. All terminal blocks shall be numbered for identification and grouped according to the function. Engraved labels shall be provided on the terminal blocks. The terminal blocks shall be arranged with atleast 100 mm clearance between two sets of terminal blocks and between terminal blocks and junction box walls. For ensuring proper connections, Contractor shall provide suitable accessories, along with insulation sleeves. The exact connecting accessory shall be finalised as
2.02.00
2.03.00
2.04.00 2.05.00
PAGE 6 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS per application during detail engineering stage subject to Employer's approval without any cost repercussions.
2.06.00
Internal wiring in factory prewired electronic equipment cabinets may be installed according to the Contractor's standard as to wire size and method of termination or internal equipment. Terminal blocks for connection of external circuits into factory prewired electronic equipment cabinets shall meet all the requirements as specified above. INTERNAL PANELS/CABINETS/SYSTEM CABINETS WIRING Internal panel/cabinet wiring shall be of multistranded copper conductor with FRLS PVC insulation without shield and outer sheath meeting the requirements of VDE 0815. Wiring to door mounted devices shall be done by 19 strand copper wire provided with adequate loop lengths of hinge wire so that multiple door opening shall not cause fatigue breaking of the conductor. All internal wires shall be provided with tag and identification nos. etched on tightly fitted ferules at both ends in Employer's approved format. All wires directly connected to trip devices shall be distinguished by one additional red colour ferrule. All external connection shall be made with one wire per termination point. Wires shall not be tapped or spliced between terminal points. All floor slots of desk/panels/cabinets used for cable entrance shall be provided with removable gasketed gland plates and sealing material. Split type grommets shall be used for prefabricated cables. All the special tools as may be required for solderless connections shall be provided by Bidder. Wire sizes to be utilised for internal wiring. (i) (ii) Current (4-20 mA), low voltage signals (48V) Power supply and internal illumination. 0.5 Sq.mm. 2.5Sq.mm. minimum (shall be as per load requirement.)
3.00.00 3.01.00
3.02.00
3.03.00
3.04.00 3.05.00
3.06.00 3.07.00
4.00.00 4.01.00
CABLE INSTALLATION AND ROUTING All cables assigned to a particular duct/conduit shall be grouped and pulled in simultaneously using cable grips and suitable lubricants. Cables removed from one duct/conduit shall not be reused without approval of Employer.
Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the higher voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of the tray stack. 4.02.00 Cables shall terminate in the enclosure through cable glands. All cable glands shall be properly gasketed.
CLAUSE NO.
TECHNICAL REQUIREMENTS All cables shall be identified by tag. Nos. provided in Employer's approved format at both the ends as well as at an interval of 5 meters. Line voltage drop due to high resistance splices, terminal contacts, insulation resistance at terminal block, very long transmission line etc. shall be reduced as far as practicable. The cables emanating from redundant equipment/devices shall be routed through different routes. CABLE LAYING AND ACCESSORIES CABLE LAYING 1 2 Cables shall be laid strictly in line with cable schedule. Identification tags for cables. Indelible tags to be provided at all terminations, on both sides of wall or floor crossing, on each conduit/duct/pipe entry/exit, and at every 20 m in cable trench/tray. 3 Cable tray numbering and marking. To be provided at every 10m and at each end of cable way & branch connection. 4 5 Joints for less than 250 Meters run of cable shall not be permitted. Buried cable protection With concrete slabs; Route markers at every 20 Meters along the route & at every bend. 6 Road Crossings Cables to pass through burried high density PE pipes encased in PCC. At least 300 mm clearance shall be provided between HT power & LT power cables, LT power & LT control/instrumentation cables,
4.03.00 4.04.00
4.05.00 5.00.00 5.01.00
Spacing between cables of same voltage grade shall be in accordance with the derating criteria adopted for cable sizing.
Segregation (physical isolation to prevent fire jumping) a All cable associated with the unit shall be segregated from cables of other Units.
CLAUSE NO.
TECHNICAL REQUIREMENTS b Interplant cables of station auxiliaries and unit critical drives shall be segregated in such a way that not more than half of the drives are lost in case of single incident of fire.
Cable clamping All cables laid on trays shall be neatly dressed up & suitably clamped/tied to the tray. For cables in trefoil formation, trefoil clamps shall be provided.
6.00.00
FIELD MOUNTED LOCAL JUNCTION BOXES (i) (ii) (iii) No. of ways Material Thickness Type 12/24/36/48/64/72/96/128 with 20% spare terminals. and 4mm thick fiberglass reinforced polyester. Screwed at all four corners for door. Door handle shall be self locking with common key. Door gasket shall be of synthetic rubber.
(iv)
Mounting clamps Suitable for mounting on walls, columns, structures etc. and accessories The brackets, bolts, nuts, screws, glands and lugs required for erection shall be of corrosion resistant material, included in Bidders scope of supply.
(v)
Type of terminal blocks
Rail mounted maxitermi or cage-clamp type suitable for conductor size upto 2.5 mm2. A M6 earthing stud shall be provided. IP:55 minimum for Indoor & IP-65 Outdoor applications To be decided during detailed engineering & subject to Employers approval.
(vi) (vii) 7.00.00 7.01.00
Protection Class Colour
CONDUITS All rigid conduits, couplings and elbows shall be hot dipped galvanised rigid mild steel in accordance with IS:9357 Part-I (1980) and Part-II (1981). The conduit interior and exterior surfaces shall have continuous zinc coating with an overcoat of transparent enamel lacker or zinc chromate. Flexible conduit shall be heat resistant lead coated steel, water leak, fire and rust proof. The temperature rating of flexible conduit shall be suitable for actual application.
PAGE 9 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS TESTS GENERAL (a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No Design Change. Minor changes if any shall be highlighted on the endorsement sheet.
8.00.00 8.01.00
(b.)
(c.)
(d.)
8.02.00 8.02.01
TYPE TEST Following type tests reports shall be submitted for one size of each type of instrumentation cables: For Conductor (including Drain Wire)
Sl. No. 1. 2. 3. Test Resistance Test Diameter Tin coating (Persulphate Test) Reference Standard VDE:0815 IS:10810 As per standard Remarks
8.02.02
test*
relevant
*Applicable for drain wire only
8.02.03
For PVC Insulation And PVC Sheath Sl.No. 1. 2. 3. 4. Reference Standard Test for thickness** IS:10810 Tensile strength and elongation test VDE:0472 before and after ageing** Ageing in air ovens** - doLoss of Mass Test -doTECHNICAL SPECIFICATION SECTION-VI, PART-B
Test
Remarks
PAGE 10 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hot deformation test Heat shock test Shrinkage test** Cold bend/ cold impact test Colour fastness to water Thermal stability test Bleeding and blooming Oxygen index test (for sheath & fillers) Smoke density test (for sheath & fillers) Acid gas generation test (for sheath & fillers) -do- do-do- do-do-do-doASTMD-2863 ASTMD-2843 IEC-754-1
8.02.04
For Al-Mylar Shield Sl.No. 1. 2. 3. 4. Test Continuity test Shield thickness test Overlap test Noise test Reference Standard As per relevant standard -do-do Remarks
interference IEEE-Transaction March'67
8.03.00
Acceptance tests and routine test Refer QA table enclosed with the specification.
PAGE 11 OF 11
CLAUSE NO.
ILLUMINATION 1.00.00 1.01.00 GENERAL This specification covers the general description of design, manufacture and construction features, testing, supply, installation and commissioning of the illumination system equipment required to be provided by the bidder. CODES AND STANDARDS All standards and codes of practice referred to herein shall be the latest edition including all applicable official amendments & revisions as on date of bid opening. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards & codes. Lighting Fixtures and Accessories IS:1913 IS:2148 IS:418 IS:1258 IS:1534 IS:1569 General and safety requirements for luminaries. Flame proof enclosures of electrical apparatus. Tungsten filament general service electric lamps. Bayonet lamp holders. Ballast for fluorescent lamps. Capacitors for use in tubular fluorescent, high pressure mercury vapour and low pressure sodium vapour discharge lamp circuit. Industrial luminaire with metal reflectors.
1.02.00 1.03.00
1.04.00
IS:1777
IS:2149 IS:2215 IS:2418 IS:3323 IS:3324
Luminaire for Street lighting. Starters for fluorescent lamps. Tubular fluorescent lamps for general lighting services. Bi-pin lamp holders for tubular fluorescent lamps. Holders for starters for tubular fluorescent lamps.
SUB-SECTION-IIIB-07 ILLUMINATION
PAGE 1 OF 12
CLAUSE NO.
IS:4013 IS:6616 IS:8224 IS:9900 IS:9974 IS:10276 IS:10322 IS:13021
Dust-tight electric lighting fittings. Ballasts for high pressure mercury vapour lamps. Electric Lighting fittings for Division 2 areas. High-pressure mercury vapour lamps. High pressure Sodium vapour lamps. Edison screw lamp holders. Luminaires. AC Supplied Electronic Ballasts for tubular fluorescent lamps.
1.05.00
Lighting Panels, Switch-boxes, Receptacles and Junction Boxes IS:2147 Degree of protection provided by enclosures for low-voltage switchgear and control gear.
IS:1293
Plugs & socket outlets of rated voltage upto and Including 250volts & rated current upto and including 16 Amps. Danger notice plates. Low voltage switchgear and controlgear Switches for domestic and similar purposes. Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto and including 1000 V AC and 1200 V DC. Low voltage fuses for voltages not exceeding 1000V AC or 1500 V DC.
IS:2551 IS:13947 IS:3854 IS:6875
IS:13703
PAGE 2 OF 12
CLAUSE NO.
1.06.00
Conduits, Pipes and Accessories IS:2667 IS:3837 IS:9537 Fittings for rigid steel conduit for electrical wiring. Accessories for rigid steel conduits for electrical wiring. Conduits for electrical installations.
1.07.00
Lighting Wires/Cables IS:694 PVC insulated cables for working voltages upto and including 1100 V Recommended current ratings for cables.(PVC Insulated and PVC sheathed heavy duty cables and light duty cables). Conductors for insulated electric cables and flexible cords. Methods of tests for cables.
IS:3961
IS:8130
IS:10810 1.08.00
Electrical Installation Practices & Miscellaneous IS:1944 IS:3646 IS:5572 Code of practice for lighting of public thorough fare Code of practice for interior illumination. Classification of Hazardous areas (other than Mines)having flammable gases and Vapours for electrical installation Code of practice for industrial lighting. National Electrical Code Indian Electricity Rules. Indian Electricity Act Colour for ready mixed paints & enamels. Mild steel wires for general engineering purposes. Electric ceiling type fans & regulators.
IS:6665 . . IS:5 IS:280 IS:374
PAGE 3 OF 12
CLAUSE NO.
IS:732 IS:1255
Code of practice for electrical wiring installations. Code of practice for installation and maintenance of power cables Upto and including 33KV rating. Steel for general structural purposes Recommended practice for hot-dip galvanizing of iron and steel. Methods for testing uniformity of coating of zinc coated articles. Tubular steel poles for overhead power lines. Code of practice for earthing Guide for safety procedures and practices in electrical work. Guide for selection of electrical equipments for hazardous areas. Mechanical cable glands
IS:2062 IS:2629
IS:2633
IS:2713 IS:3043 IS:5216
IS:5571
BS:6121
2.00.00
2.01.00
LIGHTING SYSTEM DESCRIPTION

Normal AC Lighting System Normal AC lighting system 415V, 3Phase, 4wire, will be fed from lighting panels (LPs) which will be fed from the lighting distribution boards (LDBs) which in turn will be fed from LT MCCs.
2.02.00
Emergency Lighting System Self contained emergency lighting fixtures shall be provided, 2 nos. in each control area and in each TP and in each MCC rooms, mounted suitably on wall/columns at strategic points for safe exit of the personnel. Each fixture shall be fed from a dedicated 20A, 240V socket. In the control room these fixtures shall also be provided in the control panel area for emergency operation of the plant. The fixtures shall be switched ON automatically in case of failure of AC supply. These shall be switched off automatically after the normal AC supply is restored and the luminaries have attained their full glow. Emergency lighting is to be provided through self contained 4 hour duration fixtures located strategically. Each shall be provided with Ni-Cd battery, battery charger & 2 x 10W fluorescent lamps. These emergency lamps shall be mounted in pilfer proof enclosure having pad locking arrangement.
PAGE 4 OF 12
CLAUSE NO.
In addition to the above, 3 nos. of 100W, 110V DC lighting fixtures shall also be provided in each HT Swichgear room and in each control room 2.03.00 DESIGN PHILOSOPHY 1. 2. A comprehensive illumination system shall be provided. All lighting system shall be automatically controlled by synchronous timer. Provision to bypass the timer shall be provided in the panel for manual control. The system shall include distribution boards, lighting panels, lighting fixtures, junction boxes, receptacles, switch boards, lighting pole/masts, conduits, cables and wires, etc. The system shall cover all interior and exterior lighting such as area lighting, including Transformer yard etc. The constructional features of lighting distribution boards shall be similar to AC/DC distribution boards described in chapter of LT Switchgear. Outgoing circuits in LPs shall be provided with MCBs of adequate ratings. The illumination system shall be designed on the basis of best engineering practice and shall ensure uniform, reliable, aesthetically pleasing and glare free illumination. The lighting fixtures shall be designed for minimum glare. The design shall prevent glare/luminous patch seen on VDU/ Large video screens, when viewed from an angle. The finish of the fixtures shall be such that no bright spots are produced either by direct light source or by reflection. The diffusers/ louvers used in fluorescent fixtures shall be made of impact resistant polystyrene sheet and shall have no yellowing property over a prolonged period. The Lux levels to be adopted for various area are indicated at Annexure A. Apart from maintenance factor as given below, Temperature correction factor shall be considered in the lighting design for fluorescent fixtures located in non air conditioned area. (a) (b.) (c.) 6. 7. 8. Air conditioned area Non Air conditioned and other indoor area Dust prone indoor areas and outdoor areas : 0.8 : 0.7 : 0.6
3.
4.
5.
All outdoor fixtures shall be weather proof. All lighting fixtures & control gears shall be powder coated. Wires of different phase shall normally run in separate conduit. For areas illuminated by more than one circuit, the adjacent circuits shall be from different phases. Power supply shall be fed from suitable number of conveniently located
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-07 ILLUMINATION PAGE 5 OF 12
9.
CLAUSE NO.
lighting distribution boards (LDB) and lighting panels (LP). AC lighting supply shall be isolated from main supply by isolation transformers (415/433V, delta / star, epoxy insulated, air cooled, dry type) of max. rating of 100KVA and fault level restricted to 3 KA at Lighting Panels. Minimum 2 ways shall be kept as spare feeders in the lighting panels. 10. Lighting panels shall be constructed out of 2 mm thick CRCA sheet steel. The door shall be hinged and the panel shall be gasketted to achieve specified degree of protection. The panel shall be provided with terminal bocks for incoming and outgoing circuits, earthing terminals, removable gland plates at bottom and canopy shall be provided with slope towards the rear side of the panel. Wiring inside the panel shall be carried out with 1100 V grade PVC insulated stranded copper wires of adequate size. Terminal blocks shall be 750 V grade, clip-on stud type, moulded in melamine and shrouded. All MCBs/ Isolators/ Switches/ Contactors etc. shall be mounted inside the panel and a fibre glass sheet shall be provided inside the main door such that the operating knobs of MCBs etc., shall project out of it for safe operation against accidental contact. MCBs shall be current limiting type with magnetic and thermal release suitable for manual closing and automatic tripping under fault condition with short circuit interrupting capacity of 9 KA rms. Isolators of AC lighting panels shall be of TPN, continuous duty, load make-break type and fuses shall be of HRC plug in type.
Synchronous timers shall be quartz controlled electronic type, complete with rechargeable nickel cadmium cell, 24 hours range day dial, NO/NC contacts etc. and suitable for operation on 240V AC supply. The exterior side of panel, shall be powder coated with smoke grey, shade RAL9002 and the interior side of panel, shall be white. Lighting panels shall have IP55 degree of protection in general. However LP located in dusty areas shall have IP65 degree of protection. Ladder approaches shall be provided for maintaining the fixtures wherever applicable. 12. 20A, 240V AC industrial type receptacles shall be provided in the following areas : Two in each switchgear / MCC room, Pump house and on stackerreclaimer. One on each floor of TPs and crusher house building
CLAUSE NO.
At 30m interval on both sides of the conveyor gallery and track hopper shed. At 50m interval on one side of yard conveyor These receptacles shall be energized from lighting panel. Maximum three receptacles shall be connected in one circuit.
10A, 24V AC receptacles with IP55 DOP shall be provided in the following areas. 13. One in each switchgear / MCC room, Pump house and on stackerreclaimer. One on each floor of TPs and crusher house building It shall not be possible to insert 24V plug into 240V receptacle These receptacles shall be energized from lighting panel. Maximum three receptacles shall be connected in one circuit.
All fluorescent fixtures shall have energy efficient T5 type fluorescent lamps except those in div 2 hazardous area. The louvers of these fixtures shall be designed for T5 type fluorescent lamps. All fluorescent lamps shall have cool day light colour designation. The mirror optics type fluorescent fixtures shall have no iridescence effect.
2.03.00 2.03.01
Ballasts All HPSV and HPMV lamp fixtures shall be provided with wire-wound ballasts. All fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings (DivII/Hazardous Area) shall be provided with electronic ballasts. All luminaires and their accessories and components shall be of type readily replaceable by available Indian makes. Fans & Regulator Ceiling Fans, to be provided in non air-conditioned office / control room area shall be suitable for operation on 240 V, 50 Hz, AC supply comprising of class F insulated copper wound single phase motor, 1200mm sweep, aerodynamically designed well balanced MS blades (3 Nos.), down rod, die cast aluminium housing, capacitor, suspension hook, canopies etc. finished in stove enameled white. Power factor of fans shall not be less than 0.9. Each fan shall cover approximately 10sq.m. area. Switch Box Switch boxes shall be made of 1.6 mm thick, MS sheet with 3 mm. thick decorative, perspex cover. Switchbox shall be hot dip galvanised Junction boxes Junction box for lighting fixtures shall be deep drawn or fabricated type made of min. 1.6 mm thick CRCA Sheet. The box shall be hot dip galvanised .
2.04.00 2.05.00 2.05.01
2.06.00 2.06.01 2.07.00
PAGE 7 OF 12
CLAUSE NO.
2.08.00
Conduits, Fittings & Accessories Conduits, Pipes and Accessories Galvanised heavy duty steel conduits for normal area and galvanised heavy duty steel conduits with an additional epoxy coating for corrosive area shall be offered. Alternatively glass reinforced epoxy conduits with comparable compressive and impact strength with that of heavy duty steel conduits may be offered.
2.08.01
Rigid Steel Conduits (a.) Rigid steel conduits shall be heavy duty type,hot dip galvanised conforming to IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses, threaded on both sides and threaded length shall be protected by zinc rich paint. Conduits shall be smooth from inside and outside.
2.08.02 2.08.03 2.08.04 2.09.00
Flexible Steel Conduits Flexible conduit shall be water proof and rust proof made of heat resistant lead coated steel. Pull-out Boxes Pull out boxes shall be provided at approximately 4 (four) metre interval in a conduit run .Boxes shall be suitable for mounting on Walls, Columns, Structures, etc.. Pullout boxes shall have cover with screw and shall be provided with good quality gasket lining. Pull out boxes shall be weather proof type suitable for IP :55 degree of protection. Pull out box & its cover shall be hot dip galvanised. Lighting Wires Lighting wires shall be 1100 V grade, light duty PVC insulated unsheathed, stranded copper/aluminium wire for fixed wiring installation. colour of the PVC insulation of wires shall be Red, Yellow, Blue and Black for R,Y,B phases & neutral, respectively and white & grey for DC positive & DC negative circuits, respectively. Minimum size of wire shall not be less than 1.5.sq.mm. for copper and 4 sq.mm. for aluminium. The size of the lighting wires/ cables shall be selected such that the total voltage drop from the LDB to the lighting fixture / receptacle does not exceed 3%. Lighting Poles The poles wherever required shall be of ERW tubes of specified lengths, stepped tubular or swaged tubular and joined together. Lighting poles shall be painted with two coats of red Oxide and Zinc chromate in Synthetic compound primer on the exposed outside surface and with Bituminous paint all along the inside of the pole and outside portion which shall be embedded in foundation at manufacturing stage. Lighting Masts Each lighting mast shall be provided with minimum 12 nos. of 2x400W HPSV fixtures. Lighting Masts shall be of continuously tapered polygonal cross section hot dip galvanised presenting a pleasing appearance. The Mast shall be of 30M height with lantern carriage to enable raising / lowering for ease of maintenance, including
2.10.00 2.10.01
2.11.00 2.11.01
2.12.00 2.12.01
CLAUSE NO.
the Head Frame, Double Drum Winch, continuous stainless steel wire rope, in built power tool, luminaries, suitable aviation warning light, lightning along with necessary power cables within the mast. The mast shall be delivered only in three sections & shall be joined together by slip stressed fit method at site. No site welding or bolted joints shall be done on the mast. 2.13.00 Lighting fixtures shall generally be group controlled directly from lighting panel. However, in office areas, control shall be provided through switch boxes. Each switch shall control a maximum of three fluorescent fixtures. Wiring shall run throughout in separate conduits. Wires of different phases shall run in different conduits. Wiring for lighting circuits and receptacle circuits shall be carried out in separate conduits and from separate feeders. Lighting panels etc. shall be earthed by two separate and distinct connections with earthing system. Switch boxes, junction boxes, lighting fixtures, fans, single phase receptacles etc. shall be earthed by means of separate earth continuity conductor. The earth continuity conductor 14 SWG GI wire shall be run alongwith each conduit run. Cable armours shall be connected to earthing system at both the ends. TESTS All lighting fixtures, lamps and other items shall be subjected to acceptance and routine test, as per relevant specified standards. Junction boxes, switch boxes, receptacle enclosure etc. shall be subjected to physical and dimensional checks. Galvanizing Tests The quality of galvanizing shall be smooth, continuous, free from flux stains and shall be inspected visually. In addition following tests shall be conducted as acceptance tests. (a.) Uniformity of coating - The coating of any article shall withstand four 1minute dips in standard copper sulphate solution without the formation of an adherent red spot of metallic copper upon the basic metal. (b.) The quality of cadmium/zinc plating on items with screw threads shall be free from visible defects such as unplated areas, blisters and modules and shall be inspected visually. (c.) In addition, the plating thickness microscopically/chemically or electronically. shall be determined
2.14.00
2.15.00
3.00.00 3.01.01
3.01.02
3.02.00 3.02.01
3.03.00
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CLAUSE NO.
4.00.00
COMMISSIONING CHECKS 1. On completion of installation work, the Contractor shall request the Project manager for inspection and test with minimum of fourteen (14) days advance notice. The Project manager shall arrange for joint inspection of the installation for completeness and correctness of the work. Any defect pointed out during such inspection shall be promptly rectified by the Contractor. The installation shall be then tested and commissioned in presence of the Project manager. The contractor shall provide all, men material and equipment required to carry out the tests. All rectifications, repair or adjustment work found necessary during inspection, testing and commissioning shall be carried out by the Contractor without any extra cost. The handing over the lighting installation shall be effected only after the receipt of written instruction from the Employer/his authorized representative. The testing shall be done in accordance with the applicable Indian Standards and codes of practices. The following tests shall be specifically carried out for all lighting installation. (a) (b) (c) (d) 7. Insulation Resistance. Testing of earth continuity path. Polarity test of single phase switches. Functional checks.
2.
3.
4.
5.
6.
The lighting circuits shall be tested in the following manner : (a) (b) All switches ON and consuming devices in circuit, both poles connected together to obtain resistance to earth. Insulation resistance between poles with lamps and other consuming devices removed and switches ON.
PAGE 10 OF 12
CLAUSE NO.
ANNEXURE-A Sl No. Location Average Illumination Level(Lux) rooms 200 300 Type of Fixture
(a) (b)
Switchgear
Industrial trough type fluorescent Mirror optics with anti-glare features
Control room, computer room, control equipment room
(c) (d) (e)
Offices, conference 300 rooms,etc. Battery rooms Transformer 100 yard 10(general) 50(on equipment) 150
Decorative mirror optics type Totally enclosed corrosion proof HPSV flood light
(f)
Diesel generating room, Compressor room, pump house etc.
HPSV medium bay/Industrial trough type fluorescent
(g)
Fuel oil pump house 150
Flame proof fluorescent fixtures suitable for division-2 hazardous area Industrial trough type fluorescent
(h) (i)
Cable galleries Street lightingprimary roads secondary roads
50
20 10 20
HPSV street lights Degree of Protection IP54 HPSV flood light
(j)
Outdoor storage handlingand unloading area
PAGE 11 OF 12
CLAUSE NO.
(k)
DM plant,water treatment plant Chemical stores Permanent stores Workshop.general work bench Laboratory General Analysis area
150
Industrial trough type/corrosion proof fluorescent Corrosion proof fluorescent Industrial trough type/HPSV Industrial trough type fluorescent
(l) (m) (n) (o)
150 150 150
150 300
Mirror optics fluorescent Corrosion resistant, fluorescent 50 Industrial trough type fluorescent HPSV flood light
(p) (q)
Garage/Car Parking Switchyard and all outdoor areas
20(general 50(on strategic equipment)
(r) (s)
Stone picking area Transfer points, crusher house, track hopper, track hopper shed, tunnels, bunker house. Conveyor galleries Stair cases
300 100
HPSV dust tight well glass fixture (flood light type) HPSV dust tight medium bay or well glass fixture.
(t) (u) NOTE:-
70 100
HPSV dust tight well glass fixture. Min. one landing. fixture at every
Any additional fixtures required to take care of the dark patches / shadows shall also be provided.
PAGE 12 OF 12
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-u.
CLAUSE NO.
TECHNICAL REQUIREMENTS CABLING, EARTHING & LIGHTNING PROTECTION
1.00.00 1.01.00
CODES AND STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standards, etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards/ codes as applicable. IS:513 IS:802 Cold rolled low carbon steel sheets and strips. Code of practice for the use of Structural Steel in Overhead Transmission Line Towers. IS:1079 IS:1239 IS:1255 Hot Rolled carbon steel sheet & strips Mild steel tubes, tubular and other wrought steel fittings Code of practice for installation and maintenance of power cables upto and including 33 KV rating IS:1367 Part- Technical supply conditions for threaded Steel fasteners. (Hot dip 13 IS:13947 galvanized coatings on threaded fasteners). Degree of protection provided by enclosures for low voltage switchgear and control gear IS:2309 Code of Practice for the protection of building and allied structures against lightning. IS:2629 IS:2633 IS:3043 IS:3063 Recommended practice for hot dip galvanising of iron & steel Method for testing uniformity of coating on zinc coated articles. Code of practice for Earthing Fasteners single coil rectangular section spring washers.
SUB-SECTION-IIIB-08 CABLING EARTHING & LIGHTNING PROTECTON
PAGE 1 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS IS:6745 Methods for determination of mass of zinc coating on zinc coated iron & steel articles. IS:8308 Compression type tubular inline connectors for aluminium conductors of insulated cables IS:8309 Compression type tubular terminal ends for aluminium conductors of insulated cables. IS:9537 IS:9595 Conduits for electrical installation. Metal arc welding of carbon and carbon manganese steels recommendations. IS:13573 Joints and terminations for polymeric cables for working voltages from 6.6kv upto and including 33kv performance requirements and type tests. BS:476 IEEE:80 IEEE:142 DIN (Part-II) DIN 46329 Cable lugs for compression connections, ring type ,for Aluminium conductors VDE 0278 BS:6121 Tests on cable terminations and straight through joints Specification for mechanical Cable glands for elastomers and plastic insulated cables. Indian Electricity Act. Indian Electricity Rules. Fire tests on building materials and structures IEEE guide for safety in AC substation grounding Grounding of Industrial & commercial power systems
46267 Non tension proof compression joints for Aluminium conductors.
PAGE 2 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS Equipment complying with other internationally accepted standards such as IEC, BS, DIN, USA, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. DESIGN AND CONSTRUCTIONAL FEATURE Transformer yard and Switchyard In transformer yard and switchyard area, cables shall be laid in RCC concrete trenches with RCC covers. Inter-pole cabling in switchyard shall be in GI conduits/shallow trenches. Minimum clear height of trestle shall be 3mtr and for Rail/road crossing it shall be as per rail/road crossing norms.
1.02.00
2.00.00 2.01.00
2.01.01 2.01.02
False floors are not to be provided for cabling purpose. Cable entry Cable entry from outdoor underground/cable routes to the buildings, if any, shall be above the finished floor level of the building to avoid water entry in to the room through the trenches.
2.01.03
Trenches PCC flooring of built up trenches shall be sloped for effective drainage with sump pits and sump pumps.
2.01.04
Interplant cabling for main routes shall be laid along overhead trestles/duct banks. However, from tap-offs, same can be through shallow trenches with approval of Employer. In case of Duct banks, pull-pits shall be filled with sand and provided with a PCC covering. Directly buried cables, if essential, shall not have concentration of more than 4 cables in one route. For overhead trestles, the bottom of the steel supporting structure shall be generally at 3.0M above the grade level except for rail/road crossings where it shall be at 8.0M above grade level. All overhead cable routes shall be along the route of the conveyor gallery on separate supporting structures and cables shall be laid in vertical trays. The bottom of the steel shall be such that the existing facilities, movement of trucks / human beings etc. does not get affected. The cable trestle shall have a minimum 600mm clear walk way and shall have maintenance platforms as required. Cables shall not be routed through the conveyor galleries except for the equipment located in the conveyor galleries for a particular conveyor i.e. protection switches, etc. Cables for PCS and BSS shall be routed along the conveyors through GI conduits.
2.-01.05
Cable trenches shall be provided only in Switchgear/MCC rooms.

TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-08 CABLING EARTHING & LIGHTNING PROTECTON
PAGE 3 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS EQUIPMENT DESCRIPTION Cable trays, Fittings & Accessories Cable trays shall be ladder type for power cables & perforated type for control cables complete with matching fittings (like brackets, elbows, bends, reducers, tees, crosses, etc.) accessories (like side coupler plates, etc. and hardware (like bolts, nuts, washers, G.I. strap, hook etc.) as required. Cable trays, fittings and accessories shall be fabricated out of rolled mild steel sheets free from flaws such as laminations, rolling marks, pitting etc. These (including hardware) shall be hot dip galvanized as per relevant IS. Cable trays shall be ladder type for power/control cables and shall be perforated type for instrumentation cables. Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard lengths of 2.5 metre. Minimum thickness of mild steel sheets used for fabrication of cable trays and fittings shall be 2 mm. The thickness of side coupler plates shall be minimum 3 mm. Typical details of cable trays, fittings and accessories are shown in the enclosed drawings Cable troughs shall be required for branching out few cables from main cable route. These shall be U-shaped, fabricated of mild steel sheets of minimum thickness 2 mm and shall be hot dip galvanised as per relevant IS. Troughs shall be standard width of 50 mm & 75 mm with depth of 25 mm SUPPORT SYSTEM FOR CABLE TRAYS Cable tray support system shall be pre-fabricated similar or equivalent to "Unistrut make. Support system for cable trays shall essentially comprise of the two components i.e. main support channel and cantilever arms. The main support channel shall be of two types: (i) C1:- having provision of supporting cable trays on one side and (ii) C2:-having provision of supporting cable trays on both sides. The support system shall be the type described hereunder a. Cable supporting steel work for cable racks/cables shall comprise of various channel sections, cantilever arms, various brackets, clamps, floor plates, all hardware such as lock washers, hexagon nuts, hexagon head bolt, support hooks, stud nuts, hexagon head screw, channel nut, channel nut with springs, fixing studs, etc. The system shall be designed such that it allows easy assembly at site by using bolting. All cable supporting steel work, hardware fittings and accessories shall be prefabricated factory galvanised. The main support and cantilever arms shall be fixed at site using necessary brackets, clamps, fittings, bolts, nuts and other hardware etc. to form various arrangements required to support the cable trays. Welding
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-08 CABLING EARTHING & LIGHTNING PROTECTON PAGE 4 OF 22
3.00.00 3.01.00 3.01.00
3.01.01
3.01.02
3.01.03
3.02.00 3.02.00 3.02.01
b.
c.
CLAUSE NO.
TECHNICAL REQUIREMENTS of the components shall not be allowed. However, welding of the bracket (to which the main support channel is bolted) to the overhead beams, structural steel, insert plates or reinforcement bars will be permitted. Any cutting or welding of the galvanised surface shall be brushed and red lead primer, oil primer & aluminium paint shall be applied. d. All steel components, accessories, fittings and hardware shall be hot dip galvanised after completing welding, cutting, drilling and other machining operation. The typical arrangement of flexible support system is shown in the enclosed drawings and described briefly below: The main support channel and cantilever arms shall be fabricated out of minimum 2.5 thick rolled steel sheet conforming to IS. f. Cantilever arms of 300 mm, 600 mm and 750 mm in length are required, and shall be as shown in the enclosed drawing. The arm portion shall be suitable for assembling the complete arm assembly on to component constructed of standard channel section. The back plate shall allow sufficient clearance for fixing bolt to be tightened with tray in position.
e.
3.02.02
The size of structural steel members or thickness of sheet steel of main support channel and cantilever arms and other accessories as indicated above or in the enclosed drawings are indicative only. Main support channels may be supplied in any suitable lengths to minimise the wastage. Nevertheless, the support system shall be designed by the bidder to fully meet the requirements of type tests as specified. In case the system fails in the tests, the components design modification shall be done by the Bidder without any additional cost to the Employer. Pipes, Fittings & Accessories Pipes offered shall be complete with fittings and accessories (like tees, elbows, bends, check nuts, bushings, reducers, enlargers, coupling caps, nipples etc.) The size of the pipe shall be selected on the basis of maximum 40% fill criteria GI Pipes shall be of medium duty as per IS:1239 Junction Boxes (a) Junction Boxes shall be made of Fire retardant material. Material of JB shall be thermoplastic or thermosetting or FRP type. The box shall be provided with the terminal blocks, mounting bracket and screws etc. the cable entry shall be through galvanized steel conduits of 20 mm diameter. The JB shall have suitable for installing glands of suitable size on the bottom of the box. The JB shall be suitable for surface mounting on ceiling/structures. The JB shall be of grey in color RAL 7035. All the metal parts shall be corrosion protected. Junction boxes surface should be such that it is free from crazing, blistering, wrinkling, color blots/striations. There should not be any mending or repair of surface. JBs will be provided with captive screws so that screws dont fall off when cover is opened. JBs mounting bracket should be of powder coated MS.
3.03.00 3.03.00
3.03.01 3.04.00
PAGE 5 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS Terminal blocks shall be 650 volts grade, 10 Amps rated, made up of unbreakable polyamide 6.6 grade, complete with insulating barriers. Clip on type terminals, washer, nuts and identification strips. Marking on terminal strips shall correspond to the terminal numbering in wiring diagrams. All metal parts shall be non ferrous. WAGO terminal of cage clamp with lugs shall also be acceptable. All terminal blocks shall be suitable for terminating on each side two (2) nos. stranded copper conductors of size up to 2.56 sq mm each. Terminations & Straight Through Joints Termination and jointing kits for 6.6 kV grade XLPE insulated cables shall be of proven design and make which have already been extensively used and type tested. Termination kits and jointing kits shall be pre-moulded type, taped type or heat shrinkable type. 6.6 kV grade joints and terminations shall be type tested as per IS13573. Critical components used in cable accessories shall be of tested and proven quality as per relevant product specification/ESI specification. Kit contents shall be supplied from the same source as were used for type testing. The kit shall be complete with the aluminium solder less crimping type cable lugs & ferrule as per DIN standard. Straight through joint and termination shall be capable of withstanding the fault level of 40 kA for 0.12 sec with a dynamic peak of 100 kA for 6.6 kV system. Straight through joints shall have provisions for shield connection and earthing wherever required and complete with all accessories and consumables suitable for storage without deterioration at a temperature of 50 deg. C with shelf life of more than five years. 1.1 kV grade straight through joints shall also be of proven design. 1.1 KV grade STJ shall be of proven design. Motor terminal boxes should of sufficient size to accommodate the selected cables. In case the cable sizes can not be accommodated, power Junction boxes shall be provided with cable interconnection between Junction boxes and motor terminal box. Cable glands Cable shall be terminated using double compression type cable glands. Cable glands shall conform to BS:6121 and be of robust construction capable of clamping cable and cable armour firmly without injury to insulation. Cable glands shall be made of heavy duty brass machine finished and nickel chrome plated. Thickness of plating shall not be less than 10 micron. All washers and hardware shall also be made of brass with nickel chrome plating Rubber components shall be of neoprene and of tested quality. Cable lugs/ferrules Cable lugs for power cables shall be tinned copper solder less crimping type conforming to IS: 8309 suitable for aluminium compacted conductor cables. Cable lugs and ferrules for control cables shall be tinned copper conforming to IS:8309 . The cable lugs for control cables shall be provided with insulating sleeve and shall suit the type of terminals provided on the equipments.
3.04.00
3.05.00 3.05.00
3.05.01
3.05.02 3.05.04
3.06.00 3.06.00
3.06.01 3.06.02
CLAUSE NO.
TECHNICAL REQUIREMENTS Trefoil clamps Trefoil clamps for single core cables shall be pressure die cast aluminum or fiber glass or nylon and shall include necessary fixing accessories like G.I. nuts, bolts, washers, etc. Trefoil clamps shall have adequate mechanical strength to withstand the forces generated by the system short circuit current of 105 KA peak. Cable Clamps & Straps The cable clamps required to clamp multicore cables on vertical run shall be made up of Aluminium strip of 25x3 mm size. For clamping the multicore cables, selflocking, de-interlocking type nylon clamps/straps shall be used. The clamps/straps shall have sufficient strength and shall not get affected by direct exposure to sun rays and outdoor environment Receptacles Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot dipped gavanised or of die-cast aluminium alloy of thickness not less than 2.5 mm. The boxes shall be provided with two nos. earthing terminals, gasket to achieve IP55 degree of protection, terminal blocks for loop-in loop-out for cable of specified sizes, mounting brackets suitable for surface mounting on wall/column/structure, gland plate etc. The ON-OFF switch shall be rotary type heavy duty double break, AC23 category, suitable for AC supply. Plug and Socket shall be shrouded Die-cast Aluminium. Socket shall be provided with lid safety cover. Robust mechanical interlock shall be provided such that the switch can be put ON only when the plug is fully engaged and plug can be withdrawn only when the switch is in OFF position. Also cover can be opened only when the switch is in OFF position. Wiring shall be carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of adequate size. The Terminal blocks shall be of 750 V grade For Coal Handling Plant 415V TPN 63A welding sockets with switch having degree of protection of IP-55 shall be provided in the following areas. 1) 2) 3) 4) 1 Number on each floor of TPs and 2 nos. on each floor of the crusher house building. At 50m interval (starting from one end) on both sides of the conveyor galleries. At 50m interval on one side of the yard conveyor. 1 no. in each Switchgear / MCC rooms and Pump house and in stacker / reclaimer machines. Maximum three (3) nos. of receptacles can be connected to one circuit. These receptacles shall be energised through welding distribution board.
3.07.00 3.07.00
3.08.00 3.08.00
3.09.00 3.09.00
3.10.02
PAGE 7 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS Galvanising Galvanising of steel components and accessories shall conform to IS:2629, IS:2633 & IS 4759. Additionally galvanising shall be uniform, clean smooth, continuous and free from acid spots The amount of zinc deposit over threaded portion of bolts, nuts, screws and washers shall be as per IS:1367. The removal of extra zinc on threaded portion of components shall be carefully done to ensure that the threads shall have the required zinc coating on them as specified. However nuts and bolts of size lesser than M12 can be electro galvanised / electro plated. Welding The welding shall be carried out in accordance with IS: 9595. All welding procedures and welders qualification shall also be followed strictly in line with IS:9595 EXPANSION FASTNER Expansion Fastener shall be 'HILTI' make HSA-KA type or equivalent. Expansion fastener shall only be used wherever insert plates are not available for supporting the cable structure. INSTALLATION Cable tray and Support System Installation Cables shall run in cable trays mounted horizontally or vertically on cable tray support system which in turn shall be supported from floor, ceiling, overhead structures, trestles, pipe racks, trenches or other building structures. All cable trays shall be in vertical configuration in boiler, CHP & ESP areas. Horizontally running cable trays shall be clamped by bolting to cantilever arms at an interval of 2000 mm. Vertically running cable trays shall be bolted to main support channel by suitable bracket/clamps on both top and bottom side rails at an interval of 2000 mm. For vertical cable risers/shafts cable trays shall be supported at an interval of 1000mm. Fixing of cable trays to cantilever arms or main support channel by welding shall not be accepted. Cable tray installation shall generally be carried out as per the enclosed drawings. The cantilever arms shall be positioned on the main support channel with a minimum vertical spacing of 300 mm unless otherwise indicated in the relevant tray layout drawings All cable way sections shall have identification, designations as per cable way layout drawings and painted/stenciled at each end of cable way and where there is a branch connection to another cable way. Minimum height of letter shall be not less than 75 mm. For long lengths of trays, the identification shall be painted at every 10 meter. Risers shall additionally be painted/ stenciled with identification numbers at every floor.
3.10.00 3.10.00
3.10.01
3.11.00 3.11.00 3.12.00 3.12.00
4.00.00 4.01.00 4.01.00
4.01.01
4.01.02
4.01.03
CLAUSE NO.
TECHNICAL REQUIREMENTS In certain cases it may be necessary to site fabricate portions of trays, supports and other non standard bends where the normal prefabricated trays, supports and accessories may not be suitable. In such cases the Contractor shall fabricate at site suitable sections of trays, supports and accessories to make the installation complete for the specific purpose after obtaining Project Manager's prior approval, which shall be neat in appearance and shall match with the prefabricated sections in the dimensions. They shall be applied with one coat of red lead primer, one coat of oil primer followed by two finishing coats of aluminium paint. Conduits/Pipes/Ducts Installation The Contractor shall be fully responsible for properly embedding conduit pipe sleeves wherever necessary for cabling work. All openings in the floor/roof/wall / cable tunnel/cable trenches made for conduit installation shall be sealed and made water proof by the Contractor. GI pull wire of adequate size shall be laid in all conduits before installation. Metallic conduit runs at termination shall have two lock nuts wherever required for junction boxes etc. Conduit runs/sleeves shall be provided with PVC bushings having round edge at each end. All conduits/pipes shall have their ends closed by caps until cables are pulled. After cables are pulled, the ends of conduits/pipes shall be sealed with Glass wool/Cement Mortar/Putty to prevent entrance of moisture and foreign material Exposed conduit/pipe shall be adequately supported by racks, clamps, straps or by other approved means. Conduits /pipe support shall be installed square and true to line and grade with an average spacing between the supports as given below, Conduit /pipe size (dia). Upto 40 mm 50 mm 65-85 mm 100 mm Spacing 1M 2.0 M 2.5 M 3.0 M
4.01.04
4.02.00 4.02.00
4.02.01
4.02.02
4.02.03
4.02.04
For bending of conduits, bending machine shall be arranged at site by the contractor to facilitate cold bending. The bends formed shall be smooth. Junction Boxes Installation Junction boxes shall be mounted at a height of 1200mm above floor level or as specified in the drawings or as decided by Project Manager and shall be adequately supported/mounted on masonry wall by means of anchor fasteners/ expandable bolts
4.03.00 4.03.00
CLAUSE NO.
TECHNICAL REQUIREMENTS or shall be mounted on an angle, plate or other structural supports fixed to floor, wall, ceiling or equipment
4.03.01 4.03.02
Cable Installation (for cables upto & including 6.6kV grade) Cable installation shall be carried out as per IS:1255 and other applicable standards. Cable drums shall be unloaded, handled and stored in an approved manner on hard and well drained surface so that they may not sink. In no case shall be drum be stored flat i.e. with flange horizontal. Rolling of drums shall be avoided as far as possible. For short distances, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum. In absence of any indication, the drums may be rolled in the same direction as it was rolled during taking up the cables. For unreeling the cable, the drum shall be mounted on suitable jacks or on cable wheels and shall be rolled slowly so that cable comes out over the drum and not from below. All possible care shall be taken during unreeling and laying to avoid damage due to twist, kink or sharp bends. Cable ends shall be provided with sealed plastic caps to prevent damage and ingress of moisture. While laying cable, ground rollers shall be used at every 2 mtr interval to avoid cable touching ground. The cables shall be pushed over the rollers by a gang of people positioned in between the rollers. Cables shall not be pulled from the end without having intermediate pushing arrangements. Pulling tension shall not exceed the values recommended by cable manufacturer. Selection of cable drums for each run shall be so planned so as to avoid using straight through joints. Care should be taken while laying the cables so as to avoid damage to cables. If any particular cable is damaged, the same shall be repaired or changed to the satisfaction of Project Manager. Cables shall be laid on cable trays strictly in line with cable schedule furnished. Where specific cable layouts are not shown on drawings, Contractor shall route these as directed by the Project Manager Power and control cables shall be laid on separate tiers. The laying of different voltage grade cables shall be on different tiers according to the voltage grade of the cables. In horizontal tray stacks, H.T. cables shall be laid on topmost tier and cables of subsequent lower voltage grades on lower tiers of trays. Single core cable in trefoil formation shall be laid with a distance of four times the diameter of cable between trefoil center lines and clamped at every 2mtr. All multicore cables shall be laid in touching formation. Power and control cables shall be secured fixed to trays/support with self locking type nylon cable straps with de-interlocking facilities. For horizontal trays arrangements, multicore power cables and control cables shall be secured at every five meter interval. For vertical tray arrangement, individual multicore power cables and control cables shall be secured at every one meter by nylon cable strap. After completion of cable laying work in the particular vertical tray, all the control cables shall be binded to trays/supports by aluminium strips at every five meter interval and at every bend. Bending radii for cables shall be as per manufacturers recommendations and IS:1255. Where cables cross roads/rail tracks, the cables shall be laid in hume pipe/PVC pipe.
4.03.03
4.03.04
4.03.05
4.03.06 4.03.07
PAGE 10 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS In each cable run some extra length shall be kept at suitable point to enable one LT/two HT straight through joints to made, should the cable develop fault at a later stage. Control cable termination inside equipment enclosure shall have sufficient lengths so that shifting of termination in terminal blocks can be done without requiring any splicing. Wherever few cables are branching out from main trunk route troughs shall be used. The installation work shall be carried out in a neat workman like manner & areas of work shall be cleaned of all scraps, water, etc. after the completion of work in each area every day. Contractor shall replace RCC/Steel trench covers after the Installation work in that particular area is completed or when further work is not likely to be taken up for some time. Separation In vertically stacked trays, at least 300mm clearance shall be provided between : - HT power & LT power cables, - LT power & LT control cables
4.03.08
4.03.09 4.03.10
4.03.11
4.03.12
Segregation 1) 2) Segregation means physical isolation to prevent fire jumping. All the cables of one stream shall be segregated from the cables of the other stream and shall run on either side of the trestle.
4.03.13
All field switches for equipments corresponding to a stream located within a radius of 4-5 mtr. shall be wired out to a field junction box and from field junction box to control panel/Input Output cabinet by screened instrumentation cables. Directly Buried Cables a) Cable trenches shall be constructed for directly buried cables. Construction of cable trench for cables shall include excavation, preparation of sieved sand bedding, riddled soil cover, supply and installation of brick or concrete protective covers, back filling and compacting, supply and installation of route markers and joint markers. Laying of cables and providing protective covering shall be as per IS:1255 and the enclosed drawings showing cabling details. RCC cable route and RCC joint markers shall be provided wherever required. The voltage grade of the higher voltage cables in route shall be engraved on the marker. Location of underground cable joints shall be indicated with cable marker with an additional inscription Cable Joint. The marker shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at every change in direction. They shall be located on both sides of road crossings and drain crossings. Top of cable marker/joint marker shall be sloped to avoid accumulation of water/dust on marker.
4.03.14
b)
4.03.15
Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit entry, and at every 20 meters in cable tray/trench runs. Cable tags shall also be
CLAUSE NO.
TECHNICAL REQUIREMENTS provided inside the switchgear, motor control centers, control and relay panels etc. where a number of cables enter together through a gland plate. Cable tag shall be of rectangular shape for power cables and control cables. Cable tag shall be of 2 mm thick aluminum with number punched on it and securely attached to the cable by not less than two turns of 20 SWG GI wire conforming to IS:280. Alternatively, the Contractor may also provide cable tags made of nylon, cable marking ties of TY-CAB or equivalent type with cable number heat stamped on the cable tags
4.03.16 4.04.00 4.04.00
While crossing the floors, unarmoured cables shall be protected in conduits upto a height of 500 mm from floor level if not laid in tray. Cable Terminations & Connections The termination and connection of cables shall be done strictly in accordance with cable termination kit manufacturer instructions, drawings and/or as directed by Project Manager. Cable jointer shall be qualified to carryout satisfactory cable jointing/termination. Contractor shall furnish for review documentary evidence/experience reports of the jointers to be deployed at site. Work shall include all clamps, fittings etc. and clamping, fitting, fixing, plumbing, soldering, drilling, cutting, taping, preparation of cable end, crimping of lug, insulated sleeving over control cable lugs, heat shrinking (where applicable), connecting to cable terminal, shorting and grounding as required to complete the job to the satisfaction of the Project Manager. The equipment will be generally provided with undrilled gland plates for cables/conduit entry. The Contractor shall be responsible for punching of gland plates, painting and touching up. Holes shall not be made by gas cutting. The holes shall be true in shape. All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively sealed by 2mm thick aluminium sheets. Control cable cores entering control panel/switchgear/MCC/miscellaneous panels shall be neatly bunched, clamped and tied with self locking type nylon cable ties with de interlocking facility to keep them in position. The panels where a larger number of cables are to be terminated and cable identification may be difficult, each core ferrule shall include the complete cable number as per the drawings. The ferrules shall be indelible interlocking type and shall fit tightly on cores. Spare cores shall have similarly ferrules with a suffix letter S alongwith cable numbers and coiled up after end sealing. All cable terminations shall be appropriately tightened to ensure secure and reliable connections. It is the responsibility of the Contractor to terminate the cables at motor terminals in correct phase sequence to ensure the proper direction of rotation.
4.04.01
4.04.02
4.04.03
4.04.04
4.04.05
4.04.06
PAGE 12 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS EARTHING SYSTEM Earthing system shall be in strict accordance with IS: 3043 and Indian Electricity Rules/Acts. All buildings / structures shall be interconnected together by min. two parallel conductors. Contractor shall furnish the detailed design calculations for the earthing system. Contractor shall obtain all necessary approvals for the system.
5.00.00 5.01.00
5.02.00 5.03.00
The earth conductors shall be free from pitting, laminations, rust, scale and other electrical, mechanical defects The material of the earthing conductors shall be as follows : 1) Conductors above ground level and in built up trenches. 2) Conductors buried in earth 3) Earth electrodes Galvanized steel Mild steel Mild steel rod
5.04.00
The sizes of earthing conductors for various electrical equipments shall be as below: Equipment Earth conductor buried in earth 40 mm dia.MS rod --415V Earth conductor above ground level & in builtup trenches 65x8mm GS flat 65x8mm GS flat
a) b)
Main earth grid 33KV/11KV switchgear/equipment switchgear
c)
6.6 kV switchgear / 415 V MCC/ Distribution boards / Transformers
---
50x6mm GS flat
d)
LT Motors above 125 KW 25 KW to 125 KW
-----
50 x 6mm GS flat 25 x 6mm GS flat
PAGE 13 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS 1KW to 25 KW --25 x 3mm GS flat Fractional House power motor --8 SWG GS wire
e)
Control panel & control desk
---
25 x 3 mm GS flat
f) g)
Push button station / Junction Box Columns, structures, cable trays and busduct enclosures Crane, rails, rail tracks & other non-current carrying metal parts
-----
8 SWG GI wire 50x6mm GS flat
h)
25x6mm GS flat
5.05.00
Metallic frame of all electrical equipment shall be earthed by two separate and distinct connections to earthing system, each of 100% capacity, Crane rails, tracks, metal pipes and conduits shall also be effectively earthed at two points. Steel RCC columns, metallic stairs, and rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing ensured by bonding the different sections of hand rails and metallic stairs. Metallic sheaths/screens, and armour of multi-core cables shall be earthed at both ends. Metallic Sheaths and armour of single core cables shall be earthed at switchgear end only unless otherwise instructed by the Employer. Every alternate post of the switchyard fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the earthed post. Railway tracks within the plant area shall be bonded across fish plates and connected to earthing grid at several locations. Portable tools, appliances and welding equipment shall be earthed by flexible insulated cable. One separate core in the trailing/flexible cables shall be used for earthing purposes of the moving machines. PLC equipment shall be earthed separately as per the recommendations of the PLC manufacturer. Each continuous laid lengths of cable tray shall be earthed at minimum two places by G.S. flats to earthing system, the distance between earthing points shall not exceed 30mtr. Wherever earth mat is not available Contractor shall do the necessary connections by driving an earth electrode in the ground. Neutral points of HT transformer shall be earthed through NG resistors. The Contractor shall connect the NGR earthing point to earth electrodes by suitable earth conductors. Neutral connections and metallic conduits/pipes shall not be used for the equipment earthing. Lightning protection system down conductors shall not be connected to other earthing conductors above the ground level.
5.06.00
5.07.00
5.08.00
PAGE 14 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS Connections between earth leads and equipment shall normally be of bolted type. Contact surfaces shall be thoroughly cleaned before connections. Equipment bolted connections after being tested and checked shall be painted with anti corrosive paint/compound. Suitable earth risers as approved by Project Manager shall be provided above finished floor/ground level, if the equipment is not available at the time of laying of main earth conductor. Connections between equipment earthing leads and between main earthing conductors shall be of welded type. For rust protection the welds should be treated with red lead compound and afterwards thickly coated with bitumen compound. All welded connections shall be made by electric arc welding. Resistance of the joint shall not be more than the resistance of the equivalent length of conductors. Earthing conductors buried in ground shall be laid minimum 600 mm below grade level unless otherwise indicated in the drawing. Back filling material to be placed over buried conductors shall be free from stones and harmful mixtures. Back filling shall be placed in layers of 150 mm. Earthing conductors embedded in the concrete floor of the building shall have approximately 50 mm concrete cover. A minimum earth coverage of 300 mm shall be provided between earth conductor and the bottom of trench/foundation/underground pipes at crossings. Earthing conductors crossings the road can be installed in pipes. Wherever earthing conductor crosses or runs at less than 300 mm distance along metallic structures such as gas, water, steam pipe lines, steel reinforcement in concrete, it shall be bonded to the same. Earthing conductors along their run on columns, walls, etc. shall be supported by suitable welding / cleating at interval of 1000mm and 750mm respectively. Earth pit shall be constructed as per IS:3043. Electrodes shall be embedded below permanent moisture level. Minimum spacing between electrodes shall be 600mm. Earth pits shall be treated with salt and charcoal if average resistance of soil is more than 20 ohm metre. On completion of installation continuity of earth conductors and efficiency of all bonds and joints shall be checked. Earth resistance at earth terminations shall be measured in presence of Employers representatives. All equipment required for testing shall be furnished by contractor. Earthing conductor shall be buried at least 2000mm outside the fence of electrical installations. Every alternate post of the fences and all gates shall be connected to earthing grid by one lead. LIGHTNING PROTECTION SYSTEM Lightning protection system shall be in strict accordance with IS:2309
5.09.00
5.10.00
5.11.00
5.12.00 5.13.00
5.14.00 5.15.00
5.16.00 5.17.00
5.18.00
5.19.00
6.00.00 6.01.00
PAGE 15 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS Lightning conductor shall be of 25x6mm GS strip when used above ground level and shall be connected through test link with earth electrode/earthing system Lightning system shall comprise of air terminations, down conductors, test links, earth electrode etc. as per approved drawings Down Conductors 1. 2. Down conductors shall be as short and straight as practicable and shall follow a direct path to earth electrode. Each down conductor shall be provided with a test link at 1000 mm above ground level for testing but it shall be in accessible to interference. No connections other than the one direct to an earth electrode shall be made below a test point. All joints in the down conductors shall be welded type. Down conductors shall be cleated on outer side of building wall, at 750 mm interval or welded to outside building columns at 1000 mm interval. Lightning conductor on roof shall not be directly cleated on surface of roof. Supporting blocks of PCC/insulating compound shall be used for conductor fixing at an interval of 1500 mm. All metallic structures within a vicinity of two meters of the conductors shall be bonded to conductors of lightning protection system. Lightning conductors shall not pass through or run inside GI Conduits. Testing link shall be made of galvanized steel of size 25x 6mm.
6.01.01 6.01.02 6.02.00
3. 4. 5.
6. 7. 8. 7.00.00 7.01.00
QUALITY ASSURANCE PROGRAMME Bidder shall furnish detailed Quality Assurance Program and Quality Plans for all materials and accessories to be supplied and installed under the scope of the specification as per General Technical Conditions of technical specification. The Quality Plans shall include all tests/ checks as per relevant National/International Standards and the requirements of this specification including tests listed in this section. TESTS GENERAL (a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the test conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client.
8.00.00
CLAUSE NO.
TECHNICAL REQUIREMENTS (b.) However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No Design Change. Minor changes if any shall be highlighted on the endorsement sheet.
(c.)
(d.)
8.01.00 8.01.00
Type Test reports shall be furnished for the following Type tests on Cable Trays support system
Test 1: On main support channel type-C2 for cantilever arms fixed on one side only. a) Test 1A: A 3.5 metre length of main support channel shall be fixed vertically at each end to a rigid structure as per the fixing arrangement as shown in the enclosed drawing. Eight (8) nos. 750 mm cantilever arms shall be fixed to the main channel and each arm shall be loaded over the outboard 600 mm with a uniform working load of 100 kg. Subsequently a point load of 100 kg shall be applied on arm 2. A uniform proof load on all the arms equal to twice the working load shall be then be applied. Deflections shall be measured at the points shown in the enclosed drawings and at the following load intervals: i) ii) iii) iv) v) Working load Working load + point load Off load Proof load + point load Off load
The deflection measured at working loads shall not exceed 16mm. The permanent deflection after removing the combination of working load and point load shall not exceed 10 mm at the arm tips and 6 mm on the channel. No collapse of the structure shall occur with a combination of
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-08 CABLING EARTHING & LIGHTNING PROTECTON PAGE 17 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS proof load and point load applied.
b) Test 1B: Test 2:
Test 1A shall be repeated with Eight Cantilever arms uniformly loaded and with the same point load on arm 2. On Main support channel type -C2 for cantilever arms fixed on both sides A 3.5 m length of main support channel C2 for cantilever arms fixing on both sides shall be fixed at each end to rigid structure as per the fixing arrangement as shown in the enclosed drawing. Six (6), 750 mm cantilever arms shall be attached to each sides and each arm uniformly loaded to a working load of 100 kg over the out board 600 mm. A point load of 100 kg shall than be applied to arm 2, followed by a uniform proof load of twice the working load on all the arms; deflection shall be measured at points shown in the enclosed drawings at the following load intervals. i) ii) iii) iv) v) Working load Working load + Point load Off load Proof load + Point load Off load
a)Test 2A:
The deflection measured at working loads shall not exceed 16mm. The permanent deflection after removing the combination of working load and point load shall not exceed 10 mm at the arm tips and 6 mm on the channel. No collapse of the structure shall occur with a combination of proof load and point load applied b) Test 2 B: The test 2 A shall be repeated with the assembly but with an asymmetrical load on the C2 column and point load applied to arm 8. The 100 kg and 200 kg uniformly distributed loads shall be applied to the upper three arms on one side and the lower three arms on the opposite side. Test 3: Tests on Channel Fixed on Beam/Floor A length of main support channel section shall be fixed to steel structure/floor and have loads applied as shown in the drawing enclosed and as detailed below
PAGE 18 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS a) Test 3A : A length of steel structure shall be rigidly supported. It should be fitted on a metre length of channel section using beam clamps welded/bolted. A point load of 1200 kg shall be applied to the centre point via two brackets. No distortion or pulling of the components shall take place. b) Test 3B : With the components assembled as in Test 3A, two perpendicular point loads of 600 kg shall be simultaneously applied at positions 150 mm either side of the centre line, no distortion or pulling of the components shall take place. With the components assembled as in Test 3A, a perpendicular point load shall be applied at a point 150 mm on one side of the centre line. The load shall be gradually increased to the maximum value that can be applied without causing distortion or pulling of the components. This value shall be recorded. Test 4 : Channel Insert Test
c) Test 3C :
A 2.5 m length of C1 channel fixed to the concrete wall/ steel structure as per actual site installation conditions. 6 nos. of 750 mm cantilever arms shall be attached to C1 channel as shown in enclosed drawing. Each arm uniformly loaded to a working load of 100 kg over the out board 600 mm. A point load of 100 kg shall than be applied to arm 2, followed by a uniform proof load of twice the working load on all the arms; deflection shall be measured at points shown in the enclosed drawings at the following load intervals. i) Working load ii) Working load + Point load iii) Off load iv) Proof load + Point load v) Off load The deflection measured at working loads shall not exceed 16mm. The permanent deflection after removing the combination of working load and point load shall not exceed 10 mm at the arm tips and 6 mm on the channel. No collapse of the structure shall occur with a combination of proof load and point load applied
PAGE 19 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS Test 5: Channel nut slip characteristics (what ever applicable) Tests 5A1,5A2,5A3 : A length of channel C1 section 200mm long shall have fitted bracket with the two bolts fixing as shown in drawing enclosed. With loads applied at the position shown in drawing enclosed nut slip shall be determined with bolt torque of 30NM, 50 NM and 65 NM No fewer than three measurements shall be made for each torque setting. A minimum loading of 720 kg shall be obtained before nut slip with bolt torque of 65 NM. Tests 5B1,5B2,5B3: The length of channel C1 section 200 mm long shall have fitted bracket with the one bolt fixing as shown in drawing enclosed. With loads applied at the position shown in drawing, nut slip shall be determined with bolt torques of 30 NM, 50 NM and 65 NM. No fewer than three measurements shall be made for each torque setting. A minimum loading of 350 kg shall be obtained before nut slip with a bolt torque of 65 NM. Test 6 Weld Integrity Test After deflection test as per test 1A, 1B, 2, 3, 4 & 5, weld integrity shall be checked by magnetic particle inspection to detect sub-surface cracks developed, if any.
8.01.01 8.02.00 7.03.01
Cable termination kit and straight through joints should have been tested as per IS: 13573 for above 3.3 kV class and as per VDE 0278 for 3.3 kV class. Routine/ Acceptance Tests Routine Tests a) b) c) d) e) Routine tests as per specification and applicable standards shall be carried out on all equipments/items covered in the specification. Physical & dimensional check on all equipments as per approved drawings/standards. HV/IR as applicable. Check/measurement of thickness of paint/zinc coating/nickel-chrome plating as per specification & applicable standard.
PAGE 20 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS Acceptance Test a) b) c) Galvanising Tests as per applicable standards Welding checks Deflection tests on cable trays: One piece each of 2.5m length of cable tray of 300mm & above shall be taken as sample from each offered lot. It shall be supported at both end & loaded with uniform load of 76 kg/meter along the length of cable tray. The maximum deflection at the mid-span of each size shall not exceed 7mm. d) Proof load tests on cable tray support system i) Tests on Main Support Channel shall be done if only C1 Channel are in scope of supply and cantilever arms shall be fitted on one side. This test shall be same as test 4 of type test. Test on Main Support Channel shall be done with C2 channel and cantilever arms fitted on both sides, if C2 channels are in scope of supply. This test shall be same as test 2A of type test. Then test (i) above shall not be done. Nut slip characteristic test (it shall support minimum load of 350kg before nut slips with a bolt torque of 65 NM). This test shall be same as test 5B3 of type test. The procedure for carrying out tests at d above shall be as per details given in Type Tests in specification thereafter Die-Penetration test shall be carried out to check weld integrity. e) The above acceptance tests shall be done only on one sample from each offered lot.
7.03.02
ii)
iii)
9.00.00 9.01.00
COMMISSIONING The Contractor shall carry out the following commissioning tests and checks after installation at site. In addition the Contractor shall carry out all other checks and tests as recommended by the Manufacturers. Cables a) b) c) Check for physical damage Check for insulation resistance before and after termination/jointing. HT cables shall be pressure tested (test voltage as per IS:7098) before commissioning. Check of continuity of all cores of the cables.
9.01.01
d)
PAGE 21 OF 22
CLAUSE NO.
TECHNICAL REQUIREMENTS e) Check for correctness of all connections as per relevant wiring diagrams. Any minor modification to the panel wiring like removing/inserting, shorting, change in terminal connections etc., shall be carried out by the Contractor at no extra cost. Check for correct polarity and phasing of cable connections. Check for proper earth connections for cable glands, cable boxes, cable armour, screens, etc. Check for provision of correct cable tags, core ferrules, and tightness of connections.
f) g)
h)
9.02.00
Cable trays / supports and accessories 1) Check for proper galvanizing/painting and identification number of the cable trays/supports and accessories. Check for continuity of cable trays over the entire route. Check that all sharp corners, burrs, and waste materials have been removed from the trays supports. Check for earth continuity and earth connection of cable trays.
2) 3)
4) 9.03.00
Earthing and Lightning protection system 1) 2) Earth continuity checks. Earth resistance of the complete system as well as sub-system.
9.04.00
GENERAL COMMISSIONING CHECKS (Application to all electrical equipments) (a.) (b.) (c.) (d.) (e.) (f.) (g.) Check for name plate details according to specification. Check for physical damage, if any. Check for tightness of all bolts, clamps & connecting terminals. Check for earth connection. Check for cleanliness of insulators & bushings. Check for lubrication of all moving parts. Check for provision of heater.
PAGE 22 OF 22
SECTION A-A
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FOR 6Klrnrn. TRAY 3M)rnrn. TRAY
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COUPLER PLATE
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DRG. NO.
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NTPC
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( A GOVERNMENT OF INDIA ENTERPRISE )

ENGINEERING DMSION
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0000-21 1 -POE-A-()16
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ASSEMBLY 2 ING FOR C l CHANNEL
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PURPOSE ONLY RB FORTEIIDER RA rOR TENDER PURPOSE ONLY IILV
*Wlt
M
F1
E c c&l CLFARED BY
ARCH
L
APPO D/IIE
NO.
DESCRIPTION NTTPC
T^irn-ited-
( A GryERNMET{T INDA EITIIERPRISE OF ) DMSKIiI ENGINEERING
PROJECT TITLE slzb. 44
STANDARD
FIXING OF CEANNEL IN TRENCE TAI,L
NU. suALt I luKtt. INTS I
0000-211-PoE-A-019
{tsv. Nu. RB
CAD FILE NAME' STAND-211-019,I!VG
NOTES
1) MATERIAL : MILD STEEL.
2) FINISH : HOT DIP GALVANISED.
BRACKET-C2 CHANNEL CLAMP.
BRACKET-C1 CHANNEL CLAMP.
NOTES:
1) MATERIALS -MILD STEEL 2) FINISH-HOT DIP GALV.
1) 600mm TRAY-1
TO 6 TIER-C2
2 ) 3 0 0 m m TRAY-1 TO 3 TIER-C1
3) 300mm TRAY-4 TO 6 TIER-C2 4) 150mm TRAY-1 TO 6 TIER-C1
ANTILEVER ARM
ARRANGEMENT TYPE-B1
NOTES: 1) IN CASE OF HANGING SUPPORT C2 TO BE USED AS MAIN SUPPORT.

2) ALL DIMENSIONS ARE IN MM.
ANTILEVER ARM ON BOTH SIDES
ARRANGEMENT TYPE -B2
7 INSERT PCATE
k . 1 CHANNEL
ARRANGEMENT TYPE-C1
NOTES: 1) U P TO 3 TIER C1 CHANNEL
2) ABOVE 3TIER C2 CHANNEL
& BOTH
SIDE TRAY
ARRANGEMENT TYPE-Dl
3) ALL DIMENSIONS ARE IN MM.
BEAM OR RCC FLOOR
ANTILNER ARM
CC FLOOR L N E L
R TENDER PURPOSE
( A GOVERNMENT OF INDIA EWERPRISE )

ENGINEERING DIVISION
1 ) 600mm TRAY-1 TO 6 TIER-C2
CHANNEL
2) 300mm TRAY-1 TO 3 TIER-C1 CHANNEL 3) 300mm TRAY-4 TO 6 TIER-C2 CHANNEL 4) 1 5 0 m m TRAY-1 TO 6 TIER-C1 CHANNEL
MAIN SUPPORT CHANNEL-C1 /CZ
ARRANGEMENT TYPE-S2
CHANNELS SUPPORTED BY
tLUUH BtAM
INSERT PLATE PROVIDED FOR FIXING O F MAIN SUPPORT CHANNEL
I.
-. 2
VI
MAlN SUPPORT CHANNEL IS
$
C C
SUPPORTED BY BRACKET-WELDED
I : d
E 4
.d -0
VI .s
r ' >i = E ; I E : :
X
1) UP TO 3TIER-Cl CHANNEL ABOVE 3 TIER-C2 CHANNEL. 2 ) ALL DIMENSIONS ARE IN MM.
ARRANGEMENT TYPE-S3
I :
BRACKET WELDED
-flLI7
-r L
a,
0
-5 .-
MAlN SUPPORT CHANNEL C1/C2
aJ
a , "
r4
ANTILEVER ARM
ARRANGEMENT TYPE-S4
DESCRIPTION
NOTE :
1. ALL DIMENSIONS ARE IN MM (SCALE NTs)
CONDUCTOR GRID OUTSIDE THE BLDG.
INSERT IN RETAINING WALL
WELDED
\I
EARTH RISER WELDED TO MAIN EARTH CONDUCTOR EMBEDDED IN CONCRETE. RCC FLOOR SLAB
.Q
SO MIN
E A R T H RISER
NTPC
~irxiited
-
( A C O M R N M M OF INDIA ENTERPRISE ) ENGINEERING DMSION
I
I
PROJECT
STANDARD
TITLE
EARTHING D E T W
SIZE
A4
SCALE NTS DRC. NO.
I
REV. NO.
0000-211-POE-A-041
RB
CAD FILE N N E : STAND-Zil-C4I.W;
&
CAO FL NAUE : STAND-211-MZ.D'*G IE
GROUND CONDUCTOR ALONG BUILDING WALL

h
10
I;, r ;I l11
5
q-
l1
I!
$
I'
l1
(I
z 5
OC-
GROUND CONDUCTOR 35x6 G I FLAT
T
SEC. 5 - 5
STEEL COLUMN
l1
11
) -
-'
v"
If 1 ,
GROUND CONDUCTOR ALONG STEEL COLUMN STRUCTURE
NOTES
ALL DIMENSIONS A R E IN MM (SCALE-NTS)
1
C ,
2
K~
F A
TEPBEt fbKPt&
FDR TENDER PURPOSE ONLY
REV. NO
t'&/- p P F & - 47 C
--
EL
&,4y
r P P D m
DESCRIPTION
E C Ul,m ~ c k 0 s . nM , CLEARED BY
iwX)
PROJECT
NTPC
Limited
(AcowwMENTOFlNDNDRD(TOOPR1M) ENCWWlNC DNISK)F(
STANDARD
TITLE
EARTFIWG DETAlLS
SIZE
A4
SCALE N TS
ORG. NO.
0000-211-POE-A-043
REV. '10.
R8
2MM Al SHEET
BUSHINGS THRO CABLE
EARTHING DETAILS TRANSFORMER

i 1. THE TRANSFORMER NEUTRAL FOR H.T. TRANSFORMER SHALL BE EARTHED THROUGH l
i FLATS AS SHOWN ABOVE. (SUPPLIED BY TRANSFORMER SUPPLIER)
j
j
i
TYP. MFLON. TUBINIC (TO BE SEALED AFT INSTALLATION OF CONDUCTOR)
I
LIGHTNING PROTECTION DOWN-COMER ALVANISED BOX 2MM THK SHEET STEEL
2 7 x 8 OPENING
FOR WALL/COL./
60 HOLES FOR FIXING C O M R
0
EARTH TERMINAL WLDED TO BOX (TO BE CONNECTED TO EARTHING GRID)
LIGHTING PROTECTION DOWNCOMER TEST LINK

NOTES: WATER- TIGHT AFTER LAYING OF CONDUCTOR.
1. THE DOWN COMER ENTRY AND EXIT POINTS IN TO BOX BE MADE
2. THE TEST LINK SHALL BE OF SAME WIDTH AND THICKNESS AS THE DOWNCOMER.THE NUTS BOLTS AND WASHERS TO BE OF G.S 3. ALL DIMENSIONS ARE IN MM (SCALE-NTS)
SADDLE WTH SPACER
SIDE VIEW
DESCRIPTION
[ * m]
. .
PROJECT TITLE
'
NTPC
~imited
( A C O M R N Y E N ~ O F M D ~ A ~ E ) ENWNEERIW DWSKHJ
STANDARD
LIGHTNING PROTCTION DETALIS.

DRG. NO.
SIZE A4
SCALE N TS
0000-21 1 -FOE-A-047
CAD FILE
R&.
NO-
RB
33
NAME : STANC-211-O47.DK
BLOCK SPACING
IOOOMM CENTRE TO CENTRE
TYPICAL DETAILS OF CLEATING HORIZONTAL CONDUCTOR OVER WATER PROOFING
NOTE : ALL DIMENSIONS ARE IN MM
NTPC
PROJECT
Lixxxited
( A GOVERNMN OF INDIA ENTERPRISE )

ENGINEERING DMSlON
STANDARD TITLE
SIZE
A4
SCALE N TS
DRC. NO.
0000-21 1-POE-A-048
REV. NO.
Re
CM) FILE NAME : STAND-211-O&.DHC
I
SEE DETAIL
'A'
EARTH BACK FlLLED AND RAMMED
PRECAST CONCRETE
C a M K i 50X250X4Mhi
\
T
6- , ,
DIA. HOLES FOR

4 NOS. FIXING
(NTPC]
CAST IRON / PU\TE
1''0
LIGHTING CABLE
NOTES:
1. ALL DIMENSIONS ARE I N MM. 2 . ROUTE MARKERS SHALL BE CONSTRUCTED OF CONCRETE WITH CAST IRON PLATE. WITH THE ROUTE INFORMATION ENGRAVED ON IT. BOLTED ON TOP OF THE CONCRETE BLOCK AS SHOWN. 3. CAST l2ON PLATE SHALL BE OF 6 . 0 MM THICKNESS
j C C
DETAIL- 'A'
GESCRl?T!O?4
CLEARED BY
[NTPC]
wffm
NTPC
Limited
)
( A o o M W M E N l O f INDU -RISE
- ENClNWlNC D .- -.
I
TITLE
STANDARD
BURIED CABLE TRENCH DETAILS FOR LIGHTING
SCALE NTS
DRG. NO.
SIZE
A4
0000-2 1 1 -POE-A-049
R N . NO.
RB
21 1 -049.DWG
I
\
DIRECTLY BURIED CABLES IN SINGLE LAYER

@-CABLE @-EARTH ROUTE MARKER BACK FILLED & RAMMED PROTECTIVE COVERS
o) BRICKS FOR LOW
DIRECTLY BURIED CABLES I N 'TWO LAYER

DIMENSION MIN. D1
d
l l D O V GRADE FOR 3.3 K V 22KV & 33KV CABLES TO l l K V 750 900 1050
BETWEEN CABLES OF SAME CLASS
VOLTAGE CABLES
b) RCC FOR HIGH VOLTAGE CABLES WlTH HOLE AT EACH END TO TIE THE TO EACH OTHER WlTH G.S WlRE
X300MM BETWEEN CABLES OF DEFT CLASS S X400MM BETWEEN 1/C POWER CABLE AND COMMUNICATION CABLE. X300MM BETWEEN MULTlCORE POWER CABLE & COMMUNlCATlON CABLE.
&---ARMOURED
@ -
POWR CABLE
ARMOURED CONTROL CABLE FINE SAND/RIDDLED SOIL COMPACTED
d
x
@ -
OVERALL DIAMETER OF THE BIGGER OF THE TWO CABLES SPACI~G SHALL BE TAKEN BOTH HORIZONTALLY AND VERTICALLY.
1. SINGLE CORE CABLES SHALL BE RUN IN TREFOIL FORMATION AND SHALL BE BOUND B Y SELFLOCKING CABLE n E s A T EMRY 750 MM.
2. CABLE IDENTIFICATION TAG SHALL BE TlED AT BOTH ENDS OF INTERVAL OF 1 0 METRES.
THE
CABLE AN0 ALSO AT AN
3. I F THE MINIMUM CLEARENCE AS INDICATED THE A B O M TABLE FOR CABLES OF DIFFERENT

CLASSES ARE NOT FEASIBLE,BRICK BARRIERS SHALL BE USED BETWEEN ADJACENT CABLES PIPE SHALL BE PROVlDED FOR ROAD CROSSING AT A MINIMUM DEPTH OF 600 FROM THE GRADE LEVEL UNLESS OTHER WSE SPECIFIED. 5. ALL DIMENSIONS ARE IN MM (SCALE NTS)
4. G.I.
ENGINEERING DMSlON
CAD R E NAME : STAND-XK)-W3.CWL
,
PROJECT
TITLE
NTPC
.
Limited
( A CoMRNMENT OF INDlA ENrmPRlSE )

ENGINEERING DMSION
Sm r m
TYPICAL DETAES OF F U C T U R E FOR TESTING

SIZE
A4
SCALE ORG'
0000-21 1-POE-A-03'7
CAD
REV.
NO
N TS
FILE NAUE :
STAND-211-OJ7.DW;
WORKING UDL = 100 KG
AS INDICATED
y,": :",',
PROOF UDL POINT LOAD
= 200 KG = 100 KG
CANTILEVER ARMS
ADDITIONAL POINT LOAD OF 100 KG
INSTALLATION SECTION
(ASWMETRIC
LOADING)
OSITlON FOR APPLICATION F 600 K G POINT LOAD FOR TEST 3C POINT LOAD OF 600 KG AT EACH POSITION FOR TEST 3 B
BEAM CLAMPS AS ACTUAL
TWO BRACKETS LENEHALLY FIXEL POINT LOAD OF 1200 KG FOR TEST 3 A
TEST 3 A , 3B & 3C
FIXING SHALL BE AS PER ACTUAL SITE INSTALLATION CONDITION. 2. ALL DIMENSIONS ARE IN MM
1
CAO FILE NAME : STAND-211-OJ8.D%
&
Clause No.
TECHNICAL REQUIREMENTS TRANSFORMER
1.00.00 1.01.00
CODES AND STANDARDS Transformers Bushing CTs Insulating oil IEC:60076, IEC 60354, IEC:60726 IEC :60044-1 IEC: 60296
2.00.00 2.01.00
TYPE Out-door Transformers Dry type Transformers Mineral oil filled ONAN type, Three phase unit
2.02.00
Epoxy cast resin/resin encapsulated air cooled type, three phase unit
3.00.00
FEATURES Paint shade Degree of protection: Dry type transformer Cable box, Marshalling box RAL 5012
IP-23 IP-55
4.00.00 4.01.00
TEMPERATURE RISE Out-door Transformers Dry type Transformers Winding 55oC above ambient 50oC oil 50oc above ambient 50oC. Winding (by resistance method): 90oC or lower as permissible for class of insulation offered, above an ambient of 50oC.
4.02.00
5.00.00 5.01.00
OPERATIONAL REQUIRTEMENTS Tap Changer Off-circuit, +/-5% in steps of 2.5% shall be provided. It shall be hand operated by an external handle with position markings, pad locking facility in each position and mechanical stops to prevent over cranking beyond extreme positions in case of outdoor type transformers. In case of indoor transformers, it shall be with shrouded bolted links.
TECHNICAL SPECIFICATIONS VOLUME-II, PART-B
SUB-SECTION-IIIB-09 TRANSFORMERS
Page
1of 7
Clause No. 5.02.00 Loading Capability
Continuous operation at rated KVA on any tap with voltage variation of +/-10% corresponding to the voltage of the tap as well as in accordance with IEC 60354.
5.03.00
Flux Density Not to exceed 1.9 Wb/sq.m. at any tap position with +/-10% voltage variation from voltage corresponding to the tap. Transformer shall also withstand following overfluxing conditions due to combined voltage and frequency fluctuations: a) b) c) 110% for continuous rating. 125% for at least one minute. 140% for at least five seconds. :Not to exceed values specified in NEMA TR-1.
5.04.00 6.00.00
Noise Level
DESIGN AND CONSTRUCTIONAL FEATURES All transformers shall be suitable for cable or busduct termination as contemplated. If cable connection is envisaged, a dust tight cable box shall be provided. Also, a sheet steel, vermin and dust proof marshalling box shall be furnished with each transformer to accommodate temperature indicators, terminal blocks for control cables etc. The transformer shall be provided with all fittings and accessories to be complete in all respects for satisfactory operation.
6.01.00 6.01.01
OUTDOOR TRANSFORMERS a) Tank Shall be fabricated from tested quality steel and designed to withstand continuous internal pressure & vacuum as per CBIP guidelines. All steel surfaces in contact with insulating oil shall be painted with two coats of heat resistant oil insoluble insulating paint. Tank shields, if provided, shall not resonate at natural frequency of equipment. b) Tank mounting Transformer tank shall be mounted on bi-directional rollers. Suitable locking arrangement shall be provided to prevent accidental movement of transformer. Tank shall also be provided with lifting lugs and minimum four jacking pads. c) At least two adequately sized inspection openings, one at each end of the tank for easy access to bushings and earth connections shall be provided.
TECHNICAL SPECIFICATIONS VOLUME-II, PART-B SUB-SECTION-IIIB-09 TRANSFORMERS Page
2of 7
Clause No. 6.01.02
TECHNICAL REQUIREMENTS Core shall be High grade non-ageing cold rolled grain oriented silicon steel laminations. Winding conductor shall be Electrolytic grade copper. Windings of 66kV and below shall be uniformly insulated. Conservator tank of adequate capacity for expansion of oil from min. ambient to100 deg.C. shall be provided. The transformers rated 7.5 MVA and above shall be provided with air bag breathing through silica gel breather. For lower rating transformers, conventional single compartment conservator with dry air filling the space above oil and connected to silica gel breather shall be provided. Porcelain Bushings shall be used. Bushing CTs Shall be provided in the LV neutral side of adequate rating for REF protection, Back up definite time earth fault protection (for HT transformers only), WTI, etc. Radiators shall be Tank mounted with shut off valves. Insulating oil No external inhibitors are permitted.
6.01.03
6.01.04
6.01.05 6.01.06
6.01.07 6.01.08
6.01.09 6.01.10 6.01.11
Marshalling box shall be provided with thermostatically controlled space heaters. The insulation of core to core clamp shall be able to withstand a voltage of 2 KV rms for one (1) minute. Fittings Transformer shall be provided with following fittings a) Buchholz relay shall be provided with double float type with alarm and trip contacts, along with suitable gas collecting device. At least two numbers of spring operated pressure relief devices with extension pipe to bring oil to plinth level along with electrically insulated contact for alarm and tripping shall be provided for transformer rating 2MVA and above. Diaphragm type explosion vent shall be provided for all transformers below 2 MVA rating. Winding temperature indicator (WTI) and Oil temperature indicator (OTI), Dial type (150mm) with alarm and trip contacts and max. reading pointer along with resetting device shall be provided. Magnetic oil level gauge with alarm contact shall be provided.
b)
c)
d)
e)
3of 7
Clause No. f) 6.01.12
TECHNICAL REQUIREMENTS Oil level gauge Prismatic/toughened glass type.
Neutral grounding resistors (AS APPLICABLE) for neutral point earthing of 6600 volts, 3 phase AC systems shall be of punched stainless steel grid element type. Resistor element shall be insulated from supporting base by mica tubes. NGR shall be housed in a 2.5 mm thick sheet steel enclosure having IP 33 degree of protection. NGR enclosure shall be supported on insulators placed on the mounting structures of minimum height of 2.4 metre above ground level. i) ii) iii) iv) v) vi) vii) viii) 12.7 Ohms 300A for 10 seconds Neutral Grounding of Star connected LV winding of 12.5 MVA transformer Service Outdoor Resistor material & connection Punched stainless steel grid element type Maximum allowable temperature 350 deg. C rise over ambient 50 oC Mounting 6.9 KV grade insulators. Power frequency test level 20 KV (rms) Resistance Value at 50 deg. C. Rated current Application
6.02.00 6.02.01
DRY TYPE TRANSFORMERS Enclosure Enclosure shall be of a tested quality sheet steel of minimum thickness 2 mm & shall also accommodate cable terminations. The housing door shall be interlocked such that it should be possible to open the door only when transformer is off. The enclosure shall be provided with lifting lugs and other hardware for floor mounting.
6.02.02
Core Shall be High grade non-ageing cold rolled grain oriented silicon steel laminations.
6.02.03
Winding conductor
Shall be electrolytic grade copper or aluminium. Windings shall be of class F insulation. Shall be Solid porcelain / RIP. Shall be provided in the LV neutral side with adequate rating for REF protection, WTI, etc.
6.02.04 6.02.05 6.02.06
Bushings Bushing CTs Fittings Winding temperature Indicator (WTI) Thermistors
Shall be Platinum resistance type temperature detector in each limb. Shall be embedded in each limb with alarm and trip contacts for remote annunciation.
4of 7
Clause No.
7.00.00 7.01.01
TRANSFORMER SIZING Size of the transformer shall be decided based on following : Size shall be greater than or equal to total KVA of continuous load + (coincident factor x total kVA of intermittent load other than valves) + 0.2 x total valves kVA + kVA of largest rated valve or damper motor + Employer's requirement, if any. + 10% margin on the sum of the above mentioned values. Coincident factor of intermittent load, such as lifts, cranes, hoists etc shall be taken as 0.5.
7.01.02
Normally 2 x 100% feeding arrangement shall be provided as shown in single line diagram i.e. the total loads to be considered for sizing each transformer shall be the loads working on both the buses. In case of 3 x 50% feeding arrangement, if required, the loads to be considered on each transformer shall be the loads working on any two of the buses. TYPE TESTS For each type and rating of transformers rated more than 2 MVA: The contractor shall carry out the type tests as listed in this specification on the equipment to be supplied under this contract. The Bidder shall indicate the charges for each of these type tests separately in the relevant schedule of BPS and the same shall be considered for the evaluation of the Bids. The type test charges shall be paid only for the test(s) actually conducted successfully under this contract and upon certification by the Owner's Engineer. The type tests shall be carried out in presence of the Owners representative, for which minimum 15 days notice shall be given by the Contractor. The Contractor shall obtain the Owners approval for the type test procedure before conducting the type test. The type test procedure shall clearly specify the test set-up, instruments to be used, procedure, acceptance norms, recording of different parameters, interval of recording, precautions to be taken etc. for the type test(s) to be carried out. In case the Contractor has conducted such specified type test(s) within last five years as on the date of bid opening, he may submit the type test reports to the Employer for waival of conductance of such type test(s). These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. The Employer reserves the right to waive conducting of any or all of the specified type tests
8.00.00 8.01.00 8.01.01
8.01.02
8.01.03
5of 7
Clause No.
TECHNICAL REQUIREMENTS under this contract. In case type tests are waived, the type test charges shall not be payable to the Contractor.
8.02.00 8.02.01
For each type and rating of transformers rated up to and including 2 MVA:The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last five years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. In case the Contractor is not able to submit report of the type test(s) conducted within last five years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract free of cost to the Owner and submit the reports for approval. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer conforming similarity and No design change. Minor changes if any shall be highlighted on the endorsement sheet. Following is the list of type tests to be conducted (as per IEC) for transformers of rating more than 2 MVA (For transformer of rating upto & including 2MVA, only the valid test reports are to be submitted in line with Cl 8.02.01). (a) (b) (c) Short circuit test. Temp. rise test. Lightning impulse (Chopped Wave) voltage test on all three limbs and full wave LI on neutral if grounded through NGR.
8.02.02
8.02.03
8.03.00
(d) Partial discharge test on dry type transformers only (Max. allowed PD shall be 20 PC). (e) (f) Noise level test as per NEMA TR-1. Zero sequence Impedance measurement.
8.04.00
Following type test reports in line with clause no 8.02.01 shall be submitted for each type & rating of transformer:(a) (b) Tank pressure test as per CBIP norms (for oil filled transformers). Tank vacuum test as per CBIP norms (for oil filled transformers).
6of 7
Clause No. (c) 8.05.00
TECHNICAL REQUIREMENTS Degree of protection test on marshalling box.
The following special tests on all transformers shall be conducted under this contract as routine tests in addition to all routine tests as per IEC 60076: (a) (b) (c) Oil leakage test for 24 hours (for oil filled transformers). Repeat no load loss tests after electrical tests. Measurement of capacitance & tan delta to determine capacitance between winding and earth.
TECHNICAL SPECIFICATIONS VOLUME-II, PART-B
SUB-SECTION-IIIB-09 TRANSFORMERS
Page
7of 7
Clause No.
HT SWITCHGEAR
1.00.00 CODE AND STANDARDS IEC: 62271, IS: 13118 and IS: 3427 2.00.00 2.01.00 TYPE Switchgear Free standing, Floor mounted, metal clad, fully compartmentalized draw-out type 2.02.00 Circuit Breaker Vacuum type, restrike free, trip free, stored energy operated and with electrical anti-pumping features 3.00.00 3.01.01 3.01.02 3.01.03 RATING HT Voltage: 33 KV+/- 6%, 6.6KV +/-6% Frequency: 50 Hz, 3%.-5%
Fault Level: 6.6 KV : 40 KA RMS for 1 sec. with short circuit making current of 100KA PEAK 33KV: 21KA RMS for 1 sec with short circuit making current of 52.5KA PEAK
3.01.04
Control Supply: 240 V DC
3.02.00
TEMPERATURE RISE Temperature rise of busbars shall not exceed 55 deg. C for silver plated joints and 40 deg. C for other joints, over an ambient temperature of 50 deg. C under any condition.
4.00.00
OPERATIONAL REQUIREMENT
4.01.00
The circuit breaker shall meet the following requirements a) The breaker shall be remotely controlled. Facilities shall be provided for mechanical tripping of breaker and manual charging of closing spring to cater to emergency condition.
TECHNICAL SPECIFICATIONS SECTION-VI, PART-B
SUB-SECTION-IIIB-10 HT SWITCHGEAR
Page 1 of 11
Clause No. b) c) d)
TECHNICAL REQUIREMENTS Surge arrestor shall be provided for each motor feeder. Shall have an Operation duty O-3 min -CO- 3min-CO. Closing and tripping coils operating under extreme conditions of control voltage variation. Supervision relays provided for trip coil monitoring. Suitable mechanical inter lock shall be provided to prevent inadvertent earthing of any live part. Suitable interlock shall be provided, which will ensure that breaker is OFF before opening the back doors. For Incomer/Tie panels suitable interlock shall be provided to prevent opening of any compartment doors which has any of the MV (33kV/11kV/6.6kV/3.3kV) equipment, in case the incoming supply is ON. Testing of circuit breaker shall be possible in isolated position by keeping the control plug connected. Only motor wound closing spring charging arrangement is acceptable. In a switchgear if there are more than one possible feed (including bus coupler) then lockout relay (86) contact of incoming breakers shall be connected in series in closing circuit of each of incoming breakers. Automatic change-over shall be provided for bus sections with suitable synchronizing check facility. The change-over shall be blocked in case of fault on the bus section. Dead Bus change-over after voltage collapse shall also be provided as back-up. Core balance CTs shall be provided for outgoing motor and transformer feeders having CT ratios greater than 50/1A. Each breaker truck shall have Service - Isolated - Withdrawn Position. Primary fuse replacement shall be possible with VT in isolated position.
e) f)
g)
h)
i) j)
k)
l)
m) n)
4.02.00
Contactor (a.) The Bidder shall offer only HRC fuse backed, mechanically latched type contactor for outgoing conveyor motor feeder panels. (b.) The medium voltage contactors shall be of AC-3 utilization category and shall be vacuum type. The fuse and contactor assembly shall be mounted
Page 2 of 11
Clause No.
TECHNICAL REQUIREMENTS on a withdraw able truck. Circuits shall be provided with suitable single phasing protection. If required the contactor coil shall have a suitable economy resistor in series and shall be rated for satisfactory operation at 80 to 110% of rated voltage. (c.) The fuse and overload relay shall be fully coordinated, so that the contactor operates only for a fault current less than its interrupting capability. The fuses shall be provided with mechanical trip indication. The contactors shall close satisfactorily with a control voltage between 85 to 110 per cent and trip satisfactorily with a control voltage between 70 to 100 percent of the rated control supply voltage. Mechanical indication of contactor open / closed shall be provided. An anti-pumping relay shall be provided even if it has mechanical anti-pumping feature. Trip circuit supervision relay shall be provided to monitor the healthiness of trip coil. Surge suppressors shall be provided on all contactor controlled motor feeders.
(d.)
(e.)
4.03.00
Surge Arrestor The surge arrestors shall be provided for all motor feeders and shall be metal oxide, gapless type generally in accordance with IEC 60099-4 and suitable for indoor duty. These shall be mounted within the switchgear cubicle between line and earth, preferably in the cable compartment. Surge arrestor selected shall be suitable for non-effectively earthed system and rating shall be in such a way that the value of steep fronted switching over voltage generated at the switchgear terminals shall be limited to the requirements of switchgear.
5.00.00 5.01.00
Protection, Control and Metering The switchgears shall have Communicable Numerical relays for Protection, scheme, Metering and Status monitoring. The Numerical relays shall be networked and integrated to the Coal Handling Plant PLC. Dynamic displays shall be created in the PLC for the 33 KV & 6.6KV SWITCHGEAR for diagnostics and status monitoring. All the feeders shall be remote controlled from PLC and from the local console of the numerical relays. General requirements of Numerical Relays All numerical relays, auxiliary relays and devices shall be of types, proven for the application; satisfying requirements specified elsewhere and shall be subject to Owner's approval. Numerical Relays shall have appropriate setting ranges, accuracy, resetting ratio, transient overreach and other characteristics to provide required sensitivity to the satisfaction of the Owner. All the numerical relays shall have communications on two ports, local front port communication to laptop and a second port on IEC 61850 port.
5.02.00 5.02.01
Page 3 of 11
Clause No. 5.02.02
TECHNICAL REQUIREMENTS All relays and timers shall be rated for control supply voltage as mentioned elsewhere under parameters and shall be capable of satisfactory continuous operation between 80-120% of the rated voltage. Making, carrying and breaking current ratings of their contacts shall be adequate for the circuits in which they are used. Interrogation voltage for the binary inputs shall be suitably selected to ensure avoidance of mal operation due to stray voltages. The protective relays shall have at least 10 Nos potential free contacts (Programmable) Auxiliary relays shall have contacts as required. Relay output contacts shall be suitable for directly wiring in the breaker closing and trip circuit operating from 220 V DC control voltage. Failure of a control or auxiliary supply and deenergisation of a relay shall not initiate any circuit breaker /contactor operation. All relays shall withstand a minimum test voltage of 2 KV AC Rms for one minute. Relays shall be suitable for electrical measurement including voltage, current, power (active/reactive) and energy parameters. Relays shall have separate output for individual functionality and the master trip shall be software configurable in case of multi output relays. Relays shall have event recording feature, recording of abnormalities and operating parameters with time stamping Preferably comprehensive single numerical relay shall have provision of both current and voltage inputs. The current operated relay shall have provision for 4 sets of CT inputs, 3 nos. for phase fault & 1 CT input for earth fault. Relay shall be suitable for both residually connected CT input as well as CBCT input. The voltage-operated relay shall have provision for 3 PT inputs. Relays shall be suitable for CT secondary current of 1A/5A selectable at site. Relays used in incomers and bus couplers shall have provision of two sets of voltage signal inputs for the purpose of synchronization. All CT & PT terminals shall be provided as fixed type terminals on the relay to avoid any hazard due to loose connection leading to CT opening or any other loose connection. In no circumstances Plug In type connectors shall be used for CT / PT connections. Vendor to ensure the same for all protective relay models offered. All numerical relay shall have key pad / keys to allow relay settings from relay front. All hand reset relays shall have reset button on the relay front. Relay to be self or hand reset shall be software selectable. Manual resetting shall be possible from remote. Relays shall have suitable output contact for breaker failure protection. Relays shall have self diagnostic feature with self check for power failure, programmable routines, memory and main CPU failures.
TECHNICAL SPECIFICATIONS SECTION-VI, PART-B SUB-SECTION-IIIB-10 HT SWITCHGEAR Page 4 of 11
5.02.03
5.02.04
5.02.05
5.02.06
5.02.07
5.02.08
5.02.09
5.02.10 5.02.11
Clause No.
5.02.12
Relays shall have at least two sets or groups of two different sets of adaptable settings. Relays shall have multiple IEC/ ANSI programmable characteristics. Design of the relay must be immune to any kind of electromagnetic interference. Vendor to submit all related type test reports for the offered model along with the offer. Protections: Relay Types/ Protections A. a) b) c) d) e) f) g) h) i) j) k) l) B. Motor Feeders Thermal Overload Protection (50I) Restart Inhibit Protection (49) Earth Fault Protection (50N/50N2) Negative Phase Sequence Protection (46) Reversal Phase Sequence Protection (46 R) Locked Rotor Protection (50 L/R) Number of starts limitation (66) Loss of Load Protection (37) Under Voltage protection with timer(27 M) Motor Differential protection (87 M) for Motor rating > 2 MW Energy Metering Monitoring Transformer Feeder Protections
5.02.13
5.02.14
a) Three Phase Over current and Earth Fault protection (50 & 50 N1/50 N2))(The earth fault element should be suitable for both residually connected CT input as well as CBCT input. ) b) Restricted Earth Fault protection (64 R) c) Transformer Differential protection (87 T) for Transformers with rating more than 5 MW d) Stand by earth fault protection (51 N) e) Transformer buchholz and WTI/OTI high trips f) Energy Metering g) Monitoring C. a) b) c) d) Protections for Incomers, Bus couplers and Tie feeders. Over current and earth fault protection. Synchronizing check relay as a part of fast change over scheme. Energy Metering Monitoring
Page 5 of 11
Clause No. 5.03.00 5.03.01
TECHNICAL REQUIREMENTS Other Protections and Control functions in the Relays. For Breaker control from PLC, hardwired potential free contacts shall be provided from PLC, to the numerical relays. Preferably no separate coupling relays shall be provided. Trip circuit supervision shall be provided for all feeders to monitor the circuit breaker/ contactor trip circuit both in pre trip and post trip conditions. Schematics requiring auxiliary relays /timers for protection function shall be a part of numerical relay. The number of auxiliary relay and timer function for protection function shall be as required. Auxiliary relays for interlocking purpose shall be of self reset type. Bus no volt condition shall be configured to a output contact of the relay of all incomers Timer functions shall be programmable for on/off delays. The numerical relay shall be able to provide supervisory functions such as trip circuit monitoring, circuit breaker state monitoring, PT and CT supervisions and recording facilities with Post fault analysis. The numerical processor shall be capable of measuring and storing values of a wide range of quantities, all events, faults and disturbance recordings with a time stamping using the internal real time clock. Battery back up for real time clock in the event of power supply failure shall be provided. 150 time tagged events /records should be able to store with time stamping Last 5 faults storage including the indication, protection operated , fault location relay and operating time, currents, voltage and time. Diagnostics Automatic testing, power on diagnostics with continuous monitoring to ensure high degree of reliability shall be shall be provided. The results of the self reset functions shall be stored in battery back memory. Test features such as examination of input quantities, status of digital inputs and relay outputs shall be shall be available on the user interface The alarm/status of each individual protection function and trip operation shall be communicated to PLC The numerical relay system shall have built-in features/hardware interface to provide such inputs to PLC for analog/digital values The provision of receiving the D.C. incoming supplies and its monitoring shall preferably be made in one bus P.T. Panel. Sequence of events shall have 1 ms resolution at device level. Measurement accuracy shall be 1 % for RMS Current and voltage.
5.03.02
5.03.03
5.03.04
5.03.05 5.03.06
5.03.07
5.03.08
5.03.09
5.03.10
5.03.11 5.03.12
Page 6 of 11
Clause No. 5.03.13
TECHNICAL REQUIREMENTS It shall be possible to carryout open / close operation of breakers from a laptop by interfacing from the relay front port (RS232) during initial commissioning. Auxiliary power Supply Relay shall be suitable to accept both AC & DC supplies with 110V AC or 220V DC with tolerance of 80% to 120 % of rated voltage
5.04.00
5.05.00
Input / Output Interface, Filters And Optical Isolation Relay shall be immune to capacitance effect due to long length of connected control cables. Any external hardware, if required for avoiding mal operation of the relay due to cable capacitance shall be included as a standard feature. All IOs shall have optical isolation. Analog inputs shall be protected against switching surges, harmonics etc. No separate earth bus shall be required for the relays. It shall be possible to connect the relay earth to the common earth bus in the switchgear panel which shall be connected to the plant earth mat.
5.06.00
Soft ware Security, License and up gradations Numerical relays shall have two level pass word protections, one for read only and other for authorization for modifying the setting etc.
6.00.00
DESIGN AND CONSTRUCTION FEATURES All HT switchgear panels and circuit breakers shall have the following features. a) High conductivity aluminum alloy or copper for the horizontal bus bars, vertical droppers and connectors to the fixed end of isolating contacts. Height of the Switchgear Panel Not to exceed 2600 mm.
b) c)
Insulators shall be track-resistant, high strength, non-hygroscopic, noncombustible type and suitable withstand stresses due to over-voltages and short circuit current. Inter pole barrier of inflammable material like hylam not acceptable Sealing Bushing or other sealing arrangement shall be provided between breaker and bus bar / cable compartments to avoid air communication around isolating contacts in the safety shutter area with truck in service position. Construction i) The switchgear assembly shall be rodent and vermin proof.
d)
e)
Page 7 of 11
Clause No.
ii)
In switchgear design where the breaker front itself serves as a door suitable blanking covers one for each size of panel per switch board shall be included. The switchgear enclosure shall be constructed with rolled steel section of rolled sheet steel of at least 2.0 mm thickness. Pressure relief device shall be provided in each high voltage compartment to vent out safely the gases produced in case of a fault. Contractor shall furnish calculation during detailed- engineering stage to establish the adequacy of support insulator and bus bar sizes for the declared continuous & short time current ratings. Breaker trucks shall have a secure locking in SERVICE position so that they are not displaced during a short circuit. Current ratings of all switchgears, circuit breakers, CT's etc. Shall be sufficient for carrying the connected load currents without exceeding the permissible temperature limits or reduction in service life. Use of two breakers in parallel to meet the required rating shall not be acceptable. HT switchgear shall also have at least two (2) fully equipped spare feeders (one each for highest size of motor/transformer) for any future requirement. Suitable trolley arrangement, if required, shall be provided. One trolley per switchgear room shall be provided suitable for each type of rating of breakers. Earthing Arrangement Internal earth bus shall be provided which has a capacity to withstand short circuit currents for one second and all enclosures shall be connected to this bus. Earthing arrangement through and integral earth switch or through separate Earthing truck shall be provided. Suitable mechanical interlocks shall be provided to prevent the closing of earth switch circuit on live circuit. In case of later arrangement one set of different types of earthing trucks per switch board shall be provided.
iii)
iv)
v)
vi)
vii)
viii)
ix)
f) (i)
(ii)
Page 8 of 11
Clause No. (iii)
TECHNICAL REQUIREMENTS Earthing switch/Earthing truck shall be short time (One second) current withstand capability equal to the breaker. A clearly visible warning label "ISOLATE ELSEWHERE BEFORE EARTHING" shall be provided on shutters of incoming and other connections which could be energized from other end.
iv)
g)
Switchgear panel shall be suitable for bottom entry and provided with removable gland plates. Instrument transformer CTs and VTs shall be provided for protection and metering and shall be cast-resin encapsulated type. Insulation class 'E' or better. VTs shall have suitable HRC current limiting fuses to both primary and secondary sides, under voltage relays, timers, etc. for motor tripping and remote annunciation on supply failure. Each switchgear section shall have a three phase VT. Single phase VT shall be provided for HT incomers for synchronization. Accuracy class of CTs and VTs shall be as follows CT Protection/ Metering Differential/REF 5P 10 1.0 PS Core balance CTS PS
h)
j)
Identification plates Each panel to be identified on front as well as back side by large engraved plate giving detailed feeder description. Identification labels/painted (Not stickers) plates to be provided inside each panel.
k)
Safety Requirements The switchgears shall be designed to offer adequate level of safety to operating/ maintenance personnel. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate shall be provided for each switch gear room mounting on wall describing various safe operating procedure / safety precautions for safe operation and maintenance of switchgear.
Page 9 of 11
Clause No.
TECHNICAL REQUIREMENTS Safety shutters complying with IEC-60298 shall be provided to cover up the fixed high voltage contacts on bus bar and cable sides when the truck is moved to ISOLATED position .The breaker / contactor and the auxiliary compartments provided on the front side shall have strong hinged doors. Bus bar and cabling compartments provided on the rear side shall have separate bolted covers with self retaining bolts for easy maintenance and safety. Breaker / Contactor compartment doors shall have locking facility. Suitable interlock shall be provided, which will ensure that breaker is OFF before opening the back doors. For Incomer/Tie panels suitable interlock shall be provided to prevent opening of any compartment doors which has any of the MV (33kV/11kV/6.6kV/3.3kV) equipment, in case the incoming supply is ON.
7.00.00
Type Tests GENERAL (a.) All equipments to be supplied shall be of type tested design. The Contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. In case the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost either at third party lab or in presence of client/ownerss representative and submit the reports for approval. All acceptance and routine tests as per the specification and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No design Change. Minor changes if any shall be highlighted on the endorsement sheet.
(b.)
(c.)
(d.)
The contractor shall submit the following type tests reports on the equipments to be supplied under this contract. a) The following type tests Reports shall be furnished circuit breaker / circuit breaker panels, of each voltage class and current rating.
Page 10 of 11
Clause No.
1)
Short circuit duty test on circuit breaker, mounted inside the panel offered along with CTs, bushing and separators. Short time withstand test on circuit breaker, mounted inside panel offered together with CTs, bushings and separators. Power frequency withstand test on breaker mounted in side panel. Lightning impulse withstand test on breaker mounted in side panel. Temperature rise test on breaker and panel together.
2) 3) 4) 5)
6) 7) 8) b)
Test to verify pressure relief devices operation of the panel. This shall be done on one panel of each voltage class. Measurement of resistance of main circuit. Mechanical operation test.
Contactor and Contactor panels of each type and rating. 1) 2) 3) Verification of rated making and breaking capacities of the contactor. Short time withstand test of panel. Power frequency test on the contactor mounted in side panel.
4) Lightning impulse voltage withstand test of the contactor mounted in side panel. 5) 6) Measurement of resistance of main circuit. Test to confirm coordination between fuse and contactor.
c)
Short circuit withstand test of earthling device (truck / switch). Type Tests Reports for Surge arrestors Numerical relays
Type test Reports as per IEC 61850
Page 11 of 11
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
10/01/07
CLAUSE NO.
TECHNICAL REQUIREMENTS PLC & CONTROL PANELS
1.00.00
CODES AND STANDARDS Programmable Logic Controller IEC: 1131
2.00.00
CONTROL TYPE PLC based
3.00.00 3.01.00 3.01.01
PANEL CONFIGURATION PLC based Control system Main control desk Mosaic based control desk type for mounting push buttons/meters etc. with doors at the rear. The mosaic grid tiles shall be of 24mmx48mm (or 25mmx50mm) size, made of heat and flame retardant, self-extinguishing and non-hygroscopic material with flatmatt finish without glare and non-reflecting type. Industrial PC based OWS (Operator Work Station) of PLC shall be mounted on control desk to house PC/ keyboards/ mouse etc. The profile and dimension shall be decided during detailed engineering and shall be subject to Employers approval.
3.01.02 3.01.03 3.02.00 3.02.01
Separate vertical free standing PLC panel with Perspex/glass door for visual access to LEDs. Power distribution equipment i.e. Control transformers/ UPS/Power Supplies/Backup Batteries/ MCBs etc shall be housed in a separate free standing vertical panels. Local control panels: Local control panels for Metal detectors, Sump pumps, ILMS, Belt weigher and Hoists shall be free standing, floor / wall mounting type. They shall be provided with the required Power equipment like Switches, Fuses, Contactors etc. and the required control equipment like selector switches, meters, Push buttons, indications and annunciations etc. Local control panels shall be provided for CSU, hydraulic scoop coupling and dust suppression system. However control of all these systems shall be through main PLC with starters located in main MCCs only. Separate control desk shall be provided in the Silo control room with HMI and R I/O panels and their power supply system for the local operation of the silo equipment. Necessary controls, indications and annunciations for all the above equipment shall also be provided in main control desk as described elsewhere. SYSTEM CONFIGURATION a) Control shall be normally effected through OWS/Keyboard. However miniaturised Stop push buttons shall be provided for drives/systems in coal flow path (to be finalised during detailed engineering). These shall be
TECHNICAL SPECIFICATIONS Section-VI, Part-B Sub-Section - IIIB-11 PLC CONTROL PANELS Page 1 of 11
3.02.02
3.02.03 3.02.04 4.00.00
CLAUSE NO.
TECHNICAL REQUIREMENTS sized compatible to mosaic grid. b) The mimic diagram of the HT & LT switchgear with facilities to operate 6.6KV Breakers and LT MCC incomers shall be provided on the control desk. Indicating instruments All indicating instruments (i.e. ammeters/ voltmeters) shall be digital type and of accuracy class 1.0. Ammeters shall be provided on control desk for: i) All motors in coal flow path and for other motors rated 30 kW and above 6.6KV / LT switchgear. ( KWH display for HT & LT incomers shall also be provided on OWS) Voltmeters shall be provided on control desk for 6.6KV/LT buses. Ammeters and Voltmeters shall be suitable for 4-20mA DC signals derived from analog I/O cards in the PLC. d) Mimic i) Scrolling Mimic of coal handling system shall be configured on Large Video Screen (LVS) and OWS. It shall be possible to control / monitor / operate from LVS and OWS. Different colour schemes shall be used in the mimic to indicate status of various equipment i.e. ON/OFF/Ready to start/Trip conditions etc.
c)
ii) iii)
ii)
e)
Large video screen (LVS)
LCD Projection type with rear - screen configuration (other type proven technology eg. that based on digital light processing shall also be acceptable subject to Employer approval) with redundant bulb and shall be complete with screens (1280 x 1024 pixels). Separate workstation/control unit fitted with necessary graphic control card and required software for selecting screens and for other required manipulation. The exact make, model and technical particulars of the LVS shall be approved by the employer during detail engineering stage. Specially designed plant overview mimic, display of important parameters, alarm, annunciation facility etc. shall be provided on the LVS. Size of the LVS shall be 80 84 inches diagonal minimum. CCTV system shall be connected to the LVS also.
5.00.00 5.01.00
CONTROL SYSTEM The control and sequential operation of the all the drives and equipment within the plant shall be done by field proven Programmable Logic Controller (PLC) system.
CLAUSE NO.
TECHNICAL REQUIREMENTS The PLC system shall be provided with 2x100% processors in hot standby mode. It shall be possible to keep any of the processors as master and other as hot standby. The hot standby shall be hardware based and there shall be a dedicated link between the two processors for data and program equalization. It shall be possible to keep any of the processors as master and other as hot standby. One processor shall be automatically updated in line with the changes made in software of the other processor. Automatic Forcing bit update in the secondary processor/ Controller of PLC when any Forcing is applied in the primary processor/controller of PLC shall be provided. Standby processor shall be energised and continuously monitored for healthiness. In case a failure of working processor, the standby processor shall take over the operation automatically and necessary failure alarm shall be provided. The processor along with their accessories shall be housed in a free standing vertical type PLC panel separate from control desk and shall be located in the main control room. I/O system shall be of distributed type. The number and location of I/O panels shall be subject to Employer approval during detailed engineering. The operation and supervisory system for the plant shall consist of Industrial PC (latest model), TFT Monitors with key boards which shall be mounted as an integral part of the control desk. The processor along with OWS, printer etc. and control panels shall be interlinked through independent dual data highway and independent dual I/O links. In addition to operation from HMI, it shall also be possible to operate through push buttons (stop command only) & selector switches mounted on control desk. The operation of push button shall send necessary signals through PLC. Mimic of entire system within the plant along with SLDs of HT/LT switchgear shall be provided on PLC graphic and configured on LVS also. Group annunciation through annunciation window shall be provided for various abnormal conditions through PLC. The list of required annunciations shall be finalised during detail engineering. In addition to the controls from the control desk/keyboard/local control panels, each motor shall be provided with local stop push button station near the drive and shall be wired to the PLC. The PLC shall receive 4-20mA signals from belt weighers corresponding to the coal flow rates for integration and indication. Coal flow print out shall also be provided. PLC system shall provide the outputs for the following: a) b) c) d) e) No. of starts per day conveyor wise Number of times the conveyor motor was started 3 times consecutively in a day. Total daily operating hours conveyor wise. Weekly trip reports for each trip condition Total daily coal flow conveyor wise.
5.02.00
5.03.00 5.04.00
5.05.00
5.06.00
5.07.00 5.08.00
5.09.00
The PLC Controller/processor unit shall be capable of executing the following functions:-
TECHNICAL SPECIFICATIONS Section-VI, Part-B
Sub-Section - IIIB-11 PLC CONTROL PANELS
Page 3 of 11
CLAUSE NO.
TECHNICAL REQUIREMENTS a) Receiving binary and analog signals from the field and operator initiated commands from Operator Station. b) Implementing all logic functions for control, protection and annunciation of the equipment and systems. c) Implementing modulating control function for certain applications as specified elsewhere in the specification. d) Issuing control commands. e) Providing supervisory information for alarm, various types of displays, status information, trending, historical storage of data etc. f) The PLC Control system shall have extensive self diagnostic capability which shall include module level diagnostics as well as channel level diagnostics to detect any short circuit/ open circuit at field I/O level.
6.00.00 6.01.00
CONTROL PHILOSOPHY Normal / local mode of operation shall be selected from the key board. (a) In normal mode of operation, which shall be the default mode, all drives shall be operated from control desk through keyboard. Whenever required for maintenance, the maintenance mode will be selected from the keyboard of the operation, except trip interlocks is locked using a unique password. After maintenance, the drives shall be started from operator's station through all process interlocks, by re-entering the password. Normal mode of operation can be selected then. Irrespective of any PLC mode of operation, the running equipment can be stopped from keyboard or from desk/panel or from emergency stop push button. Incomers, bus couplers & transformers feeder including spares of HT switchgear and Incomers & bus-coupler feeders of LT switchgear shall be switched ON/OFF from the control desk through key board and also through control switches/push buttons. PLC system shall have facilities to detect the operated pull cord switch and belt sway switch of the conveyor. In addition to the pull cord switch and belt sway switch operation annunciation, conveyor number & operated pull cord / belt sway switch number shall also be displayed in the CRT.
b)
c)
7.00.00
TRAINING Further to the relevant clause regarding training specified elsewhere, Contractor's experienced personnel/engineers shall also provide training courses on offered PLC system to Employer's engineers in the following areas: (a.) (a.) (a.) Operator training Hardware Maintenance training Software training
CLAUSE NO.
TECHNICAL REQUIREMENTS (a.) Any other specalised training as required for system operation and maintenance.
The maintenance training shall include lectures and hands on experience on similar type of equipment / system at manufacturer works and recently commissioned operating plant and / or training simulator. The Employer shall require training of two hardware and two software engineers and the duration of each course shall be minimum two weeks. The details of hardware and software training shall be finalised during detailed engineering and shall be subject to Employer's approval. 8.00.00 8.01.00 PLC EQUIPMENT AND SYSTEM REQUIREMENTS PLC system shall consist of redundant processors. redundant Industrial PC with TFT Monitors (latest version with latest application software) & keyboard, I/O modules, UPS/power supply with battery backup, printer etc. The configuration of PLC shall be as per enclosed drawing. Details of various components shall be as given below : a) b) Processor Memory Two (2) numbers. one as hot standby Non volatile EPROM, Lithium or Ni-Cd battery for 360 hours backFPC up, 40% spare capacity for future use. c) d) Selection Monitors & Keyboard Normal/Test/Programme/Off facility shall be provided. In test mode all outputs shall be blocked. Twenty (20) inches TFT flat monitors with resolution of 1280 x 1024 pixels non interfaced, refresh rate minimum 75 Hz. with flat membrane type keyboard/ mouse. CRT shall have graphic display facility. CRT & keyboard/ mouse shall be used for controlling, monitoring and programming function. Provision for erasing and duplicating the user program and long storage facility, forcing facility for changing the status of inputs and outputs, timers and flags to facilitate fault finding and other testing requirements shall be provided Modular design. Possible to change any module without disconnection of any wire. Keying in of individual wire connectors shall be provided to ensure that only the correct card is plugged on the I/O module. Twenty(20) percent spare capacity in input output modules in each rack and forty(40) percent spare capacity in CPU memory modules & in I/O handling capability shall be provided over and above system requirement. One additional Ethernet port shall be made available in each PLC system so that wireless communication modem can be connected by
Sub-Section - IIIB-11 PLC CONTROL PANELS Page 5 of 11 Section-VI, Part-B
e)
Processors & I/O racks
TECHNICAL SPECIFICATIONS
CLAUSE NO.
TECHNICAL REQUIREMENTS the Employer in future. All Output cards shall be sourcing type and Input cards shall be sinking type. The Contractor shall provide the following monitoring features:a) Power supply monitoring. b) Contact bounce filtering. Further, keying-in of individual wire connectors shall be provided to ensure that only the correct card is plugged on the I/O module. It shall be possible to remove the I/O module without disconnecting wiring from field inputs or outputs. Wiring between I/O cards & terminal blocks shall be through pre-fabricated cables. f) Isolation between Input, Output and controller Indication Fail safe mode 1.5 KV with opto couplers.
g) h)
Individual signal status of each Input / Output, power supply status. On power supply failure / both PLCs failure / communication failure etc. the output shall be automatically switched over to fail safe mode. In CPU, memory should exist where the sequence was aborted. Further, in case of such failures, operating drives / equipment shall be tripped or kept running as per a pre-determined programmable requirement finalised during detail engineering. Individual fuses with blown fuse indicator for each output. Individual fuses for each input/ group of inputs, keeping in view of system availability. Output modules shall be rated to switch on/off coupling relays of 2.5 VA at 24V DC and solenoid valves at 110 V AC. Coupling relays are provided in HT/LT Switchgears and in local panels. Hundred percent redundant Communication links through fiber optic cables routed in separate GI conduits Type and number of printers shall be as shown in the tender drawing PLC Configuration. Color laser printer shall be suitable for A4 size
Sub-Section - IIIB-11 PLC CONTROL PANELS Page 6 of 11
i)
Fusing philosophy
j)
Switching capacity
k)
HMI /CPU and Input output communication links Printer
l)
CLAUSE NO.
TECHNICAL REQUIREMENTS paper, 4 pages per minite, 600 dpi (black) and heavy duty(>_ 30000 pages per month) Dot matrix printer shall be Line impact type suitable for 132 column continuous fan fold type paper, 1000 LPM and heavy duty (>_ 50000 pages per month)
m)
Power supply
i)
Two(2) nos 415V AC feeders shall be provided for each control panel / desk and remotely located I/O panels. Power supply to PCs, printers, OWS, LVS, control desk and CCTV system shall be fed through 2x100% UPS with battery back-up rated for 30 minutes at full load. Main and standby OPS shall have separate battery back ups.The UPS shall be smart type line interactive complete with software & hardware for remote management along with features of surge suppression & AVR facility. The UPS and batteries shall be rated for 20% spare capacity. All separate UPS systems as indicated shall be provided in each OWS system. The batteries for 24V DC system and for UPS shall be sealed maintenance free NI-CD type. For PLC (processor and I/O) panels, the power supply shall be 24V DC. Necessary redundant transformers and redundant 24V chargers with redundant battery back-up rated for 30 minutes shall be provided for each separately mounted I/O racks/PLC panels. Power supply modules shall be of ample capacity with 20% spare capacity for future use. All voltage supplies shall be monitored. Manual command shall prevail over auto command. Protection command shall have priority over all other commands. Hundred percent redundant. Necessary interface hardware and software for dual fiber optic connectivity and interconnection with CHP PLC for two way transfer of signals shall also be provided for integration with Employers PLC through OPC compliant Ethernet link following TCP/IP standards. To be synchronised with other PLC systems of Employer. No disturbance due to change of date/year.
ii)
iii) iv) v)
n)
Command hierarchy Databus
o)
p)
Time Synchronisation system. Date
q)
Page 7 of 11
CLAUSE NO.
TECHNICAL REQUIREMENTS Insensitivity r) s) t) System reaction time Display response Communication speed at I/O level Feedback/field interrogation Less than 100 msec. from input signal to output signal including logic processing. Max 1 sec for control related displays. 2 to 3 sec for other displays. Min. 5 MBPS
u)
By 24V DC. Status feedback from MCC/field shall be in the form of one changeover contact. Discrepancy shall be alarmed. All analog signals shall be routed through analog cards. Flow chart/Block logic ladder diagram. Tag based addressing format shall be used for programming in the controller. The same shall be submitted for Employer's review before programming of the system. 168 hours latest data on hard disc. Data to be stored:
v)
Programming format
w)
Long time storage & retrieval i) ii) iii) iv) v) vi) Software
Alarm list. Five analog points at scan rate. Fifteen analog points at one secs rate. Balance analog points at 5 minutes rate. Binary points on status change. Log reports. All application software with locks and passwords for PLC functioning like input/output scanning, acquisitions, condition processing, control and communication, operator interface of monitors, display trends, curves, bar charts, historical storage/ retrieval and alarm functions. Complete set of documents for modifications / editing / additions/ deletions of features in software. Comprehensive list of all application/system software. Industrial grade furniture shall be provided along with control desk/OWS/printer. The contractor shall provide software license for all software being used in PLC based control system including HMI. The software licenses shall be
x)
y) z)
Accessories Software license
Page 8 of 11
CLAUSE NO.
TECHNICAL REQUIREMENTS provided for the project and shall not be hardware/machine specific. All licenses shall be valid for the continuous service life of the plant. Software upgrades As a customer support the contractor shall periodically inform the designated officer of the employer about the software upgrades / new releases that would be taking place after the system is commissioned so that if required, same can be procured and implemented at site.
8.02.00
Annunciation System i) ii) a) b) c) d) iii) Facia Operation On occurrence of trouble Acknowledge button pressed Reset button pressed Test button pressed Monitoring Translucent engraving. Through PLC. Audible horn and flashing of facia lamp. Audible horn and flashing of facia lamp shall stop. Facia lamp will become steady. If fault is removed then facia lamp will go off. All lamps will glow. Power supply monitored. to annunciator shall be glass/plastic window with
9.00.00
DESK/PANEL CONSTRUCTION a) Type Fabricated from cold rolled sheet steel Frame thickness 2.0 mm
Enclosure thickness 1.6 mm Gland plate thickness 3.0 mm b) c) d) Switches Fuses AC22 category HRC cartridge with visual operation indicator.
Name Plates & Each panel shall be identified by a name plate. Labels Panel internal equipment shall be identified by paint marking. Nameplates shall be non rusting metal or 3-ply lamicoid, with engraved lettering and shall be subjected to Employers approval.
CLAUSE NO.
TECHNICAL REQUIREMENTS e) f) g) h) i) j) k) Grounding Space heater Terminal block Type Spare terminals Wiring Panel Lighting 25 x 3 mm copper ground bus to be provided for each panel 240V AC, single phase, thermostatically controlled space heaters to be provided. 650V grade. clip-on type. Elmex - CATD type for CTs. Elmex - CSLT for other application. 20 percent. 650V grade. PVC insulated stranded copper wire. Each free standing panel shall be provided with a door switch operated fluorescent lamp and a 240V AC plug point. Treatment as per IS:6005. Two coats of lead oxide primer followed by powder painting with final paint shade of RAL 9002. The paint shade of the side end covers shall be RAL 5012. For panels located in i) Air conditioned areas ii) Other areas iii)In dusty areas like Conveyor galleries, Transfer points, Bunker area etc. : IP-32 : IP-52 : IP-65
l)
Painting
m)
Degree of enclosure protection
10.00.00
TYPE TESTS (a.) All equipments to be supplied shall be of type tested design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract, at no additional
(a.)
CLAUSE NO.
TECHNICAL REQUIREMENTS cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. (a.) All acceptance and routine tests as specified below and in relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects if NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No Design Change. Minor changes if any shall be highlighted on the endorsement sheet
(d.)
10.02.00 10.02.01
Programmable logic controller Following test reports shall be submitted for the equipment: a). b). c). d). e). f). Dry heat withstand test Variation of temperature immunity test Variation immunity test Temperature cycle test Noise immunity test Dielectric test.
10.02.02
Following tests shall be conducted under this contract as routine tests: a). b). c). d). e). Tests on internal and external wiring. Incoming power supply voltage and frequency variation test. Test for verification of functional characteristics of I/Os. Task transition test (for each task, the contractor will list out the user accessible conditions which shall be used in the simulation of the task). Functional testing of software and hardware in accordance with the approved block logic diagram with simulation of the system with switches, relays and solenoid valves etc. or equivalent loads.
Page 11 of 11
CLAUSE NO.
BATTERY 1.00.00 BATTERY RATINGS As per system requirement. PART-A: NICKEL-CADMIUM BATTERY 2.00.00 2.01.00 CODES AND STANDARDS All standards, specifications and codes of practice referred to herein, shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, Standards etc.) referred to herein, the former shall prevail. All works shall be carried out as per the following standards and codes: IS : 10918 IS : 1069 Specification for vented type Nickel Cadmium Batteries. Quality tolerances for water for storage batteries Indian electricity rules Indian Electricity Acts. 2.02.00 Equipment complying with other internationally accepted standards such as IEC., BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards along with copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. GENERAL TECHNICAL REQUIREMENT Equipments (a.) DC Batteries shall be stationary Nickel Cadmium Pocket plate type conforming to IS:10918. For the purpose of design an ambient temperature of 50 degree centigrade and relative humidity of 85% shall be considered. DC batteries shall be suitable for standby duty. The batteries shall normally be permanently connected to the load in parallel with a charger and shall supply the load during emergency conditions when AC supplies are lost. Batteries shall be suitable for a long life under continuous float operations and occasional discharges. The batteries shall be boost charged at about 1.54 to 1.7 volts per cell maximum and float charged at about 1.42 V/cell. The number of cells for the 110 Volts shall be 84.
3.00.00 3.01.00
(b.)
(c.)
SUB-SECTION-IIIB-12 BATTERY
PAGE 1 OF 9
CLAUSE NO.
(d.)
Batteries should be suitable for continuous operation for the maximum ambient temperature as defined in technical parameters.
3.02.00 3.02.01
Construction Features Containers Containers shall be made of polypropylene plastic material. Containers shall be robust, heat resistance, leak proof, non absorbent, alkali resistant, non-bulging type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines shall be marked on container in case of translucent containers.
3.02.02
Vent Plugs Vent plugs shall be provided in each cells. They shall be anti splash type, having more than one exit hole shall allow the gases to escape freely but shall prevent alkali from coming out. The design shall be such that the water loss due to evaporation is kept to minimum. In addition the ventilator shall be easily removed for topping up the cells and of such dimensions that the syringe type hydrometer can be inserted into the vent to take electrolyte samples.
3.02.03
Plates The plates shall be designed for maximum durability during all service conditions including high rate of discharge and rapid fluctuations of load. The construction of plates shall conform to latest revisions of IS:10918. The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. Separators should be suitable for continuous immersion in the electrolyte without distortion. The positive and negative terminal posts shall be clearly marked.
3.02.04
Sediment Space Sufficient sediment space shall be provided so that cells will not have to be cleaned during normal life and prevent shorts within the cells.
3.02.05
Cell Insulator Each cell shall be separately supported on PVC/porcelain/hard rubber insulators fixed on to the racks with adequate clearance between adjacent cells. Minimum distance between the adjacent cells shall be more than the budge allowed for two cells in accordance with IS: 1146.
PAGE 2 OF 9
CLAUSE NO.
3.02.06
Electrolyte The electrolyte shall be prepared from battery grade potassium hydroxide conforming to BS: 1069. The cells can be shipped either in charged condition or in dry condition Necessary electrolyte for make-up shall be supplied separately.
3.02.07
Connectors and Fasteners Nickel coated copper connectors shall be used for connecting up adjacent cells and rows. Bolts, nuts and washers shall be effectively Nickel coated to prevent corrosion. The thickness of Nickel coating of connectors should be not less than 0.02 mm. All the terminals and cells inter-connectors shall be fully insulated or have insulation shrouds. End take off connections from positive and negative poles of batteries shall be made by single core cables having stranded aluminium conductors and XLPE insulation. Necessary supports and lugs for termination of these cables on batteries shall also be supplied by the contractor. All connectors and lugs shall be capable of continuously carrying the 30 minutes discharge current of the respective batteries and through fault short circuit current which the battery can produce and withstand for the period declared. Contractor shall furnish necessary sizing calculations to prove compliance to the same. Suitable number of Inter-rack connectors shall be supplied by the Bidder to suit the battery room layout during detailed engineering.
3.02.08
Battery racks Mild steel racks for all the batteries shall be provided. They shall be free standing type mounted on procelain/hard rubber/PVC pads insulators. Batteries shall preferably be located in the single tier arrangement. However, batteries having a complete cell weight of lower than 50 Kg could be located in the double tier arrangement. The batteries racks and supports for cable termination shall be coated with three (3) coats of anti-alkali paint of approved shade. Name plates, resistant to alkali, for each cell shall be attached on to the necessary racks. The bottom tier of the stand shall not be less than 150 mm above the floor. Wherever racks are transported in dismantled conditions, match markings shall be provided to facilitate easy assembly.
3.02.09
Manufacturers Identification System The following information shall be indelibly marked on outside of each cell. (a.) (b.) (c.) Manufacturers name and trade marks Country and year of manufacture. Manufacturer type designation.
PAGE 3 OF 9
CLAUSE NO.
(d.) (e.) 4.00.00
AH capacity at 5 hour discharge rate. Serial number
THE FOLLOWING INFORMATION SHALL BE GIVEN ON THE INSTRUCTION CARDS SUPPLIED WITH THE BATTERY: (a.) (b.) (c.) (d.) Manufacturer's instructions for filling and initial charging of the battery together with starting and finishing charging rate. Maintenance instructions. Designation of cell in accordance with IS:10918. Storing conditions of electrolyte.
5.00.00 5.01.00
TESTS GENERAL (a.) All equipment to be supplied shall be of type test design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as per latest IS-1146 (for all applicable tests for containers) / IS-10918 (for Ni-Cd Batteries) and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. The complete type tests shall be for any rating of battery in a particular group, based on plate dimensions. However if the contractor is not able to submit reports of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract at no additional cost to the owner either at third party lab or in presence of client/owners representative and submit the reports for approval. All acceptance and routine tests shall be as per Quality assurance and Inspection table of batteries. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No design Change. Minor changes if any shall be highlighted on the endorsement sheet.
(b.)
(c.) (d.)
5.02.00
Commissioning checks. All tests as listed below shall be carried out on sample cell selected at random by the employer at site after completion of installation.
PAGE 4 OF 9
CLAUSE NO.
(a.) (b.) (c.) (d.) (e.) (f.) (g.) (h.)
Physical Examination Dimensions, Mass & layout MARKING Polarity and absence of short circuit. Air pressure test Ampere - hour capacity Retention of charge Insulation resistance
The Contractor shall arrange for all necessary equipment, including the variable resistor, tools, tackles and instruments. PART-B: 6.00.00 6.01.00 LEAD ACID PLANTE BATTERY
CODES & STANDARDS All standards, specification and codes of practice, referred to herein, shall be the latest edition including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS Codes Standards etc.) referred to herein, the former shall prevail. All works shall be carried out as per the following standards and codes : IS : 266 IS : 1069 IS : 1146 Specification for sulphuric acid Specification for water for storage batteries Specification for rubber & plastic containers for lead acid storage batteries. Specification for stationary cells and batteries, lead acid type (with plant positive plates). Specification for sealing compound for lead acid batteries. General requirements and methods of tests for lead acid storage batteries. Specification for synthetic separators for lead acid batteries.
IS : 1652
IS : 3116 IS : 8320
IS : 6071
PAGE 5 OF 9
CLAUSE NO.
Indian Electricity Rules Indian Electricity Acts 6.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. GENERAL TECHNICAL REQUIREMENTS Equipments DC Batteries shall be stationary lead acid Plante positive plate type conforming to IS:1652. For the purpose of design an ambient temperature of 50 degree centigrate and relative humidity of 85% shall be considered. DC Batteries shall be suitable for standby duty. The Batteries shall normally be permanently connected to the load in parallel with a charger and shall supply the load during emergency conditions when AC supplies are lost. Batteries shall be suitable for a long life under continuous float operations and occasional discharges. The batteries shall be boost charged at about 2.7 volts per cell maximum and float charged at about 2.25 V/cell: The number of cells for the110 Volts shall be 53. Batteries should be suitable for continuous operation for the maximum ambient temperature as defined in technical parameters. 7.02.00 7.02.01 Construction Features Containers Containers shall be made of transparent glass, hard rubber, suitable robust, heat resistance, leak proof, non absorbent, acid resistant, non-bulging type and free from flaws, such as wrinkles, cracks, blisters, pin holes etc. Electrolyte level lines shall be marked on container in case of transparent containers. Float type level indicator shall be provided in case of opaque containers. The stem portion of the float should be long enough to prevent falling of the float inside the container even if there is no electrolyte in the container. The marking for the electrolyte level should be for the upper and lower limits. The material of level indicator shall be acid proof and oxidation proof. Container shall be closed/sealed lid type. Lid and sealing compound shall be non-cracking type. The container made of hard rubber and plastics shall be type tested as per IS : 1146. All type tests shall be carried out for sealing compound as per IS:3116.
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-12 BATTERY PAGE 6 OF 9
7.00.00 7.01.00
CLAUSE NO.
The pole sealing arrangement should be such that no acid particle gets entrapped due to acid creep as a result of capillary action and it should be possible to remove and refix the sealing to carry out the maintenance. 7.02.02 Vent Plugs Vent plugs shall be provided in each cell. They shall be antisplash type, having more than one exit hole shall allow the gases to escape freely but shall prevent acid from coming out. The design shall be such that the water loss due to evaporation is kept to minimum. In addition the ventilator shall be easily removed for topping up the cells and of such dimensions that the syringe type hydrometer can be inserted into the vent to take electrolyte sample. 7.02.03 Plates The plates shall be designed for maximum durability during all service conditions including high rate of discharge and rapid fluctuations of load. The construction of plates shall conform to latest revisions of IS: 1652 as applicable. The separators shall maintain the electrical insulation between the plates and shall allow the electrolyte to flow freely. Separators should be suitable for continuous immersion in the electrolyte without distortion. The positive and negative post shall be clearly marked. 7.02.04 Sediment Space Sufficient sediment space shall be provided so that cells will not have to be cleaned during normal life and prevent shorts within the cells. 7.02.05 Cell Insulator Each cell shall be separately supported on PVC/porcelain/hard rubber insulators fixed on the racks with adequate clearance between adjacent cells. Minimum distance between adjacent cells shall be more than the buldge allowed for two cells in accordance with IS: 1146. 7.02.06 Electrolyte The electrolyte shall be prepared from battery grade sulphuric acid conforming to IS:266 and distilled water conforming to IS:1069. The cells shall be shipped dry uncharged. The electrolyte shall be supplied separately. 7.02.07 Connectors and Fasteners Lead or Lead coated copper connectors shall be used for connecting up adjacent cells and rows. Bolts, nuts and washers shall be effectively lead coated to prevent corrosion. The thickness of lead-coating of connectors should not be less than 0.025 mm. The lead coating thickness shall be measured in accordance with APPENDIX F of IS: 6848 (latest edition). All the terminals and cells interconnectors shall be fully insulated or have insulation shrouds. End take off connections from positive and negative poles of batteries shall be made by single
PAGE 7 OF 9
CLAUSE NO.
core cables having stranded aluminium conductors and XLPE insulation. Necessary supports and lugs for termination of these cables on batteries shall also be supplied by the contractor. All connectors and lugs shall be capable of continuously carrying the 30 minutes discharge current of the respective Batteries and through fault short circuit current which the battery can produce and withstand for the period declared. Contractor shall furnish necessary sizing calculations to prove compliance to the same. 7.02.08 Battery racks Wooden racks for all the batteries shall be provided. These racks shall be made of good quality first class seasoned teak wood in line with CPWD specification. They shall be free standing type mounted on porcelain/hard rubber/PVC pads insulators. Batteries shall preferably be located in the single tier arrangement. However, batteries having a complete cell weight of lower than 50 Kg could be located in the double tier arrangement. The batteries rack and wooden support for cable termination shall be coated with three (3) coats of anti-acid paint of approved shade. Numbering tags, resistant to acid, for each cell shall be attached on to the necessary racks. The bottom tier of the stand shall not be less than 150 mm above the floor. Wherever racks are transported in dismantled condition, suitable match markings shall be provided to facilitate easy assembly. 7.02.09 Manufacturers Identification Systems The following information shall be indelibly marked on outside of each cell. (a.) (b.) (c.) (d.) (e.) 8.00.00 8.01.00 TESTS GENERAL (a) All equipment to be supplied shall be of type test design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as per latest IS-1146 (for rubber & plastic containers for Lead acid storage batteries) and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have Manufacturer's name and trade marks Country and year of manufacture. Manufacturer type designation. AH capacity at 10 hour discharge rate. Serial number
PAGE 8 OF 9
CLAUSE NO.
been witnessed by a client. The complete type tests shall be for any rating of battery in a particular group, based on plate dimensions. (b) However if the contractor is not able to submit reports of the type test(s) conducted within last ten years from the date of bid opening, or in case the type test report(s) are not found to be meeting the specification requirements, the contractor shall conduct all such tests under this contract at no additional cost to the owner either at third party lab or in presence of client/owners representative and submit the reports for approval. (c) All acceptance and routine tests shall be as per Quality assurance and Inspection table of batteries. (d) The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No design Change. Minor changes if any shall be highlighted on the endorsement sheet. 8.02.00 Commissioning checks All tests as listed below shall be carried out on sample cell selected at random by the employer at site after completion of installation. 1) 2) 3) Verification of markings. Verification of dimensions. Test for capacities for 10 hrs discharge rate alongwith the test for voltage during discharge.
The Contractor shall arrange for all necessary equipment, including the variable resistor, tools, tackles and instruments. If a battery fails to meet the guaranteed requirements the Employer shall have the option of asking the Contractor to replace the same.
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CLAUSE NO.
TECHNICAL REQUIREMENTS BATTERY CHARGER
1.00.00 1.01.00
CODES AND STANDARDS All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions as on date of opening of bid. In case of conflict between this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall be carried out as per the following standards and codes. ANSI-C 37.90a IS:5 IS : 694 IS : 1248 Guide for surge withstand capability tests
Colours for ready mix paints. PVC Insulated Cable for working voltages upto and including 1100 V. Specification for Direct measuring instruments. acting indicating analogue electrical
IS:13947 Part-1 IS : 13947 IS : 3231 IS : 3842 IS : 3895 IS : 4540 IS:6005 IS:6619 IS:6875
Degree of protection provided by enclosures for low voltage switch gear and control gear. Specification for low voltage switch gear and control gear Electrical relays for power system protection. Application guide for Electrical relays for AC System Mono-crystalline semi-conductor Rectifier Cells and Stacks Mono crystalline semi-conductor Rectifier assemblies and equipment. Code of practice for phosphating of Iron and Steel. Safety Code for Semi-conductor Rectifier Equipment. Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages upto 1000 V AC or 1200 V DC. Basic environmental testing procedures for electronic and electrical items. Low voltage fuses for voltages not exceeding 1000 V AC or 1500 V DC. Performance requirements for electrical Alarm Annunciation System Indian Electricity Rules
IS : 9000
IS:13703
EEUA-45D
SUB-SECTION-IIIB-13 BATTERY CHARGER
PAGE 1 OF 11
CLAUSE NO.
Indian Electricity Act. 1.02.00 Equipment complying with other internationally accepted standards such as IEC, BS, VDE. etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in English of the latest revision of the standards alongwith copies of all official amendments and revisions in force as on date of opening of bid and shall clearly bring out the salient features for comparison. EQUIPMENT DESCRIPTION PART-I (a.) BATTERY CHARGER FOR LEAD ACID PLANTE TYPE BATTERY
2.00.00 2.01.00
The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Trickle mode i.e. Trickle charging the associated DC lead-acid Batteries while supplying the D.C. loads. The Batteries shall be Trickle charged at 2.25 Volts per cell. All chargers shall also be capable of Boost charging the associated D.C. Battery at 2.0 to 2.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, at an ambient air temperature of 50C. Battery Chargers shall have a selector switch for selecting the battery charging mode i.e. whether Trickle or Boost charging. All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature which may arise during changeover from Auto to Manual mode or vice-versa under normal operating condition. Soft start feature shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall neither damage the Charger nor shall it cause blowing of any of the changer fuses. The Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage shall build up automatically when working in automatic mode. When on automatic control mode during Trickle charging, the Charger output voltage shall remain within +/-1% of the set value for AC input voltage variation of +/-10%, frequency variation of +3/-5%, a combined voltage and frequency (absolute sum) variation of 10% and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire Trickle charging output range
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-13 BATTERY CHARGER PAGE 2 OF 11
(b.) (c.)
(d.)
(e.)
CLAUSE NO.
TECHNICAL REQUIREMENTS specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Trickle charging mode. (f.) During Boost charging, the Battery Chargers shall operate on constant current mode (When automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. The charger output voltage shall automatically go on rising, when it is operating on boost mode, as the battery charges up. For limiting the output voltage of the charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage anywhere in the output range specified for boost charging mode. All voltage and current setting potentiometers shall be vernier type. Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits as mentioned elsewhere, shall be less than fifteen seconds. Momentary output voltage of the Charger, without the Battery connected shall be within 94% to 106% of the voltage setting during sudden load Change from 100% to 20% of full load or vice-versa. Output voltage shall return to, and remain, within the limits specified as mentioned elsewhere in less than 2 seconds after the above mentioned change. The Charger manufacturer may offer an arrangement in which the voltage setting device for Trickle charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the trickle charging mode is also used as Boost charging current setting device. Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 1% irrespective of the DC load, even when they are not connected to a battery. The DC System shall be ungrounded and float with respect to the ground potential when healthy. An earth fault relay shall be provided by the Employer in the DC distribution board for remote annunciation. BATTERY CHARGER FOR NICKEL-CADMIUM TYPE BATTERY
(g.)
(h.)
(i.)
(j.)
(k.)
2.02.00
PART-II (a.)
The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall be capable of continuous operation at the respective rated load in Trickle mode i.e. Trickle charging the associated DC Nickel-Cadmium Batteries while supplying the D.C. loads. The Batteries shall be Trickle charged at 1.4 to 1.42 Volts per cell. All chargers shall be capable of Boost charging the associated D.C. Battery at 1.53 to 1.7 Volts per cell at the desired rate. The Chargers shall be designed to operate, as mentioned above, at an ambient air temperature of 50C.
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CLAUSE NO.
TECHNICAL REQUIREMENTS (b.) (c.) Battery Chargers shall have a selector switch for selecting the battery charging mode i.e. whether Trickle or Boost charging. All Battery Chargers shall be provided with facility for both automatic and manual control of output voltage and current. A selector switch shall be provided for selecting the mode of output voltage/current control, whether automatic or manual. Means shall be provided to avoid current/voltage surges of harmful magnitude/nature which may arise during changeover from Auto to Manual mode or vice-versa under normal operating condition. Soft start features shall be provided to build up the voltage to the set value slowly within fifteen seconds. The chargers shall have load limiters which shall cause, when the voltage control is in automatic mode, a gradual lowering of the output voltage when the DC load current exceeds the load limiter setting of the Charger. The load limiter characteristic shall be such that any sustained overload or short circuit in DC system shall not damage the Charger, nor shall it cause blowing of any of the charger fuses. The Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage shall build up automatically when working in automatic mode. When on automatic control mode during Trickle charging, the Charger output voltage shall remain within +/-1% of the set value for AC input voltage variation of +/-10%, frequency variation of +3 to -5%, a combined voltage and frequency (absolute sum) variation of 10% and a continuous DC load variation from zero to full load. Uniform and stepless adjustments of voltage setting (in both manual and automatic modes) shall be provided on the front of the Charger panel covering the entire Trickle charging output range specified. Stepless adjustment of the load limiter setting shall also be possible from 80% to 100% of the rated output current for Trickle charging mode. During Boost charging, the Battery Chargers shall operate on constant current mode (When automatic regulator is in service). It shall be possible to adjust the Boost charging current continuously over a range of 50 to 100% of the rated output current for Boost charging mode. The charger output voltage shall automatically go on rising, when it is operating on boost mode, as the battery charges up. For limiting the output voltage of the charger, a potentiometer shall be provided on the front of the panel, whereby it shall be possible to set the upper limit of this voltage anywhere in the output range specified for boost charging mode. All voltage and current setting potentiometers shall be vernier type. Energising the Charger with fully charged battery connected plus 10% load shall not result in output voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits as mentioned elsewhere shall be less than fifteen seconds. Momentary output voltage of the Charger, without the Battery connected shall be within 94% to 106% of the voltage setting during sudden load Change from 100% to 20% of full load or vice-versa. Output voltage shall return to,
(d.)
(e.)
(f.)
(g.)
(h.)
PAGE 4 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS and remain, within the limits specified as mentioned elsewhere in less than 2 seconds after the above mentioned change. (i.) The Charger manufacturer may offer an arrangement in which the voltage setting device for Trickle charging mode is also used as output voltage limit setting device for Boost charging mode, and the load limiter of the trickle charging mode is also used as Boost charging current setting device. Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the output voltage to 1% irrespective of the DC load, even when they are not connected to a battery. The DC System shall be ungrounded and float with respect to the ground potential when healthy. An earth fault relay shall be provided by the Employer in the DC distribution board for remote annunciation.
(j.)
(k.)
2.03.00
Printed Circuits Boards (PCB) PCB shall be made of glass epoxy of 1.6 mm thick, fire resistant, bonded with 99.8% pure copper foil, free of wrinkles, blisters, scratches and pinholes. The contact surface of the edge connectors of the PCBs shall be plated with hard gold to a minimum thickness of 5 microns. Component identification shall be printed on PCB by silk screen method. All PCBs shall be tropicalised and masked.
2.04.00
CONTACTORS All Battery Chargers shall have an AC contactor on the input side. It shall be of air break type and suitable for continuous duty. The operating coil shall be rated for 415 Volts AC.
2.05.00
Thermal Overload Relay A thermal overload relay incorporating a distinct single phasing protection (using differential movement of bimetal strips) shall also be provided for the AC input. The relay shall trip the above contactor.
2.06.00
Rectifier-Transformers and Chokes The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating of the rectifier-transformers and chokes shall correspond to the rating of the associated rectifier assembly. The rectifier-transformers and chokes shall have class-B insulation with temperature rise limited to class-A insulation value.
2.07.00
Rectifier Assembly The rectifier assembly shall be full wave bridge type and designed to meet the duty as required by the respective Charger. The rectifier cells shall be provided with their own heat dissipation arrangement with natural air cooling. The rectifier shall utilise diodes/thyristors and heat sinks rated to carry 200% of the load current continuously and the temperature of the heat sink shall not be permitted to exceed 85C absolute duly considering the maximum charger panel inside temperature. The Contractor shall submit calculations to show what maximum junction temperature will be and
PAGE 5 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS what the heat sink temperature will be when operating at 200% and 100% load current continuously duly considering the maximum surrounding air temperature for these devices inside the charger panel assuming air ambient temperature of 50C outside the panel. Necessary surge protection devices and rectifier type fast acting fuses shall be provided in each arm of the rectifier connections.
2.08.00
DIGITAL INDICATING INSTRUMENTS Digital indicating instruments with built in communication port for remote data transfer shall be provided for all chargers. The instruments shall indicate DC current, DC voltage & AC voltage and instrument shall be 96 x 96 sqmm, with display accuracy 0.5%, 4 digit 7 segment LED/LCD display and RS 485 serial Bus port.
2.09.00
AIR BREAK SWITCHES All Chargers shall have AC input and DC output switches of air break, single throw, load break and fault make type. The contacts of the switches shall open and close with a snap action. Switches shall be rated for 120% of the maximum continuous load. ON & OFF position of the switch shall be clearly indicated.
2.10.00
CONTROL AND SELECTOR SWITCHES Control and selector switches shall be of rotory stayput type with escutcheon plates showing the functions and positions. The switches shall be of sturdy construction and suitable for mounting on panel front. Switches with shrouding of live parts and sealing of contacts against dust ingress shall be preferred. The contact ratings shall be atleast the following : (a.) (b.) (c.) Make and carry continuously 10 Amps. Breaking current at 220 V DC 0.5 Amp. (inductive) Breaking current at 240 V AC 5 Amp. At 0.3 p.f.
2.11.00
FUSES Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse carriers which are mounted on fuse bases. Wherever it is not possible to mount fuses on fuse carriers, fuses shall be directly mounted on plug in type bases. In such cases one insulated fuse pulling handle shall be supplied for each charger. Kick-off fuses (trip fuses) with alarm contacts shall be provided for all D.C. fuses.
2.12.00
Indicating Lamps Three (3) indicating lamps shall be provided to indicate A.C. supply availability. The indicating lamp shall be of panel mounting, filament type low wattage or LEDs and capable of clear status indication under the normal room illumination. The lamps shall be provided with series resistors (non-hygroscopic) preferably built in the lamp assembly and replaceable from front. The lamp covers shall be preferably screwed type, unbreakable and moulded from heat resistant material.
PAGE 6 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS Blocking Diode Blocking diode shall be provided in the output circuit of each Charger to prevent current flow from the D.C. Battery into the Charger.
2.13.00
2.14.00
Annunciation System Visual indications through indicating lamps/LEDs or annunciation facia as per EEUA-45D shall be provided in all Chargers for the following: (a.) (b.) (c.) (d.) (e.) (f.) (g.) A.C. supply failure Rectifier fuse failure Surge circuit fuse failure Filter fuse failure Load limiter operated Charger trip Battery on Boost
Potential free NO contacts of all above conditions shall be provided for following remote alarms in the Employers Unit Control Board: (h.) (i.) 2.15.00 Battery on Boost Charger trouble (this being a group alarm initiated by any of the faults other than Battery on Boost)
Name Plates and Marking The name plates shall be made of non-rusting metal/3 ply Lamicoid and shall have black back-ground with white engraved letters and secured by screws. These shall be provided near top edge on the front as well as on rear side of Charger. Name plates with full and clear inscriptions shall also be provided on and inside the panels for identification of the various equipments.
3.00.00 3.01.00
CONSTRUCTION The Chargers shall be indoor, floor mounted, self supporting sheet metal enclosed cubicle type. The Contractor shall supply all necessary base frames, anchor bolts and hardware. The Charger shall be fabricated using cold rolled sheet steel shall not less than 1.6 mm and shall have folded type of construction. The panel frame shall be fabricated using cold rolled sheet steel of thickness not less than 2.0 mm. Removable undrilled gland plates of at least 3.0 mm sheet steel and lugs for all cables shall be supplied by the Contractor. The lugs for cables shall be made of electrolytic copper with tin coat. Cable sizes shall be advised to the Contractor at a later date for provision of suitable lugs and gland plates. The Charger shall be tropicalised and vermin proof. Ventilation louvers shall be backed with fine brass wire
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-13 BATTERY CHARGER PAGE 7 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS mesh. All doors and covers shall be fitted with synthetic rubber gaskets. The Chargers shall have hinged double leaf doors provided on front and/or backside for adequate access to the Charger internals. All the Charger cubicle doors shall be properly earthed. The degree of protection of Charger enclosure shall be atleast IP42.
3.02.00
All indicating instruments, control & selector switches and indicating lamps shall be mounted on the front side of the Charger. Design of panels shall be based on the following dimensions. 1) 2) Overall height Maximum 2350 mm Maximum 1800 mm Minimum 350 mm
Operating handles (highest and lowest positions reached by operators hands), protective mechanical indicators Doors and panel handles and locks -
3) 3.03.00
Maximum 1800 mm Minimum 300 mm
Electronic equipments shall be of modular design consisting of plug in modules in standard 19 inches metallic racks with metallic card guides. The cards should be provided with proper handles. Card to card wiring should be preferably through a mother board. Unplanned jumpering and track modifications are not permitted. Mechanical interlocks to prevent wrong insertion of cards should be provided. Each card shall have its junction and test points identified. Maintenance aids such as extension printed wiring boards and jumper leads shall be provided. The layout of Charger components shall be such that their heat losses do not give rise to excessive temperature within the Charger panel surface. Location of the electronic modules will be such that temperature rise of the location, in no case, will exceed 10C over ambient air temperature outside the Charger. Each Charger panel shall be provided with an illuminating lamp and one 5 Amp. Socket. Switches and fuses shall be provided separately for each of the above. Locking facilities shall be provided as following: (a.) For locking Trickle/Boost selector switch in the trickle position only. This would be used for having key mechanical interlock between Trickle/Boost selector switch and isolator in D.C. distribution board which is being procured separately by the employer. The Charger enclosure door locking requirements shall be met by the application of padlocks. Padlocking arrangement shall allow ready insertion of the padlock shackle but shall not permit excessive movement of the locked parts with the padlock in position.
3.04.00
3.05.00 3.06.00
(b.)
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CLAUSE NO.
TECHNICAL REQUIREMENTS Wiring Each Charger shall be furnished completely wired upto power cable lugs and terminal blocks ready for external connection. The power wiring shall be carried out with 1.1 KV grade PVC insulated cables conforming to IS:1554 (Part-I). The control wiring shall be of 1.1KV grade PVC insulated stranded copper conductors of 2.5 sq.mm. conforming to IS:694. Control wiring terminating at electronic cards shall not be less than 1.0 sq. mm. Control terminal shall be suitable for connecting two wires with 2.5 sq.mm. stranded copper conductors. All terminals shall be numbered for ease of connections and identification. At least 20% spare terminals shall be provided for circuits. Power and control wiring within panels shall be kept separate. Any terminal or metal work which remains alive at greater than 415 V, when panel door is opened, shall be fully protected by shrouding. An air clearance of at least ten (10) mm shall be maintained throughout all circuits, except low voltage electronic circuits, right upto the terminal lugs. Whenever this clearance is not available, the live parts should be insulated or shrouded. PAINTING Treatment as per IS:6005. Two coats of lead oxide primer followed by powder painting with final shade of RAL9002 for complete panel except end covers & RAL 5012 for end covers.
3.07.00 3.07.01
3.07.02
3.07.03
3.08.00
4.00.00 4.01.00
TESTS GENERAL 1. All equipment to be supplied shall be of type test design. During detailed engineering, the contractor shall submit for Owners approval the reports of all the type tests as listed in this specification and carried out within last ten years from the date of bid opening. These reports should be for the tests conducted on the equipment similar to those proposed to be supplied under this contract and the test(s) should have been either conducted at an independent laboratory or should have been witnessed by a client. a) b) c) d) e) f) Complete physical examination Temperature rise test at full load. Temperature rise test of rectifier assembly at 200% of full load. Insulation resistance test. High voltage (power frequency) test on power and control circuits except low voltage electronic circuits. Ripple content test at i) ii) No load Half load
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CLAUSE NO.
TECHNICAL REQUIREMENTS iii) Full load Automatic voltage regulator operation test at specified A.C. supply variations at i) ii) No load Half load
g)
h) i) j)
iii) Full load Load limiter operation test Efficiency and power factor measurement. Input and output surge withstand capability test. Surge Voltage as per ANSI-C37.90a shall be applied for period not less than 2 sec. At the following points of the Charger operating at 50 deg. C at full load : i) ii) iii) iv) Across each A.C. input phase Across AC input line to ground. Across D.C. output terminals. Across each D.C. output terminal to ground
The Charger shall not exhibit any component damage and there shall be no change in performance as per (g) and (h). k) Environmental Tests Steady state performance tests (g) and (h))shall be carried out before and after each of the following tests. i) Soak Test The electronic modules shall be subjected to continuous operation for a minimum period of 72 hours. During last 48 hours, the ambient temperature shall be maintained at 50 deg. C. The 48 hour test period shall be divided into four equal 12 hour segments. The input voltage during each 12 hours shall be nominal voltage for 11 hours followed by 110% of nominal voltage for 30 minutes, followed by 90% of nominal voltage for 30 minutes. ii) 2. Degree of protection test.
However if the Contractor is not able to submit report of the type test(s) conducted within last ten years from the date of bid opening, or in case the
PAGE 10 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS type test report(s) are not found to be meeting the specification requirements, the Contractor shall conduct all such tests under this contract at no additional cost to the Owner either at third party lab or in presence of client/owners representative and submit the reports for approval. 3. All routine tests as per QA table and relevant standards shall be carried out. Charges for these shall be deemed to be included in the equipment price. The type test reports once approved for any projects shall be treated as reference. For subsequent projects of NTPC, an endorsement sheet will be furnished by the manufacturer confirming similarity and No design Change. Minor changes if any shall be highlighted on the endorsement sheet.
4.
5.00.00 5.01.00
COMMISSIONING The contractor shall carryout the following commissioning tests and checks after installation of the equipment at site: (a.) (b.) (c.) (d.) (e.) (f.) (g.) Complete physical examination. Checking of proper operation of annunciation system. Temperature rise test at full load. Insulation resistance test. Automatic voltage regulator operation. Load limiter operation. Dynamic response test.
Overshoot/Undershoot in output voltage of the Charger as a result of sudden change in load from 100% to 20% and 20% to 100% shall be measured with the Batteries connected/disconnected. Output voltage of the Charger connected with Battery shall be within 94% to 106% of the voltage setting in above conditions and shall return to, and remain, within the limits specified as mentioned elsewhere, in less than 2 seconds (as applicable).
PAGE 11 OF 11
CLAUSE NO.
TECHNICAL REQUIREMENTS MEASURING INSTRUMENTS
1.00.00 1.01.00
MEASURING INSTRUMENTS Measuring instruments/equipment and subsystems offered by the Bidder shall be from reputed experienced manufacturers of specified type and range of equipment, whose guaranteed and trouble free operation has been proven. Further, all instruments shall be of proven reliability, accuracy, and repeatability requiring a minimum of maintenance. They shall comply with the acceptable international standards and shall be subject to Employer's approval. All instrumentation equipment and accessories under this specification shall be furnished as per technical specifications, ranges, makes/numbers as approved by the Employer during detailed engineering. Every panel-mounted instrument requiring power supply shall be provided with a pair of easily replaceable glass cartridge fuses of suitable rating. Every instrument shall be provided with a grounding terminal and shall be suitably connected to the panel grounding bus. All local gauges as well as transmitters, sensors, and switches for parameters like pressure, temperature, level, flow etc. as required for the safe and efficient operation and maintenance as well as for operator and management information (including all computation) of equipment under the scope of specification shall be provided on as required basis within the quoted lump sum price. The necessary root valves, impulse piping, drain cocks, gauge-zeroing cocks, valve manifolds and all the other accessories required for mounting/erection of these local instruments shall be furnished, even if not specifically asked for, on as required basis. The contacts of equipment mounted instruments, sensors, switches etc. for external connection including spare contacts shall be wired out in flexible/rigid conduits, independently to suitably located common junction boxes. The proposal shall include the necessary cables, flexible conduits, junction boxes and accessories for the above purpose. Double root valves shall be provided for all pressure tapping where the pressure exceeds 40 Kg./sq.cm. SPECIFICATION FOR ELECTRONIC TRANSMITTER FOR PRESSURE AND D.P. ELECTRONIC TRANSMITTERS Sr. No. 1. 2. 3. Features Type of Transmitter Accuracy Output signal range Essential/Minimum Requirements Microprocessor based 2 wire type, HART protocol compatible. 0.1% of calibrated span ( minimum) 4-20 Ma DC (Analog) along with superimposed digital signal (based on HART protocol)
1.02.00
1.03.00
1.04.00
2.00.00 2.01.00
SUB-SECTION-IIIB-14 MEASURING INSTRUMENTS
PAGE 1 OF 10
CLAUSE NO.
TECHNICAL REQUIREMENTS 4. Turn down ratio 10:1 for vacuum/very low pressure applications. 30:1 for other applications. 5. Stability 0.1% of calibrated span for six months for Ranges up to and including70 Kg/cm. 0.25% of calibrated span for six months for Ranges more than 70 Kg/cm (g). 6. Zero and span drift +/- 0.015% per deg.C at max span. +/-0.11% per deg.C at min. span. 7. 8. 9. 10. 11. 12. Load impedance Housing Over Pressure 500 ohm (min.) Weather proof as per IP-55 corrosion resistant coating. 150% of max. Operating pr. with durable
Connection (Electrical) Plug and socket type Process connection Span and Zero 1/2 inch NPT (F) Continuous, tamper proof, Remote as well as adjustability manual from instrument with zero suppression and elevation facility. -Diaphragm seal, pulsation dampeners, siphon etc. as required by service and operating condition. -2 valve manifold for absolute pressure transmitters (3-valve manifold for gauge/ vacuum pressure transmitters) and 5 valve manifold for DP/level/flow transmitters. -For hazardous area, explosions proof enclosure as described in NEC article 500.
13.
Accessories
14. 15. 16.
Diagnostics Power supply Adjustment/calibration /maintenance
Self Indicating feature 24V DC 10%. Total two (2) no. of hand- held type universal calibrators compatible with HART protocol , shall be provided (for all three units).
PAGE 2 OF 10
CLAUSE NO.
TECHNICAL REQUIREMENTS Note. In case it becomes necessary to use a DP transmitter for pressure measurement, then a 3-valve manifold should be used in place of 2-valve manifold. LVDT type is not acceptable. Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm seals shall be provided. Parts below the diaphragm shall be removable for cleaning. The entire volume above the diaphragm shall be completely filled with an inert liquid suitable for the application.
2.02.00
ULTRASONIC LEVEL TRANSMITTERS
Sl. no
1.
Features
Type of Transmitter
Essential/Minimum requirements
Non contact Microprocessor based 2 wire type, HART protocol compatible Ultrasonic transmitter. Galvanic ally isolated 4-20mA DC (Analog) along with superimposed digital signal (based on HART protocol). +/- 0.5% of calibrated span. 3 mm or better. 24 V DC +/- 10% To be provided within transducer. Sensor unit and Electronic units are to be separate. It shall be possible to mount the Electronic unit at a remote accessible location from the transducer. All cables and weather proof fittings to interconnect transducer to electronic unit shall be provided by Bidder. Weather proof as per IP-55 with durable corrosion resistant coating. Through HART Communicator. Span Continuous, tamper proof, remote as well as manual adjustability from instrument. It shall be possible to calibrate the instrument without any level in the tank/sump etc Corrosion resistant material to suit individual application requirement.
2.
Output signal
3. 4. 5. 6. 7.
Sensor Accuracy Sensor Repeatability Power supply Temperature compensation Configuration
8. 9. 10.
Housing Calibration Zero and adjustment
11.
Sensor Material
PAGE 3 OF 10
CLAUSE NO.
12.
False signal tolerance
Transmitter shall be capable of ignoring false echoes from internal tank/sumps obstructions such as pipes, heating coils or agitator blades. Also transmitter shall have adjustable damping circuitry Range of transmitter shall be capable of covering the complete level span of tank taking care of blocking distance, frequency attenuation due to surface, obstructions, vapors etc Minimum 4 character display with integral keypad, access protected by user code. Loss of echo alarm etc 500 ohms minimum Plug and socket All weather canopy for protection from direct sunlight and direct rain. All mounting hardware and accessories required for erection and commissioning mounting fittings material shall be SS 316. For hazardous areas, explosion proof enclosure as described in NEC article 500.
13.
Range
14. 15. 16. 17. 18.
Display Diagnostics Load Impedance Electrical Connection Accessories
Note:Contractor can also provide Radar type transmitter in place of ultrasonic transmitters subject to approval by Employer during detailed Engineering. 3.00.00 3.01.00 TEMPERATURE ELEMENTS RESISTANCE TEMPERATURE DETECTOR ( RTD ) Sr. No. 1 2 3 Features Type of RTD. No. of element Housing/Head : : : Essential/Minimum Requirements Pt-100 (100 Ohms resistance at zero degree centigrade) Duplex IP-55/Diecast Aluminium. Plug in connectors are to be provided for external signal cable connection. Metal sheathed, ceramic packed As per DIN-43760 Class-A Linear with respect to temp, within 1/2
SUB-SECTION-IIIB-14 MEASURING INSTRUMENTS PAGE 4 OF 10
4 5 6
Sheathing of RTD Calibration and accuracy Characteristic
: : :
CLAUSE NO.
TECHNICAL REQUIREMENTS percent of top range value. Thermo well (as specified below) and shall be spring loaded for positive contacts with the well. DIN-43760 for RTD and ASME PTC-19.3 for Thermo-well.
Accessories
8 3.02.00
Standard
THERMO WELL Thermo well shall be one piece solid bored type of 316SS of Step-less tapered design (as per ASME PTC 19.3, 1974). TEMPERATURE TRANSMITTER Following type of 2-wire temperature transmitter (directly powered from 4-20mA input cards of DDCMIS) shall be provided. The temperature transmitter shall be fully compatible with thermocouples and RTDs being provided by the contractor. Temperature compensation of the thermocouples shall be performed in the temperature transmitter itself. Single Input DIN-rail mounted Temperature Transmitter These shall be suitable for mounting on DIN-rails in JBs. The specifications of the JBs shall be same as indicated in Subsection INST CABLE with additional DINrails and IP 65 Protection class. This temperature transmitter shall be the ones which are especially designed for DIN-rail mounting with IP 20 protection class. These shall have terminals for input/output provided on front side when mounted on DIN-rail. Head mounted temperature transmitter with clamps to make it suitable for DIN-rail mounting shall not be acceptable under this category. Requirements for each of the above type of temperature transmitters Output : 2-wire (power supply from input card of Control System) with 4-20mA output with superimposed HART protocol signal. Same transmitter shall be capable to handle Pt-100 RTD , Thermocouples K&R types (input type to be selectable at site through HART terminal) min. 500 V AC as per EN 61326 0 to 85 deg C (without indicator) 0 to 70 deg C (with indicator) Power supply compatible with input module of System
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIB-14 MEASURING INSTRUMENTS
Input
Isolation EMC compatibility Operating temperature
: : ambient :
Control
PAGE 5 OF 10
CLAUSE NO.
Accessories
Mounting arrangements including clamps etc.
Composite Accuracy (Refer note 2) RTD T/C-K type T/C-R type =<0.4% of 0-250 deg C span =<0.4% of 0-600 deg C span =<0.4% of 0-1000 deg C span
CJC accuracy (for thermocouples) shall be =< 1 deg C
Notes:1. In case of failure (open or burn-out) of RTD/thermocouple, temp. Transmitter shall provide low temperature output. Composite Accuracy is to be calculated as summation of all applicable accuracies of temp transmitter, for converting sensor input to output in 4-20 mA (e.g., basic accuracy, digital accuracy, D/A accuracy, etc.) and temperature effect on these accuracies at ambient temperature of 50 deg C, based on the figure/ formula given in the standard product catalogue for span as specified above for various types of Temperature Elements specified. All such accuracy/ temp effect figures in catalogue shall be first converted to deg C, and then percentage of this converted accuracy in specified span shall be calculated to compare with the specified composite accuracy figures.
2.
3.04.00
Hand held calibrator Hand held calibrators (2 nos) shall be provided for adjustment/calibration/ maintenance of the HART compatible temperature transmitters.
PAGE 6 OF 10
CLAUSE NO.
TECHNICAL REQUIREMENTS SPECIFICATIONS FOR PR. GAUGE, D.P. GAUGE, TEMP. GAUGE AND LEVEL GAUGE. Sl. No FEATURES ESSENTIAL/MINIMUM REQUIREMENTS Pr. Gauge/ DP Temperature Gauge/ Gauge Draught gauges 1 Sensing Bourdon for Element and high pressure, material Diaphragm/Bel low for low pr. Of 316 SS Mercury in steel for below 450C and inert gas actuated for above 450C of SS bulb and capillary. Die-cast aluminium 150 mm Level Gauge
4.00.00
Tempered * toughened Borosilicate gauge glass steel armoured reflex or transparent type.
2 3 4
Body material Dial size End connection Accuracy Scale
Die-cast aluminium 150mm
Forged steel/304 SS
carbon
Tubular covering entire range Process connection as per ASME PTC and drain/vent 15 NB 2%
1/2 inch NPT 3/4" NPT (M) (M) 1% of span 1% of span
5 6
Linear, 270 Linear, 270 arc Linear vertical arc graduated graduated in C in metric units Cover 125% of Cover 125% of Cover 125% of max. of max. of scale max. of scale scale
7 8 9
Range selection Over test
range Test pr. for the assembly shall be1.5 to the max. Design pr. at 38C. Weather and Weather and dust CS/304 SS leak proof dust proof as proof as per IP-55 per IP-55 Provided Provided --
Housing
10
Zero/span adjustment
PAGE 7 OF 10
CLAUSE NO.
TECHNICAL REQUIREMENTS 11 Identification Engraved with service legend or laminated Phenolic name plate
12
Accessories
Blow out disc, SS Thermo well siphon, snubber, pulsation dampener, chemical seal (if required by process) gauge isolation valve
Gasket for all KEL-F shields for transparent type vent and drain valves of Steel/SS as per CS/Alloy process Requirement.
13
Material of 316 SS / 304 316 SS / 304 SS Bourdon/ SS movement
Notes:*Bicolor type level gauges will be provided for applications involving steam and water except for condensate and feed water services. Length of gauge glass shall not be more than 1400 mm. If the vessel is higher, multiple gauge glasses with 50 mm overlapping shall be provided. Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm seals shall be provided. Parts below the diaphragm shall be removable for cleaning. The entire volume above the diaphragm shall be completely filled with an inert liquid suitable for the application. 5.00.00 ROTAMETERS Sr. No. 1. 2. 3. 4. 5. 6. Features Type Fluid media Tube body Material of float Indicator Accessories Essential / minimum requirements Variable Area Metal Tube Water/oil SS316 316 SS Linear scale Flange orifice in case of bypass rotameter (for line size above 100 mm)
PAGE 8 OF 10
CLAUSE NO.
TECHNICAL REQUIREMENTS 7. 8. Housing protection class Accuracy IP-55 + 2% of measured value.
6.00.00
PROCESS ACTUATED SWITCHES FEATURES ESSENTIAL / MINIMUM REQUIREMENTS Pressure/ Draft Switches/ DP Switches Sensing Element Piston actuated for high pressure and diaphragm or bellows for low pr./ vacuum Temperature switches Level switches
Vapor pressure sensing, liquid filled bellow type with SS bulb and capillary (10 m minimum)
Capacitance types for oil and dirty medium, water, condensate application. Float type switches for applications as decided by Employer during detailed engineering. Capacitance/ Conductivity/ Ultrasonic type for acid and alkali application.
Material End connection
316 SS
Bulb 316 SS/ 316 SS capillary 304 SS Manufacturer standard 150% of pressure max. design
inch NPT inch NPT (F) (F)
Over range 150% of proof max. design pressure pr. Repeat-ability No. contacts Rating contacts + 0.5% of full range
of 2 No.+2NC. SPDT snap action dry contact
of
60 V DC, 6 VA (or more if required by DDCMIS or PLC)*
PAGE 9 OF 10
CLAUSE NO.
TECHNICAL REQUIREMENTS Elect. Connection Plug in socket
Set point/ Provided over full range dead band adjustment Enclosure Accessories Weather and dust proof as per IP-55 Thermo well of All mounting accessories Siphon, 316 SS and snubber, packing glands chemical seal, pulsation dampeners as required by process Suitable for Suitable for rack mounting or enclosure/ direct mounting rack mounting or direct mounting
Mounting
Where the process fluids are corrosive, viscous, solid bearing or slurry type, diaphragm seals shall be provided. Parts below the diaphragm shall be removable for cleaning. The entire volume above the diaphragm shall be completely filled with an inert liquid suitable for the application.
PAGE 10 OF 10
CLAUSE NO.
TECHNICAL REQUIREMENTS CLOSE CIRCUIT TELEVISION SYSTEM (CCTV)
1.00.00 1.01.01
GENERAL REQUIREMENTS The intent of the specification is to define the functional & design requirements for the CCTV System meant for gathering video information from the various operational areas of the Coal Handling Plant. The Contractor shall be responsible for selection, design, engineering, manufacture, testing at manufacturers works/site, installation and commissioning of the system to the satisfaction of Employer. All the cables, cable trays, power packs, erection hardwares etc. are also included in contractors scope. The Contractors scope shall also include successful demonstration of performance testing specified herein complete in all respects alongwith cables, cable trays, junction boxes, earth wire and accessories like standard brackets, nut-bolts, glands, lugs, conduit sleeves, etc., as required, to complete the proper installation conforming to IS:1881, IS:1882 of all the equipments supplied as covered in this specification. All equipment, accessories and facilities required for completeness of this system are included in Contractor's scope, whether these are specifically mentioned herein or not. The CCTV System offered by the Contractor shall be from reputed manufacturer who should have designed, manufactured, tested and commissioned a distributed type CCTV systems as specified in any coal handling plants or any large industrial installation as on the date of bid opening. All major equipment such as Cameras, Video Switcher/Control System, Key Boards, Receiver Drivers, Pan Tilt Units, Post equalisation Video amplifiers, Digital Video Recorder, (DVR) Archiving System etc. shall be of the same make. Dome type cameras are also acceptable. The system and all the equipment shall conform to the latest edition of Indian / International and CCITT standards as applicable. The Contractor shall guarantee satisfactory performance of the equipment under stipulated variations of voltage and frequency. The design and manufacture shall be such that equipments/components of same type and rating shall be interchangeable. All the cameras shall be connected to a central redundant microprocessor based video switcher/control system to be located in CHP control room. Any other equipment, module required for the safe and satisfactory operation, control, protection, monitoring, testing and maintenance of the system are also included in Contractor's scope. POWER SUPPLY ARRANGEMENT The Contractor shall provide power to the CCTV System from UPS system for microprocessor based switching / control unit, monitor, digital video recorder, etc. in the control room.
1.01.02
1.01.03
1.01.04 1.01.05
1.01.06 1.01.07
2.00.00 2.01.00
Sub-Section - IIIB-15 CCTV
Page 1 of 8
CLAUSE NO.
TECHNICAL REQUIREMENTS DESIGN AND TECHNICAL REQUIREMENTS The CCTV system shall be able to provide surveillance of different locations of the plant. The system shall comprise of Redundant Switcher/Control System capable of controlling Microprocessor based Video
3.00.00 3.01.00 3.02.00
32 nos. of Cameras for Zoom, Pan/Tilt, Multiple pre positionsand auxiliaries 1 no. of digital video recorder. Multiplexor Required no. of 21 colour monitors with key board for controlling both manually and automatically and all other accessories required to provide best quality video with controls for making the system complete. It shall be possible to view the CCTV out put on the large video screen also.
3.03.00
The system operation would be of covering the complete view of the areas with pan / tilt, zoom, propositioning of the cameras and with programmability to monitor any camera or number of cameras at a time on any monitor either manually or automatically in a defined switching. The system shall be suitable for installation and shall be able to work successfully in Coal dusty environment. The system shall have the following facilities: a) b) c) d) e) f) g) h) i) Zooming Pan control Tilt control Computer interface Logging printer part Multiple prepositions SALVO switching Programmability Alarm interface
3.04.00
3.05.00
The system supplied shall be complete in all respects for reliable performance. The Contractor shall submit the details block schematic, video, signal & power wiring diagram, describing the connections between the Microprocessor based Video Switcher/Control System and various cameras, pan tilt, receiver driver units, monitors, DVR and keyboard. Programming required shall be done by the Contractor for satisfactory operation.
Page 2 of 8
CLAUSE NO.
TECHNICAL REQUIREMENTS The system should be completely compatible to be integrated to Fire Alarm System. When the fire is detected by a particular detector the camera assigned should automatically focus the site of the fire. The video switcher/control system shall permit the design of a distributed matrix video switching system with control at one central location and individual control at the local sites. The main control site could view/control local cameras plus cameras located at any of the remotely distributed sites. DETAILED DESCRIPTION OF THE SYSTEM COMPONENTS : Microprocessor based Video Switcher/Control System The Video Switcher/Control System shall be Redundant, Microprocessor based and modular in construction. It should offer full matrix switching capability, i.e., the system should be programmable to display the video from any camera or number of cameras at a time on any monitor, either manually or via independent automatic switching sequences. The Video switcher/Control System should have provision for minimum 32 camera inputs 2 monitor outputs, keyboards, Digital video recorders, 32 direct connect alarm input points, an integral signal distribution unit, a computer interface port, and a logging printer port including all other hardware / software. The Video Switcher/Control System should be programmable with up to 30 sequences, which can run independently of each other in either forward or reverse direction. Any of the sequences should utilise the Salvo Switching capability where any number of system monitors may be selected to switch as a group. The video switcher/control system should have easy provision for integral signal distribution ports, connections to on-site receiver/drivers. It should have built-in alarm interface capability, any monitor or group of monitors could be set to display cameras under alarm conditions. In addition, 16-character alarm title could be selected to appear instead of the camera title during alarm conditions. The video switcher/control system should include on screen display for time-date, camera number, camera Id, and monitor or status information. The system should have provision for logging printer output port to provide permanent record of system status showing time and date of changes such as : incoming alarms, acknowledgement of alarms, loading of sequences, user log-on to keyboard, transfer of system tables and sequence, video loss messages, and a power up reset message, so that a hard copy of the systems configuration tables and sequences can be obtained. The system shall also have the following provisions. User friendly spreadsheet format providing the ability to enter camera titles, operator names, timely events, change system parameters, program camera sequences and install lockouts. It should provide high performance programming, control and monitoring of all the system functions by using on-screen icons to reflect real time status of the devices being controlled by the system.
TECHNICAL SPECIFICATIONS Section-VI, Part-B Sub-Section - IIIB-15 CCTV Page 3 of 8
3.06.00
3.07.00
4.00.00 4.01.00 4.01.01
4.01.02
4.01.03
4.01.04
4.01.05
4.01.06
CLAUSE NO.
TECHNICAL REQUIREMENTS Software should also provide the ability to monitor system status events. System alarms, switching functions, sequence events, keyboard actions, and video loss information. All the video switcher/control system shall be connected to a 10/100 Base Fiber Optic full Duplex Ethernet network, to be provided by the Contractor. In case it is the standard practice of the Contractor to provide PC based video switcher / control system to achieve all the above functions, the same is also acceptable. The CCTV system shall be connected to LVS also. Keyboard : Keyboard should have full function used for system control and programming and should be ergonomically designed. It should include integral pan/tilt joystick and zoom lens controls. This would be connected to the video switcher/control system for signal and power. Keyboard shall have full function used for system control and programming for selection of various video switcher/ DVR / camera functions including pan/tilt and zoom lens controls and shall be ergonomically designed. The Key board shall be able to access DVR and video switcher. Incase it is the standard practice of the contractor to offer PC based integrated keyboard and monitor, then the same is also acceptable, subject to Employers approval. Cameras : The cameras shall be rugged, 1/4 inch image format, full performance color CCD cameras. These cameras should provide high resolution and high sensitivity suitable for operation in a coal handling plant, both in natural and artificial lighted areas. The cameras should have features as mentioned below : Suitable for night-time surveillance Manual or Automatic colour/infra red switching Automatic picture enhancement to give a balanced picture where there is too little/too much light Remote camera setup, with on screen menu display. Character generator giving up to 24 character text-in-picture. Backlight composition Automatic white balance, with mode selection options Contour correction and contrast compression control. Synchronisation selection for Gen lock, external V-lock, mains lock and internal free-running. All cameras shall be network compatible.
TECHNICAL SPECIFICATIONS Section-VI, Part-B Sub-Section - IIIB-15 CCTV Page 4 of 8
4.01.07
4.01.08 4.02.00 4.02.01
4.02.02
4.03.00 4.03.01
4.03.02
CLAUSE NO.
TECHNICAL REQUIREMENTS Detailed technical specifications are as under : Imager : Interline transfer CCD, 1/4 inch image format Horizontal resolution : 480TVL in PAL B mode Sensitivity (at f1/4, 6dB), scene illumination 0.7 lux ( at 50 IRE color) Light Range Signal-to-noise : > 50dB. AGC : Upto 18 dB Shutter Speed : 1/50-1/1,00,000 LUX. Auto select Lens Mount : Video Iris Gamma Correction : 0.45/1.0 Auto-black contour correction : Colour Contrast compensation : 2.5x Power Supply : 230V AC
4.03.03
4.04.00 4.04.01
Lens : The lens should be Auto-iris lens of 1/4 inch to be mounted on the above camera. It should be zoom lens with CS-Mount. The details are as under: Focal Length : 6 90 mm zoom lens (approx.) Iris range : 1.2 to 360
4.05.00 4.05.01
Camera Housing All the cameras and accessories are to be housed in Weather Proof (IP-65) environmental housing made of aluminum. The housing with heater and blower installed should provide protection for camera/lens assemblies in the ambient temperature range of - 0 deg. C to 60 deg. C. The housing should also have thermostatically controlled heater kit, continuous duty blower kit, purge air arrangement and Window wipers available within the housing. Complete assembly including camera shall be suitable for hot and highly polluted environment of Coal Handling Plant. Pan & Tilt Unit : The Pan & Tilt unit should be weather proof (IP-65) with pan/tilts designed to meet the rigorous requirement and should be constructed with corrosion resistant hardware.
4.05.02
4.06.00 4.06.01
Page 5 of 8
CLAUSE NO.
TECHNICAL REQUIREMENTS They should be capable of handling loads up to 10 kg and should be having 100% duty cycle motors to permit continuous operation. The pan & tilt should comply with the following : - Electrical 230V AC, 50 Hz - Pan range : 120 deg movement in horizontal plane. - Pan speed : 6 deg./sec. - Tilt : +3 deg to 90 deg movement in vertical plane - Tilt speed : 3 deg./sec. - Construction : Cast aluminum base and yoke, corrosion resistant cover.
4.06.02 4.06.03
4.07.00 4.07.01
On-site Receiver/Driver Unit : The on-site receiver/drive unit should be able to control the motor drives for pan/tilt and cameras for zoom and aux control. These would be used in conjunction with the Microprocessor based video switcher/controller systems. The on-site receiver/driver unit should have features like focus/zoom/iris controls, 99 prepositions lockable enclosure latches, an integral local test function and IP 65 rated environmental enclosure. The On-site receiver/driver unit should be operated from 230V AC, 50 Hz and provision to be within hazardous are in the vicinity of the camera and pan tilt unit. The cable from the receiver drive unit to the pan/tilt unit and the camera is to be provided with the receiver driver unit. Monitor & Key board: The monitors should be colour video monitors that the versatile and attractive units to be mounted on the wall/desk. It should have built in audio. Monitors are to be operable at 230V AC, 50 Hz. They should comply to the following specifications. General : Automatic degaussing, Fast warm up time Display tube : 51 cm diagonal, 90 deg deflection, integral implosion protection. Resolution : 450 TVL minimum Controls : Colour system select, volume, colour, brightness, contrast, power, video input select and Y/C termination.
4.07.02
4.07.03
4.08.00 4.08.01
4.09.00
Digital Video Recorder: Parameter Horizontal Resolution Specification 720x570 lines

Sub-Section - IIIB-15 CCTV Page 6 of 8
CLAUSE NO.
TECHNICAL REQUIREMENTS Color system Recording system Recording speed Inputs PAL/ NSTC, compatible with the CCTV system being proposed by the contractor. Applied JPEG, MPEG, Wavelet or better with Motion detection-Hi performance system. 1-50 frames per second ( fps) , programmable 16 channel with Inbuilt Multiplexer and storage for minimum eight days on HDD for all the connected camera signals. Date, hours, minutes and seconds. Minimum range from 5 sec. To 3 min, to be finalised during detailed engineering stage. Compatible with the finally selected cameras/ network Multiple, 2x2, 4x4, single to be finalised during detailed engineering stage. Manufacturers standard By date, time or cameras Minimum 8. 1V p-p 75 Ohm to be finalised during detailed engineering stage. 1 V p-p 75 Ohm to be finalised during detailed engineering stage. Minimum 5 User Customizable Zones per camera The recorder shall be fully compatible with any standard 10/100 Base FO full Duplex Ethernet port for networking to a central DVD or AIT or Hard Disk Arrays after seven days of recording is over on the HDD. All or selected portions of the recorder material shall be shifted on to AIT or DVD and archived. The Archiving unit shall be common for the stations.
Characters generation Record time by alarm Input signal View Power supply Search Alarm Inputs Video I/P Video O/P
Zones Archiving
4.09.01
In case the contractors standard practice is to provide Digital video recorder which integrates the function of video switcher / controller, then the same is also acceptable. In that case, the DVR shall record multiple camera signals while simultaneously providing live multiscreen viewing and playback. The images per second rate and image quality shall be selectable for each connected camera. The digital recorders shall allow selectable frames per second (fps) record rates from zero fps to minimum twenty five fps. DVR shall also have features: on screen display which records time, date, number of alarms etc Post Equalisation Video Amplifier :
4.09.02
4.09.03 4.10.00
Page 7 of 8
CLAUSE NO.
TECHNICAL REQUIREMENTS The post equalisation video amplifier should provide of controls of adjustable overall gain and frequency boost while maintaining full video amplitude, contrast and detail. It should work on 230V AC, 50Hz. The post equalisation video amplifier should comply to the following : Gain : adjustable from 1 dB to +8 dB Frequency response : Adjustable from flat (+/- 1 dB) at 12 Mhz to greater than +18 dB at 12 Mhz. Controls : Gain, HF boost, LF boost and indication of red LED when power is on.
4.10.01
4.10.02
5.00.00
OPERATIONAL REQUIREMENTS : The CCTV system should comply to the following operational requirement. 1. 2. From the master control panel(keyboard) it shall be possible to select any camera and display the picture on any of the monitors. Commands from the video switcher/control unit is sent via a onsite receiver/drive unit to the camera which in turn controls the pan/tilt zoom etc., functions. Operator shall be able to control all the cameras, pan / tilt and zoom functions manually. The video recorder shall record the activities of all the places where alarm have been alerted. The time-lapse video recorder shall be able to record up to 720 hrs without reloading.
3. 4.
6.00.00 6.01.00
CABLES : Power, control and instrumentation cables shall conform to the relevant section of this specification. Any special cables for use in CCTV shall conform to the relevant Indian/International standards. The signal / Video transfer from Cameras to the main control room equipment shall be through fibre optic cable. However all cables shall be FRLS type as specified elsewhere.
Page 8 of 8
CLAUSE NO.
CONTENTS
CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 GENERAL LAYOUT & LEVELS DRAWINGS/DOCUMENTS WORK DESCRIPTION 4.01.00 - Overhead / Ground Conveyor Galleries and Trestles 4.02.00 Transfer Houses 4.03.00 Control Buildings, MCC Buildings 4.04.00 Staircases 4.05.00 Trenches 5.00.00 Drainage & Water Supply Works 5.01.00 Drainage System 5.02.00 Internal and external water supply, drainage 6.00.00 7.00.00 8.00.00 9.00.00 10.00.00 11.00.00 12.00.00 13.00.00 14.00.00 15.00.00 COLOUR COATED AND OTHER SHEETING WORK ROOF DETAILS FLOOR AND GRADE DETAILS BRICKWORK & ALLIED MASONRY WORKS EARTHING MAT FENCING LOADING DESIGN CRITERIA CONCRETE EXCAVATION DETAILS 15.01.00 Excavation in soil 15.02.00 Excavation in rock 15.03.00 Dewatering of deep foundations 15.04.00 Backfilling, disposal & stacking of materials 16.00.00 17.00.00 Galvanising Architectural Features 17.01.00 Glazing
DESCRIPTION
TECHNICAL SPECIFICATIONS SECTION VI, PART-B BID DOC. NO.:CS-
Sub-Section - IIID-01 CHP CIVIL WORKS
Page 1 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS 17.02.00 False ceiling 17.03.00 Acid/Alkali Resistant Lining 17.04.00 Finishing Schedule 17.04.01 Flooring 17.04.02 Interior wall/ ceiling finish 17.04.03 Exterior finish 17.05.00 Door, windows & rolling shutters 17.05.01 Doors & Windows 17.05.02 Rolling Shutters 18.00.00 19.00.00 20.00.00 21.00.00 22.00.00 23.00.00 24.00.00 25.00.00 Annexure A Annexure B Painting Miscellaneous Packaging & Transportation Plant Life PTFE Bearing Tests for Materials/Workmanship Materials Codes and Standards Criteria for Earthquake Resistant Design of structures & Equipment Criteria for Wind Resistant Design of structures & Equipment
Page 2 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS 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 Engineering, fabrication, erection and construction of the necessary civil, structural and architectural works associated with the coal handling plant to be installed at FARAKKA SUPER THERMAL POWER PROJECT. The work shall have to be carried out both below and above ground level and shall be involving, basements, equipment foundations, slabs, beams, columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, finishes, complete architectural aspects, drainage, sanitation, water supply (from terminal points to various buildings, conveyor galleries), Bituminous access roads (3.75m wide) to all structures and all other civil and structural works associated with the Coal Handling Plant. The specifications are intended for the general description of the work, quality and workmanship. The specifications are not, however, intended to cover minutest details and the work shall be executed according to the relevant latest Indian Standard Codes / I. R. S. / I. R. C. specifications. In absence of the above, the work shall be executed according to the best prevailing local Public Works Department practices or to the recommendations of relevant American and British Standards or to the instructions of the Engineer. List of I. S. Codes to be followed is mentioned in the Technical Specifications. The Contractor is expected to get clarified on any doubts about the specifications, etc. before bidding, in writing with the Employer in respect of interpretation of any portions of this document. LAYOUT AND LEVELS 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. 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 and approved by the Engineering. 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 be prepared in Auto Cad (latest version). The analysis shall be done by using STADD PRO / ANSYS / STRAPP (latest version). However design may be carried out by manually, using computer work sheets or by using suitable software programmes, as mutually agreed by Employer. Final calculations and drawings shall be submitted in Compact Disc (CD) (2 Sets)
1.00.00 1.01.00
1.02.00
1.00.00 2.01.00
2.00.00 3.01.00
3.02.00
3.03.00
Page 3 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS 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 N.T.P.C. record. However each drawing shall indicate 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. However, the Contractor for 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 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):
3.04.00
3.05.00
3.06.00
3.07.00
4.00.00
4.01.0
Overhead / Ground Conveyor Galleries and Trestles Overhead conveyors shall be located in a suitably enclosed gallery of structural steel. The overhead gallery shall consist of two vertical latticed girders having rigid jointed portal frame at both ends. Cross beams at floor level supporting conveyor stringer beams shall be made of single rolled steel beam or single channel section (ISMB or ISMC) or plate girder. Horizontal bracings are to be provided at top & bottom plan of the gallery (latticed girders shall be braced together in plan at the top and bottom). Common end portal frame shall not be used for adjacent conveyor spans. Roof truss shall be provided at upper node points of latticed girders to form an enclosure. The maximum span of overhead gallery shall be limited to 25 meters unless higher span is required due to site conditions, which shall be subject to approval of the Engineer. The gallery should as far as possible be erected as a box section keeping all the vertical and horizontal bracing tied in proper position. The gallery should be checked for all erection stresses that are likely to develop during handling and erection and if required, temporary strengthening of gallery members during erection shall be made. Seal plates under the conveyor galleries shall be provided in such a way that complete gallery bottom shall form a leak proof floor. The ground conveyors shall be located in suitably enclosed gallery of structural steel consisting of rigid portal frames spaced at regular intervals and suitably braced. Plinth protection along with drains shall be routed along the ground conveyors. For double stream conveyor gallery, two side and one central walkway of width 800 mm and 1100 mm respectively shall be provided. The width of two side walkways for single stream conveyor gallery shall be 800 mm and 1100 mm respectively. Both sides of central and side walkways shall be provided with pipe handrails all along the
Page 4 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS conveyor gallery. Hand railing should not be supported on conveyor supporting stringers. The walkways shall be chequered plate construction with anti - skid arrangement. The anti - skid arrangement will consist of welding of 10 mm square steel bars at a maximum spacing of 500 mm along the length of the gallery. Where the slope of walkway is more than 10o, chequered plate steps with nosing and toe guard shall be provided. The floor of conveyor gallery all along the gallery length, shall be provided with minimum 12 gauge thick seal plates and other drainage arrangements as specified elsewhere Conveyor gallery shall have permanently colour coated steel sheet covers on roof and both sides. However in roof, a panel of minimum 1.5 m x 1.5 m area at about 6.0 m center shall be provided with translucent sheets of polycarbonate material for natural lighting. A continuous slit opening of 500 mm shall be provided on both sides just below the roof sheeting. Adequate provision of windows shall be kept on both sides of conveyor gallery as appended in Mechanical Section (Belt conveyor system). Windows shall be provided with wire mesh as specified elsewhere in this specification. Cross - over with chequered plate platform and ladder for crossing over the conveyors shall be provided at approximately every 100 M intervals of conveyor. Crossover shall preferably be located over four-legged rigid trestle location. For railway tracks passing below overhead conveyor gallery and along conveyors, the railway clearances both underground as well as over ground shall have to be adhered to for design, execution and erection of foundations, trestles, galleries etc., so that movement of locomotives and wagons is not hampered in any way during execution and afterwards. However at the location where the overhead conveyor gallery crosses road / rail line, minimum clearance of 8.0m above the road crest / rail top shall be provided. For calculation of coal load on moving conveyor, a multiplication factor 1.6 shall be used to take care of inertia force, casual over burden and impact factor etc. Thus coal load per unit length of each moving conveyor shall be
Rated Capacity of Conveyor system 1.6 X -----------------------------------------------Conveyor Belt Speed X
1100 --------800
It should be noted that for structural design, unit weight of coal shall be assumed as 1100 Kgs. / Cu. M. instead of 800 Kgs. / Cu. M. considered for system sizing purpose. Conveyor Gallery structure shall be designed considering both conveyors operating simultaneously.
Page 5 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Conveyor gallery and supporting trestles located between transfer houses / buildings shall be arranged in any one of the following ways. a) All gallery supporting trestles shall be four legged type only. One end of each gallery span shall be hinged to the supporting trestle and the other end shall be slide type. Slide type support shall be with P. T. F. E. bearings to allow both rotation & longitudinal movements. In between transfer houses / buildings, four legged trestles shall be placed at a maximum interval of 90 metres. The arrangement shall be such so as to ensure that force in the longitudinal direction (i. e. along the conveyor length) of conveyor gallery of length not more than 90 m is transferred to any four legged trestle. In the space between each successive four legged trestles, two legged trestles shall be provided at regular intervals. The end supports resting on the four-legged trestle can have either ends hinged or one hinge and the other on slide type depending on the arrangements. Slide type support shall be with P. T. F. E. bearings to allow both rotation & longitudinal movements.
b)
End of conveyor gallery which will be supported over transfer house, shall be so detailed that only vertical reaction is transferred from conveyor gallery and no horizontal force in longitudinal direction is transferred from conveyor gallery to transfer house structure and vice - versa. For trestles and trestle foundations for conveyor galleries located adjacent to existing structures, over ground and under ground facilities, location and details of these trestles and foundations shall have to be decided such that there is no interference both underground as well as over ground with existing structures and facilities. Trestle columns / ground conveyor portal column base shall be kept 300 mm higher than the existing ground level. 4.02.00 Transfer Houses The over ground portion of the transfer house shall be framed structure of structural steel work with permanently colour coated profiled steel sheet side cladding and R. C. C. floors over structural beams. However the lower portion of side cladding for a minimum height of 0.9 m above the finished floor level at ground shall be one brick thick wall plastered on both side. In some areas like MCC floors etc., one brick thick wall cladding shall be provided. Brick wall cladding shall be supported on encased wall beams and suitably anchored to adjoining columns and beams. Adequate steel doors and windows for proper natural lighting and ventilation shall be provided. In addition to steel windows, panels of suitable size to suit the architectural treatment and made of translucent sheets of polycarbonate material shall also be provided on the side cladding for natural lighting. Roof shall be provided with troughed profile permanently colour coated sheet on outside and plain permanently colour coated sheet on inside with 50mm thick mineral wool insulation in between the two sheets. A slope of 1 in 5 shall be provided for quick drainage of rain water.
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CLAUSE NO.
TECHNICAL REQUIREMENTS Control building, M. C. C. Buildings These shall be R. C. C. framed structures with columns, beams, slabs and foundations etc. Cladding shall be of brickwork with plastering on both sides. Roof shall be provided with roof water proofing treatment, as specified elsewhere in the Technical specification. In case of control building suitable permanent interconnection shall be provided at appropriate level with the existing respective buildings. All air - conditioned areas, shall be provided with the suspended permanently colour coated aluminium false ceiling system (details specified elsewhere). Adequate aluminium doors and windows shall be provided for natural lighting, ventilation and view.
4.03.00
4.04.00
Pump Houses These shall be of R.C.C. or steel framed structure with columns, beams, slab and foundations etc. cladding shall be of brick work with plastering on both sides. Roof shall be provided with roof water proofing treatment as specified elsewhere. Underground sump and water tanks shall be of R.C.C. Adequate number of doors, Windows and Rolling Shutters shall be provided. Galvanized steel ladder / rung ladder shall be provided for access to the roof level of the pump house and water tanks.
4.05.00
Staircases All floors of transfer houses shall be accessible through staircase. However, for the pump houses, access to the roof will be provided by cage ladder All stairs other than those of M. C. C. rooms and control rooms shall be of steel (minimum 1000 mm wide)and maximum rise should not be more than 180 mm and minimum tread width 250 mm. Stringers shall be of rolled steel channel( minimum ISMC 250 )and tread shall be of steel gratings. Stairs shall be provided with 32 mm dia nominal bore medium duty M. S. pipe hand rail. Handrails (for staircases, around openings, in walkways etc.) shall be of standard weight steel pipe of flush welded constructions, ground smooth using 32 mm nominal bore medium class pipe provided with double rail, top rail about 1.0 metre above platform level and pipe posts spaced not more than 1.5 metres apart. Angle handrail post may be provided when specifically called for in drawings approved by Engineering. Handrails around openings should have toe plates. Smooth uniform curves and bends shall be provided at stair returns and also where so ever required. Posts connected to curb plates shall have a neat closure at the bottom and a 6 mm thick plate neatly welded to posts for attachment to curb plate. All necessary fittings including inner dowels at splices, brackets, belts, bends, flanges and chains, where required shall be plugged and welded. A minimum radius of 3 times the pipe diameter shall be provided at all points of direction changes in the handrail.
Page 7 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Treads and landing shall be suitable for the prescribed loading. The maximum width of openings in gratings shall not exceed 40 mm. The minimum thickness of main bars shall be 6 mm. The usual span of grating will not generally exceed 1.5 meters. Stair case gratings shall be galvanized to grade 610g/m2. Out side stairs to transfer points shall be open type. However sheeting shall be provided at the top. All floors and roof of MCC/Control rooms shall be accessible through staircase. Stairs of control room and M. C. C. room shall be of R. C. C. construction, and minimum 1200 mm wide, maximum rise should not be more than 180 mm and minimum tread with 250 mm. Numbers and arrangement (including enclosures etc.) of stair cases shall be such as to meet the fire safety requirement as per guide lines of statutory regulatory bodies.
4.06.00
Trenches All trenches for cables or any other underground facility as detailed out elsewhere shall be of R. C. C. Cable trenches shall be provided with pre - cast R. C. C. covers / chequered plate cover. Cable trenches as well as pre - cast covers shall be provided with edge protection angles and lifting hooks. All embedments / block outs as required and specified elsewhere in these specifications shall be provided. Proper drainage arrangement shall be provided. Trench pre - cast cover weight shall not be more than 65 Kgs. Trench covers near entry or at road crossings shall be designed for 10 T wheel load at centre. Pre - cast covers shall be designed for central point load of 75 Kgs. R. C. C. cable trenches shall be filled with sand after erection of cables, up to top level and covered with pre - cast R. C. C. covers. For cable trenches outside buildings, top level shall be 200 mm above G. L. Minimum 50 x 50 x 6 mm size angles with lugs shall be provided as edge protection all around cut outs / openings in floor slabs, edges of drains supporting grating/precast RCC covers, edges of R. C. C. trenches supporting pre - cast covers, supported edges of pre - cast cover, treads of RCC stairs.
5.00.00 5.01.00
Drainage & Water Supply Works Drainage System:The drainage arrangements shall be so planned so as to ensure quick disposal of drainage water without stagnation and / or overflow. It is envisaged to clean the conveyor galleries, transfer points, crusher building, penthouse etc. with water periodically. Minimum 4 nos. down comers shall be provided in each transfer house / crusher house. In case of enclosed conveyor galleries, the down comer shall be provided at every trestle location. For enclosed conveyor galleries each down comer shall lead the water / coal slurry to pit (of 2 Cu.M capacity) to allow settling of coal. The water from the pit shall overflow into contractors R.C.C drain, which will lead the discharge finally into existing drain/water body.
Page 8 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS For Non-Drive House/Transfer House each down comer shall lead the water / coal slurry into the peripheral drains (Brick drains with steel gratings provided around the building) which will lead the water / coal slurry to contractors RCC drain and finally to the existing drain/water body. In case of Control rooms and M. C. C. buildings Pump houses, etc, water / coal slurry coming from down comers shall discharge into peripheral drains (Brick drains with steel gratings provided around the building) which will lead the water / coal slurry into contractors R.C.C drain, which will lead the discharge finally into existing drain/water body. Suitable kick plates/Curb beams shall be provided around the floor openings, stair case landings, in the transfer points, and other buildings. Contractors scope shall also include construction of necessary culverts under the rail lines / roads as per railway / I. R. C. standards and approval of Railway culverts from concern Railway authorities.
5.02.00
Internal and external water supply, drainage etc.:The scope for potable water supply includes all distribution systems, tanks, pipes, fittings etc. as required and as described here or elsewhere in these specifications. The scope for service water supply and dust control water supply shall be as described elsewhere in these specifications. For water supply, medium class galvanized mild steel pipes conforming to IS: 1239 shall be used. The scope for drainage of surface water shall include design, layout and construction of drains for and from buildings. Drainage system shall be designed for maximum intensity of rainfall as 75 mm/hr and 60 % runoff coefficient. All buildings (including transfer houses/drive house) shall be provided with open surface brick drains of minimum size of 300 mm width and 300 mm depth all around the periphery. All drains excepting the peripheral drains around the transfer points, crusher house, control / M. C. C. buildings, pumps house etc., shall be of R. C. C. construction. All open drains shall have removable steel grating designed for loads as specified under loading clause. Minimum thickness of grating (Galvanised to 610 gm/m2) shall be 12 mm. However at entry or road crossing 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 shall be provided with edge protection angles and lifting hooks. For rain water down comer and those to be used for conveying water / coal slurry generated from cleaning of conveyor gallery and buildings floors, Galvanised MS pipes conforming to IS: 1239 (for 150 mm NB Medium grade pipes) with welded joints shall be used for MCC buildings, pump houses, penthouse, control rooms. Galvanised steel ERW pipes (273mm OD, 4mm thk) of steel grade Fe330 conforming to IS: 3589 with welded joints shall be used for all TPs, Crusher house, and Conveyor galleries. Galvanising shall be as per IS: 4736. The minimum mass of zinc coating shall not be less than 400 gms/sq.m. as per IS:6745. The zinc coating shall be smooth and shall
Page 9 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS be subjected to testing as per IS: 2633, for uniformity of coating. The zinc coating shall be free from all defects as per IS: 2629. All rain water down comers shall be provided with roof drain heads and complete with shoes bends, junctions, sockets, adapters, brackets and finished with anti corrosive painting over a coat or primer. For design of building drainage system IS: 1742 shall be followed. For sanitary / sewerage pipes above ground, sand cast iron pipes conforming to IS : 1729 with leak proof lead joints. For underground drain pipes, minimum class NP - 2 pipes conforming to IS: 458. At road crossings, concrete pipes of class NP 3 conforming to IS: 458 and at rail crossing R.C.C. box culvert to be provided. For sewerage below ground stoneware pipes conforming to IS: 651 with concrete bedding and haunch.
6.00.00 6.01.00
COLOUR COATED AND OTHER SHEETING WORK For floor/roof decking, troughed permanently colour coated metal decking sheet, shall conform to any one of the following (i) of steel with zinc coated to class Z275 with minimum bare metal thickness ( i.e. excluding the thickness of coating and painting) of 0.8mm of grade G250 as per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per EN 10326. of steel with zinc coated to class Z275 with minimum bare metal thickness ( i.e. excluding the thickness of coating and painting) of 0.6mm of grade G350 as per AS1397 / grade SS340 class 4 as per ASTM A653M / grade S350GD as per EN 10326 / grade G550 as per AS1397 / grade SS550 as per ASTM A653M / grade S550GD as per EN 10326.
(ii)
6.02.00
For roofing & side cladding, troughed permanently colour coated sheets (internal or external) shall conform to any one of the following (i) of steel with zinc coated to class Z275 with minimum bare metal thickness (i.e. excluding the thickness of coating and painting) of 0.6mm of grade G250 as per AS1397 / grade SS255 as per ASTM A653M / grade S250GD as per EN 10326. of steel with aluminium-zinc alloy coated to class AZ150 with minimum bare metal thickness (i.e. excluding the thickness of coating and painting) of 0.5mm of grade G350 as per AS1397 / grade SS340 class 4 as per ASTM A792M / grade S350GD as per EN 10326. of steel with aluminium-zinc alloy coated to class AZ150 with minimum bare metal thickness (i.e. excluding the thickness of coating and painting) of 0.4mm of grade G550 as per AS1397 / grade SS550 as per ASTM A792M / grade S550GD as per EN 10326.
(ii)
(iii)
Page 10 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Steel shall be colour coated with total coating thickness of 35 microns (nominal) dry film thickness (DFT) comprising of Silicon Modified Polyester paint (SMP with silicon content of 30% to 50%) or Polyester paint, of 20 microns (nominal) SMP or polyester paint on one side (exposed side) over 5 micron (nominal) primer coat and 5 micron (nominal) SMP or Polyester paint over 5 micron (nominal) primer coat on other side,(SMP and Polyester paint shall conform to Product type 4 of AS/ANZ 2728. Coated surface shall be provided with a protected guard film (polyethylene) of about 40 microns to avoid any damage to the coating during handling. Sheet shall be of approved profile, sectional properties, colour and shade. Chemical composition of troughed permanently colour coated metal decking sheets and metal sheet for roofing and side cladding, shall conform to the provisions of the same reference code to which the mechanical properties conform to. Mechanical properties shall be confirmed by relevant tests. Tolerance on minimum BMT (bare metal thickness) shall be (-)0.00mm and (+)0.06mm. Plain permanently colour coated steel metal sheets for ridge and hips, flashings, trimmings, closure for vertical and horizontal joints, capping etc shall confirm to the same requirements as those of troughed permanently colour coated metal sheet for roofing and side cladding. For metal decking the sectional modulus and moment of inertia of troughed profile per meter width shall be so as to limit the deflection of sheets to span/250 for two span condition. The sectional modulus and moment of inertia of troughed profile shall be computed as per the provisions of IS:801 for satisfying the deflection and strength requirements. For metal roofing and side cladding, the sectional modulus and moment of inertia of troughed profile per metre width shall be such that the deflection of sheets is limited to span/250 for two span condition. The sectional modulus and moment of inertia of troughed profile shall be computed as per the provisions of IS: 801 for satisfying the deflection and strength requirements. No increase in allowable stress is permissible under wind load condition. Maximum spacing of the fasteners shall be 390 mm c/c along the length of beams/purlins / runners. However exact spacing shall be as per the design done by the bidder for the fasteners considering the wind load, self load and other associated loads. Minimum diameter of the fastener shall be 5.5 mm and at least 3 nos. of fasteners shall be used per sheet. Sealant used for cladding shall be butyl based, two parts poly sulphide or equivalent approved, non-staining material and shall be flexible enough not to interface with fit of the sheets. Filler blocks as a trough filler shall be used to seal cavities formed between the profiled sheet and the support or flashing. The filler blocks shall be manufactured from black synthetic rubber or any other material approved by the Engineer. For insulation of cladding, mineral wool conforming to IS: 8183 shall be used. The density shall be 32 or 48 kg. /Cu.M. for glass or rock wool respectively. The nominal thickness of insulation shall be 50mm.
TECHNICAL SPECIFICATIONS SECTION VI, PART-B BID DOC. NO.:CSSub-Section - IIID-01 CHP CIVIL WORKS Page 11 of 46
6.03.00
6.04.00 6.05.00
6.06.00
6.07.00
6.08.00
6.09.00
6.10.00
6.11.00
6.12.00
6.13.00
CLAUSE NO.
6.14.00
Special coated fasteners shall be used conforming to corrosion resistant class 3 as per AS3566 and shall be tested to 1000 hours salt spray test. The dimensional tolerances of profiled sheets for sheet length, sheet cover width, straightness, squareness, depth of profile, radius and angle of curved sheets, ripple of side lap, etc. shall be as per Manufacturing tolerances for profiled metal roof and wall cladding & roofing by The Metal Cladding & Roofing Manufacturers Association Limited, UK. Sheets shall be laid with a minimum overlap of 15 cm at the ends and side laps shall be of one trough length subject to a minimum of 50 mm, having a proper water tight arrangement. The minimum lap of sheets with ridges, hips and valleys shall be 15 cm measured at right angles to the line of the ridge, hip and valley respectively. Metal decking sheets shall be laid over the supporting beams/purlins with a minimum bearing of 50 mm and end projection of 75 mm at lap joints. Flashings, cappings, trimming, closure for vertical/horizontal joints, ridge and hips etc. shall be provided with a minimum lap of 15 cm. The lapping of sheets shall provide the dust free, airtight enclosure. If required, this may be achieved by using 2-parts polysulphide sealing compound or butyl tape. Distorted, blemished or water stained sheets shall not be used. Side and end laps of the sheets shall be made weather proof by securing them with the fasteners not less than 4.8mm dia with 2.0 mm thick neoprene washer. Maximum spacing of the fasteners should not exceed 500 mm. Precautions shall be taken during the erection of the sheets to ensure that partially erected sheets are protected from damage at all times and particularly during inclement weather. Sheets shall be laid over the supporting purlins/runners with a minimum bearing of 50 mm and end projection of 75 mm at lap joints. Side cladding for Transfer points & conveyor galleries(including roof) shall have single skin troughed profile permanently colour coated sheets. However, roof of transfer points shall be provided with troughed profile permanently colour coated sheet on outside and plain permanently coated sheet on inside with 50mm thick mineral wool insulation in between the two sheets. The polycarbonate sheet to be used for cladding and glazing purpose in conveyor galleries shall have toughed profile to match with the metal cladding profile. Minimum 2.0mm thick fire retardant and UV resistant polycarbonate clean sheet of GE plastic or equivalent approved make shall be used. The polycarbonate sheet shall be installed along with the metal cladding so as to have a watertight lapping arrangement. Suitable detailing shall be made to cater for the thermal expansion. IS:14434 to be referred for other details. Polycarbonate sheet minimum 6mm thick multi (twin) wall fire retardant (Continuous use under temperature 100oC), impact resistant and ultraviolet resistant sheet shall be provided (as glazing) in transfer houses etc.
6.15.00
6.16.00
6.17.00
6.18.00
6.19.00 6.20.00
6.21.00
6.22.00
6.23.00
6.24.00
Page 12 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Roof Details Roof slab shall be minimum 150 mm thick and shall have minimum 10 dia HYSD reinforcement bars placed at 200 mm center both ways at top and bottom. For efficient disposal of rain water, the run off gradient for the roof shall not be less than 1: 100. This gradient can be provided either in structure or subsequently by screed concrete M-15 (using 12.5 mm coarse aggregate) and / or cement mortar (1: 4). However, minimum 25 mm thick cement mortar (1: 4) shall be provided on top to achieve smooth surface. 900 mm high and minimum 100 mm thick R. C. C. parapet wall shall be provided over roofs of all buildings. Parapet wall shall have suitable coping. External face of parapet wall of the buildings provided with metal cladding shall also be finished with metal cladding of design and colour as per approved architectural drawings. Junction of roof and parapet shall be provided with 150 x 150 mm size concrete fillet. Drain level shall be provided with 45 x 45 cm size khurras having minimum thickness of 30 mm of M-15 concrete over PVC sheet of 1 m x 1m x 400 micron and finished with 12 mm 1 : 3 cement : sand plaster. Roofs of all transfer houses, crusher houses, control rooms, M. C. C. rooms, penthouse etc., shall have roof water proofing treatment. Roof water proofing treatment shall be as follows: 1) Application of polymerised mastic over the RCC roof to achieve smooth surface as primer coat. 2) Application of high solid content liquid applied urethane based elastomeric water proofing membrane, over the primer coat, to give uniform joint less dry film thickness of minimum 1.5 mm (as per ASTM C 836 and C 898). 3) For efficient disposal of rain water, the run off gradient for the roof shall not be less than 1: 100. This gradient shall be provided by screed concrete M-15 (using 12.5 mm coarse aggregate) and / or cement mortar (1: 4) over the elastomeric water proofing membrane with 25mm thick cement mortar (1:4) topping. 4) Wearing course at top, shall consist of 25 mm thick P. C. C. (M-15) cast in panels of maximum 1.2 x 1.2 m size and reinforced with 0.56 mm diameter galvanized chicken wire mesh and sealing of joints using sealing compound / elastomeric water proofing membrane. Pathways for handling of materials and movement of personnel shall be provided with 22 mm thick chequered cement concrete tiles as per IS : 13801 for a width of 1000 mm in place of P. C. C.
7.00.00
8.00.00
Floors and Grade level details The floor slabs shall be minimum 150 mm thick and shall have minimum 10 dia HYSD reinforcement bars placed at 200 mm center both ways at top and bottom Floors of transfer points/drive house shall have cross slope of not flatter than 1: 80, towards the floor washing drainage outlets, for efficient drainage. For ground conveyor & crusher house slope shall be 1:100. Chequered plates (used for floors, walkways etc.) shall be minimum 6 mm thick o/p or as indicated on drawings. The chequered plate pattern shall be approved by
Page 13 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Employer / Engineer. Mild steel flats/angles of suitable size shall be welded to the bottom portion of chequered plates at a designed spacing to stiffen chequered plates suitably. Chequered plates shall be fixed by staggered welding of suitable size. Floors of trenches shall have integral finish to concrete base. Toe guard of size 100 x 6 mm shall be provided at various openings provided in floors e.g. around stair case openings, chute openings and other similar cutouts. For conveyor walkways, angle runner to act as toe guard shall be provided. All along the periphery of R. C. C. floors (where no brick masonry walls are provided) shall be provided with one brick thick 300 mm high brick wall and 700 mm high steel hand rails all around over this brick work. The grade slab shall consists of 230 mm thick rubble soling (63 mm downgraded hard stone aggregate as per IRC specification, watering and compaction to minimum of 90% Standard Proctor density, including filling the interstices of stone aggregates with sand), over well compacted earth, overlaid by 75 mm thick P. C. C. M-7.5 and 100 mm thick R. C. C. of grade M-20 with minimum 8 mm dia bars placed at 200 mm C / C in either direction respectively. There will be minimum 50 mm thick metallic hardener finish over the R. C. C. slab. All buildings (including transfer houses/drive house) and ground conveyors shall be provided with 750 mm wide plinth protection all around. It consists of 50 mm thick P.C.C. M-20 grade with 12 mm maximum size aggregate over 200 mm thick stone soling using 40 mm nominal size rammed, consolidated and grouted with fine sand. An area of 5 m width all round the transfer houses /drive house shall be paved. This paving will be in addition to plinth protection. The paving construction shall be as per specifications for the grade slab at ground level. However, 50 mm thick metallic hardener finish is not required to be provided in paved area. Plinth level of all buildings shall be kept at least 500 mm above the finished grade / formation level.
9.00.00
Brickwork and allied masonry works All brick walls shall be non - load bearing in-filled panel walls. All brickwork shall be designed as per Indian Standards and shall be plastered on both faces. All external walls shall be minimum one brick thick in 1: 6 cement: sand mortar. Brick walls shall be provided with 12 mm and 18 mm thick 1: 6 cement: sand plaster on smooth and rough face of the brick work respectively. Bricks to be used in brickwork shall be of minimum Class designation 50. Brickwork cladding for various structures shall be so provided that there is a clear gap of 40 mm between inside face of external brick wall and outside face of column flange. Structural steel wall beams supporting brickwork shall be suitably encased with plaster or 1: 2: 4 concrete as the case may be. In case of box type steel beam, encasement shall be done with cement sand plaster in specified thickness and proportions over G. I. wire netting of 0.9 mm thickness.
Page 14 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Parapets, chajjas, windows and door heads, architectural faces, fins etc. shall be provided with drip course in 1 : 4 cement sand mortar. 50 mm thick Damp proof course shall be provided at plinth level for all brick wall. All R. C. C. ceilings shall be rendered smooth and finished with whitewash unless otherwise specified. Ceiling of control rooms, M. C. C. rooms (except areas provided with false ceiling) shall be provided with 6 mm thick plaster.
10.00.00
Earthing Mat 40 mm Dia MS Rods as earthing mat, placed at a distance of 1.0M away and at depths between 0.60M and 1.00M shall be supplied and laid all around the periphery of buildings, structures, and outdoor equipment, as per the approved drawings. Risers of 40 mm Dia MS Rods and connecting to the above Earthing mat shall also be supplied and laid in position by the Contractor, as per the approved drawings. Risers shall be laid up to a height of 300 mm above the local Ground level, at each of the columns of the buildings on outside of the buildings, and minimum 2 (Two) numbers for structures and outdoor equipment. The contractor also supply and lay necessary number of 3.0 M deep vertical 40 mm Dia MS Rods Earthing electrodes and connecting them to the Earthing mat, as per the approved drawings and the supplying and laying of 40 mm Dia MS Rods for connecting the Contractor's earthing mat with the Employer's earthing mat separately at two locations. 11.00.00 Fencing
Fencing with toe wall and steel gates shall be provided around the transformers. Fencing shall comprise of PVC coated GI chain link fencing of minimum 8G (including PVC coating) of mesh size 75 mm and of height 2.4 m above the toe wall. The diameter of the steel wire for chain link fence (excluding PVC coating) shall not be less than 12G. Fence posts shall be of pre cast R. C. C. of minimum M20 grade. All corner posts will have two stay posts and every tenth post will have transverse stay post. Suitable R. C. C. foundation for the post and stays shall be provided based on prevailing soil conditions. Gates shall be sturdy with locking provisions. Toe walls of brick masonry shall be provided between fence posts all along the run of the fence with suitable foundation. Toe wall shall be minimum 200 mm above the formation level with 50 mm thick P. C. C. coping (1: 1. 5: 3) and shall extend minimum 300 mm below the formation level. Toe wall shall be plastered on both sides and painted with two coats of cement paint of approved colour and shade. Toe wall shall be provided with weep holes at suitable spacing. 12.00.00 LOADING For consideration of loads on structures IS : 875 - Code of practice for structural safety of buildings shall be followed. In addition to the dead load, live load, equipment load (including impact / vibration). Temperature loads etc. various loading conditions arising due to operation and maintenance of equipment shall be considered in the design. The structure and equipment shall also be designed for seismic loads as per the Criteria for Earthquake Resistant Design of Structures and equipment" and the Criteria for Wind Resistant Design of Structures and equipment" specified in the Annexure A and B respectively in Civil Section, whichever is governing. Wind and seismic forces shall not be considered to act simultaneously.
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION VI, PART-B BID DOC. NO.:CSSub-Section - IIID-01 CHP CIVIL WORKS Page 15 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS The following minimum live loads shall be adopted for the design of various structures. If actual expected load is more than the specified load, then actual load is to be considered.
a ) Roofs
150 Kgs. / Sq. M. for accessible roofs and 75 Kgs. / Sq. M. for non accessible roofs. In addition to this coal dust load (Dead load) of 150 Kgs. / sq. m. on flat roofs & 75 Kgs. / sq. m. on inclined roofs shall also be considered. 500 Kgs. / Sq. M. 500 Kgs. / Sq. M. 200 Kgs. / Sq. M. 400 Kgs. / Sq. M.
b ) R. C. C. floors c ) Stair and balconies d ) Toilet rooms e ) Chequered plate floors
f ) Walkways ( including walkways in 300 Kgs. / 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 members are to be checked for supporting fire fighting pipes/ Service water pipes. Tentative locations and diameter for pipes are shown in Tender Drawing.
h ) Road Culverts and its allied 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 also be considered for design. Covers for channels & trenches, shall be designed for a live load of 0.4T Sq. M. and loading as mentioned under clause in trenches, whichever is critical. other In addition to earth pressure with a type surcharge of 2T / Sq. M. (or surcharge due to Railway loading whichever is critical for Railway load bearing
Sub-Section - IIID-01 CHP CIVIL WORKS Page 16 of 46
j ) Covers for trenches / channels
k ) Sumps and underground structures
tanks and basement
CLAUSE NO.
TECHNICAL REQUIREMENTS structures etc.) and sub - soil water pressure etc. These are also to be designed for the following conditions : i) Water / liquid inside and no earth outside (applicable only to such structures which are liable to be filled up with water or any liquid ). ii ) Earth with surcharge outside and no water / liquid inside iii ) For underground (basement) structures protection against buoyancy during execution and after execution shall be ensured without superimposed loadings with minimum factor of safety of 1.2 against buoyancy.
l ) Unit weight of coal shall be taken as 1100 Kgs. / cum. for design purposes.
If the erection load is higher than the specified live loads on any floor or part thereof, then the erection loads are to be considered for the design. Permissible increase in stresses of materials and bearing pressure of soil due to wind load or seismic load shall be as per relevant I. R. S. and I. S. code. 13.00.00 DESIGN CRITERIA The design of all R. C. C. structures shall be carried out as per code of practice for plain and reinforced concrete for general building construction, IS : 456 ( latest ). The steel structures shall be designed and fabricated as per code of practice for use of structural steel in general building construction, IS : 800 ( latest ) and other relevant IS Standards. Minimum size of the angle section to be used as structural members shall be 50 X 50 X 6. Minimum weld size shall be 6 mm. Connections shall be designed for 70 % of shear capacity of the member or the actual shear force, whichever is higher. The building shall conform to local bye - laws, rules and regulations for industrial buildings and also B. I. S. publications, SP 32 and 41. Slotted holes shall not be assumed to act as expansion joint for relieving of stresses and suitable bearings shall be provided at the supports. All gallery supporting trestles shall be so proportioned that the transverse deflection of gallery due to wind / seismic load should not exceed trestle height / 1000 as stipulated in IS: 11592. This deflection condition shall be strictly followed. Peak wind speed method shall be considered for checking the transverse deflection.
Page 17 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS The transfer house structures shall be so designed that transverse deflection at places where conveyor galleries meet, should be equal to the respective transverse deflection of conveyor supporting trestles. Stresses for all CHP structures shall be checked for the higher of the forces obtained from gust factor method and the peak wind speed method. The permissible vertical deflection for beams supporting drive machinery shall be restricted to span / 500 and for other beams it shall be within span / 325. Horizontal bracing system shall be provided at floor levels around the openings. Shear force in steel columns shall be transferred to the pedestals / foundations exclusively either through foundation bolts or the shear key arrangement. For design of liquid retaining structures, IS : 3370 ( Part - I to IV ) ( latest ) shall be followed. Face of the structure in contact with liquid shall be designed as un cracked section. For design of R. C. C. pipes for culverts, latest editions of IS : 458, IS : 783 should be followed. For design of all underground structures / foundations, ground water table shall be assumed at the formation level ( i. e. the adjoining ground level ). Design of masonry walls shall be made as per IS : 1905. Civil task drawing indicating various equipment loading and supporting arrangement and floor loads to be submitted along with the design calculation. For metal roofing and side cladding, the spacing of purlins/runners shall be such that the deflection of metal sheet used is limited to span/250 under adverse loading condition. Minimum reinforcement shall be provided at the top face of the footing, even if, no reinforcements are required as per design.
14.00.00
CONCRETE All R. C. C. works to the done under this specification, unless specified otherwise shall be design mix concrete. Minimum grade of concrete for various structures shall be as follows:
a)
M30 -
For underground / sub structural R. C. C. work (other than railway load bearing structures).
b)
M25 -
For R. C. C. superstructure works including ground floor slabs, trenches & drains.
Page 18 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Minimum 75 mm thick P.C.C M-7.5 shall be provided as mud mat below all foundations. For concreting of underground structures requiring water tightness, plasticizer cum water proofing admixture shall be added to the concrete mix. Both coarse and fine aggregates shall conform to IS: 383 for concrete, shotcreting etc. unless otherwise mentioned.
15.00.00 15.01.00
Excavation Details Excavation in soil Excavation for foundation shall be to the bottom of lean concrete and as shown on drawing or as directed by the Engineer. The bottom of all excavations shall be trimmed to required levels and when excavation is carried below such levels by error, it shall be brought back to the specified level by filling with concrete of nominal mix 1 : 3 : 6 (cement: coarse sand: 40 mm down aggregates ), as directed by the Engineer. The Contractor shall ascertain for himself the nature of materials to be excavated and the difficulties, if any, likely to be encountered in executing this work. Cofferdams, sheet piling, shoring, bracing to maintain suitable slopes, draining etc. shall be provided and installed by the contractor, to the satisfaction of the Engineer. Surplus excavated materials shall be disposed off by the contractor at locations up to a lead of 5 kms from the plant boundary wall as directed by the engineer. The Contractor shall have to constantly pump out any water collected in excavated pits and other areas due to rain water, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, concreting, Backfilling is completed. The Contractor shall remove all slush/muck from the excavated areas to keep the work area dry. The Contractor, if required, shall employ sludge pumps, for this purpose. For other details, excavation clauses as given in Sub-Section III-D-02 are to be referred.
15.02.00
Excavation in rock For the work of excavation in rock, Contractor shall engage specialised agency having experience of excavation in rock involving wedging and blasting. The agency shall be subject to approval of Engineer and the Contractor shall furnish details of relevant experience in support while seeking approval for the agency. Blasting shall be resorted to only with the written permission of the Engineer. All the statutory laws, (Explosives Act etc.) rules, regulations, Indian Standards etc. pertaining to the acquisition, transport, storage, handling and use of explosives etc. shall be strictly followed. The contractor shall obtain Licenses from Competent Authorities for undertaking blasting work as well as for procuring, transporting to site and storing the explosives
Page 19 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS as per Explosives Act. The Contractor shall be responsible for the safe transport, use, custody and proper accounting of the explosive materials. Surplus excavated materials shall be disposed off by the contractor at locations up to a lead of 5 kms from the plant boundary wall as directed by the engineer. The Contractor shall have to constantly pump out any water collected in excavated pits and other areas due to rain water, springs etc. and maintain dry working conditions at all times until the excavation, placement of reinforcement, shuttering, concreting, backfilling is completed.
15.03.00
De-watering of Deep Excavations For deep underground structures like track hopper, machinery hatches, tunnels and underground transfer houses, requiring open excavation with extensive de - watering, completely dry working conditions during excavation, shuttering, placement of reinforcement, concreting, water proofing of structures, backfilling and any other operation shall be maintained by suitable de - watering method of suitable capacity.
15.04.00
Backfilling, Disposal and Stacking of materials Backfilled earth shall be compacted to minimum 90 % of the standard proctor density at OMC. Sand filling shall be compacted to minimum 80 % of the relative density. Also refer Sub-section III D-02 for more details. However, the backfill under the rail lines and roads shall be compacted to minimum 95 % of the standard proctor density at OMC unless otherwise stated by rail Authorities. The contractor is required to excavate upto any depth as shown on the drawings or as directed by the Engineer. Lifting of excavated materials shall be done either by manual or mechanical or both means if called for by the Engineer. The disposal / stacking areas for excavated materials shall be indicated by the Engineer. The carriage of excavated materials shall be done by the methods mentioned below: The excavated materials shall be carried beyond the initial lead of 50 m but upto 500 m by manual / animal labour or by mechanical means. If directed by the Engineer this material shall be used directly for filling purposes. For leads exceeding 500 m the Contractor shall transport the excavated materials by mechanical means only and as directed by the Engineer. The Contractor may be allowed to carry materials through Kuccha roads. Providing and maintaining of the Kuccha roads shall be the responsibility of the Contractor. The transported material shall be neatly stacked as directed by the Engineer. Some excavated materials required for filling purposes, may have to be carried upto a lead of 500 m and stacked as per instructions of the Engineer. Excavated materials carried beyond 500 m shall normally be for disposal purpose only. Double handling of materials shall be avoided as far as possible. However, depending on site condition
Page 20 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS excavated materials carried beyond a lead of 500 m may also be required to be brought back for filling purpose. Materials to be used for filling purpose shall be stone, sand or other inorganic materials and they shall be clean and free from shingle, salts, organic matter, large roots and excessive amount of sod, lumps, concrete or any other foreign substances which could harm or impair the strength of the substances in any manner. All clods shall be suitably broken to small pieces. When the materials are mostly rock boulders, these shall be broken into pieces not larger then 150 mm size. Sand used for filling shall be clean, medium grained and free from impurities. Fines less than 75 microns shall not be more than 20%. In any case, the materials to be used for filling purposes shall have the prior written approval of the Engineer. In case the materials have to be brought from pits / quarries, then it shall be the Contractors responsibility for identification of such quarry areas, obtaining approval from their use from concerned authorities, excavation / quarrying loading and carriage of such material, unloading and filling at specified locations. The Contractor shall pay any fees, royalties etc. that may have to be pain for utilisation of borrow areas.
16.00.00
GALVANISING All burrs and irregular edges of the structural steel members to be galvanised shall be ground smooth before galvanising. Purity of Zinc to be used for galvanising shall be 99.5 % as per IS : 209 ( latest edition ). The weight of the zinc coating shall be at least 610 Gms. / m2 unless noted otherwise.
18.00.00
Architectural Features All architectural features of buildings like control rooms, crusher houses, M. C. C. rooms, transfer houses and conveyor galleries etc. shall be detailed by contractors qualified architect. Necessary projections, fins etc. in addition to the minimum specified elsewhere in this specification shall be provided as required. The Contractor for Employers approval shall submit detailed architectural drawings along with colour schemes. Nothing extra shall be payable for any changes required while getting the drawings / schemes approved and for executing the same. In case structural column base plates are proposed below the floor level, the same shall be encased with adequate cover up to the finished floor level with minimum M 20 grade concrete. Dowels shall be left from the pedestals to be lapped to the skin reinforcement of the encasing.
18.01.00
Glazing Window glazing for various locations shall be as below: (i) In transfer houses, crusher house and pump houses etc:
Page 21 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS 6mm. thick toughened float glass & Polycarbonate sheet (Details described elsewhere). (ii) In Switchgear / M. C. C. buildings (a) In air conditioned (A / C) areas: Composite double glazing with clear float glass of 6 mm thick on one side and 6mm thick tinted glass on the other side hermetically sealed and separated by 12 mm thick gap for thermal insulation at partition of A / C and non A / C areas. Composite double glazing with clear float glass of 6 mm thick on inside and 6mm thick toughened reflective glass hermetically sealed and separated by 12 mm thick gap for exterior windows. (b) In toilets: Frosted glass of minimum thickness 6 mm. (c) In other areas: Toughened glass of minimum thickness 6 mm The above mentioned glass thickness are bare minimum only and actual thickness will depend on the panel size of the glazing to be provided.
18.02.00
False Ceiling All air - conditioned areas, shall be provided with the suspended permanently colour coated aluminium false ceiling system with corrosion resistance aluminium alloy panels of minimum thickness 0.5 mm. The suspension system for false ceiling shall be as per manufacturers guidelines. Additional hangers and height adjustment clips shall be provided for returns air grills, light fixtures, A. C. ducts etc. Under deck insulation shall be provided on the ceiling (underside of roof slab) and underside of floor slab of air - conditioned areas depending upon the functional requirements. This under deck insulation shall consist of 50 mm thick mineral wool insulation mat conforming to IS: 8183 having a density of 32 kg/cum for glass wool or 48 kg/cum for rock wool, backed with 0.05mm thick aluminium foil and 24G x 25 mm mesh wire netting and shall be fixed to the ceiling with 14G wire ties.
18.03.00 Acid / Alkali Resistant Lining Battery Room Acid, alkali and oil resistant high build self smoothing, seamless epoxy resin floor finish, on horizontal and vertical surfaces, at all levels, for all types of works, including all labour, material, equipment, scaffolding, handling, transportation, preparation of surface, application of epoxy based primer coat, of approved colour,
Page 22 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS quality and make to give minimum thickness of 300 micron (in two coats) and dado upto 1200 mm, etc., all complete, shall be provided.
18.04.00 FINISHING SCHEDULE The contractor's scope also includes all doors, windows, glazing, rolling shutters, finishes, damp proofing, inserts, anchor bolts, embedments, stairs, nosing, railings, toe - guards, ladders, edge protection angles, etc. The Contractor shall adhere to the finishing schedule as given. 18.04.01 Flooring I. P. S. (cement concrete flooring) with metallic hardener topping shall be provided for all floors in track hopper, wagon tipplers, reclaim hopper, transfer houses, including ground floors of transfer houses, ground conveyors, operating floor of pump houses, M. C. C. rooms, cable vault / cable spreader rooms, maintenance and unloading areas, general storage areas and all other areas in plant buildings where heavy duty flooring is required. Heavy Duty Ceramic Tiles (matt finish), 300mm x 300mm x 7mm of approved colour shade & finish, shall be provided for floors of toilets, pantry, etc with 300 x 200mm designer wall ceramic tiles for dado in toilets & pantries. Vitrified ceramic tile (mirror polished) 600 x 600 x 10mm thick shall be provided for floors of office rooms, conference room, laboratories, control room & control equipment room and for dado upto false ceiling. Well polished marble stone (20mm thick) shall be provided for staircases, passages, lobbies and general circulation areas. The nominal total thickness of floor finish shall be 50 mm i.e. under bed and topping. The floor shall be laid on an already laid and matured concrete base. Sunken R. C. C. slab shall be provided in false flooring area and toilet area so as to keep the finished floor level of these areas same as that of the surrounding area. Wherever specified metallic hardener topping shall be 12 mm with ordinary grey cement. Paving details shall be similar to grade slab excluding metallic hardener. Skirting in general shall be 150 mm high. Dado in toilets and pantries shall be up to 2.1 m height from finished floor level. Skirting and dado shall match with the floor finish. 18.04.02 Interior Wall / Ceiling Finish For all air conditioned control room, 600 x 600 x 10mm th. Vitrified ceramic tile dado shall be provided upto false ceiling and for other air - conditioned areas acrylic emulsion paint of approved make and shade over 2 mm thick plaster of paris punning shall be provided.
CLAUSE NO.
TECHNICAL REQUIREMENTS For toilets and pantries minimum 300 x 200 mm thick decorative coloured ceramic tiles of approved make and shade with approved pattern up to 2.10 m. height from finished floor level shall be provided. Oil bound distemper over plaster of paris punning above 2.10 m height shall be provided. For all other areas oil bound distemper ( IS : 428 ) of approved shade over 2 mm thick plaster of paris punning shall be provided. For battery room and other areas coming in contact with acid / alkali fumes, chemical resistant chlorinated rubber paint shall be provided above 2.1 m height. Up to 2.1 m height from finished floor level acid alkali resistant epoxy resin finish shall be provided as specified elsewhere. All R. C. C. ceilings shall be finished with acrylic distemper.
18.04.03
Exterior Finish Permanently colour coated M. S. / High tensile steel metal cladding ( non - insulated ) of approved colour combination shall be provided for transfer points, conveyor galleries, elevator shafts, and parapet walls of buildings where metal cladding is specified. The cladding sheets shall be coated with silicon modified paint as specified elsewhere. Solvent based acrylic exterior paint in combination with textured paint with 2.5mm stone chips in the ratio of 3 : 1 shall be provided for the under mentioned areas : (a.) All buildings with R. C. C. framework unless specified otherwise in this specification. (b.) Brick work in the lower portion of metal cladding. (c.) Fire walls
(d.) Projections and facia : R. C. C. parapets ( excepting parapets of buildings where metal cladding is specified ) (e.) Exterior brick walls. 18.05.00 18.05.01 DOORS, WINDOWS AND ROLLING SHUTTERS. Doors and Windows All doors, windows and ventilators of control room building, S and T control room and M. C. C. buildings shall have Electro colour coated (anodised) aluminium frame work with glazing. All doors of office and toilet areas shall be of factory made prelaminated particle board (M D F exterior grade). All other buildings shall have steel doors, windows and ventilators. Single glazed panels with aluminium framework shall be provided as partition between two air - conditioned areas wherever clear view is necessary.
Page 24 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Coal conveyor galleries shall have steel windows of openable type. The window shutters shall be provided with M. S. louvers. All steel doors shall consist of double plate flush door shutters. The door shutter shall be 45 mm thick with two outer sheets of 18 G rigidly connected with continuous vertical 20 G stiffeners at the rate 150 mm centre to centre. Side, top and bottom edges of shutters shall be reinforced by continuous pressed steel channel with minimum 18G. The door shall be sound deadened by filling the inside void with mineral wool. Doors shall be complete with all hardware and fixtures like door closer, tower bolts, handles, stoppers aldrops, etc. Windows of coal galleries shall be provided with welded wire fabric of 1.6 mm thick wire as per IS: 4948 and 12 mm x 30 mm mesh size. Wherever functionally required rolling shutters shall be provided and these shall be either electrically operated or manually operated or with geared arrangement. In transfer points, windows near floors shall be steel and openable types. The window shutters shall be provided with MS louvers. Windows / ventilators at higher level can be of steel with fixed glazing. All openable windows shall be provided with suitable stays. All windows and ventilators on ground floor of all switchgear and M. C. C. buildings shall be provided with suitable anodized aluminium grill. Fire - Proof doors with panic devices and all necessary fixtures shall be provided at all fire exit points as per the recommendations of statutory regulatory bodies These doors shall generally be as per IS : 3614 ( Part I and Part II ) meeting TAC requirements. Fire rating of the doors shall be as per requirements of statutory regulatory bodies. However minimum rating shall be 2 hours. These doors shall be double cover-plated types with mineral wool insulation. Hollow extruded section of minimum 2 mm wall thickness as manufactured by INDAL or equivalent shall be used for all aluminium doors, windows, and ventilators. All doors should have opening as indicated in the drawings. Doors and windows on external walls of the buildings having brick enclosures i.e. enclosure other than with permanently colour coated steel sheet cladding, shall be provided with sunshade over the openings with width 600 mm more than the opening width. Projections from the wall for the sunshade shall be 500 mm over window openings and 500 mm over door openings. Minimum size of door provided should be 2.1 m high and 1.2 m wide, except for toiler rooms, where door may be 0.75 m wide. All doors ( other than those in W/C and urinal area ) shall be double plate flush door shutters. For W/C and urinals area, wooden panel doors shall be provided. Area of windows shall be at least 10 % of the floor area of the respective building. The area of translucent polycarbonate sheet panels shall also be at least 10 % of the floor area of the respective building. Monorail doors shall be provided with steel stays / chains etc for convenient operation of the shutters. The louvre blade shall be Z shaped and made out of 18G sheets in EZ7 steel frames. The frames shall be of ISMC 100.
Page 25 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Rolling Shutters Rolling Shutters/ grills shall be with motor drives, gear arrangement including all accessories and shall conform to IS: 6248. All electrical work shall be in strict accordance with the relevant Indian Electricity Rules. After installing the shutters, the Contractor shall test the performance of the shutter in presence of the Engineer. The shutters shall be smoothly operable under all ambient conditions. All control and locking devices shall give fault free performance.
18.05.02
19.00.00
PAINTING Painting of all steel structures, including seal plates, hand rails, steel doors & windows, ventilators, louvers, Rolling Shutters Stair Cases (except gratings), etc. shall be with paints as per following:
19.01.00
Materials Zinc silicate primer (minimum 75 micron Dry Film Thickness - DFT) shall be inorganic (Ethyl) self curing high built (Solid by volume minimum 60%) formulation as per BS : 5493 (Inorganic Zinc rich systems). Intermediate (Under) coat (minimum 75 micron DFT) shall be of polyamide cured titanium di-oxide / micaceous iron oxide pigmented high performance (solid by volume minimum 60%) epoxy coating as per BS : 5493 ( two pack chemical resistant under coats). Finish coat (minimum 75 micron DFT) shall be of polyamide cured colored pigmented high performance (solid by volume minimum 60%) epoxy coating as per BS: 5493 (two pack chemical resistant finishes). Final finish coat (minimum 25 Micron DFT) shall be of polyurethane colour pigmented (solid by volume minimum 40%) as per BS: 5493 (two pack chemical resistant finishes). All paints including primer shall be of reputed brand / manufacturer and as approved by the engineer.
19.02.00
Preparation of Surface The surfaces shall be blast cleaned to near white metal surface (Sa 2 ) i.e. 2nd quality (requiring at least 95% of the surface completely cleaned) as given in BS : 4232 . For blast cleaning shot blasting shall be used. Approved type of abrasives shall only be used for blast cleaning of steel surfaces by shot blasting. Suitable enclosure shall be provided to carry out the blast cleaning operation. If required prior approval from the factory inspector / pollution control board etc. shall be obtained regarding the method of blast cleaning and abrasives used therein. Immediately after blast cleaning of the steel surfaces, primer coat shall be applied onto the surfaces.
Page 26 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Application of paint The contractor shall submit the total painting scheme and works shall be started after the approval of the scheme, from the engineer. Painting works shall be carried out on structural as per the approved scheme. The total painting scheme to be submitted to the engineer shall include the following: i) Method of blast cleaning giving the details and sizing of various equipment required, abrasive used, enclosure provided to avoid contamination of the adjoining area, expected productivity on an eight (08) hour shift working etc. Arrangement of airless spray with the equipment rating. Drying time to be allowed before the application of subsequent coat. Recommended paint for primer, intermediate (under) coat, finish coat and final finish coat with their brand name and designation, considering the requirements of BS : 5493 for long range (typical time to first maintenance 10 to 20 years), life for exterior exposed non polluted inland atmosphere.
19.03.00
ii) iii) iv)
v) Number of coat and the thickness of each coat to be applied to achieve the specified thickness of each coat i.e. primer, intermediate (under), finish and final finish coats. vi) Environmental conditions i.e. ambient temperature and humidity at the time of application of the paint. vii) Quality control setup for painting i.e. checking of surface preparation, thickness of each coat, quality of applied paints vis--vis the approved sample etc. viii) Method of touch up painting for surfaces damaged during handling, transit, erection, welding, subsequent to painting, removal of the temporary supports etc. ix) Reference of relevant Indian / International standards for the testing and acceptance. Before application of inorganic zinc silicate primer, the steel surfaces shall be blast cleaned to near white metal surface (Sa 2 ). Primer paint and intermediate (Under) coat shall be done by airless spray. However finish coat and final finish coat can be applied either by spray and or brush. All subsequent coats shall be applied only after acceptance of the previous applied coat. Inaccessible surfaces shall be primer painted before shop assembly. For final touch up painting of surfaces, which are damaged during handling, transit, erection, etc. surfaces shall be well prepared, by rubbing the entire damaged area using wire brush, emery paper etc. and shall be provided with minimum 100 micron (DFT) of self priming high build epoxy based primer followed by intermediate, finish and final finish coats as described elsewhere in this document. Touch up painting of
CLAUSE NO.
TECHNICAL REQUIREMENTS areas welded subsequent to painting and areas exposed after removal of temporary supports shall also be carried out in same way. Rectification of the damaged painted surfaces on account of welding / handling etc. of each coat shall be done by touch up painting, before the application of next coat, using minimum 100 micron (DFT) self priming high build epoxy based primer followed by various coats in sequence of thickness as specified elsewhere.
19.04.00
Acceptance Criteria All painted surfaces shall be uniform and pleasing in appearance. Dry film thickness of each coat shall be checked and measured by using elchometer. The thickness as measured shall not be less than the minimum thickness specified for the coat of paint under relevant clauses of the technical specification. Measurement of paint thickness shall be as per SSPC : The society for Protective Coatings Paint Application Standard no. 2 titled Measurement of Dry Coating thickness with magnetic gages. Colour, texture shall match exactly with the approved sample.
20.00.00 20.01.00
Miscellaneous Ordinary form work shall be used in roofs and floor slabs in transfer houses, footings, pedestals, cable trenches, pits etc., Plywood form work shall be used for all over ground exposed work like columns, beams, floors and ceilings in control room and M. C. C. buildings. Monorail girders and fixtures shall be provided for monorails at the locations as required and as described elsewhere in these specifications or drawings. Monorail openings in the walls shall be provided with steel frame doors preferably sliding type or otherwise open able inside, access platforms and ladders. Steel frame around openings in roof and on external walls for mounting of exhaust fans shall be provided. Ready mix non - shrink cementitious grout of reputed manufacturer as approved by the Employer shall be used for grouting of block outs and foundation bolts, underpinning of base plates and machine bases. Crushing strength of grout shall be one grade higher than the foundation concrete. Minimum crushing strength shall be 30 N / mm2 unless higher strength requirement is specified by the equipment supplier or the grout manufacturers. The bottom of steel in case of cable / pipe galleries and trestles shall be generally 3m above the ground except for rail / road crossing where it shall be 8m above the rail top / road crest/ground. Further in bunker areas it shall be 8 m above the ground. Polysulphide Sealing Compound shall be two-part polysulphide sealant and shall be from approved manufacturer, conforming to IS : 12118. Materials shall consist of polysulphide polymer and a curing agent. Gun grade material shall be used unless
20.02.00
20.03.00
20.04.00
20.05.00
20.06.00
Page 28 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS otherwise specified. The application of the sealant shall be strictly followed as per manufacturers guidelines.
24.00.00
Packaging and Transportation. All the equipment shall be suitably protected coated, covered or boxed and crated to prevent damage or deterioration during transit, handling and storage at site till the time of erection. While packing all the materials the limitations from the point of view of availability of railway wagon sizes in India should be taken into account. The contractor shall be responsible for any loss or damage during transportation, handling and storage due to improper packing.
25.00.00
Plant Life The plant shall be designed for a minimum operating life of 30 years under the conditions of operation. Assurance shall be given that plant components are adequate for this lifetime. If there are any exceptional items of the plant on which an assurance of meeting this clause cannot be given, life of such components and the difficulties associated with them shall be stated.
26.00.00
PTFE (Poly Tetra Fluoroethylene) Bearing The bearing shall be of reputed make and manufacturer as approved by the Engineer, for required vertical load and end displacement/rotation. PTFE bearing shall be sliding against highly polished stainless steel and the coefficient of friction between them shall be less than 0.06 at 55 kg/sq.cm. In order to prevent cold flow in PTFE surface it shall be rigidly bonded by a special high temperature resistance adhesive to the stainless steel substrata. The stainless steel surface that slides against the PTFE is mirror polished. The stainless steel shall be bonded to the top plate by special high strength adhesive. The thickness of stainless steel plate shall be between 1.0 mm to 1.5 mm.
27.00.00
TESTS FOR MATERIAL / WORKMANSHIP All tests required for all materials, quality of workmanship or any other tests as desired by the Engineer shall be at contractors cost.
28.00.00 28.01.00
MATERIALS For Civil, Structural and Architectural works Employer will not supply any material. All materials including cement, reinforcement steel and structural steel, whatsoever required for execution and completion of the entire scope of work covered under this specification shall be arranged by the contractor at his own cost. All materials procured by the contractor shall meet the quality requirements specified in this specification. The contractor shall keep sufficient stock of cement and steel at site at any point of time when the work is in progress excluding what has been already incorporated in the works, so that any disruption / delay in availability of these materials during procurement will not affect the progress of work at site. The minimum quantity of such materials in stock at site shall not be less then the Requirement of one ( 1 )
Page 29 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS month in case of Cement and Requirement of two ( 2 ) Consecutive months in case of Steel.
28.02.00 Structural steel 28.02.01 Mild Steel (a.) Rolled sections shall conform to E250A of IS 2062:2006 in as rolled and semi killed condition. (b.) Plates up to 20mm thickness shall conform to E250A of IS 2062:2006 in as rolled and semi killed condition. (c.) Plates beyond 20mm and up to 40 mm shall conform to E250B of IS 2062:2006 as rolled in killed condition.
(d.) Plates beyond 40mm shall conform to E250B of IS 2062:2006 in normalized and ultrasonically tested quality. (e.) Pipes for handrail shall conform to medium grade of IS : 1161. (f.) Chequered plates shall conform to IS : 3502. Tensile properties shall conform to E250A of IS 2062:2006.
(g.) Seal plates shall conform to IS : 1079 ( semi - skilled quality ) 28.02.02 Medium & High Tensile Steel (a.) Rolled section shall conform to Grade E350 of IS 2062:2006, Semi Killed. (b.) Plates up to 20 mm thickness shall conform to Grade E350 of IS 2062:2006, Semi Killed. (c.) Plates beyond 20 mm and 40mm shall be as per Grade E350 of IS 2062:2006, Killed type.
(d.) Beyond 40mm shall conform to Grade E350 of IS 2062:2006, in normalized condition and ultrasonically tested quality. 28.02.03 All plates up to and including 40mm thickness shall be ultrasonically tested on audit basis to check the laminations. Fly ash based Portland pozzolona cement conforming to IS: 1489 Part - I shall preferably be used. However, the contractor may use other types of cements conforming to IS: 269, IS: 8112, IS: 12269, & IS: 455. However Ordinary Portland cement conforming to IS: 269 or IS: 8112 shall necessarily be used for Crusher Deck.
28.03.00
28.04.00 Reinforcement steel shall conform to: a) b) Mild steel grade I of IS: 432 Part I and grade A of IS: 2062. High yield strength deformed bar of Gr. Fe 415/ Fe 500 produced by thermomechanical treatment process, having elongation more than 14.5 percent and
CLAUSE NO.
TECHNICAL REQUIREMENTS conforming to other requirements of IS 1786 shall be used for the reinforcement.
28.00.00 28.01.00
BITUMINOUS ROADS Contents This section deals with specifications for construction of flexible road pavements. The details of work shall consist of : a) b) c) Construction of sub grade Construction of Water Bound Macadam base and sub base Bituminous surfacing
28.02.00 28.02.01
GENERAL REQUIREMENTS The Contractor shall mobilise at site all equipment, including paver, roller, water tanker, etc. The Contractor shall carry out the survey and setting out works, including alignment, layout, grading, curves etc. The contractor shall also hire the services of a specialized agency, wherever required. Construction of Sub-grade The subgrade shall be either in embankment, cutting or on the existing leveled ground. The cutting and embankment works, wherever involved shall be carried out, as per relevant specification of excavation and filling. The excavation for laying of base and sub-base courses shall be carried out in the required profile using box cutting. The lower 500 mm of the sub-grade shall be compacted to 95% of the Proctor Density at Optimum Moisture Content, if not done earlier; otherwise the top surface of the sub-grade shall be compacted using 8 to 10 Tonne roller with 6 passes. All undulations in the surface that develop due to rolling shall be made good with material or quarry spoils, as the case may be and the sub grade shall be re-rolled. The finished surface shall be uniform, and conform to the lines, grades and typical cross-section shown in the drawings, when tested with the template and straight edge. The permissible variation shall be 25 mm in the longitudinal profile and 15 mm in the cross profile. The shoulders area shall also be compacted in the same way maintaining the required profile on the top surface.
28.02.02
28.02.03
28.03.00 28.03.01
28.04.00
WATER BOUND MACADAM
Page 31 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Water bound macadam using crushed stone aggregate shall be used for construction of subbase and base material.
28.04.01
Materials Coarse aggregates shall be of crushed or broken stone meeting the requirements of IRC specification with respect to physical properties and grading. Grade I material having size range of 90 to 45 mm shall only be used for subbase. Grade II and III having size range of 63 to 45 mm and 53 to 22.4 mm respectively shall be used for base construction. Moorum (Non Plastic Material) shall be used in the screenings as the filling material to fill the voids in the coarse aggregate. The moorum shall be obtained from pits of weathered disintegrated rocks. It should preferably contain silicious material and natural mixture of clay of calcareous origin. The size of moorum shall not be more than 20 mm.
28.05.00
Binding Materials No separate binding material is required and the same moorum used as screening material shall also serve the purpose.
28.06.00
Construction Operations The construction operation shall involve preparation of base, spreading of coarse aggregates followed by rolling, application of binding material, setting and drying. The details of construction activities quantity and the quality of various materials to be used shall be as per the stipulations of IRC specification. The spreading shall be done from stockpile along the side of the roadway or directly from the vehicle. The segregation of large and fine aggregates shall be avoided. It may be ensured that the thickness of each compacted layer is not more than 100 mm for grading 1 material and 75 mm for grading 2 and 3 materials, for sub-base and base respectively. The number of layers and actual thickness of the base and subbase shall depend upon the CBR value of the sub-grade. The surface evenness and finishes of the Water Bound Macadam shall be checked and defects, if any, shall be rectified. In no case shall depressions be filled up with screenings and binding materials.
28.07.00 28.07.01
Bituminous Macadam The work shall consist of construction, in a single course of 75 mm thickness of compacted crushed aggregates, premixed with a bituminous binder, to serve as base / binder course, laid immediately after mixing, on a base prepared previously in accordance with the requirements of these specifications and in conformity with the line, grades and cross sections shown on the drawings or as directed by the Engineer. Materials Bitumen
28.08.00 28.08.01
CLAUSE NO.
TECHNICAL REQUIREMENTS The bitumen shall be paving bitumen of suitable penetration grade within the range S 35 to S 90 or A 35 to A 90 (30 / 40 to 80 / 100), as per Indian standards specifications for Paving Bitumen IS : 73. The actual grade of bitumen to be used shall be decided by the Engineer appropriate to the region, traffic, rainfall and other environmental conditions.
28.08.02
Aggregates The aggregates shall consist of crushed stone. They shall be clean, strong, durable of fairly cubical shape and free from disintegrated pieces, organic or other deleterious matters and adherent coating. The aggregates shall satisfy the physical requirements set forth in IRC standards.
28.08.03
Proportioning of Materials The bitumen content for premixing shall be 4 percent by weight of the total mix except when otherwise directed by the Engineer. The quantities of aggregates to be used shall be sufficient to yield the specified thickness after compaction.
28.08.04
Construction Operations The construction operation shall be carried out as per the stipulations of IRC standards. This shall involve preparation of base, application of tach coat, preparation and transportation of mix, spreading of mix, rolling, surface finish and quality control. The mix shall be prepared in a hot mix plant of adequate capacity and capable to yield a mix of proper and uniform quality works thoroughly coated aggregates. The mix transferred from the tipper at site to the paver shall be spread immediately by mixer, if self propelled. Mechanical road paver with suitable screeds capable of spreading temping and finishing the mix trial to the specified lines, grades and cross sections shall be used.
28.09.00 28.09.01
BITUMINOUS SURFACING This shall involve laying and compacting of an open graded premix carpet of 25 mm thickness in a single course composed of suitable small sized aggregates premixed with a bituminous binder on a previously prepared base to serve as a wearing course. This surface finish shall be provided directly on WBM or on Bituminous Macadam depending on the type / category of road. Materials Binder Bitumen of suitable grade conforming to IS: 73 shall be used as a binder.
28.09.02 28.09.03
28.09.04
Aggregates Stone chips size, grading, physical properties shall be as specified in IRC standards.
Page 33 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Proportioning of different types of materials shall be as given in IRC specifications. However, due to higher thickness of 25 mm, the quantity of material shall be proportionately increased. Construction operations The construction operations shall involve the preparation of base, application of tack coat, preparation of premix, spreading and rolling followed by a seal coat. The details of construction activities and the quantity of various materials to be used shall be as per the stipulations of IRC specifications. A mechanical road paver finisher shall be used for laying of premix carpet. Seal coat A premixed seal coat (type-B) for sealing the voids in the bituminous surface comprising of a thin application of fine aggregate (Stone dust / grit) premixed with bituminous binder shall be provided, as per the stipulations of IRC specifications. Tack Coat Tack coat of low viscosity conforming to IRC shall be applied, as mentioned in Schedule of Items.
28.09.05
28.10.00 28.10.01
28.11.00 28.11.01
28.11.02
28.12.00 28.12.01
SHOULDERS Content This section deals with specifications for construction of shoulder (hard) on either side of the pavement, in accordance with the requirements of these specifications and in conformity with the lines, grades and cross sections shown on the drawings or as directed by the Engineer.
28.12.02
Materials Shoulder on either side of the road shall be of WBM using stone aggregate.
28.12.03
Size of shoulder Shoulder (hard) dimensions shall be minimum 10m wide.
28.12.04
Construction operations Except in the case of bituminous constructions, shoulders shall be constructed in advance of the laying of pavement courses. The compacted thickness of each layer of shoulder shall correspond to the compacted layer of the pavement course to be laid adjacent to it. After compaction, the inside edges of shoulders shall be trimmed vertical and included area cleaned of all spilled material before proceeding with the construction of the pavement layer. In the case of bituminous courses, work on shoulder (hard) shall start only after the pavement course has been laid and compacted.
Page 34 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS During all stages of shoulder (earthen/hard) construction, the required cross-fall shall be maintained to drain off surface water. Regardless of the method of laying, all shoulder construction material shall be placed directly on the shoulder. Any spilled material dragged on to the pavement surface shall be immediately removed, without damage to the pavement and the area so affected thoroughly cleaned.
28.12.05
Surface finish and quality control of works The surface finish of construction shall conform to the requirements of IRC. Control on the quality of materials and works shall be exercised by the Engineer in accordance with IRC.
28.12.06
Brick edging Brick edging shall be provided on both sides of the road all along the length. Fly ash based bricks having strength not less than 7.5 MPa shall be used for this purpose, unless otherwise specified. The edging shall be of one brick width and half brick depth. In the case of hard shoulder, the brick edging shall not be provided. Trenches shall be excavated after construction of the road and the bed of trenches shall be compacted to a firm and even surface. The bricks shall be abutting to the wearing course, true to line, gradient and in camber with the finished road surface at the edges.
28.13.00
INSPECTION AND TESTING The surfaces finish, alignment, profile, gradient, tolerance, quality control during construction and characteristics of different materials shall be checked, as per the requirements of IRC specifications, for road and bridge works.
29.00.00
CODES AND STANDARDS
All standards, specifications, acts and code of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. Other Indian, foreign Codes and Standards not listed here but referred to elsewhere within this specification shall also be deemed to be part of this list. In case of conflict between this specification and those (IS standards, codes etc.) referred to herein, the former shall prevail. Some of the relevant Indian standards, Acts and Codes applicable to this section of the specification are listed below
IS : 383
Specification for coarse and fine aggregates from natural sources for Concrete.
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CLAUSE NO.
TECHNICAL REQUIREMENTS IS : 432 Specification for mild steel and medium tensile steel bars and hard drawn steel wire for concrete reinforcement. Code of practice for plain and reinforced concrete. Specification for concrete pipes. Method of test for strength of concrete. Code of practice for use of structural steel in general building construction. Specification for covered electrodes for metal arc welding for weld steel. Code of practice for use of metal arc welding for general construction. Code of practice for training and testing of metal arc welders.
IS : 456 IS : 458 IS : 516 IS : 800 IS : 814 IS : 816 IS : 817
IS : 875 (Pt. I to V) Code of practice for design loads other than earthquake) for buildings and structures. IS : 1038 IS : 1172 IS : 1361 IS : 1786 IS : 1892 IS : 1893 IS : 1904 IS : 1905 IS : 1948 IS : 2062 IS : 2131 IS : 2212 IS : 2645 IS:2720 Steel doors, windows and ventilators. Basic requirements for water supply, drainage and sanitation. Steel windows for industrial buildings. Specification for high strength deformed steel bars and wires for concrete reinforcement. Code of practice for subsurface investigation for foundation. Criteria for earthquake resistant design of structures. Code of practice for design and construction of foundations in soils; general requirements. Code of practice for structural safety of buildings Masonry walls. Specification ventilators. for aluminium doors, windows and
Steel for general structural purposes. Method of standard penetration test for soils. Code of practice for brickwork. Specification for Integral cement water proofing compounds. (Part-II, Methods of test for soils - determination for water
CLAUSE NO.
TECHNICAL REQUIREMENTS IV TO VIII, XIV, content etc code of practice for earth work on canals. XXI, XXIII, XXIV, XXVII TO XXIX, XL) IS : 2911 (Part-1/Sec.1) (Part-1/Sec.2) (Part-IV) Code of practice for design and construction of pile foundations. Driven cast in situ concrete piles. Bored cast-in-situ concrete piles. Load test on piles.
IS : 2974 (Part - I Code of practice for design and construction of TO V) machine foundations. IS : 3370 (Part I Code of practice for concrete structures for the storage to IV) of liquids. IS : 3658 IS : 3664 IS : 4326 IS : 4990 IS : 5624 IS : 7215 IS : 8112 IS : 9103 IS : 9595 IS : 10262 IS : 13311 IS : 13755 ASTM 898 -89 Code of practice for liquid penetrant flaw detection. Code of practice for ultra sonic testing by pulse echo method. Code of practice for earthquake resistant design and construction of buildings. Specification for plywood for concrete shuttering work. Specification for foundation bolts. Tolerances for fabrication steel structures. Specification for 43 grade Ordinary Portland Cement. Specification for admixtures for concrete. Code of procedure of manual metal arc welding of mild steel. Recommended guidelines for concrete mix design. Method of non - destructive testing of concrete. Dust pressed ceramic tiles with water absorption of 3%, E6% (Group B11a) Standard guide for use of high solid content, cold liquid-applied elastomeric water proofing membrane for use with separate wearing course. Pre finished / pre painted sheet metal product for interior / exterior building applications Performance requirements. Standards for steel manufacturing. A steel sheet & strip hot dipped-zinc-coated or
AS/NZS 2728
AS : 1365 AS : 1397
Page 37 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS Aluminium-Zinc coated. AS : 3566 IRC : 37 Self drilling screws for building and construction industry. 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 38 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS ANNEXURE-A
CRITERIA FOR EARTHQUAKE RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT
All structures and equipment shall be designed for seismic forces adopting the site specific seismic information provided in this document and using the other provisions in accordance with IS:1893 (Part 1):2002 and IS:1893 (Part 4):2005. Pending finalisation of Parts 2, 3 and 5 of IS:1893, provisions of part 1 shall be read along with the relevant clauses of IS:1893:1984, for structures other than the buildings and industrial structures including stack-like structures. A site specific seismic study has been conducted for the project site. The peak ground horizontal acceleration for the project site, the site specific acceleration spectral coefficients (in units of gravity acceleration g) in the horizontal direction for the various damping values and the multiplying factor (to be used over the spectral coefficients) for evaluating the design acceleration spectra are as given at AnnexureI. Vertical acceleration spectral values shall be taken as 2/3rd of the corresponding horizontal values. The site specific design acceleration spectra shall be used in place of the response acceleration spectra, given at figure-2 in IS:1893 (Part 1) and Annex B of IS:1893 (Part 4). The site specific acceleration spectra along with multiplying factors specified in Annexure-I includes the effect of the seismic environment of the site, the importance factor related to the structures and the response reduction factor. Hence, the design spectra do not require any further consideration of the zone factor (Z), the importance factor (I) and response reduction factor (R) as used in the IS:1893 (Part 1 and Part 4). Damping in Structures The damping factor (as a percentage of critical damping) to be adopted shall not be more than as indicated below for: a) b) c) d) e) Steel structures Reinforced Concrete structures Reinforced Concrete Stacks ND Cooling Towers Steel stacks : : : : : 2% 5% 3% 2% 2%
Page 39 of 46
CLAUSE NO.
Method of Analysis Since most structures in a power plant are irregular in shape and have irregular distribution of mass and stiffness, dynamic analysis for obtaining the design seismic forces shall be carried out using the response spectrum method. The number of vibration modes used in the analysis should be such that the sum total of modal masses of all modes considered is at least 90 percent of the total seismic mass and shall also meet requirements of IS:1893 (Part 1). Modal combination of the peak response quantities shall be performed as per Complete Quadratic Combination (CQC) method or by an acceptable alternative as per IS:1893 (Part 1). In general, seismic analysis shall be performed for the three orthogonal (two principal horizontal and one vertical) components of earthquake motion. The seismic response from the three components shall be combined as specified in IS:1893 (Part 1). For buildings, if the design base shear (VB) obtained from modal combination is less than the base shear (VB) computed using the approximate fundamental period (Ta) given in IS:1893:Part 1 and using site specific acceleration spectra with appropriate multiplying factor, the response quantities (e.g. member forces, displacements, storey forces, storey shears and base reactions) shall be enhanced in the ratio of VB/ VB. However, no reduction is permitted if VB is less than VB. For regular buildings less than 12m in height, design seismic base shear and its distribution to different floor levels along the height of the building may be carried out as specified under clause 7.5, 7.6 & 7.7 of IS:1893 (Part 1) and using site specific design acceleration spectra. The design horizontal acceleration spectrum value (Ah) shall be computed for the fundamental natural period as per clause 7.6 of IS:1893 (Part 1) using site specific spectral acceleration coefficients with appropriate multiplying factor given in Annexure-I. Further, the spectral acceleration coefficient shall get restricted to the peak spectral value if the fundamental natural period of the structure falls to the left of the peak in the spectral acceleration curve.
Design/Detailing for Ductility for Structures The site specific design acceleration spectra is a reduced spectra and has an in-built allowance for ductility. Structures shall be engineered and detailed in accordance with relevant Indian/International standards to achieve ductility.
Page 40 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS ANNEXURE I
SITE SPECIFIC SEISMIC PARAMETERS FOR DESIGN OF STRUCTURES AND EQUIPMENT The various site specific seismic parameters for the project site shall be as follows:
1) 2)
Peak ground horizontal acceleration Multiplying factor to be applied to the site specific horizontal acceleration spectral coefficients (in units of gravity acceleration g) to obtain the design acceleration spectra for moment resisting steel frames designed and detailed as per IS:800 and moment resisting RC frames designed and detailed as per IS:456 for braced steel frames designed and detailed as per IS:800 for moment resisting RC frames designed and detailed as per IS:456 and IS:13920 For steel chimney for design of structures not covered under 2 (a) to 2 (d) above and under 3 below Multiplying factor to be applied to the site specific horizontal acceleration spectral coefficients (in units of gravity acceleration g) for design of equipment and structures where inelastic action is not relevant or not permitted
: 0.24g
a)
: 0.08 : 0.06
b)
c)
: 0.048 : 0.12 : 0.08
d) e)
3)
: 0.16
Note: g = Acceleration due to gravity The horizontal seismic acceleration spectral coefficients are furnished in subsequent pages.
Page 41 of 46
CLAUSE NO.
ANNEXURE I
HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS In units of g Time Period (Sec) 0.000 0.030 0.050 0.100 0.150 0.162 0.170 0.200 0.250 0.300 0.350 0.400 0.450 0.500 0.525 0.550 0.600 0.650 0.670 0.700 0.750 0.809 0.849 0.900 0.950 1.000 1.050 1.100 1.150 1.200 1.250 1.300 1.350 1.400 1.450 1.500 1.550 1.600
Damping Factor (as a percentage of critical damping) 5% 1.000 1.000 1.353 2.040 2.593 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.714 2.587 2.440 2.312 2.196 2.091 1.996 1.910 1.830 1.757 1.689 1.627 1.569 1.514 1.464 1.417 1.373 2% 1.000 1.000 1.479 2.515 3.431 3.639 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.774 3.559 3.372 3.203 3.050 2.912 2.785 2.669 2.562 2.464 2.373 2.288 2.209 2.135 2.066 2.002
Sub-Section - IIID-01 CHP CIVIL WORKS Page 42 of 46
CLAUSE NO.
HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS In units of g Time Period (Sec) 1.650 1.700 1.750 1.800 1.850 1.900 1.950 2.000 2.050 2.100 2.150 2.200 2.250 2.300 2.350 2.400 2.450 2.500 2.550 2.600 2.650 2.700 2.750 2.800 2.850 2.900 2.950 3.000 3.050 3.100 3.150 3.200 3.250 3.300 3.350 3.400 3.450 3.500 Damping Factor (as a percentage of critical damping) 5% 1.331 1.292 1.255 1.220 1.187 1.156 1.126 1.098 1.071 1.046 1.021 0.998 0.976 0.955 0.934 0.915 0.896 0.878 0.861 0.845 0.829 0.813 0.799 0.784 0.771 0.757 0.744 0.732 0.720 0.708 0.697 0.686 0.676 0.665 0.656 0.646 0.637 0.627 2% 1.941 1.884 1.830 1.779 1.731 1.686 1.643 1.602 1.562 1.525 1.490 1.456 1.424 1.393 1.363 1.335 1.307 1.281 1.256 1.232 1.209 1.186 1.165 1.144 1.124 1.104 1.086 1.068 1.050 1.033 1.017 1.001 0.986 0.971 0.956 0.942 0.928 0.915
Page 43 of 46
CLAUSE NO.
HORIZONTAL SEISMIC ACCELERATION SPECTRAL COEFFICIENTS In units of g Time Period (Sec) 3.550 3.600 3.650 3.700 3.750 3.800 3.825 3.850 3.900 3.950 4.000 Damping Factor (as a percentage of critical damping) 5% 0.619 0.610 0.602 0.594 0.586 0.578 0.574 0.570 0.563 0.556 0.549 2% 0.902 0.890 0.878 0.866 0.854 0.843 0.837 0.832 0.821 0.811 0.801
Page 44 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS ANNEXURE-B CRITERIA FOR WIND RESISTANT DESIGN OF STRUCTURES AND EQUIPMENT
All structures shall be designed for wind forces in accordance with IS: 875 (Part-3) and as specified in this document. See Annexure B for site specific information. Along wind forces shall generally be computed by the Peak (i.e. 3 second gust) Wind Speed method as defined in the standard. Along wind forces on slender and wind sensitive structures and structural elements shall also be computed, for dynamic effects, using the Gust Factor or Gust Effectiveness Factor Method as defined in the standard. The structures shall be designed for the higher of the forces obtained from Gust Factor method and the Peak Wind Speed method. Analysis for dynamic effects of wind must be undertaken for any structure which has a height to minimum lateral dimension ratio greater than 5 and/or if the fundamental frequency of the structure is less than 1 Hz. Susceptibility of structures to across-wind forces, galloping, flutter, ovalling etc. should be examined and designed/detailed accordingly following the recommendations of IS:875(Part-3) and other relevant Indian standards. It should be estimated if size and relative position of other structures are likely to enhance the wind loading on the structure under consideration. Enhancement factor, if necessary, shall suitably be estimated and applied to the wind loading to account for the interference effects. Damping in Structures The damping factor (as a percentage of critical damping) to be adopted shall not be more than as indicated below for: a) Welded steel structures b) Bolted steel structures c) Reinforced concrete structures d) Steel stacks : 1.0% : 2.0% : 1.6% : As per IS:6533 & CICIND Model Code whichever is more critical.
Page 45 of 46
CLAUSE NO.
SITE SPECIFIC DESIGN PARAMETERS The various design parameters, as defined in IS: 875 (Part-3), to be adopted for the project site shall be as follows: a) The basic wind speed Vb at ten metres above the mean ground level b) The risk coefficient K1 c) Category of terrain
: 47 metres/second : 1.07 : Category-2
Note: Notwithstanding the values of the above mentioned parameters, the design wind pressure so computed at any point shall not be taken less than 1500 N/Sq. meter for all classes of structures, i.e. A, B & C, as defined in IS: 875 (Part-3).
Page 46 of 46
CLAUSE NO.
TECHNICAL REQUIREMENTS GEOTECHNICAL INVESTIGATION & FOUNDATION SYSTEM Geotechnical investigation for the scope of work shall be done by the bidder. Owner has carried out geotechnical investigation within plant. The details of few borelogs are enclosed at Annexure-I. These are solely for the purpose of guidance of the Bidder. The onus of correct assessment/interpretation and understanding of the existing sub soil conditions/data is on the Bidder. The geotechnical investigation shall be carried out in all work areas for establishing the sub-soil conditions & to decide type of foundations for the structures envisaged, construction methods, any special requirements/ treatment called for/ remedial measures for sub-soil/ foundations etc. for soft sub-soils, aggressive sub-soils & water, expansive/ swelling soils etc. Scheme of Soil Investigation The diameter of borehole shall be minimum 150 mm in soil and 76 mm in rock. The diameter of UDS sampler shall be 90 mm minimum. Drilling in rock shall be done by means of hydraulic feed equipment using double tube core barrel with diamond bid attachment. Field test shall include but not be limited to the following:Boreholes, Standard Penetration Test (SPT), collection of disturbed and undisturbed soil samples (UDS), Trial Pits (TP), Electrical Resistivity Test (ERT), collection of water samples, etc.
1.00.00 1.01.00
1.01.01
1.02.0 1.02.01
1.02.02
1.02.03
The minimum tests are indicated in Annexure A. Adequate number of tests shall be conducted upto sufficient depth for complete determination of subsoil conditions. The depth of boreholes shall be as specified in Annexure A. SPT shall be carried out in all types of soil deposits and in all rock formations with core recovery upto 20%, met within a borehole. This test shall be conducted at every 3.0 m interval or at change of strata, upto the final depth. Number of blows shall be recorded for every 15 cm of penetration upto 45 cm or 100 blows whichever occurs earlier. SPT N of 100 and above shall be referred as refusal. UDS shall be collected at every 3.0 m interval or at change of strata upto depth of borehole. UDS may be replaced by additional SPT, if SPTN value in the strata is above 50. Laboratory tests shall be done as per relevant IS codes. The laboratory tests, not be limited to the following shall be conducted on disturbed and undisturbed soil / rock samples & water samples collected during field investigations in sufficient numbers. Laboratory tests shall be carried out on disturbed and undisturbed soil samples for Grain Size Analysis, Hydrometer Analysis, Atterberg Limits, Trixial Shear Tests (UU), Natural Moisture Content, Specific Gravity and Bulk Unit Weight, Consolidation Tests, Unconfined Compression Test, Free swell Index, Shrinkage Limit, Swell Pressure Test, Chemical Analysis test on soil and water samples to determine the carbonates, sulphates, chlorides, nitrates, pH, organic matter and any other chemicals harmful to concrete and reinforcement/ steel. Geotechnical investigation shall be carried out in accordance with the provisions of relevant Indian Standards.
1.02.04
1.02.05
TECHNICAL SPECIFICATIONS SECTION VI, PART-B BID DOC. NO.:CS- -
Sub-Section - IIID-02
GEOTECHNICAL INVESTIGATION & FDN. SYSTEM
Page 1 of 6
CLAUSE NO.
TECHNICAL REQUIREMENTS On completion of all field & laboratory work, geotechnical investigation report shall be submitted for Owners information/review. The Geotechnical investigation report shall contain geological information of the region, procedure adopted for investigation, field & laboratory observations/ data/ records, analysis of results & recommendations on type of foundation for different type of structures envisaged for all areas of work with supporting calculations. Recommendations on treatment for soil, foundation, based on subsoil characteristics, soft soils, aggressive chemicals, expansive soils, etc. Foundation System General Requirements:
1.02.06
1.03.00 1.03.01 a)
Contractor can either provide open foundations (isolated footing/ raft) or pile foundations depending upon the results of the geotechnical investigations to be carried out by him along with any special requirements/ remedial measurement/ treatment called for subsoil/ foundations as approved by the Owner. All foundations shall be designed in accordance with provisions of the relevant parts of the latest revisions of Indian Standards. For design purpose, ground water table shall be considered at Finished Ground Level (FGL) Roads, ground floor slabs, trenches, channels/ drains and other lightly loaded structures (such as staircase foundation, pipe pedestals with foundation loading intensity less than 5 T/ M2) may be supported on open/ shallow foundations resting on virgin/ controlled compacted filled up soil. Minimum depth of foundation shall be 1.0 m below Finished Ground Level (FGL) for pipe pedestals and stair case foundation. No other foundation shall rest on the filled up ground/ soil. Foundation shall be designed for worst combination of loads as described elsewhere in the specification. Open Foundations In case open foundations are adopted following shall be adhered to: a) b) c) Minimum width of foundation shall be 1.0 m Minimum depth of foundation shall be 1.0 m below NGL. Permissible settlement of foundations.
b)
c)
d) 1.03.02
The total permissible settlement and differential settlement shall be governed by IS:1904 and IS: 13063 and from functional requirements, whichever is more stringent. However, total settlement shall be restricted to the following: i) All foundations including pipe supports, isolated/ strip/ continuous) for widths upto 6.0 m ii) 40 mm 75 mm
Footings width greater than 6.0 m (raft)
Incase pile foundations are to be adopted the requirements under para "pile foundations" shall be adhered to. 1.03.03 Pile Foundations
Page 2 of 6
CLAUSE NO.
TECHNICAL REQUIREMENTS The pile foundation shall be cast-in-situ bored piles as per IS: 2911 (relevant part). Piles shall be installed by using self erecting / supporting rotary hydraulic rig or conventional tripod rigs. Two stage flushing of pile bore shall be ensured by air lift technique or any other international method duly approved by Owner. The construction methodology to be adopted shall be suitable to ensure proper termination of pile in the strata as specified elsewhere to ensure pile bore free from spoils. a) b) Only RCC piles shall be provided. Minimum diameter, vertical (compression) capacity and pile termination criteria of reservoir side piles for the approach walk way / bridge shall be as mentioned below. Diameter 600 760 Vertical Capacity 140 T 250 T
The uplift and lateral load capacities shall be restricted to 35% and 5% respectively of the allowable load capacity in vertical compression. However, the pile capacities to be adopted shall be the least of the estimated design values and that obtained from the pile load tests. c) d) e) Only Straight piles shall be used. The piling work shall be carried out in accordance with the provisions of IS: 2911. The Contractor shall furnish the design of piles (in terms of rated capacity, length, diameter, termination strata and criterion to locate the founding level for construction of pile, reinforcement for job as well as test piles etc.), construction methodology/ specifications for construction of piles and scheme of initial pile load tests in vertical, lateral and uplift, and the details of equipment for Owners approval. The Contractor shall submit the proposed locations of initial test piles for Owners information prior to their installation. Testing of piles and interpretation of pile load test results shall be carried out as per IS:2911 (Part-4). Contractor shall ensure that all the measuring equipment and instruments are properly calibrated at a reputed laboratory / institute prior to their use. Settlement / movement of the pile top shall be made by Linear Variable Differential Transducers (LVDT) having a least count of 0.01mm. The test load on initial test piles shall be applied by means of reaction from anchor piles / rock anchors alone or combination of anchor piles / rock anchors and kentledge. Low Strain Pile Integrity test shall be conducted on all test piles and job piles. This test shall be used to identify the routine load test and not intended to replace the use of static load test. This test is limited to assess the imperfection of the pile shaft and shall be undertaken by an independent specialist agency. The test equipment shall be of TNO or PDI make or
f)
g)
h)
Page 3 of 6
CLAUSE NO.
TECHNICAL REQUIREMENTS equivalent. The process shall confirm to ASTM D 5882 and method of testing shall be Pulse Echo Method (PEM). Regular QA checks for density of circulation mud, contaminated mud and samples from pile bore bottom, slump of concrete, pile integrity test on all piles etc. shall be done by the Contractor.
i)
1.03.04
Pile Load Tests Contractor shall install the piles for initial load test. Number of initial load tests to be performed for each diameter and rated capacity of pile shall be as under: i) ii) iii) Vertical (Compression) Lateral (Horizontal) Uplift (Tension) 2 2 2
The initial pile load test shall be conducted with test load upto three times the estimated pile capacity. In case of vertical load test, the method of loading shall by cyclic as per IS:2911 (relevant part). Safe load interpretation from pile load test shall be as per IS:2911 (Part-IV). Number or routine pile load tests to be performed for each diameter/ allowable capacity of pile shall be as under. i) ii) Vertical Lateral 0.5% of the total number of piles provided subject to a minimum of one. 0.5% of the total number of piles provided subject to a minimum of one. The routine test on piles shall be conducted upto test load of one and half times the allowable pile capacity by direct loading method. Piles for routine load test shall be approved by the Owner. 1.03.05 A report on the pile load tests shall be submitted for Owners approval. In case, routine pile load test shows that the pile has not achieved the desired capacity or pile (s) have been rejected due to any other reason, then Contractor shall install additional pile (s) as required and accordingly, pile cap design should be reviewed and modified if required at no extra cost to the Owner. Low strain integrity test shall be conducted on all the test and job piles through an approved agency and as directed by the Engineer. The system shall have the computer read out facility and report on the findings of this shall be furnished to the Owner. This test shall be used to identify the piles for routine load test. Other Requirements i) Cement type Concrete grade As approved by the Owner based on soil water chemical environment. Minimum grade of concrete for piles shall be M-25 unless specified otherwise elsewhere. Concrete shall be dense & durable. Min 400 kg/cum in case of piles. Admixtures are not permitted in concrete used for piling.
1.03.06
1.04.00
Cement content
Page 4 of 6
CLAUSE NO.
TECHNICAL REQUIREMENTS TMT bars Fe 500 grade As per IS:456, subject to minimum of 50 mm. For excavation works, comprehensive dewatering with well point or deep wells arrangement wherever required shall be adopted. Scheme for dewatering and design with all computations and back data for dewatering shall be submitted for the owners information. The water table shall be maintained at 0.5m below the founding depth. The founding level for trenches/ channels shall be decided as per functional requirement. The bottom of excavation shall be properly compacted prior to casting of bottom slab of trenches/ channels. Excavation for open foundations shall be covered with PCC immediately after reaching the founding level. In case of any local loosening of soil at founding level during excavation, the same shall be removed and compensated by PCC. Backfilling, around foundations and bottom of pipes, thrust blocks, etc. shall be compacted to 90% standard proctor density for cohesive soil and to 75% of relative density for non-cohesive soils. Reinforcement steel type Cover to reinforcement -
(ii)
(iii)
(iv)
(v)
Page 5 of 6
CLAUSE NO.
TECHNICAL REQUIREMENTS ANNEXURE - A S.No 1 Structure Junction House Tests One borehole at each identified Junction House Depth of borehole shall be i) ii) 35 m below ground level. 5 m into rock with RQD 50% continuously
Whichever above occurs earlier. 2 Conveyors One borehole at 100 m c/c along the identified conveyor. Depth of borehole shall be i) 25 m below ground level ii) 5 m into rock with RQD 50% continuously Whichever above occurs earlier. 3 MCC room, One borehole at each structure. Pump house Depth of borehole shall be 20m Two Electrical Resistivity Test (ERT) at each structure.
NOTE: Investigation in any other new building / structure / facilities / and associated works / items in the scope of the package, which are not listed above shall also be carried out.
Page 6 of 6
KND Engineering Technologies Ltd

BORELOG DATASHEET
Projects NTPC-FSTPP, Stage-Ill Location: Transformer Yard Borehole No . Q3 Commenced on:23.07.2006 Completed on: 27.07.2006 Cosrdinafe: S-1147 / ---- -- E-250 Depth Description of soil
Barehaie diameter. 1SOmm
at: l.Wm BEGL

---
Details of samples Ref. No. Type ~apth(m)
grey siRy clay, mixed with

--
1 50
soh light brwnleh grey,
- --
--
-. -
3 00
~oderagy stiff, li&j brownish grey Sllty Clay small pockets of rust bro
12.00
stiff dark grey 8iG Cly.

Small pockets of rust b m sills are also observed in the strata occas~iona!ly. Cotour of the strata changes to Muiah grey belovv 21.Elm
nodubs are observed in the strara below 26.50m depth.

.
4.75
27 25
- --
- --
--
Very Dense to compact, light reddish brown Sandy
-- - - --
P PanelmmelerTesl
UD undtslurttedTube Sample
DC Dlslurtted Sanlples Callecled From lubes Culttm Shoe
o r I3wulaad aacnprs CMleMma rroril petlslmfiieter

D Daunma Sample
KND Engineerin( Technologies Ltc

BORELOG DATA-SHEET
Projects: NTPCFSTPP, Stage-Ill Location: TG Hall Borehole No.: 12 Commenced on:21.08.2006 Completed on: 23.08.2006 Co-ordinate: S-1108 IE-219 Thickness
---Details of sampbs
Borehole diameter. 150mm R.L. of ground: 26.50m Soil boring termination depth: 26.15m BEGL Ground water struck at: 1.90 m BEGL Standing water level. 1.80 m BEGL
Ref. ~ o - ~ ~~epth(m) p e
- -.
0
I
,
I
Penetration Blows115cm
-I
I
--0711
-
- - --
oALap~---
I - - - -7 - I/ - - - & - 1 i
I
i
0715 0716 ti717 0718
- .. --.
-
u
D P U D P
5719 (3720 0721 14.25 0722 0723 0724 . . 0725 0726 0727 0728
0731 Q730 0 3 0733 0734
U
D P P U D P
1.35-1.80 2.95-3.40 3.50 4.45-4.90 6.154,6Q 6.70 7.55-8.00 9.05-9.50 ' 9.60 10.50-10.95 12.00-12.45 73.80-14.05 14.15 15.00-95.45
-
- --
3 2
i
depth. Colour of the strata changes to brownish grey below 22.00m depth.
-
- ---P U
3
-
U '16.50-16.95 D 17.05*-'1
D P U D
18 00-18.45 79.50-19.B 20.05 21.00-21.45 22.55-23.00 23.10 3
8 1 3 '
W
0736 0737'
-
fi.
! i
- -
I
60/12cm
sleo
0740 D 2.40
--
BEGL, as boring could not be progressed more than 15cm from 16.60m
I
Projects: NTPC-FSTPP, Stage-Ill Location: Boiler And mills Borehole No.:28 Commenced on:04.09.2006 Completed on: 05.09.2006 Co-ordinate: S-I - . --1 -I 065 84 .
BORELOG DATA-SHEET
KND Engineering Technologies Ltd I

Borehole diameter: 150mm . R.L. of ground:26.50m Soil boring termination depth. 28.50m BEGL Ground water struck at. 1 40m BEGL Standing water level: 1 25 m BEGL Method of bor~ng; Shell &Auger
Details of samples Blows/l5cm
0.60
Fill consisting of dark grey silty clay, mixed with fine grained sand, stone pieces,
16.60
kankars and nodules. Pockets of rust brown silts are found occassionally Colour of the strata changes to dark bluish grey below
075 076 077 078 079 OBO 081 082 083
D 1.00 P 1.45-l.9tli
U 3.15.3.60
D 3.70 P 4.55-5.00 U 8.124.57 D 6.67
P 7.*-7.95
U 9.10-9.55
"U 12.70-12.55 D 12.85
OM
089 090
D 45.70
P 1&10-16.55
3
093
bl
20.05-20.50
OM
21.50-2-
088
099 100
ote:
I BH-28 is m i n a t e d at 28.50m BEGL, as boring wutd not be progressed more than 15cm from 28.35m
I
I
b & ln of 2 houw y Wi g
P P D
21.5027.95 28.10-28.33 28.50
20 40
i 6518crn 1
I
28
31
59 >lo0
1I
I
b No. CS-3236-
P PenemmeterTest DP: Disturbedtarnpie Collected From penelmmeter b: D l t t u W Sample
UD undlslurbedTube Sample DC, Disturbed Samples Collected From lubes Cutllng Shoe WS Water sampte
(1IlOIl5 L
KND Engineering Technologies Ltc

BORELOG DATA-SHEET
Projects. NTPC-FSTPP, Stage-Ill Location:Air Compressor House. Boiler And Mills Borehole No.: 33 Commenced on:08.09.2006 Completed on: 10.09.2006 Co-ordinate S-1040 1E-216 -- .
Depth in metre1
--I
--
--
Borehole diameter. 150mm R.L. of ground: 26.75m Soil boring termination depth: 28.10 m BEGL Ground water struck at. 1.45 m BEGL Standing water level: 1. O m BEGL O Method of boring; Shell &Auger -.penetration test Blows 1 15cm 050 45
I
8
Description of soil
of layer
Details of samples
N' value! Remarks

I 1
. .-
EGL
--
- --
> -
2 75
Fill consisting of coal, ash, stone pieces followed by brownish grey silty clay, mixed with coal pieces, brick bats, stone chips etc.
2.75
__
2 75
-1._.___
2
I
2 2
4
I
I
-
,ModeratelyStiff, brownisg 'grey Silty Clay, wirh occassional pockets of rust brown silt Colour of the strata changes to Bluish lgrey below 7.00m depth.
i^--- 11.9
1
/
--
'
11
4.75
1110 1111 11112 1113
D P
U D
3.65 4.60-5.05 612-6.57 6.67
1
1
strata changes to reddish brown with bluish patchec below 17.00 m depth.
I
1
1148 1149 1150
P P P
20.00-20.45 21.50-21.9523.00-23.45
-
16
--
by chiselling of 2 hours.
P: P e R e m n ~ W a l T DP: D8 e sample Ce&@w Fmm prnrelrompter 1Wd D: QbkBnd S@@e
UD undlsiulbstd Tube Sample
DC. Dlslufbed Samples Collecled From tubes Cult~ng Shoa wS Water sample

I
BORELOG DATA-SHET
Projects: NTPC-FSTPP, Stage-Ill Location: ESP Borehole No.: 41 Commenced on:23.07.2006 Completed on: 26.07.200@Co-or din at^: 5-962 1E-178 Depth in.fm@ Borehole diameter: 150mm R.L. of ground: 26.2511 Soil boring termination depth: 27.25m BEGL Ground water struck at: 3.25m BEGL Standing water level: 3.20 m BEGL Method of boring; Shell &A Thickness of laym
I
I
---
Description of soil
Details of s m p l m
- i n metre
-.--
Penehtion test
! N' value
!
- -- -.. .
EGL
--
----0930
1. a 5
a
1 50 1.50
-t
Fill consisting of light /brownishgrey Silty Clay mixed with brick bats etc.
1.00
,ModeratelyStiff, light browniosh grey Silty Clay with pockets of rust b r o w
#031
'
tB32
W 3 MI35 h a 7 m 8
SR
1
10.50 10.50 - % f f z e y kitty Claywith p;ockets of rust brown Silts. jColour of the strata changes I /to yellowish brown below 18.00m depth.
P U D P U P U D
l29 x3
0041 0042 0043 0044 0045 10046 ' 0047 0048
-
1.50-1.95 3.05-3.50 3.60 4.50-4.95 6.25-6.5Q 6.60 7.50-7.95 9.05-9.S 9.60
I - - - - L----
9'00
1950 19.50
!
'
.
U D P U D P U D
12.15-12.50 12.60 13.50-13.95; 1505-15.50 15.60 16.50-16.951 18.17-18.67 18.67
1
I
5
I
'
3'00 22.50 . - --- -.. -- 22.50 Very dense light yellowish brown, very fine r--'ned 3.00 Silty sand 25.50 -25.50 ' ~ a r d yellowish-b&-Clayey Silt mixed & v&y fine grained sand partilck, 27.25 Fragmented rock pieces are ' ?-74 observed below 26.25111 depth. I
I
~edium dense brownish grey Sandy Silt with very fine grained mica pieces.
- - ---
--
0049 0860 0851 0182 8783
U D
19.50119.9%'21.14-21.m 21.49 22.57-23.02 24.00-24.45
-- P P P
P P
-.--
. . -
17 16
38
64
0184 0185 0186
25.35-2538' 9 26.25-26.70 27.25-27.35 100/10m

I
I I
Note:
BH-43 is terminated at 27.25rn BEGL, $s baring could not be progressed more than 10cm by chisellin$ qf 2 bowa .
P: P s n a m t e r Tea
UD: undislwhsd Tube Sam* Dislwbed Samples CollectedFmm tubes CutUng Srtoa WS: Water smnple
DP: D i a M m p l e Colleoled Fmrn penekimler

0: Dlsbrbed Sample
nrl r) ri f;

BORELOG DATA-SHEET
Projects: NTPC-FSTPP, Stage-Ill Location: ID ducts Borehole No.: 51 Commenced on: 10.08.2006 Completed on: 14.08.2006 Co-ordinate 5-870 1 E-344
Depth In metre1
'
Borehole diameter: 150mm R.L. of ground: 26.75m Soil boring termination depth: 26.50m BEGL Ground water struck at: 1.75m BEGL Standing water level: 1.65 m BEGL - Method- boring; Shell &Auger . - -- -of . . . -
I I
Description of so11
m metre
EGL 1 50
F~ll consisting of coal, waste materials, stone chips, brick /bats etc. 'followed by, 1 brownosh grey silty clay, ,mixedwith stone pieces, Icoal, brick bats etc.
,- -
Details of samples Penetrat~on test N' value; Remarks ------ -. Ref. No. Type Depth(m) 1 -- - i o w.s-l 5 c m -- , . ~ - l 30 45 04427 D 0.53 0428 D 1.00 1 I 1
1.50
, moderately stiff brownish 1 grey Silty Clay mixed with
-- -.
--
very small pockets of black 1 silt nodulss.

5
"Sample Slipped
I
light brownish grey Silty Clay. Colour of the strata changes to bluish grey below 10.25m depth.
Dense dark grey, coarse grained Clayey Sand

1
-
---
1
-
Very. stiiclslrk grey Silty
Clay. Colour orthe strata changes to brownish grey /below 19.50m depth. Calcareous nodules of various sizes are also observed in We strata. Very dense to compact,
y e l M ~ h row, R b w
pained Silty wnd. Fragmented rock pieces mix& with eYaygy silt A observed below 26.60rn depth.
'
BH-51 is terminated at 26.50mI BEGL, as 5.00m in refusal strata with SPT-'N' value >I00
I I
P: PenelpmeterTest
UD: ufl@~turbed emple Tube

DG DtsiluTbed SarnpIn~~ C01bet.d Fmm lubrss CuW@ O %. W5: WaMC samph
DP M.lrrrhn0 r.~qD(e @~@$*d Fmm pnralmtn@(ar 0. Proiwbea Sunpla
----< b
-KND Engineerin( .
--7-
Technologies Ltc
BORELOG DATA-SHEET
Projects: NTPC-FSTPP, Stage-Ill Location: Chimney Borehole No.: 55 Commenced on:22.08.2006 Completed on: 24.08.2006 Co-ordinate: S-847 1E-216 -- -,
-,
--
Borehole diameter: 150mm R.L. of ground: 26.75 Soil boring termination depth: 26.15m BEGL Ground water struck at:1.15m BEGL Standing water level: 0.80m BEGL .--Method of - . -boring; Shell &Auger .~ - . . . .. - ..
-
i Thickness
Depth in metre,
~ e s c r i ~ t i o nsoil of
-.
,N ' value! Remarks
EGL
{Fill consisting of brownish grey silty day mixed with I brick bats, boulders, stone chips, coal etc.
iI
I
(
2.75
/
I
2,75
! 0628 I 0629 I 0630
i
...
/
1
11
!
0.50 1.00 1.50-1.95
:
1
2
30
'
45
'
2.75
i ~ o d e r i estiff, brownish l~ I igrey Silty Clay. Coal pieces : 'and stone chips are I 1 observed at upper depth :
I...
- .
[TI
'
I
P
1 1
I
i !.
i
.
1 I
.
4
1
1 11.75
9.00
2.85-3.30 *U 4.05-4.50 0 6 3 5 ) D 4.50 ; 0633 P 4.75-5.20 i 0634 U I 5.90-6.35 0635 D 6.45 7.40-7.85
'Samle Slipped 2
,
'
8 6
1
'
;
I
.
i1
j
--
0638
-~..
9.10-9.55 9.65 1 , 10.50-10.95
1 1
I
-.
1
I
'
I
3 .
:'
2
-
i
1~~
11.75
20.75 I 20 75
'very stiff to hard, bluish grey 1 ;Silty Clay. Colour of the , 1 strata changes to bluish ; lgreyl yellowush brown I ;below 15.00m depth. / kankars and nodules are ~occassionally observed in jthe strata between 15.00m i ;to 17.00m depth.
. -. -
4.
. .
I
1
'1
9.00
0641 I D , 12.70 0642 1 P 13.45-13.90 i 0643 U 15.10-15.55 10644 D m 15.65 I 0645 P 16.56-17.01 i 0646 U 18.20-18.65 I1 ' 0647 , D 18.75 0648 P 19.40-19.85
I
/
1 ;
18 22
'
10
14
32
40
>I& >I00 >I00 .I00
.
1
13 36 42 49 50
18
60t7cm &/8crn 66/8crn BSBcm
'
I I
Very dense to compact, yellowish brown, fine grained Silty Sand.
5.61
26 36
,
I
0649 1650 0486 0487
P P P P
'
20 85-21.07 22 70-22.93 24 30-24 53 26 15-26 36
--
Note:
BH-55 is terminated at 26.15m BEGL. in 5.00m refusal strata, with SPT-'N' >I00 .
P Penelmmeter Twl
DP Dlslurb~d mnpla ColIecIed Fmrn penelmmeler
UD umslumed Tube Sample DC Dlslurbed Samples Collected From lubes Cullvlg Shoe WS Waler sample
D DlSIurtMd Sample
CLAUSE NO.
TECHNICAL REQUIREMENTS Brakes and Clamps Final testing of brakes shall include load, HV/IR & heat run tests. Monorails and Hoists All electric hoist shall be tested as per IS 3938 and chain pulley block shall be tested as per IS 3832. Hoppers & Liners Rack & Pinion Gates/Flap Gates/Rod Gates a) MPI/DP test shall be conducted on rack and pinion / rod / weld joint b) Functional checks on the gates shall be carried out alongwith respective actuator, if applicable. Belt Conveyor System The details of the checks to be carried out in the various equipments are to be submitted by the Contractor for Owners approval. However, some indicative checks on different items are given below which should necessarily form a part of the Quality Assurance Plan to be agreed with the Owner.
1.01.00 1.01.01 1.02.00 1.02.01
1.03.00 1.03.01
1.04.00
1.04.01
Idlers a) Check for run out and free movement shall be carried out on idlers. Run out shall be restricted as per IS:8598 Test for dust proofness, water proofness and dynamic friction factor of the Idlers shall be conducted at shop. The detailed procedures for the same shall be submitted for review and approval.
b)
1.04.02 (a)
Belting Rubber cover of finished belt shall be checked for tensile strength and elongation at break before and after ageing. Rubber cover shall also be checked for abrasion, tear strength and hardness. For finished belts, checks for elongation at 10% nominal tensile strength, tensile and elongation at break in longitudinal (warp) direction and tensile in transverse (weft) direction shall be carried out. Adhesion test between ply to ply and cover to ply shall be carried out. Troughability test and Test for fire resistance shall be carried out. Test for procedure qualification for belt vulcanizing joint (at site) shall be done. Procedure for belt vulcanizing joint shall be discussed and finalized during FQP finalization.
TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIE-01 Coal Conveyors Belt PAGE 1 OF 7
(b)
(c) (d) (e)
CLAUSE NO.
TECHNICAL REQUIREMENTS There will be a limitation on the no. of repairs allowed on the belts. Following will be the acceptance norm for the cover repairs. i) The maximum size of a repair shall be limited to a size equivalent to one fifth the belt width. No single dimension shall exceed one fifth(1/5) of belt width. Small local repair by dough filling of size 25mm x 25mm to a limited extent shall not be counted of repairs. However, in case of cluster of repairs, same shall be counted as a patch repair. The maximum number of patch repair shall not exceed 5 per 100 mts. However, the total number of patch and dough filling repairs shall not exceed 10 per 100 meters.
(f)
ii)
iii)
(g)
In addition to above, Steel Cord belt shall also be tested for following. Cord dia and breaking strength Finished belt shall be tested for cord pull-out strength before and after aeging, peeling resistance. Dynamic cord pull out test Cord dia, pitch and number of cords
i. ii. iii. iv.
(h) In no case shall the cover thickness or the width of belt be less than that given in specification. (i) For testing purpose,belt sample shall be taken from anywhere of the belt roll length offered 1.04.03 Belt Vulcanizing Machine a) Check for tensile strength shall be carried out on a sample vulcanized belt joint for each type of belt in shop.However if such test has been done earlier, the report for same shall be submitted for verification. Complete assembly shall be tested at shop for temp. and pressure developed
b) 1.04.04
Pulleys a) In addition to chemical,mechanical,hardness,microstructure as per applicable material specification, pulleys shaft forgings shall be subjected to ultrasonic testing. 100% MPI/DPT on all welds shall be conducted and 10% RT/UT on butt welds shall be conducted. Static balancing of pulleys shall be carried out after rubber lagging.
b)
c)
CLAUSE NO.
TECHNICAL REQUIREMENTS d) Checks on rubber lagging to include abrasion loss, shore hardness test, peeloff strength test and physical properties. Peel-off strength shall be 10 Kg/Cm, Abrasion loss shall be less than 250 cubic mm when tested as per DIN 53516.
1.04.05
Pull Chord & Belt Sway Switches a. i) ii) iii) Acceptance tests
Over all dimension and functional test. HV & IR test Degree of protection test report.
1.04.06
Zero Speed Switch, Under Belt Switch and Chute Blockage Switch a Acceptance test i) Burn in test at 50 degree C for 48 hours shall be done for electronic switches. ii) Over all dimension and functional test shall be carried out. iii) HV & IR iv) Degree of protection test
1.05.00 1.05.01
Drive Equipments Gear Boxes : (a) In addition to checks for physical, chemical, hardness, microstructure as per relevant standard, the shaft and gear/pinion forgings shall be subjected to ultrasonic testing . MPI to be carried out on Gears/Pinions after machining. Case depth, hardness and MPI after hardfacing shall be checked to ensure freedom from defects. Gear reducer shall be checked for reduction ratio, backlash and contact pattern. No load shop trial run to be conducted on gear boxes to check for oil leakage, temperature rise, noise level and vibration.
(b)
(c)
1.05.02
Flexible Coupling (a) Ultrasonic testing shall be conducted on forgings for gear sleeve and gear hub, if gear coupling is provided. MPI shall be carried out after machining to ensure freedom from cracks.
(b)
SUB-SECTION-IIIE-01 Coal Conveyors Belt
PAGE 3 OF 7
CLAUSE NO.
TECHNICAL REQUIREMENTS Fluid Coupling (a) (b) (c) Dynamic balancing shall be carried out for the rotating parts. Check for leak tightness of the coupling shall be carried out. Functional test on fusible plug for each type of coupling shall be conducted at shop. All couplings to be run tested at shop on no load Check for temperature rise, torque-speed, torque-slip characteristics and over speed test shall be included during performance test of one coupling of each type preferably at full load.
1.05.03
(d) (e)
1.06.00
Belt Scales The details of the checks to be carried out in the various equipments are to be submitted by the Contractor for Employers approval. However, some indicative checks are given below which should necessarily form a part of the quality assurance plan to be agreed with the Employer.
1.06.01
Mounting arrangement/Overall dimensional check shall be carried out on the Belt Scales. Belt scale shall be calibrated with test weight/test chain in static at works and with test weight for dynamic condition at site. All electronic modules shall be subjected to burn in test at hours. General check for load cell shall be carried out. Test report for degree of protection on enclosure shall be furnished. Accuracy/performance check shall be demonstrated at site. Dust Control & Miscellaneous Systems (Dust Suppression System) The details of the checks to be carried out on the various equipments are to be submitted by the Contractor for Owners approval. However some indicative checks on different items are given below which should necessarily form a part of the Quality Assurance Plan to be agreed with by the Owner. 50 Degree C for 48
1.06.02
1.06.03
1.06.03.1.1 1.06.04 1.06.04.1.1 1.07.00
1.07.01
Pumps (a) (b) (c) All materials should be of tested quality and test certificates to be provided. DPT of machined shaft and impeller shall be done. Shaft forgings to be also subjected to ultrasonic testing.
CLAUSE NO.
(d) (e)
Impellers to be dynamically balanced to ISO 1940 Gr.6.3 All pressure parts shall be hydraulically tested at 150% of the shut-off head or 200% of rated head, whichever is higher for 30 minutes. No leakage is allowed. All pumps to be performance tested as per Hydraulic Institute Standard/Indian Standard. Performance test to include check for noise, vibration level and temperature rise.
(f)
1.07.02
Valves & Specialties (a) (b) Valves and Specialties shall be tested as per relevant standards / codes. Seat Leakage and hydraulic test to be carried out as per relevant standards / codes.
1.07.03
Pipes and Fittings Pipes and fittings shall be tested as per relevant standards/ codes.
1.07.04
Air Compressor a) All pressure parts shall be hydraulically tested at not less than 150% of design pressure for a duration of 30 minutes prior to painting. b) All other parts including inter-connecting piping shall be hydraulically tested wherever possible, as per relevant codes. c) Ultrasonic testing shall be carried out on all forgings and rotor for dia 50mm and above. MPI/DPT shall be done on machined area of the components. d) During assembly all clearances and alignments shall also be checked and recorded e) Rotor shall be statically and dynamically balanced f) Performance Test(Shop Test) i. Performance test on the compressor shall be carried out in accordance with ISO:1217/Eq. The test shall also include demonstration of loading and unloading mechanism(Capacity control) and operation of safety valve ii. Vibration and Noise level measurement shall be done during shop performance test.
PAGE 5 OF 7
CLAUSE NO.
TECHNICAL REQUIREMENTS Air Receiver a) Each finished vessel shall be hydraulically tested at 150% of the design pressure for a duration of 30 minutes b) NDT on weld joints shall be as per respective code requirements or the minimum as specified below i. ii. iii. 100% DPT on root run of butt welds 100% DPT on all finished butt welds and fillet welds 10% RT on butt welds which shall include all T-Joints
1.07.05
1.08.00 1.08.01
Dust Extraction, Ventilation Systems Fan (a) All materials should be of tested quality and test certificates should be provided. Dynamic balancing of the fan impellers to be carried out. Shop run test shall be conducted on all centrifugal fans including check for noise and vibration level. Performance test shall be conducted on one fan of each type at shop for capacity, pressure, efficiency and power consumption.
(b) (c)
(d)
1.08.02
Valves and Specialties Refer 1.08.02 above
1.08.03
Pipes and Fittings Refer 1.08.03 above
1.09.00
Vibrating Feeders (a) Shaft forgings to be checked for ultrasonic testing in addition to check for chemical, mechanical, hardness, microstructure etc. as per applicable material specification (b) Following minimum NDT requirements to be ensured for welds: i) ii) (c) Butt welds Fillet Welds 10% UT/RT and 100% MPI/DPT. 10% MPI/DPT.
Shop trial run test shall be conducted to checks for speed(RPM), amplitude(stroke), temperature rise and noise level.
CLAUSE NO.
1.10.00
In-Line Magnetic Separators i) ii) iii) Overall Dimensional, Visual check alongwith control panel. HV & IR. Operation, temperature rise, lifting capacity, force index and gauss strength.
1.11.00
Metal Detectors i) Functional test including sensitivity, Burn in test, operation of liquid spray marker, detection of smallest piece of different materials as specified. Test report for Degree of protection test to be furnished.
ii) 1.12.00
Coal Sampling Units (a) Free carriage and cutter movement, speed of cutter and dust door closing and sealing shall be tested for samplers. No load test shall be carried out for crushers.
(b)
PAGE 7 OF 7
INDUCTIONMOTOR&SYNCHRONOUSMACHINESQE_7
All Routine tests as per IS-325/IS4722 / 9283
TESTS/CHECKS
Make/Type/Rating/TC/General Physical Inspection Hydrualic/Leak/Pressure Test Welding/Brazing(WPS/PQR)
TEMS/COMPONENTS
Plates for stator frame,end shield, spider etc. Shaft Magnetic Material Rotor Copper/Aluminium Stator copper SC Ring Insulating Material Tubes for Cooler Sleeve Bearing Stator/Rotor, Exciter Coils
Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y
SUB-SECTION-IIIE-02 INDUCTION MOTOR & SYNCHRONOUS MACHINE
PAGE 1 OF 2
Tan delta, shaft voltage polarisation index test
Electrical Characteristics
Magnetic Characteristics
Thermal Characteristics
Mech/Chem. Properties
Dynamic Balancing
NDT /DP/MPI/UT
Heat Treatment
Metallography
Dimensional
Over speed
Vibration
Run out
Visual
&
TECHNICAL REQUIREMENTS Castings, stator frame,terminal box and bearing housing etc. Fabrication & machining of stator, rotor, terminal box Wound stator Wound Exciter Rotor complete Exciter, Stator, Rotor, Terminal Box assembly Accessories, RTD, BTD,CT, Brushes, Diodes,Space heater, antifriction bearing, cable glands, lugs, gaskets etc. Motor ( IS 325 / 4722/ 9283) Y Y Y Y Y Y
Y Y Y Y Y Y
Y Y Y Y Y Y Y
Y Y Y Y Y Y Y
Y1
Note: 1. This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality Plan indicating the practices & Procedure followed along with relevant supporting documents during QP finalization. However, No QP for LT motor up to 50KW. 2. Makes of all major bought out items will be subject to NTPC approval. Y1 = for HT Motor / Machines only.
SUB-SECTION-IIIE-02 INDUCTION MOTOR & SYNCHRONOUS MACHINE
PAGE 2 OF 2
CLAUSE NO.
TECHNICAL REQUIREMENTS SQE _10
LTSWITCHGEAR
All Routine tests as per NTPC spec. & IS Y Y Y Y Y Y Y Y Y Degree of Protection Routine test as per NTPC spec (By physical verification of gasketting arrangement and by paper insertion method)
PAGE 1 OF 2
Functional & Operational Features as per NTPC Spec.
Paint Shade, Adhesion, Thickness & Fi i h Functional Checks
Item to conform to relevant Standards
( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL MOTOR STARTERS) ATTRIBUTES / CHARACTERIS-TICS Make, Model, Type, Rating & TC
Pretreatment as per IS 6005
Mechanical Properties
Dimensions & Finish
Chemical properties
Electrical properties
Milli-volt drop Test Y
ITEMS/ COMPONENTS/ SUB SYSTEM ASSEMBLIY Sheet Steel (IS : 513) Y Aluminum Bus bar Material (IS : 5082) Copper Bus bar Material (IS : 613) Support Insulator Air Circuit Breaker ( IS: 13947) Energy Meters ( IS : 13010, 13779 ) Power & Aux. Contactors (IS : 13947 ) Protection & Aux. Relays (IS : 3231) Control & Selector Switches ( IS : 13947) CTs & PTs ( IS 2705 / 3156) MCCB ( IS : 13947 ) Indicating Meters ( IS : 1248 ) Indicating Lamps ( IS : 13947 ) Air Break Switches ( IS : 13947 ) Control Terminal Blocks Y
Y Y Y
Y Y
Y Y
Y Y
Y Y Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y
Y Y Y Y Y
Y Y Y Y
SUB-SECTION-IIIE-03 LTSWITCHGEAR
IR HV IR Test
CLAUSE NO.
LTSWITCHGEAR
Functional & Operational Features as per NTPC Spec. Degree of Protection Routine test as per NTPC spec Paint Shade, Adhesion, Thickness & Finish ( MCC, PCC, ACDB, DCDB, FUSE BOARDS, LOCAL PUSH BUTTON STATION, LOCAL MOTOR STARTERS) ATTRIBUTES / CHARACTERIS-TICS All Routine tests as per NTPC spec. & IS Item to conform to relevant Standards Make, Model, Type, Rating & TC
Chemical properties
Dimensions & Finish
Functional Checks
Milli-volt drop Test
ITEMS/ COMPONENTS/ SUB SYSTEM ASSEMBLIY
Fuse ( IS 13703) Control Transformer ( IS : 12021) Push Buttons ( IS : 4794 ) Transducer (IEC : 60688) MCB ( IS : 8828) Breaker Handling Trolley Synthetic Rubber Gasket (IS : 11149 ) LT SWITCHGEAR ( IS : 8623 )
Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
Y Y
IR HV IR Test
Notes: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. Makes of all major Bought Out Items will be subject to NTPC approval.
SUB-SECTION-IIIE-03 LTSWITCHGEAR
PAGE 2 OF 2
CLAUSE NO.
LT BUSDUCT
Galvanizing Test as per IS 2629/ 2633/ 4759 IR HV IR Test Paint Shade, Thickness, Adhesion & Tightness by Torque measurement Degree of Protection routine test as per NTPC spec. Y
PAGE 1 OF 1
Dimension & Surface Finish
Make, Type, Rating & TC
Weld Quality Check ( DP test & x-ray
WPS Approval, Welder Qualification
ATTRIBUTES CHARACTERISTICS
Item to conform to relevant IS
ITEM, COMPONENTS, SYSTEM ASSEMBLY
SUB
Aluminum Sheets / Plates / Strips / Flexibles / tubes ( IS : 5082 / 737 ) CRCA Flats / ISMC ( IS 2062 ) Neoprene / Synthetic Rubber Gaskets ( IS 11149 / 3400 ) Rubber Bellows (IS : 3400) Support Insulator ( BS : 2782, IEC : 660, IS : 10912 ) Galvanized Structure & GI Earthing Flat (IS : 2629 / 2633 / 4749 ) Space Heater & Thermostat LT Busduct (IS : 8623 PART 2) Notes:
Y Y
Y Y Y Y Y
Y Y Y Y
Y Y Y Y Y
Y Y Y Y
Chemical Properties
Y Y Y Y Y Y
Y Y
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2. Makes of all major Bought Out Items will be subject to NTPC approval.
SUB-SECTION-IIIE-04 LT BUSDUCT
Phase Sequence Check
Electrical Properties
Electrical Clearances
CLAUSE NO.
Armour coverage, Cross over, looseness, Gap between two armour wire/strip
& after
Thermal Stability of insulation and outer sheath *
Constructional / requirement as per NTPC Spec.
Sequential marking/surface finish /cable length
Attributes / Characteristics
Make, Rating, Type & TC
Dimension/surface finish
Chemical Composition
Spark Test
Aluminum (IS-8130) PVC Compound (IS-5831) XLPE Compound(IS-7098 Part-I) FRLS PVC Compound(IS-5831 ) ASTM-D-2843/ ASTM-D-2863 IEC-754 Part-I Armour wire/strip (IS-3975) Insulated Core Laid up core PVC Inner sheath Armouring Outer sheath Finish cable (IS-1554 & 7098 Part-1) ASTM-D-2843/ IS 10810 ( Part- - 58 ) IEC-754 Part-I Swedish Chimney SS 4241475 for (F3 category) Flammability test IEC-332 Part 3 Cat-B Wooden drum (IS-10418) / Steel drum
Y Y Y Y
Y Y Y Y
Y Y Y
Y Y Y
Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
Note: 1.This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the practice and procedure along with relevant supporting documents. All major BoIs to be of makes approved from owner. 2. Not applicable for XLPE insulation
SUB-SECTION-IIIE-05 L.T POWER CABLES
PAGE 1 OF 3
FRLS Test
Item / Components / Sub System Assembly
Hot set test (XLPE)
Anti ternite treatment on wooden drums
Tensile strength, elongation before ageing of insulation & outer sheath
Lay length / Sequence
Routine and acceptance test as per Relevant Standard and NTPC specification
CLAUSE NO.
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all types & sizes. Following shall constitute routine tests:
1) Conductor Resistance test
2)
High voltage test at room temperature
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 1554 Part 1 & IS 7098 Part-I
A) 1) 2) 3) 4) B) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) C) 1) 2) 3)
For Conductor
Annealing test Tensile test Wrapping test Resistance test For copper conductor only For aluminium conductor only For aluminium conductor only
For Armour Wires / Formed Wires ( If applicable )

Measurement of Dimensions Tensile Tests Elongation Test Torsion Test For Round wires only Wrapping Test Resistance Test Mass of Zinc coating test For G S wires / Formed wires only Uniformity of Zinc coating For G S wires / Formed wires only Adhesion test For G S wires / Formed wires only Freedom from defects
For PVC / XLPE insulation & PVC Sheath

Test for thickness Hot set test For XLPE insulation only Tensile strength & Elongation before ageing
PAGE 2 OF 3
CLAUSE NO.
D) 1) 2) E) 1)
For completed cables

Insulation resistance test ( Volume resistivity method ) High voltage test at room temperature
Following tests shall be carried out and only one sample shall be taken from each offered lot of all sizes for these tests:Tensile strength & elongation after ageing on PVC / XLPE insulation and PVC outer sheath Thermal stability test on PVC insulation and outer sheath
2)
3)
Oxygen index test on outer sheath
4)
Smoke density rating test on outer sheath as per ASTM D 2843
5)
Acid gas generation test on outer sheath as per IEC 754 (Part 1)
6)
Flammability test as per IEC-332 - Part- 3 ( Category- B ) on completed cable Fire resistance test as per SS 4241475 (F3 Category ) on completed cable
7)
F)
Following tests shall be carried on one length of each size of offered lot:
Surface finish, length measurement, sequence of cores, armour coverage, Gap between two consecutive armour wires / formed wires
1)
PAGE 3 OF 3
CLAUSE NO.
Armour coverage, cross over, looseness gap between two armour Sequential marking/surface finish/cable length Tensile strength, elongation before & after ageing of insulation &outer Thermal stability of insulation and outer sheath
Copper Conductor (IS-8130) Y Y Y Y Y PVC Compound (IS-5831) Y Y Y Y Y Y Y FRLS PVC Compound IS- Y 5831 ASTM-D-2843/ IS 10810 (Part-58 ) IEC-754 Part-1 Armour wire/strip (IS-3975) Y Y Y Insulated Core Y Y Y Y Laid up core Y Y PVC Inner sheath Y Armouring Y Y Outer sheath Y Y Y Y Y Y Y Y Y Y Y Y Y Y Finish cable (IS-1554- 1 ) ASTM-D-2843/ IS 10810 (Part-58 ) IEC-754 Part-1 Swedish Chimney: SEN SS 424-1475( F3 category) Flammability test IEC-332 Part-3 Cat-B Wooden drum( IS : 10418) / Y Y Steel drum 1.Note : This is an indicative list of test/checks. The manufacturer is to furnish a detailed quality plan indicating the Practice and procedure along with relevant supporting documents.
Spark Test
SUB-SECTION-IIIE-06 CONTROL CABLE
Constructional feature as per NTPC S Routine & Acceptance test as per relevant standard & page 2 & 3 of FRLS Test
PAGE 1 OF 3
Attributes / Characteristics
Anti termite treatment on wooden drums
Make, Type, Rating, T.C
Lay length/Sequence
CLAUSE NO.
TECHNICAL REQUIREMENTS CONTROL CABLE ROUTINE TESTS Routine tests shall be carried out on each drum of finished cables for all types & sizes. Following shall constitute routine tests:
1)
Conductor Resistance test
2)
High voltage test at room temperature
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 1554 Part 1
A) 1) 2) B) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) C) 1) 2)
For Conductor
Annealing test Resistance test For copper conductor only

For PVC insulation & PVC Sheath

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

Insulation resistance test ( Volume resistivity method ) High voltage test at room temperature
PAGE 2 OF 3
CLAUSE NO.
E) 1)
Following tests shall be carried out and only one sample shall be taken from each offered lot of all sizes for these tests:Tensile strength & elongation after ageing on PVC insulation and PVC outer sheath Thermal stability test on PVC insulation and outer sheath
2)
3)
Oxygen index test on outer sheath
4)
Smoke density rating test on outer sheath as per ASTM D 2843
5)
Acid gas generation test on outer sheath as per IEC 754 (Part 1)
6)
Flammability test as per IEC-332 - Part- 3 ( Category- B ) on completed cable Fire resistance test as per SS 4241475 (F3 Category ) on completed cable
7)
F)
Surface finish, length measurement, sequence of cores, armour coverage, Gap between two consecutive armour wires / formed wires
1)
PAGE 3 OF 3
CLAUSE NO.
TESTS
INSTRUMENTATIONCABLE
FRLS Test * (A) ++ Tensile & Elongation before & after aging (A) ++ Outer-Sheathe/core marking, end sealing (A) Swidesh chimney Test (SS-4241475) (A) ++ Vol. Resistivity. at room & Elevated Temp. (A) ++
Overall/Coverage/Continuity (A)
ITEMS
Conductor Resistance & (A) Insulation Resistance & (A)
Constructional detail, dimensions (A)
Electrical Parameters ** (A) +
Visual, Surface finish (A) +
1. Instrument cable twisted and shielded Conductor(IS-8130) Y Y Y Insulation(VDE-207) Y Y Y Y Y Y Pairing/Twisting Y Y Y Shielding Y Y Y Drain wire Y Y Y Y Y Inner Sheath Y Y Y Y Y Y Outer Sheath Y Y Y Y Y Y Over all cable Y Y Y Y Y Y Y Y Y CableDrums(IS-10418) Y Y Note : High Temp. cables shall be subjected to tests as per VDE-207(Part-6) Compensating cables shall be checked for Thermal EMF/Endurance test as per IS 8784. Note : This is an indicative list of tests/checks. The manufacture is to furnish a detailed Quality Plan indicating his practice & Procedure along with relevant supporting documents during QP finalization for all item. Note : - Routine Test A - Acceptance Test Y - Test Applicable Note : Sampling Plan for Acceptance test shall be as per IS 8784 (As applicable) * FRLS Tests: Oxygen / Temp Index ( ASTM D-2863), Smoke Density Rating ( ASTM D 2843), HCL Emission ( IEC-754-1) ** Characterisitic Impedence, Attenuation, Mutual Capacitance, Cross Talk ( As applicable) + Sample size will be One No. of each size/type per lot. ++ Sample size will be One No. sample for complete lot offered irrespective of size/type.
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIE-07 INSTRUMENTATION CABLE PAGE 1 OF 1
Persulphate Test (A) +
Thermal Stability (A) +
High Voltage & (A)
Spark test report review
CLAUSE NO.
STATION LIGHTING
Paint Shade Thickness Adhesion & Finish Routine Test as per relevant std and spec Y Y Y Y Y Y Y Y Y Constructional Feature as per NTPC spec. Acceptance Test as per relevant std and spec Item to conform to relevant standard Y Y Y Y Y Y Y Y
PAGE 1 OF 1
Bought Out Items/ Bill of Material
Item Components Sub System Assembly
Attributes Characteristics
Luminaries (IS-10322 Part- Y 5 Sec.1) Electronic Ballast Y Lighting Wire (IS-694) Y Fans (IS-374) Y Pole (IS-2713) Y Lamps (IS-9800, IS-9974) Lighting Mast Wall Mounted Lighting Panel (IS-513, IS-5) Switch Box/ Junction Box/Receptacles/ Local Push Button Station,Lighting Panel (IS513, 2629, 2633, 4759, 6745) Cable Gland (BS-6121) Cable Lug (IS-8309) Flexible Conduit Y Y Y Y Y Y Y
Y Y Y Y
Functional Check as per spec. Y Y
Make, Type , Rating/ TC
Pre-Treatment of sheet
Galvanization Test
Dimension
HV & IR
IP Test
Y Y Y Y
Y Y
Y Y
Y Y
Y Y
Y Y
Y Y Y
Y Y
Y Y Y
Lighting Transformer (IS- Y Y Y 1117) Epoxy & Galvanised Y Y Y Y Conduit (IS-9537, 2629, 2633, 4759, 6745) Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2. Make of all major Bought Out Items will be subject to NTPC approval.
SUB-SECTION-IIIE-08 STATION LIGHTING
CLAUSE NO.
QUALITYASSURANCE&INSPECTIONMODULE NO.SQE16
Page 1 of 1 CABLING, EARTHING, LIGHTNING PROTECTION
IP protection (By physical verification of gasketting arrangement and by paper insertion relevant standard & Y Routine tests as per specification Acceptance tests as per relevant standard & specification Constructional feature as per NTPC Y Y Y Y Y Y Y Y Y Y
PAGE 1 OF 2
ATTRIBUTES / CHARACTERISTICS
Paint shade, paint thickness, adhesion
Dimension
ITEMS/COMPONENTS/
SUB SYSTEMS Wall Mounted-Lighting Panel (IS-513, IS:5, IS:2629, 2633, 6745) Switch box/junction box/ Receptacles Panel (IS-513, IS:5, IS:2629, 2633, 6745) Cable glands(BS-6121) Cable lug(IS-8309) Lighting wire(IS-694) Flexible conduits Conduits(Galvanise & Epoxy) IS-9537 & IS2629,2633 ,6745 RCC Hume Pipe (IS-458) Cable termination & straight through joint (VDE-0278) Cable Trays, Flexible supports system & accessories IS-513, 2629,2633,6745 Trefoil clamp
Bought out items/Bill of material Y
Galvanise Test (If Applicable)
Pre-treatment of sheet
Deflection test*
Surface finish
Proof load*
Functional
HV & IR
Y Y Y Y Y
Y Y Y Y Y
Y Y Y Y Y Y Y Y Y
Y Y Y
SUB-SECTION-IIIE-09 CABLING, EARTHING, LIGHTNING PROTECTION
CLAUSE NO.
TECHNICAL REQUIREMENTS Y Y Y Y
GI flats for earthing & Y lighting protection (IS 2062, 2629, 6745,2633) GI wire (IS-280) Y Fire Sealing System ( BS 476)
Y Y
.Note:1.This is an indicative list of tests /checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2.* Deflection Test on cable trays and Proof Load test on cable trays support system will be as per details given in the NTPC technical specification & approved MQP. The above acceptance tests shall be done only on one sample from each size of offered lot. 3. Make of all items will be subject to NTPC approval.
SUB-SECTION-IIIE-09 CABLING, EARTHING, LIGHTNING PROTECTION
PAGE 2 OF 2
CLAUSE NO.
T.S & elongation before & after ageing on outer sheath & insulation
Constructional requirements feature as per NTPC specification Y Y
Metallic ( Cu ) Screening ( If applicable)
Hot Set Test/ Eccentricity & Ovality
Make, Type, Rating & T.C
Spark Test(as applicable)
Mechanial properties Chemical Composition

Aluminium (IS-8130) Semiconducting Compound XLPE Compound (IS-7098 Part-II) FRLS PVC Compound (IS-5831, ASTMD2843, IS10810( Part 58) ,IEC-60754 Part-1) Triple Extrusion & curing /Manufacturing of Core Copper Tape Polyster tape Armour wire/strip Copper tapping Inner sheath Armouring Outer Sheathing Power Cable (Finished) (IS : 7098 Part II, IEC : 60332 (Part 3 Cat. B), IS-5831, ASTM-D2843, IS10810(Part 58) , IEC-60754 Part-1) Wooden drum(IS10418) /Steel Drum
Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y
Y Y
Y Y Y Y Y
Y Y Y Y Y Y Y Y
Y Y
Lay length & Sequence
SUB-SECTION-IIIE-10 H.T CABLES
Anti termite coating on wooden drums
Attributes/ Characteristics
PAGE 1 OF 3
Routine & Acceptance Test as per relevant t d d & NTPC ifi ti FRLS Test
Armour coverage, cross over, looseness, gap between two wire
Sequential marking/surface finish/ cable length
Curing Properties
Thermal seability on outer sheath
CLAUSE NO.
TECHNICAL REQUIREMENTS Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2. Make of all major Bought Out Items will be subject to NTPC approval.
ROUTINE TESTS
Routine tests shall be carried out on each drum of finished cables for all types & sizes. Following shall constitute routine tests:
1) 2) 3) Conductor Resistance test High voltage test Partial discharge test ( for Screened cables only )
ACCEPTANCE TESTS
Following Acceptance tests shall be carried out for each type and size of the cables on the cable drums selected at random as per sampling plan mentioned in IS: 7098 Part 1I
A) 1) 2) 3) B) 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) C) 1)
For Conductor
Tensile Test Wrapping Test Resistance test

For XLPE insulation & PVC Sheath

Test for thickness
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIE-10 H.T CABLES PAGE 2 OF 3
CLAUSE NO.
TECHNICAL REQUIREMENTS Tensile strength & Elongation before ageing Hot set test (For XLPE insulation)
2) 3) D) 1) 2) 3 E) 1)

Insulation resistance test ( Volume resistivity method ) High voltage test Partial discharge test ( for Screened cables only )
Following tests shall be carried out and only one sample shall be taken from each offered lot of all sizes for these tests:Tensile strength & elongation after ageing on XLPE insulation and PVC outer sheath Thermal stability test on outer sheath Oxygen index test on outer sheath Smoke density rating test on outer sheath as per ASTM D 2843 Acid gas generation test on outer sheath as per IEC 60754 (Part 1) Flammability test as per IEC-60332 - Part- 3 ( Category- B ) on completed cable
2) 3) 4) 5) 6)
F)
Surface finish, length measurement, sequence of cores, armour coverage, Gap between two consecutive armour wires / formed wires Measurement of Eccentricity & Ovality
1)
2)
SUB-SECTION-IIIE-10 H.T CABLES
PAGE 3 OF 3
CLAUSE NO.
TECHNICAL REQUIREMENTS SQE_5 Degree of Protection Routine test as per NTPC spec. (By physical verification of gasketting arrangement and by paper insertion method) Functional & Operational Features as per NTPC Spec. Paint shade, thickness, adhesion & Item to conform to relevant Standards relevant CB Operation timing check Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
PAGE 1 OF 2
HT SWITCHGEAR ATTRIBUTES / CHARACTERISTICS Make, Type, Model, Rating & TC
Mechanical properties
ITEMS, COMPONENTS, SUB-SYSTEM ASSEMBLY Aluminum Bus bar material ( IS : 5082 ) Copper Bus bar material ( IS : 613 ) Bus bar Support Insulator (IS : 9431 ) HT Circuit Breaker (IEC : 56 ) HT Contactors ( IS : 9046 ) Protection & Auxilliary Relays ( IS : 3231 / 8686 ) HT CTs & PTs ( IS : 2705 / 3156 ) HT Fuses ( IS : 9385 ) Surge Arrester ( IEC : 99 4 ) LT Contactors ( IS : 13947) Control & Selector Switches ( IS : 6875 ) Indicating Meters ( IS : 1248) Indicating Lamps ( IS : 13947) Push Buttons ( IS : 4794) Control Transformer ( IS : 12021 ) LT Fuses ( IS : 13703) Energy Meters ( IS : 722 ) Transducers ( IEC : 60688) Diodes Terminal Blocks Synthetic Rubber Gasket ( IS : 11149 / 3400 ) Breaker Handling Trolley HT Switchgear Panel ( IS : 3427)
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y
Y Y Y
Y Y Y Y Y Y Y Y
SUB-SECTION-IIIE-11 HT SWITCHGEAR
All Routine Tests as per standard
Dimensions & Finish
Chemical Properties
Functional Checks
HV & IR Test
CLAUSE NO.
Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2. Make of all major Bought Out Items will be subject to NTPC approval.
SUB-SECTION-IIIE-11 HT SWITCHGEAR
PAGE 2 OF 2
CLAUSE NO.
HT Capacitor Bank
Functional & Operational Features as per NTPC Spec. Y Y relevant Y Y Y Y All Routine Tests as per standard
PAGE 1 OF 1
Make, Type, Model, Rating & TC
ITEMS, COMPONENTS, SUB-SYSTEM ASSEMBLY Enclosure
Oil / Paper
Insulator
Accessories
Supporting Structure (Galvanized) Complete Capacitor Y
Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2. Make of all major Bought Out Items will be subject to NTPC approval.
SUB-SECTION-IIIE-12 HT Capacitor Bank
Dimensions & Finish
Chemical Properties
CLAUSE NO.
MEASURING INSTRUMENTS (PRIMARY AND SECONDARY) TESTS Make, Model, Type, Rating (R) Process / Electrical connection (R) IBR Certification (if applicable )(R)
Dimensions (R)
Calibration (R) Test as per standard(R)
Insulation Resistance (R)
ITEMS
1. PR Gauge (IS-3624) Y Y Y Y Y 2. Temp. Gauge (BS-5235) Y Y Y Y Y 3. Pr./D.P.Switch(BS-6134) Y Y Y Y Y Y Y Y Y 4. Electronic Y Y Y Transmitter(BS-6447 / IEC60770) 5. Temp. Switch Y Y Y Y Y Y 6. Recorder(IS-9319/ANSI Y Y Y Y Y Y C-39.4) 7. Vertical indicators Y Y Y Y Y 8. Digital Indicators Y Y Y Y Y 9. Integrators Y Y Y Y 10. Electrical Metering Y Y Y Y Y Y Instrument (IS-1248) 11. Transducer (IEC-688) Y Y Y Y Y Y 12. Thermocouples (ANSI- Y Y Y Y Y Y MC-96.1) 13. RTD(IEC-751) Y Y Y Y Y Y 14. Thermowell Y Y Y Y Y R-Routine Test A- Acceptance Test Y Test applicable : Note: 1) Detailed procedure of Environmental Stress Screening Test shall be as per Quality Assurance Programme in General Technical Conditions 2) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed quality plan indicating the Practices and Procedure adopted alongwith relevant supporting documents.
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIE-13 MEASURING INSTRUMENTS PAGE 1 OF 2
Material Test certificate
Hydro Test(R)
CLAUSE NO.
TESTS Process / Electrical connection (R) IBR Certification as applicable (R) Requirement as per standard (R) Make, Model, Type, Rating (R)
Calculation for accuracy (R)
Non-destructive testing (R)
ITEMS Dimensions (R)
15. Cold junction Y compensation box 16. Orifice plate(BS-1042) Y 17. Flow nozzle(BS-1042) 18. Impact head type element 19. Level transmitter/float type switch 20. Flue Gas analyser 21. Dust emission monitors *Calibration to be carried out on one flow element of each type and size if calibration carried out as type test same shall not be repeated. Y Y Y Y Y
Y Y Y Y Y Y Y
Y Y Y Y Y Y Y
Y Y * Y * Y Y Y Y Y Y ** Y Y ** Y Y
Y Y Y Y ** Y Y Y Y Y
** If applicable R-Routine Test A- Acceptance Test Y Test applicable Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality Assurance Programme in General Technical Conditions 2) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed quality plan indicating the Practices and Procedure adopted alongwith relevant supporting documents.
SUB-SECTION-IIIE-13 MEASURING INSTRUMENTS
Material test certificate (A)

PAGE 2 OF 2
Insulation Resistance (R)
WPS approval (A)
Calibration (R)
Hydro test (R)
CLAUSE NO.
Visual/dimension/rating/ Paint Adhesion/ Thickness (R) General arrangement/BOM/make of components /Mimic Efficiency ,regulation(R)
POWER SUPPLY FOR C&I SYSTEMS (UPS/BATTERY/BATTERY CHARGER/ACDB/DCDB) TESTS

Restart with PRI A.C and battery (separately)(R)
ITEMS
UPS/CONVERTER (IECY Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y 146 PT-4) VOLTAGE STABILISER Y Y Y Y Y Y Y Y LEAD ACID BATTERY(TUBLAR)-ISY 1651 LEAD ACID BATTERY Y (PLANTE)-IS-1652 NICKEL CADMIUM BATTERY(IS-10918/IECY 623) SMF BATTERY Y ACDB/DCDB Y Y Y Y BATTERY CHARGER Y Y Y Y Y Y Y Y Y Y R-Routine Test A- Acceptance Test Y Test applicable * Transfer time and Over shoot /under shoot during load & system transfer shall be recorded . Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality Assurance Programme in General Technical Conditions 2) This is an indicative list of tests/checks. The manufacturer is to furnish a detailed quality plan indicating the Practices and Procedure adopted alongwith relevant supporting documents.
SUB-SECTION-IIIE-14 POWER SUPPLY FOR C&I SYSTEMS
PAGE 1 OF 1
Tests as per standard &specification (R)&(A)
Out put voltage and frequency adj.range(A)
Parralel operation and current divison(R)
System transfer and retransfer (R)*
AC input faliure and return test (R)
Load transfer retransfer test (R) *
Relative harmonic content(R)
Premilinary light load test(R)
Input voltage variation (A)
Asynchronous transfer(R)
Load limiter operation (R)
Ripple content(R)
IR/HV(R)
CLAUSE NO.
Quality Assurance
AUX. TRANSFORMER Make / Type / Rating / Model / TC / General Physical Inspection. & Voltage Ratio, Vector Group Polarity, Magnetic Balance Test
Attributes / Characteristics Visual & Dimensional Checks
Thermal properties
Electrical strength
Compatibility with oil
Items/Components Sub Systems
Routine Test as per relevant test
NDT / DPT / MPI / UT
Core Loss*, Hot Spot
WPS & PQR
Tank, H.V. & L.V. Cable Box / Flange throat Conservator / Radiator / Cooler / Pipes
Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y Y
Y Y
Copper Conductor (IS:191) Insulating Material CRGO Lamination & Built Core Bushing / Insulator ( IS:2544 / 5621) Gasket Transformer Oil ( IS:335) Off-Circuit Tap Changer Core Coil Assembly & Pre-tanking Marshalling Box Attributes / Characteristics
Y Y Y Y Y Y Y Y
Y Y
Y Y Y Y Y Y Y Y
Y Polarity, Make / Type / Rating / Model / TC / General Physical Inspection.
Group
&
Visual & Dimensional Checks
Items/Components Sub Systems
Routine Test as per relevant test
Voltage Ratio, Vector Magnetic Balance Test
NDT / DPT / MPI / UT
Core Loss*, Hot Spot
Compatibility with oil
Thermal properties
Electrical strength
WPS & PQR
Vacuum & Pressure Test
WTI, OTI, MOG, PRD, Breather, Terminal Connector, Bucholz Relay, Globe & Gate Valve,
Ageing Test.
Welding (ASME Sect-IX)
Complete Transformer (IS:2026) Y Y
* Core Loss on first Job Note: 1) This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2) All major Bought Out Items will be subject to NTPC approval.
TECHNICAL SPECIFICATIONS SECTION VI, PART-B
Sub-Section - IIIE-15 Aux. Transformer
Page 1 of 1
Routine Test
Routine Test
Ageing Test.
CLAUSE NO.
LEAD ACID BATTERY

Conformance to relevant part drg. & Manufacturers standards Chemical composition Conformance to CPWD Spec. for Teak Constructional requirements as per NTPC S Insulation Resistance Paint Process checks, Paint Shade, Thickness, Adhesion & Finish Lead Coating Thickness (min. 25 microns, IS: 6848 App.F) & Adhesion Test for Capacities for 10 hrs. discharge rate along with the test for voltage during discharge ( Acceptance Test) Y
PAGE 1 OF 2
ITEMS, COMPONENTS, SUB SYSTEM ASSEMBLY
Container & Lids ( IS : 1146) Vent Plugs Sealing Compound ( IS : 3116 ) Positive & Negative Plates Separators ( IS : 6071 ) Electrolyte ( Water / Sulphuric Acid ) ( IS : 1069 / 266 ) Inter-cell Connectors & Fasteners Battery Stand Cell Insulators Stack Assembly Lead Acid Battery ( IS : 1652 )
Y Y
Y Y Y Y
Y Y
Y Y
Y Y Y Y Y
Y Y Y Y
Y Y Y Y Y Y Y
Note: This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents.
SUB-SECTION-IIIE-16 BATTERY
Marking ( Routine & Acceptance Test)
Dimensions & Finish
Checking of Polarity & absence of short circuit (Routine & Acceptance Test)
CLAUSE NO.
Ni- Cd BATTERY
Polarity & absence of short circuit (Routine & Acceptance Test) Y Y Marking & Mass (Routine & Acceptance Test) Retention of Charge Test ( Acceptance Test) ATTRIBUTES / CHARACTERISTICS & drg.
Paint Shade, Thickness, Adhesion & Finish
part
Air Pressure Test after heat sealing
Air Pressure Test (Acceptance Test)
Conformance to relevant Manufacturers standards
Nickel Plating thickness
Chemical composition
Container & Lids Vent Plugs Perforated Steel Strips Active Material for Positive & Negative Plates Separators Electrolyte Inter-cell Connectors & Fasteners Battery Stand Cell Insulators Stack Assembly Ni-Cd Battery ( IS : 10918) Notes:
Y Y Y Y Y Y Y Y
Y Y Y Y
Y Y Y Y Y Y
Y Y Y
Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
Y Y
1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2. Makes of all major Bought Out Items will be subject to NTPC approval.
SUB-SECTION-IIIE-16 BATTERY
Insulation Resistance (Acceptance Test)
Dimensions & Finish
Impact Strength
Resistance to Alkali
ITEMS, COMPONENTS, SUB SYSTEM ASSEMBLY
AH Test (Acceptance Test)
PAGE 2 OF 2
CLAUSE NO.
BATTERY CHARGER (220 / 110 V)

Verification of Routine test reports as per relevant IS Sheet Steel Pretreatment & Painting h k Conform to relevant Standard & NTPC spec Complete physical examination for constructional features as per NTPC Temperature Rise Test on one unit of each rating if Type testing is waived off Ripple Content Test, Load Limiter & AVR Operation Test Dimensional check and Paint shade, thickness, adhesion & Finish checks Attributes / Characteristics Make, Model, Type, Rating & Finish Burn-In Test at 50^C for 48 hrs in energised Alternating current measurement test Degree of Protection Test as per NTCP Spec. (By physical verification of gasketting t d b i ti
Rectifier Transformer and Y Y Y Y Y Reactors IS : 4540, 2026) Electronic Components Y Y Y including Potentiometer ( Vernier Type) Electronic Cards Y Y Y PCB & racks for electronic Y Y cards Control & Selector Switches Y Y Y ( IS : 6875) Indicating Meters (IS: 1248 ) Y Y Y Indicating Lamps (IS: 13947) Y Y Y Air Break Switches / Fuses Y Y Y ( IS : 13947 / 13703 ) Control Terminal Blocks Y Y (IS : 13947) Control Transformer Y Y Y ( IS : 12021) Push Buttons ( IS : 4794 ) Y Y Y MCB ( IS : 8828) Y Y Y PVC insulated Copper Y Y control wires (IS : 694 ) Sheet Steel ( IS : 513 ) Y Y Y Synthetic Rubber Gaskets Y Y Annunciator Y Y Y Battery Charger Y Y Y Y Y Y Y Y Y Y Y Notes: 1. This is an indicative list of tests / checks. The manufacturer is to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. 2. Makes of all major Bought Out Items will be subject to NTPC approval.
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATION SECTION-VI, PART-B SUB-SECTION-IIIE-17 BATTERY CHARGER PAGE 1 OF 1
HV & IR Test
Items / Components / Sub- assembly
Dynamic Response Test
Operational & Functional Checks
CLAUSE NO.
TECHNICAL REQUIREMENTS SQE_25 Make, Degree of Protection Test (By physical verification of gasketting arrangement and by paper Specification requirement Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y
shade/thickness
Type/ Rating/Functional check
Sheet Steel (IS-513)
Y Y Y Y
Aluminum / Copper Y Y Y Bus-bar(IS-5082/IS613/IS-1987) Support Insulator Y Y Y (BS-2782/IEC660/IS-10912) Control / Selector Switch(IS-6875) Contractor/ MCB(IS13947) O/L Protection relays(IS-3231) C.T /V.T/ Indicating Meter(IS2705/3156/1248) Fuse/ Fuse carrier(IS13703) Terminals/lugs/pvc Y wires(IS-13947//IS694) Timers(IS-3231) LVS, Mosaics Push Button/ Lamp/ (IS-6875) Control Transformer (IS-12021) Mimic, Annunciater GASKET(IS-11149) Y Y Fabrication Pretreatment & Painting Control panel
Y Y Y Y Y Y Y Y
Y Y Y
Y Y Y Y Y Y Y
Y Y Y
Mountings / Completeness Y
Item Components Sub System Assembly
Dimensions / Finish
Interlock Functional & Operation Testing / Simulation check Y
Routine test as per relevant std.
CONTROL PANEL ( AHP & CHP) Attributes Characteristics
IS:6005 ,Seven tank process
Constructional Features
Chemical Properties
HV/IR
Paint
finish/
BOM/
Y
PAGE 1 OF 2
SUB-SECTION-IIIE-18 CONTROL PANEL ( AHP & CHP)
CLAUSE NO.
NOTE: 1. 2. This is an indicative list of Test/ Checks. The manufacturer to furnish a detailed Quality Plan indicating the practice and procedure along with relevant supporting documents. All major Bought Out Items will be subject to NTPC approval.
SUB-SECTION-IIIE-18 CONTROL PANEL ( AHP & CHP)
PAGE 2 OF 2
CLAUSE NO.
CONTROL DESK, PLC PANEL, SMOKE DETECTOR, FIRE ALARM & CONTROL SYSTEM Review of TC for instruments/ Devices/ Recorders, Indicators/ osaic Items/ Transducers TESTS , Accessibility of TBS/ Devices for Control Test as per IEC 1131 * Element
GA, BOM ,Lay Out of components
Paint Shade/Thickness/Adhesion
Component Rating/ Make / Type
ITEMS
1. Control Desk
2. Annunciation/ Y Y Y Y Y Y Y Y Y Y Y Y Control/ PLC Panel Y 3.Smoke Detectors ( UL-268,EN-54 PT-7), Heat Detectors( UL521/EN 54 PT-5 ) Annunciation/ Control Panel ( UL -864, EN-54, PT-2) Note: 1) Detailed procedure of Environmental Stress Screening test shall be as per Quality Assurance Programme in General Technical Conditions 2) This is an indicative list of test/ checks. The manufacturer is to furnish a detailed quality plan indicating the Practice and Procedure alongwith relevant supporting documents. *Applicable for PLC Y - Test Applicable , - Routine Test (A) - Acceptance Test
SUB-SECTION-IIIE-19 CONTROL SYSTEM
Test as per Std & ( A)
Alignment of Section
Dimensions
Illumination
IR & HV
Functional
Wiring
Visual
Check Mimic
PAGE 1 OF 1
CLAUSE NO.
QUALITY ASSURANCE
CHP System - Civil Works

1.00.00 1.01.00 1.01.01 SAMPLING, TESTING AND QUALITY ASSURANCE GENERAL REQUIREMENT This part of the specification covers the sampling, testing and quality assurance requirement ( including construction tolerances and acceptance criteria for all works and structures covered in this specification i.e. excavation and filling, cast in situ concrete and allied works, fabrication and erection of structural steel works, masonry / sheeting and allied works, finishing items, water supply and sanitation, modular aerated concrete panel, pre-engineered building, special items of works, and piling. This part of the technical specification shall be read in conjunction with other Parts of the technical specification. All tests required for all materials ( bought by Contractor ) and workmanship shall be done / got done by the contractor at his own cost. The unit rate for respective items of the schedule of items shall include the cost for all works, activities, equipment, instrument, personnel, material etc. whatsoever associated to comply with sampling, testing and quality assurance requirement including construction tolerances and acceptance criteria and as specified in subsequent clauses of this part. The Contractor shall provide the facilities whatsoever required and also bear all cost for all sampling, testing and quality assurance in the field and in the laboratory. The Contractor shall carry out all sampling and testing in accordance with the relevant Indian standards and / or international standards and this technical specification. Where no specific testing procedure is mentioned, the tests shall be carried out as per the best prevalent engineering practices and to the directions of the Engineer. All sampling shall be done in the presence of the Engineer or his authorised representative. The Contractor shall establish the Field Quality Assurance ( F. Q. A. ) laboratory and field tests shall be done in the presence of the Engineer and / or his authorised representative. The tests which cannot be carried out in the field laboratory shall be done at a laboratory of repute ( CSMRS, NCBM, IITs, Shriram Test House, New Delhi / National Test House, New Delhi etc. ), as agreed by the Engineer, If the Engineer desires to witness such tests at laboratory, Contractor shall arrange to conduct the test in his presence. The recommendations and suitability of material including petrographic examination of fine and coarse aggregates shall be sought from the testing agency. The Contractor shall submit the test results to the Engineer in triplicate, within three (03) days after completion of any test. The Contractor shall maintain Records of all Inspection and Testing, which shall be made available to the Engineer. All records shall be submitted, unless specified otherwise, as per the format developed by the Contractor and approved by the Engineer. Work found unsuitable for acceptance shall be removed and replaced by the Contractor, as per Technical Specification requirements and to the satisfaction of the Engineer. Representative samples shall be procured by the Contractor (from approved vendors) and submitted to the Engineer for his approval before bulk procurement. Approval of material / sample by the Engineer shall not relieve the Contractor of his
1.01.02 1.01.03
1.01.04
1.01.05
1.01.06 1.01.07 1.01.08
1.01.09
TECHNICAL SPECIFICATIONS SECTION VI, PART-B BID DOC. NO.: CS-2140-157-2
Sub-Section - IIIE-20 CHP System
Page 1 of 17
CLAUSE NO.
QUALITY ASSURANCE responsibility, for their conformance to the specification, the requisite quality and performance of material.
1.01.10
All Equipment and Instruments shall be calibrated before the commencement of Tests and then at regular intervals, as directed by the Engineer. If the Engineer so desires, the Contractor shall arrange for having the Instruments / Equipment get Tested for their calibration, at an Approved Laboratory and the Test report shall be submitted to the Engineer. The F. Q. A. laboratory shall have all necessary equipment and instruments and shall be managed by a qualified / experienced person. F. Q. A. laboratory shall be equipped with minimum equipment, as appended at Appendix I to these technical Specifications. The F. Q. A laboratory shall be managed by personnel specially trained for such job and approved by the Engineer. The personnel who have been trained for carrying out the relevant tests shall do all testing. The Contractor shall engage all such personnel for the duration of the Contract. The F. Q. A laboratory building shall be constructed by the Contractor at his own cost. The laboratory building shall be constructed and installed with the appropriate facilities. Temperature and humidity controls shall be available wherever necessary during testing of samples. Indicative (not exhaustive) list of typical F. Q. A. laboratory equipment shall be as specified elsewhere in this specification. The contractor at his owns cost shall provide all these equipment. The contractor shall maintain the equipment in good working condition for the duration of the contract. Any other equipment though required for testing but not listed in the equipment list shall be provided / arranged by the contractor at his own cost. If any facility for testing or the trained personnel for conducting test is not available with the Contractor then the Contractor may get the test done from reputed / approved laboratory or out source the personnel as approved by the Engineer. An indicative (not exhaustive) Field Quality Assurance organisational set up is placed at Appendix - II. The set up shall be suitably augmented as and when directed by the Engineer to cope with the work demand. Based on the schedule of work and the approved Field Quality Plan (F. Q. P.). The Contractor shall prepare a schedule of F. Q. A. tests and shall submit to the owner and shall organise the tests as scheduled. The contractor shall prepare and obtain the approval of the Owner of the F. Q. P. before the award of the work. This F. Q. P. shall cover for all the items / activities covered in the schedule of items and required for the completion of the work. Owner at their discretion shall also carry out quality audit and quality surveillance of systems and procedures of contractors quality control activities. However generally the field quality audit shall take place at an interval of three months all through the construction stage. The contractor shall store and handle the materials as per the requirements of the relevant standards at his own cost. CONSTRUCTION TOLERANCE AND ACCEPTANCE CRITERIA EXCAVATION AND FILLING Tolerance Finished surface level shall be within 20 mm of the level shown in the drawing.
1.01.11
1.01.12
1.01.13
1.01.14
1.01.15
1.01.16
1.01.17
1.01.18
1.01.19 2.00.00 2.01.00 2.01.01
Page 2 of 17
CLAUSE NO.
QUALITY ASSURANCE Acceptance Criteria Following Acceptance Criteria shall be followed. (a.) When only one set of sample is tested, then all individual samples collected and tested should pass without any deviation (b.) For retest of any sample two additional samples shall be collected and tested, and both should pass without any deviation. (c.) Where a large number of samples are tested for a particular test than 9 samples out of every 10 consecutive samples tested shall meet the specification Requirement.
2.01.02
(d.) Tolerance on finished levels for important filling areas at approved interval shall be + 20 mm. However, for an unimportant area, tolerance upto +75 mm shall be acceptable at the discretion of the Engineer. However, these tolerances shall be applicable for localised areas only.
2.02.00 2.02.01
CAST-IN-SITU CONCRETE AND ALLIED WORKS Tolerances (a.) CAST-IN-SITU CONCRETE Unless otherwise specified, the dimensions of concrete as cast when compared with those on the drawings i. e. the tolerance in construction shall be as given hereunder : DESCRIPTION OF ITEM / STRUCTURAL ELEMENT Faces of concrete in foundations and structural members against which backfill is placed Location of footing (for RCC framed structures only) Eccentricity of footing PERMISSIBLE DEVIATION IN MM (MAX) + 25 - 10
+25
- 25
Top surfaces of slabs and of concrete to receive base plates to be grouted Alignment of beams, lintels, columns, walls, slabs and similar structural elements Cross sectional dimensions of walls, slabs and similar structural elements Deviation from specified dimensions of cross section of columns and beams. Alignment of holding down bolts without sleeves Alignment of holding down bolts with sleeves. Level of holding down bolt assemblies. Embedded parts (in any direction) Centres of pockets or holes with greatest lateral dimension not exceeding 150mm
FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE TECHNICAL SPECIFICATIONS SECTION VI, PART-B BID DOC. NO.: CS-2140-157-2
2% of footing width in direction of misplace - ment but limiting to 50mm +5 -5 +5 +5 +12 +1.5 +5 +10 +5 +10 -5 -5 -6 - 1.5 -5 - 10 -5 - 10
Page 3 of 17
CLAUSE NO.
QUALITY ASSURANCE Variation in steps : Riser Tread Plumb
+1.5 - 1.5 +3.0 - 3.0 3mm for every meter subject to a maximum of 10mm.
(b.) Reinforcement Tolerance on placing of reinforcement and for cover shall be as per clause number 12.3 of IS : 456. Reinforcement shall be placed within the following tolerances:
Sl. No. a) b) For effective depth 200 mm or less For effective depth more than 200 mm 10 mm 15 mm Description Tolerance limits
(c.) Cover Actual concrete cover should not deviate from the required nominal cover by + 10 mm (d.) Pre cast concrete Tolerance on dimensions of pre-cast units shall be as follows: (1.) Length : +/- 0.1 percent subject to minimum of +/- 5 mm and maximum of + 10 mm. (2.) Cross-sectional dimensions : +/- 3 mm or +/- 0.1 percent whichever is greater. (3.) Straightness or Bow : 1/750 of the length subject to minimum of +/- 5 mm and maximum of +/- 10 mm. (4.) Squareness : When considering the squareness of the corner the length of the two adjacent sides being checked shall be taken as the base line. The shorter side shall not vary in length from the perpendicular by more than 5 mm. (5.) Flatness : The maximum deviation from a 1.5m straight edge placed in any position on a nominal plant surface shall not exceed 5 mm. (e.) FORMWORK AND STAGING (1.) Staging shall be checked for its soundness as a whole and for adequacy of the joints and its foundations. Formwork joints shall be inspected for soundness of connections. All joints shall be either vertical or horizontal and shall be such as to avoid loss of liquid through the FormWork. (2.) Dimensional tolerance for formwork shall be as per Clause 9.6 of IS : 14687 and 11.1 of IS : 456 and as given below :
Page 4 of 17
CLAUSE NO.
QUALITY ASSURANCE
Description Levels and heights Plumb
Tolerances +6mm 3mm for every meter subject to a maximum of 10mm. +3mm +12mm +15mm In case of inclined surfaces like folded plates etc., the deviation in the alignment of inclined surfaces, shall not exceed 3mm with reference to the theoretical alignment, for a length of 1000 mm measured vertically, subject to a maximum of 10mm.
Unevenness of any surfaces Length or breadth Diagonals
Deviation from specified dimensions of cross section of columns and beams Deviation from dimensions of footings 1 ) Dimensions in plan 2 ) Eccentricity
+12 mm / - 6 mm
+ 50 / - 12 mm 0.02 times the width of the footing in the direction of deviation but not more than 50 mm 0.05 times the specified thickness
3 ) Thickness
The above tolerances apply to concrete dimensions only, and not to positioning of vertical reinforcing steel or dowels (3.) Checklist for formwork shall be as per Clause 9.9 of IS : 14687. Format as per Annexure - C of IS : 14687 shall necessarily be made for all important structures including all machine foundations. 2.02.02 Acceptance Criteria (a.) The acceptance criteria of concrete shall be in accordance with clause no. 16 of IS : 456. However in exceptional circumstances, and that too in non-critical areas, the Engineer may accept concrete work which is marginally unacceptable as per the criteria laid down in IS : 456. For such accepted work, payment shall be made at a reduced rate pro rate to the concrete cube strength obtained, against that stipulated.
Page 5 of 17
CLAUSE NO.
QUALITY ASSURANCE (b.) Unacceptable Concrete Work shall be dismantled by the Contractor and replaced by fresh Work, meeting the specification Requirements. In the course of dismantling, if any damage is done to the Embedded items or adjacent structures, the same shall be made good, by the Contractor, to the satisfaction of the Engineer, at no extra cost to the Owner. (c.) Test shall be conducted for the Water tightness of the liquid retaining structures as per IS : 3370 and IS : 6494.
2.03.00 2.03.01
FABRICATION AND ERECTION OF STRUCTURAL STEEL WORK Fillet Welds (a.) Check for size and visual examination. (b.) Macroetch examination on production test coupons for main fillet welds with minimum one joint per built up beams, columns and crane girder etc. (c.) 25% weld length of tension member of crane girder shall be subjected to Dye Penetration Test ( D. P. T. )
(d.) On all other fillet welds, D. P. T. on 5% of weld length with minimum 300 mm at each location shall be carried out. 2.03.02 Butt Welds (a.) 100% visual examination (b.) D. P. T. on all butt welds after back gouging (c.) Mechanical testing of production test coupons with minimum one joint per built up beam, column and crane girder.
(d.) 100% radiography test on butt welds of tension flange ( bottom flange ) of crane girder. All other butt welds shall be subjected to Radiography Test ( R. T. ) on 10% weld length of each welder. Wherever R. T. is not feasible, U. T. shall be carried out. (e.) Full penetration welds ( other than butt welds ) shall be subjected to Ultrasonic Testing in following quantum : (1.) 100% U. T. on web to flange joint of crane girder. (2.) 10% U. T. on other full penetration joints. (f.) In case of failure of any welds in 10% R. T. / U. T., the %age for retesting shall be doubled at that particular location. Acceptance criteria of Non Destructive Tests ( N. D. T. ) on welds shall be as per AWS D1.1.
2.03.03
All structure components / members shall be checked for following dimensional tolerances during fabrication and erection. (a.) Fabrication tolerances (1.) maximum permissible gap in built up members. (2.) maximum permissible deviation in depth and / or width of girder at the joints. (3.) maximum permissible out-of-square of flanges in built-up girders. (4.) length of beams and girders and their components. (5.) permissible deviation in column heights. All tolerances for above shall be as per drawings / IS : 7215.
Page 6 of 17
CLAUSE NO.
QUALITY ASSURANCE (b.) Erection tolerances (1.) permissible tolerances in erected steel columns. (2.) permissible tolerances in erected steel trusses. (3.) permissible tolerances in crane girder and rails. All tolerances for above shall be as per approved drawings / IS : 12843. (c.) Requirement of pre-heating
Welding other than using low Welding using low hydrogen welding electrodes submerged welding IS:2062 None 20o C 66o C 110o C or arc
Thickness of thickest part at the point of welding electrodes
hydrogen welding electrodes 2062 Upto 20 mm ( including ) Over 20 mm to 40 mm ( including ) Over 20 mm to 63 mm (including) Over 63 mm None 66o C Not allowed Not allowed IS :
2.03.04
Acceptance Criteria (a.) The acceptance criteria of Non Destructive Testing ( N. D. T. ) on welds shall be as per AWS D1.1 ( Dynamically Loaded Structures - tension welds ). In case of failure of any of the tests, the Contractor at his own cost shall also carry out rectification of such defective welds. The Contractor, at his own cost shall also carry out re-testing of the rectified joint. (b.) Every 1st and further every 10th set of identical structure shall be checked for control assembly in shop before erection.
2.04.00 2.04.01
Embedded Parts Tolerances Tolerances shall be as specified under concrete works.
2.05.00 2.05.01
Masonry, Sheeting, and Allied works Tolerances (a.) All masonry shall be built true and plumb within the tolerances prescribed as below. Care shall be taken to keep perpends properly aligned. Unless specified otherwise the tolerances in construction of masonry shall be as below : (1.) Deviation in verticality in total height of any wall of a building more than one storey in height shall not exceed ( 12.5 mm.
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CLAUSE NO.
QUALITY ASSURANCE (2.) Deviation from vertical within a storey shall not exceed ( 6 mm per 3m height. (3.) Deviation from the position shown on the plan of any brickwork more than one storey in height shall not exceed 12.5 mm. (4.) Relative displacement between load bearing walls in adjacent storey intended to be in vertical alignment shall not exceed 6 mm. (5.) Deviation of bed joint from horizontal in any length upto 12m shall not exceed 6 mm, and in any length over 12m it shall not exceed 12.5 mm total. (6.) Deviation from the specified thickness of bed-joints, cross-joints or perpends shall not exceed ( 3 mm. (b.) The plastered surface shall be checked for (1.) Blistering, bond failure or loss of adhesion, cracking, crazing, efflorescence, grinning, irregularity of surface texture, popping or blowing, recurrent surface dampness, softness or chalkiness defects and the remedial measures for the same shall be adopted as per IS: 1661. (2.) The finished plastered surface shall not show any deviation more than 4 mm when checked with a straight edge of 2 metre length placed against the surface. (3.) The thickness of the plaster shall be measured exclusive of the thickness of key i.e., grooves or open joints in brickwork. The average thickness of plaster shall not be less than the specified thickness. The minimum thickness over any portion of the surface shall not be less than the specified thickness by more than 3 mm for plaster thickness above 12 mm and 1 mm for ceiling plaster. Extra thickness required in dubbing, behind rounding of the corners, at junctions of wall or in plastering of masonry cornices etc. shall be ignored. (c.) Sheeting works shall be checked for the following (1.) Material Test Certificate ( M. T. C. ) for structural steel submitted by the contractor shall be checked for compliance with the applicable IS code. (2.) Material test certificate for coated sheet ( issued by an approved laboratory ) submitted by the contractor for each supply of batch. (3.) At least three random samples of sheet, from three different batches of supply, shall be selected by the Engineer, which shall be got tested by the Contractor, for salt spray test for 1000 hrs, type of coating, physical properties, thickness of coating at an approved laboratory. (4.) Constructional tolerances for sheeting works shall be similar to those allowed for masonry works
2.05.02
Acceptance Criteria Following acceptance criteria shall be followed: (a.) General workmanship is being good and as recommended by the manufacturer and approved by the Engineer. (b.) Tolerances are within the specified limits. (c.) Material test certificate is in compliance with the applicable codes/standards. (d.) Bought out material is from the approved manufacturer / vendor.
Page 8 of 17
CLAUSE NO.
QUALITY ASSURANCE (e.) Bought out material is matching with the approved sample.
2.06.00 2.06.01
FINISHING AND ALLIED WORKS Floor Finish The tolerances shall be checked specially for the following : (a.) Level, slope, plumb as the case may be (b.) Pattern and symmetry (c.) Alignment of joints, dividing strips etc. (d.) Colour, texture (e.) Surface finish (f.) Thickness of joints (g.) Details of edges, junction etc. (h.) PERFORMANCE (i.) Precautions specified for durability Local depressions on account of faulty workmanship shall not be acceptable. Tiles / natural stones with cracked or broken / chipped edges shall not be acceptable.
2.06.02
Door, Window, Ventilator, Partitions (a.) Before fitting and fixing in position following shall be checked : (1.) Overall dimensions shall be within + 1.5 mm of the size shown on drawing. (2.) Mullions, transoms etc. shall be in one length and permissible deviations from straightness shall be limited to + 1.5 mm from the axis of the member. iii ). Door leaves shall be undercut where shown on drawings. (3.) Doors, windows, ventilators, partition frames, etc., shall be on a true plane, free from warp or buckle. (4.) All welds shall be dressed flush on exposed and contact surfaces. (5.) Correctness of location and smoothness of operation of all shop installed hardware and fixtures. (6.) Provision for hardware and fixtures to be installed at site and compliance with relevant IS codes. (7.) Glazing beads shall be cut with mitered corners. (8.) Glazing clips, fixing devices etc. shall be supplied in adequate numbers. (9.) Shop coats shall be properly applied. (10.) Exposed aluminium surface shall be free from scratches, stains and discoloration. Anodised surfaces shall present a uniform and pleasant look. (11.) Correlating the material with the test certificate ( M. T. C. ) (12.) Matching the material supplied with the approved sample (13.) Thickness of paint / anodized coating
Page 9 of 17
CLAUSE NO.
QUALITY ASSURANCE (14.) All welds shall be dressed flush on exposed and contact surfaces. (b.) During and after fitting and fixing in position following shall be checked. (1.) Installation shall be at correct locations, elevations and in general on a true vertical plane. (2.) Fixing details shall be strictly as shown on drawings. (3.) Assembly of composite units shall be strictly as per drawing, with mastic caulking at transoms and mullions, gaskets, weather strips etc. complete. (4.) All frames on external wall shall be mastic caulked to prevent leakage through joint between frames and masonry. (5.) All openable sections shall operate smoothly without jamming. Lock, fasteners, etc, shall engage positively. Keys shall be non-interchangeable. (6.) Cutting to concrete or masonry shall be made good and all abrasions to shop paint shall be touched up with paint or same quality as shop paint. (7.) Aluminium doors, windows, ventilators, partitions etc., shall be free from scratches, stains or discoloration. (8.) Door and window shutters shall operate without jamming. The clearance at head and jamb for door shutters shall not exceed 1.5 mm. For double leaf doors, the gap at the meeting stiles shall not be more than 2.5 mm.
2.06.03
Fire Proof Doors (a.) Fire Proof doors shall be tested for the requirements mentioned in IS-3614 Part-II. The doors shall have minimum 2 hours fire rating. (b.) D. F. T. and fire retardancy of paint of fireproof doors shall be checked.
2.06.04
Rolling Shutters / Grills / Sliding doors (a.) After installing the shutters, the contractor shall test the performance of the shutter in the presence of the engineer. The shutter shall be smoothly operable under all ambient conditions. All controls and locking devices shall give fault free performance. (b.) Sliding doors : The sliding mechanism shall provide for smoothly operable by gentle push / pull of a single person.
2.06.05
GLASS AND GLAZING Following shall be checked for : (a.) All Glazing is free from cracked, broken or damaged glass. (b.) Edges of large panes of glass shall be inspected carefully for chipped, cracked or ungrounded edges. (c.) At completion, the panes shall be free from dirt, stains, excess putty, etc., to the complete satisfaction of the Engineer.
(d.) All glasses shall be embedded in martie or fixed by neoprene gaskets to give a leak proof installation. 2.06.06 False Ceiling System (a.) Following shall be checked for : (1.) as installed shall be true to shape, level.
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CLAUSE NO.
QUALITY ASSURANCE (2.) correctness for the opening for the fixtures, colour and shade. (3.) All joints shall be in the same line and cross-joints shall be securely fixed to walls. (4.) There shall not be any sagging and / or unevenness in the surface (b.) Acceptance Criteria Ceiling panels shall be best quality material in thickness and properties called for in the schedule of items. Material Test Certificate to be submitted before bulk supply. Finished ceiling shall be at the correct plane and prevent an aesthetically pleasing and uniform appearance, free from sags and warps. Joints and exposed grids shall be in true lines and symmetrically placed in manner as shown in drawings. Cut outs for light fixtures, diffusers and other relevant services shall be of exact dimensions and in exact locations.
2.06.07
Water proofing Water proofing shall be tested for water tightness by creating a pond of water minimum 25 mm height on area of 6 m x 6 m, for the period of 48 hrs on fully dried elastomeric membrane surfaces. Minimum 5% area of the roof shall be subjected to water tightness test. Such test necessarily be conducted on vulnerable areas like drain channel/ drain head. No dampness shall be visible on the underneath side of roof ( i.e. ceiling ), parapet and well junctions etc. which have been subjected for testing. The above testing shall be carried out prior to application of wearing course.
2.07.00 2.07.01 2.07.02 2.07.03 2.07.04
PAINTING AND ALLIED WORKS Various materials used shall conform and tested for the requirements of Indian/International Codes specified in the technical specification. Surface to receive paint shall be made smooth. Painting shall be checked for thickness and or number of different coats as specified in schedule of items/drawing. Acceptance Criteria Following acceptance criteria shall be followed: (a.) General workmanship is being good and as recommended by the manufacturer and approved by the Engineer. (b.) Tolerances are within the specified limit. (c.) Material test certificate is in compliance with the applicable codes/standards. (d.) Bought out material is from the approved manufacturer / vendor. (e.) Bought out material is matching with the approved sample.
2.08.00 2.08.01
WATER SUPPLY, DRAINAGE AND SANITATION Tolerances (a.) All soil pipes, waste pipes, ventilating pipes and all other pipes, when above ground, shall be gas tight. All sewers and drain laid below ground shall be watertight.
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CLAUSE NO.
QUALITY ASSURANCE (b.) Obstruction / Straightness Test The obstructions shall be checked by inserting a smooth ball, of diameter 13 mm less than the pipe bore at the high end of the sewer or drain. If absence of any obstructions, such as yarn or mortar projecting through the joints, ball shall roll down the invert of the pipe and emerge at the lower end. The straightness shall be checked by means of a mirror at one end of the line and lamp at the other. If the pipeline is straight, the full circle of the light may be observed. The mirror will also indicate obstruction in the barrel, if the pipeline is not straight. (c.) Service Pipes Testing with Water The service Pipes shall be slowly and carefully charged with Water, allowing all air to escape avoiding all shock or Water hammer. The service Pipe shall then be inspected under Working condition of Pressure and flow, when all draw off Taps are closed. The service Pipes shall be checked for satisfactorily support and protection from damage corrosion and frost. (d.) Fixtures etc. Watertight joints shall connect all fixtures and fittings. No dripping of water shall be acceptable.
2.08.02
Acceptance Criteria Following acceptance criteria shall be followed: (a.) General workmanship is being good and is recommend by the manufacturer and approved by the engineer. (b.) Tolerances are within the specified limit. (c.) Material test certificate is in compliance with the applicable IS Codes. (d.) Bought out material is from the approved manufacturer / vendor. (e.) Bought out material is matching with the approved sample.
2.09.00 2.09.01
Bored Cast - in - Situ Piles Tolerances (a.) Founding level of the piles shall be checked as per the criteria given elsewhere in the Technical specifications and Standard Penetration Test ( S. P. T. ), core recovery of rock, as applicable. (b.) The permissible limits for deviation with respect to position and ( inclination ) alignment shall conform to IS : 2911 Part - I and as given below. (1.) The maximum deviation of vertical piles shall not exceed 1.5 per cent in alignment. (2.) Piles shall not deviate more than 75 mm or D / 10 whichever is higher from their designed position at cut-off-level. (c.) Limits for Bentonite for piling work shall satisfy the following requirements (1.) Liquid limit of bentonite when tested in accordance with IS : 2720 ( Part V ) shall be more than 300 percent and less than 450 percent. (2.) Sand content of the bentonite powder shall not be greater than 7 percent. (3.) Bentonite solution should be made by mixing it with fresh water using pump for circulation. The density of the freshly prepared bentonite suspension shall be between 1.034 and 1.10 gm/ml depending upon the
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CLAUSE NO.
QUALITY ASSURANCE pile dimensions and type of soil in which the pile is to be installed. However, the density of bentonite suspension after getting mixed with deleterious materials in the pile bore may be upto 1.25 gm / ml. (4.) The Marsh viscosity when tested by a Marsh cone shall be between 30 to 60 seconds. (5.) The differential free swell shall be more than 540 percent. (6.) The pH value of the bentonite suspension shall be between 9 and 11.5. (d.) Check for pile bore: on completion of boring and cleaning, the bottom of each pile bore shall be checked from the samples of the contaminated drilling mud collected from near the bottom of pile bore. (e.) Slump of concrete shall be 150 - 180 mm (f.) Cover to reinforcement shall be as per technical specifications. (g.) Concrete above Cut-off-Level ( C. O. L. ) shall be 1.0 m.
2.09.02
Acceptance Criteria (a.) The founding level shall be as per technical specification. (b.) Density of drilling mud from pile bore bottom shall not be more than 1.25 T / m3 before concreting. (c.) Tolerances are in the specified limits.
2.10.00 2.10.01
SPECIAL ITEMS Vibration Isolation System ( V. I. S. ) Stiffness values shall be checked. The permissible deviations shall be as per DIN 2096. For accepting, following acceptance criteria shall be followed: (a.) General workmanship is being good and as recommended by the manufacturer and approved by the Engineer. (b.) Tolerances are within the specified limit. (c.) Material test certificate ( M. T. C. ) is in compliance with the applicable codes / standards.
(d.) Bought out material is from the approved manufacturer / vendor. (e.) Bought out material is matching with the approved sample.
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CLAUSE NO.
QUALITY ASSURANCE ANNEXURE I TYPICAL FIELD QUALITY LAB EQUIPMENT
Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Equipment
Minimum Nos.
Vicat Apparatus with deskpot Le chatelier flask Le chatelier Mould Cube Moulds for cement testing Vibration Machine Laboratory cement autoclave Length comparator Shrinkage Bar mould Sieve shaker Sieves for sand, coarse and fine aggregate Sieves for coarse aggregate for Road Proctor testing equipment Slump testing equipment Oven Physical balance Rapid moisture meter Thermometer Burret Measuring cylinders Measuring flasks Compression testing machine
2 2 2 6 1 2 2 2 1 1 set for each 1 set 1 sets + 9 cores 3 sets 1 1 2 2 1 5 2 1 sets of 200 kN capacity each
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CLAUSE NO.
QUALITY ASSURANCE Cube moulds Electronic balance 15 1 (12 kg capacity ), 2 (200 mg capacity) 1 Party should deploy BARC approved agency for carrying out R. T. 1 (100 kg capacity) As per requirement 5 2 2 1 2 2 2 As per requirement
22 23
24 25
pH balance Radiographic facilities
26 27 28 29 30 31 32 33 34 35 Note :
Mechanical weighing machine Ultrasonic testing machine D. P. Test kit Vernier 300 mm, 600 mm Micrometer ( 0.25 mm ) out side ( 25.00 ) Radiography film viewer Inside Micrometer 25-750 dia Digital elcometer for paint thickness Baking oven for electrode Portable ovens
The list of equipment above is only indicative and shall be suitably modified depending upon the size and capacity of package and project.
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CLAUSE NO.
QUALITY ASSURANCE ANNEXURE - II Notes : (i.) All test reports / inspection reports have to be computerized and maintained on LAN with an access to the owner. Computers - 2 Nos shall be deployed with Windows operating system and connected to the NTPC server. Based on the schedule (L2 Network), Quality control and Quality Assurance work plan including the schedule of tests shall be generated on the computer which shall be accessed by the owner for database and day to day monitoring. The above organisation setup is indicative only. The contractor shall mobilize required number of skilled and supporting staff and additional resources, if any to meet the work schedule.
(ii.)
(iii.)
(iv.)
TECHNICAL SPECIFICATIONS SECTION VI, PART-B BID DOC. NO.:CS-9558-156-2
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CLAUSE NO.
QUALITY ASSURANCE APPENDIX II
FQA ORGANISATION SET UP
Project Manager
Manager (Quality)
CIVIL ENGINEER FOR CONCRETING WORK CUM EARTH WORK & LAB INCHARGE
ENGINEER (NDT) STRUCTURE
Lab Assistance & Sufficient skilled manpower
Qualified Manpower RT Level II UT Level II
NOTE : 1. All test reports/inspection reports have to be computerized and maintained on LAN with an access to the Employer. Computers 2 Nos. shall be deployed with Windows operating system and connected to the NTPC server. Based on the schedule (L2 Network), Quality Control & Assurance work plan shall be generated on the computer to be accessed by the Employer for database and day to day monitoring. The above organisation setup is indicative only. The contractor shall mobilise required number of skilled & supporting staff and additional resources, if any to meet the work schedule.
2.
3.
4.
TECHNICAL SPECIFICATIONS SECTION VI, PART-B BID DOC. NO.:CS-9558-156-2
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LIST OF TENDER DRAWINGS
---------------------------------------------------------------------------------------------------------------S.NO. DRG. NO. TITLE ---------------------------------------------------------------------------------------------------------------A MECHANICAL 1. 2. 3. 4140-999-POM-A-001 4140-999-POM-A-002 4140-999-POM-A-003 General Layout Plan GA of Junction Houses Single Line Diagram for DS, SW, CW & Potable Water System
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ELECTRICAL 4140-999-POE-A-001 (Two sheets) Coal Conveyors Plant Single Line Diagram
TECHNICAL SPECIFICATIONS SECTION-VI PART - E LIST OF TENDER DRAWINGS PAGE 1 OF 1

Schedule ETechnical Specification NTPCHQ120111

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Schedule ETechnical Specification NTPCHQ120111

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NTPC Limited

(A Government of India Enterprise)

FARAKKA SUPER THERMAL POWER PROJECT

COAL CONVEYING PLANT PACKAGE

FARAKKA SUPER THERMAL POWER PROJECT

COAL CONVEYING PLANT PACKAGE

Sub Section II : Scope of Supply & Services IIA-01 Intent of Specification

SECTION NO IIIB-13 IIIB-14 IIIB-15

List of Tender Drawings

SCOPE OF SUPPLY AND SERVICES

(x) (xi) (b.)

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

DETAILED SCOPE PHASE-I

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

Motors :All HT and LT motors along with lugs and glands.

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

Electrical buildings :i) Phase-I

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATION SECTION-VI PART-A BID DOCUMENT NO.:

SUB-SECTION-IIA-01 INTENT OF SPECIFICATION

SYSTEM PARAMETERS AND OPERATION & CONTROL PHILOSOPHY

800 dia (min.) 630 dia (min)

FARAKKA SUPER THERMAL POWER PROJECT COAL CONVEYING PLANT PACKAGE

TECHNICAL SPECIFICATIONS SECTION-VI PART-B

SUB-SECTION-IIIA-01 SYSTEM PARAMETERS AND OPERTION & CONTROL PHILOSOPHY

Capacity & Pressure at inlet of spray head

Potable Water System