General Technical Specifications

Saptang Khola Hydropower Project Bid Documents for Hydromechanical Works
General Technical Specifications
Table of Contents
1. GENERAL REQUIREMENTS OF WORKS ......................................................................... 1
1.1 Scope of Works ........................................................................................................... 1
1.2 Reference to the other Sections ................................................................................... 1
1.3 Drawings to be furnished to the Bidder ........................................................................ 1
1.4 Specifications............................................................................................................... 3
1.5 Deviation from Specifications ....................................................................................... 3
1.6 Weight Variation .......................................................................................................... 3
1.7 Schedule and Progress ................................................................................................ 4
1.8 Site Erection ................................................................................................................ 4
1.8.1 General ................................................................................................................. 4
1.8.2 Procedure ............................................................................................................. 5
1.9 Tools and Tackles ........................................................................................................ 5
1.10 Defective Materials/Machinery ..................................................................................... 5
1.10.1 Defects disclosed prior to final acceptance ........................................................... 5
1.10.2 Defects disclosed after final acceptance ............................................................... 5
1.11 Operation of unsatisfactory Materials, Machinery etc. .................................................. 6
1.12 Co-operation with other agencies................................................................................. 6
1.13 Emergency Arrangements ........................................................................................... 9
1.14 Management Meeting .................................................................................................. 9
1.15 Side Records ............................................................................................................... 9
1.16 Daily log book/Site diary............................................................................................... 9
1.17 Progress Reports ........................................................................................................10
1.18 Record Progress Photographs ....................................................................................10
1.19 Metric Unit ..................................................................................................................10
1.20 As Built drawings ........................................................................................................11
1.21 Health and Sefety .......................................................................................................11
1.21.1 General Provision ................................................................................................11
1.21.2 Specific Provisions ...............................................................................................12
1.21.3 Project Specific Safety Plan .................................................................................14
1.22 Environment and Community ......................................................................................15
1.22.1 Public Relations ...................................................................................................15
1.22.2 Employment .........................................................................................................16
1.22.3 Land Interest ........................................................................................................16
1.22.4 Protection against Damage ..................................................................................16
1.22.5 Watercourses.......................................................................................................16
1.22.6 Waste Disposal ....................................................................................................17
1.22.7 Final Clean-up .....................................................................................................17
2. GENERAL TECHNICAL SPECIFICATIONS ......................................................................18
2.1 Design and Drawings ..................................................................................................18
2.2 Types of Electrodes, Wires and Fluxes .......................................................................18
2.2.1 General ................................................................................................................18
2.2.2 Covered Electrodes .............................................................................................19
2.2.3 Wire and Flux for Submerged Arc Welding ..........................................................19
2.2.4 Wire for Gas Metal Arc Welding ...........................................................................19
2.2.5 Conditions and Storage .......................................................................................19
2.2.6 Heating and Baking Requirements.......................................................................19
2.3 Qualification of Welding Procedures ...........................................................................20
2.3.1 General ................................................................................................................20
2.3.2 Parameters in the Welding Procedure Specification.............................................20
2.3.3 Welding Procedure Qualification Test ..................................................................21
2.3.4 Procedure Qualification Record ...........................................................................21
2.3.5 Non Permitted Welding Processes.......................................................................21
2.3.6 Testing Requirement for Procedural Qualification Test ........................................21
2.3.7 Acceptance Criteria..............................................................................................22
2.3.8 Retest ..................................................................................................................22
2.4 Qualification of Welders and Welding Operators .........................................................23
2.4.1 General ................................................................................................................23
2.5 Production Welding .....................................................................................................24
2.5.1 General ................................................................................................................24
2.5.2 Welding Sequence ...............................................................................................24
2.5.3 Weld Preparations ...............................................................................................24
2.5.4 Weld Execution ....................................................................................................25
2.5.5 Preheating and Interpass Temperature ................................................................28
2.6 Testing of Welds .........................................................................................................28
2.6.1 Reporting .............................................................................................................28
2.6.2 Mandatory Stages of Inspection ...........................................................................29
2.6.3 Visual Inspection..................................................................................................29
2.6.4 Radiographic Inspection ......................................................................................29
2.6.5 Ultrasonic Inspection............................................................................................29
2.6.6 Magnetic Particle Inspection (MPI).......................................................................29
2.6.7 Dye Penetrate Inspection (DPI)............................................................................30
2.6.8 Increased Inspection ............................................................................................30
2.6.9 Mechanical Tests .................................................................................................30
2.7 NDT Reporting Requirements .....................................................................................30
2.8 Inspection Requirements ............................................................................................31
2.8.1 Inspection Personnel ...........................................................................................31
2.8.2 Welding Inspection ..............................................................................................31
2.9 Inspection and Testing ................................................................................................32
2.9.1 General ................................................................................................................32
2.9.2 Material Tests in Foundry and Steel Manufacturer's Mill ......................................32
2.9.3 Pressure Tests.....................................................................................................33
2.9.4 Parts Exposed to Gas Pressure ...........................................................................34
2.9.5 Parts Exposed to Liquids without Overpressure ...................................................34
2.9.6 Welding Tests at Works and at Site .....................................................................34
2.9.7 Dimensions and Finish.........................................................................................35
2.9.8 Acceptance ..........................................................................................................36
2.10 Packing, Marking, Transportation and Nameplates .....................................................36
2.10.1 General ................................................................................................................36
2.10.2 Packing ................................................................................................................36
2.10.3 Marking ................................................................................................................36
2.10.4 Transportation......................................................................................................37
2.10.5 Storage ................................................................................................................38
2.10.6 Nameplates .........................................................................................................38
2.11 Erection ......................................................................................................................38
2.12 Maintenance ...............................................................................................................39
2.13 Tests on Completion, Commissioning .........................................................................39
2.14 Documentation............................................................................................................39
2.14.1 Final Documentation ............................................................................................39
2.15 Hydraulic Steelworks ..................................................................................................42
2.15.1 Corrosion allowance ............................................................................................42
2.15.2 Design and Calculation ........................................................................................42
2.15.3 General Design Particulars ..................................................................................43
2.15.4 Oils and Lubricants ..............................................................................................43
2.15.5 Bolts, Studs, Nuts and Screws .............................................................................44
2.16 Electrical Equipments and Wring ................................................................................44
2.16.1 General ................................................................................................................44
2.16.2 Electric Motors .....................................................................................................44
2.16.3 Motor Brakes .......................................................................................................45
2.16.4 Electric Cable and Wiring .....................................................................................45
2.16.5 Motor Stator and ammeters .................................................................................45
2.16.6 Conduits ..............................................................................................................45
2.16.7 Enclosure.............................................................................................................45
2.16.8 Convenience Outlets............................................................................................45
2.16.9 Limit Switches ......................................................................................................46
2.16.10 Indicating Lights ...............................................................................................46
2.16.11 Instruments and Meters ....................................................................................46
2.16.12 Lighting Fixtures ...............................................................................................46
2.16.13 Electrical Relays ...............................................................................................46
2.16.14 Terminal Strips .................................................................................................46
1. GENERAL REQUIREMENTS OF WORKS

1.1 Scope of Works
The Scope shall cover Supply, Fabrication, Transportation, Installation, Testing and
Commissioning of following works including additional works to complete these works
Gate, Stoplog, Hoist & Liner at Undersluice
Trash Rack, Gate, Stoplog and Hoist at Intake
Gate, Stoplog, Hoist & Liner at Gravel Trap
Gate & Hoist at Sand Flushing
Trash Rack at Forebay
Headrace Pipe and Accessories
Surge Tank and Accessories
Penstock Pipe and Accessories
Specific requirements are as described in the relevant sections of the specification.
1.2 Reference to the other Sections
The Bidder shall carefully study the specifications and drawings and shall intimate the
Employer in case any error/omission / inconsistency is found. As a result of such intimation,
if some corrections/ modifications are required, the same will be brought to the notice of the
entire Bidder by the Employer.
Any item/accessories, not specifically mentioned in the specifications but necessary for the
operation of gates/equipment/penstock/headrace pipe shall be deemed to have been
included in the Bid. The Bidder shall read this specification in conjunction with other
bidding/Bid documents.
1.3 Drawings to be furnished to the Bidder
a. Following drawings are enclosed to indicate general arrangement and requirements

and referred as Specification Drawing elsewhere in this Bid:
S. No. Description
a. Layout Plan and Profile of Head works, Headrace Pipe, Penstock Pipe
b. Layout Plan of Power House
c. General Arrangements of Gates & Hoists, Trash racks and Steel Linings in
Headworks.
April 2017 1
b. Within 60 (Sixty) calendar days after signing the agreement of the Bid, the Bidder
shall submit to the Employer for approval, not less than three sets of assembly
drawings and detailed drawings of the various parts along with the computations to
demonstrate fully the designs and show that the gates/equipment/machinery/ trash
rack; to be supplied conform to the provisions and intent of these specifications.
c. The drawings or accompanying data shall show the specifications of the heat
treatment where used.
d. All drawings submitted will form part of the Bid. The sequence of submission of
drawings will also form a part of the Bid. The sequence of submission of all drawings
shall be such that all the information is available for checking each drawing, when it
is received by the Employer. The Employer will return a copy of each drawing to the
Bidder marked either àpproved’, àpproved as noted’ or `returned for corrections’.
The notation àpproved’, àpproved as noted’ shall authorize the Bidder to proceed
with the manufacture of the machinery covered by such drawings subject to the
corrections, if any noted thereon. When prints of drawings have been returned for
correction, the Bidder shall revise the drawings as necessary and shall resubmit
fresh prints for approval in the same routine as before.
e. Following Shop Drawings shall be prepared by the Bidder and submitted for approval
before starting manufacturing/fabrication:
Gate, Stoplog, Hoist & Liner at Under-sluice
Trash Rack, Gate and Hoist at Intake
Gate, Hoist and Liner at Gravel Trap
Gate, Hoist at Sand Flushing
Trash Rack at Forebay
Headrace and Accessories
Surge Tank and Accessories
Penstock Pipe and Accessories
f. Any fabrication work performed prior to the approval of drawings will be at the
Bidder's risk. The Employer shall have the right to ask the Bidder to make changes
in the design, which may be necessary in the opinion of the Employer to make the
equipment/machinery conform to the stated provisions and intent of the
specifications, without any additional cost.
Approval by the Employer of the Bidder's drawings shall not be held to relieve the
Bidder or any part of the Bidder's obligation to meet all the requirements of these
specifications or the responsibility for the correctness of designs and drawings. The
Bidder shall furnish six complete sets of the prints of the final corrected drawings of
the various parts as per the opinion of the Employer which may be required for
erection, maintenance and repair, identification of parts and for making of ordering
replacement of parts. The drawings shall show all changes and revisions made up to
April 2017 2
the time, the gates/machinery is completed and ready for dispatch. The Bidder shall
also supply one set of soft copy of all the above approved drawings.
g. The design calculations shall be prepared for all the components based on relevant
latest IS codes and by adopting the best engineering practices and shall be clear and
easily understandable. All relevant references quoted in the calculations shall be
supplied along with the design. Views of Employer for any procedural dispute
regarding practices to be adopted in the design shall be binding on the Bidder and he
will have to modify the design based on that; if warranted, at no extra cost,
whatsoever.
h. The drawings shall be prepared by the Bidder as per best prevailing practices.
Drawings should be conveniently sized as per relevant Indian standards.
i. The Bidder shall be responsible for and shall pay for any alterations of the work done
due to any discrepancies, errors or omissions in the drawings or other particulars
supplied by him whether such drawings or particulars have been approved by the
Employer or not.
j. Should there be any discrepancy between the specification and/or Bill of Quantities
and /or drawings or any inconsistency, error or omission in any of them, reference
must be made to the Employer for a detailed explanation of the same and the Bidder
will be held responsible for any errors that may occur in the work through neglect of
this precaution.
1.4 Specifications
The specifications are intended for the general description of quality, workmanship etc.,
desired for the items covered in the schedule of items and detailed scope of work. The
specifications are not, however, intended to cover all the minutest details and the works shall
be executed according to the spirit of the tender specification. In the absence of
specifications for any particular item of work, it shall be executed as per relevant IS Codes
(latest revision). In case neither of the above mentioned specifications and codes are
available, the work shall be executed in the best workmanship like manner and / or as
directed.
The specifications shall be read in conjunction with the description of the items in the Bill of
Quantities and vice versa.
1.5 Deviation from Specifications
As the work covered by this Bid is to be carried out strictly in accordance with these
specifications, the Bidder is expected not to deviate from the specifications while quoting for
any item.
1.6 Weight Variation
No claim in the quoted prices towards variation in the actual weight of gates, hoists etc.
supplied by the Bidder shall be permitted. The payment is made for each item of supply as
per the rates quoted by the Bidder in his bid.
April 2017 3
1.7 Schedule and Progress
Within 15 (fifteen) calendar days after the receipt of approval of drawings, the Bidder shall
submit to the Employer for approval the schedule of fabrication and transport of the gates,
equipment, and machinery so as to ensure its delivery within the specified period. The
schedule shall clearly state all the stages of fabrication to enable the Employer to plan his
inspection accordingly as stated in these specifications. The Bidder shall also (during the
course of fabrication) submit a monthly progress report along with photographs of fabrication
completed, to the Employer, apprising him of the progress of work for the preceding month.
Time of delivery at the project site is important and the Bidder shall abide by the approved
time schedule of different tasks as shown in the Schedule of Milestones, the time being
reckoned from the start date. The Bidder shall further submit the detailed activity schedule
as per the following table:
I. GATES & HOISTS: Date
i. Supply of all the embedded parts of Headworks.
ii. Erection of all the embedded parts & concreting.
iii. Supply and erection of Intake gate, Under sluice gate,

Gravel flushing gate, Sand flushing gate, including their
Hoist Painting, Finishing etc.
iv. Testing & Commissioning.
II. TRASH RACKS:
i. Supply of embedded parts.
ii. Erection of embedded parts.
iii. Supply and erection of Trash racks including painting,

finishing, etc.
III. HEADRACE PIPE AND PENSTOCK PIPE & ITS

ACCESSORIES
i. Supply of embedded parts.
ii. Erection of embedded parts.
iii. Supply and erection of Pipe including painting, finishing, etc.
1.8 Site Erection
1.8.1 General
The gates/equipment/ trash racks/ stop logs/hoist / headrace/ penstocks components to be

furnished as per these specifications shall be erected completely by the Bidder, maintaining
April 2017 4
accuracy, quality and correct alignment required. Welding at site shall be done with utmost
care to eliminate distortion.
The Bidder shall arrange all tools and equipment required for the erection, testing and
maintenance of equipment including arrangement for necessary power supply required for
his work (30 KVA or more capacity power backup supply with minimum stock of fuel required
for period of one month supply is mandatory at site).
The Employer has purchased some land in the project site and some part of that may be
available for Bidder's use, however if the land is insufficient, the Bidder shall have to lease
without additional cost to the Employer.
1.8.2 Procedure
The gates/equipment/ trash racks/ stop logs/hoist / headrace/penstocks covered by this Bid
shall be furnished and erected by the Bidder at site, and Bidder shall furnish all fabrication &
erection detailed drawings.
The Bidder shall submit a complete erection procedure describing the sequence of
operations to be carried out, the method proposed to be used, the measurements to be
taken and the tolerances to be followed in the erection and alignment of the equipment for
approval of Employer before commencement of fabrication. This, when approved, shall form
basis for erection and inspection of erection. The Bidder, as per the time schedule, shall
agree to carry out all the erection works.
1.9 Tools and Tackles
The Bidder shall supply a complete set of tools and tackles, grease gun and a complete set
of wrenches in a steel box that may be necessary for erection, commissioning, operation and
maintenance of gates, equipment and machinery. Each tool and wrench shall be marked for
easy identification. The Bidder shall submit a list of such Tools and Tackles and include the
cost of the same in the rates of finished item of works quoted in the Bill of quantities.
1.10 Defective Materials/Machinery
In case any part of the material/machinery is found to be defective in material or

workmanship or develops defects or does not otherwise meet the requirements of the
specifications including errors or omissions on the part of the Bidder the following shall
apply.
1.10.1 Defects disclosed prior to final acceptance
Any defect in materials or workmanship or other failure to meet the requirements of these
specifications including errors or omission on the part of the Bidder, which are disclosed
prior to final payment or prior to final acceptance tests, whichever occurs at a later date,
shall, if so directed by the Employer, be corrected entirely at the expense of the Bidder.
1.10.2 Defects disclosed after final acceptance
Any latent defect not disclosed before date of final acceptance shall be corrected promptly
by the Bidder entirely at his expense provided that the total period during which the Bidder is
April 2017 5
liable for replacement due to latent defects shall not exceed twelve months after date of final
acceptance of the machinery.
1.11 Operation of unsatisfactory Materials, Machinery etc.
a. The Employer shall have the right to operate the machinery as soon as and as long
as it is in operating condition, whether or not such machinery has been accepted.
Such operation by the Employer shall not lessen or impair any express or implied
warranties concerning such machinery. All repairs or alterations required shall be
made at such times as directed by the Employer and in such a manner as will cause
the minimum interruption in the use of the machinery by the Employer.
b. Operation of the machinery pursuant to this section shall not relieve the Bidder of his
responsibility to supply all machinery in complete accordance of technical
specifications. While unsatisfactory articles can be taken out of service, for correction
of latent defects, errors or omissions, the period of such operation of any use
pending the correction of latent defects, errors or omissions shall not exceed one
month without mutual consent of the Bidder and the Employer.
1.12 Co-operation with other agencies
The Hydro-Mechanical Bidder shall exchange with the Civil Bidder all necessary drawings,
dimensions and other information required to ensure proper block outs and embedment of
parts Hydro-mechanical works. The Bidder assigns Engineers to inspect the works of civil
Bidder at site during critical concreting woks affecting his fabrication/erection works. No
compensation shall be claimed by the Hydro Mechanical Bidder because of any
modifications required to his fabrication works/ equipment due to any errors in the civil
construction.
All adjustments to the works shall be made by the Hydro-Mechanical Bidder without
involving extra cost to the Employer.
Following work interfaces are expected between Civil Bidder and Hydromechanical Bidder
and similarly between Hydromechanical Bidder and Electromechanical Bidder.
Hydro-mechanical Works ↔ Civil Works
Location Hydromechanical Works Civil Works
General Responsible for the supply of drawings Responsible for

showing all hydro mechanical equipment to be excavation and all
delivered and erected, with dimensions of all related concrete
the equipment and indicating the necessary works.
space required for installation, operation and
maintenance of the equipment. Responsible for
installing all rock bolts
Responsible for specifying the necessary and anchor steel to be
space required for transportation of his embedded in the
deliveries to the different erection sites during primary concrete with
erection and later during overhaul and the help of
maintenance of the equipment. Hydromechanical
April 2017 6
Responsible for drawings showing detailed Bidder.

locations of embedded plates and foundation
bolts required in primary concrete as
anchoring and foundations for
hydromechanical equipment. These drawings
shall also show all forces to be transferred to
the rock and/or primary concrete.
Responsible for calculation, delivery and

installing all foundation bolts, steel beams for
connection to the bolts and construction parts
to be embedded.
Responsible for necessary anchoring to bolts

and stiffening of his equipment in connection
with embedding the hydromechanical
equipment and for determining maximum
allowable rise speed of concrete in pours in
embedment forms.
Responsible for specifying required locations

and capacities of suspension bolts/lugs for
lifting and pulling for moving and erection of
his equipment.
Responsible for assessing permissible rate of

rise of concrete during pours for embedment
of hydromechanical equipment and
permissible pressures to be used for injection
of the boundary between steel parts and
concrete.
Responsible for all surface protection

treatment after erection.
Gates, Responsible for delivering the equipment at Responsible before

Trashracks, the dedicated storage yards near the erection the commencement
Surge tank, sites. starts for delivery and
washouts embedment of
etc. Responsible for undertaking and carrying out reinforcing bars as
the local transport and site erection of all parts well as lifting lugs in
of the supply, except parts to be embedded in the first stage concrete
the first stage concrete. Responsible for according to
supplying all necessary equipment for this specifications supplied
transportation, loading and unloading. by the HM Bidder.
Responsible for all local transport, handling Responsible for
and site erection of parts to be embedded in embedding guides and
April 2017 7
the first stage concrete. The erection shall frames etc. in the
include welding, tests, compliance with second stage
tolerance requirements, stiffening and concrete, and
anchorage before concreting, managing the performing grouting as
time schedule for erection, etc. deemed necessary
and taking all
Responsible for delivering dowel bars/ plates measures required to
and special items required for erection. avoid deformation of
Responsible for the adjustment and alignment steel linings or other
of frames and guides etc., and performing the embedded parts.
necessary bolted and welded connections and
anchorage. Responsible for finalizing the
erection.
Electro-mechanical Works ↔ Hydro-mechanical Works
Location Electromechanical Works Hydromechanical Works
Penstocks / Responsible for delivery and

inlet pipes adjustment at site of the inlet pipes Responsible for delivering,
and designing the weld groove for transporting, and installing the
welding the connection between bifurcations. Responsible for
the penstock and the inlet valves delivering, installing and
in the power station. embedding (performed by the
Civil Bidder) according to the
Responsible for delivery of the instructions of the HM Bidder
inlet cone/pipe with 200 mm over- for the branch pipes from each
length with flange and adjustment bifurcation to the powerhouse
of the length to fit the previously wall and adjusting and
installed branch pipes. securing the pipes to their final
position according to the
Responsible for performing and
requirements of the EM
testing the weld seam between the
Bidder. The Welding of
branch pipe linings and the turbine
cone/pipe with flange is the
inlet pipes.
scope of this HM Bidder.
Responsible for cleaning the weld
The downstream end of the
seams between the penstock and
pipes shall be chamfered
the turbine inlet pipes and cones
according to the weld groove
down to the upstream side of the
designed by the EM Bidder.
turbine inlet valve. Finally
responsible for the painting of the
weld seam and the inlet pipes.
April 2017 8
1.13 Emergency Arrangements
The Bidder shall maintain arrangements whereby he can quickly call out labor outside
normal working hours to carry out any work needed for an emergency associated with the
Works. The Engineer shall be provided at all times with a list of addresses and telephone
numbers of the Bidder's staff who are currently responsible for organizing emergency work.
1.14 Management Meeting
Site meetings will normally be held weekly but will be called for whenever the progress of the
works so requires, or when required by the Engineer. Other management meetings will be
held in Kathmandu as required.
The Bidder shall be represented at all meetings by the Bidder's Representative who shall be
the powers to commit the Bidder in all matters concerning the Bid.
1.15 Side Records
Daily records of on-site testing and inspection shall be kept on forms of approved format.
Test results shall be certified by the responsible member of the Bidder's staff. All test
certificates and inspection records (including any from suppliers or other outside testing
agencies) shall be clearly identified with the appropriate part of the Works to which they
refer, and they shall be submitted to the Engineer together with the respective Passing
Certificate.
Once each month, or at such longer intervals as the Engineer may allow, the Bidder shall
submit in an approved form a summary of all quality control inspections and tests performed
at Site and elsewhere in the Intervening period.
Test results shall be summarized in tabular form or graphically or both in a way which best
illustrate the trends, specific results and specification requirements. Where the tests show
that the specified requirements were not achieved, the report shall describe the action which
was taken.
Each report shall also contain a forecast of quality control work likely to be carried out during
the period to be covered by the succeeding report.
The Bidder shall keep detailed and up-to-date inventories in an approved form of goods and
materials already approved by the Engineer for which Passing Certificates have been issued
as well as of all other goods and materials subject to quality control which are on order,
delivered, found faulty, lost during the work or to be surplus to requirements. The Engineer
shall have access to these records at all times.
1.16 Daily log book/Site diary
The Bidder shall keep a Site diary wherein full details of all work carried out each day shall
be recorded. The diary shall be available for inspection by the Employer or Engineer any
time during normal office hours. At least the following details shall be included:
 location of the various works undertaken
April 2017 9
 type and quality of work achieved
 equipment and plant that arrive on site
 number of employees and plant working
 tests carried out and results
 Delays (cause, effects such as idle time etc.)
 unusual events (earthquakes, floods, fires, storms, accidents, etc )
 weather conditions
 accidents
 visitors to the Site
 interaction with local people
 any other relevant to this Bid.
1.17 Progress Reports
The Bidder shall submit monthly 2 copies of progress reports to the Employer, on the first
day of the week following the week concerned, containing at a minimum the following
information:
 location of the various works undertaken

 any work delays
 anticipated problems
 tests carried out including results
 prepared materials
 supplied materials
 two week look-ahead schedule
 accidents, injuries and near misses
 photographs of works
1.18 Record Progress Photographs
The Bidder shall arrange on his own for at least 15 Nos. of photographs monthly or as asked
by the Engineer as Record Photographs and shall provide at least 2 sets of color prints each
on glossy paper unmounted and of a size not less than 210 mm x 297 mm (A4) in
transparent plastic pockets contained in hard cover album. Each print shall contain upon its
back the date and description of the view taken
The Bidder shall ensure that no use is made of any negative or print without permission from
the Employer. Out of these Record Photographs the Bidder shall select 10 characteristic
ones as Progress Photographs attached to the Progress Reports.
1.19 Metric Unit
S.I. units of measurement shall be used throughout the Bid. All information and data
originating in another system shall be transferred by the Bidder into the S.I. system.
April 2017 10
1.20 As Built drawings
A set of ’as-built’ drawings shall be prepared by the Bidder using AutoCAD drafting software
to show the Permanent Works as finally built or installed. The ’as-built’ drawings shall be
prepared by the Bidder shall use only the exact system of standard representations, layers,
line types etc. stipulated by the Engineer. The Bidder shall keep records of 'as-built'
drawings up to date throughout the progress of the works.
Six full size prints and two electronic copies on separate CDs or DVDs of all ’as-built’
drawings shall be submitted by the Bidder as coherent sets of drawings within one month of
the date of completion of the relevant part of the Works shown on the drawings and in any
case not later than one month after the date of completion of the whole of the Works.
No separate payments will be made for the preparation, reproduction, review, corrections
and obtaining of the Engineer's approval for the 'as-built' drawings.
1.21 Health and Sefety
1.21.1 General Provision
The Bidder shall comply with the health and safety provisions of the Nepal Labour Act 1992
and other prevailing laws. In addition the Bidder shall comply with the following Clauses.
a) Safety of employees
The Bidder shall ensure, so far as is reasonably practicable, the health, safety and welfare at
work of all his employees.
The Bidder shall provide such information, instruction, training and supervision as is
necessary to ensure, so far as is reasonably practicable, the health and safety at work of his
employees.
b) Safe place of work
The Bidder shall, so far as is reasonably practicable, as regards any place of work under the
Bidder’s control, maintain it in a condition that is safe and without risks to health, and provide
and maintain means of access to and egress from it that are safe and without such risks.
The Bidder shall provide and maintain a working environment for his employees that are, so
far as is reasonably practicable, safe, without risks to health, and adequate as regards
facilities and arrangements for their welfare at work.
c) Safe systems of work
The Bidder shall provide and maintain plant and systems of work that are, as far as
reasonably practicable, safe and without risks to health.
The Bidder shall make arrangements to ensure, so far as is reasonably practicable, safety
and absence of risks to health in connection with the use, handling, storage and transport of
articles and substances.
April 2017 11
d) Safety of others entering the Site
The Bidder shall be responsible for the safety of all subBidders, suppliers and other persons
entering the Works (including day labor, family members of personnel) and shall take all
measures necessary to ensure their safety.
e) Safety of public
The Bidder shall ensure, so far as is reasonably practicable, that his operations do not
endanger the safety and welfare of the public. The Bidder shall, as far as is reasonably
practicable, prevent the public from entering the Works.
1.21.2 Specific Provisions
a) Safety officer
The Bidder shall appoint a competent safety officer who shall be conversant with the
hazards associated with the form of construction to be undertaken and who shall be
responsible for ensuring the compliance with all management directives, rules and
regulations concerning safety.
b) Site induction procedure
The Bidder shall conduct a site induction procedure for all personnel who will work on the
Site. The Bidder shall prepare a written statement of ‘Safe systems of working’ in English
and Nepali which shall be issued to all persons at Site in whatever language is appropriate.
The Bidder shall maintain a record of all persons instructed and each person shall be
required to sign such record confirming that instruction has been received.
The Bidder shall ensure that all his employees, sub-Bidders and direct hire labour are fully
conversant with the safety regulations, emergency and rescue procedures and the Bidder
shall enforce the rule that any employee, sub-Bidder or direct hire labour committing a
serious breach of such regulations shall be instantly dismissed and shall not be re-
employed. At the site induction the entire Bidder's staff shall sign a statement that they
understand the consequences of committing a serious breach of safety regulation.
c) Personnel Protective Equipment ( PPE)
The Bidder shall provide effective safety helmets for all the Bidder’s personnel, his
subBidders and direct hire labour, as well as for any authorised visitors to the Site as
required. The Bidder shall provide as necessary safety boots and gumboots for all the
Bidder’s personnel, his subBidders, direct hire labour and any authorised visitors to the Site.
The Bidder shall provide other protective clothing for the Bidder’s personnel, his subBidders
and direct hire labour, as well as for any authorised visitors to the Site as required.
Protective clothing shall include but not be limited to:
 Safety gloves
 Safety goggles
 Safety boots
 Ear protectors
April 2017 12
d) Lighting of the Works
The Bidder shall provide and maintain, if required, suitable lighting to provide adequate
illumination of the Works with appropriate spares and standby equipment.
e) Fencing
The Bidder shall provide and maintain, so far as is reasonably practicable, fences or guards
to keep unauthorized persons away from the Site.
f) Warning notices
The Bidder shall provide and maintain safety notices written in Nepali and English language
to be erected at points likely to be used by the workers or visitors to enter the relevant parts
of the Works as required.
g) Fire fighting
The Bidder shall establish on the Site adequate procedures and equipment for fire fighting.
h) Visitors
Visitors to the Site shall receive training in the scope of works being undertaken and the
relevant hazards that may be encountered. Visitors must be escorted by a designated
person at all times.
i) Welfare and first aid facilities
The Bidder shall establish on site welfare and first aid facilities with appropriately trained
personnel as required by the scale of the Works. The facilities shall include stretchers and
first aid boxes, together with appropriate rescue facilities.
j) Safety procedures
Before commencing any work on the Site the Bidder shall establish in writing proper safe
working procedures. The procedures shall include but not be limited to:
 Avoidance of danger from overhead electric cables

 Working in confined spaces
 Working at height
 Use of specific items of plant and equipment
 Excavations
 Use of explosives
 Stacking of materials
 Lifting by hand
 Fire precautions – use of fire extinguishers
 Use of substances hazardous to health
 Metal welding and cutting
 Working with electrical apparatus
The Bidder shall provide a copy of the safe working procedures to the Engineer.
April 2017 13
k) Emergency procedures
The Bidder shall establish written emergency procedures. The Bidder shall organize and
train a rescue team composed of Bidder's employees to evacuate personnel from the Site in
the event of an accident.
The Bidder shall maintain and operate a vehicle for emergency use to be on standby at all
times on Site. All emergency procedure training shall be reinforced by regular practice drills.
The Bidder shall notify the Engineer of the emergency procedures.
l) Procedures in the event of a death
The Bidder shall establish a written procedure to be followed in the event of the death of a
person on the Site. The Bidder shall notify the Engineer of the procedure in the event of a
death.
m) Reporting of accidents
The Bidder shall maintain an ‘accident book’ and record all accidents which cause a person
to stop work. For each accident the following details shall be recorded:
 the date and time of the accident

 the place of the accident
 the nature of the accident (first aid, minor, serious, major or fatal)
 the full name of the person who had the accident
 the full address of the person who had the accident
 the full name and address of the guardian of the person who had the
accident
 the occupation of the person who had the accident
 details of how the accident happened
 details of the injury
 action to be taken to ensure that the accident is not repeated
The Engineer shall be immediately notified of all accidents. All accidents shall be reported at
the weekly site co-ordination meetings.
1.21.3 Project Specific Safety Plan
Reference is made to the relevant stipulations of the Conditions of Bid.
Including the above mentioned safety measure, the Bidder shall at all times in the conduct of
his work and that of his Sub Contractors adhere to the established rules and regulations
concerning all safety matters at Site such as the recommendations contained in the "Manual
of Accident Prevention in Construction", published by the Associated General Bidders of
America, Inc., or other internationally recognized recommendations to the extent that such
provisions do not conflict with the applicable laws. This is especially important wherever it is
necessary to enable the free passage of the public through the Site.
The Bidder's Safety Officer shall have the qualification and the authority to issue instructions
to the Bidder's personnel regarding protection measures to prevent accidents.
April 2017 14
During construction the Bidder shall erect, maintain and subsequently remove sufficient
barricades, guards, lighting, sheeting, shoring, temporary sidewalks and bridges, danger
signals as well as temporary covering of potential accident areas.
If and where required the Bidder shall erect and maintain suitable and approved temporary
fencing to enclose such areas of the works and areas of land occupied by the Bidder within
the Site as may be necessary to implement his obligations under the Conditions of Bid.
Where temporary fencing has to be erected alongside a public road, foot-path, etc., it shall
be of the type required by and shall be erected to the satisfaction of the Engineer and
authority concerned.
All open excavations along pipe lines shall be protected sufficiently to keep out livestock,
and ensure the safety of workmen and members of the public.
Where work is to be carried out in the proximity of buildings, bridges, tanks or other
structures, the Bidder shall take all necessary precautions, including shoring and strutting,
where necessary, to ensure the safety of the structures that are at risk.
The Bidder shall be responsible for all damages or injury which may be caused on any
property by trespass by the Bidders or his Sub Contractor's employees in the course of their
employment, whether the said trespass was committed with or without the consent or
knowledge of the Bidder.
1.22 Environment and Community
The Bidder shall comply with the following social and environmental Sections of the
Specification.
1.22.1 Public Relations
 Employer’s Public Relations Officer (PRO)
The Employer will appoint a Public Relations Officer (PRO). It is intended that the PRO will
establish strong links into the community, and he should be kept informed of all project
activities that affect the community. Should the Bidder be required to liaise with the local
community or landowners the PRO or other representative of the Employer shall be present.
On matters concerning the local community the Bidder shall take direction from the
Employer.
 Land leasing
The Bidder shall only lease land with the approval of the Employer. Land leased shall be
returned in an equivalent or better condition than when it was acquired. No extra provision of
cost shall be made to Bidder for this work.
 Access
Where the Bidder proposes to construct new foot trails or improvements to existing foot
trails, the Employer shall be involved in planning and consultation with the community.
April 2017 15
 Behaviour of workforce
The Bidder shall discourage the abuse of alcohol and gambling among his employees, sub-
Bidders and direct hire workforce. Inappropriate interaction with members of the opposite
sex in the local community shall be reason for dismissal of the concerned employee, sub
Bidder or direct hire.
1.22.2 Employment
The Bidder shall have an equal opportunity policy of employment which shall take into
account and give priority to:
a) locally available workers

b) women
c) low caste people
d) maximizing the employment opportunity across the local community
1.22.3 Land Interest
 Interference with land interests
The Bidder shall confine his constructional operations within the Site, or such other areas of
land as may be negotiated and agreed with the Employer, and shall instruct his employees
not to trespass.
Before exercising any right negotiated by him in connection with way leaves or
accommodation outside the Site, the Bidder shall notify the Engineer in writing of such
arrangements.
 Forests
The Bidder will not be permitted to cut any timber or firewood from the local forests. The
Bidder shall instruct his employees, direct labor and sub-Bidders not to damage any trees in
the project area. The Bidder shall require all of his employees, direct labor and sub-Bidders
(except local hires eating in their own home) cook with kerosene or bottled gas and not with
firewood.
 Fishing and hunting
Subject to any unavoidable disturbance which may be necessitated by the execution of the
Bid, the Bidder shall not interfere with any fishing or hunting rights which may be enjoyed
near the Site by the local people.
The Bidder shall enforce ‘no-fishing’ and ‘no-hunting’ regulations in the project area.
1.22.4 Protection against Damage
The Bidder shall take all necessary precautions to avoid causing any unwarranted damage
to roads, lands, properties, trees and other features and, during the currency of the Bid, shall
deal promptly with any complaints by owners or occupiers on his own cost and resources.
1.22.5 Watercourses
April 2017 16
The Bidder shall take care to maintain the water quality in watercourses. The Bidder shall
take all practicable measures, which shall be to the prior approval of the Engineer, to prevent
the deposition of silt to a level above the prevailing conditions at that time.
The Bidder shall prevent the deposition of any other material in, and the pollution of, any
existing watercourse, canal, lake, reservoir, borehole, aquifer or catchment area, arising
from his operations. The Bidder shall get approval of the working plan and work on his own
cost.
1.22.6 Waste Disposal
Burnable waste shall be burned on the Site in a location and method approved by the
Employer.
The Bidder shall be permitted to bury organic and non-toxic waste on the Site. The site for
burying waste shall be to the approval of the Employer. After waste is buried a layer of soil
shall be placed over all rubbish in order to reduce odor and deter vermin.
Toxic waste shall be taken off the Site and removed to a designated tipping area approved
by concerned authority.
The Bidder shall encourage recycling of waste where this is practicable.
Workshop facilities shall have adequate grease and oil traps that are properly maintained to
ensure clean runoff from the sites even during periods of heavy rain. Waste grease and oil
shall be disposed of as specified or directed by the Engineer.
1.22.7 Final Clean-up
 Clean-up
All land retained for the Permanent Works shall be left in a safe and tidy condition. All waste
materials shall be properly disposed of in such a way that there is no risk of them causing
harm to the environment or injury to people or animals by the Bidder on his own cost after
the completion of the project.
On completion of the works, the project should ensure that all temporary sites are restored
as near as possible to their original condition, or to some other use as specified in the Bid.
April 2017 17
2. GENERAL TECHNICAL SPECIFICATIONS

2.1 Design and Drawings
The Bidder shall be submitted the design and drawing of Gates & its all accessories,
Stoplogs & its all accessories, Trashracks & its all accessories and Penstock Pipe & its all
accessories before manufacturing for the approval.
The Drawings shall include the shop drawings, erection drawings, piping drawings, process
diagrams, part lists, etc., showing the dimensions, design and data of all apparatus and
equipment to be furnished under this Bid.
Further, for all technical documents which employ designation or plant identification
numbers, a respective list shall be furnished.
Execution drawings of standard components not specifically designed for the project need
not be submitted if they fulfil the following requirements:
 Proven standard product (e.g. bolts, seals, valves pumps, compressors, motors, relays,
switches),
 Certified product (e.g. steel cables, ladders, servomotors),
 Product certified by an underwriter's society (e.g. hoists and cranes, elevators, fire
protection equipment, pressure vessels).
For all components, however, which do not require the submission of execution drawings,
the respective assembly drawings or catalogue sheets and detailed part lists shall be
submitted.
Execution drawings shall show the following:
 Materials, dimensions, tolerances, surface roughness, weight, adjustment, clearance,
 Reference to assembly or sub-assembly drawings and part lists,
 Details of fabrication, manufacturing and treatment,
 Assembly of the equipment in plan and elevation with main dimensions,
 All necessary details of the parts connecting to equipment supplied by others,
 Location and sizes of connections for oil, grease, water, air, etc.
 Location and size of the instruments and accessories provided,
 Methods of lubrication and sealing,
 Instructions for heat treatment (if any), pressure tests (if any), surface preparation and
anti-corrosive protection,
 Full details of parts for which adjustment is provided or which are subject to wear,
 Method and sequence of installation, field joints, erection and lifting devices, jacks, grout
plugs, anchoring details, etc., if not shown on foundation drawings.
2.2 Types of Electrodes, Wires and Fluxes
2.2.1 General
The electrodes, wires and fluxes used in fabrication shall be selected to produce welds with
mechanical properties equivalent to those required for the base metal or as specified by the
Employer/Engineer.
When steels of different strengths are joined, the tensile properties of the weld metal shall be
matched to the lower strength steel.
April 2017 18
2.2.2 Covered Electrodes
All covered electrodes for welding of structural steel shall be low hydrogen electrodes. The
hydrogen content shall not exceed 10 ml per gram of deposited weld metal.
Electrodes shall be selected from a list of approved types of electrodes, such a list to be
submitted to the Employer/Engineer for approval prior to selection being made.
Electrodes shall only be used under conditions, in positions, and using the welding
parameters recommended by the manufacturer
2.2.3 Wire and Flux for Submerged Arc Welding
Wire and flux shall be carefully selected and the flux shall be of the fully basic type. The
storage and use of wire and flux shall be as recommended by the manufacturer. The flux
supplier shall define the range of chemical composition of wire to be used for his particular
flux. No low-alloy wires shall be accepted. The proposed wire and flux shall be submitted for
approval to the Employer/Engineer.
2.2.4 Wire for Gas Metal Arc Welding
The gas metal-arc process may only be used on mild steel in enclosed shop fabrication
conditions, and provided that the filler wire selected is such that the welds produced have
the same mechanical properties as the base metal.
2.2.5 Conditions and Storage
Electrodes shall be supplied in hermetically sealed metal boxes and stored in a dry storage
room where the minimum temperature is 20 C. All manual type electrodes shall be properly
identifiable (see AWS A 5.1 and 5.5) up to the time of usage, each electrode being
distinguishable by colour code marking. If baking, handling or other causes destroy colours,
the electrodes shall not be used. Batch numbers shall be recorded.
Low hydrogen electrodes shall not be stored in heated cabinets containing electrodes of
other types, such as rutile or organic type electrodes.
Wire spools for automatic and semi-automatic processes shall be stored in cabinets with
supplier wrapping not removed and remain clearly identifiable up to the time of usage.
Unidentifiable wire shall not be used.
Flux shall be supplied and stored in accordance to this Specification.
Each batch of flux and wire shall be labelled with the information from the supply container.
The labels with batch number shall be recorded for reference.
All unidentifiable, damaged, wet, rusty or otherwise contaminated consumables shall be
scrapped.
A consumable handling, storage and issuing procedure shall be submitted to the Employer
for approval prior to the start of any fabrication.
2.2.6 Heating and Baking Requirements
All low hydrogen electrodes shall be baked at 270ºC to 330°C one hour prior to use. On
completion of baking, the electrodes shall be transferred to a holding oven at 150ºC. When
later removed from the holding, the electrodes shall be transferred to heated quivers or
containers at 75ºC and used within 8 hours.
April 2017 19
Electrodes not used within 8 hours or for some reason exposed to adverse atmospheric
conditions shall be re-baked for one hour then transferred to the holding oven for later use.
Electrodes shall be re-baked only once.
Flux for submerged arc welding shall be issued as required for immediate use. They shall be
held in heated silo at 70 ºC.
2.3 Qualification of Welding Procedures
2.3.1 General
Detailed welding procedures for typical structural welding of plates, shapes and tubular
members shall be established and qualified in accordance with DIN EN 286/287, ASME
Boiler and Pressure Vessel Code, Section VIII and IX or AWS D1.1 and further required in
this Specification. All procedures shall be submitted to the Employer and/or the
Employer/Engineer for review and approval before any welding is commenced and the
procedure test shall be witnesses by the Employer/Engineer if required.
Welding procedures and qualification records already qualified shall be acceptable solely at
the discretion of the Employer/Engineer.
No fabrication welding shall commence until the appropriate procedure tests have been
approved by the Employer/Engineer.
Copies of the approved welding procedure specification (WPS) shall be readily available for
reference at any time by the welders or welding operators and the Employer/Engineer. Any
structural repair welding shall be limited to two attempts and approved by the
Employer/Engineer. Repair welding procedures shall be established and qualified.
2.3.2 Parameters in the Welding Procedure Specification
A welding procedure specification (WPS) shall contain the following parameters with all
explanatory details necessary:
(a) Material specification of the base metal.
(b) Welding process, manual or semi-automatic.
(c) Material thickness range for which the procedure is valid.
(d) Geometry of welding grooves showing allowable tolerances.
(e) Root gap showing allowable tolerances.
(f) Welding position and direction.
(g) Filler metal specification and brand.
(h) Filler metal classification.
(i) Specification of flux.
(j) Gas shielding - flow, mixture and composition.
(k) Number and sequence of passes.
(l) Welding current, voltage, polarity and heat input (including ranges).
(m) Travel speed and electrode run-out length for each pass and range.
(n) Preheat and interpass temperature.
(o) Post-weld heat treatment including heating and cooling rates.
(p) Method of cleaning and gouging.
April 2017 20
2.3.3 Welding Procedure Qualification Test
Welding Procedure Qualification tests shall be carried out at the cost of the Bidder, to verify
the WPS and shall simulate, as far as is practicable, the conditions and materials to be used
for production welding. Limitations imposed by the essential variables of the procedure
qualification shall be adhered to in production welding.
Changes in any of the essential variables will call for a new qualification test. Changes in
one or more of the non-essential variables will not call for a new qualification test, but a new
WPS is required.
A qualified procedure is valid for materials and thickness in accordance with paragraph 5.5.1
and Table 4.1 of AWS D1.1.
Qualification of a fillet weld by a groove weld is not acceptable.
2.3.4 Procedure Qualification Record
The specific facts from the WPS and test results from the welding procedure qualification
test shall be recorded in the procedure qualification record (PQR). The PQR shall be
submitted to the Employer and/or the Employer/Engineer for approval before any production
welding is commenced. The form used for the WPS and PQR shall be such as described in
AWS D1.1.
2.3.5 Non Permitted Welding Processes
High heat input welding processes such as electro -gas, electro-slag or high power density
welding would not normally be permitted.
2.3.6 Testing Requirement for Procedural Qualification Test
Non Destructive Testing (NDT)

Each Test specimen shall be non-destructively tested for soundness using the following
methods:
(a) Visual inspection.
(b) Ultrasonic inspection.
(c) Magnetic particle or dye penetrates inspection.
Destructive Testing
(1) Tensile and Bend Test
(a) Complete Penetration Groove Welds:
The type and number of specimens that must be taken to qualify a welding
procedure are shown in Section 5.10.1 of AWS D1.1.
(b) Partial Penetration Groove Welds:
procedure are as shown in Section 5.10.2 of AWS D1.1.
(c) Fillet Welds:
procedure are shown in Section 5.10.3 of AWS D1.1.
(2) Hardness Test
A hardness survey shall be carried out on one of the macrotech cross-section test
specimens.
April 2017 21
(3) Impact Test
This shall be required if ambient temperature at the fabrication yard is likely to fall below
20 ºC.
2.3.7 Acceptance Criteria
Visual Inspection
The weld shall be inspected in accordance with 9.25.1 of AWS D1.1.
Ultrasonic Inspection
The weld shall be inspected in accordance with 10.19 and 10.17.4 of AWS D1.1.
Magnetic Particle Inspection (MPI) / Dye Penetrate Inspection (DPI)

The weld shall be inspected in accordance with 9.25.2 and 9.25.4 of AWS D1.1.
Tensile Test
The tensile strength shall not be less than the minimum of the specified tensile strength of
the base metal used.
Bend Test
The specimen shall be inspected in accordance with 5.12.2 of AWS D1.1.
Hardness Test
The maximum hardness allowed shall be 400 HV 10.
Impact Test
Impact requirements shall be as in this Specification.
2.3.8 Retest
When Retest is not allowed

Unacceptable defects evaluated by visual, MPI, DPI, ultrasonic and macrotech testing shall
be cause for rejection. A new test weld shall be required.
When Retest is allowed

When one of the following mechanical test specimens fails to meet the required acceptance
criteria, two additional specimens shall be prepared for re-testing. The location of the two
additional specimens shall reflect the location of the failed specimens. If one or both of the
retest specimens fail, then this shall be cause for rejection. A new test weld shall be
required.
(a) Tensile test
(b) Bend test
(c) Impact test (when applicable)
(d) Hardness test
April 2017 22
2.4 Qualification of Welders and Welding Operators
2.4.1 General
Qualification Required
Welders and welding operators shall be qualified in accordance with the requirements of DIN
EN 287, ASME or AWS D1.1 and this Specification. Only qualified welders shall be
employed during the fabrication including tack welding, structural welding and repair welding
of any structural steel part. They shall only perform welding for positions and processes for
which they are qualified. Backing materials shall not be used during testing. The Bidder shall
ensure that welders of any subBidder or of any otherwise nominated Bidder are qualified in
accordance with this Specification. The purpose of a welder qualification test is to verify that
the welder can apply a qualified welding procedure making welds of satisfactory quality.
Witness and Approval of Test before Welding

All welders and welding operator’s tests shall be witnessed and approved by the
Employer/Engineer before the welder or welding operator is permitted to work on the
structure. The decision by the Employer/Engineer regarding qualification of any welder or
welding operator shall be final. Evidence of previous qualification tests may be accepted
solely at the discretion of the Employer/Engineer.
Provision of Equipment and Costs of Test

The Bidder shall provide equipment for the welder qualification tests and shall bear all costs
for the non-destructive testing, the cutting and machining of test specimens and mechanical
testing of specimens.
Welder Identification System

An identification system shall be worked out for welders and welding operators. The system,
which shall include a numbering and identification card index, shall be established and
agreed with the Employer. Whilst on the Works, the welder/welding operator shall always be
identifiable by a badge bearing his name. In the event that a welder leaves the Works, his
mark shall not be assigned to another welder employed on the Works.
Marking of Welds
Each qualified welder and welding operator shall be supplied with an identification marker.
The welder shall clearly mark the plate or pipe adjacent to his weld using soft die stamps
with the identification mark assigned to him in his qualification certificate. Tack welding of
components need not be marked.
Base Material
As far as it practicable, welders and welding operators shall be qualified on the same
material to be used for fabrication. Similar types of materials may be substituted at the
discretion of the Employer/Engineer provided that it can clearly be demonstrated that the
weldability is equivalent to the material intended for use in the fabrication.
Retest
If the test joint does not meet the requirements, the welder or welding operator may at the
discretion of the Employer/Engineer, carry out a new joint of the same type as the one
rejected. Failing of both these tests shall result in the welder or welding operator not being
employed further for the Bid.
April 2017 23
Welder Qualification Record
A record of the welder’s qualification tests, including a reference to the corresponding WPS
number, the essential variables according to Clause 2.4above and the test results shall be
issued for each welder or welding operator for each test they pass.
Period of Effectiveness
(a) Welders and welding operators who will perform welds in the process/position
combinations for which they were previously qualified need not re-qualify for those
combinations if both of the following requirements are met:
 The Bidder can show that the welder’s performance has been monitored and proven
satisfactory since the qualification test.
 A recognised Certifying Authority has endorsed the welder certificate at a date less than
six months before construction starts.
(b) During construction, the Bidder shall provide evidence indicated in a) above to the
Employer so that the welder certificates can be re-endorsed within six months of the
previous endorsement date. Any certificate not endorsed every six months shall be
considered invalid.
(c) A qualified welder or welding operator may, at the discretion of the Employer/Engineer,
be required to re-qualify if inspection reveals that an unacceptable number of repairs
are necessary.
2.5 Production Welding
2.5.1 General
Preparation and welding of structural members shall be in accordance with the appropriate
qualified welding procedure specifications. Manual electrodes, wires and flux shall be of the
same type and manufacture as those used in the procedure qualification tests.
Welding equipment shall confirm to the appropriate sections of AWS, ASME, DIN or BS 638.
Any equipment found not to comply with these requirements should be replaced. Welding
current and voltage shall be the same as the test values, or within the range specified in the
welding procedure.
No welding shall be done until as much of the structure as will be stiffened thereby has been
properly aligned.
2.5.2 Welding Sequence
The Bidder shall develop welding sequences to control warping, creeping and the build-up of
excessive internal stresses in the structure. The sequences shall be submitted to the
Employer/Engineer for approval before the assembly of any components. The Bidder shall
furnish the necessary supervision to ensure that the planned sequences are followed.
Sequences shall include:
(a) Welding procedure specification to be applied.
(b) Sequence of plates to be welded.
(c) Any differences from the specified welding procedures, such as areas of pre-heating,
reinforcements, etc.
(d) Post weld heat treatment, heating and cooling rates.
(e) Number and location of welders at each stage of assembly.
(f) Tack welds and spacers used in the assembly of components.
2.5.3 Weld Preparations
April 2017 24
Alignment
(a) At Splices (butt welding)
The offset at butt joints shall not exceed T/10 (where T is the thickness of the thinner
material) or 4 mm, whichever is less. The offset in longitudinal seams shall not exceed T/10,
or 3 mm, whichever is less. All offsets greater than 2 mm shall be given a 1:4 transition.
(b) At Welded Intersections

The utmost attention shall be paid to good alignment of the structural parts on opposite sides
of the through member.
Surface Cleaning Before Welding

Surface to be welded shall be free from loose scales, slag, rust, grease, paint and any other
foreign material.
Edge Preparation
Preparation of weld edges by gas cutting shall, wherever practicable, be done with a
mechanically guided torch. Edges shall be left free of slag and the cut surface shall be
ground to a smooth uniform surface by removing approximately 0.5 mm of metal. After
grinding, the weld edges shall be visually examined to ensure freedom from defects.
Cleaning During and After Welding

Upon completion of each welding pass, the weld shall be cleaned of spatter, slag and flux
deposits. After welding is complete, adjacent surfaces shall be thoroughly cleaned of all
spatter and deposits.
2.5.4 Weld Execution
Welding Position and Progression

(a) SMAW, GMAW Welding
Electrodes shall only be used in the position recommended by the manufacturer. Weld
progression in vertical joints shall utilise the uphill method. For the 1G, 2G, 1F and 2F
positions, the maximum size of electrode allowed is 6.4 mm. For any other position, the
maximum size of electrode shall be 5.0 mm. The capping passes shall always be done with
4.0 mm maximum electrode.
(b) SAW Welding
This shall be done in the flat position and in the case that it is done on pipe, the pipe shall be
mechanically rotated.
Size of Welds
To obtain optimum toughness, a small bead multipass technique shall be used. The weave
width for SMAW, i.e. maximum oscillation of the electrodes, shall not exceed two and a half
times the electrode diameter and the welding speed shall be 375 mm per minute minimum.
The width of SAW beads shall not exceed six times the electrode diameter and the welding
speed shall be 375 mm per minute minimum.
Fillet welds shall be completed in three or more runs except for welds, which may be done in
one run. Two run fillet welds are not permitted.
The Employer shall have the right to limit the thickness of each weld bead or pass when this
exceeds those given in the weld procedure qualification test.
Intermittent Welding
Stitch welding i.e. partial seal welds shall not be allowed.
April 2017 25
Seal Welds
Where stress bearing welds are required by Bid drawings to extend only partially around a
member, including plates joining another member, a seal weld of 4 mm minimum fillet shall
be applied continuously to the remainder, but note should be taken that a hardness of HV
325 maximum shall not be exceeded.
Tack Welds
Bridge tacking is the preferred method to avoid the tack becoming part of the final weld. If
another method is selected, tack welding shall be performed with the same qualified welding
procedure as will be used for structural welds. These tack welds shall be ground (feathered)
and checked before actual welding commences. Tack welds are to be a minimum of
approximately 50 mm long and spaced so that shrinkage forces cannot cause cracking.
Butt Welds
Design of the groove and performance of welding shall be in accordance with the approved
WPS. However, in general, the groove shall be bevelled to give an included angle of not less
than 30 degrees and shall be of the V type or X type (single bevel or double bevel). The root
opening shall not be less than 2 mm and not greater than 5 mm and the root face, if any,
shall not be greater than 3 mm.
Where access to both sides is possible, double bevel groove welds shall be used to
minimise welding stresses and shrinkage effects.
When different thickness is to be butt welded, a 1:4 taper shall be provided on the thicker
member stating at the toe of the weld cap.
At any joint, no butt weld shall be located such that an incoming member will result in a weld
overlapping the butt weld.
Plate Joints
Design of the groove and performance of welding shall be in accordance with the approved
WPS. The bevel shall be preferably be feather edged and the root opening shall be 3 - 5 mm
or according to an approved procedure.
Welding of minor members shall be full penetration type weld and where fabrication method
permits; welding from both sides shall be carried out.
Weld Compatibility
All weld joints shall develop the mechanical properties specified for the steel being welded.
Where different grades of steel are joined, the weld metal shall be matched to the lower
strength steel. The procedure shall be such as to safeguard the mechanical properties of the
higher strength member.
Weld Finish
Welds shall be left as welded and not be doctored with a torch or by any mechanical means
to change their appearance. Any grinding or other mechanical dressing is only being
permitted, after authorisation through the Employer/Engineer.
Weld Interruption
Welding of each weld shall be a continuous operation, with the exception of manually welded
root runs for submerged arc welding. In the case that welding must be discontinued, this
shall not take place before at least half of the final weld thickness is achieved. The maximum
time that a production weld will remain part welded is two days. The maximum number of
heat cycles that will be used in a production weld shall be two. Slow cooling of the weld area
shall be ensured. Before continuation of welding, the weld shall be inspected for cracks
visually and by MPI.
April 2017 26
Weather Protection
Shelters shall be provided at all times to give protection to the weld area from winds, rain
and moisture. No welding shall be carried out when the weld surface is wet or the work area
is exposed to high winds.
Precautions required:
(a) The weld surfaces shall be thoroughly dried by preheating (not above 300º C).
Temperature control shall be carried out.
(b) Special precautions made to provide conditions maintaining a satisfactory surrounding
temperature and freedom from the effects of winds shall be subjected to the approval of
the Employer/Engineer.
(c) If any fabrication is to be carried out in the vicinity of equipment already installed in
connection with the Work, then, before such fabrication work commences, the Bidder
shall provide adequate protection to prevent any damage from weld spatter, flame
cutting droplets and the like. Such protection shall be subject to the approval of the
Employer/Engineer.
Peeling
The peeling of welds is not permitted.
Arc Strikes
Arc shall be struck only on fusion faces and contact of electrodes or the non-insulated parts
of the electrode holder with the assembly shall be avoided.
Places where any stray arcs have accidentally occurred shall be subject to repair or rejection
at the discretion of the Employer/Engineer.
Where permission to repair arc strikes mechanically has been given, the procedure shall
include, but not necessarily be limited to, the mechanical removal of the defective material,
blending of the excavation, checking by MPI and confirmation that the thickness of the
repaired material is within permitted tolerances.
Welding of Structural Steels

To enable full throat thickness to be provided at the ends of butt-welded points “run-on” and
“run-off” plate extension pieces shall used. “Run-on” plates and “run-off” plates shall comply
with the following requirements:
(a) One pair of ‘run-on’ plates and one pair of ‘run-off’ plates prepared to the same
thickness and profile as the parent metal shall be attached, preferably by clamps, to the
start and finish of all butt welds:
(b) Butt welds shall extend at the full weld profile for a minimum distance of 25 mm into
both the ‘run-on’ and the ‘run-off’ plates:
(c) When removing the ‘run-on’ and ‘run-off’ plates by cutting, the cut shall not be nearer
than 3 mm to the sides of the parent metal and the remaining metal shall be removed by
grinding or another method agreed by the Employer/Engineer.
Welding of Steel Casting

Fusion welding of steel castings shall comply with requirements of DIN-Standards and
BS 4570.
The proposed welding procedures shall be submitted in writing, in accordance with the
requirements of either BS 4570: Part 1, BS 4570: Part 2 or approved DIN-Standards, for
approval of the Employer/Engineer before commencing welding of steel castings.
April 2017 27
Pins and Pin Holes
Pins shall be parallel throughout and shall have smooth surface free from flaws. They shall
be of sufficient length to ensure that all types connected thereby will bear fully on them.
Where ends are threaded they shall be turned to a smaller diameter and shall be provided,
where necessary, with a pilot nut to protect the thread.
The pinholes shall be bored smooth, straight and true to gauge and at right angles to the
axis of the member. Boring shall be done only after the member is finally bolted or welded
unless otherwise agreed with the Employer.
For pins up to and including 250 mm diameter. The diameter of the pin shall be within a
tolerance of –0.25 mm and –0.40 mm and the diameter of the pin hole shall be within a
tolerance of 0 mm to + 0.15 mm.
For pins exceeding 250 mm diameter, the clearance between the pin and the pinhole shall
be not less than 0.40 mm and not more than 0.75 mm.
2.5.5 Preheating and Interpass Temperature
General
Preheating shall be carried out by electrical resistance induction equipment or with gas
burners specifically made and shaped for this type of operation. Torches for flame cutting or
gouging shall not be used.
The preheating temperature shall be established to a distance of at least 75 mm on either
side of the weld line and throughout the wall thickness prior to welding and be maintained
over the full length of the weld joint until the weld is completed unless specifically agreed
otherwise by the Employer/Engineer.
The weld area shall be protected from draughts and lagging shall be provided on adjacent
areas, if necessary, to maintain the required temperature of preheating during welding.
The temperature measurements for preheating may be by thermocouples or temperature
sensitive crayons, or a combination of both as may be appropriate for the type of joint being
heated and the method of heating.
Before welding commences at all joints where preheating is required, the joint must be
subjected to temperature checks through the Employer/Engineer.
During welding particularly where preheat has been used and for high heat input processes,
care shall be exercised to control the interpass temperature and in no event should it exceed
300ºC or that indicated in the WPS. The interpass temperature shall be monitored by means
of thermo sticks or another approved method.
Temperature Requirements
a) Preheat temperature shall be as indicated in the approved WPS.
b) Preheat temperature for lifting lugs or pad eyes shall be 150ºC minimum.
c) For tack welding where the tack becomes part of the main weld. The preheat
temperature shall be 150ºC higher than specified on the WPS with a maximum of
300ºC.
2.6 Testing of Welds
2.6.1 Reporting
a) Inspection shall be recorded in a form, which clearly identifies the work and the area of
inspection, method(s) and procedure(s), and the acceptability of the item inspected.
b) Datum used for reporting weld inspections shall be clearly marked on the work in paint,
such that it is possible to exactly relocate any weld defects reported.
April 2017 28
c) The Bidder shall establish a system to provide trace ability between documentation and
weld testing before fabrication starts.
2.6.2 Mandatory Stages of Inspection
As a minimum, the inspection stages employed by the Bidder for welded joints shall be as
follows:
a) All incoming materials are subject to visual inspection for surfaces defects, laminations
etc.
b) Fit-up prior to first pass.
c) Following root pass.
d) Following any back gouging operation.
e) Following completion of weld.
Inspection at stage a) will be visual and dimensional. Inspection at stages b), c) and d) will
normally be visual/MPI inspection. Stages e) will be visual inspection and as instructed by
this Specification.
For Joint repairs, visual and MPI inspection shall be carried out following grinding and/or
gouging operations to ensure that all unacceptable defects have been removed. After
welding, the weld shall be subjected to the same NDT method prescribed for the original
weld.
2.6.3 Visual Inspection
All welds, which are examined by visual inspection, shall be judged in accordance with AWS
D1.1 Paragraph 9.25.1 except that weld reinforcement shall not exceed 2 mm.
2.6.4 Radiographic Inspection
All welds, which are examined by radiography, shall be judged in accordance with AWS
D1.1 Paragraph 10.17.3, but this may be subjected to change at the discretion of the
Employer.
Radiography shall be supplemented by ultrasonic testing accompanied by magnetic particle
testing when there is reason to suspect planer defects such as cracks or lack of fusion. This
shall also apply to all butt welds where the root pass or the whole weld is made by GMAW
welding.
If, in the opinion of the Employer/Engineer, additional radiography of butt weld is required,
the Bidder shall radiography all additional welds designated and shall perform the work.
2.6.5 Ultrasonic Inspection
All welds, which are examined by means of ultrasonic, shall be judged in accordance with
AWS D1.1 Paragraph 9.25.3.
Adherent layers of paint of any thickness need not be removed unless inconclusive results
are obtained.
Laminations found during forming, cutting or welding of tubular, rolled shapes and plates
shall be inspected to determine the extent. Weld area of tubular joints and beam-to-beam
connections shall be checked for lamination(s).
2.6.6 Magnetic Particle Inspection (MPI)
All welds, which are examined by means of MPI, shall be judged in accordance with 9.25.2
of AWS D1.1 but this may be subjected to change at the discretion of the
Employer/Engineer.
April 2017 29
The wet method shall be used employing yoke type equipment. White background paint and
black magnetic ink shall be used. The white background paint is to be applied to a thickness
not exceeding 20 microns using a spray can.
Inspection shall be carried out no sooner than 48 hours after completing welding. After
removal of temporary attachment and grinding flush the remaining weld, the ground area
shall be inspected 100 %. This includes the grinding of spatters and arc strikes.
2.6.7 Dye Penetrate Inspection (DPI)
Dye penetrate inspection may be substituted at the discretion of the Employer/Engineer in

lieu of other surface inspection methods. Welds subjected to this inspection method shall be
evaluated on the basis 9.25.4 of AWS D1.
2.6.8 Increased Inspection
For welds subject to less than 100 % NDT and found to contain unacceptable weld defect(s),
the entire weld length(s) shall be inspected using the method specified for the spot
examination. At the discretion of the Employer/Engineer, other NDT methods mentioned in
the Specification may also be required. In addition, all other welds made by the same
welder/welding operator shall be subjected to a higher level of inspection (up to 100 %) at
those locations previously not subject to NDT.
2.6.9 Mechanical Tests
When NDT cannot be carried out or gives inconclusive results, the Bidder shall at the
Employer/Engineer request, cut out and remove for testing any section of steel plate or
welded area and restore the area by welding back in a piece of steel similar in quality,
thickness and size of plate or pipe removed.
Subsequent mechanical tests shall be carried out in accordance with this Section 5 of this
specification.
2.7 NDT Reporting Requirements
For each NDT process applied to a weld an individual report shall be produced.
Each NDT report shall include following details as a minimum:
a) Weld Identification Number(s)
b) Welding Procedure Specification Number
c) NDT Procedure Number
d) Percentage NDT required
e) Date and Time of NDT
f) Weld or Weld Repair
g) Member Thickness and Dimensions of Weld
h) “As Welded” or Heat Treated Condition
i) Defect Location(s)
j) Conclusions
Magnetic Particle Inspection (MPI) reports shall also include:

a) Method of Magnetisation
b) Field Strength
April 2017 30
Ultrasonic testing (UT) report shall also include:
a) Probe Angles and Frequencies
b) Equipment Identification
c) Basic Sensitivity
d) Primary Reference Level sensitivity
e) Surface Correction Factor for Calibration and Examination
f) Joint configuration sketch
g) Scan direction(s)
h) Locations(s) and Depth(s) of all Defects exceeding the 20 % DAC Reference
i) Curve and Signal Amplitude.
2.8 Inspection Requirements
2.8.1 Inspection Personnel
The non-destructive examination (NDE) operator must be qualified at NDT Level II as

defined in ASNT-TC-1A (American Society of Non-destructive Testing) or equivalent rules.
2.8.2 Welding Inspection
Welding inspectors shall be qualified as follows:

a) AWS Certified Welding Inspectors
b) CSWIP31 (Certification Society for Welding Inspection Procedures) Certified Welding
Inspectors
c) P.C.N Certification in Non Destructive Testing
The above need to be approved at the discretion of the Employer/Engineer taking into
consideration the nature of work involved.
Ultrasonic Operators
Ultrasonic operators shall be qualified as follows:
a) In accordance with CSWIP document No. UST-1-83 ultrasonic practitioner Grade II.
Weld groups 3.1, 3.2, 3.7, 3.8 and 3.9.
b) Alternative qualifications, for example to ASNT requirements, may be approved at the
sole discretion of the Employer/Engineer, taking into account the nature of the work
involved.
Radiographic Operators
Radiographic technicians shall be qualified as follows:
a) To CSWIP industrial radiographer ASNT Level II or MLVKI. (Certification of
Radiographic Operators Multi-Level)
b) Technicians interpreting radiographic shall hold recognised formal qualification e.g.
PCN or MLVK II.
MPI and DPI Personnel

MPI and DPI technicians shall be qualified to ASNT II or MLVK.
April 2017 31
2.9 Inspection and Testing
2.9.1 General
For the purpose of coordinating shop inspection and tests, the Bidder shall prepare and
submit to the Engineer/client detailed manufacturing time schedules for each major
component of the Works. Such schedules shall clearly show the planned dates of
commencement and termination of a certain phase of work or operation (e.g. design,
ordering of materials, pre-assembly, machining etc.) and the expected dates of agreed shop
inspections and tests. These detailed progress schedules shall be updated monthly by the
Bidder. The first submission shall be effected within 28 days after the Commencement Date.
The Bidder shall also enter on these time schedules the actual progress of work each time
an updated schedule is submitted.
Written confirmation of the date and place of inspections and tests shall be given to the
Employer/client by the Bidder 15 days at the latest prior to the date of any such inspection or
test. The Employer/client shall inform the Bidder at a reasonable time of his intention to
attend.
The Bidder shall submit, in due time, before tests are carried out, a detailed procedure for
the tests to be performed, with reference to the standards to be applied and special
equipment to be used.
The test procedures shall at least comply with the requirements stated under the various
articles of the Particular Specifications, but the Bidder shall be obliged to complete the test
programme in order to verify the quality of the relevant equipment and its accessories.
The procedure shall be subject to approval by the Employer/client.
The inspection and testing of materials and components shall comprise, but not necessarily
be limited to the following:
2.9.2 Material Tests in Foundry and Steel Manufacturer's Mill
Certificates shall be issued according to approved standards as for example EN 10 204,

Certificate min. 3.1.
Each plate as rolled (as rolled refers to the unit plate rolled in one piece, and later cut into
smaller sizes) is to be tested in the laboratories of the steel mill according to approved
quality standards. Test certificates shall be prepared by the inspection agency or the
manufacturer as required in the Particular Specifications, giving the following information:
 Number of melt
 Chemical analysis of melt
 Plate thickness and size
 The following tests along rolling direction:
 Yield strength, tensile strength, elongation at rupture
 3 (three) ISO V notch impact tests at 0ºC or temperature as required
The findings shall at least conform to minimum requirements for the material approved for
the relevant structure.
A complete ultrasonic test shall be made on all plates subject to lateral stresses.
Each plate shall be stamped in the mill, showing:
 Melt number
 Plate number
 Quality designation
April 2017 32
 The Steel Manufacturer's signature.
Such tests for special items like penstocks and steel linings may be witnessed by the
Employer/client.
All principal castings and forgings, i.e. those castings and forgings subject to high service
stress, impact, fatigue, or vibration stresses, shall be subject to the following tests and
inspections:
(a) Chemical Analysis
Chemical analysis of the material shall be taken in accordance with normal practice to show
that the components conform to the Specifications.
(b) Mechanical Tests
Mechanical tests shall be carried out on the material for all main components according to
normal practice and relevant standards to ascertain that material properties conform to the
requirements and Specifications. Such tests shall include the determination of the yield
strength, UTS, elongation/Bidion and impact strength in aged/non aged condition as
required.
(c) Non Destructive Tests
Non destructive tests of the materials shall include ultrasonic tests, radiographic tests,
magnetic particle tests and dye penetrant tests as specified.
Unless otherwise specified, the requirements of EN 13445 part 4 and 5, as an alternative
CCH 70-3 or Section VIII and IX of the ASME Boiler and Pressure Vessel Code shall apply:
 Magnetic Particle Inspection
 Ultrasonic Inspection
 Liquid Penetrant Inspection
Major defects disclosed by such testing and/or examination shall be removed by suitable
means to sound metal. The completeness of removal shall be confirmed by means of
magnetic particle or dye penetrant inspection. If major defects are disclosed, complete
information on the nature and location of the defect and the proposed repair procedure shall
be submitted to the Employer/client for approval prior to making any repairs.
Castings and forgings containing injurious defects may, by the decision of the
Employer/client, be rejected. Castings and forgings with major defects repaired by welding
shall be subject to NDT inspection as required, and completely stress relieved subsequent to
all welding. All weld repairs of minor defects shall be magnetic particle or dye penetrant
inspected. After all welding has been completed stress relieving shall be performed on such
castings and forgings at the Employer/client's request.
2.9.3 Pressure Tests
Parts subject to internal or external pressure or containing any liquids or gases temporarily
or permanently during operation shall be pressure tested prior to painting. The extent of
testing as well as test procedure is subject to the Employer/client's approval.
Distinction shall be made among parts exposed during operation to hydraulic pressure, to
gas pressure and to any liquid without pressure.
In addition to the Specifications, applicable and approved standards and official regulations
shall be observed. If any liquid used for the test may cause corrosion, all the equipment and
piping shall be thoroughly cleaned immediately after the test.
Pipe systems shall in general be pressure tested with water. Corrosion protecting inhibitors
should, when necessary, be added. Air or oil may be used if special precautions against
damage are taken.
April 2017 33
The test pressure shall in general be 50% higher than the design pressure, or, in the case of
pipe systems, 50% higher than the working pressure at the lowest point. Before testing, the
pipe systems shall be thoroughly cleaned.
Valve bodies are subject to pressure tests. Tightness of valve seals shall be tested at the
design pressure.
Test pressures shall be applied and maintained at the required pressure for a sufficient
length of time to permit a visual examination of all surfaces and joints, but in no case for less
than 30 min. The vessel shall exhibit no sign of general plastic yielding or leakage or
damage.
Coated vessels, (galvanised, rubber lined etc.) shall be tested before coating, at the
standard hydraulic test pressure, and after coating, at the design pressure.
Embedded pipe systems which are pressure tested before embedding shall again after the
embedding be tested at the design pressure. After completed pressure test, the pipe
systems shall be drained and properly closed to prevent entrance of foreign matter.
Re-tests
If any repairs are found to be necessary during or subsequent to the pressure test, the
vessel shall be subjected to a new pressure test as specified in this Article after completion
of the repairs and after any heat treatment.
2.9.4 Parts Exposed to Gas Pressure
Components which during operation will be subjected to gas pressure, for example the
hydraulic unit accumulators, shall be inspected and tested according to the design code. The
pressure test is to be executed applying water at the prescribed test pressure in accordance
with the relevant standards and specifications.
2.9.5 Parts Exposed to Liquids without Overpressure
Those parts which may not or shall not be closed and which are exposed during operation to
only a low pressure of any liquid (e.g. bearing housings, oil containers, etc.) shall be subject
to a tightness test with a suitable liquid of low viscosity. The period of testing shall not be
less than 10 hours, unless otherwise agreed.
2.9.6 Welding Tests at Works and at Site
Inspection and testing after welding

After welding, the compliance with relevant acceptance criteria shall be checked:
 by visual inspection;
 by non-destructive testing;
 by destructive testing;
 form, shape and dimensions of the construction;
 results and records of post-weld operations (e.g. post-weld heat treatment, ageing)
The ISO documents to which it is required to conform to fulfil the quality requirements are
specified in ISO 3834-5:2005, Table 8, for arc welding, electron beam welding, laser beam
welding and gas welding, and in ISO 3834-5:2005, Table 10, for other fusion welding
processes.
Acceptance criteria shall be as given in EN 1289 (PT), EN 1291 (MT), EN 1712 (UT) or as
agreed with the Employer/client.
April 2017 34
The welding properties shall be demonstrated by the Bidder as required by the
Employer/client.
For penstocks and circular steel linings 10% of all pipes of each quality and thickness shall
be tested as follows:
For longitudinal joints two test plates (tablets) shall be fixed to the ends of the rolled plates
which are to be joined and welded together as a continuous prolongation of the longitudinal
weld. The tablet base material and plate thickness, filler material, flux and any heat
treatment shall be identical for the plates proper and the test tablets. The tablet size, etc., is
subject to the Employer/client's approval. Samples shall be cut from the test tablets for
testing as follows:
 Two elongation specimens with parallel side faces, cut normal to the directions of weld for
testing of tensile strength, elongation at rupture, position of rupture (in the weld, in the
heat affected zone (HAZ), or in the base material).
One elongation test shall be performed with reduced section at the weld, for testing of yield
strength and tensile strength of the weld deposit material itself. The specimen is to be cut
from along the weld seam if possible.
Two bending tests are to be performed, executed with tension on both faces of the weld
seam, mandrel diameter = 2.5 a (a = thickness of specimen).
Three ISO V-notch impact tests (at 0ºC or temperature as agreed), each with notch normal
to direction of weld, are to be performed as follows:
 Two with notch in HAZ
 One with notch in the first weld pass
No impact test shall be accepted if the impact strength is less than 27 J or as given in the
relevant standards
The welded joint shall prove to have a quality and property not inferior to that of the base
material.
Re tests
Tested welds showing doubtful indications shall be rechecked by radiography if requested by
the Employer/client. Defects in welds disclosed by ultrasonic or radiographic testing or dye
penetrant/magnetic particle testing shall be completely removed.
After re-welding the new weld shall be subject to radio-graphic examination. Stress relieving
after the weld repair has been completed shall be performed on major welds at the
Employer/client's request.
2.9.7 Dimensions and Finish
Dimensional checks shall be performed on all major parts, components and partial
assemblies, especially when close tolerances and fits are involved (tolerance of shafts,
between stationary and moving parts, connecting dimensions for the assembly with other
supplies, etc.). If the dimensional checks show discrepancies in measurement which may
affect the fit, assembly or dismantling of the respective part or component, then this will have
to be corrected correspondingly. Such correction or modification shall, however, in no way
lead to sacrifices with respect to reliability of operation or interchangeability, and shall be
performed only after the agreement of the Employer/client has been obtained. If the
correction or modification cannot be carried out in accordance with the terms mentioned
above, the part or component concerned may be subject to rejection. Faulty machine parts
or equipment shall under no circumstance be delivered.
All major finished surfaces shall be subject to a visual inspection in the presence of the
Employer/client.
Compliance with surface finishes indicated on the shop drawings will be determined by
comparing of the finish to applicable "Standard Roughness Specimens".
April 2017 35
2.9.8 Acceptance
Should the tests and inspections prove that any materials or components are of
unsatisfactory quality or dimension, the Employer/client shall have the right to demand any
additional tests as required. The related costs shall be carried by the Bidder.
The Bidder shall provide all facilities, equipment and goods required for carrying out the tests
in the shop and at the site. The costs shall be included in the sums for the supply items.
When the Plant or parts of the Plant have passed any tests specified, the Employer/client
shall furnish to the Bidder a certificate or endorse the Bidder's certificate to that effect.
2.10 Packing, Marking, Transportation and Nameplates
2.10.1 General
The Bid includes all handling and transport from place(s) of manufacture to site.
The Bidder must at his own expense, conduct any route survey of all roads, bridges, by-
passes, etc. from the Port of Entry to the Site and examine the conditions of all roads and
bridges.
The Bidder shall co-ordinate his own transport program and shall advise the proper
authorities of the transit of the heaviest items to be transported and shall comply with the
instructions given by said authorities.
All damages caused to public roads, streets or public structures due to the transport shall be
compensated by the Bidder at his own expense.
2.10.2 Packing
The Bidder shall prepare, pack and load all materials and plant in such a manner so as to
protect them from damage in transit, and he shall be responsible for and replace any
materials or parts of the Plant damaged or lost in transit, and he shall bear the costs for the
repair or replacement of such materials or parts.
After shop assembly, inspection and testing, all parts of the Plant shall be carefully packed
and marked to ensure quick identification and erection at site.
All packing shall be seaworthy for on-deck/under-deck transport, as the case may be, and
long time storage under outdoor conditions with high humidity and temperatures. The
packing and transport protection shall comprise every means and materials necessary to
prevent corrosion, condensation or any mechanical, chemical or physical damage to the
Plant.
2.10.3 Marking
Each package, box and crate shall be clearly marked with address, identification of the
project, package number, weights (net and gross), dimensions, special instructions for
slinging, etc. Marks shall be brand-marked or stencilled with good quality waterproof ink or
paint, so as to be clearly visible throughout the transport and construction period.
The following information must be clearly stencilled or printed on each packing case, crate,
cask, drum, bundle or loose piece, care being taken that the number and other particulars on
each package agree with those entered in the packing list accompanying the Invoice:
 Employer's Identity
 Supplier's Identity
 Destination
April 2017 36
 Bid No.
 Package No.
 Item Code
 Weight, dimensions
 Sub-Project (Substation Identity)
The marking shall be durable. The marking shall be upon the body of the package. Marking
upon a batten fastened on the case, etc. shall not be used.
In the case of bags, bundles and loose pieces, the shapes of which do not permit the marks
to be put on the actual package, each bag, bundle or loose piece shall have two metal labels
fastened to it by wire. Each label shall be die-stamped with the above particulars. The label
must have two holes preferably one at each end and must be securely fastened to the
package by wire, no smaller than 16 SWG, passing through the two holes, each fastening
being independent of the other.
2.10.4 Transportation
None of the main components shall be shipped to Site, after completed manufacture, from
the Bidder’s place of manufacture (or from his sub Contractor' (if any) without the Employer's
consent.
The Plant shall be manufactured and packed in conformity with the loading limitations and
gauges of the chosen route to site. The Bidder shall be responsible for respecting all such
transport limitations.
When plant and materials is specified for export shipment, the Bidder shall include
packaging adequate for export shipment, and this packaging shall be such as to obtain
approval and acceptance by transportation companies.
The type and number of shipping documents to be sent to the Employer are given in the
Special Conditions of Bid. One copy of each packing list shall be enclosed with the
shipment; it shall be well protected against humidity and damage.
All transport from the Manufacturer's place of manufacture to the Site and at the Site shall be
carried out by the Bidder and every cost regarding insurances and transport shall be
included in the Tender Price, - and later in the Bid Price.
Larger assemblies shall when necessary be split to facilitate transportation and storage, and
the size and weight of any packed part shall not unduly require special precautions in
transportation and storage.
The Bidder shall inform the Employer of the final weights and dimensions of particularly
heavy goods such as turbines, gates, valves, steel liners, generators and transformers and
present packing and transport plans for the approval of the Employer prior to packing. Local
storage and handling at site shall be arranged and carried out by the Bidder at his own
expense. Subsequent to the completion of the powerhouse overhead travelling crane it may
be used for unloading, installation and erection works under the Bidder's guidance and
responsibility.
The Schedules shall be duly completed with respect to information on dimensions and
weights. Any item of 10 tonnes or more shall be listed.
Should the Bidder be prevented from shipping or despatching any portion of the works in
due time by a cause not reasonably within the Bidder's control, he shall arrange proper
storage to the approval of the Employer and shall insure the goods against all risks during
the storage period.
The Supplier shall provide such packing of the Goods as is required to prevent their damage
or deterioration during transit to their final destination as indicated in the Bid. The packing
shall be sufficient to withstand, without limitation, rough handling during transit and exposure
April 2017 37
to extreme temperatures, salt and precipitation during transit and open storage. Packing
case size and weights shall take into consideration, where appropriate, the remoteness of
the Goods' final destination and the absence of heavy handling facilities at all points in
transit.
2.10.5 Storage
The Bidder shall be responsible for proper storage of plant and materials under his Bid. Care
shall be taken to ensure adequate storage to avoid damage to plant due to rain, dust or
strong sunshine.
The storage shall be in an environment similar to the installed location, i.e., indoor plant shall
be stored indoors (without heating), and outdoor plant may be stored outdoors. Where
required to protect against condensation and humidity, a desiccant shall be provided and its
presence, with the need of periodic removal and dry-out, shall be so marked.
Items, which may be subjected to open storage for several months on site shall be suitably
packed and protected from the weather.
The Bidder shall provide storage and handling instructions including descriptions for periodic
inspection and/or storage maintenance to ascertain that no deterioration will occur during
storage. One set of these instructions shall be fastened securely to the outside of the
shipping unit.
The Bidder shall provide at the Employer’s request, the Bidder’s recommended instructions
for long-term storage.
All plant shall be shipped from the factory completely assembled as far as practicable,
subject to any limitations of length, height, depth, and weight, etc. described in the Technical
Data Sheets or due to limitations in road and bridge conditions or other transport facilities.
2.10.6 Nameplates
All items of plant shall be provided with a securely fixed nameplate showing the maker's
name, model, serial number, year of manufacture, main characteristic data of the respective
item and further relevant information specified in the applicable standards or necessary for
the proper identification of the item involved. All main items of plant shall have the
nameplates in English.
The Bidder shall supply all label plates and other labelling (of the screw-on type) on control
boards, control desks, panels and other places where required for operational, functional
and safety reasons. The labelling, size of the plates and their location shall be subject to
approval by the Employer. A sample label plate indicating the material and lettering to be
used shall be submitted for this purpose. The number of sizes of the various plates shall be
kept to a minimum.
The Employer may direct special labelling or nameplates to be written in the English
language.
2.11 Erection
The Plant shall be erected and installed by the Bidder using qualified English-speaking
personnel.
The Bidder shall provide and use all such tools and consumables, equipment, drawings, etc.,
as required for the erection and site testing of the works.
The above mentioned tools, equipment, etc., will remain the Bidder’s property and will be
returned to him in the as-is-condition when the plant has been commissioned. All costs
related to the use, wear and tear, depreciation, etc., as well as cost of consumable, possible
April 2017 38
repairs, etc., shall be included in the supply price, and no separate or additional payment will
be made.
Tools, special keys, etc., which are part of the permanent supply, as specified in the
Particular Specification, are the property of the Employer and shall not be used by the Bidder
for erection purposes unless approved by the Employer.
2.12 Maintenance
The Bidder shall maintain all part of the Works from the date that the parts arrive at Site until
Taking Over.
2.13 Tests on Completion, Commissioning
When all Works are completed according to the specifications and requirements of the Bid,
the Works shall be Taken Over by the Employer. The Employer may, however, accept minor
works having no bearing on the safety or proper operation of the works to be finalised after
the commissioning has started. Well ahead of the commissioning period each Bidder shall
forward a detailed commissioning programme to the Employer. The Employer or his
representative will coordinate the programmes and will manage the overall programme on
site.
2.14 Documentation
2.14.1 Final Documentation
General
This specification describes the data and information required by the Employer as As-Built
Documentation. Delivery of this documentation in the form specified herein is part of the
overall Bid. The documentation requirements are applicable for all work classified as
permanent work. The As-Built Documentation shall comprise all work under the Bid.
Final plant documentation shall be handed over to the Employer not later than 120 days after
Taking Over. The final documentation shall consist of the complete documents incorporating
all modifications carried out during the erection and installation of the Works.
Spare parts catalogues shall be supplied, giving all necessary data for ordering of spare
parts directly from the manufacturers.
Following the final documentation, the Bidder shall submit the Commissioning Report bound
in a separate volume.
Responsibility for Filing and Traceability

 Documents that provide direct evidence of the quality (conformance to specification) of
delivered plant and work performed shall be retained by the Bidder for a minimum period
of 10 years. All information in these records shall be traceable from documents included
in the As-Built Documentation
 Within this period, the Bidder is responsible for meeting all Employer requirements for
retained documentation and related information
 The Bidder is responsible for co-ordinating his sub Contractors traceability systems to
make them comply with the project requirements and make sure that all sub Contractor
documentation, as required in the specification, is identified
Final Documentation Structure

(a) Introduction
The documentation shall be arranged in the following groups:
A Drawing file
April 2017 39
B Test Reports & Certificates
C Plant Data
D Operation and Maintenance
All drawings and documents should reflect the As-Built stage including all modifications
and/or adjustments performed during Employer/clienting, fabrication and installation if
applicable.
Additional to paper copy deliverance described below, all written documentation shall also
be delivered on CD.
The documentation shall be compatible with the Employer's software, Microsoft Word and
Excel and the Auto Cad 2000.
(b) Group A - Drawing File
The Drawing file shall contain all necessary drawings and diagrams for identification,
installation, testing, operation and maintenance purposes.
Drawings should be reduced to A3 size, folded to A4 size with the title visible, inserted two
by two in plastic wallets (opening on top) and bound in A4 binders.
A drawing index shall be incorporated at the start of the drawing file and the drawings shall
be filed in drawing number sequence.
(c) Group B - Test Reports & Certificates
Group B shall contain all computer analysis documentation, test and certification
documentation relating to the plant which has to be produced according to Bid, i.e.:
 Specifications and procedures
 Test Reports
 Certificates (bulk certificates to be retained by the Bidder)
A detailed index shall be incorporated in the beginning of the book and the documentation
should be collated in the sections indicated above and presented by plant name/tag number.
All documentation shall be collated in document number sequence within the sections.
(d) Group C - Plant Data
Group C shall contain all relevant technical data relating to the plant. The documentation
should be structured as below:
List of plant (i.e. list of separately tagged items together with the plant serial number and the
name of the supplier of sub-supplier as appropriate)
 Consumption List
 Data Sheets
 Calculations
 Other relevant technical information
A detailed index shall be incorporated in the beginning of the book and the documentation
should be collated in the sections indicated above.
All documentation shall be collated in document number sequence within the sections.
(e) Group D - Operation and Maintenance
Operation and maintenance manuals shall give information of safe, correct and efficient
operation and maintenance of the plant.
All manuals and descriptions for daily use and operation shall be in English language.
Maintenance and troubleshooting instructions shall be included together with a detailed
description of manual start procedures.
System descriptions that are only to be used by specialists shall also be in English language.
April 2017 40
Maintenance documentation for all plant included in the Bid shall be submitted. The
documentation shall be completed with regard to all kinds of components and assemblies,
detailed repair work at component level, and testing and adjustment of the plant.
The relevant data/information shall be collated and presented in the following sections and
sequence as applicable:
 Technical specification and reference data
 Handling, installation, storage and transit
 Operating information
 Technical description
 Maintenance information
 Parts list - spare parts
A detailed index shall be incorporated at the beginning of the book. All documents shall be
collated in document number sequence within the sections.
The maintenance documentation shall also be handed over in electronic form for
implementation in a future computer assisted maintenance management system and shall
contain the following information:
 Maintenance instructions for routine maintenance, indicating all periodic inspections
required, the inspection procedure and the period between inspections
 "Trouble shooting" instructions describing procedures for error diagnosis and identification
of faulty modules and assemblies and the replacing of such modules or assemblies
 Condition monitoring with respect to levels of vibration
 Repair instructions describing procedures for repair work at sub-module and sub-
component level, using fault-tree diagnosis diagrams, logic signature and analysis,
oscilloscope patterns, logic bit patterns, etc., and any necessary diagnostic programs and
instruction manuals, etc.
 Detailed maintenance drawings shall be supplied enabling the Employer to carry out
proper maintenance and repair work. These drawings shall indicate sufficient details,
dimensions, tolerances, clearances and material specifications to enable the repair or
replacement of such parts as is common practice to perform
 Testing and adjustment instructions describing procedures for testing and adjusting plant,
modules or sub-modules during operation, as routine maintenance work or after repair
work
The maintenance instructions shall provide lists of required test instruments and
maintenance tools, diagrams showing test instruments connections and instruments setting,
and detailed step-by-step procedures for identifying faulty plant where at each step are
specified the instrument set-up, the correct measurement at this stage and the route(s) to
follow when incorrect measurements.
The detailed technical descriptions, diagrams and charts which are required as reference
documentation for the detailed fault identification, repair and tests and adjustment
procedures, are assumed included in the system documentation.
It is further assumed that those parts of the maintenance instructions which cover the
preventive and routine maintenance and "first-aid" maintenance of the computer systems,
and which do not require specific test instruments or maintenance tools except for such plant
that may be built into the particular computer assembly, shall be incorporated in the user
documentation as well as in the maintenance documentation.
April 2017 41
Documentation Requirements
(a) Covers/Binders
The documents shall be bound loose-leaf in four holed covers with locking mechanisms and
must be suitable for the inclusion of amendment data. The covers shall have plastic wallets
in front and spine where the contents and facility covered by the documentation shall be
identified.
The documents shall be A4 size of good quality for long-term storage.
(b) List of Contents

The list of contents shall be on two levels.
(i) Level 1
Content list for all volumes related to the Bid. The list of contents shall be included in all
volumes.
The index shall give a brief description of content in each volume (title of sections).
(ii) Level 2
Content list for all documentation included in each specific volume.
The index shall contain document/drawing number, document/drawing title and revision.
(c) Dividers
If one volume is divided into more than one section, the sections shall be separated by
plastic dividers marked with the section numbers.
All dividers shall protrude beyond the leading edge of the documentation.
Each document shall be separated by coloured sheets of the same size as the documents.
The same colour shall be used throughout all volumes. Coloured sheets shall not be used
between drawings.
(d) Size
With the exception of drawings, all documents shall be A4 size. For drawing size, reference
is made to "Group A Drawing File" chapter 1.15.3
(e) Margins
Margins shall be wide enough to allow for printing, filing or binding and shall not be less than
20 mm.
(f) Paper Quality
Paper quality shall be suitable for long-term storage and shall carry a strong image to allow
for photo copying and microfilming.
(g) Clarity
Characters must be clearly typed. Hand-printed characters are acceptable only on
drawings, reports, certificates, etc.
2.15 Hydraulic Steelworks
2.15.1 Corrosion allowance
Unless otherwise specified, a general corrosion allowance of 2 mm shall be used on steel

faces exposed to water.
2.15.2 Design and Calculation
Gates and Hydraulic Steel Structures

The equipment shall in general be designed with safety factors etc according to this general
specification and the particular technical specification. Further details can be based on
April 2017 42
DIN 19704 “Hydraulic steel structures”, part 1, part 2 and part 3. or other approved
standards.
All supporting structural parts and connections of the hydraulic steel structure shall be
calculated on the basis of normal, unusual and extreme load assumptions.
Where multi axial stresses occur, the comparative stresses shall be computed according to
the hypothesis of deformation energy (von Mises Criterion). Deformation of structural parts
shall be permissible to an extent, agreeable with the operation requirements.
For dimensioning of the hoists, all unfavourably occurring load cases shall be taken into
account. The lifting forces shall be calculated according to DIN 19704, under consideration
of all dead weights, friction forces, solid sediment forces towards the gate face, acceleration
forces, efficiency of hoists, etc. In addition, the weight on the structures from sediments
settled at 35 degrees angle at beams and stiffeners etc, as well as cavities filled with
sediments shall be considered.
The nominal maximum lifting force for gates calculated in this way shall be increased by a
safety factor of 25%.
The safe closing of gates shall be guaranteed and the net closing pressure at the sills shall
be at least 5000 N/m. The course of the lifting forces occurring with opening and closing
shall be graphically represented in relation to the gate position as an annex to the design
calculation.
Special care shall be taken in designing the gates considering all possible hydraulic
influences. The shape of the bottom edges of the gates shall be designed to avoid
resonance as a result of harmonics. Vibration free operation at different water levels and
gate openings shall be guaranteed.
2.15.3 General Design Particulars
For any structural parts of the hydraulic steelworks acting under load against the concrete
structures, the permissible mean compressive stress on concrete shall in general be limited
to 10 N/mm2. If higher compressive stress is unavoidable, the conditions shall be calculated
in detail, using the actual material properties for the involved materials, including concrete
reinforcement.
During embedding in concrete, steel linings shall be regarded as partly surrounded by the
liquid concrete mix. The lining, as well as the anchorage and possible stiffeners, shall be
designed for an unbalanced pressure resulting from 0.5 m level difference in the fluid
concrete on side, as well as an uplift or partial external pressure resulting from 0.5 m of fluid
concrete.
During embedding in concrete, and during grouting of any section, the safety factor against
buckling shall be at least 2.0, considering the effect of internal provisional stiffeners.
2.15.4 Oils and Lubricants
Oil of an approved grade and quality shall be used for all purposes. Preferably bearings,
governors and other hydraulic systems should use the same grade. All lubricants required
shall be commercially available in the Employers country.
Oils shall free from bacteria and it shall contain suitable microbiocides to prevent any
bacteriological growth when in service on during normal storage. The Employer/client may
have the oil tested and the Bidder shall replace the entire volume of any contaminated oil
systems and carry out satisfactory cleaning of the affected systems.
The Employer reserves the right to request the different Bidders to use certain brands of
lubricants, oils, etc. The Bidder shall not be entitled to claim extra payment because of this
request.
April 2017 43
Unless otherwise stated in the Particular Specifications, the first oil or grease filling for
bearings, pressure oil systems, transformers, etc., including the necessary quantity for
flushing, shall be included in the Bid Price. Also shall be included a spare volume of
minimum 25% of the net amount required.
Points requiring grease lubrication shall be provided with ample and easily accessible
greasing nipples marked for identification.
Self-lubricating types of bearings and bushings will be preferred. Bearings and bushings
subject to contamination from dirty water or air shall be additionally protected by suitable
seals, and, if necessary by additional grease.
Bearings and other components, in which oil is circulated, shall be designed to avoid air
foaming.
The contamination of air, water and ground by lubricants and fuel shall be avoided by means
of appropriate designs and layouts of the equipment in conformity with the latest recognised
standards for modern practice.
2.15.5 Bolts, Studs, Nuts and Screws
All bolts, studs, nuts, and screws shall have standard threads and be of high quality steel.
All bolts, studs, nuts and screws (including their washers) shall be protected against
corrosion or made of stainless steel.
Nuts, bolts and screws, which might become loose during operation, shall be locked in
fastened position by means approved by the Employer/client.
Additionally, bolts, thread ends and the like shall be protected against condensation water or
adverse climatic conditions by protective non-metallic caps with locking edge and sealing lip.
2.16 Electrical Equipments and Wring
2.16.1 General
All internal electrical connections between the various components and terminal block shall
be part of the Bid. Electrical supply to the terminal block is part of the Electrical Works Bid.
2.16.2 Electric Motors
The motors shall be of horizontal shaft, high starting torque, low starting current, squirrel
cage, induction type, designed for full voltage starting, weatherproof and totally enclosed.
Wound rotor motors will be accepted only if a squirrel cage type would not be satisfactory for
the duty.
The motors shall have class E insulation and continuous rating at 35 degree centigrade
ambient temperature. Motor lead insulation shall be class E and cable terminal boxes shall
be provided preferably with stud-type connectors.
The capacity of motor shall be more than 100 per cent against the value calculated from the
most adverse combination of loads, which will occur during opening and closing operation of
the gate. The starting and maximum torque of motors shall be more than 200 and less than
300 per cent of its rated torque respectively.
Windings and connections shall be suitable impregnated to render them moisture proof, non-
hygroscopic and unaffected by conducting dust. All motor bearing shall be of the ball or roller
type with an inner grease seal to prevent grease entering the winding. Bearing housing shall
be fitted with a “ball in head” grease fitting and a removable plug for the escape of grease.
April 2017 44
2.16.3 Motor Brakes
The brakes mounted on motors shall be offspring-applied and A.C solenoid released type.
The rated capacity capacity shall not be less than 150 per cent of the rated full load torque of
the motor. The brake shall be arranged for automatic application, when the motor power
supply is cut off and release when the motor is energized. The brake enclosure shall be
weather proof with convenient access for maintenance operation.
2.16.4 Electric Cable and Wiring
The Bidder shall be responsible for wiring, laying and furnishing of control and power cables
and/or wires which are necessary for required operation.
All wiring in the control cabinets shall be with PVC insulated stranded conductor, formed
neatly into groups and properly supported. There shall be no splices in the wires or cables
and all connection shall be made only at terminal blocks or studs.
All external wiring between the control cubicles, motors, limit switches, etc., shall be with
multicore copper, PVC insulated, PVC sheathed, 600 volt grade jacket type cable.
2.16.5 Motor Stator and ammeters
All starters shall be suitable for direct-on-line starting of motors, provided with 3 phase
induction type over current relays for overload phenomenon with manual resetting, open-
phase relays and undervoltage release feature. Overcurrent relays shall be field adjustable
to be rated full load currents of motors. Backup protection shall provide with high rupturing
capacity enclosed fuses or moulded case circuit breakers. The control voltage shall be 230
volt. AC.
All motors shall be provided with disconnect switches or quickbreak no-fuse circuit brekers
with operating handles locakable in “off position”. They shall be rated to interrupt the full load
current of motor or other equipment in the circuit.
2.16.6 Conduits
Rigid steel conduit shall be galvanized. It shall be of a minimum thickness of 2.3 millimeters
and have a minimum inside diameter of 16 millimeters.
2.16.7 Enclosure
Motors enclosures shall be weatherproof and totally enclosed. Enclosures for all other
equipment shall in general be dustproof, weatherproof and vermin proof where required.
Enclosures, trim and doors shall be coated with two coats of a suitable primer and finished
with enamel paint, the colour of which will be decided by the Employer.
2.16.8 Convenience Outlets
Convenience outlets shall be of 2-pin with scraping earth or 3-pin type rated for amps at 230
volts, suitable for English pattern plug used inside the power plant. Outlets shall be in
weatherproof enclosure or suitably protected from weather.
April 2017 45
2.16.9 Limit Switches
The limit switches shall have weatherproof enclosures and shall be mounted suitable for
easy adjustment and for rigidly locking in position after being adjusted. They shall be of
heavy-duty rating and shall have stainless steel rotating parts and permanently lubricated
bearing. They shall allow the arms to be fully deflected by operator without damage to the
switch.
2.16.10 Indicating Lights
All indicating lights shall be of filaments with colored plastic lenses type for long life and
service under conditions of shock, vibration and rough handling.
2.16.11 Instruments and Meters
All instrumental and meters shall have approximately 110 millimeters dial, shall be of heavy-
duty, industrial type suitable for extreme shock and severe vibration applications.
2.16.12 Lighting Fixtures
The lighting fixtures shall be complete with lamps. Fluorescent lighting fixtures shall be
equipped with complete fittings for A-C, 230-volts, 50 Hz source and a ballast or ballasts of
high power factor.
Incandescent lighting fixture shall have lamp holders in accordance with the local standards.
The lighting fixtures for outdoor use shall be weatherproof type.
Special care shall be exercised on selection of fixtures so that illumination of the lamps is not
obstructed by accumulation of insects and dust.
2.16.13 Electrical Relays
Electrical relays for controls and auxiliary relays for protection circuits shall be of the plug-in
type and the plug-in connection shall be made and broken by pressure contacts.
Alternatively, the Employer/client may approve the use of plug-in trays containing groups of
relays.
Relays shall be provided with non-flammable dust and moisture proof cases.
Relay contacts shall be adequately rated for the service conditions. Relay coils shall be
continuously rated whether the control scheme require them to be continuously energized or
not.
At least one spare normally opened contact and one spare normally closed contact shall be
provided on each relay in addition to the contact required by the control scheme.
2.16.14 Terminal Strips
Terminal strips shall be of double stud and 2-hole solid link design with the studs moulded
into an insulating base. Pinch-type terminal blocks and slotted links are not acceptable.
Studs shall be of brass and 6 mm diameter expects that studs of 4.7 mm diameter in
stainless steel or phosphor-bronze may be approved.
Terminal strips shall be arranged in vertical rows not less than 225 mm above floor level.
Sufficient terminals shall be provided on each item of equipment to permit the connection of
all incoming cable cores plus 10 per cent spare terminals.
April 2017 46
Removable transparent insulating covers shall be provided over all terminals. An insulating
barrier shall be provided between adjacent pairs of studs.
April 2017 47

General Technical Specifications

Diunggah oleh

Informasi Dokumen

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

General Technical Specifications

Diunggah oleh

Hak Cipta:

Format Tersedia

Saptang Khola Hydropower Project Bid Documents for Hydromechanical Works

General Technical Specifications

1. GENERAL REQUIREMENTS OF WORKS

Gate, Stoplog, Hoist & Liner at Undersluice

Trash Rack, Gate, Stoplog and Hoist at Intake

Gate, Stoplog, Hoist & Liner at Gravel Trap

Gate & Hoist at Sand Flushing

Trash Rack at Forebay

Headrace Pipe and Accessories

Surge Tank and Accessories

Penstock Pipe and Accessories

Specific requirements are as described in the relevant sections of the specification.

1.2 Reference to the other Sections

1.3 Drawings to be furnished to the Bidder

a. Following drawings are enclosed to indicate general arrangement and requirements

b. Layout Plan of Power House

Gate, Stoplog, Hoist & Liner at Under-sluice

Trash Rack, Gate and Hoist at Intake

Gate, Hoist and Liner at Gravel Trap

Gate, Hoist at Sand Flushing

Trash Rack at Forebay

Headrace and Accessories

Surge Tank and Accessories

Penstock Pipe and Accessories

1.5 Deviation from Specifications

1.6 Weight Variation

I. GATES & HOISTS: Date

i. Supply of all the embedded parts of Headworks.

ii. Erection of all the embedded parts & concreting.

iii. Supply and erection of Intake gate, Under sluice gate,

iv. Testing & Commissioning.

II. TRASH RACKS:

i. Supply of embedded parts.

ii. Erection of embedded parts.

iii. Supply and erection of Trash racks including painting,

III. HEADRACE PIPE AND PENSTOCK PIPE & ITS

i. Supply of embedded parts.

ii. Erection of embedded parts.

iii. Supply and erection of Pipe including painting, finishing, etc.

1.8 Site Erection

The gates/equipment/ trash racks/ stop logs/hoist / headrace/ penstocks components to be

1.9 Tools and Tackles

1.10 Defective Materials/Machinery

In case any part of the material/machinery is found to be defective in material or

1.10.1 Defects disclosed prior to final acceptance

1.10.2 Defects disclosed after final acceptance

1.11 Operation of unsatisfactory Materials, Machinery etc.

1.12 Co-operation with other agencies

Hydro-mechanical Works ↔ Civil Works

Location Hydromechanical Works Civil Works

General Responsible for the supply of drawings Responsible for

Responsible for drawings showing detailed Bidder.

Responsible for calculation, delivery and

Responsible for necessary anchoring to bolts

Responsible for specifying required locations

Responsible for assessing permissible rate of

Responsible for all surface protection

Gates, Responsible for delivering the equipment at Responsible before

Electro-mechanical Works ↔ Hydro-mechanical Works

Location Electromechanical Works Hydromechanical Works

Penstocks / Responsible for delivery and

1.14 Management Meeting

1.15 Side Records